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Steam Turbine Chiller Service Manual
Transcript of 160 67-m3_
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SERVICE INSTRUCTIONS
MAXETMCENTRIFUGAL LIQUID CHILLERS
Supersedes: New Release Form 160.67-M3 (108)
mMetric Conversions
377-12421-101 (NEMA 1)377-12421-102 (NEMA 1 with Compressor VGD)377-15243-101 (NEMA 4/12)377-15243-102 (NEMA 4/12 with Compressor VGD)
MODEL YST
OPTIVIEW CONTROL CENTER
LD09731
(BUILT AFTER 01/01/08)
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JOHNSON CONTROLS2
Form 160.67-M3 (108)
This equipment is a relatively complicated apparatus. During installation, operation, maintenance or service, in di vid u als may be exposed to certain components or conditions including, but not limited to: refrigerants, oils, materials under pressure, rotating components, and both high and low voltage. Each of these items has the po ten tial, if misused or handled improperly, to cause bodi ly injury or death. It is the obligation and re spon -si bil i ty of operating/service per son nel to identify and rec og nize these inherent hazards, protect themselves, and pro ceed safely in completing their tasks. Failure to com ply with any of these requirements could result in se ri ous dam age to the equipment and the property in
IMPORTANT!READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is sit u at ed, as well as severe personal injury or death to them selves and people at the site.
This document is intended for use by owner-authorized operating/service personnel. It is expected that this in- di vid u al possesses independent training that will en able them to perform their assigned tasks properly and safe ly. It is essential that, prior to performing any task on this equipment, this individual shall have read and un der -stood this document and any referenced materials. This in di vid u al shall also be familiar with and comply with all ap pli ca ble governmental standards and regulations per tain ing to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
WARNING indicates a potentially haz ard ous sit u a tion which, if not avoid ed, could result in death or se- ri ous in ju ry.
DANGER indicates an im mi nent ly hazardous situation which, if not avoid ed, will re sult in death or se ri ous injury.
CAUTION identifi es a hazard which could lead to damage to the ma chine, damage to other equip ment and/or en vi ron men tal pollution. Usually an in struc tion will be given, together with a brief ex pla na tion.
External wiring, unless specifi ed as an optional connection in the man u fac tur ers prod uct line, is NOT to be connected inside the micro pan el cab i net. De vic es such as re lays, switch es, transducers and controls may NOT be installed inside the mi cro pan el. NO ex ter nal wir-ing is al lowed to be run through the micro panel. All wir ing must be in ac cor dance with YORKs pub lished spec i fi ca tions and must be per formed ONLY by qual i fi ed YORK personnel. YORK will not be re spon si ble for dam ag es/problems re sult ing from im prop er connections to the con trols or ap pli ca tion of im prop er con trol sig nals. Failure to fol low this will void the man u fac tur ers warranty and cause serious dam age to property or injury to per sons.
NOTE is used to highlight ad di tion al information which may be helpful to you.
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3JOHNSON CONTROLS
Form 160.67-M3 (108)
REFERENCE INSTRUCTIONS
NOMENCLATUREThe model number denotes the following characteristics of the unit.
YST VF VD J4 - KD71750090 - 14 - 0.6 - 33192C - F SChiller Model Special (Mandatory)
Evaporator Code Design Level
Condenser Code Steam Condenser Model
Compressor Code Turbine Expansion Ratio
No. of Turbine Nozzles
Steam Turbine Base Model
DESCRIPTION FORM NO.
INSTALLATION 160.67-N2
OPERATING & MAINTENANCE 160.67-O2
WIRING DIAGRAM MODEL YST 160.67-PW6
START-UP CHECKLIST MODEL YST 160.67-CL1
RENEWAL PARTS CONTROLS AND INSTRUMENTATION - MODEL YST 160.67-RP2
CHANGEABILITY OF THIS DOCUMENTIn complying with YORKs policy for continuous prod uct improvement, the information contained in this doc u ment is subject to change without notice. While YORK makes no commitment to update or pro- vide current in for ma tion automatically to the manual own er, that in for ma tion, if applicable, can be ob tained by con tact ing the nearest YORK Applied Systems Service offi ce.
It is the responsibility of operating/service personnel as to the applicability of these documents to the equip- ment in question. If there is any question in the mind of op er at ing/service personnel as to the applicability of these documents, then, prior to working on the equip- ment, they should verify with the owner wheth er the equipment has been modifi ed and if current lit er a ture is available.
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JOHNSON CONTROLS4
Form 160.67-M3 (108)
TABLE OF CONTENTSSECTION 1 - INTRODUCTION ..........................................................................................................................11
SECTION 2 - SYSTEM ARCHITECTURE .........................................................................................................12FOR RETROFIT APPLICATIONS ...............................................................................................................14
SECTION 3 - MICROBOARD 031-02430-004 ...................................................................................................18TEST POINTS .............................................................................................................................................18BOOT-UP PROGRAM .................................................................................................................................18CHILLER OPERATING PROGRAM ...........................................................................................................18PROGRAM CARD .......................................................................................................................................19DIAGNOSTIC DISPLAY CODES ................................................................................................................19PROGRAM DOWNLOAD CONNECTOR U33 ............................................................................................20PARALLEL PORT CONNECTOR ...............................................................................................................20BRAM (U38) ................................................................................................................................................20WATCHDOG CIRCUIT ................................................................................................................................20PROGRAM JUMPERS/PROGRAM SWITCHES ........................................................................................21KEYPAD INTERFACE .................................................................................................................................21PRINTER INTERFACE ................................................................................................................................21MICROGATEWAY INTERFACE ..................................................................................................................21DIGITAL INPUTS .........................................................................................................................................21DIGITAL OUTPUTS .....................................................................................................................................21ANALOG INPUTS .......................................................................................................................................22SERIAL DATA PORTS ................................................................................................................................22DISPLAY INTERFACE ................................................................................................................................23REMOTE SETPOINTS ................................................................................................................................24CONFIGURATION/SETUP ..........................................................................................................................24MICROBOARD SERVICE REPLACEMENT ...............................................................................................25PROGRAM CARD SERVICE REPLACEMENT ..........................................................................................25
SECTION 4 - I/O BOARD 031-01743-002 .........................................................................................................35RELAY TIMING ............................................................................................................................................36
SECTION 5 - LIQUID CRYSTAL DISPLAY .......................................................................................................45DISPLAY REPLACEMENT KIT 331-01771-000: ........................................................................................47
Display Handling: ................................................................................................................................47BACKLIGHT LAMP REPLACEMENT: ........................................................................................................47
SHARP LQ10D367/368 (031-01774-000) Display: ..............................................................................47SHARP LQ10D421 Display ..................................................................................................................47NEC NL6448AC33-24 Display .............................................................................................................48LG Semicon LP104V2-W (031-02046-000) Display ..........................................................................48
SECTION 6 - DISPLAY INTERFACE BOARD ...................................................................................................54SHARP LQ10D367/368 (031-01774-000) & LQ10D421 DISPLAYS: .........................................................54NEC NL6448AC33-24 DISPLAY: ................................................................................................................54
SECTION 7 - DISPLAY BACKLIGHT INVERTER BOARD ...............................................................................56
SECTION 8 - KEYPAD .......................................................................................................................................59
SECTION 9 - POWER SUPPLY .........................................................................................................................62
SECTION 10 - ANALOG I/O EXPANSION BOARD 031-02472-000 ................................................................64COMMUNICATIONS LEDS ........................................................................................................................64
Electrical Connections ........................................................................................................................64Logic Voltage (Power) LED's ..............................................................................................................64 Active LED ...........................................................................................................................................65Analog Inputs .......................................................................................................................................65Analog Outputs ....................................................................................................................................65Troubleshooting the Analog Inputs ..................................................................................................65
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5JOHNSON CONTROLS
Form 160.67-M3 (108)
TABLE OF CONTENTS (CONT'D)REPLACING A DEFECTIVE ANALOG BOARD .........................................................................................66JUMPER AND DIPSWITCH SETTINGS .....................................................................................................71
SECTION 11 - TURBINE INSTRUMENTATION ................................................................................................72FREQUENCY TO ANALOG CONVERTERS ..............................................................................................72SPEED SWITCH .........................................................................................................................................72PRESSURE TRANSMITTERS ....................................................................................................................73RESISTANCE TEMPERATURE SENSORS AND TRANSMITTERS ..........................................................75RTD TEMPERATURE VS. RESISTANCE IN OHMS ...............................................................................77SHAFT VIBRATION PROBES AND TRANSMITTERS .............................................................................84PROBE REPLACEMENT ............................................................................................................................85
SECTION 12 - DIGITAL I/O EXPANSION BOARD 371-04182-000 ..................................................................86AC OUTPUT MODULES .............................................................................................................................87AC INPUT MODULES ................................................................................................................................87
SECTION 13 - COMPRESSOR PROXIMITY PROBE .......................................................................................93TWO PIECE PROXIMITY PROBE ..............................................................................................................94
Installation ............................................................................................................................................94SECTION 13A - COMPRESSOR HIGH SPEED THRUST BEARING LIMIT SWITCH .....................................98
SECTION 14 - REFRIGERANT LEVEL CONTROL ........................................................................................100AUTOMATIC ZONE LEVEL CONTROL OPERATION .............................................................................100MANUAL OPERATION .............................................................................................................................101ACTUATORS .............................................................................................................................................102
SECTION 15 - COMPRESSOR OIL PUMP VARIABLE SPEED DRIVE .........................................................104AUTOMATIC OPERATION ........................................................................................................................104MANUAL OPERATION .............................................................................................................................105OIL HEATER OPERATION .......................................................................................................................106
SECTION 16 - MICROGATEWAY ....................................................................................................................108
SECTION 17 - PRESSURE TRANSDUCERS .................................................................................................110REPLACEMENT STALL PRESSURE TRANSDUCER ............................................................................112PRESSURE TRANSDUCER APPLICATIONS CHART ............................................................................112
SECTION 18 - TEMPERATURE THERMISTORS ...........................................................................................113
SECTION 19 - REMOTE SETPOINTS .............................................................................................................131HORSEPOWER LIMIT ..............................................................................................................................131
SECTION 20 - CAPACITY / ANTI-SURGE / OVERRIDE CONTROLS ..........................................................137OVERVIEW ................................................................................................................................................137FIXED SPEED CHILLER CAPACITY CONTROLS OPERATION ............................................................137FIXED SPEED CHILLER LOADING SEQUENCE ....................................................................................137FIXED SPEED CHILLER UNLOADING SEQUENCE ...............................................................................138
Fixed Speed - PRV Unloading .........................................................................................................138Fixed Speed - Hot Gas Ratio Unloading .........................................................................................138Fixed Speed - HGV Temperature Controller Unloading .................................................................138
FIXED SPEED - CHILLER OVERRIDE CONTROLS ...............................................................................138Fixed Speed - High and Low Refrigerant Pressure Override .......................................................138Fixed Speed - Turbine Governor Position Horsepower Limiting Override ..................................139Fixed Speed - Turbine Horsepower Limiting Override ...................................................................139
VARIABLE SPEED CHILLER CAPACITY CONTROLS OPERATION .....................................................139VARIABLE SPEED CHILLER LOADING SEQUENCE ............................................................................140
Variable Speed - Hot Gas Mode Loading ........................................................................................140Variable Speed -PRV Mode Loading ................................................................................................140Variable Speed - Speed Mode Loading ............................................................................................140
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JOHNSON CONTROLS6
Form 160.67-M3 (108)
TABLE OF CONTENTS (CONT'D)
VARIABLE SPEED CHILLER UNLOADING SEQUENCE .......................................................................140Variable Speed - Speed Mode Unloading ........................................................................................140Variable Speed - PRV Mode Unloading ...........................................................................................141Variable Speed - Hot Gas Mode Unloading .....................................................................................141
VARIABLE SPEED CHILLER OVERRIDE CONTROLLERS ...................................................................141Variable Speed - High and Low Refrigerant Pressure Override ....................................................141Variable Speed - Turbine Governor Position Horsepower Limiting Override ..............................142Variable Speed - Turbine Horsepower Limiting Override ..............................................................142
SECTION 20A - CAPACITY CONTROL DEVICES ........................................................................................143HOT GAS BYPASS OVERVIEW ..............................................................................................................143
Hot Gas Bypass Automatic Operation ............................................................................................144Hot Gas Bypass Manual Operation ..................................................................................................144
PRE-ROTATION VANES OVERVIEW .......................................................................................................144Pre-rotation Vanes Automatic Operation ........................................................................................146Pre-rotation Vanes Manual Operation .............................................................................................146
SPEED CONTROL OVERVIEW ................................................................................................................147Speed Control Automatic Operation ...............................................................................................147Speed Control Manual Operation .....................................................................................................147
SECTION 21 - SMART FREEZE PROTECTION .............................................................................................149
SECTION 22 - VARIABLE GEOMETRY DIFFUSER .......................................................................................151STALL DETECTION ..................................................................................................................................151EARLY VINTAGE YST ...............................................................................................................................151AUTOMATIC OPERATION ........................................................................................................................151MANUAL OPERATION .........................................................................................................................152SETPOINTS ...............................................................................................................................................152PRE-ROTATION VANES POSITION .........................................................................................................152I/O BOARD ................................................................................................................................................153VGD OVERIDE OPERATION ....................................................................................................................153
Stall Sensor Validation ......................................................................................................................153Extreme Stall Monitor ........................................................................................................................153PRV VGD Inhibit Setpoint .................................................................................................................153VGD Limit Switch ...............................................................................................................................153
SECTION 23 - SYSTEM CALIBRATION, SERVICE SETPOINTS AND RESET PROCEDURES ..................156PID TUNING ..............................................................................................................................................156
Setpoint (SP) ......................................................................................................................................156Proportional (P) .................................................................................................................................156Integral (I) .......................................................................................................................................156Derivative (D) ..................................................................................................................................156Offset (O) .........................................................................................................................................157
TUNING PROCEDURE OVERVIEW .........................................................................................................157SPEED CONTROL TUNING .....................................................................................................................157
Tuning in the Variable Speed Mode .................................................................................................157Tuning in the Fixed Speed Mode .....................................................................................................158
ANTI-SURGE TUNING ..............................................................................................................................158Anti-Surge (Minimum Speed) Tuning ..............................................................................................159Anti-Surge (Minimum Vane Position) Tuning ..................................................................................159The default tuning values are as follows: .......................................................................................159
TESTING TO DETERMINE ANTI-SURGE TUNING ................................................................................159PRE-ROTATION VANES CALIBRATION .................................................................................................161
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7JOHNSON CONTROLS
Form 160.67-M3 (108)
LOAD DEFAULTS .....................................................................................................................................161FREQUENCY TO ANALOG CONVERTER CALIBRATION .....................................................................162
Factory Calibration ............................................................................................................................162Speed Input Calibration ....................................................................................................................162Kenwood FG-273A Frequency Generator, Front Panel Functions ..............................................163Frequency-to-Analog Converter Test Wiring ..................................................................................164Confi guring the IFMA ........................................................................................................................164Operating Mode (Analog Output) .....................................................................................................164On-Line Input Range Setting Using Actual Input Signal or Frequency Generator. .....................165Input Range Setting Using the Rotary Switch ................................................................................166Minimum Response Time Setting High Freq ..................................................................................167Maximum Response Time Setting (Low Frequency Cut-Out Setting) ..........................................167Calibration ..........................................................................................................................................168Calibration Direction .........................................................................................................................169Calibration Example (Scaling) ..........................................................................................................170
COMPRESSOR PROXIMITY PROBE ......................................................................................................170Calibration: .........................................................................................................................................171Reference Position Entry: .................................................................................................................171Safety Shutdown Reset/Inspection Procedure: .............................................................................171Reset Procedure: ...............................................................................................................................171
COMPRESSOR HIGH SPEED THRUST BEARING LIMIT SWITCH .......................................................171REFRIGERANT LEVEL AND LEVEL SENSOR CALIBRATION ..............................................................172
Enabled/Disabled: .............................................................................................................................172Setpoints: ...........................................................................................................................................172Changing Setpoints ...........................................................................................................................172Level Sensor Calibration: .................................................................................................................173
COMPRESSOR OIL PUMP VARIABLE SPEED DRIVE ..........................................................................174Setup: .................................................................................................................................................174Setpoints: ..........................................................................................................................................174Manual Control: ................................................................................................................................174
STANDBY LUBRICATION ........................................................................................................................174HIGH CONDENSER PRESSURE WARNING THRESHOLD ...................................................................175BRINE LOW EVAPORATOR PRESSURE CUTOUT ................................................................................175DROP LEG REFRIGERANT TEMPERATURE .........................................................................................175SMART FREEZE PROTECTION ..............................................................................................................176EVAPORATOR REFRIGERANT TEMPERATURE ...................................................................................176HOT GAS BYPASS CONTROL ................................................................................................................176
Enabled/Disabled: .............................................................................................................................176CHILLER STARTS AND OPERATING HOURS RESET ...........................................................................176SERVICE PHONE NUMBERS ..................................................................................................................176SALES ORDER DATA ...............................................................................................................................177CUSTOM USER ID AND PASSWORDS ...................................................................................................178RECORD SETPOINT CHANGES .............................................................................................................178FLOW SWITCH .......................................................................................................................................179MICROBOARD 031-02430-004 SETUP/CONFIGURATION ...................................................................179VARIABLE GEOMETRY DIFFUSER ........................................................................................................180
Enable/Disable: ..................................................................................................................................180VGD Count: ........................................................................................................................................180Setpoints: ...........................................................................................................................................180Manual Control: ................................................................................................................................181
TABLE OF CONTENTS (CONT'D)
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JOHNSON CONTROLS8
Form 160.67-M3 (108)
TABLE OF CONTENTS (CONT'D)
TURBINE ROTATING (SPEED SWITCH) CALIBRATION .......................................................................182Con guring the IFMR ........................................................................................................................182Relay Indication .................................................................................................................................182Operating Mode .................................................................................................................................183On-Line Trip Frequency Setting Using Actual Input Signal or Frequency Generator. ................183Set Trip Frequency Using the Rotary Switch ..................................................................................184Set Minimum Response Time ...........................................................................................................185Set Relay Trip Point (Offset) .............................................................................................................186Set Relay Release Point (Hysteresis) ..............................................................................................187
RESISTANCE TEMPERATURE TRANSMITTERS FUNCTION DESCRIPTIONS ...................................187Open Sensor Detection .....................................................................................................................187Calibration Malfunction .....................................................................................................................187Field Calibration ................................................................................................................................188Field Calibration with an Accurate Adjustable Resistance Source ..............................................188Basic Calibration (Factory Calibration) ...........................................................................................189
TURBINE NOZZLE SOLENOID SETUP ...................................................................................................190ANALOG EXPANSION BOARD CALIBRATION ......................................................................................190
Calibration Procedure for Channels 21 and 22 ...............................................................................191Calibration Procedure for Channels 1-8, 10-13, 16-20 and 23 .......................................................192Calibration Procedure for Channel 7 ...............................................................................................192Calibration Procedure for Channels 1-4, and 8. .............................................................................193Calibration Procedure for Channels 5 and 6. ..................................................................................193
SECTION 24 - DIAGNOSTICS & TROUBLESHOOTING ...............................................................................194MAIN DIAGNOSTICS SCREEN ................................................................................................................195KEYPAD TEST ..........................................................................................................................................196DISPLAY TEST ..........................................................................................................................................197SERIAL INPUTS / OUTPUTS TESTS .......................................................................................................200DIGITAL INPUTS / OUTPUTS TESTS ......................................................................................................202
Procedure ...........................................................................................................................................202 Digital Inputs: ............................................................................................................................202 Digital Outputs: .........................................................................................................................203 Digital Inputs Troubleshooting: ..............................................................................................204 Digital Outputs Troubleshooting: ...........................................................................................205
ANALOG INPUTS TESTS .........................................................................................................................206DIGITAL I/O EXPANSION TESTS .............................................................................................................208
Digital I/O ............................................................................................................................................208 Digital Inputs: ............................................................................................................................209General Checks: ...............................................................................................................................210
ANALOG I/O EXPANSION TESTS ...........................................................................................................212Analog Inputs .....................................................................................................................................212 Trouble Shooting Faulty Speed Inputs ...................................................................................213 Trouble Shooting Resistance Temperature Sensors and Transmitters ..............................213 Trouble Shooting Shaft Vibration Probes and Transmitters ...............................................214Analog Outputs ..................................................................................................................................214General Checks: ...............................................................................................................................215
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9JOHNSON CONTROLS
Form 160.67-M3 (108)
FIG. 1 OPTIVIEW CONTROL CENTER ...................................................................................................15FIG. 2 OPERATION SEQUENCE TIMING DIAGRAM (MANUAL START) .............................................16FIG. 2A OPERATION SEQUENCE TIMING DIAGRAM (AUTOMATIC START) .....................................17FIG. 3 MICROBOARD 031-02430-004 ....................................................................................................30FIG. 4 PROGRAM CARD 031-02501-001 ...............................................................................................31FIG. 5 MICROBOARD (031-02430-004) DC POWER SUPPLY TEST POINTS .....................................31FIG. 6 MICROBOARD LAMP DIMMER CIRCUIT ....................................................................................32FIG. 7 MICROBOARD SERIAL DATA COMMUNICATIONS PORTS .....................................................33FIG. 8 CONFIGURABLE ANALOG & REMOTE SETPOINT INPUTS ....................................................34FIG. 9 I/O BOARD 031-01743-002 ..........................................................................................................39FIG. 10 I/O BOARD DIGITAL INPUTS .....................................................................................................40FIG. 11 I/O BOARD TYPICAL OPTO-COUPLER CIRCUIT ....................................................................41FIG. 12 I/O BOARD TYPICAL FIELD CONNECTIONS ...........................................................................41FIG. 13 I/O BOARD DIGITAL OUTPUTS .................................................................................................42FIG. 14 DISPLAY, MOUNTING .................................................................................................................48FIG. 15 LIQUID CRYSTAL DISPLAY ASSEMBLY SHARP LQ10D367/368 (031-01774-000) DISPLAY ..........................................................................................................49FIG. 16 LIQUID CRYSTAL DISPLAY ASSEMBLY SHARP LQ10D421 DISPLAY ...............................49FIG. 17 LIQUID CRYSTAL DISPLAY ASSEMBLY NEC NL6448AC33-24 DISPLAY ...........................50FIG. 18 LIQUID CRYSTAL DISPLAY ASSEMBLY - LG SEMICON LP104V2-W (031-02046-000) ........51FIG. 19 LIQUID CRYSTAL DISPLAY TYPICAL CONTROL SIGNAL TIMING ........................................51FIG. 20 DISPLAY (SHARP LQ10D367/368) LAMP REPLACEMENT (031-02046-000) .........................52FIG. 21 DISPLAY (SHARP LQ10D421) LAMP REPLACEMENT ............................................................52FIG. 22 DISPLAY (NEC NL6448AC33-24) LAMP REPLACEMENT .......................................................53FIG. 23 DISPLAY (LG SEMICON LP104V2-W (031-02046-000)) LAMP REPLACEMENT ....................53FIG. 24 DISPLAY INTERFACE BOARD ..................................................................................................55FIG. 25 DISPLAY BACKLIGHT INVERTER BOARD (SHARP LQ10D367/368 (031-01774-000) & LG SEMICON LP104V2-W (031-02046-000)) .........................................................................57FIG. 26 DISPLAY BACKLIGHT INVERTER BOARD (SHARP LQ10D421) ............................................58FIG. 27 DISPLAY BACKLIGHT INVERTER BOARD (NEC NL6448AC33-24) .......................................58FIG. 28 KEYPAD ......................................................................................................................................60FIG. 29 KEYPAD ......................................................................................................................................61FIG. 30 POWER SUPPLY ........................................................................................................................62FIG. 31 POWER SUPPLY DC POWER DISTRIBUTION .....................................................................63FIG. 32 ANALOG I/O EXPANSION BOARD 031-02472-000 ..................................................................67FIG. 33 ANALOG I/O EXPANSION BOARD INTERFACE ......................................................................68FIG. 34 ANALOG I/0 EXPANSION BOARD - BLOCK DIAGRAM ..........................................................70FIG. 35 PRESSURE TRANSMITTER ......................................................................................................74FIG. 36 TEMPERATURE TRANSMITTER WIRING CONNECTIONS .....................................................76FIG. 37 TURBINE OIL TEMPERATURE SENSOR (025-36755-000) ......................................................83FIG. 38 TURBINE BEARING TEMPERATURE SENSOR (025-38784-000) ...........................................83FIG. 39 INLET STEAM TEMPERATURE SENSOR (025-39545-000) .....................................................83FIG. 40 DIGITAL I/O EXPANSION BOARD .............................................................................................88
LIST OF FIGURES
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JOHNSON CONTROLS10
Form 160.67-M3 (108)
FIG. 41 DIGITAL I/O EXPANSION BOARD BLOCK DIAGRAM ........................................................89FIG. 42 DIGITAL I/O EXPANSION BOARD INTERFACE ...................................................................90FIG. 43 DIGITAL I/O EXPANSION BOARD PLUG-IN MODULES TYPICAL CIRCUITS ..................92FIG. 44 COMPRESSOR PROXIMITY PROBE INTERFACE-PROBE PART NUMBER 025-35900-001 .................................................................................................95FIG. 45 COMPRESSOR PROXIMITY PROBE - PART NUMBER 025-35900-001 ..................................95FIG. 44A PROXIMITY PROBE INTERFACE PROBE PART NUMBER 025-40496-000 ......................96FIG. 45A COMPRESSOR PROXIMITY PROBE (PART NUMBER 025-40496-000) ...............................97FIG. 46 COMPRESSOR HIGH SPEED THRUST BEARING LIMIT SWITCH - INTERFACE .................98FIG. 46A COMPRESSOR HIGH SPEED THRUST BEARING LIMIT SWITCH .......................................99FIG. 47 REFRIGERANT LIQUID LEVEL SENSOR ...............................................................................102FIG. 48 REFRIGERANT LIQUID LEVEL CONTROL - INTERFACE ....................................................103FIG. 49 COMPRESSOR OIL PUMP VARIABLE SPEED DRIVE (VSD) ................................................106FIG. 50 COMPRESSOR OIL PUMP VSD / OIL HEATER CONTROL INTERFACE ...........................107FIG. 51 COMPRESSOR OIL PUMP VSD SPEED CONTROL SIGNAL ................................................107FIG. 52 MICROGATEWAY INTERFACE ................................................................................................108FIG. 53 PRESSURE TRANSDUCERS ................................................................................................... 111FIG. 54 LEAVING CHILLED LIQUID TEMPERATURE .........................................................................114FIG. 55 RETURN CHILLED LIQUID TEMPERATURE .........................................................................119FIG. 56 RETURN AND LEAVING CONDENSER (COOLING) LIQUID .................................................122FIG. 57 COMPRESSOR OIL AND DISCHARGE TEMPERATURE .......................................................125FIG. 58 DROP LEG REFRIGERANT SENSOR .....................................................................................130FIG. 59 EVAPORATOR REFRIGERANT SENSOR ...............................................................................130FIG. 60 HOT GAS BYPASS CONTROL - INTERFACE ........................................................................145FIG. 61 VARIABLE GEOMETRY DIFFUSER - INTERFACE .................................................................154FIG. 62 VARIABLE GEOMETRY DIFFUSER STATE DIAGRAM ..........................................................155FIG. 63 KENWOOD MODEL FG-273A FREQUENCY GENERATOR ...................................................163FIG. 64 FREQUENCY-TO-ANALOG CONVERTER TEST WIRING ......................................................164FIG. 65 MAIN DIAGNOSTICS SCREEN ................................................................................................195FIG. 66 KEYPAD TEST SCREEN ..........................................................................................................196FIG. 67 DISPLAY TEST MAIN SCREEN ...............................................................................................197FIG. 68 BIT PATTERNS TEST SCREEN ...............................................................................................198FIG. 69 SERIAL INPUTS / OUTPUTS TEST SCREEN .........................................................................200FIG. 70 MICROBOARD - COM 5 SERIAL DATA PORT ........................................................................201FIG. 71 DIGITAL INPUTS / OUTPUTS TEST SCREEN ........................................................................202FIG. 72 ANALOG INPUTS TEST SCREEN ...........................................................................................206FIG. 73 DIGITAL I/O EXPANSION TEST SCREEN ...............................................................................208FIG. 74 ANALOG I/O EXPANSION TEST SCREEN ..............................................................................212
LIST OF FIGURES (Cont)
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11JOHNSON CONTROLS
Form 160.67-M3 (108)
1This document explains the operation of the printed cir cuit boards and major components of the OptiView Con trol Cen ter to a level that allows a Service Tech ni cian to trou ble shoot and locate the source of a prob lem.
The overall system architecture is described and il lus trat ed with block diagrams. This describes the general function of each component and provides the system in ter face and signal fl ow. The function of each com po nent and signal fl ow between components must be un der stood before effective troubleshooting can com mence.
The operation of each printed circuit board is de scribed and illustrated with a block diagram that is a simplifi ed representation of board circuitry. The expected voltage level at all inputs and outputs of each board for any operating condition is provided.
Included in this document are procedures that have to be performed at chiller commissioning or during ser vice. They should not be performed by anyone other than a Service Technician. For example, cal i bra tion pro ce dures have to be performed or verifi ed at sys tem com mis sion ing or when a component is replaced. Certain safety shutdowns require special reset pro ce dures to be performed before the chiller can be re start ed. Since the op er at ing program sup plied in each OptiView Con trol Center is universal to all ap pli ca tions, Special Setpoints, Program Jumpers and Program switches are required to con fi g ure the chiller for local operating con di tions.
A System Commissioning Checklist is provided as ref er ence of items to be performed during chiller com mis sion ing.
In addition to this document, several levels of sup port ing documentation are required while servicing the sys tem. Field Control Modifications Diagram 160.67-PW2 pro vides details of the interface to remote devices. Operation Manual 160.67-O1 explains the operation of the OptiView Control Center keypad, how to enter setpoints and ex plains all the messages displayed on the OptiView Control Cen ter display. Wir ing diagram 160.67-PW6 provideS the con nec tions between the print ed circuit boards and com po nents within the OptiView Control Center.
SECTION 1 - INTRODUCTION
When the chiller shuts down on a SAFETY or CY- CLING shutdown or is being prevented from starting, a mes sage is displayed providing the reason for the shut- down. This message, along with all the chiller op er at ing con di tions at the instant of the event are stored in the Microboard battery-backed memory. This history data can be displayed or printed using an optional print er. The Operation Manual 160.67-O1 provides a detailed description of this mes sage, including the con di tions re quired to produce the message and conditions required to restart the chiller.
Diagnostic Routines allow service analysis of the following functions:
Display Analog Inputs Digital Inputs Digital Outputs Serial Data Ports
Before beginning any troubleshooting, observe the shut down message and retrieve the HISTORY data of that event. Refer to the Operation Manual for an ex pla na tion of the message. The conditions required to pro duce the message must be clearly understood before pro ceed ing. (If this is not heeded, much time will be wast ed). Armed with a knowledge of the overall sys tem architecture and the function of each printed cir cuit board and signal fl ow provided by this manual, pro ceed with the appropriate wiring diagram listed above to trace the problem through the system. Use the Di ag nos tic Routines where appropriate.
-
JOHNSON CONTROLS12
Form 160.67-M3 (108)System Ar chi tec ture
SECTION 2 - SYSTEM ARCHITECTURE
The OptiView Control Center performs the following functions:
Controls chiller capacity to chill liquid to the chilled liq uid temperature setpoint.
Controls chiller solenoid valves, relays, ac tu a tors and motor contactors per the operating program.
Displays chiller operating conditions, alarms, shut down messages and history data.
Accepts operator-programmed setpoints and con trols the chiller accordingly.
Allows Manual control of chiller motor contactors and actuators.
Monitors chiller operating conditions and shuts down chiller when Safety or Cycling thresh olds are ex ceed ed.
Allows local Manual start/stop and accepts start/stop commands from remote devices, via contact clo sures or serial communications.
Allows setpoints to be changed from a remote lo ca tion via 0-10VDC, 2-10VDC, 0-20mA, 4-20 mA, con tact clo sures or se ri al com mu ni ca tions.
Provides chiller operating data and status to re mote devices via serial communications and con tact clo sures.
Allows real-time data and history data to be print ed on an optional printer.
Controls the turbine speed from slow roll warm-up through the ramp up to rated speed.
The OptiView Control Center is a microprocessor based control system that receives analog, digital and serial data in puts and controls analog, digital and serial data outputs per instructions in the operating program. A panel mount ed display and touch-sensitive keypad per mit lo cal operation.
System refrigerant and compressor oil pressures are sensed by pressure transducers. The out put of each transducer is a DC volt age that is anal o gous to the pressure input. System cooling refrigerant, chilled and cooling liquid tem per a tures are sensed by thermistors. The out put of each ther mistor is a DC voltage that is analogous to the tem per a ture it is sens ing. Typical output voltage range of both is 0.5 to 4.5VDC. These are analog inputs to the Microboard in the OptiView Control Center.
Turbine oil and steam pressures are sensed by pressure transmitters. The output of each transmitter is a 4-20 mA DC current that is analogous to the pressure input. Turbine oil, bearing, and steam temperatures are sensed by 100 Ohm platinum resistance temperature detectors. Each RTD is connected to a Temperature Transmitter located in the turbine box on the chiller which converts the resistance changes to a 4-20 mA DC signal analogous to a specifi c range of temperature sensed by the RTD. These are analog inputs to the Analog I/O Expansion Board in the OptiView Control Center.
Turbine shaft vibration (when supplied) is sensed by Proximity Probes monitoring two planes of shaft move-ment on each end of the turbine. Compressor casing vibration (when supplied) is sensed by Accelerometers monitoring two planes of vibration on the compressor rotor support. Each sensor is connected to a Vibration Transmitter located in the turbine box on the chiller which converts the vibration to 4-20 mA DC signals analogous to a specifi c range of vibration sensed by the Proximity Probe or Accelerometer. These are ana-log inputs to the Analog I/O Expansion Board in the OptiView Control Center.
Digital Inputs are on/off inputs to the OptiView Con trol Center in the form of switch and relay contacts. These inputs are 115VAC when the contacts are closed and 0VAC when open. These include fl ow switches, local start/stop switch, remote cycling and high pres sure safe ty de vice, etc. Digital Outputs are on/off outputs from the OptiView Control Cen ter in the form of relay contacts and triacs. The re lay con tacts typically switch 115VAC and the triacs typ i cal ly switch a nominal 30VAC. relay out puts include status/alarm, chill er solenoid valves, oil heater, oil pump starter and chilled and condenser wa ter pump starters, etc. Triac outputs include pre-ro ta tion vane control and Vari able Geometry Diffuser (VGD) control. Serial Data is transmitted to and received from de vic es in RS-232, RS-485 and TX/RX (opto-couple) form.
The OptiView Control Center supports three types of starters; Electro-Mechanical Starter, Solid State Start er and Variable Speed Drive. However, all OptiView
-
13JOHNSON CONTROLS
Form 160.67-M3 (108)
2
Control Centers contain the following standard com po nents, regardless of the starter type applied:
Microboard I/O (Input/Output) Board Keypad Display Power Supply Analog I/O Expansion Board Digital I/O Expansion Board
Fig. 1 is the YST OptiView Control Center block diagram. On the block diagram, the stan dard components are shown, along with all the optional I/O points that support the available optional equipment. Fig ures 2 and 2A are operation sequence timing diagrams of the applications available.
The microprocessor and all supporting logic circuits, along with the memory devices containing the op er at ing pro gram, reside on the Microboard. All chiller op er at ing de ci sions are made here. It receives analog and dig i tal in puts from the chiller and remote devices and provides both analog and digital outputs as well. The analog in puts are con-nected directly to the Microboard and also received via the Analog I/O Expansion Board (see be low). The digital inputs are received via the I/O Board (see below) and the Digital I/O Expansion Board (see below). digital inputs are routed through both the I/O Board and the Digital I/O Expansion Board. Analog outputs are routed through the An a log I/O Ex pan sion Board.
The control center on YST chillers is equipped with Microboard 031-02430-004. The program resides in non-removable onboard memory. The software version is C.OPT.14.xx.yzz, and is viewable on the DIAGNOSTICS screen in SERVICE access level. The program can be upgraded by downloading a new program from a Program Card. Program Cards are shirt-pocket-size portable memory storage devices available from YORK.
The software version C.OPT.12.xx.yzz is an alphanumeric code that is interpreted as follows. Each time the controls section or language section is revised, the respective revision level increments.
C Commercial chiller OPT - Used on Microboard 031-02430-000 12 YST chiller
xx - controls revision level (00, 01, etc) y language package (0=English only, 1=NEMA,
2=CE, 3=NEMA/CE ) zz language package revision level (00, 01, etc)
The I/O Board acts as an input/output device for the Microboard. It conditions the digital input signals for the Microboard and contains relays and triacs that are con trolled by the Microboard to control solenoids, mo tor contactors and actuators. The 115VAC digital in puts from switch and relay contacts are converted to logic level voltages by Opto-Couplers. The relays have +12VDC coils that are energized and de-energized by the Microboard. The contacts of these relays control the 115VAC system solenoids, relays and motor contactors. The triacs are turned on and off by the Microboard. The outputs of these triacs control ac tu a tors.
YST chillers are equipped with I/O Board 031-01743-002. This board is populated with the required Triacs Q3 and Q4 that apply the open and close signals to the Variable Geometry Diffuser ring actuator. Refer to Variable Geometry Diffuser Section 22A. Relay K6, K7, K8, and K9 are also included to provide additional outputs required for control of turbine and steam condenser components.
The Analog I/O Expansion Board provides ad di tion al analog input/output capability for the Microboard. This board is actually a small microprocessor board and is programmed to control analog outputs, or accept ana-log inputs, from external electrical devices. It has the capability of 24 independent input channels. These I/O channels are dedicated through the software and external wring, as to the function of each channel. Each channel is confi gured by the software for the type of device that is connected to it. The data is transferred to/from the Microboard via an RS-485 serial interface. The analog input values are converted to digital words prior to transfer to the Microboard. The analog output values are transferred from the Microboard in digital word form and con vert ed to analog values on this board.
The Digital I/O Expansion Board provides ad di tion al digital input/output capability for the Microboard. It ac cepts AC volt age inputs and provides AC voltage outputs. Removable input modules and out put modules confi gure each point ap pro pri ate ly. The digital values are transferred to/from the Microboard via an RS-485 serial interface.
-
JOHNSON CONTROLS14
Form 160.67-M3 (108)System Ar chi tec ture
A front panel-mounted Keypad allows Operator and Ser vice Technician user interface. Membrane keys are used to display chiller and system parameters, enter setpoints and perform chiller and OptiView Control Center di ag nos tics. It also contains a START-RUN-STOP/RE SET switch that is used to locally start and stop the chill er and per form manual reset functions.
A front panel mounted liquid crystal Display allows graph ic animated display of the chiller, chiller sub systems and system parameters. The chiller and work ing com po nents of the chiller are displayed, along with chiller operating pressures and temperatures. The key pad is used to select displays showing increasing levels of de tail of chiller working components.
A self-contained Power Supply supplies the nec es sary DC volt ag es for all the components within the OptiView Control Cen ter.
Style F (and later) chillers are supplied with factory-mounted fl ow sensors on the evaporator and condenser. These are electronic thermal-type sensors. The operating principle of the sensor is thermal conductivity. It uses the cooling effect of a fl owing liquid to sense fl ow. The temperature of the heated sensor tip is sensed by a thermistor located in the tip. A second thermistor, located higher in the tip in a non-heated area, is only affected by changes in liquid temperature. The temperatures sensed by the thermistors are compared. Flowing liquid carries heat away from the heated sensor tip, lowering its temperature. The lower temperature differential between the two thermistors indicates the liquid is fl owing. A higher differential indicates no fl ow. These sensors are interfaced to Microboard analog inputs. Refer to Section 3 for a detailed explanation of this fl ow sensor and interface.
FOR RETROFIT APPLICATIONSThe various chiller style/compressor combinations are equipped differently and have different control requirements. The variables include: Flow Sensor Differential Pressure type,
Paddle type or Factory Mounted Thermal type. The Differential Pressure and Paddle types apply 115 VAC to the I/O Board Digital inputs TB4-12 (evaporator) and TB4-11 (condenser) (refer to Fig. 10). The Factory Mounted Thermal type (available with Style F and later chillers), applies +5VDC to the Microboard analog inputs at J7-14 (evaporator)
and J7-16 (condenser) (refer to Fig. 8). The YST software allows use of either the Thermal type or the Paddle type fl ow sensors on Style F and later chillers. With these versions, the actual fl ow sensor type present must be entered using the Flow switch Setpoint (refer to Section 23).
Hot Gas Bypass Valve - In order to use the analog output on the Analog I/O Expansion Board, this must be set for Enabled on the Operations screen.
Subcooler Level Control - In order to use the analog output on the Analog I/O Expansion Board, this must be Enabled on the Operations screen. If this is set for Disabled, the analog output is fi xed at 100% (10V).
Variable Geometry Diffuser (VGD) - This may be set for Enabled or Disabled on the Operations screen. Refer to Section 22.
Compressor Oil Pump Package - Style C and earlier chillers are equipped with Fixed Speed Oil Pumps. Style D and later chillers are equipped with Variable Speed Oil Pumps. This selection is made on the SETUP screen. See Section 23.
Serial data interface to the YORK ISN Building Au to -ma tion System is through the optional MicroGateway. This print ed circuit board re quests the re quired data from the Microboard and makes it avail able for the ISN net work. Certain compressors are equipped with a Variable Geometry Diffuser (VGD). It is used to reduce rotating stall conditions and associated stall noise. Stall may occur at low load conditions with high head. A mechanical ring, located in the compressor diffuser passage is operated to open or close the diffuser gap. Stall noise is detected as gas pressure pulsations. A Stall Pressure Transducer, mounted in the discharge scroll of the compressor, detects the gas pressure pulsations and outputs DC voltage pulsations to the Stall Detector Board. This board converts the voltage pulsations into an analog voltage that represents the magnitude of the stall noise. This analog voltage is input to the Microboard where it is compared to thresholds that determine if the stall noise is acceptable or unacceptable. The VGD is pulsed toward the closed position in response to unacceptable stall noise. Otherwise, it is modulated to maintain the most open position possible without stall occurring.
-
15JOHNSON CONTROLS
Form 160.67-M3 (108)
2
FIG
. 1
OPT
IVIE
W C
ON
TRO
L C
ENTE
RLD
1005
7A
VAR
IAB
LE G
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ME
TRY
DIF
FUS
ER
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M B
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LEN
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+5V
DC
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EX
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+12V
DC
/-12V
DC
/+5V
DC
TO
AN
ALO
G I/
O
EX
PAN
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N B
OA
RD
+12V
DC
/-12V
DC
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TO
MIC
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BO
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BIN
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RY
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PU
MP
CO
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TAC
TS
-
JOHNSON CONTROLS16
Form 160.67-M3 (108)System Ar chi tec ture
TIMING DIAGRAM (MANUAL START)
FIG
. 2
OPE
RAT
ION
SEQ
UEN
CE
TIM
ING
DIA
GR
AM
(MA
NU
AL
STA
RT)
NO
TES
: 1.
Te
xt in
quo
tatio
ns in
dica
tes
a D
ispl
ay M
essa
ge.
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rt-U
p Ti
me,
Run
Tim
e, S
oft S
hutd
own
Tim
e, a
nd S
yste
m C
oast
dow
n Ti
me
will
var
y de
pend
ing
on th
e sy
stem
con
ditio
ns a
nd p
rogr
amm
able
set
poin
ts.
3.
Spe
eds
and
times
sho
wn,
if p
rogr
amm
able
, are
sho
wn
with
Def
ault
valu
es.
4.
Dur
ing
the
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Tim
e, th
e O
pera
ting
Spe
ed m
ay b
e an
ywhe
re fr
om 3
200-
4500
RP
M d
epen
ding
on
Load
and
Sys
tem
Ope
ratin
g C
ondi
tions
. 5.
O
nly
appl
icab
le to
the
follo
win
g sh
utdo
wns
: Lo
w W
ater
Tem
pera
ture
, Rem
ote/
Loca
l Cyc
ling
(TB
4-13
), R
emot
e S
top
(TB
4-8)
, Rem
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p (IS
N S
eria
l Por
t).
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rato
r ini
tiate
d S
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hutd
own.
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ING
5
00
1500
1000
3000
3200
4000
4500
RA
MP
ING
TO
RAT
ED
SP
EE
D
TIM
E IN
SE
CO
ND
S(M
INU
TES
)
SP
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RP
M
CO
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SE
R L
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SW
ITC
H B
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UM
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N
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(30.
0)36
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RT
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ED
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UM
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N
EN
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OO
LER
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UID
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AC
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OR
S
TU
RB
INE
S
TAB
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ING
SY
STE
M R
UN
MA
N. O
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UM
PD
ISA
BLE
DE
NE
RG
IZE
TU
RB
INE
TRIP
SO
LEN
OID
LD12
576
-
17JOHNSON CONTROLS
Form 160.67-M3 (108)
2
TIMING DIAGRAM (AUTOMATIC START)
FIG
. 2A
O
PER
ATIO
N S
EQU
ENC
E TI
MIN
G D
IAG
RA
M (A
UTO
MAT
IC S
TAR
T)LD
1257
7
NO
TES
: 1.
Te
xt in
quo
tatio
ns in
dica
tes
a D
ispl
ay M
essa
ge.
2.
Sta
rt-U
p Ti
me,
Run
Tim
e, S
oft S
hutd
own
Tim
e, a
nd S
yste
m C
oast
dow
n Ti
me
will
var
y de
pend
ing
on th
e sy
stem
con
ditio
ns a
nd p
rogr
amm
able
set
poin
ts.
3.
Spe
eds
and
times
sho
wn,
if p
rogr
amm
able
, are
sho
wn
with
Def
ault
valu
es.
4.
Dur
ing
the
Run
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-
JOHNSON CONTROLS18
Form 160.67-M3 (108)Microboard
All new production YST chillers are supplied with Microboard part number 031-02430-004 (refer to Fig. 3).
The board is supplied with +12VDC (J1-3), -12VDC (J1-4), +5VDC (J1-1) and ground (J1-2) from the Power Supply (ref fi g 5). The -12VDC is not used. The +5VDC (fused by F1) can be monitored at TP3. It is applied to a +3.3VDC regulator, +2.5VDC regulator and used directly by the Microboard circuits as the Vcc voltage. The outputs of these regulators are applied to Microboard circuits and can be monitored at TP2 and TP5 respectively. The +12VDC (fused by F2) can be monitored at TP4. It is applied to a +5VDC regulator and used directly by Microboard circuits. The output of the regulator is the +5VDC (analog) supply that pow-ers all analog circuits and is the source voltage for all transducers and thermistors. It can be monitored at TP10 as a 2.5VDC value created by 1K Ohm resistors voltage divider circuit as shown.
TEST POINTS(Ref Fig 5)The power supply voltages can be measured at following test points:
TP1 GNDTP2 +3.3VDCTP3 +5VDCTP4 +12VDC TP5 +2.5VDC TP10 +2.5VDC
BOOT-UP PROGRAMThe BIOS (Basic Input Output System) EPROM (U37) contains the boot-up program. It is a replaceable part. The YORK part number is 031-02429-002. This BIOS is required to enable the fl oating point unit (FPU) in the processor for the YST chiller horsepower limit-ing algorithm. It is available from the Baltimore Parts Distribution Center as a replacement part. The version
is an alphanumeric code that identifi es the application and the program revision level. The part number and version are printed on a label adhered to the surface of the EPROM. It is also displayed on the DIAGNOSTICS screen in SERVICE access level.
The version is as follows:
When power is fi rst applied to the OptiView Control Center, a white screen is displayed while the boot-up is performed. During the boot-up, the program in the BIOS EPROM confi gures the microprocessor and related com-ponents and performs testing of certain components to assure those components are operational.
The sequence of events in the boot-up process are listed in the "Diagnostics Display Codes" table. The progress and pass/fail status of each step is displayed on the Microboard 7-segment LED display (U22). Due to the speed at which the boot-up proceeds, not all steps will be visible during the process. Not all pass/fail status is displayed on the white screen. CHILLER OPERATING PROGRAMThe Chiller Operating Program is a set of instructions to control the chiller. It contains the Safety and Cycling shutdown thresholds (non-changeable) and display screen messages and graphics.
Microboard
SECTION 3 - MICROBOARD 031-02430-004(REFER TO FIGS. 3-8)
C. OPT. 00. NN.
Revision level. In cre ments 01, 02 etc.
BIOS EPROM
OptiView Control Center Commercial chiller
-
19JOHNSON CONTROLS
Form 160.67-M3 (108)
3
TESTPASSCODE
FAIL ACTION DISPLAY ON
WHITE SCREEN
First init table complete 00 Watchdog will cause reboot NoSDRAM regs. Confi gured 01 Watchdog will cause reboot NoSwitch to Protected Mode 02 Watchdog will cause reboot NoJump to 32-bit code 03 Watchdog will cause reboot NoLow memory test start 04 Watchdog will cause reboot NoLow memory test complete P1 F1 on display and halt NoFull memory test complete P2 F2 on display and halt NoFPGA confi guration 05 P2 will remain on LED display NoDisplay Cont. confi gured 06 05 will remain on LED display NoFlash Checksum Test P3 F3 will remain on LED display YesBRAM test P4 F4 will remain on LED display YesFlash Query Test passed failed and halt YesFlash checksum passed failed,halt & display code = F3 YesBRAM Test passed failed and halt Yes
MISCELLANEOUS CODESLED DISPLAY CODE Description
FF FPGA Confi guration Failed, trying againCH Flash Checksum Test in progressAP Application setup in progress
CRITICAL CODESLED DISPLAY CODE Description
Ni NMI handler invoked (should never occur)[ ] GPF has occurred (should never occur)
DIAGNOSTIC DISPLAY CODES
The Chiller Operating Program is stored in a non-removable Flash Memory chip (U35) that is soldered to the Microboard. New chillers are supplied programmed with the latest program available at the time of manufacture. The program version that is currently residing in the Microboard Flash Memory chip is displayed on the DIAGNOSTICS screen in SERVICE access level. The on-board program can be upgraded by downloading the latest version from a Program Card using the procedure in the Service Replacement section of this manual.
PROGRAM CARDThe on-board program can be upgraded by downloading the latest program version from a Program Card. This is a 2 1/8 x 3 3/8 x 1/8 inch plastic card weighing 1.1oz
(refer to Fig. 4). It is a portable memory storage device that is programmed with the Chiller Operating Program. The Program Card part number for YST chillers is 031-02501-001 and is available from the Baltimore Parts Distribution Center (PDC). A label affi xed to the Program Card contains the part number and version. The version is an alpha-numeric code that identifi es
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