Johnson Controls Frick 572 Installation Operation & Maintenance Download Page 11

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100.210-IOM (FEB 2015)

Page 11

VYPER

™

VARIABLE SPEED DRIVE

INSTALLATION - OPERATION - MAINTENANCE

HARMONIC FILTER

The.VSD.system.may.include.an.harmonic.filter.designed.to.

meet.the.IEEE.Std.519.-1992,.“IEEE.Recommended.Practices.

and.Requirements.for.harmonic.Control.in.Electrical.Power.

Systems”..The.filter.is.offered.as.a.means.to.“clean.up”.the.

input.current.waveform.drawn.by.the.VSD.from.the.power.

mains,.thus.reducing.the.possibility.of.causing.electrical.inter-

ference.with.other.sensitive.electronic.equipment.connected.

to.the.same.power.source.
Figure.3.is.a.plot.of.the.typical.input.current.waveform.for.the.

VSD.system.without.the.harmonic.filter.when.the.system.is.

operating.at.50%.load..Figure.4.is.a.plot.of.the.typical.input.

current.waveform.for.the.VSD.system.with.the.harmonic.filter.

installed. when. operating. at. the. same. load. conditions.. The.

plots.show.that.the.input.current.waveform.is.converted.from.

a.square.wave.to.a.fairly.clean.sinusoidal.waveform.when.the.

filter.is.installed..In.addition,.the.power.factor.of.the.system.

with.the.harmonic.filter.installed.corrects.the.system.power.

factor.to.nearly.unity.
The.power.section.of.the.harmonic.Filter.is.composed.of.four.

major.blocks:.a.precharge.section,.a.“trap”.filter.network,.a.

three.phase.inductor.and.an.IGBT.Phase.Bank.Assembly...See.

the.elementary.wiring.diagram.in.Figures.5A.and.5B.for.wiring.

and.component.reference

The Precharge Section

.is.formed.by.three.resistors.(11RES.

-.13RES).and.two.contactors,.the.precharge.contactor.(2M),.

and.the.supply.contactor.(3M)..The.precharge.network.serves.

two.purposes,.to.slowly.charge.the.DC.link.filter.capacitors.

associated. with. the. filter. Phase. Bank. Assembly. (via. the.

diodes.within.the.IGBT.modules.Q13-Q18).and.to.provide.a.

means.of.disconnecting.the.filter.power.components.from.

the.power.mains..When.the.drive.is.turned.off,.both.contac-

tors.are.dropped.out.and.the.filter.phase.bank.assembly.is.

disconnected.from.the.mains.
When.the.drive.is.commanded.to.run,.the.precharge.resistors.

are.switched.into.the.circuit.via.contactor.2M.for.a.fixed.time.

period.of.five.(5).seconds..This.permits.the.filter.capacitors.

in.the.phase.bank.assembly.to.slowly.charge..After.the.five-

second. time. period,. the. supply. contactor. is. pulled. in. and.

the.precharge.contactor.is.dropped.out,.permitting.the.filter.

phase.bank.assembly.to.completely.charge.to.the.peak.of.the.

input.power.mains..Three.power.fuses.(11FU.-13FU).connect.

the.filter.power.components.to.the.power.mains..Very.fast.

semiconductor. power. fuses. are. utilized. to. ensure. that. the.

IGBT.modules.do.not.rupture.if.a.catastrophic.failure.occurs.

on.the.DC.link.of.the.filter.phase.bank.assembly.

The “Trap” Filter

. is. composed. of. a. series. of. capacitors.

(C84-C92),.inductors.(4L-6L).and.resistors.(16RES-18RES)..

The.“trap”.filter.acts.as.a.low.impedance.for.a.range.of.fre-

quencies.centered.at.the.PWM.switching.frequency.of.the.

filter.(20.khz)...The.purpose.of.the.trap.is.to.block.currents.

at. the. switching. frequency. of. the. filter. from. getting. onto.

the.power.mains.

The Three-Phase Inductor

. provides. some. impedance. for.

the. filter. to. “work. against”.. The. inductor. effectively. limits.

the.rate.of.change.of.current.at.the.input.to.the.filter.to.a.

reasonable.level.

The IGBT Phase Bank Assembly

. is. the. most. complicated.

power.component.in.the.harmonic.filter..The.purpose.of.the.

assembly.is.to.generate.harmonic.currents.required.by.the.

drive’s.AC.to.DC.converter.so.that.these.harmonic.currents.

are. not. drawn. from. the. power. mains.. The. phase. bank. is.

composed.of.a.series.of.IGBT.modules.(Q13-Q18).mounted.to.

a.liquid-cooled.heatsink,.a.filter.capacitor.“bank”.(C67-C76).

and.an.IEEE.519.Filter.Gate.Driver.board.(031-01786).which.

provides.the.On.and.Off.gating.pulses.to.the.IGBT’s.as.de-

termined.by.the.519.Filter.Logic.board..In.order.to.assure.an.

equal.sharing.of.the.voltage.between.the.series.connected.

capacitors.on.the.filter.bank,.“bleeder”.resistors.14RES.and.

15RES.are.connected.across.the.banks..In.order.to.counteract.

the.parasitic.inductances.in.the.mechanical.structure.of.the.

phase.bank,.the.filter.incorporates.“laminated.bus”.technology.

and.a.series.of.small.film.capacitors.(C77-C83)..The.technology.

used.is.identical.to.that.used.in.the.VSD’s.DC.to.AC.inverter.

section.of.the.drive..
Various.ancillary.sensors.and.circuit.boards.are.used.to.convey.

information.back.to.the.harmonic.filter.logic.board..The.fol-

lowing.list.describes.some.of.these.components.

•. A.thermistor.temperature.sensor,.RT5,.is.mounted.onto.the.

liquid-cooled.heatsink.to.provide.temperature.information.

•. Current. Transformers. 6T. and. 7T. sense. the. input. current.

drawn.by.the.VSD’s.AC.to.DC.converter.

•. DC. Current. Transformers. (DCCT1. and. DCCT2). sense. the.

current.generated.by.the.harmonic.filter.

•. The.Line.Voltage.Isolation.Board.(031-02022).senses.the.

input.voltage.to.the.system,.steps.the.voltage.down.to.a.

safe.level.and.provides.isolation.between.the.Filter.Logic.

board.and.the.power.mains.

•. The.Bus.Isolation.Board.(031-01624).incorporates.three.re-

sistors.to.provide.a.“safe”.impedance.between.the.DC.filter.

capacitors.located.on.the.phase.bank.assembly.and.the.filter.

logic.board..The.bus.isolation.board.provides.the.means.to.

sense.the.positive,.midpoint,.and.negative.connection.points.

of.the.filter’s.DC.link.

Summary of Contents for Frick 572

Page 1: ...INS RIGGING ASSEMBLY START UP AND MAINTENANCE INSTRUCTIONS READ THOROUGHLY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH DAMAGE TO THE UNIT OR IMPROPER OPERATION 700 60 Hz 572 50 Hz Horsepower 912 60 Hz 752 50 Hz Horsepower Please check www jci com frick for the latest version of this publication ...

Page 2: ...PACKAGE MOUNT 32 VYPER WIRING AND WIRING DIAGRAMS 33 QUANTUM LX COMMUNICATIONS WIRING 33 MOTOR THERMAL PROTECTION OPTIONS 33 VYPER PRE OPERATION SITE CHECKLIST 36 BLOWER MOTOR ROTATION 37 COOLANT CONTAMINATION AND PROPERTIES 37 ADDING AND REPLACING COOLANT 38 OPERATION QUANTUM LX CONTROL PANEL 41 VYPER OPERATION 41 QUANTUM LX PANEL SETUP 42 ACCESSING THE VYPER SETUP 42 SETTING USER LEVEL 43 CONFIG...

Page 3: ...igure 44 Quantum LX Compressor Configuration Screen 44 Figure 45 Communications Screen 45 Figure 46 PID Setup Screen Page 2 46 Figure 47 Operating Values Menu 47 Figure 48 Pulldown for Vyper Screen 47 Figure 49 Vyper Screen 48 Figure 50 Harmonic Filter Screen 49 Figure 51 Low Motor Amps 50 Figure 52 Motor Screen 50 Figure 53 High Motor Amps 51 Figure 54 Ex 1 Motor Amps Safety Calculation Table 51 ...

Page 4: ...igh current and voltage electrical equipment should be strictly enforced JOB INSPECTION Immediately upon arrival of the unit examine all crates boxes and exposed compressor and component surfaces for damage Unpack all items and check against shipping lists for any possible shortage Examine all items for damage from unit transit TRANSIT DAMAGE CLAIMS All claims must be made by consignee This is an ...

Page 5: ...er 400 Volts Package Mount 7 5 HP Oil Pump VYF_RH_S 50 720C0168G19 572 HP Water Cooled 400 Volts Remote Mount 3 HP Oil Pump VYF_RH_M 50 720C0168G20 572 HP Water Cooled 400 Volts Remote Mount 5 HP Oil Pump VYF_RH_L 50 720C0168G21 572 HP Water Cooled 400 Volts Remote Mount 7 5 HP Oil Pump VYF_RHFS 50 720C0168G22 572 HP Water Cooled w Filter 400 Volts Remote Mount 3 HP Oil Pump VYF_RHFM 50 720C0168G2...

Page 6: ...Environment in the INSTALLATION section of this manual Verify that all control power 120 VAC communications analog wiring and 460 VAC power are in separate metallic conduits Properly shielded and grounded analog cables are not required to be in EMT Vyper Pre Operation Site Check List Prior to Quantum LX setup and starting operation of the Vyper Drive system review the following checklist to ensure...

Page 7: ...the tables in this manual to calculate what they should be 7 Verify proper operation of the motorized coolant mixing valve on the back of the drive Locate the Coolant mixing valve on the back of the drive remove the cover from the motor and check that the dip switches are set as 1 ON 2 OFF 3 ON 4 OFF If a change needs to be made the power must be cycled at the panel for the change to be in effect ...

Page 8: ...citors in series to form a pair and then paralleling a suitable number of pairs to form a capacitor bank In order to assure an equal sharing of the voltage between the series connected capacitors and to provide a discharge means for the capacitor bank when the VSD is powered off bleeder resistors 3RES and 4RES are connected across the capacitor banks The DC to AC Inverter section of the VSD See Fi...

Page 9: ...9 VYPER VARIABLE SPEED DRIVE INSTALLATION OPERATION MAINTENANCE Figure 2A Vyper Elementary Wiring Diagram NOTE Drawings for specific units can be found in the door of the VyperTM Drive or check with Frick Engineering department ...

Page 10: ...10 VYPER VARIABLE SPEED DRIVE INSTALLATION OPERATION MAINTENANCE Figure 2B Vyper Elementary Wiring Diagram NOTE Drawings for specific units can be found in the door of the VyperTM Drive or check with Frick Engineering department ...

Page 11: ...tilized to ensure that the IGBT modules do not rupture if a catastrophic failure occurs on the DC link of the filter phase bank assembly The Trap Filter is composed of a series of capacitors C84 C92 inductors 4L 6L and resistors 16RES 18RES The trap filter acts as a low impedance for a range of fre quencies centered at the PWM switching frequency of the filter 20 kHz The purpose of the trap is to ...

Page 12: ...100 210 IOM FEB 2015 Page 12 VYPER VARIABLE SPEED DRIVE INSTALLATION OPERATION MAINTENANCE Figure 3 VSD Input Current Without Harmonic Filter Figure 4 VSD Input Current With Harmonic Filter ...

Page 13: ...PER VARIABLE SPEED DRIVE INSTALLATION OPERATION MAINTENANCE Figure 5A Harmonic Filter Elementary Wiring Diagram NOTE Drawings for specific units can be found in the door of the VyperTM Drive or check with Frick Engineering department ...

Page 14: ...PER VARIABLE SPEED DRIVE INSTALLATION OPERATION MAINTENANCE Figure 5B Harmonic Filter Elementary Wiring Diagram NOTE Drawings for specific units can be found in the door of the VyperTM Drive or check with Frick Engineering department ...

Page 15: ... crucial applications such as hospitals computer networks airports etc GENERAL OPERATION DESCRIPTION The Vyper serves as the motor starter and capacity control for a Frick screw compressor The Vyper controls capacity by reducing compressor speed and optimizing the compressor efficiency at all loads The Vyper varies the screw compressor speed by control ling the frequency and voltage of electrical ...

Page 16: ...100 210 IOM FEB 2015 Page 16 VYPER VARIABLE SPEED DRIVE INSTALLATION OPERATION MAINTENANCE Notes ...

Page 17: ...mounted on a Frick RWF II refrigeration package Individual systems configurations will vary according to model and horsepower sizes selected On package mounted units the Vyper cabinet is mounted on a rectangular welded steel channel which provides both an attachment point for the cabinet s side brackets and also helps to maintain the rigidity of the cabinet during service The channel assembly VSD ...

Page 18: ...100 210 IOM FEB 2015 Page 18 VYPER VARIABLE SPEED DRIVE INSTALLATION Figure 7 Vyper Cabinet and Stand ...

Page 19: ...ilter 130 F 54 C 135 F 57 C 145 F 63 C Baseplate Temp 160 F 71 C 165 F 74 C 175 F 79 C the foundation must be able to support the weight of the cabinet and base In addition the Vyper cabinet must be located so that no more than fifty 50 feet 15 meters of motor wiring length is needed between the VSD cabinet and the package motor The remote mounted units have fastener holes located on the bottom of...

Page 20: ...to perform normal service and maintenance work should be provided around the entire unit Figure 8 Minimum Flow Rates WATER An upstream strainer is recommended to stop particulate matter from entering the heat exchanger The strainer should be cleaned several times during the first twenty four hours of operation Refer to the charts in Figures 8 and 9 for minimum flow rates WATER RECOMMENDATIONS John...

Page 21: ...RE DROP 912 752 700 572 Models Figure 9 Minimum Flow Rates GLYCOL In order to adequately size piping and booster pump require ments the pressure drop of the coolant across the heat exchanger must be known Figure 10 provides installation designers with pressure drop reference for different mixtures of propylene glycol and water ...

Page 22: ...100 210 IOM FEB 2015 Page 22 VYPER VARIABLE SPEED DRIVE INSTALLATION Figure 11 Liquid Cooled Vyper P I Diagram Noneconomized Figure 12 Liquid Cooled Vyper P I Diagram Economized ...

Page 23: ...instructions thoroughly before beginning the project Make sure you have drawings and instructions with your equipment If not call the manufacturer and request the proper instructions and drawings Every manufacturer of elec tronic equipment should have a knowledgeable staff willing to answer your questions or provide additional information Following correct wiring procedures will ensure proper inst...

Page 24: ...ts to ground which could create Ground Loops In many installations that are having electronic control prob lems this essential wire is usually missing is not insulated or improperly sized NEC size ratings are for safety purposes and not necessarily for adequate relaying of noise EMI to earth ground to avoid possible interference with sensitive equipment Therefore sizing this conductor 1 2 sizes la...

Page 25: ... grounded Separation 0 33 feet 0 10 meters 12 inches 3 meters 33 66 feet 10 20 meters 24 inches 6 meters Since PVC conduit does absolutely nothing to protect lower voltage lines from the magnetic field effects of higher voltage conductors running either the lower or the higher voltage lines in PVC does not reduce these requirements on separation Only running in metal conduit can relieve these requ...

Page 26: ...panel that does not already have knockouts provided If knockouts are not provided for this purpose it is obvious this is not recommended and could VOID WARRANTY Never add relays starters timers transformers etc in side an electronic control panel without first contacting the manufacturer Contact arcing and EMI emitted from these devices can interfere with the electronics Relays and timers are rout...

Page 27: ...ouple of fault scenarios are 1 The 3 phase bus has power on and off in a continuous cycle manner which may cause the motor to overheat due to repeated exces sive in rush current experiences 2 The motor cycling may damage the coupling or cause other mechanical damage due to the repeated high torque from rapid sequential motor bumps 3 Prolonged low voltage may cause the motor to stall and possibly o...

Page 28: ... 175 5 6 1100 220 5 6 1470 275 5 6 1750 330 5 6 1990 440 5 5 6 5 2700 550 5 5 6 5 3100 660 5 5 6 5 3600 750 6 7 4600 880 6 7 5300 990 6 7 5800 1250 6 5 7 5 6200 1500 6 5 7 5 6800 1750 6 5 7 5 7500 2000 6 5 7 5 8200 POWER FACTOR CAPACITORS Power factor correction capacitors are not required since the Vyper has a 0 95 minimum power factor at all operational loads and conditions Capacitors can be loc...

Page 29: ...per circuitry Never use 120V supply to feed the VSD control wiring The Vyper has it s own internal power supply Using an external power supply may damage the Vyper and may also cause hazardous working conditions for service and operating personnel SYSTEM OPERATING CONDITIONS Refrigeration systems considered for Vyper application must be in good operating condition A site survey should be completed...

Page 30: ...be removed for the proper sized holes to be punched and then reinstalled For remote mounted cabinets the power exits through the top of a separate motor connection box The holes on this box can be punched in place since there is no chance for metal filings to fall into the electronics of the drive Under no circumstances is it acceptable to bring power into or take power out of a Vyper at any other...

Page 31: ...it requires the wiring to be properly installed in order to supply power to the unit for processing The Vyper also outputs processed power to the motor of a compressor package The two connection points are at the following locations INPUT POWER CONNECTION For remote mounted units the input power junction is lo cated on the upper left side of the cabinet See Figure 19 This location provides a junct...

Page 32: ...of a dV dt snubber filter between the Vyper and the motor to ensure a clean power signal into the motor OUTPUT POWER CONNECTION PACKAGE MOUNT Package mounted Vyper drives have a different output configuration than the remote mount Vyper The Package mounted Vyper uses 3 8 inch 0 375 in terminal lugs for the output power connection to the compressor motor Ap propriate motor lead hardware should be u...

Page 33: ... Figure 25 Quantum LX Communications Terminal Block QUANTUM LX COMMUNICATIONS WIRING Figure 25 shows the junction points for the Quantum LX panel control wiring into the Vyper cabinet This wiring location is in the lower left corner of the Vyper cabinet The control wiring enters the Vyper cabinet from the left side cabinet wall through a connection port MOTOR THERMAL PROTECTION OPTIONS The Nationa...

Page 34: ...D S LK10 LK8 A B B A LK17 LK7 LK6 LK2 LK5 LK3 LK4 LK8 LK16 422 485 COM1 BAT 1 B LK7 1 LK5 COM2 422 485 LK6 A TB2 4 3 2 2 3 4 LK2 PL10 PL1 2 1 3 COM2 COM2 FLASH SOCKET MEMORY MOD B B PL11 LK3 PL5 LK4 A A PL15 232 STANDARD LK1 KYPD TB3 SW1 FLAT PANEL HEAT SINK LK11 PL14 DC POW ANALOG BD P3 1 16 LK1 P8 CUR XFMR 640D0168H01 1 LK2 ROCKER OFF DOWN P1 LK3 LK4 SW1 1 8 P2 9 2 1 8 7 ñ COM 12 12 5 P4B 2 P4A ...

Page 35: ...100 210 IOM FEB 2015 Page 35 VYPER VARIABLE SPEED DRIVE INSTALLATION Figure 28 Thermistor Motor Protection Wiring Figure 29 RTD Motor Protection Wiring ...

Page 36: ...ing drawings for the specific installation b Verify power wiring has been connected at the correct connection points and properly seated in accor dance with the provided engineering drawings for the specific installation c Separate grounded metal conduits must be provided for input power output power and control wir ing Failure to provide separate conduits could result in disruption of other elect...

Page 37: ...ace with new If the color of the coolant turns a brown or green this indicates that a bacteria growth is taking place within the coolant If the coolant turns milky white or if the inside of the tubing has a white coating the nitrate concentration has fallen below 990 ppm This is an indication that the nitrate is corroding the inner surfaces of the cooling system and oxidizing the aluminum If any o...

Page 38: ...he internal passages free from contaminants The illustration in Figure 32 shows the cooling circuit of a remote mounted water cooled Vyper The cooling circuit for the glycol cooled version is identical Figure 32 Coolant Circulation System Prior to starting the Vyper for the first time drain and re place the shipping fluid from the Vyper cooling system with new running coolant appropriate for the t...

Page 39: ...ughout the system Allow the pump to run at least 5 minutes until all trapped air is purged from the coolant system Figure 37 VSD Logic Board Connection J2 Step 6 Figure 38 Top off the cooling system until the fluid level remains constant about one inch 25 mm from the top of the manifold Figure 38 Topping Off the Coolant Supply Step 7 Figure 39 Replace and tighten the plug on the top of the manifol...

Page 40: ...100 210 IOM FEB 2015 Page 40 VYPER VARIABLE SPEED DRIVE INSTALLATION OPERATION MAINTENANCE Notes ...

Page 41: ... will remain at its minimum speed until the slide valve loads above the capacity control Slide Valve setpoint If the slide valve cannot load due to a slide valve load inhibit condition or because the compres sor cannot build differential pressure particularly between suction and oil pressure the motor speed will increase to meet the capacity requirement When the slide valve reaches the capacity co...

Page 42: ...anel Additionally the Quantum LX control panel will control the Vyper Drive and compressor to the user defined parameters programmed at the control panel interface ACCESSING THE VYPER SETUP Specific options and setpoints must be configured at the Quantum LX control panel These settings will provide the Quantum LX with the necessary information to safely control the Vyper Drive and to shut the driv...

Page 43: ...re 42 Quantum LX Session Screen Step 2 See Figure 43 Once the User Level is programmed press the panel Enter and Submit keys to return to the Operating Status Screen As shown in Figure 42 the Operat ing Status Screen now shows additional information Figure 43 Quantum LX Operating Status Screen pull down menu Use the keypad to enter Service Level 2 under the User Level Parameter on the Session Scre...

Page 44: ...ate time and select the capacity regulations and miscellaneous setpoints as neces sary using the cursor arrow and Tab keys to move around the screen to each setpoint Press the Enter key to accept the new value for each setpoint 1 Figure 44 Quantum LX Compressor Configuration Screen Step 3 See Figure 44 At the Drive field under the Package heading verify the compressor with Vyper is programmed See ...

Page 45: ...g Setpoints and Communications Step 2 See Figure 45 Use the cursor arrow and Tab keys to navigate between setpoints Use the keypad to program the parameters listed in Table 12 under Comm1 Callout 1 at the Communications Screen Press the Enter key to accept each setpoint 1 Table 12 Comm1 Setpoints Comm 1 Parameter Setpoint Baud Rate 19200 Data Bits 8 Stop Bits 1 Parity None RS 485 Connection No Pro...

Page 46: ...gate between setpoints With the keypad program the parameters listed in Table 13 under PID 5 on the PID Setup Screen Press the Enter key to accept each setpoint Figure 46 PID Setup Screen Page 2 Table 13 PID Channel 5 Setpoints PID Parameter Value Name Drive Cooling Control Running Action Forward Control Point Vyper Coolant Device Source Analog Board 2 Device Channel 1 Setpoint 100 F Dead Band 0 0...

Page 47: ... and then selecting Setpoints and Operating Values using the down cursor arrow key Step 2 See Figure 48 The Operating Values menu al lows the operator to select the Vyper or Harmonic Filter Screen Select Vyper or Harmonic Filter and press the Enter key The display will show values accessible under User Level 2 Figure 47 Operating Values Menu Figure 48 Pulldown for Vyper Screen ...

Page 48: ...is function clears the accumulated kWh totals from the counter since the last reset The value returns to zero upon selecting this option The following Vyper screen parameters display measured values in accordance with the user defined unit selections Average Current Amps Current Phase A Amps Current Phase B Amps Current Phase C Amps Full Load Amps Output Frequency Hz Output Voltage Volts DC Bus Vo...

Page 49: ...rrent Leg 1 2 3 Amps Voltages L1 N L2 N L3 N L1 L2 L2 L3 L3 L1 Voltage Total Supply kVA kVA Total Power Factor Baseplate Temperature F or C DC Bus Voltage Volts Manual Speed Switch Status RPM Figure 50 Harmonic Filter Screen The status of the following parameters are indicated using a binary number next to the field description See Table 16 Supply Contactor Energized Precharge Contactor Energized ...

Page 50: ...plate Press the Enter key to accept the value for each field Figure 51 Low Motor Amps High Motor Amps See Figures 52 and 53 The setpoints in High Motor Amps section of the Motor Screen are critical to protect the compressor motor and drive from damage due to excessive current The operator calculates the values for these setpoints using the formulas in Tables 15 through 18 Step 1 See Table 15 Deter...

Page 51: ...Line 1 x Line 2 780 A 4 HP rating of Vyper Drive 700 HP 5 Vyper Amp Limit If Line 4 is 700 572 HP value is 880 A If Line 4 is 912 752 HP value is 1180 A 880 A 6 Multiply Line 5 x 1 05 924 A Figure 54 Ex 1 Motor Amps Safety Calculation Table The value of Line 3 is 780 Amps this is less than Line 6 Value of 924 Amps Therefore use Table A Table 17 for High Motor Amp setpoint calculation Refer to Figu...

Page 52: ...le B High Motor Amp Setpoint Calculations Parameter Equation Value Load Inhibit Vyper Amp Limit x 0 97 1144 A Force Unload Vyper Amp Limit 1180 A Warning Vyper Amp Limit x 1 01 1191 A Shutdown Vyper Amp Limit x 1 03 1215 A Figure 61 Ex 4 Motor Amp Setpoint Calculations Table B VFD Setpoints See Figures 52 and 62 This section of the Motor Screen describes programmable parameters that regulate the l...

Page 53: ... VSD control is obtained only by fixing the slide valve and modulating the capacity via Speed control The objective is to get the system into total speed control as quickly as possible and to maintain this strategy in the expected operating range This is accomplished by the use of the proportional control ramp profile during the period that the slide valve is loading This allows higher speeds and ...

Page 54: ...e is little or no proportional control present for this setting The slide valve remains loaded throughout the range of operation Capacity is totally controlled by motor speed Often the Vyper controlled screw compressor is used as a trim compressor handling the fluctuating portion of the load while used in combination with other reciprocating compressors for the base load This allows the required q...

Page 55: ...Mode Minimum Capacity Callout 2 Use the keypad to program the set points to 97 Press the Enter key to accept the value for each field Step 3 Press the Submit key to accept the changes and return to the operating status screen VFD Maximum Drive Output 100 Minimum Drive Output 20 Delay Rate of Increase 12 1 SEC Rate of Decrease 12 1 SEC Capacity Control The Drive Speed will increase and decrease pro...

Page 56: ... strategy described previously Not all applications require or are suitable for the very low speeds obtainable by the Vyper drive Many times the motor is the limiting factor and is not suitable for 20 speed but is capable of 50 speed For these applications the settings within the Quantum LX can assure that the motor never runs slower than the allowable minimum speed Figure 69 provides the VFD and ...

Page 57: ...sition to allow proper com munication Refer to Figure 72 Figure 72 Logic Board SW3 With the actual pressure at 21psig the proportional com ponent would be 20 The Proportional Component is calculated as Actual Value Setpoint PB x Maximum output Mini mum Output 21 20 4 x 100 20 20 When this proportional component is added to the minimum outpoint setpoint the total output is 40 proportionally at an a...

Page 58: ...per control to be set at Refrigeration mode Refer to callout 1 on Figure 73 for the location of JP3 on the logic board Figure 73 Vyper Logic Board There is also a dipswitch to select 60Hz or 50Hz depending on the application Ensure that it is properly set See callout 2 on Figure 73 SETTING THE JOB FLA The final item for operational setup of the Vyper is adjusting the Job Full Load Amps FLA calibra...

Page 59: ...ndicators RX TX Logic Board to Quantum LX 8 J16 Communications Cable Logic Board to Quantum LX 9 Communications Indicators RX TX Logic Board to Filter Board 10 J15 Communications Cable Logic Board to Filter Board 11 DC Bus Voltage Input 12 J2 Remove to manually engage circula tion pumps and internal fans 13 JOB FLA Potentiometer 14 Frequency Switch 60 50Hz 15 Output Current input Phase A B C The c...

Page 60: ...100 210 IOM FEB 2015 Page 60 VYPER VARIABLE SPEED DRIVE INSTALLATION OPERATION MAINTENANCE Notes ...

Page 61: ...e clear over time but cooling performance is not affected Do not dilute the premixed coolant Inspect the coolant and coolant level regularly and replace the coolant annually using the steps described previously in this manual Any time the coolant is removed from system always discard the old coolant and replace with new coolant Coolant that is any other color than pink or clear indicates bacterial...

Page 62: ...odule DO NOT tighten these screws 14 Tighten the Allen head screws to 48 in lb 5 5 Nm 10 in the numerical sequence shown in Figure 78 Figure 78 Power Module Screw Tightening Sequence 15 Install the three 3 power wire connector tabs using 6 Phillip head screws and torque the screws to 48 in lb 5 5 Nm 10 16 Remove the six 6 Phillips head screws not yet tight ened at the bus structure and install the...

Page 63: ... peak voltage as measured by an oscilloscope Phase to neutral is normally the phase to phase voltage divided by the square root of three or 265 VAC phase to neutral for a 460 VAC system The peak value of the 265 VAC measurement is approximately that number times the square root of two When is a booster pump required on a Vyper compres sor drive The Frick Vyper requires eight 8 foot of head for pro...

Page 64: ...ues can be seen on page 2 of the Analog Auxiliaries setpoints screens Default settings are 85 F for the warning 80 F for the shutdown NOTICE If the compressor has been down for an extended period and the ambient temperature is less than the Low Vyper Coolant Temp warning or shutdown values it may be necessary to lower these settings temporarily in order to get the drive running WARNING This setpoi...

Page 65: ...ce Board Power Supply Fault 3 VSD Interface Board Motor Current 15 4 VSD Interface Board Run Signal Fault 5 VSD Interface Board to Panel Comms Loss 7 VSD Initialization Fault 8 VSD Stop Contacts Fault 9 Harmonic Filter Logic Board Or Comms Fault 10 Harmonic Filter High Total Demand Distortion 11 VSD High Phase B Inverter Baseplate Temp 12 VSD High Phase C Inverter Baseplate Temp 13 VSD Low Phase B...

Page 66: ...t the filter is not operating cor rectly or the input current to the Vyper filter system is not sinusoidal This fault occurs when any one of the three phases of Total Demand Distortion TDD is greater than 25 0 for forty five continuous seconds while the Vyper is running TDD is defined by the IEEE Std 519 1992 standard as the total root sum square harmonic current distor tion in percent of the maxi...

Page 67: ... except applying to Phase B Instantaneous Current Fault 19 High Phase C Instantaneous Current Message Quantum Fault 19 Quantum LX VSD High Phase C Instantaneous Current Same comments as Fault 17 except applying to Phase C Instantaneous Current Fault 21 Vyper Phase A Gate Driver Message Quantum Fault 21 Quantum LX VSD Phase A Gate Driver Fault The unit s phase bank assembly shall contain one IGBT g...

Page 68: ... unit will trip and the Quantum LX Panel will display the fault message The Vyper Logic Board generates this shutdown and in dicates that one of the low voltage power supplies for the Vyper Logic Board has dropped below the allowable operat ing limits The power supplies for the logic boards are derived from the secondary of the 120 to 24 VAC transformer which in turn is derived from the 480 to 120...

Page 69: ...e Quantum LX panel and all other wiring involved in energizing 24 in the Vyper cabinet Also check to ensure that the serial communications wiring between the micro board and the Interface board and Vyper Logic board and the Interface board are connected properly Fault 39 Vyper High Converter Heat Sink Temperature Message Quantum Fault 39 Quantum LX VSD High Converter Heat Sink Temp Fault A thermis...

Page 70: ...F 3 C If the inverter baseplate tempera ture or the converter heat sink temperature falls below 37 F 3 C the message displayed is Fault 44 In addition if both temperatures fall below the 37 F 3 C limit the unit will trip and the fan s and water pump will be energized This feature provides service personnel with the ability to run the water pump while filling the cooling system by pulling VSD logic...

Page 71: ...gs should be less than 5 ohms Fault 52 Harmonic Filter High Phase B Current Message Quantum Fault 52 Quantum LX Harmonic Filter High Phase B Current Fault Same as Fault 51 except for applying to Phase B Fault 53 Harmonic Filter High Phase A Current Message Quantum Fault 53 Quantum LX Harmonic Filter High Phase A Current Fault Same as Fault 51 except for applying to Phase A Fault 54 Harmonic Filter...

Page 72: ...is particular shutdown and the accompanying message is generated if the filter s DC link voltage drops to a level less than 80 VDC below the filter DC link voltage setpoint The filter DC link voltage setpoint is determined by the filter logic board via the sensing of the three phase input line to line voltage This setpoint is set to the peak of the sensed input line to line voltage plus 59 volts n...

Page 73: ...be cancelled If the Run Command signal is engaged the actual speed command is set to the initial speed command and the Motor Current is monitored every two seconds If the Motor Current rises above 103 the unit enters current limit and a warning condition will be set Thereafter as long as the Motor Current stays above 100 the actual speed command will be reduced by 6 RPM every two seconds Once the ...

Page 74: ...ctuator Valve Coolant Mixing 1 ALL 025 40386 000 Board SCR Trigger 60Hz 1 ALL 031 01472 000 Board SCR Trigger 50Hz 1 ALL 031 01472 001 Circuit Breaker 1100 Amp with GFCI 1 700 572 224 36981 000 Circuit Breaker 1200 Amp with GFCI 1 912 752 224 36982 000 Board VSD Logic 1 ALL 331 02506 605 Assembly Replacement VSD Output Pole 3 700 572 371 05172 344 Assembly Replacement VSD Output Pole 3 912 752 371...

Page 75: ...Converter Heat Sink Temperature 66 High DC Current Bus Voltag 65 High Internal Ambient Temperature 66 High Inverter Baseplate Temperature 66 High Phase A Instantaneous Current 63 64 High Phase B Instantaneous Current 64 High Phase C Instantaneous Current 64 Initialization 62 Interface Board Motor Current Limit Override 70 Interface Board NovRAM Failure 70 Interface Board Panel Communications Loss ...

Page 76: ...nel 65 QuantumLX Control Panel 18 27 32 35 40 63 65 66 67 68 69 70 R Rate of Decrease 51 Rate of Decrease Delay Time 51 Rate of Increase 51 Rate of Increase Delay Time 51 reset button 65 66 RFI 28 35 RMS input 70 RMS output 70 running coolant 35 37 58 S saturation voltage 64 SCR 64 65 66 67 68 SCR diode modules 8 66 SCR Trigger Control 64 SCR Trigger Control board 64 Serial Communications 63 Seria...

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Summary of Contents for Frick 572

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Johnson Controls Frick 572, Installation Operation & Maintenance, Page: 11 / 76

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Summary of Contents for Frick 572

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