Johnson Controls York AYK550 User manual

AYK 550

AIR MODULATORS

Supersedes: 100.42-01 (604) Form: 100.42-01 (506)

USER’S MANUAL

User’s Manual

AYK550-UH HVAC DRIVES (1...150HP)









!""#

$… %

• Safety

• Installation

• Start-Up

• Diagnostics

• Maintenance

• Technical Data

&%'*&"#

(Fieldbus Adapters, I/O Extension Modules etc., manuals

delivered with optional equipment)

!+&,,/,223 (typical title)

• Installation

• Programming

•Faulttracing

• Technical data

BACnet is a registered trademark of ASHRAE.

CANopen is a registered trademark of CAN in Automation

e.V.

ControlNet is a registered trademark of ControlNet International.

DeviceNet is a registered trademark of Open DeviceNet Vendor Association.

DRIVECOM is a registered trademark of DRIVECOM User Organization.

Ethernet is a registered trademark of Xerox Corp.

Interbus is a registered trademark of Interbus Club.

LonWorks is a registered trademark of Echelon Corp.

Metasys is a registered trademark of Johnson Controls Inc.

Modbus and Modbus Plus are registered trademarks of Schneider Automation Inc.

Profibus is a registered trademark of Profibus Trade Org.

Profibus-DP is a registered trademark of Siemens AG.

AYK550-UH User’s Manual

Table of Contents

Safety

Use of Warnings and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation

Installation Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Start-Up

HVAC Control Panel Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Application Macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

YORK Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Serial Communication – EFB

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Mechanical and Electrical Installation – EFB . . . . . . . . . . . . . . . . . . . . . . . . . 142

Communication Set-up – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Activate Drive Control Functions – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Feedback from the Drive – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Diagnostics – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Modbus Protocol Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

YORK Drives Profile Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

N2 Protocol Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

FLN Protocol Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

BACnet Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Serial Communication – FBA

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Mechanical and Electrical Installation – FBA . . . . . . . . . . . . . . . . . . . . . . . . . 193

Communication Set-up – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Activate Drive Control Functions – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Feedback from the Drive – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Diagnostics – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

YORK Drives Profile Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Generic Profile Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Diagnostics

Diagnostic Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Correcting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Correcting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

AYK550-UH User’s Manual

Table of Contents

Maintenance

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Main Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Technical Data

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Degrees of Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Liability Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

Appendix A

Factory-Mounted Solution and AHU VFDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1

Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2

Mechanical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2

Appendix B

Field-Mounted Ship Loose Air Mods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1

Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1

Mechanical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1

Appendix C

Quick Start-Up Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1

Analog Input Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2

RS485 Interface Termination for Serial Communication . . . . . . . . . . . . . . . . . .C2

Customer Control Terminal Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2

Typical Motor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3

IGBT Test Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4

Inverter Component Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4

Inverter Diodes and IGBT Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4

AYK550-UH User’s Manual

Table of Contents

Appendix D

Solution AHU Drawing #205662. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1

#205648 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2

#205647 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3

#205651 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4

#205649 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5

#205653 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6

#205663 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D7

#205652 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8

#205650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D9

#205654 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10

#205633 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11

Appendix E

Solution Dimensions

AYK550 Frame Size Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1

Base Drive (OO Option) Outside Dimensions . . . . . . . . . . . . . . . . . . . . . . . E2

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2

Base Drive w/Fused Disconnects (AO Option) Dimensions & Weights . . . . E3

Field Mounted Shipped Loose AirMods

Base Drive, 2 Contactor, Drive Input Service Disconnect Switch,

Main Fused Disconnect Switch (CM Option) Enclosure

Drawings & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4

Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E5

Outside Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E6

Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E7

Appendix F

YORK Solution XTO VFD Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1

Index

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YORK, A Johnson Controls Company 

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678'9?,,,2@,=+4,,2,7

,,24,9/,=2@@32>

678'99,W@+=9979,@,>#['=9=,[2

7FF>

678*4,93?;342,7,?2WB@2=?,

3Q\@Z!!]B2\3\F\@Z!2!^>#

37@27F37Q=,+>

2,8 For more technical information, contact the factory or your local YORK sales

representative.



 YORK, A Johnson Controls Company

246732,

'9,?2,+244,+,=,2,92792,,9@_

• Notes draw attention to a particular condition or fact, or give information on a

subject.

• Warnings caution you about conditions which can result in serious injury or death

and/or damage to the equipment. They also tell you how to avoid the danger. The

warning symbols are used as follows:

722,7?7?249792,7?9=9==9+=

:+3`23@7,2,9<@,>

?7?;2,=23,2B2,9,9,92=3;+

=,=,+B?9=9=,9+=:+3`23@7,2,9<@,

 

YORK, A Johnson Controls Company 

*,,2

Study these installation instructions carefully before proceeding. \,22;

,9?73,=,2@+=@4=,2229Z3>

678J42+2;73[#4,+[27>

*,,2\2?9,

The installation of the AYK550 adjustable speed AC drive follows the outline below.

The steps must be carried out in the order shown. At the right of each step are

references to the detailed information needed for the correct installation of the unit.

'W #

%!%! for installation "Preparing for Installation" on page 4.

%!%! the Mounting Location "Prepare the Mounting Location" on page 7.

!&the front cover "Remove Front Cover" on page 7.

&'the drive "Mount the Drive" on page 8.

*#'"" wiring "Install the Wiring" on page 8.

 installation "Check Installation" on page 13.

!*#'"" the cover "Re-install Cover" on page 13.

%%"power "Apply Power" on page 14.

#'!'% "Note! For drives with bypass, if motor is running in

reverse switch incoming power lines at input disconnect."

on page 14.



 YORK, A Johnson Controls Company

%742*,,2

"4,7,9

Lift the drive only by the metal

chassis.

=W ,9

1. Unpack the drive.

2. Check for any damage and

notify the shipper immediately

if damaged components are

found.

3. Check the contents against

the order and the shipping label to verify that all parts have been received.

*3,4=,2

!"

To determine the type of drive you are installing, refer to either:

• Serial number label attached on upper part of the chokeplate between the

mounting holes.

• Type code label attached on the heat sink – on the right side of the unit cover.

IP2040

#>2>

cc]

dFQgd



*F

%

8.8 A

3~ 380...480 V

#>2>

cc]

dFQgd

*,

*

4

&,,F

*F

2,2%

48...63 Hz

8.8 A

3~ 380...480 V

3~ 0...U1V

8.8 A

0...500 Hz

 

YORK, A Johnson Controls Company 

#$%&

Use the following chart to interpret the type code found on either label.

'(&)*+

The chart in "Ratings" on page 221 lists technical specifications, and identifies the

drive’s frame size – significant, since some instructions in this document, vary,

depending on the drive’s frame size. To read the Ratings table, you need the “Output

current rating” entry from the type code (see above). Also, when using the Ratings

tables, note that there are two tables based on the drive’s “Voltage rating”.

2,22@,;,+

The motor, drive, and supply power must be compatible:

2,2

#=4=,2 4+ !4=

Motor type 3-phase induction motor –

Nominal current Motor value is within this

range: 0.15…1.5 * I2N

(I2N = normal use current)

• Type code label on drive, entry for Output I2N,

• Type code on drive and rating table in

"Technical Data" on page 225.

Nominal frequency 10…500 Hz –

Voltage range Motor is compatible with

the AYK550 voltage range.

208…240 V (for AYK550-UH-XXXX-2) or

380…480 V (for AYK550-UHXXXX4)

500...600 V (for AYK550)

Insulation 500...600 V drives: Either

the motor complies with

NEMA MG1 Part 31, or a

du/dt filter is used between

the motor and drive.

For AYK550

Bh23=,

See Ratings chart for details

4 = 380…480 VAC

UH = Setup and parts specific to US installation and NEMA compliance

2 = 208…240 VAC

2,=,272=4=

&,,=,,7

2,7,7

01 = Setup and parts specific to IEC installation and compliance

=22,=,2=

6 = 500…600 VAC

No specification = IP 21 / UL type 1

AYK550-UH-08A8-4+...

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