Johnson Controls Frick vyper VYA PG -46 Service Manual
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Johnson Controls Frick vyper VYA PG -46 Service Manual

Johnson Controls Frick vyper VYA PG -46 Service Manual

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305 / 254 Horsepower
437 / 362 Horsepower
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,
AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER
Please check www.johnsoncontrols.com for the latest version of this publication.
Form S100-200 IOM (MAY 2008)
INSTALLATION - OPERATION - MAINTENANCE
File:
Replaces:
Dist:
OPERATION OF THE UNIT.
SERVICE MANUAL - Section 70
S100-200 IOM (NOV 2007)
3, 3a, 3b, 3c

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  • Page 1 Form S100-200 IOM (MAY 2008) INSTALLATION - OPERATION - MAINTENANCE File: SERVICE MANUAL - Section 70 Replaces: S100-200 IOM (NOV 2007) Dist: 3, 3a, 3b, 3c 305 / 254 Horsepower 437 / 362 Horsepower THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND MAINTENANCE INSTRUCTIONS.

  • Page 2: Table Of Contents

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 2 INSTALLATION - OPERATION - MAINTENANCE Contents ELECTRICAL CONDUITS ..........21 PREFACE ................3 WIRING DIAGRAM OPTIONS ........21 JOB INSPECTION .............3 MOTOR Thermistor PROTECTION .........21 TRANSIT DAMAGE CLAIMS ..........3 MOTOR RTD THERMAL PROTECTION ......22 UNIT IDENTIFICATION .............3 TEMPERATURE CONTROL VALVE WIRING ....22 INSTALLATION ..............4...

  • Page 3: Preface

    Request immediate inspec tion by the agent of the jury or death. carrier and be sure the proper claim forms are executed. Contact Johnson Controls-Frick, Sales Administration Depart ment, in Waynesboro, PA to report dam age or short- age claims. NOTE: Damage must be photographically...

  • Page 4: Installation

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 4 INSTALLATION RIGGING AND HANDLING Installation ™ The Vyper cabinet unit is best moved via lifting lugs on the FOUNDATION top sides of the cabinet. Special care must be exercised not to damage the pump or peripheral equipment on the rear of ™...

  • Page 5: General Description

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INSTALLATION Page 5 GENERAL DESCRIPTION In addition, the drive is capable of operating without a load for ease of service. ™ The Vyper serves as the motor starter and capacity control •...

  • Page 6: Coolant Temperature Limits

    • A dV/dt fi lter must be installed on remote-mounted units • Johnson Controls-Frick recommends a closed-loop system with motor power lead lengths between 3 to 50 feet. for the water side of the heat exchanger.

  • Page 7: Heat Exchanger Pressure Drop

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INSTALLATION Page 7 Figure 3 - Minimum Flow Rates - GLYCOL HEAT EXCHANGER PRESSURE DROP exchanger must be known. Figure 4 provides installation designers with pressure drop reference for different mixtures In order to adequately size piping and booster pump require- of propylene glycol and water.

  • Page 8: Power Wiring

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 8 INSTALLATION POWER WIRING Unshielded cable is acceptable if it can be separated from sensitive circuitry. Allow a spacing of 12 inches for every ™ Power wiring conductor and ground wiring for the Vyper 33 feet of length.

  • Page 9: Transformers

    At start-up, both the motor and slide valve begin to load to 3 phase, 50 Hz. a preset value. Johnson Controls offers a line of Recommended Vyper NOTE: There is a 30 second delay at initial start-up to VSD Transformers. These transformers have the following ™...

  • Page 10: System Operating Conditions

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 10 INSTALLATION fi elds, which are transmitted through the air. EMI refers to cooled heatsink. The use of the SCRs in the semiconverter electrical currents, which are conducted in wiring connected confi...
  • Page 11 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INSTALLATION Page 11 NOTE: Drawings for specifi c units can be found in the door of the Vyper drive or check with Frick Engineering department. Figure 6 - Vyper ™ Elementary Wiring Diagram...
  • Page 12 S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 12 INSTALLATION A HARMONIC FILTER (See Figure 8) and high frequency the Harmonic fi lter. The IGBT transistor module contains a ™ trap may be added to a Vyper system. The harmonic fi lter thermistor temperature sensor (RT3) that provides tempera- is designed to meet the IEEE Std 519 -1992, “IEEE Recom- ture information back to the Harmonic Filter Logic Board via...
  • Page 13 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INSTALLATION Page 13 NOTE: Typical! Check with engineering for latest drawings. Figure 8 - Harmonic Filter Elementary Wiring Diagram...

  • Page 14: Configuration

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 14 INSTALLATION ™ CONFIGURATION: sociated with the Vyper coolant temperature reading. These wil also be factory set for a Low Temp. alarm and shutdown ™ The Frick Vyper is internally cooled with a factory calibrated at 85°F and 80°F with a 90 second delay, when running.

  • Page 15: Liquid Cooled Vyper P & I Diagram-Economized

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INSTALLATION Page 15 Liquid Cooled Vyper P & I Diagram Economized...

  • Page 16: Liquid Cooled Vyper P & I Diagram-Noneconomized

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 16 INSTALLATION Liquid Cooled Vyper P & I Diagram Noneconomized...

  • Page 17: Package-Mounted Vyper

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INSTALLATION Page 17 ™ ™ PACKAGE-MOUNTED VYPER The Vyper cabinet is mounted on a rectangular welded steel channel, which provides both an attachment point for ™ The package-mounted version of the Frick Vyper performs the cabinet’s side brackets, and also helps to maintain the identically to the remote-mounted versions.

  • Page 18: Vyper Preinstallation Site Checklist

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 18 INSTALLATION ™ VYPER PREINSTALLATION SITE CHECKLIST (Where Applicable) Before attempting to install a Vyper ™ Drive system, please perform a site inspection to assure that the following require- ments are met....................

  • Page 19: Power And Control Wiring Entry Locations

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INSTALLATION Page 19 POWER AND CONTROL WIRING ENTRY LOCATIONS Dimensions in Inches * Drive HP 305/254 1.63 4.50 9.00 6.38 4.38 35.00 5.50 3.56 6.63 2.00 437/362 6.63 6.75 10.13 2.00 3.25 40.53 2.25...

  • Page 20: External Power And Control Wiring

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 20 INSTALLATION EXTERNAL POWER AND CONTROL WIRING the interior of the cabinet. Be sure to leave enough relief in the leads so no undue stresses are transferred to the motor External power and control signals must be brought in and connection location in the interior of the unit.

  • Page 21: Electrical Conduits

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INSTALLATION Page 21 ™ cutout on the back wall of the Vyper cabinet (See Figure 15). • Oil pump motor wiring must be in a separate metallic Output power connections should be tightened as shown in conduit.

  • Page 22: Motor Rtd Thermal Protection

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 22 INSTALLATION MOTOR RTD THERMAL PROTECTION Figure 17 TEMPERATURE CONTROL VALVE WIRING Figure 18...

  • Page 23: Motor Cooling Blower Wiring

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INSTALLATION Page 23 MOTOR COOLING BLOWER WIRING Figure 19 DRAWING NOTES Figure 20...

  • Page 24: Analog Board Wiring

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 24 INSTALLATION ANALOG BOARD WIRING Figure 21...

  • Page 25: Quantum Lx Communications Wiring

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INSTALLATION Page 25 ™ QUANTUM LX COMMUNICATIONS WIRING INSTALLATION CHECK LIST ™ ™ Figure 22 shows the junction points for the Quantum Before starting the Vyper , be sure that all of the following panel control wiring into the Vyper ™...

  • Page 26: Three Installation Steps

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 26 INSTALLATION b. Verify power wiring has been connected at the correct connection points and properly seated in accordance with the engineering drawings for the specifi c installation. c. Separate grounded metal conduits must be provided for input power, output power, and control wiring.
  • Page 27 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INSTALLATION Page 27 Figure 27 - Step 3, Opening the Drain Valve Figure 30 - Step 6, Top Off the Cooling System Figure 31 - Step 7, Replace the Pipe Plug and Tighten Step 7: Replace and tighten the plug on the top of the mani- Figure 28 - Step 4, Close the Drain and Refi...

  • Page 28: Operation

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 28 OPERATION When the slide valve reaches the Capacity Control Slide OPERATION Valve setpoint, the motor speed can increase. At this point the slide valve and motor speed can continue to increase ™...
  • Page 29 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ OPERATION Page 29 Figure 33 - Home Screen Service Level 2: Press the [Menu] Button then Select Operating Values from the Flydown Figure 34 - Home Screen Service Level 2: Select Vyper From the Menu ™...
  • Page 30 S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 30 OPERATION Figure 35 - Home Screen Service Level 2: Select Vyper Drive Setup Figure 36 - Home Screen Service Level 2: Select Vyper Drive Setup Vyper ™ screen Service Level 2 is similar to Level 1 but adds permits fast acceleration when the load returns.
  • Page 31 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ OPERATION Page 31 Figure 37 - Harmonic Filter Screen Clear VSD Memory: Clear the existing trending values in “0” - no /off “1” - yes / on the Vyper ™ memory. •...

  • Page 32: Quantum Lx Panel Set Up

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 32 OPERATION The following parameters display status information desig- • Interface Board Version nated by: • VSD Version “0” - no / off “1” - yes / on • Modbus Node ID •...

  • Page 33: Setting The User Level

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ OPERATION Page 33 Figure 39 - Setting User Level Figure 40 - Home Screen After Changing to Service Level 2 SETTING THE USER LEVEL Return to the menu and the Home screen. The home screen will now provide additional information as shown in Press: [Menu→Session].

  • Page 34: Programming

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 34 OPERATION PROGRAMMING is selected under the package Drive fi eld. This will allow the ™ Vyper specifi c screens to be displayed (See Figure 41). ™ ™ Verify that the Vyper is set to Quantum LX control.

  • Page 35: Pid Setup

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ OPERATION Page 35 PID SETUP Press: [Setpoints→PID Setup] Figure 43 - PID Setup Drive cooling is set to PID Channel #5. Use the table below to program the proper settings. Parameter Value Name Drive Cooling...

  • Page 36: Setting The Motor Screen

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 36 OPERATION SETTING THE MOTOR SCREEN Press: [Setpoints→Motor] Figure 44 - Motor Screen Nameplate “Applied Motor FLA” Calculation These fi elds should be populated with the motor nameplate information. This is for reference only. Mtr Nameplate SF=1.0 Mtr Nameplate FLA / 1.15 Mtr Nameplate SF=1.15...
  • Page 37 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ OPERATION Page 37 Example 2 Table B Parameter Equation Value What are the High Motor Amp setpoints if a 437 HP Vyper ™ is to drive a motor with 1.15 SF and a 534 Amp FLA? Using Load Inhibit = Vyper Amp Limit x 0.97 the Values, determine whether Table A or Table B should be...
  • Page 38 S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 38 OPERATION Example 3 Example 4 ™ What are the High Motor Amp setpoints if a 305 HP Vyper is What are the High Motor Amp setpoints if a 437 HP Vyper to drive a motor with 1.00 SF and a 340 Amp FLA? Using is to drive a motor with 1.00 SF and a 552 A FLA? Using the Values, determine whether Table A or Table B should be...

  • Page 39: Vfd And Capacity Control Settings

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ OPERATION Page 39 VFD and Capacity Control Settings setting works in conjunction with the Cycle Time setting to provide variability in the desired speed change step rate. The This section of the motor page provides programmable pa- Vyper ™...
  • Page 40 S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 40 OPERATION Example 1 - Suggested Control Strategy for 5 to 1 (5:1) Turndown Figure 45 - 5:1 Turndown Suggested Control Strategy Example 1 (Figure 45) depicts the 5 to 1 (5:1) control strategy, Figure 46 provides the VFD and Capacity Control setpoints which is characterized by rapid response to highly dynamic typical for the operation shown in Figure 45.
  • Page 41 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ OPERATION Page 41 Compressor Safeties Screen To prevent the Slide Valve from unloading beyond a high setpoint level (97%) and permit rapid compressor response under load, make the following setting adjustments on the Compressor Safeties Screen: Step 1: Press the [MENU] key and then selecting “Setpoints”...
  • Page 42 S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 42 OPERATION Example 2 - Suggested Control Strategy for Standard 2 to 1 (2:1) Turndown Figure 48 - 2:1 Turndown Suggested Control Strategy The standard 2:1 Turndown Control Strategy is depicted in NOTE: The Variable Speed Minimum Slide Valve Position Figure 48.
  • Page 43 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ OPERATION Page 43 Figure 50 - Capacity Control Setpoints Screen With the actual pressure at 21 psig the proportional com- This control strategy is a variation on the generic control ponent would be 20%. The Proportional Component is strategy shown previously.

  • Page 44: Setting The Job Fla

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 44 OPERATION SETTING THE JOB FLA ™ The fi nal item for setup of the Vyper is adjusting the Job FLA via trim pot on the Vyper ™ Logic board. The trim pot sets a value for the Job Full Load Amps (FLA).

  • Page 45: Frick Interface Boarddip Switch Settings

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ OPERATION Page 45 Figure 53 - Vyper ™ Level 2 Screen FRICK INTERFACE BOARD DIP SWITCH SETTINGS (Used before Jan 2008) ™ On the Frick Interface Board (Figure 54) on the Vyper right door there is a dip switch array.
  • Page 46 S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 46 MAINTENANCE The callouts on Figures 56 and 57 point out components, indicators and test points that can be used to aid in maintenance amd troubleshooting of fault codes. DC Voltage Test Points 24VAC Input Gate Drive Connections J8, J9 &...

  • Page 47: Maintenance

    1000 volts AC & DC. Frick certifi ed technicians. All service on this equipment should Power module replacement procedure: be performed by Johnson Controls -certifi ed service personnel only. ™ 1. Be certain the Vyper has been de-energized for over fi ve...

  • Page 48: Replacement Of The Vyper Harmonic Filter Module

    Electrical levels still be loose. within the unit can cause serious injury or death. Please call Johnson Controls-Frick for trained service personnel ™ 13. Align the Vyper power module so that the (6) Phillips head to work on your unit.

  • Page 49: Addendum

    VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ MAINTENANCE Page 49 ™ ™ When is a booster pump required on a Vyper compres- VYPER ALARMS / SHUTDOWNS sor drive? ™ In addition to the Alarms and Shutdowns that the Quantum The Frick Vyper ™...

  • Page 50: Frick Vyper Fault Codes

    S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 50 MAINTENANCE ™ FRICK VYPER FAULT CODES Fault 5: Interface Board Panel Communications Loss ™ Quantum Message Quantum ™ LX Failure Message Failure Code Quantum: “Fault 5” VSD Interface Board Power Supply Fault Quantum LX: “VSD Interface Board to Panel Comms Loss”...
  • Page 51 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ MAINTENANCE Page 51 Fault 9: Harmonic Filter - Logic Board Or Communications Fault 12: High Phase C Inverter Baseplate Temperature Message Message Quantum: “Fault 9 “ Quantum: “Fault 12” Quantum LX: “ Harmonic Filter Logic Board or Comms Fault “ Quantum LX: “High Phase C Inverter Baseplate Temperature”...
  • Page 52 S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 52 MAINTENANCE Same comments as Fault 17 except applying to Phase B Same comments as Fault 21 except applying to Phase C Instantaneous Current Gate Driver. Fault 19: High Phase C Instantaneous Current Fault 24: Vyper Single Phase Input Power Message Message...
  • Page 53 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ MAINTENANCE Page 53 The various DC power supplies which power the Logic Board Many times the actual bus voltage imbalance conditions are monitored via hardware located on the Logic Board. If are caused by a shorted capacitor or a leaky or shorted any of these power supplies fall outside their allowable limits, IGBT transistor in the power unit.
  • Page 54 S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 54 MAINTENANCE Upon receipt of either of the two run commands, a 5-second Fault 42: Vyperdrive - Serial Communication timer will start. If the missing run signal is not asserted within Message the 5-second window, the unit will trip and the Quantum ™...
  • Page 55 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ MAINTENANCE Page 55 Fault 44: Vyper ™ Low Converter Heat Sink Temperature bus voltage at the laminated bus structure, verify the wiring ™ ™ ™ between the Vyper Logic board and Quantum LX Vyper Message trigger board, and the input SCR’s, and the DC bus isolator...
  • Page 56 S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 56 MAINTENANCE Hz 519 fi lter and at least 41 VDC within 100 msec on the 50 Fault 52: Harmonic Filter High Phase B Current ™ Hz 519 fi lter. If not, the Quantum LX panel will display the Message message Fault 66.
  • Page 57 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ MAINTENANCE Page 57 The DC link voltage magnitude should remain within -80 VDC Fault 76: Harmonic Filter 110% Input Current Overload of the bus voltage setpoint determined from the peak input Message voltage.
  • Page 58 S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 58 MAINTENANCE Fault 83: Harmonic Filter Serial Communication (Warning Only) Message Quantum: “Fault 83” Quantum LX: “ Harmonic Filter Serial Communication (Warn- ing Only)” When requesting Status data, the response data from the Harmonic Filter includes a bit that indicates whether commu- nications were lost from the Vyper ™...
  • Page 59 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INDEX Page 59 Index Harmonic Filter Phase Locked Loop 56 Harmonic Filter Precharge High DC Bus Voltage 56 AC choke 49 Harmonic Filter Precharge Low DC Bus Voltage 56 Harmonic Filter Run Signal 57 Harmonic Filter Serial Communication 58 booster pump 7, 27, 49 High Converter Heat Sink Temperature 54...
  • Page 60 S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 60 INDEX jumper confi guration 54 IGBT 52 IGBT Module 53 kWh record 30 IGBT module 49 IGBT transistor 53 impedance 5 liquid-cooled 10 input fuses 52 Logic Board 53 INSTALLATION 3, 8 Low Condenser Flow 53 AC line choke 10...
  • Page 61 VYPER VARIABLE SPEED DRIVE S100-200 IOM (MAY 08) ™ INDEX Page 61 Applied motor FLA 38 RMS output 57 Applied Service Factor 38 running coolant 25 Automanual Switch 32 Average Current 31 saturation voltage 52 Baseplate Temperature 31 SCR 10, 49, 52, 54, 55 Capacity Regulations 34 SCR/Diode block 54 Clear Standby Time 30...
  • Page 62 S100-200 IOM (MAY 08) VYPER VARIABLE SPEED DRIVE ™ Page 62 NOTES...
  • Page 63 S100-200 IOM (MAY 08) VYPER ™ VARIABLE SPEED DRIVE Page 63 NOTES...
  • Page 64 Supersedes: S100-200 IOM (NOV07) 100 CV Avenue • P.O. Box 997 Subject to change without notice Waynesboro, PA USA 17268-0997 Published in USA • GUI 2C Phone: 717-762-2121 • FAX: 717-762-8624 www.johnsoncontrols.com © 2008 Johnson Controls Inc. - ALL RIGHTS RESERVED...

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