ServiceInformation Retrofit instructions for replacing a VFD66 condenser fan

drive with the ABB ACS255 condenser fan drive

File In/With: –

Equipment Affected:

YLAA, YLUA, YCAL, and YCUL Air-Cooled Chillers

RevSI0391

Product Technical Support

The VFD66 condenser fan drives are no longer available. The ABB ACS255 drive in a NEMA 4X enclosure will replace the obsoleted VFD66 drive. This replacement drive is larger than the VFD66, therefore, a new mounting bracket is needed (found in the retrofit kit). This service information letter will provide the ordering and installation instructions needed to replace the drive.

The following chiller models are affected:

• YLAA and YLUA models (with Low Ambient Drives) NOTE: Only Available on systems with 2 or 3 fans per circuit.

Not Available for systems with 4 fans or more per circuit.

• YCAL and YCUL 0028-0033 (single circuit)

• YCAL and YCUL 0043-0066 (dual circuit)

ORDERING THE REPLACEMENT DRIVE KITNOTE: The new replacement drive kit contains a bracket that fits two drives. Due to the obsolescence of the

VFD66 drive, it is advisable (but not mandated) to replace both drives at the same time.

The table on page 2, show the kit part numbers for the drives/brackets that replace the VFD66. These parts are avail-able through Baltimore Parts Center. These kits contain only one drive with a bracket that may hold two drives. If you are replacing both drives, you will need to order a kit and a second drive listed in the table.

Work on this equipment should only be done by properly trained personnel who are qualified to work on this type of equipment. Failure to comply with this requirement could expose the worker, the equipment and the building and its inhabitants to the risk of injury or property damage. The instructions on this service information letter are written assuming the individual who will perform this work is a fully trained HVAC & R journeyman or equivalent, certified in refrigerant handling and recovery techniques, and knowledgeable with regard to electrical lock out/tag out procedures. The individual performing this work should be aware of and comply with all Johnson Controls, national, state and local safety and environmental regulations while carrying out this work. Before attempting to work on any equipment, the individual should be thoroughly familiar with the equipment by reading and understanding the associated service literature applicable to the equipment. If you do not have this literature, you may obtain it by contacting a Johnson Controls Service Office. Should there be any question concerning any aspect of the tasks outlined in this bulletin, please consult a Johnson Controls Service Office prior to attempting the work. Please be aware that this information may be time sensitive and that Johnson Controls reserves the right to revise this information at any time. Be certain you are working with the latest information.

1019Supersedes SI0391 (919)

SI0391 (1019)

2 JOHNSON CONTROLS

NOTE: The highlighted kits contain a bracket that fits two drives. There is no bracket that can accommodate a VFD66 and the new ACS255 drive. Order a single VFD using the VFD ONLY PART NUMBER.

KIT PART NUMBER DESCRIPTION VFD ONLY PART NUMBER327 04211 000 Kit, Retrofit VFD (YLAA and YLUA 230 Drive) 025-47497-003327 04212 000 Kit, Retrofit VFD (YCAL and YCUL 0028-0033 230 Drive) 025-47497-003327 04213 000 Kit, Retrofit VFD (YCAL and YCUL 0043-0066 230 Drive) 025-47497-003327 04214 000 Kit, Retrofit VFD (YLAA and YLUA 460 Drive) 025-47497-013327 04215 000 Kit, Retrofit VFD (YCAL and YCUL 0028-0033 460 Drive) 025-47497-013327 04216 000 Kit, Retrofit VFD (YCAL and YCUL 0043-0066 460 Drive) 025-47497-013327 04217 000 Kit, Retrofit VFD (YLAA and YLUA 575 Drive) 025-47497-130327 04218 000 Kit, Retrofit VFD (YCAL and YCUL 0028-0033 575 Drive) 025-47497-130327 04219 000 Kit, Retrofit VFD (YCAL and YCUL 0043-0066 575 Drive) 025-47497-130

Although mounting brackets are included in the above kits, the individual brackets maybe purchased separately.

• YLAA and YLUA: 075-55889-061 (Bracket)

• YCAL: 075-55889-064 (Bracket)

• YCAL: 075-55889-062 (Support) and 075-55889-063 (Bracket)

Retrofit Procedure Summary1. Lockout/Tagout the chiller according to proper electrical safety requirements.

2. Disconnect the VFD66 drive from the chiller.

3. Install the new brackets (and the new support for the YCAL models)

4. Mount the new ACS255 drive onto the bracket.

5. Wire the chiller according to the appropriate chiller wiring diagram.

6. Remove the Lock/Tag from the chiller and apply power to the chiller.

7. Follow the instructions in the ACS255 manual and the following pages to power and set up the drive parameters.

SI0391 (1019)

3JOHNSON CONTROLS

YLAA 075-55889-061 (BRACKET)

INVERTER60 HZ System 1 System 2 60 HZ System 1 System 2

YLAA0041 YES YES YLAA0120 YES YESYLAA0048 YES YES YLAA0125 NO NOYLAA0058 YES YES YLAA0136 NO NOYLAA0065 YES YES YLAA0139 NO NOYLAA0070 YES YES YLAA0142 NO YESYLAA0080 YES YES YLAA0150 NO NOYLAA0081 YES YES YLAA0155 NO NOYLAA0082 YES YES YLAA0156 NO NOYLAA0089 YES YES YLAA0170 NO NOYLAA0092 YES YES YLAA0175 NO NOYLAA0100 YES YES YLAA0200 NO NOYLAA0101 YES NO YLAA0230 NO NOYLAA0115 YES YES

YLUA 075-55889-061 (BRACKET)

INVERTER60 HZ System 1 System 2

YLUA0078 YES YESYLUA0088 YES YESYLUA0095 YES YESYLUA0098 YES YESYLUA0108 YES NOYLUA0130 YES YESYLUA0148 NO NOYLUA0158 NO NO

SI0391 (1019)

4 JOHNSON CONTROLS

YCAL / YCUL (Single Circuit) 0028-0033: 075-55889-064

LD27053

LD27054

YLAA / YLUA (Dual Circuit): 075-55889-061

YCAL / YCUL (Dual Circuit) 0043-0066: 075-55889-062 (SUPPORT) &

075-55889-063 (BRACKET)

SI0391 (1019)

5JOHNSON CONTROLS

LD27051

6

5

4

3

2

1

6

5

4

3

2

1

+EXT=1-BDP

+EXT=2-BDP

B A C B A C

-AMB

150

151

153

148

147

146

250

251

253

246

247

248

GND GND

TB2TB2

7 6

WVU

L3L2L1TB2TB2

7 6

WVU

L3L2L1TB1

= 1-FSC+EXT

TB1=2-FSC+EXT

21 21

12

139

FOR575 V.ONLY

12

139

FOR575 V.ONLY

21

21

12

139

7 6

7 6

FIGURE 1 - YLAA AND YLUA ACS 255 DRIVE WIRING

SI0391 (1019)

6 JOHNSON CONTROLS

LD27050

21

21

12

139

7 6

7 6

FIGURE 2 - YCAL AND YCUL ACS 255 DRIVE WIRING

SI0391 (1019)

7JOHNSON CONTROLS

Drive Programming Instructions (Instructions to access Service Mode are also located on the chiller control panel)

1. To enable Service Mode, set the unit rocker switch to OFF.

2. Press the Program Key.

3. Press Up Arrow twice and then Down Arrow twice (↑↑↓↓).

4. Press Enter/Advance Key.

5. Press the Enter/Advance key until Liquid Line solenoid option is displayed.

6. Use the up/down arrow keys to enable Liquid Line solenoid output and press Enter/Advance key.

7. Turn On System 1 Fan Output 1. This will send voltage to the drive allowing the drive parameters to be ad-justed.

8. Set up the drive as required (See page 8).

Setup of ABB ACS255 VSD for Low Ambient KitRefer to the ABB ACS255 manual for more detailed instructions on entering modes and making adjustments to drive. Ensure the drive is set for “Par L” to see all parameter code settings.

Parameter StructureThe parameters within the drive are split into 2 groups. Group 1 is titled “Short Parameter Mode” and is displayed as “PAr S on the drive display. Group 2 is titled “Long Parameter Mode” and is displayed as “PAr L” on the drive display.

• “PAr S” group brings together the most commonly used parameters to aid in quick setup.

• “PAr L” group includes all of the drive parameters.

GROUP NAVIGATION PARAMETER STRUCTURE

LD26763

SI0391 (1019)

8 JOHNSON CONTROLS

All other settings not listed below are to be left in their default values.

PARAMETER CODE DESCRIPTION SETTING9902 Function Select 0

9905 Motor Rated VoltageSee motor nameplate

(208V,230V,460V)9906 Motor Rated Current See motor nameplate

9907 Motor FrequencySee motor nameplate

(50 Hz, 60 Hz)1103 Command Source Mode 01300 Analog Input 1 Signal Format U 0-101301 Analog Input 1 Offset 23.51302 Analog Input 1 Scaling 18502007 Min Frequency Limit 0

2008 Max Frequency LimitSee motor nameplate

(50 Hz, 60 Hz)2102 Stop Mode 02202 Accel Time 30.02203 Decel Time 30.02601 Energy Optimizer 0