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YORK MEDIUM VOLTAGE Solid State Starter

TECHNICAL DATA Supersedes: 160.00-TD5 (606) Form 160.00-TD5 (1006)

YORK MEDIUM VOLTAGE Solid State Starter YK CHILLERS WITH OPTIVIEW CONTROL CENTER

Contents APPLICATION ...............................................................................................................................................................2 A. Environment ..................................................................................................................................................2 B. Power Wiring ..................................................................................................................................................2 C. Field Installation ..................................................................................................................................................2 D. Special Requirements .....................................................................................................................................2 E. Voltage Range ..................................................................................................................................................3 CONSTRUCTION ..................................................................................................................................................3 A. Factory Tests ..................................................................................................................................................4 B. Fuses ...............................................................................................................................................................4 C. Control Panel Interface .....................................................................................................................................4 D. Overload Protection .....................................................................................................................................4 OPERATION ...............................................................................................................................................................4 A. Characteristics ..................................................................................................................................................4 B. Current ...............................................................................................................................................................4 C. Effect on Motor Life ..................................................................................................................................................5 D. Heat Generated ..................................................................................................................................................5 E. Interrupting Capacity .....................................................................................................................................5 F. Motor Shorts and Ground Faults ........................................................................................................................5 G. Phase Sequence (Reversal) ........................................................................................................................5 H. ElectroMagnetic Compatability (EMC) and Total Harmonic Distortion (THD) ..........................................5 I. Reliability ...............................................................................................................................................................5 J. Response Time ..................................................................................................................................................6 K. Servicing ...............................................................................................................................................................6 L. Single-Phasing ..................................................................................................................................................6 M. Surge Protection ..................................................................................................................................................6 N. Power Fault ...............................................................................................................................................................6 O. Voltage ...............................................................................................................................................................7 ELECTRO-MECHANICAL STARTERS ........................................................................................................................7 A. Characteristics Electro-Mechanical Starters ..............................................................................................7 B.Types Electro-Mechanical Starters ...........................................................................................................8 GUIDE SPECIFICATIONS ...................................................................................................................................12

MEDIUM VOLTAGE Solid State Starter TECHNICAL FACTS

APPLICATION A. Environment The Medium Voltage Solid State Starter is designed for indoor installation. Typical installation environments were taken into account in the design of the starter. Following are comments pertaining to specific ambient conditions. 1. Dust and Dirt The starter enclosure is NEMA Type 1 (ventilated). Therefore, the starter is designed to withstand the dirt contamination encountered in the normal commercial/industrial environment. Power switching is by vacuum contactors or semiconductors eliminating most common contamination by dust and dirt. The adherence to U.L.-specified spacing between components, the use of a conformal insulation coating on all circuit boards, and the inherent immunity of solid state components to the direct effects of dirt products, all give the starter a high degree of dirt and dust tolerance.

or inadequate air flow. Whether or not the temperature rise reaches the safety settings, depends upon many variables, including equipment room temperatures, and motor size. B. Power Wiring Power wiring to the Medium Voltage Solid State Starter must be copper. Aluminum wire conductors are unsatisfactory and their use may be hazardous. Aluminum forms an oxide on its surface. This characteristic makes aluminum wire a poor choice for electrical conductors. since the oxide is an insulator. It is almost impossible to adequately clean aluminum stranded wire, when the initial connections are made, because oxides reform immediately in the presence of air. The resulting poor connections at the supply wiring lugs of YORK Medium Voltage Solid State Starter, due to these oxides, will cause excessive voltage drop, and overheating. The starter is U.L. approved for use with copper wire only. C. Field Installation The Medium Voltage Solid State Starter is available as a field-installed kit, to use for retrofit of existing and newchillers. D. Special Requirements 1. Power Factor Correction Capacitors As with any large induction motor, it is often desirable (and sometimes necessary) to increase the lagging power factor of the chiller motor. For general use, the most practical and economical power factor correction device is the capacitor. Because of their space requirements, factory-mounted power capacitors are not available with the Medium Voltage Solid State Starter enclosure. However, power factor correction capacitors may be ordered as a special option or field-installed with a chiller equipped with a YORK Medium voltage Solid State Starter. The two constraints that must be met, in sizing power capacitors (regardless of type of starter), are: a. Capacitor KVAR may not exceed the motor noload KVA. b. The corrected power factor may not exceed .95 at rated load. Improperly-sized capacitors can cause serious damage to the chiller motor. A third constraint, in the application of power factor correcting capacitors, concerns their installation location. In application with the Medium Voltage Solid State Starter, power capacitors JOHNSON CONTROLS

2. Humidity There are two design measures taken in the starter to counter the potential problems due to humidity levels found in normal commercial/industrial environments. One measure is the use of the conformal surface-insulating coating. The second measure is the use of spacing between components, which allows a sufficient insulating air gap to prevent flashover even in a humid atmosphere. (Flashover is electrical arcing between current-carrying elements and other conducive elements within the equipment.) Proper spacing is achieved by adherence to CSA (Canadian Standards Association) and U.L. (Underwriters Laboratories) standards.. 3. Temperature The ambient temperature limitations for application of YORKs Medium voltage Solid State Starter are the same as those for the standard chiller: 40-110F (4.4 - 43.3C). If the heatsinks are at an excessive elevated temperature, the Control Center will display the fault message MVSSS High Heatsink Temperature Stopped,The SCRs are protected from excessive temperature during operation by three temperature-sensitive switches (one per phase on each SCR) which shut down the starter/chiller. The Control Center will display the fault message High Heatsink Temperature Running if safe temperatures are exceeded. Abnormal conditions which can cause a rise in cabinet temperature include high ambient temperature, 

FORM 160.00-TD5

used to raise lagging plant power factor must be installed on the line side of the starter. Excessive current into the capacitors during acceleration will result from connection to the load side of the starter. Neither the Medium Voltage Solid State Starter nor the capacitors will function properly if the capacitors are connected on the load side of the starter. Properly applied, these capacitors must be wired to the power source which supplies the starter. There is no room in the starter cabinet to permit mounting and wiring of power factor correction capacitors between starter input terminals. 2. Disconnect Switch The Medium Voltage Solid State Starter contains a factory-mounted load break input disconnect switch, located within the starter enclosure, and includes a door interlock device and padlocking capability. The disconnect switch is a positive disconnecting means with a viewable window from the outside of the enclosure. All doors are interlocked with the disconnect switch. 3. Interrupting Capacity The starter is suitable for use on circuits capable of delivering not more than 50KA RMS symmetrical amperes at nameplate voltage. 4. Incomplete Starting Sequence Electro-mechanical starters are often specified with incomplete starting sequence option. The incorporation of this feature prevents the motor from running indefinitely on the starting winding. Of course, the Medium Voltage Solid State Starter does not have a transition step. If, for any reason, the motor does not come up to speed, however, the 105% overload will shut down the chiller after a maximum 40 seconds. These features make incomplete starting sequence a standard feature of YORKs Medium Voltage Solid State Starter. 5. Lightning Arrestors Factory-mounted lightning arrestors are included with the Medium Voltage Solid State Starter. 6. Shunt-Trip Attachment This is an option specified for electro-mechanical starters to overcome the problem of welded contacts (see discussion under ELECTRO-MECHANICAL STARTERS, Characteristics). The shunt-trip attachment is used to trip the breaker electrically, from a remote position, by closing its circuit either manually through a control switch or automatically through relay contacts, in the event that the main contactor points become welded together. 7. Wattmeter and Watt-Hour Metering The Control Circuit in the Medium Voltage Solid State Starter calculates instantaneous power (kW) and total energy (kWh). This information is communicated to the JOHNSON CONTROLS

micropanel and displayed with other pertinent motor and motor starter information. 8. Ground Fault Protection Is standard with the Medium Voltage Solid State Starter. E. Voltage Range The allowable voltage range of the application of a Medium Voltage Solid State Starter is the same as that for a chiller and is tabulated, as shown below.
FREQ. 60 HZ 50 HZ RATED VOLTAGE 4160 2300 3300 NAMEPLATE VOLTAGE 4160 2300 3300 OPERATING VOLTAGE MIN. MAX. 3744 4576 2070 2530 2970 3630

Generally, voltage transformation is accomplished by utility transformers electrically upstream from the chiller. Because of the extent of the network they feed, these transformers are sized such that the chiller start-up has only a slight effect on transformer voltage drop. In rare instances, a transformer may be part of the electrical system of a chiller installation and be sized to furnish power to the chiller alone. In those instances where the chiller (with a Medium Voltage Solid State Starter) comprises all, or a major portion, of the transformer load, the transformer must be sized so that voltage drop from standby voltage does not exceed 10% on the start-up. (Standby voltage is that voltage measured at the transformer secondary without the starter activated or the chiller in operation.) This requirement is in addition to the requirement that the voltage be within the allowable range shown in the table above. For example, if standby voltage is 4200 volts at the transformer secondary, voltage may not drop below 3780 volts when the chiller starts even though this voltage is within the voltage tolerance range. Otherwise, operation of the starter may be erratic. CONSTRUCTION The Medium Voltage Solid State Starter was designed specifically for use with the YORK chiller. Accordingly, many of the features and operating sequences required of a general purpose starter are not necessary nor desirable for YORKs definite-purpose application to a chiller. This is comparable to the differences between a general purpose, NEMA-rated contactor and a definite-purpose contactor as used in the air conditioning industry. Some features of YORKs Medium Voltage Solid State Starter design and testing are described as follows. A. Factory Tests Individual starter components are manufactured and tested in accordance with procedures typical for solid state components. For example, each circuit is subjected to 

a burn-in prior to adjustment and testing. Burnin is a process whereby electrical power is applied to the device for some period of time, at an elevated temperature. The intent is to power up the device to electrically load it, to the greatest extent possible, to verify that all circuits are tested. It is a characteristic of solid state devices that they are reliable and long-lived. The exceptions, or failures, if they are going to occur, usually take place early. The reason for burn-in, therefore, is to weed out these infant mortalities to ensure the long range reliability of the device. In addition, the following tests and adjustments are made: 1. The starter undergoes a high potential test to verify the systems dielectric strength. 2. Each starter is functionally tested and operated at rated voltage. 3. All circuit boards are functionally tested prior to assembly in the starter and shipment for service replacement parts. 4. The starting current and overload current settings are factory-set to design values, during starter testing, thus ensuring that settings are correct when the starter arrives at the job site. B. Fuses The main fuses in the starter are for the main power circuit. Control circuit time-delay fuses are included for the control circuit, control supply transformer, and optional unit oil pump, as shown on the starter wiring diagrams. C. Control Panel Interface The Medium Voltage Solid State Starter communicates with YORKs Control Center via a serial Modbus RTU communication link. The Control Center displays 3phase RMS voltage, 3-phase RMS current, 100% job FLA, instantaneous 3-phase power and total energy. The Control Center also provides detailed troubleshooting messages as well as a corresponding history log. D. Overload Protection The Medium Voltage Solid State Starter contains two sets of 3-leg-sensing solid state overload protection as follows: 1. 105% Overload. When current exceeds 105% of FLA for 40 seconds, this overload is tripped. The chiller will be shut down and display the message MVSSS 105% Motor Current Overload if current exceeds 105% of FLA for 40 seconds, maximum. 2. High Instantaneous Current Overload: When current exceeds 115% of starting current (inrush) for 1 second, this overload is tripped. The chiller will be shut down if current exceeds 115% of starting current for 

one second and the Control Center will indicate the message MVSSS High Instantaneous Current. See OPERATION, Current, for further discussion of Medium Voltage Solid State Starter overload protection. OPERATION A. Characteristics The Medium Voltage Solid State Starter is a bypass starter with vacuum bottle contactors in parallel with semiconductor SCR switches. An input vacuum contactor is also provided for added protection. The bypass arrangement carries the load current during operation. Start-up and shutdown current transitions are handled by the semiconductor SCRs eliminating any electrical wear on the vacuum contactors. The SCRs provide a continuous smooth starting current profile for transient free starts and stops. The input contactor removes power from the SCRs in the stopped mode preventing unnecessary stresses to the semiconductors. B. Current 1. Overcurrent For a description of overcurrent protection see CONSTRUCTION, Overload Protection. These protective devices functions are located in the starter logic control. The functions provide locked rotor protection as well as protection during certain other operating fault conditions (e.g. voltage unbalance). See also discussion under OPERATION, Voltage. 2. Starting Current The starting current, or inrush, of a Medium Voltage Solid State Starter is 45% of Locked Rotor Amperes (LRA). Across the line electromechanical starters require full locked rotor current for starting and auto-transformer starters can be set for various starting currents typically 42% LRA with a 65% tap selection. The effect of inrush (about 10-20 seconds is typically required to get the motor up to speed) on electrical demand charge is comparable to auto-transformer starters. The size of power supply wiring to the unit is independent of starting current. It is sized according to FLA and is, therefore, the same size regardless of starter type, for the same voltage.

4. Current Unbalance The Medium Voltage Solid State Starter utilizes the phase current values displayed via the Control Center to calculate the % current unbalance. If the starter is loaded to 80% FLA/RLA or above, and the % current unbalance exceeds 30% for 45 consecutive seconds, system shutdown is initiated and the message MVSSS Motor or starter current Imbalance is displayed on the Control Center. JOHNSON CONTROLS

FORM 160.00-TD5

5. Current Metering The true RMS value of the three phases of line current are calculated every line cycle and displayed on the Control Center. C. Effect on Motor Life Motor life depends upon the combined effects of average winding temperature and mechanical stress, primarily imposed during starting. Winding temperature is raised during reduced voltage starting because of reduced motor ventilation and cooling caused by slow starting. Regardless of starting method, motor life is reduced a very small amount due to this extra heating. The initial inrush of current at starting produces mechanical forces in the end turns of motor winding. The end turns rub together harder with the greater and faster application of current to the motor windings. The Medium Voltage Solid State Starter limits this change to an order of magnitude of 1,000 amps per second compared to the 100,000 amps per second of the electro-mechanical starter. The difference can be visualized in a gradual increase in current caused by incrementing voltage changes 120 times per second compared to one large switch closure applying the full line voltage or a fixed percentage of full voltage all at once. Reduced voltage electromechanical starters have yet another transient at the final switch to full voltage causing another shock to the motor. This greatly reduced mechanical stress in the end turns results in substantially less rubbing action to wear away at insulation. Motor life tends to be extended due to the smooth accelerating current and torque profile produced by the Medium Voltage Solid State Starter. D. Heat Generated The Medium Voltage Solid State Starter generated about the same amount of heat as for an auto-transformer electromechanical starter. E. Interrupting Capacity The Medium voltage Solid State Starter is rated for 50KA RMS symmetrical amps at starter rated voltage. This current is the amount the mains are capable of supplying during a short circuit. Tests are required by U.L. to ensure that if the short circuit currents are imposed on the starter, damage and secondary effects (e.g., sparks, flame) will be confined within the enclosure. Such extreme currents could however, destroy some internal components. See also discussion under OPERATION, Current Motor Shorts and Ground Faults, Surge Protection, Transient Fault and Voltage.

F. Motor Shorts and Ground Faults The most likely starter response to motor shorts and ground faults (similar to a short circuit) would be to shut down the chiller on the Fault Overload. (See CONSTRUCTION, Overload Protection). Ground fault protection is also included with the YORK Medium Voltage Solid State Starter. G. Phase Sequence (Reversal) Phase reversal is the term used to describe the result of wiring errors in which the incoming power wiring to the starter is not in the same phase sequence as the wiring from the starter to the motor. This field wiring error could cause the motor to rotate in the reverse direction and damage the equipment. The Medium Voltage Solid State Starter detects incorrect phase sequence before startup and prevents power from being applied to the chiller motor in reverse rotation. The Control Center will indicate this condition by displaying the message, MVSSS Phase Rotation. H. ElectroMagnetic Compatability (EMC) and Total Harmonic Distortion (THD) The source of man-made radio noise comes from high frequency sources such as microwave ovens, industrial heaters and similar equipment which generates and uses radio frequency energy or from non-linear switching loads such as light dimmers which chop the incoming sine wave power. This equipment which generates EMI (electromagnetic interference) is regulated by the US Federal Communications Commission (FCC). Parts 15 and 18 of the FCCs Rules and Regulations and CE EN61000 in Europe. The Medium Voltage Solid State Starter will generate a small amount of EMI during the starting sequence. The SCRs in the starter are phaseangle-fired devices, the same as used in light dimmers. As the compressor comes up to speed, less and less of the wave is reduced. Once the chiller is in full speed operation the EMI generated by the starter logic is insignificant. The YORKs Medium Voltage Solid State Starter meets the FCC and CE regulations. Total Harmonic Distortion is the effect of non-linear loads on the voltage and current delivered to equipment in a building. The York Medium Voltage Solid State Starter has a short effect on THD during the 40 second starting cycle and no effect on THD while operating the chiller. The THD present with the starter running will not exceed that on the power mains line to line voltage THD I. Reliability There are two aspects of reliability associated with YORKs Medium Voltage Solid State Starter. One is its favorable effect on the reliability of the chiller motor. For a discussion of this subject, see OPERATION, Effect on Motor Life. 

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The other aspect of reliability is of the starter itself. Solid state devices have a very long life as compared to moving mechanical switches. Mechanical switches are at risk for pitting, welding, and open actuator coils. Considerable stress is placed on a mechanical contactor during energizing and de-energizing the motor load. Conversely, the SCR semiconductor is subject to junction failure due to high voltage transients and overheating. The York Medium Voltage Solid State Starter uses six SCRs in line with the motor, isolated by a series vacuum contactor and bypassed by another vacuum contactor. The SCRs handle all the energizing and de-energizing switching currents while the contactors pass through the current without making or breaking the load. The stressful switching burden is removed from the contactors. While in the off state and in the run state the contactors protect the SCRs from voltage transients and overheating. To ensure maximum reliability and ease of serviceability, both shorted and open SCR detection circuitry is included in the YORK starter. If an SCR fails open the chiller will shut down. If an SCR fails shorted the series input vacuum bottle contactor will prevent damage to the chiller. The display MVSSS-Failed SCR will appear on the Control Center J. Response Time The Medium Voltage Solid State Starter has the capability of giving faster safety response time than can electromechanical starters. Solid state devices are inherently faster than electro-mechanical devices, however, this characteristic is not generally obvious in the operation of the starter. Faults like single-phasing, phase loss and power fault protection rely on this fast switching capability to prevent damage. (See OPERATION, Transient Fault). To prevent nuisance trips, both overloads are timed (1.0 sec. for High Instantaneous Current Overload and 40 secs. for 105% Overload) so that the millisecond capability of the solid state device switching is not apparent. K. Servicing Working around Medium voltage is inherently more dangerous than working around low voltage. York has adopted strict safety standards and has trained their qualified service technicians in safety practices and starter maintenance. The starter door is interlocked to disconnect power. As noted on the front of the starter door, positive and visible isolation must be used, in the form of disconnects, prior to service work being performed on the starter. The inherent reliability and thorough factory testing of Medium Voltage Solid State Starters result in minimal servicing required. Should servicing ever be needed, 

YORKs own technicians are thoroughly trained in this specialty and are aided by built-in features of the starter, such as the history logging of starter related parameters and starter initiated shutdowns with the control panel and modular design. L. Single-Phasing Single-phasing (also called phase failure or phase loss) is a term which describes the loss of power in one of the three incoming power phases to a three-phase motor. The most common cause of phase-failure is a blown fuse. If phase loss occurs, the missing phase is detected within one input line cycle by voltage sensors and the Medium Voltage Solid State Starter automatically shuts down the chiller, and the Control Center will indicate MVSSS Phase Loss. M. Surge Protection Surge refers to steep and (usually) rapid increase or decreases in voltage to the starter. Large surges may occur from such events as lightning strikes and ground faults. See discussion of this subject under APPLICATION, Special Requirements. The Medium Voltage Solid State Starter contains distribution class surge arrestors to protect the system against voltage surges. In addition all power SCRs in the Medium Voltage Solid State Starter have minimum voltage ratings of 250% of the starter input RMS voltage. N. Power Fault Severe electrical disturbances, such as lightning, can cause circuit breakers to open in power utility distribution lines. Utilities are gradually upgrading their equipment to reduce such power interruptions to 10 or 15 cycles (1/4 of a second or less at 60 Hz). Under some conditions, these fast reclosure times can cause damage to large induction motors such as those used on chillers. As soon as the breaker disconnects the incoming power, the motor starts acting like a generator, generating its own voltage. The frequency of this self-generated power changes as the motor coasts down in speed. If the incoming power comes back on before the motor has slowed down enough for its self-generated voltage to be somewhat low and if the incoming power comes back on seriously out of phase with the self-generated voltage, high electrical currents and high torque can result. These high currents and torque can damage driveline components and/or the electrical system of the motor. YORKs chiller Control Center contains electronic circuitry which will detect as little as one-half cycle current interruption in any phase, and shut the chiller down safely and display the message MVSSS Power Fault on the Control Center display. The prompt action of this circuit requires that the starter drop out within 4 cycles of removal of the 115 volt RUN signal. The Medium Voltage Solid State JOHNSON CONTROLS

FORM 160.00-TD5

Starter meets this requirement. O. Voltage 1. Low Voltage Protection The Medium Voltage Solid State Starter should not be applied outside of the range of allowable voltage variation listed under APPLICATION, Voltage Range. See the discussion under that Section. If, during operation of the chiller, supply voltage to the starter should fall below the minimum allowable, motor current and temperature will rise. The Medium Voltage Solid State Starter will detect excessive current, if operating at design load, and reduce the allowable refrigerant load to keep the motor motor current at 100% FLA. The Medium Voltage Solid State Starter also utilizes three-phase line-to-line voltage sensors to detect any under voltage as well as display line voltages via the Control Center. If any one of the three input lines drop below 89% of the lowest allowable voltage (for the applicable voltage range see APPLICATION Voltage Range) for 20 consecutive seconds, a system shut down is initiated and the Control Center will display the message MVSSS Low Supply Line Voltage. 2. Low Voltage Starting See also discussion under APPLICATION, Voltage Range. If the voltage is within the allowable range, the Medium Voltage Solid State Starter will maintain the normal starting current level and bring the motor up to full speed in a normal manner. The starter logic module will simply vary the delay angle to compensate for the low voltage condition. If the input voltage is below 89% of the lowest allowable voltage for 20 consecutive seconds (see APPLICATION, Voltage Range), the unit will shut down. Upon initiation of a system start, the low voltage monitoring function is disabled for twenty seconds. In contrast, an electro-mechanical reduced voltage starter operating under low-voltage conditions may not be able to bring the motor up to full speed in the start connection. When transition occurs at this low-speed condition, the motor will draw close to full locked rotor current. This defeats the purpose of using a reduced voltage starter, causing a current surge in the power lines that was sought to be avoided. If voltage at startup is below the minimum allowable, or if, during starting, transformer voltage drop exceeds 10% (see discussion under APPLICATION, Voltage Range), the chiller may not start. Obviously, the Medium Voltage Solid State Starter, as is true of any equipment, should not be applied under conditions outside of its allowable range. It should be noted, in passing, that extreme low voltage conditions, such as these that have been discussed, have not been common in developed countries such as the United States.

3. High Voltage Protection The Medium Voltage Solid State Starter should not be applied outside of the range of allowable voltage variation listed under APPLICATION, Voltage Range. See the discussion under that Section. The Medium Voltage Solid State Starter utilizes three phase line to line-to-line voltage sensors to detect any overvoltage as well as display line voltages via the Control Center. If the magnitude of any one of the three RMS line-to-line voltages exceeds the limits shown in the Voltage Range Table continuously for 20 seconds, the control will initiate a shutdown and the Control Center will display the message MVSSS High Supply Line Voltage. 4. Transients see discussion under OPERATION, Surge Protection. 5. Unbalance In general, a small voltage unbalance between phases on any type of induction motor results in a considerably greater current unbalance. For a given voltage variation, the current variation is greatest at no load and decreases with loading with the least effect being exhibited under locked conditions. If the voltage unbalance (the inequality of voltage as measured at each phase) is not this serious, the chiller will continue to run. Both % current unbalance and under voltage are continually monitored by the Medium Voltage Solid State Starter and Control Center. See OPERATION, Current Unbalance and Voltage for further information. When the voltage unbalance is kept within tolerable limits, the compressor motor speed is not affected appreciably. If speed is effected, it may be slightly decreased.

ELECTRO-MECHANICAL STARTERS A. Characteristics Electro-Mechanical Starters For comparison purposes, here is a description of some of the general characteristics of electromechanical starters. Until the development of the Solid State Starter, all centrifugal chillers required the use of starters using electro-mechanical contactors, which are limited to operating totally ON, or totally OFF. There was no alternative to this mechanical equipment with its inability to control applied voltage or power. This contrasts markedly with the YORK Medium Voltage Solid State Starter which automatically maintains a predetermined current during starting, regardless of variations in line voltage or motor load, to give optimum acceleration without surges. Even with the addition of transformers, reactors, resistors and additional contactors, timers and relays, the mechanical controllers offer limited adjustment, no positive control during starting and impose an objectionable transition 

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spike. Some also require modified motors. The most common failure mode of mechanical contactors is OFF. This occurs due to the coil open-circuiting or failure of a pole to make an electrical contact when it closes. However, failure in the ON mode is not completely uncommon and can be a more dramatic type of failure, particularly if this failure mode exists at the same time that equipment safety controls are demanding a shutdown. When contacts are made, the current builds up to its maximum value from zero, but when contacts are separated the current tends to flow through the gap thus formed and causes an arc. This arcing depends upon the voltage between the separating contacts. For medium voltage the use of vacuum contactors mitigates this problem somewhat by providing an environment to extinguish the arc. In the alternating current circuit, the separation of contacts may take place when the current is zero or maximum or at any value in between. An alternating current passes through zero and reverses its polarity twice during each cycle. If two or more contacts, one in each leg of a polyphase system, are separated simultaneously, the current values in each will vary. In a three-phase system, if one contact has zero current when opened, the other two contacts will have 86.6% of their maximum values, as an example. Additionally, when inductive circuits are broken, the voltage is increased at the contacts due to the counter (induced) EMF of the circuit. The instant the contacts separate, the voltage between them momentarily rises from zero to the maximum of the circuit, or higher if inductance is present

in the circuit. In practice, every time the contacts close, they bounce. When they bounce, they arc. The arcing which occurs as the contacts make or break may result in rapid and excessive erosion of the contacts, causing prematurely short contact life. B.Types Electro-Mechanical Starters YORK chillers are designed for use with the following types of electro-mechanical starters, here briefly described. 1. Across-the-Line (ACL) These are the simplest and lowest-cost starters available. They apply full voltage to the three motor leads at the instant of starting. Since inrush is 100% of LRA and starting torque is 100%, this is the roughest type of starting on the motor and driveline. In physical size, the ACL is the smallest of electro-mechanical starters and there is no transition surge. In most areas, utilities will not permit the use of this type of starter for chiller-size motors because of their large currentdraw on startup. 2. Auto-Transformer (AT) These starters are reducedvoltage starters. Transformers are used to step down the voltage to the motor during startup. The result is reduced inrush current and starting torque at the level of 42% or 64% depending upon whether 65% or 80% voltage taps are used. They provide closed transition (with three-lead motors) with reduced line disturbance.

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FORM 160.00-TD5

TABLE 1 D FLANGE OPEN MOTOR INRUSH (STARTING) CURRENT (60 HZ) AMPERES (NOTES 1 AND 2 )

MOTOR CODE CF CG CH CJ CK CL CM CN CP CR CS CT CU CV CW CX CY CZ CA CB DA DB DC DD DE DF DH DJ DK DL

2,300 Volts Inrush Amps 16 18 21 25 28 32 33 36 39 43 48 51 56 61 66 69 74 79 84 89 101 112 120 131 140 150 175 197 222 247

4,160 Volts Inrush Amps 9 10 12 14 16 17 19 20 22 24 26 28 31 34 37 39 41 44 47 50 56 62 67 72 78 83 97 109 123 137

NOTES: 1. Check to make sure FLA is within Starter Limitations. 2. Inrush values in the table have been calculated for voltages of 2300 and 4160 by multiplying .45 x LRA @ 2300 and 4160 respectively. 3. LRA exceeds starter limitations.

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TABLE 2 D FLANGE OPEN MOTOR INRUSH (STARTING) CURRENT (50 HZ) IN AMPERES, NOTES 1 AND 2

MOTOR CODE 5CC 5CD 5CE 5CF 5CG 5CH 5CI 5CJ 5CK 5CL 5CM 5CN 5CO 5CP 5CQ 5CR 5CS 5CT 5CU 5CV 5CW 5CX 5DA 5DB 5DC 5DD 5DE 5DF 5DG 5DH 5DJ 5DK 5DL

3300 Volts Inrush Amps 72 73 94 106 109 123 132 143 143 175 190 205 225 232 257 276 290 312 326 335 369 394 392 511 511 511 637 637 637 750 716 1004 1116

NOTES: 1. Check to make sure FLA is within Starter Limitations. 2. Inrush values in the table have been calculated for voltages of 3300 by multiplying .45 x LRA @ 3300. 3. LRA exceeds starter limitations.

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FORM 160.00-TD5

TABLE 3 RATINGS OF MEDIUM VOLTAGE SOLID STATE STARTER

York Model Number MVSSS0853RK042-80 MVSSS0853RK050-80 MVSSS0853RK065-80 MVSSS0853RK095-80 MVSSS0853RK105-80 MVSSS0853RK140-80 MVSSS0853RK190-80 MVSSS0853RK280-80 MVSSS0853RK310-80 MVSSS0853RK360-80 MVSSS1708RK360-80 MVSSS1708RK550-80 MVSSS0853RK042-92 MVSSS0853RK050-92 MVSSS0853RK065-92 MVSSS0853RK095-92 MVSSS0853RK105-92 MVSSS0853RK140-92 MVSSS0853RK190-92 MVSSS0853RK280-92 MVSSS0853RK310-92 MVSSS0853RK360-92 MVSSS1708RK360-92 MVSSS1708RK550-92 MVSSS0853RK042-84 MVSSS0853RK050-84 MVSSS0853RK065-84 MVSSS0853RK095-84 MVSSS0853RK105-84 MVSSS0853RK140-84 MVSSS0853RK190-84 MVSSS0853RK280-84 MVSSS0853RK310-84 MVSSS0853RK360-84 MVSSS1708RK360-84 MVSSS1708RK550-84

Voltage 2300 2300 2300 2300 2300 2300 2300 2300 2300 2300 2300 2300 3300 3300 3300 3300 3300 3300 3300 3300 3300 3300 3300 3300 4160 4160 4160 4160 4160 4160 4160 4160 4160 4160 4160 4160

LRA max 1896 1896 1896 1896 1896 1896 1896 1896 1896 1896 3796 3796 1896 1896 1896 1896 1896 1896 1896 1896 1896 1896 3796 3796 1896 1896 1896 1896 1896 1896 1896 1896 1896 1896 3796 3796

100 % FLA max 42 50 65 95 105 140 190 280 310 360 360 550 42 50 65 95 105 140 190 280 310 360 360 550 42 50 65 95 105 140 190 280 310 360 360 550

Size (in) H x W x D 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X72X36 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92x72x36 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X36X32 92X72X36

JOHNSON CONTROLS

11

GUIDE SPECIFICATIONS The Mechanical Contractor shall furnish a reduced-voltage, Medium Voltage Solid State Starter, in accordance with the chiller manufacturers starter specifications. The starter shall be of modular construction with complete access to all parts. The starter shall be tested and the design starting current and overload settings adjusted at the factory. The starter shall provide, through the use of six in-line (not inside the Delta) silicon controlled rectifiers (2 per phase), a smooth acceleration of the motor without current transitions or transients. The following protective devices and convenience items shall be factory mounted and wired to the starter: a. 3-leg sensing electronic overloads shuts unit down if current exceeds 105% of FLA to protect the motor windings. b. Phase rotation protection circuit denies start-up when detecting incorrect power wiring phase sequence to the starter which could cause reverse motor rotation and damage the equipment. c. Single-phase failure protection circuit ensures against motor burnout by shutting the unit down if power loss occurs in any of the incoming lines during start-up. d. High temperature safety protection system temperature activated switches on heat sinks will shut the unit down if the SCR temperature exceeds acceptable limits. e. 3-phase digital ammeter and digital voltmeter readout via control center easily cross-check design current and voltage limitations against supply characteristics.

f. Starter mounted load break rated input disconnect switch with interlocked padlockable handle. Positive disconnecting means shall be visible from outside the enclosure, in operator area. All doors shall be interlocked with the disconnecting means. (Available primaries: 60 Hz 4160V, 2300V, 50 Hz 3300V g. Open/Shorted SCR Protection Failed semiconductor devices are automatically detected and reported via the Control Center. h. Power Fault Protection momentary power interruption protection detects power interruptions within 3 line cycles and interrupts power to the compressor motor within 1 additional line cycle. i. Electrical connections these tin-plated or copper bus bars provide easy connection to incoming copper power lines. k. Wattmeter An instantaneous wattmeter tells the customer how much power the chiller is consuming. A kilowatt-hour energy meter is also provided to measure power consumption over a period of time. l. Shut down History The Medium Voltage Solid State Starter shall provide the system control panel with ten histories of previous unit shutdowns initiated by the starter. In addition, the Starter shall include as standard, the following convenience items already mounted and wired to the starter at the factory: Auxiliary control supply transformer eliminates the need for running separate 115V - 1 ph - 50/60 Hz power source wiring to the chiller Control Center.

Form 160.00-TD5 (1006) Supersedes: 160.00-TD5 (606)

SHU 2M 706 1.08 Code: EYK

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