MANUAL DESCRIPTION. FORM NUMBER. Centrifugal Chiller Long Term Storage. 50.20-NM5. Equipment Pre-Startup and Startup Checklist. 201.23-CL2.
AIR-COOLED SCREW LIQUID CHILLERS
INSTALLATION, OPERATION, MAINTENANCE Supersedes: 201.23-NM2 (418) Form 201.23-NM2 (919) 035-21506-101
YCIV STYLE A MODELS YCIV0157-0397, 60 HZ
(150-260 TONS) AIR-COOLED SCREW LIQUID CHILLERS E/V HIGH EFFICIENCY AND S/P STANDARD EFFICIENCY
R-134a
Issue Date: September 30, 2019
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. During rigging, installation, operation, maintenance, or service, individuals may be exposed to certain components or conditions including, but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and both high and low voltage. Each of these items has the potential, if misused or handled improperly, to cause bodily injury or death. It is the obligation and responsibility of rigging, installation, and operating/service personnel to identify and recognize these inherent hazards, protect themselves, and proceed safely in completing their tasks. Failure to comply with any of these requirements could result in serious damage to the equipment and the property in
which it is situated, as well as severe personal injury or death to themselves and people at the site.
This document is intended for use by owner-authorized rigging, installation, and operating/service personnel. It is expected that these individuals possess independent training that will enable them to perform their assigned tasks properly and safely. It is essential that, prior to performing any task on this equipment, this individual shall have read and understood the on-product labels, this document and any referenced materials. This individual shall also be familiar with and comply with all applicable industry and governmental standards and regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken.
Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution if proper care is not taken or instructions and are not followed.
Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment if proper care is not taken.
Highlights additional information useful to the technician in completing the work being performed properly.
External wiring, unless specified as an optional connection in the manufacturer's product line, is not to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls and any external wiring must not be installed inside the micro panel. All wiring must be in accordance with Johnson Controls' published specifications and must be performed only by a qualified electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of improper control signals. Failure to follow this warning will void the manufacturer's warranty and cause serious damage to property or personal injury.
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls' policy for continuous product improvement, the information contained in this document is subject to change without notice. Johnson Controls makes no commitment to update or provide current information automatically to the manual or product owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson Controls Service office or accessing the Johnson Controls QuickLIT website at http://cgproducts. johnsoncontrols.com.
It is the responsibility of rigging, lifting, and operating/ service personnel to verify the applicability of these
The Control/VSD Cabinet contains lethal high AC and DC voltages. Before performing service inside the cabinet, remove the AC supply feeding the chiller and verify using a non-contact voltage sensor.
The DC voltage on the VSD DC Bus will take 5 minutes to bleed off, after AC power is removed. Always check the DC Bus Voltage with a Voltmeter to assure the capacitor charge has bled off before working on the system.
documents to the equipment. If there is any question regarding the applicability of these documents, rigging, lifting, and operating/service personnel should verify whether the equipment has been modified and if current literature is available from the owner of the equipment prior to performing any work on the equipment.
CHANGE BARS
Revisions made to this document are indicated with a line along the left or right hand column in the area the revision was made. These revisions are to technical information and any other changes in spelling, grammar or formatting are not included.
NEVER allow the Control Panel VSD Cabinet doors to remain open if there is a potential for rain to enter the panel. Keep doors closed and assure all latches are engaged on each door unless the unit is being serviced.
ALWAYS lockout the disconnect supplying AC to the chiller.
NEVER short out the DC Bus to discharge the filter capacitors.
NEVER place loose tools, debris, or any objects inside the Control Panel/VSD Cabinet.
The 1L Line Inductor will reach operating temperatures of over 150°C (300°F.). DO NOT open panel doors during operation. Assure the inductor is cool whenever working near the inductor with power OFF.
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ASSOCIATED LITERATURE
MANUAL DESCRIPTION Centrifugal Chiller Long Term Storage Equipment Pre-Startup and Startup Checklist Installation, Operation and Maintenance, 50 Hz Unit Replacement Parts, Style A, 50 Hz Unit Replacement Parts, Style A, 60 Hz Unit Replacement Parts, Style A, 50 Hz and 60 Hz All Products - Replacement Parts Electrical Connectors All Products - Replacement Parts Fittings
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
FORM NUMBER 50.20-NM5 201.23-CL2 201.23-NM1 201.23-RP1 201.23-RP2 201.23-RP3 50.20-RP1 50.20-RP2
SYSTEM NOMENCLATURE
Y CI
V - 0187 - S - A - 46 - V - A - A
YORK
Air Cooled Chiller
VSD Driven Screw Compressor
Model Number 0187 0720
Unit Designator E = High Efficiency with Standard IPLV S = Standard Efficiency with Standard IPLV P = Standard Efficiency with Optimized IPLV V = High Efficiency with Optimized IPLV
Development Code
Design Series
Starter - VSD
Voltage Code 17 = 200-3-60 28 = 230-3-60 40 = 380-3-60 46 = 460-3-60 50 = 380/400/415-3-50 58 = 575-3-60
A = Refrigerant R-134a B = Refrigerant R-513a
LD26906
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
TABLE OF CONTENTS
SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY....................................................................... 11 Introduction...................................................................................................................................................... 11 Warranty.......................................................................................................................................................... 11 Safety.............................................................................................................................................................. 11 About this Manual............................................................................................................................................ 12 Misuse of Equipment....................................................................................................................................... 12
SECTION 2 - PRODUCT DESCRIPTION................................................................................................................15 Introduction...................................................................................................................................................... 15 Accessories and Options................................................................................................................................. 22 Complete Pin Number Description.................................................................................................................. 25
SECTION 3 - RIGGING, HANDLING AND STORAGE...........................................................................................29 Lifting Weights................................................................................................................................................. 29 Delivery and Storage....................................................................................................................................... 29 Inspection........................................................................................................................................................ 29 Moving the Chiller............................................................................................................................................ 30 Unit Removal from Shipping Container........................................................................................................... 30 Lifting Using Lugs............................................................................................................................................ 30 Lifting Using Shackles..................................................................................................................................... 30
SECTION 4 - INSTALLATION.................................................................................................................................33 Location Requirements................................................................................................................................... 33 Outdoor Installations....................................................................................................................................... 33 Indoor Installations.......................................................................................................................................... 33 Location Clearances........................................................................................................................................ 33 Vibration Isolators............................................................................................................................................ 34 Shipping Braces.............................................................................................................................................. 34 Chilled Liquid Piping........................................................................................................................................ 34 Water Treatment.............................................................................................................................................. 35 Pipework Arrangement.................................................................................................................................... 36 Connection Types and Sizes........................................................................................................................... 36 Cooler Connections......................................................................................................................................... 36 Refrigerant Relief Valve Piping........................................................................................................................ 36 Ductwork Connection ..................................................................................................................................... 37 Electrical Connection....................................................................................................................................... 37 Power Wiring................................................................................................................................................... 38 Power Supply Wiring....................................................................................................................................... 38 115 VAC Control Supply Transformer.............................................................................................................. 38 Control Panel Wiring....................................................................................................................................... 38 Volts Free Contacts......................................................................................................................................... 39 System Inputs.................................................................................................................................................. 39
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TABLE OF CONTENTS (CONT'D)
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 5 - COMMISSIONING.............................................................................................................................41 Preparation...................................................................................................................................................... 41 Preparation General..................................................................................................................................... 41 First Time Start-Up.......................................................................................................................................... 42
SECTION 6 - TECHNICAL DATA............................................................................................................................51 Glycol Correction Factors................................................................................................................................ 55 Electrical Notes............................................................................................................................................... 80 Electrical Wiring Diagrams - 2 Compressor Models........................................................................................ 82 Electrical Wiring Diagrams - 3 Compressor Models........................................................................................ 96 Dimensions - 2 and 3 Compressor SI........................................................................................................... 112 Technical Data - Clearances......................................................................................................................... 132 Isolator Information for Units Shipped on or After June 15, 2008.................................................................. 133 Isolator Information for Units Shipped Before June 15, 2008........................................................................ 156 Refrigerant Flow Diagram............................................................................................................................. 161 Process and Instrumentation Diagram.......................................................................................................... 162 Component Locations................................................................................................................................... 163 Glycol System Components.......................................................................................................................... 184 Compressor Components............................................................................................................................. 186 Chiller Electronic Components...................................................................................................................... 187 Chiller Configuration Jumpers....................................................................................................................... 195 VSD Logic to Chiller Microprocessor Board RS-485 Communication Configuration Jumpers...................... 196 Maximum VSD Frequency/Model designator................................................................................................ 196
SECTION 7 - OPERATION....................................................................................................................................197 Operating Controls........................................................................................................................................ 197 Basic Operating Sequence............................................................................................................................ 198 Number of Compressors to Start................................................................................................................... 199 Minimum VSD Compressor Start / Run Frequency.......................................................................................200 Acceleration / Deceleration Rate when Starting / Stopping Compressors.................................................... 201 Standard IPLV Capacity Control.................................................................................................................... 201 Optional High IPLV Capacity Control ........................................................................................................... 203 Load Limiting Control.................................................................................................................................... 206 Flash Tank Drain and Feed Valve Controller................................................................................................. 208 Economizer Control....................................................................................................................................... 211 Condenser Fan Control................................................................................................................................. 212 VSD Temperature Control, Operation of the Coolant Pump, and VSD Cabinet Cooling Fans...................... 213 Remote Temperature Reset Control.............................................................................................................. 214 Remote Current Limit Reset Control............................................................................................................. 215 Sound Limit Control....................................................................................................................................... 217
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
TABLE OF CONTENTS (CONT'D)
SECTION 8 - MICROPANEL.................................................................................................................................219 VSD Operation and Controls......................................................................................................................... 219 VSD Safeties (Faults).................................................................................................................................... 223 Unit Warnings................................................................................................................................................ 229 Microboard (331-03478-xxx)......................................................................................................................... 229 Program Update............................................................................................................................................ 231 Data Logging................................................................................................................................................. 232 Unit Safeties.................................................................................................................................................. 233 System Safeties (Faults)............................................................................................................................... 235 Status Key..................................................................................................................................................... 240 Unit Data Key................................................................................................................................................ 243 System Data Keys 1 Through 4.................................................................................................................... 245 VSD Data Key............................................................................................................................................... 248 Operating Hours / Start Counter Key............................................................................................................ 250 History Key.................................................................................................................................................... 251 Setpoints Key................................................................................................................................................ 258 Program Key................................................................................................................................................. 260 Options Key................................................................................................................................................... 263 Date / Time and Schedule Keys.................................................................................................................... 266 Manual Override Key..................................................................................................................................... 270 Print Key........................................................................................................................................................ 271 Service Key................................................................................................................................................... 274 System Switches Key.................................................................................................................................... 280 Serial Number Programming......................................................................................................................... 281 Enabling Optimized High IPLV Mode............................................................................................................ 282 Unit Setup Mode............................................................................................................................................ 283 Default Programmable Values....................................................................................................................... 284 Serial Port Connections................................................................................................................................. 284 Analog Input Connections............................................................................................................................. 285 Digital Intput Connections............................................................................................................................. 287 Analog Output Connections.......................................................................................................................... 288 Digital Output Connections............................................................................................................................ 289 BACNET, MODBUS and YORKTALK 2 Communications............................................................................. 291
SECTION 9 - MAINTENANCE...............................................................................................................................305 General Requirements.................................................................................................................................. 305 Evacuating a System..................................................................................................................................... 305 R-134a Conversion Tables............................................................................................................................ 306 Maintenance Requirements for YCIV Chillers............................................................................................... 307 Troubleshooting Guide ................................................................................................................................. 308 Limited Warranty........................................................................................................................................... 310 Chilled Liquid and Suction Temperature Sensor Input Voltage .................................................................... 311 Printer Wiring................................................................................................................................................. 318 Operating Log Sheet..................................................................................................................................... 320 Recommended Spare Parts.......................................................................................................................... 324
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LIST OF FIGURES
FIGURE 1 - Chiller Control System16 FIGURE 2 - Compressor16 FIGURE 3 - PWM Current Waveform21 FIGURE 4 - PWM Voltage Waveform21 FIGURE 5 - Pipework Arrangement36 FIGURE 6 - Grooved Nozzle36 FIGURE 7 - Flange Attachment36 FIGURE 8 - Two Compressor Wiring Diagram With Circuit Breaker66 FIGURE 9 - Two Compressor Wiring Diagram With Terminal Block66 FIGURE 10 - Three Compressor Wiring Diagram With Circuit Breaker Single Point 67 FIGURE 11 - Three Compressor Wiring Diagram With Terminal Block Single Point 67 FIGURE 12 - Elementary Control Wiring Diagram 2 Compressor Models 82 FIGURE 13 - Elementary Power Wiring Diagram - YCIV0157-0267 2 Compressor Models 84 FIGURE 14 - Power Wiring Connection Diagram - YCIV0157-0267 2 Compressor Models 86 FIGURE 15 - Control Wiring Connection Diagram - YCIV0157-0267 2 Compressor Models 88 FIGURE 16 - Power Elementary Wiring Diagram - YCIV0157-0267 2 Compressor Models 91 FIGURE 17 - Control Elementary Diagram - YCIV0257-0397 3 Compressor Models 96 FIGURE 18 - Power Elementary Diagram - YCIV0257-0397 3 Compressor Models 100 FIGURE 19 - Control Wiring Connection Diagram - YCIV0257-0397 3 Compressor Models 102 FIGURE 20 - Power Wiring Connection Diagram - YCIV1050-1500 3 Compressor Models 106 FIGURE 21 - Power Elementary Diagram - YCIV0257-0397 3 Compressor Models 108 FIGURE 22 - Refrigerant Flow Diagram161 FIGURE 23 - Process and Instrumentation Diagram162 FIGURE 24 - Component Locations163 FIGURE 25 - Control and VSD Cabinet Components164 FIGURE 26 - Chiller Control Board, Relay Boards, Microgateway, and Optional Circuit Breaker 165 FIGURE 27 - Chiller Control Board, Relay Boards, and Microgateway, 2 Compressor 166 FIGURE 28 - Chiller Control Board, Relay Boards, and Microgateway, 3 Compressor 167 FIGURE 29 - VSD Logic Board168 FIGURE 30 - VSD Logic Board (Original - Obsolete), P/N 031-02477-000 169 FIGURE 31 - VSD Logic Board (New), P/N 031-02507-XXX 170 FIGURE 32 - Power Components, 2 Compressor171 FIGURE 33 - Power Components, 3 Compressor172 FIGURE 34 - Fan Contactors and 3T Transformer, 2 Compressor173 FIGURE 35 - Fan Contactors, 3 Compressor174 FIGURE 36 - VSD Components175 FIGURE 37 - VSD Components, 2 Compressor176 FIGURE 38 - VSD Components, 3 Compressor177 FIGURE 39 - VSD Components, 2 Compressor178 FIGURE 40 - VSD Components, 3 Compressor179 FIGURE 41 - Inverter Power Components, 2 Compressor180 FIGURE 42 - Inverter Power Components, 3 Compressor181 FIGURE 43 - Inverter Power Components182 FIGURE 44 - Glycol Pump and Fill Tube Locations184 FIGURE 45 - Glycol Piping and Fill Tube Location185 FIGURE 46 - Compressor Components186 FIGURE 47 - New Board P/N 031-02507-000192 FIGURE 48 - Obsolete Board P/N 031-02477-000192 FIGURE 49 - Chiller Control (Cooling) Range199 FIGURE 50 - Number of Compressors to Start200 FIGURE 51 - Minimum VSD Start Frequency200 FIGURE 52 - Minimum VSD Run Frequency201 FIGURE 53 - Flash Tank Drain and Feed Valve Controller208 FIGURE 54 - LED Locations210 FIGURE 55 - Power and Comms LED's 210
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LIST OF FIGURES (CONT'D)
FIGURE 56 - Power, Comms and System Open/Close LED's210 FIGURE 57 - Condenser Fan Locations212 FIGURE 58 - Standard IPLV Fan Control213 FIGURE 59 - High IPLV Fan Control213 FIGURE 60 - Microboard 331-03478-xxx230 FIGURE 61 - Control Board Connections292 FIGURE 62 - Print Cable - Chiller to Serial Printer318
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LIST OF TABLES
TABLE 1 - Typical Compressor Starting Current (First Four Seconds Of Start-Up) 80 TABLE 2 - Voltage Utilization Range80 TABLE 3 - Compressors and the Appropriate Jumper Positions195 TABLE 4 - VSD Logic Board Address Jumper196 TABLE 5 - Maximum Frequency / Model Designator Jumper196 TABLE 6 - Fuzzy Logic Loading/Unloading vs. Error203 TABLE 7 - Fuzzy Logic Loading/Unloading vs. Error205 TABLE 8 - Current Limit Load Limiting/Unloading206 TABLE 9 - Discharge Pressure Load Limiting/Unloading207 TABLE 10 - Suction Pressure Load Limiting/Unloading207 TABLE 11 - VSD Internal Ambient Load Limiting/Unloading207 TABLE 12 - VSD Baseplate Temperature Load Limiting/Unloading208 TABLE 13 - Fan Stages and Corresponding Outputs212 TABLE 14 - VSD Operating Display Parameters223 TABLE 15 - Flash Card Update Error XXXXX232 TABLE 16 - Data Logging 232 TABLE 17 - Low Differential Oil Pressure Cutout237 TABLE 18 - Start Inhibit Sensor Thresholds239 TABLE 19 - Sensor Min/Max Outputs247 TABLE 20 - Setpoint Limits259 TABLE 21 - Programmable Operating Parameters262 TABLE 22 - Printout Types271 TABLE 23 - Unit Setup Programmable Values283 TABLE 24 - Serial Port Connections285 TABLE 25 - Analog Input Connections285 TABLE 26 - Digital Input Connections 287 TABLE 27 - Analog Output Connections288 TABLE 28 - Digital Output Connections289 TABLE 29 - Minimum, Maximum and Default Values292 TABLE 30 - Values Required for BAS Communication293 TABLE 31 - Real Time Error Numbers293 TABLE 32 - Bacnet and Modbus Communications Data Map295 TABLE 33 - YorkTalk 2 Communications Data Map301 TABLE 34 - R-134a Pressure to Saturated Temperature Conversion306 TABLE 35 - Temperature Input Voltage Sensor (Measured Signal to Shield at the Sensor) 311 TABLE 36 - Outside Air Temperature Sensor Input Voltage (Measured Signal to Shield at the Sensor) 312 TABLE 37 - Pressure Transducer Output Voltage (Measured Signal to Return at the Transducer) 313 TABLE 38 - Motor Temperature Sensor Resistance (Check at the Motor) 314 TABLE 39 - Compressor Motor Overload Settings and Max. VSD Frequency 315
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY
1
INTRODUCTION
YORK YCIV0157 through 0397 chillers are manufactured to the highest design and construction standards to ensure high performance, reliability and adaptability to all types of air conditioning installations.
The unit is intended for cooling water or glycol solutions and is not suitable for purposes other than those specified in this manual.
Rigging and lifting should only be done by a professional rigger in accordance with a written rigging and lifting plan. The most appropriate rigging and lifting method will depend on job specific factors, such as the rigging equipment available and site needs. Therefore, a professional rigger must determine the rigging and lifting method to be used, and it is beyond the scope of this manual to specify rigging and lifting details.
This manual contains all the information required for correct installation and commissioning of the unit, together with operating and maintenance instructions. The manuals should be read thoroughly before attempting to operate or service the unit.
All procedures detailed in the manuals, including installation, commissioning and maintenance tasks must only be performed by suitably trained and qualified personnel.
The manufacturer will not be liable for any injury or damage caused by incorrect installation, commissioning, operation or maintenance resulting from a failure to follow the procedures and instructions detailed in the manuals.
WARRANTY
Johnson Controls warrants all equipment and materials against defects in workmanship and materials for a period of eighteen months from date of shipment, unless labor or extended warranty has been purchased as part of the contract.
The warranty is limited to parts only replacement and shipping of any faulty part, or sub-assembly, which has failed due to poor quality or manufacturing errors. All claims must be supported by evidence that the failure has occurred within the warranty period, and that the unit has been operated within the designed parameters specified.
JOHNSON CONTROLS
All warranty claims must specify the unit model, serial number, order number and run hours/starts. Model and serial number information is printed on the unit identification plate.
The unit warranty will be void if any modification to the unit is carried out without prior written approval from Johnson Controls.
For warranty purposes, the following conditions must be satisfied:
· The initial start of the unit must be carried out by trained personnel from an authorized Johnson Controls Service Center. See SECTION 5 - COMMISSIONING.
· Only genuine YORK approved spare parts, oils, coolants, and refrigerants must be used. Recommendations on spare part stocking can be found on Recommended Spare Parts on page 324.
· All the scheduled maintenance operations detailed in this manual must be performed at the specified times by suitably trained and qualified personnel.
See SECTION 9 - MAINTENANCE.
· Failure to satisfy any of these conditions will automatically void the warranty. See Limited Warranty on page 310.
SAFETY
Standards for Safety YCIV chillers are designed and built within an ISO 9002 accredited design and manufacturing organization.
The chillers comply with the applicable sections of the following Standards and Codes:
· ANSI/ASHRAE Standard 15, Safety Code for Mechanical Refrigeration.
· ANSI/NFPA Standard 70, National Electrical Code (N.E.C.).
· ASME Boiler and Pressure Vessel Code, Section VIII Division 1.
· ARI Standard 550/590-98, Water Chilling Packages Using the Vapor Compression Cycle.
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SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY
· ASHRAE 90.1 Energy Standard for Building Except Low-Rise Residential Buildings.
· ARI 370 Sound Rating of Large Outdoor Refrigeration and Air Conditioning Equipment.
In addition, the chillers conform to Underwriters Laboratories (U.L.) for construction of chillers and provide U.L./cU.L. Listing Label.
Responsibility for Safety Every care has been taken in the design and manufacture of the unit to ensure compliance with the safety requirements listed above. However, the individual rigging, lifting, maintaining, operating or working on any machinery is primarily responsible for:
· Personal safety, safety of other personnel, and the machinery.
· Correct utilization of the machinery in accordance with the procedures detailed in the manuals.
ABOUT THIS MANUAL
The following terms are used in this document to alert the reader to areas of potential hazard.
A WARNING is given in this document to identify a hazard, which could lead to personal injury. Usually an instruction will be given, together with a brief explanation and the possible result of ignoring the instruction.
A CAUTION identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution. Usually an instruction will be given, together with a brief explanation and the possible result of ignoring the instruction.
A NOTE is used to highlight additional information, which may be helpful to you but where there are no special safety implications.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
This manual and any other document supplied with the unit are the property of Johnson Controls which reserves all rights. They may not be reproduced, in whole or in part, without prior written authorization from an authorized Johnson Controls representative.
MISUSE OF EQUIPMENT
Suitability for Application
The unit is intended for cooling water or glycol solutions and is not suitable for purposes other than those specified in these instructions. Any use of the equipment other than its intended use, or operation of the equipment contrary to the relevant procedures may result in injury to the operator, or damage to the equipment.
The unit must not be operated outside the design parameters specified in this manual.
Structural Support
Structural support of the unit must be provided as indicated in these instructions. Failure to provide proper support may result in injury to the operator, or damage to the equipment and/or building.
Mechanical Strength
The unit is not designed to withstand loads or stresses from adjacent equipment, pipework or structures. Additional components must not be mounted on the unit. Any such extraneous loads may cause structural failure and may result in injury to the operator, or damage to the equipment.
General Access
There are a number of areas and features, which may be a hazard and potentially cause injury when working on the unit unless suitable safety precautions are taken. It is important to ensure access to the unit is restricted to suitably qualified persons who are familiar with the potential hazards and precautions necessary for safe operation and maintenance of equipment containing high temperatures, pressures and voltages.
The contents of this manual include suggested best working practices and procedures. These are issued for guidance only, and they do not take precedence over the above stated individual responsibility and/or local safety regulations.
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Pressure Systems
The unit contains refrigerant vapor and liquid under pressure, release of which can be a danger and cause injury. The user should ensure that care is taken during installation, operation and maintenance to avoid damage to the pressure system. No attempt should be made to gain access to the component parts of the pressure system other than by suitably trained and qualified personnel.
Electrical
The unit must be grounded. No installation or maintenance work should be attempted on the electrical equipment without first switching power OFF, isolating and locking-off the power supply. Servicing and maintenance on live equipment must not be attempted. No attempt should be made to gain access to the control panel or electrical enclosures during normal operation of the unit.
Rotating Parts
Fan guards must be fitted at all times and not removed unless the power supply has been isolated. If ductwork is to be fitted, requiring the wire fan guards to be removed, alternative safety measures must be taken to protect against the risk of injury from rotating fans.
Sharp Edges
The fins on the air-cooled condenser coils have sharp metal edges. Reasonable care should be taken when working in contact with the coils to avoid the risk of minor abrasions and lacerations. The use of gloves is recommended.
Frame rails, brakes, and other components may also have sharp edges. Reasonable care should be taken when working in contact with any components to avoid risk of minor abrasions and lacerations.
SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY
Refrigerants and Oils Refrigerants and oils used in the unit are generally non-
1
toxic, non-flammable and non-corrosive, and pose no
special safety hazards. Use of gloves and safety glasses
is, however, recommended when working on the unit.
The buildup of refrigerant vapor, from a leak for ex-
ample, does pose a risk of asphyxiation in confined or
enclosed spaces and attention should be given to good
ventilation.
Use only the refrigerant specifically designated for the unit. Any other type of refrigerant may cause damage to the equipment and will void the warranty.
High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods (e.g. steam cleaning) should not be used on any part of the pressure system as this may cause operation of the pressure relief device(s). Detergents and solvents, which may cause corrosion, should also be avoided.
Emergency Shutdown
In case of emergency, the control panel is fitted with a UNIT switch to stop the unit in an emergency. When operated, it removes the low voltage 120VAC electrical supply from the inverter system, thus shutting down the unit.
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 2 - PRODUCT DESCRIPTION
INTRODUCTION
YORK YCIV R-134a chillers are designed for water or glycol cooling. All units are designed to be located outside on the roof of a building or at ground level.
The units are completely assembled with all interconnecting refrigerant piping and internal wiring, ready for field installation.
Prior to delivery, the unit is pressure tested, evacuated, and fully charged with refrigerant and oil in each of the two independent refrigerant circuits. After assembly, an operational test is performed with water flowing through the cooler to ensure that each refrigerant circuit operates correctly.
The unit structure is manufactured from heavy gauge, galvanized steel. Many external structural parts are coated with "Champagne" baked-on enamel powder paint. This provides a finish which, when subjected to ASTM B117, 1000 hour, 5% salt spray conditions, shows breakdown of less than 1/8 in. either side of a scribed line (equivalent to ASTM D1654 rating of "6").
All exposed power wiring is routed through liquidtight, non-metallic conduit.
General System Description
The Latitude (YCIV) Air-Cooled Chiller line combines
the best of modern screw compressor design with the 2
latest technology in variable speed drives. The result is superior control and efficiency in real world conditions. The VSD enables slowing the speed of the compressor to match the load on the system resulting in precise chilled liquid control, minimized sound, maximum energy efficiency, and reduced cost of ownership. The VSD also provides soft starts with no electrical inrush. The lack of heat build-up on start also enables required off time between starts to be reduced to a period of 2 minutes.
The YCIV Air-Cooled Screw Chiller utilizes many components, which are the same or nearly the same as a standard screw chiller of a similar size. This includes modular frame rails, condenser, fans, compressors and evaporator.
The chiller consists of 2 or 3 screw compressors in a corresponding number of separate refrigerant circuits, a single shell and tube DX evaporator, an air-cooled condenser, flash tanks, drain/feed valves, oil separators, and compressor mufflers. Oil separators utilize no moving parts and are rated for a 405 psig design working pressure. Oil cooling is accomplished by routing oil from the oil separator through several rows of tubes in the air cooled condenser.
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SECTION 2 - PRODUCT DESCRIPTION
An integral liquid cooled, transistorized, PWM, Variable Speed Drive (VSD) is controlled by the chiller microprocessor control panel to start/stop, select compressors to run, and select compressor speed. Power Factor is 95% at part or full load.
The chiller microprocessor communicates with the VSD Logic Board via a 3-wire RS-485 opto coupled data link. The VSD Logic Board runs the number of compressors required to meet the load and the compressors to the speed requested by the chiller microprocessor.
The basic system control architecture is shown in the diagram below:
CHILLER CONTROL SYSTEM
INPUTS
Pressure Transducers Temperature Sensors Level Sensor Switches
Liquid Flow High Pressure Start/Stop
Customer Supplied Contacts
COMMUNICATIONS
Building Automation Printer Modem
CONTROL PANEL
(Chiller Control Board)
Microprocessor User Interface
Display &
Keypad
OUTPUTS
(Relay Output Board)
Solenoids Contactors
Alarm Pump Compressor Heater Run Status Evap Heater
VSD
VSD Logic Board SCR Trigger Board Power Components PWM (Speed Control)
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Refrigerant gas is injected into the void created by the un-meshing of the five lobed male and seven lobed female rotors. Further meshing of the rotors closes the rotor threads to the suction port and progressively compresses the gas in an axial direction to the discharge port. The gas is compressed in volume and increased in pressure before exiting at a designed volume at the discharge end of the rotor casing. Since the intake and discharge cycles overlap, a resulting smooth flow of gas is maintained.
The rotors are housed in a cast iron compressor housing precision machined to provide optimal clearances for the rotors. Contact between the male and female rotor is primarily rolling on a contact band on each of the rotor's pitch circle. This results in virtually no rotor wear and increased reliability, a trademark of the screw compressor.
The MTS compressor incorporates a complete antifriction bearing design for reduced power input and increased reliability. Separated, cylindrical, roller bearings handle radial loads. Angular-contact ball bearings handle axial loads. Together they maintain accurate rotor positioning at all pressure ratios, thereby minimizing leakage and maintaining efficiency.
MOTOR
Figure 1 - CHILLER CONTROL SYSTEM
LD10478
The chiller is designed to operate in ambient temperatures of 0°F to 125°F (-18°C to 52°C). Capacity control is capable of reducing chiller capacity to 10% of full load without the need for Hot Gas Bypass.
Compressor
The direct drive semi-hermetic rotary twin-screw MTS compressor is designed for industrial refrigeration applications and ensures high operational efficiencies and reliable performance. Capacity control is achieved by stepless VSD speed changes. No slide valve is required. Smooth capacity control is achieved between 10% and 100% of chiller capacity in most operating conditions. The compressor is a positive displacement type characterized by two helically grooved rotors, which are manufactured from forged steel. The 4 pole motor operates at speeds up to 6000 RPM to direct drive the male rotor, which in turn drives the female rotor on a light film of oil.
16
Figure 2 - COMPRESSOR
LD10481 LD10482
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Motor cooling is provided by suction gas from the evaporator flowing across the motor. Redundant overload protection is provided using both internal thermistor and current overload protection on all three phases.
The MTS compressor is lubricated by removing oil from the refrigerant using an external oil separator. The pressurized oil is then cooled in the condenser coils and piped back to the compressor through a removable 2.5 micron oil filter to provide compressor lubrication. The cast iron compressor housing design working pressure is 450 psig (31 bar). Each chiller receives a 300 psig (21 bar) low side and a 450 psig (31 bar) high side factory test. A 350 watt (115-1-60 Hz) cartridge heater is located in the compressor. The heater is temperature activated to prevent refrigerant condensation.
The following items are also included:
· Acoustically tuned, external discharge muffler to minimize noise, while optimizing flow for maximum performance.
· Discharge shutoff valve.
· Rain-tight terminal box.
· Suction gas screen within the compressor housing.
Evaporator
The system uses a high-efficiency shell and tube type Direct Expansion Evaporator. Each of the two or three refrigerant circuits consists of two (2) passes with the chilled liquid circulating back and forth across the tubes from one end to the other.
The design working pressure of the cooler on the shell side is 150 psig (10 bar), and 235 psig (16 bar) for the tube (refrigerant) side. The evaporator is constructed and tested in accordance with applicable sections of the ASME Pressure Vessel Code, Section VII, Division (1). Waterside exempt per paragraph U-1, c, (6).
The water baffles are fabricated from galvanized steel to resist corrosion. Removable heads are provided for access to internally enhanced, seamless, copper tubes. Water vent and drain connections are included.
The cooler is equipped with a thermostatically controlled heater for protection to -20°F (-29°C) ambient and insulated with 3/4 in. (19 mm) flexible closed-cell insulation.
SECTION 2 - PRODUCT DESCRIPTION
The water nozzles are provided with grooves for mechanical couplings and should be insulated by the contractor after pipe installation.
A 300 psig (20.7 bar) waterside design working pressure option is available.
2
Two compressor chillers utilize a typical 2-pass "E" type evaporator with liquid inlets and suction outlets at the same end. Entering chilled liquid enters the refrigerant liquid inlet end of the cooler and leaving chilled liquid exits at the opposite end.
Three compressor chillers utilize a single pass "J" type evaporator with liquid inlets at one end and suction outlets at the opposite end. Entering chilled liquid is split and half flow enters at each end of the evaporator with leaving chilled liquid exiting in the center of the evaporator. "J" type evaporators have fewer, longer tubes than a comparable "E" type. This results in a smaller diameter, longer shell. Water flow rate internally in the evaporator is ½ of the total loop flow rate since the flow is split between two inlets. This results in a low evaporator water pressure drop.
Condenser
The fin and tube condenser coils are manufactured from seamless, internally enhanced, high-condensing coefficient, corrosion-resistant copper tubes arranged in staggered rows and mechanically expanded into corrosion resistant aluminum alloy fins with full height fin collars. The condenser has a design working pressure of 450 psig (31 bar).
Multiple, standard low sound, high efficiency, TEAO motor driven fans move air through the coils. They are dynamically and statically balanced, direct drive with corrosion-resistant glass fiber reinforced composite blades molded into low-noise, full airfoil cross sections, providing vertical air discharge from extended orifices for efficiency and low sound. Fans or pairs of fans are located in a separate compartments separated by "V" panels to prevent cross flow during fan cycling. Guards of heavy-gauge, PVC-coated galvanized steel are provided.
The standard fan motors are high-efficiency, direct drive, 6-pole, 3-phase, Class- "F," current overload protected, totally enclosed (TEAO) type with doublesealed, permanently lubricated ball bearings.
JOHNSON CONTROLS
17
SECTION 2 - PRODUCT DESCRIPTION
Flash Tank Feed Valve/Drain Valves
A flash tank is fitted to both refrigerant circuits. The flash tank is a shell type refrigerant reservoir designed to sustain 2 phase refrigerant. The purpose of the flash tank is to increase the efficiency of the system. A portion of the liquid fed into the flash tank gases off, cooling the remaining liquid in the tank another 25°F to 35°F. Both liquid and gas exist in the flash tank. The refrigerant gas in the flash tank is fed to the economizer port on the compressor at a point on the rotors approximately 1.7 x suction when the economizer solenoid is activated. The liquid in the tank is fed to the evaporator.
The vapor feed to the economizer port of the compressor is at an intermediate pressure between discharge and suction (1.7 x suction) and therefore little energy is required to pump it back through the compressor to condenser pressure. This results in a very small loss to system efficiency.
The design working pressure of the flash tank is 450 psig (31 bar). The Drain and Feed Valves on the flash tank are activated on start-up. The Feed Valve on the flash tank acts like a liquid line solenoid, but also functions to control the liquid level in the flash tank. The Drain Valve functions similar to an electronic expansion valve (EEV). The Drain Valve controls refrigerant flow to the evaporator based on suction superheat. Both valves are stepper motor valves. An economizer solenoid is placed between the flash tank and the economizer port of the compressor. The economizer solenoid valve is generally activated at speeds above 90 Hz to 120 Hz, depending upon a number of other factors.
Both valves are controlled by 2 phase drive signals from a stand-alone controller in the Control. Signals from sensors such as suction pressure and temperature are sent to the Chiller Control Board, which in turn sends control signals to the Drain and Feed Valve Controller. The control algorithm in the Chiller Control Board will attempt to control the liquid level in the flash tank to 35% on the level sensor and the system will fault if the flash tank level exceeds 87.5%.
During operation, it will be noted the flash tank level will typically remain between 30-40% level when the economizer solenoid is ON. The economizer solenoid valve will typically be on most of the time. When the economizer solenoid is OFF, the liquid level will vary greatly as the Drain and Feed Valves directly affect the level as they open and close.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Oil Separator/Oil System
The external oil separators, with no moving parts and designed for minimum oil carry-over, are mounted in the discharge line of the compressor. The high pressure discharge gas is forced around a 90 degree bend. Oil is forced to the outside of the separator through centrifugal action and captured on wire mesh where it drains to the bottom of the oil separator and is then forced into the condenser.
The oil (YORK "L" oil a POE oil used for all refrigerant applications), flows from the oil separator, through the condenser where it is cooled, and back into the compressor through a replaceable 0.5 micron oil filter at high pressure. This high pressure "oil injection" forces the oil into the compressor, where it is fed to the bearings and rotors for lubrication. After lubricating the bearings, it is injected through orifices on a closed thread near the suction end of the rotors. The oil is automatically injected because of the pressure difference between the discharge pressure and the reduced pressure at the suction end of the rotors. This lubricates the rotors as well as provides an oil seal against leakage around the rotors to ensure refrigerant compression efficiency.
The oil also provides cooling by transferring much of the heat of compression from the gas to the oil, keeping discharge temperatures down and reducing the chance for oil breakdown. Oil injected into the rotor cage flows into the rotors at a point about 1.2 x suction. This ensures that a required minimum differential of at least 30 PSID exists between discharge and 1.2 x suction, to force oil into the rotor case. A minimum of 10 psid (0.6 bar) is all that is required to ensure protection of the compressor. The oil pressure safety is monitored as the difference between suction pressure and the pressure of the oil entering the rotor case.
Maximum working pressure of the oil separator is 450 psig (31 bar). Oil level should be above the midpoint of the "lower" oil sight glass when the compressor is running. Oil level should not be above the top of the "upper" sight glass.
Relief Valves
Two relief valves are installed in each refrigerant circuit. A 325 psig relief valve is located on each flash tank and a 250 psig relief valve is located on the suction line of the compressor near the evaporator.
18
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Oil Cooling Oil cooling is provided by routing oil from the oil separator through several of the top rows of the condenser coils and back to the compressor.
Capacity Control When cooling is needed, one or more compressors, as determined by the system microprocessor based on deviation from setpoint, will start at minimum speed with low inrush current. Variable speed operation of the compressor reduces the capacity and allows smooth balancing of the compressor capacity with the cooling load.
Capacity control is accomplished by varying the number of compressors and the speed of the compressors with the VSD to promote stable, smooth, and precise loading/unloading.
Hot Gas Bypass is not required with VSD control of the compressors.
The chiller is available with Standard IPLV or High IPLV software (EPROM). High IPLV software optimizes the performance of the chiller capacity and fan controls. High IPLV chillers also require additional factory programming.
Power and Control Panel All controls and the VSD are factory-wired and function tested. The panel enclosures are designed to NEMA 3R (IP65) rating and are manufactured from powder-painted steel with hinged, latched, and gasket sealed outer doors with wind struts for safer servicing.
The power and micro control panels are combined into a single control/power cabinet and include:
· Compressor VSD Controls.
· Chiller Microprocessor Controls.
· Fan Controls.
· All Other Chiller Controls.
The Display and keypad are accessible through an access door without opening the main doors to the electrical cabinet.
Each Power Compartment Contains Incoming single point power is standard utilizing either a lockable circuit breaker or terminal block, 115 VAC control transformer, VSD, fan contactors, ON/ OFF unit switch, microcomputer keypad and display, Chiller Control and VSD Logic Boards, and relay boards.
JOHNSON CONTROLS
SECTION 2 - PRODUCT DESCRIPTION
Current transformers sense each phase of motor current, and send corresponding signals to the Chiller Logic Board. Current monitoring protects the compressor motors from damage due to low motor current,
high motor current, short circuit current, single phas- 2
ing, and compressor overload.
Short Circuit Withstand Rating of the chiller electrical enclosure is 30,000 Amps for standard terminal block connection. Ratings are in accordance with UL508C. A Circuit Breaker Option can be added to increase the Short Circuit Withstand Rating to 200/230 V equals 100,000 A, 380/460 V equals 65,000 A, and 575 V equals 42,000 A.
Microprocessor and VSD Controls Microprocessors on the Chiller Control Board and VSD Logic Board control starting, stopping, loading, unloading, safeties, and chilled liquid temperature control. Chilled liquid control decisions are a function of temperature deviation from setpoint and the rate of change of temperature.
The standard controls include:
· Brine Chilling.
· Thermal Storage.
· Run Signal Contacts.
· Unit Alarm Contacts.
· Chilled Liquid Pump Control.
· Automatic reset after power failure.
· Automatic system optimization to match operating conditions.
Remote cycling, optional current limiting, optional temperature setpoint reset, and optional remote sound limit can be accomplished by connecting user-supplied signals to the microprocessor.
Unit operating software is stored in non-volatile memory. Field programmed setpoints are retained in lithium battery backed real time clock (RTC) memory for 10 years.
Display The display consists of a liquid crystal 2 line by 40 characters per line display, with backlighting for outdoor viewing of operating parameters and program points.
19
SECTION 2 - PRODUCT DESCRIPTION
Parameters are displayed in 5 languages in either English (°F and psig) or Metric (°C and bar) units, and for each circuit, the following items can be displayed:
· Entering and leaving chilled liquid, and ambient temperature.
· Day, date and time. Daily start/stop times. Holiday and Manual Override status.
· Compressor operating hours and starts. Automatic or manual lead/lag. Lead compressor identification.
· Run permissive status. Compressor run status.
· Anti-recycle timers.
· System suction (and suction superheat), discharge (and discharge superheat), and oil pressures and temperatures.
· Percent full load compressor motor current and average motor current. Compressor motor speed (frequency).
· Cutout status and setpoints for supply chilled liquid temperature, low suction pressure, high discharge pressure and temperature, high oil temperature, low ambient, and low leaving liquid temperature.
· Unloading limit setpoints for high discharge pressure and compressor motor current.
· Status of evaporator heater, condenser fans, load/ unload timers, and chilled water pump.
· "Out of range" message.
· Up to 10 fault shutdown histories.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Keypad An operator keypad allows complete control of the system from a central location. The keypad utilizes an overlay to allow use in 5 languages. The keypad is a color-coded, 36 button, sealed keypad with keys for Display, Entry, Setpoints, Clock, Print, Program, Unit ON/OFF and other functions. Details on a few of the keys follow:
Status Allows viewing present unit or system status displayed by the microprocessor.
Entry Numeric keypad and supporting keys used to confirm Setpoint changes, cancel inputs, advance day, and change AM/PM.
Setpoints For setting chilled liquid temperature, chilled liquid range, remote reset temperature range.
Date/Time Used to set time, daily or holiday start/ stop schedule, manual override for servicing, and sound limiting schedule.
Print Used to display or print operating data or system fault shutdown history for last ten faults. Printouts are generated through an RS-232 port via a separate printer.
Program For setting low leaving liquid temperature cutout, average motor current limit, and pulldown demand limit.
Displays are also provided for programming low ambient cutout, low suction pressure cutout, superheat setpoint, etc., under the PROGRAM key.
Unit Switch A master UNIT switch allows activation or de-activation of the chiller system. Separate system switches for controlling each system are provided as part of the chiller control panel keypad.
20
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Variable Speed Drive (VSD)
The VSD (variable speed drive) is a liquid cooled, transistorized, PWM inverter, which provides speed control to vary the speed of 2, 3 or 4 compressor motors. The VSD changes the duration of the voltage pulses supplied to the motor to enable control of compressor speed to match the system load. A PWM generator, on the VSD Logic Board, with a switching frequency of 3125 Hz modulates the voltage signal to provide a relatively pulses constant V/F ratio. In some cases, the V/F ratio is slightly modified to provide additional torque to the motor. Sample 3 phase current waveforms are shown in Figure 3 on page 21 to show the sinusoidal characteristics of the current drawn by the compressor motors.
Figure 3 - PWM CURRENT WAVEFORM
LD10479
A Sample PWM voltage waveforms is shown in Figure 4 on page 21. The pulses near the sides of the rectangular groups of waves are notably narrower, representing the lower voltage of a sinusoidal waveform as it rises or falls from the "0" crossing.
Figure 4 - PWM VOLTAGE WAVEFORM
LD10480
SECTION 2 - PRODUCT DESCRIPTION
The power section of the drive is composed of four ma-
jor blocks consisting of an AC to DC rectifier section
with accompanying pre-charge circuit, a DC link filter
section, a three phase DC to AC inverter section, and
an output suppression network.
2
The AC to DC rectifier utilizes a semi-converter formed by the connection of three SCR/diode modules (1SCR through 3SCR) in a three phase bridge configuration. The modules are mounted on a liquid cooled heatsink. Use of the semi-converter configuration permits implementation of a separate pre-charge circuit to limit the flow of current into the DC link filter capacitors when the drive is switched on and it also provides a fast disconnect from the power mains when the drive is switched off. When the drive is turned off, the SCR's in the semi-converter remain in a non-conducting mode and the DC link filter capacitors remain uncharged. When the drive is commanded to run, the DC link filter capacitors are slowly charged via the semi-converter. The SCR's are then gated fully on.
Three power fuses (1FU - 3FU), an optional circuit breaker (1SW) and a standard 5% impedance minimum 3-phase line reactor connect the AC to DC converter to the incoming power. Very fast semiconductor power fuses are utilized to ensure that the SCR/diode module packages do not rupture if a catastrophic failure were to occur on the DC link. The SCR Trigger Board provides the gating pulses for the SCR's as commanded by the VSD Logic Board.
The DC Link filter section of the drive consists of a group of electrolytic filter capacitors (C1-C6). This capacitor bank effectively smoothes the ripple voltage from the AC to DC rectifier while simultaneously providing a large energy reservoir for use by the DC to AC inverter section of the drive. In order to achieve the required voltage capability for the capacitor portion of the filter, filter capacitor "banks" are formed by connecting two groups of parallel capacitors in series 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 (1RES and 2RES) are connected across the capacitor banks.
JOHNSON CONTROLS
21
SECTION 2 - PRODUCT DESCRIPTION
The DC to AC inverter section of the VSD serves to convert the rectified and filtered DC back to AC at the magnitude and frequency commanded by the VSD Logic Board. The inverter section is actually composed of two to four identical inverter output phase assemblies. These assemblies are in turn composed of 3 pairs of Insulated Gate Bipolar Transistor (IGBT) modules mounted to a liquid cooled heatsink, and a IGBT Gate Driver Board, which provides the ON and OFF gating pulses to the IGBT's as determined by the VSD Logic Board. In order to minimize the parasitic inductance between the IGBT's and the capacitor banks, copper plates, which electrically connect the capacitors to one another and to the IGBT's are connected together using a "laminated bus" structure.
This "laminated bus" structure is a actually composed of a pair of copper bus plates with a thin sheet of insulating material acting as the separator/insulator. The "laminated bus" structure forms a parasitic capacitor, which acts as a small valued capacitor, effectively canceling the parasitic inductance of the bus bars themselves. To further cancel the parasitic inductances, a series of small film capacitors are connected between the positive and negative plates of the DC link.
The VSD output suppression network is composed of a series of capacitors and resistors connected in a three phase delta configuration. The parameters of the suppression network components are chosen to work in unison with the parasitic inductance of the DC to AC inverter sections in order to simultaneously limit both the rate of change of voltage and the peak voltage applied to the motor windings. By limiting the peak voltage to the motor windings, as well as the rate-ofchange of motor voltage, we can avoid problems commonly associated with PWM motor drives, such as stator-winding end-turn failures and electrical fluting of motor bearings.
The VSD is cooled by a propylene glycol cooling loop. The loop utilizes a glycol pump, which pumps glycol through the VSD heatsinks to cool the power components. The glycol is then circulated through the condenser to reject the heat from the VSD. The cooled glycol is then circulated back through the loop.
Various ancillary sensors and boards are used to send information back to the VSD Logic Board. Each IGBT Power Module within the DC to AC inverter section contains a thermistor heatsink temperature sensor to provide temperature information to the VSD Logic Board. The Bus Isolator board utilizes three resistors on the board to provide a "safe" impedance (resis-
22
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
tance) between the DC link filter capacitors located on the output phase bank assemblies and the VSD Logic Board. It provides the means to sense the positive, midpoint and negative connection points of the VSD's DC link without applying high voltage to the VSD Logic Board. A Current transformer is included on each output phase assembly to provide motor current information to the VSD Logic Board.
ACCESSORIES AND OPTIONS
Sound Reduction Options
The standard chiller has fans that operate at normal speed, no compressor enclosure, and is typically used in non-sensitive sound areas such as industrial areas or locations with loud traffic background noise. One or more of the following sound reduction options may be employed by the system designer as normally generated machine noise is considered in the overall project design.
Ultra Quiet Fans
With this option, the basic chiller is equipped with specially designed fans and motors to provide lower sound levels and retain appropriate airflow. The result is reduced fan generated noise with minimal effect on the chiller capacity or efficiency at standard AHRI conditions. (Factory-mounted)
Two-Speed Fans
With this option, the basic chiller is equipped with fans designed with two operating speeds. At high ambient conditions the fans operate at the normal speed with sound levels equivalent to Ultra Quiet Fans. As the ambient temperature falls, the fans automatically reduce to slow speed reducing sound levels. If very low sound is required at all ambient conditions normal fan speed can be inhibited. (Factory-mounted)
Reduced Sound Option
With this option the chiller is equipped with an unlined compressor enclosure. This option is typically used for daytime operation where background noise is lower than normal city traffic etc. (Factory-mounted)
Low Sound Option
This option is only available with the selection of Ultra Quiet Fans or Two-Speed Fans. The chiller is equipped with an acoustically lined compressor enclosure. This option is typically for locations near residential areas, hotels, or hospitals etc., where background noise is limited. When paired with the Two-Speed Fan op-
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
tion the unit can operate at normal speed during the day, when background noise levels are noticeable, and at low speed in the evening and at night when background levels are lower. (Factory-mounted)
SilentNightTM
Standard variable speed compressors result in a chiller system that has lower part load sound values than conventional air-cooled chillers. Over 99% of chiller operating hours occur when building loads are less than design and/or ambient temperatures are less than design. As a result, all YCIV model chillers will operate with less than full load sound output nearly all the time. This is especially important on evenings and weekends when neighbors are home the most. Due to time of day based sound regulations it may be desirable to force the chiller to a lower sound level on demand. The SilentNightTM control option provides a control input to limit sound output of the chiller based on time of day. This feature is programmable at the chiller panel or can be controlled remotely via signal (4 mA to 20 mA or 0 VDC to 10 VDC) from a BAS system.
High Static Fans - (400 V / 50 Hz and 380 V / 60 Hz)
Condenser fans with higher power motors suitable for high external static pressure, up to 100 Pa (0.4 in. water), across condenser coils. Select this option if additional air-flow resistance may be present due to flow restrictions such as field installed ducts, filters, soundenclosures etc. (Factory-mounted)
High Airflow Fans - (400 V / 50 Hz and 380 V / 60 Hz)
Condenser fans with airfoil type blades and high power motors providing extra airflow across coils. In some chiller configurations, this option can provide an increase in chiller capacity. Contact your local Johnson Controls representative for more information. (Factory-mounted)
Condenser Coil Protection
Standard condenser coil construction materials include aluminum fins, copper tubes, and galvanized tube supports for generally good corrosion resistance. However, these materials are not adequate for all environments. The system designer can take steps to inhibit coil corrosion in harsh applications and enhance equipment life by choosing from these options based on project design parameters and related environmental factors. (Factory-mounted)
SECTION 2 - PRODUCT DESCRIPTION
Pre-Coated Fin Condenser Coils The air-cooled condenser coils are constructed of epoxy-coated aluminum fins. This can provide corrosion resistance comparable to copper-fin coils in typical seashore locations. Either these or the post coated coils
(below), are recommended for units being installed at 2
the seashore or where salt spray may hit the unit.
Post-Coated Epoxy Dipped Condenser Coils The unit is built with dipped-cured epoxy condenser coils. This is another choice for seashore and other corrosive applications (with the exception of strong alkalis, oxidizers and wet bromine, chlorine and fluorine in concentrations greater than 100 ppm).
Copper Fin Condenser Coils The unit constructed with copper tube condenser coils, which have copper fins. (This is not recommended for units in areas where they may be exposed to acid rain.)
Protective Chiller Panels
Wire Panels (Full Unit) UV stabilized black polyvinyl chloride coated, heavy gauge, welded wire mesh guards mounted on the exterior of the unit. Protects condenser coil faces and prevents unauthorized access to refrigerant components (compressors, pipes, cooler, etc.), yet provides free air flow. This can cut installation cost by eliminating the need for separate, expensive fencing. (Factory-mounted)
Louvered Panels (Condenser Coils Only) Louvered panels, painted the same color as the unit, are mounted over the exterior condenser coil faces on the sides of the unit to visually screen and protect coils. (Factory-mounted)
Louvered Panels (Full Unit) Louvered panels, painted the same color as the unit, enclose the unit to protect condenser coils from incidental damage, visually screen internal components, and prevent unauthorized access to internal components. (Factory-mounted)
Louvered (Condensers)/Wire Panels (Mechanical) Louvered panels, painted the same color as the unit, are mounted on external condenser coil faces. Heavy gauge, welded wire-mesh, coated to resist corrosion, around base of machine to restrict unauthorized access. (Factory-mounted)
JOHNSON CONTROLS
23
SECTION 2 - PRODUCT DESCRIPTION
Evaporator Options
Double Thick 1 1/2 in. Insulation Double thickness insulation is provided. (Factorymounted)
Raised Face Flange Accessory Used for cooler nozzles:
· 150 psig (10.3 barg), welded flanges (field kit, matching pipe flange by contractor).
· 150 psig (10.3 barg) companion weld flanges (field kit - not available with 460 V units).
· 150 psig (10.3 barg), ANSI/AWWA C-606 couplings (field kit, matching pipe flange by contractor).
Opposite Handed Evaporator Water Connections Easily installed standard water connections are on the left-hand side of the unit, when viewed from the control panel end.
General Options
Flow Switch Accessory Vapor proof SPDT, NEMA 3R switch, 150 psig (10.3 barg) DWP, 20°F to 250°F (-7°C to 121°C) with 1 in. NPT (IPS) connection for upright mounting in horizontal pipe (This flow switch or equivalent must be furnished with each unit). (Field-mounted)
Differential Pressure Switch Alternative to the paddle-type flow switch. Range is 3 psig to 45 psig (0.2 barg to 3 barg) with 1/4 in. NPTE pressure connections. (Field-mounted)
Building Automation System Interface Chiller will accept 4 mA to 20 mA or 0 VDC to 10 VDC input to reset the leaving chilled liquid temperature. (Factory-mounted)
Multi-Unit Sequence Control Separate sequencing control center provided to permitting control of up to eight chillers in parallel based on mixed liquid temperature (interconnecting wiring by others). (Field-mounted)
Service Isolation Valve Service suction isolation valve added to unit for each refrigerant circuit. (Factory-mounted)
24
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Chicago Code Relief Valve Special relief valves per Chicago code. (Factorymounted)
Pressure Relief (CE/PED) Service Valve Kit Each relief valve is mounted on a sealable ball valve to aid maintenance. (Factory-mounted)
Circuit Breaker Power panel will come equipped with a factory mounted circuit breaker at the point of incoming single or multi-point connections that provides the following:
· A means to disconnect power mounted on chiller.
· Circuit breaker(s) sized to provide the motor branch circuit protection, short circuit protection and ground fault protection for the motor branchcircuit conductors, the motor control apparatus and the motors. (Chiller mounted circuit breaker option sized for branch circuit protection eliminates the need to provide a separate `line of sight' disconnect and separate branch circuit protection device.)
· A lockable operating handle that extends through power panel door. This allows power to be disconnected without opening any panel doors.
· A Short Circuit Withstand Rating of 65,000 A when the chiller electrical enclosure when using circuit breaker option is 380 V, 400 V, and 460 V. Rated IAW UL508.
Vibration Isolation
Elastomeric Isolation This option is recommended for normal installations. It provides very good performance in most applications for the least cost. (Field-mounted)
One Inch Spring Isolators Spring and cage type isolators for mounting under the unit base rails. They are level adjustable. Nominal deflection is 1 in. and may vary slightly by application. (Field-mounted)
Two Inch Seismic Spring Isolators Restrained Spring-Flex Mounting isolators incorporate a rugged welded steel housing with vertical and horizontal limit stops. Housings designed to withstand a minimum 1.0g accelerated force in all directions up to 2 in. (51mm). The deflection may vary slightly by application. They are level adjustable. (Field-mounted)
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 2 - PRODUCT DESCRIPTION
FEATURE CONTRACT
ORDER USA
SHIP WT MODEL
CAP
UNIT REF. VOLTS STARTER DESIGN DEV POWER TRANS PFC AMB BAS
COMPLETE PIN NUMBER DESCRIPTION
DESCRIPTION Contract Number
Order Quantity USA Origin
Shipping Weight Model (PIN 1-4)
Nominal Capacity (PIN 5-8)
Unit Designator (PIN 9) Refrigerant (PIN 10)
Voltage (PIN 11, 12)
Starter (PIN 13) Design Series (PIN 14) Modification Level (PIN 15) Power Fld (PIN 16, 17)
Control Transformer (PIN 18)
Convenience Outlet (PIN 19) PIN 20
BAS Interface (PIN 21)
OPTION
DESCRIPTION
NUM
Contract Number = {num}
QTY
Order quantity = {ord_qty}
N
USA origin not required
Y
USA origin required
2
LBS
Crane/Rigging Shipping Weight = {lb}
KG
Crane/Rigging Shipping Weight = {kg}
YCIV
YCIV
0157
0157
0177
0177
0187
0187
0197
0197
0207
0207
0227
0227
0247
0247
0267
0267
0287
0287
0307
0307
0327
0327
0357
0357
0397
0397
S
Standard Efficiency, Standard IPLV
P
Standard Efficiency, Optimized IPLV
E
High Efficiency/High Ambient Unit, Standard IPLV
V
High Efficiency/High Ambient Unit, Optimized IPLV
H
Standard Efficiency, Optimized IPLV (ARI Only)
A
R-134a
17
200/3/60
28
230/3/60
40
380/3/60
46
460/3/60
50
380-415/3/50
58
575/3/60
V
Variable Speed Drive
A
Design Series A
K
Design Series K
B
Mod Level B
SX
SP Supply TB
BX
SP Circuit Breaker w/Lockable Handle
SS
SP Supply TB w/Ind. Sys. Disconnect Switches
CS
SP Circuit Breaker w/Ind. Sys. Disconnect Switches
QQ
Special Power Option
T
Control Transformer required
Q
Special Transformer or Power Strip required
X
No Option Required
O
Convenience Outlet, 115 V GFI (Customer Powered)
Q
Special quote
X
No option required
Q
Special quote
X
No Selection
L
LON E-Link
S
SC-EQ Board
Q
Special Quote
JOHNSON CONTROLS
25
SECTION 2 - PRODUCT DESCRIPTION
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
COMPLETE PIN NUMBER DESCRIPTION (CONT'D)
FEATURE
DESCRIPTION
LCD
LCD (PIN 22)
RDOUT
Silent Night (PIN 23)
SAFETY SENSOR
PUMP REMOTE
Safety Code (PIN 24) PIN 25
Pump Control (PIN 26) Remote Ctrl Panel (PIN 27)
SEQ TEMP
Sequence Kit (PIN 28) Water Temp (PIN 29, 30)
CHICAGO
Chicago Code Kit (PIN 31)
VALVES HGBP GAUGE OVERLOAD PIN36 HTR
Valves (PIN 32) PIN 33 PIN 34 PIN 35 PIN 36
Crankcase Heater (PIN 37)
DWP
DWP (PIN 38)
INS
Insulation (PIN 39)
OPTION
X S F G I P H L X N Q L C Q X Q X Q X O Q X S Q NUM QQ X C S B R G Q X Q X Q X Q X Q X Q H Q X 3 Q X D Q
DESCRIPTION
English LCD and Keypad Display (std) Spanish LCD and Keypad Display French LCD and Keypad Display German LCD and Keypad Display Italian LCD and Keypad Display Portuguese LCD and Keypad Display Hungarian LCD and Keypad Display Polish LCD and Keypad Display No option required Silent Night sound limiting control option Special quote N. American Safety Code (cUL/cETL) CE listing Special Safety Code No option required Special quote No Pump Control required Special Pump Control required No Remote Control Panel required OptiView Remote Control Panel required Special Remote Control Panel required No Sequence Kit required Sequence Control & Automatic Lead Transfer = {seq} Special Sequence Kit required Leaving Water Temp. = {temp} degrees Special LWT requirements No Chicago Code Kit required Chicago Code Kit required Service Isolation Valve Both Isolation Valve and Chicago Code Dual Pressure Relief Dual Pressure Relief & Suction Service Isolation Special Chicago Code Kit required Standard Valves required Special Optional Valves required No option required Special quote No option required Special quote No option required Special quote No option required Special quote Compressor Crankcase Heaters Special quote 150 psig DWP 300 psig DWP Special DWP 3/4 in. Cooler Insulation 1 1/2 in. Cooler Insulation Special Cooler Insulation
26
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 2 - PRODUCT DESCRIPTION
COMPLETE PIN NUMBER DESCRIPTION (CONT'D)
FEATURE
DESCRIPTION
OPTION
DESCRIPTION
X
No Flanges required
W
Weld Flange Kit required
FLANGES
Flanges (PIN 40)
V
Grooved Flange Kit required
M
Weld Flange with Mating Flange
2
F
Grooved Flange with Welded Mating Flange
Q
Special Flanges required
X
No Flow Switch required
S
One Flow Switch required
T
Two Flow Switches required
FLOW
Flow Switch (PIN 41)
U
Three Flow Switches required
D
One Differential Pressure Switch required
E
Two Differential Pressure Switches required
F
Three Differential Pressure Switches required
Q
Special Switch required
A
ASME Pressure Vessel Codes
VESSEL
Vessel Codes (PIN 42)
E
PED Pressure Vessel Code
Q
Special Pressure Vessel Codes
X
Standard Cooler
CLR
Cooler (PIN 43)
R
Remote Cooler
Q
Special Cooler requirements
L
Handed cooler left, view from control panel end
PIN44
Connections (PIN 44)
R
Handed cooler right, view from control panel end
Q
Special quote
X
Aluminum Coils
C
Copper Fin Coils
COILS
Coils (PIN 45)
B
Pre-Coated Fin Coils
P
Post-Coated Dipped Coils
E
Pre-coated Epoxy Non-slit ripple fins
Q
Special Coils
X
Partial Heat Recovery not required
HEAT
Heat Recovery (PIN 46)
H
Partial Heat Recovery required
D
Desuperheater
Q
Special quote
FANMOTORS
Fan Motors (PIN 47)
X
TEAO Fan Motors
Q
Special Fan Motors
X
No Enclosure Panels required
1
Wire (Full Unit) Encl Panels (factory)
2
Wire (Full Unit) Encl Panels (field)
3
Wire/Louvered Encl Panels (factory)
PANEL
Enclosure Panels (PIN 48)
4
Wire/Louvered Encl Panels (field)
5
Louvered (cond only) Encl Panels (factory)
6
Louvered (cond only) Encl Panels (field)
7
Louvered (full unit) Encl Panels (factory)
8
Louvered (full unit) Encl Panels (field)
Q
Special Enclosure Panels required
X
No Sound Enclosure required
ACOUSTIC
Acoustical arrgt (PIN 49)
R
Reduced Noise
N
Low Noise
Q
Special Sound Enclosure required
JOHNSON CONTROLS
27
SECTION 2 - PRODUCT DESCRIPTION
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
COMPLETE PIN NUMBER DESCRIPTION (CONT'D)
FEATURE PIN 50
DESCRIPTION PIN 50
PIN 51
PIN 51
FANS
Fans (PIN 52)
PAINT
Overspray Paint (PIN 53)
ISOL
Isolators (PIN 54)
WARRANTY REFRIGERANT WTY
Warranty (PIN 55) Refrigerant Wty (PIN 56)
SHIP
Ship Instructions (PIN 57)
PIN58 PIN59
PIN60 MFG LOC
YW SQ
PIN 58 PIN 59
PIN 60 Plant of Mfg (PIN 61)
Mfg Location
YorkWorks Version Special Quote
OPTION X A B M Q X Q X L H T V X Q X 1 S N Q
X
A
B
C
M
N
P
U
X Q X Q R MEX SAT CV UV Q
DESCRIPTION
Base, Material and Witness Documents Base Documents Base and Material Documents Base and Witness Documents Special Quote No option required Special quote Standard Low Sound Fans Ultra Quiet Fans High Static Fans Two Speed Fans VSD Fans No Final Overspray Paint required Special Final Overspray Paint required No Vibration Isolators required 1 in. Deflection Isolators required Seismic Isolators required Neoprene Pad Isolators required Special Vibration Isolators required For Marketing Purposes For Marketing Purposes No Containerization Required with Shipping Bag Buy American Act Compliance with Shipping Bag Both Buy America Act Compliance and Container Shipped without Shipping Bag (Factory Prep) Container Shipped without Shipping Bag (Factory Load US Port) Container Shipped without Shipping Bag (Factory Load Mexico Port) No Containerization Required without Shipping Bag Container Shipped without Shipping Bag (Factory Prep) Buy America Act Compliance without Shipping Bag For Marketing Purposes No option required Special quote No option required Special quote Plant of Manufacture - Monterrey Monterrey San Antonio YorkWorks configuration version {cv} YorkWorks upload version {uv} Special quote
28
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 3 - RIGGING, HANDLING, AND STORAGE
3
LD19197
Rigging and lifting should only be done by a professional rigger in accordance with a written rigging and lifting plan. The most appropriate rigging and lifting method will depend on job specific factors, such as the rigging equipment available and site needs. Therefore, a professional rigger must determine the rigging and lifting method to be used, and it is beyond the scope of this manual to specify rigging and lifting details.
LIFTING WEIGHTS
Refer to the unit nameplate for unit shipping weight. Note that weight may vary depending on unit configuration at the time of lifting.
DELIVERY AND STORAGE
To ensure consistent quality and maximum reliability, all units are tested and inspected before leaving the factory. Units are shipped completely assembled and containing refrigerant under pressure. Units are shipped without export crating unless crating has been specified on the Sales Order. If the unit is to be put into storage, prior to installation, the following precautions should be observed:
· The chiller must be "blocked" so that the base is not permitted to sag or bow.
· Ensure that all openings, such as water connections, are securely capped.
· Do not store where exposed to high ambient air temperatures that may exceed relief valve settings. Refer to Long-Term Storage Requirement - Field Preparation (Form 50.20-NM7).
JOHNSON CONTROLS
· The condensers should be covered to protect the coils and fins from potential damage and corrosion, particularly where building work is in progress.
· The unit should be stored in a location where there is minimal activity in order to limit the risk of accidental physical damage.
· To prevent inadvertent operation of the pressure relief devices the unit must not be steam cleaned.
· It is recommended that the unit is periodically inspected during storage.
INSPECTION
Remove any transit packing and inspect the unit to ensure that all components have been delivered and that no damage has occurred during transit. If any damage is evident, it should be noted on the carrier's freight bill and a claim entered in accordance with the instructions given on the advice note.
Major damage must be reported immediately to your local Johnson Controls representative.
29
SECTION 3 - RIGGING, HANDLING, AND STORAGE
MOVING THE CHILLER
Prior to moving the unit, ensure that the installation site is suitable for installing the unit and is easily capable of supporting the weight of the unit and all associated services.
The unit must only be lifted by the base frame at the points provided. Never move the unit on rollers, or lift the unit using a forklift truck.
Care should be taken to avoid damaging the condenser cooling fins when moving the unit.
UNIT REMOVAL FROM SHIPPING CONTAINER
1. Place a clevis pin into the holes provided at the end of each base rail on the unit. Attach chains or nylon straps through the clevis pins and hook onto a suitable lift truck for pulling the unit out of the container.
2. Slowly place tension on the chains or straps until the unit begins to move and then slowly pull the unit from the container. Be sure to pull straight so the sides do not scrape the container.
3. Place a lifting fixture on the forks of the lift truck and reattach the chain or strap. Slightly lift the front of the unit to remove some weight from the floor of the container. Continue pulling the unit with an operator on each side to guide the lift truck operator.
4. Pull the unit until the lifting locations are outside of the container. Place 4 X 4 blocks of wood under the base rails of the unit. Gently rest the unit on the blocks and remove the chains and lift truck.
5. Attach lifting rigging from the crane and slowly complete the removal from the container then lift up and away.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LIFTING USING LUGS
Units are provided with lifting holes in the base frame which accept the accessory lifting lug set as shown in the figure below. The lugs (RH and LH) should be inserted into the respective holes in the base frame and turned so that the spring loaded pin engages into the hole and the flanges on the lug lock behind the hole. The lugs should be attached to the cables/chains using shackles or safety hooks.
CORRECT
INCORRECT
LUG
LIFTING HOLE IN BASE FRAME
FLANGE
LUG FLANGE
LOCKING PIN
LOCKING PIN
LIFTING HOLE IN BASE FRAME
LUG
LOCKING PIN
FLANGE
LD19197b
LIFTING USING SHACKLES
The shackles should be inserted into the respective holes in the base frame and secured from the inside.
Use spreader bars to avoid lifting chains hitting the chiller. Various methods of spreader bar arrangements may be used, keeping in mind the intent is to keep the unit stable and to keep the chains from hitting the chiller and causing damage.
Never lift the chiller using a forklift or by hooking to the top rails. Use only the lifting holes provided.
Lifting Instructions are placed on a label on the chiller and on the shipping bag.
LD19197a
30
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
2 COMPRESSOR
SECTION 3 - RIGGING, HANDLING, AND STORAGE
UNIT RIGGING
3 COMPRESSOR
#4 #3 #2 #1
#4 #3 #2
3
#5
#1
LD18957
60 HZ
0157 0157 0177 0177 0187 0187 0197 0207 0207 0227 0227 0247 0247 0267
60 hz
0267 0287 0287 0307 0327 0357 0357 0397
EFF
HIGH STD HIGH STD HIGH STD HIGH STD HIGH HIGH STD STD HIGH STD
EFF
HIGH STD HIGH STD HIGH STD HIGH STD
LIFT POINTS DIMENSIONS TAKEN FROM
(NOT ALL POINTS ON UNITS)
#1 INCH METRIC
Y = 33.3 Y = 846
2 COMPRESSOR MODELS
#2 INCH METRIC
#3 INCH METRIC
Y = 136.7 Y = 3473 Y = 216.7 Y = 5505
#4 INCH METRIC
---
---
#5 INCH METRIC
---
---
Y = 33.3 Y = 846 Y = 136.7 Y = 3473 Y = 216.7 Y = 5505
---
---
---
---
Y = 33.3 Y = 846 Y = 136.7 Y = 3473 Y = 224.7 Y = 5708
---
---
---
---
Y = 33.3 Y = 846 Y = 136.7 Y = 3473 Y = 216.7 Y = 5505
---
---
---
---
Y = 33.3 Y = 846 Y = 136.7 Y = 3473 Y = 224.7 Y = 5708
---
---
---
---
Y = 33.3 Y = 846 Y = 136.7 Y = 3473 Y = 224.7 Y = 5708
---
---
---
---
Y = 33.3 Y = 846 Y = 136.7 Y = 3473 Y = 224.7 Y = 5708
---
---
---
---
Y = 33.3 Y = 846 Y = 136.7 Y = 3473 Y = 224.7 Y = 5708
---
---
---
---
Y = 33.3 Y = 846 Y = 92.7 Y = 2355 Y = 180.7 Y = 4590 Y = 284.9 Y = 7235
---
---
Y = 33.3 Y = 846 Y = 92.7 Y = 2355 Y = 180.7 Y = 4590 Y = 284.9 Y = 7235
Y = 33.3 Y = 846 Y = 136.7 Y = 3473 Y = 224.7 Y = 5708
---
---
---
---
Y = 33.3 Y = 846 Y = 92.7 Y = 2355 Y = 180.7 Y = 4590 Y = 284.9 Y = 7235
---
---
Y = 33.3 Y = 846 Y = 92.7 Y = 2355 Y = 180.7 Y = 4590 Y = 284.9 Y = 7235
---
---
Y = 33.3 Y = 846 Y = 92.7 Y = 2355 Y = 180.7 Y = 4590 Y = 284.9 Y = 7235
---
---
#1 INCH METRIC
3 COMPRESSOR MODELS
#2
#3
INCH METRIC INCH METRIC
#4 INCH METRIC
#5 INCH METRIC
Y = 33.2 Y = 843.8 Y = 141.1 Y = 3584.8 Y = 238.6 Y = 6061.3 Y = 357 Y = 9067.4 ---
---
Y = 33.2 Y = 843.8 Y = 141.1 Y = 3584.8 Y = 238.6 Y = 6061.3 Y = 357 Y = 9067.4 ---
---
Y = 33.2 Y = 843.8 Y = 123.7 Y = 3142.2 Y = 216.7 Y = 5504.2 Y = 320.5 Y = 8139.9 Y = 401 Y = 10185
Y = 33.2 Y = 843.8 Y = 141.8 Y = 3584.8 Y = 238.6 Y = 6061.3 Y = 357 Y = 9067.4 ---
---
Y = 33.2 Y = 843.8 Y = 120.7 Y = 3064.9 Y = 216.7 Y = 5504.2 Y = 320.5 Y = 8139.9 Y = 401 Y = 10185
Y = 33.2 Y = 843.8 Y = 120.7 Y = 3064.9 Y = 216.7 Y = 5504.2 Y = 320.5 Y = 8139.9 Y = 401 Y = 10185
Y = 33.2 Y = 843.8 Y = 120.7 Y = 3064.9 Y = 217.8 Y = 5531.5 Y = 328.1 Y = 8334.6 Y = 445 Y = 11302.6
Y = 33.2 Y = 843.8 Y = 120.7 Y = 3064.9 Y = 217.8 Y = 5531.5 Y = 328.1 Y = 8334.6 Y = 445 Y = 11302.6
NOTE: Weights and approximate center of gravity location shown for base unit. Any options selected may add weight to the unit and affect the center of gravity. Locate the center of gravity through trial lifts to account for possible variations in unit configuration. Contact your nearest Johnson Controls Sales Office for weight data.
JOHNSON CONTROLS
31
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
THIS PAGE INTENTIONALLY LEFT BLANK
32
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 4 - INSTALLATION
LOCATION REQUIREMENTS
To achieve optimum performance and trouble-free service, it is essential that the proposed installation site meets the location and space requirements for the model being installed. For dimensions, see SECTION 6 - TECHNICAL DATA.
It is important to ensure that the minimum service access space is maintained for cleaning and maintenance purposes.
OUTDOOR INSTALLATIONS
The units can be installed at ground level on a suitable flat level foundation easily capable of supporting the weight of the unit, or on a suitable rooftop location. In both cases an adequate supply of air is required. Avoid locations where the sound output and air discharge from the unit may be objectionable.
The location should be selected for minimum sun exposure and away from boiler flues and other sources of airborne chemicals that could attack the condenser coils and steel parts of the unit.
If located in an area accessible to unauthorized persons, steps must be taken to prevent access to the unit by means of a protective fence. This will help to prevent the possibility of vandalism, accidental damage, or possible harm caused by unauthorized removal of protective guards or opening panels to expose rotating or high voltage components.
For ground level locations, the unit must be installed on a suitable flat and level concrete base that extends to fully support the two side channels of the unit base frame. A one-piece concrete slab, with footings extending below the frost line is recommended. To avoid noise and vibration transmission, the unit should not be secured to the building foundation.
On rooftop locations, choose a place with adequate structural strength to safely support the entire operating weight of the unit and service personnel. The unit can be mounted on a concrete slab, similar to ground floor locations, or on steel channels of suitable strength. The channels should be spaced with the same centers as the unit side and front base rails. This will allow vibration isolators to be fitted if required. Isolators are recommended for rooftop locations.
Any ductwork or attenuators fitted to the unit must not have a total static pressure resistance, at full unit airflow, exceeding the capability of the fans installed in the unit.
INDOOR INSTALLATIONS
The unit can be installed in an enclosed plant room, provided the floor is level and of suitable strength to support the full operating weight of the unit. It is essential that there is adequate clearance for airflow to the
unit. The discharge air from the top of the unit must be 4
ducted away to prevent re-circulation of air within the plant room. If common ducts are used for fans, non-return dampers must be fitted to the outlet from each fan.
The discharge ducting must be properly sized with a total static pressure loss, together with any intake static pressure loss, less than the available static pressure capability for the type of fan fitted.
The discharge air duct usually rejects outside the building through a louver. The outlet must be positioned to prevent the air being drawn directly back into the air intake for the condenser coils; as such re-circulation will affect unit performance.
LOCATION CLEARANCES
Adequate clearances around the unit(s) are required for the unrestricted airflow for the air-cooled condenser coils and to prevent re-circulation of warm discharge air back onto the coils. If clearances given are not maintained, airflow restriction or re-circulation will cause a loss of unit performance, an increase in power consumption, and may cause the unit to malfunction. Consideration should also be given to the possibility of down drafts, caused by adjacent buildings, which may cause re-circulation or uneven unit airflow.
For locations where significant cross winds are expected, such as exposed roof tops, an enclosure of solid or louver type is recommended to prevent wind turbulence interfering with the unit airflow.
When units are installed in an enclosure, the enclosure height should not exceed the height of the unit on more than one side. If the enclosure is of louvered construction, the same requirement of static pressure loss applies as for ducts and attenuators stated above.
JOHNSON CONTROLS
33
SECTION 4 - INSTALLATION
Where accumulation of snow is likely, additional height must be provided under the unit to ensure normal airflow to the unit
Clearance dimensions provided elsewhere are necessary to maintain good airflow and ensure correct unit operation. It is also necessary to consider access requirements for safe operation and maintenance of the unit and power and control panels. Local health and safety regulations, or practical considerations for service replacement of large components, may require larger clearances than those given in the SECTION 6 - TECHNICAL DATA (Page 51).
VIBRATION ISOLATORS
Optional sets of vibration isolators can be supplied loose with each unit.
Using the Isolator tables shipped with the unit in the information pack, see the Dimensions - 2 and 3 Compressor SI on page 112, Isolator Selection and Mounting on page 133 and One Inch Deflection Spring Isolators Cross-Reference on page 150 for units shipped on or after June 15, 2008 and One Inch Deflection Spring Isolators Installation Instructions on page 151 for units shipped before June 15, 2008). Identify each mount and its correct location on the unit.
Installation
Place each mount in its correct position and lower the unit carefully onto the mounts ensuring the mount engages in the mounting holes in the unit base frame.
On adjustable mounts, transfer the unit weight evenly to the springs by turning the mount adjusting nuts (located just below the top plate of the mount) counterclockwise to raise and clockwise to lower. This should be done two turns at a time until the top plates of all mounts are between 1/4 in. and 1/2 in. (6 mm and 12 mm) clear of top of their housing and the unit base is level.
A more detailed installation instruction is provided on Pages 164 through 169 for units shipped on or after June 15, 2008 and Pages 170 through 174 for units shipped before June 15, 2008.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SHIPPING BRACES
The chiller's modular design does not require shipping braces.
CHILLED LIQUID PIPING
General Requirements
The following piping recommendations are intended to ensure satisfactory operation of the unit(s). Failure to follow these recommendations could cause damage to the unit, or loss of performance, and may invalidate the warranty.
The maximum flow rate and pressure drop for the cooler must not be exceeded at any time. See SECTION 6 - TECHNICAL DATA (Page 51)
The liquid must enter the cooler at the inlet connection. The inlet connection for the cooler is at the control panel end of the cooler.
A flow switch must be installed in the customer piping at the outlet of the cooler and wired back to the control panel using shielded cable.
There should be a straight run of piping of at least 5 pipe diameters on either side. The flow switch should be wired to Terminals 2 and 13 on the 1TB terminal block (See Figure 32 on page 171 and Figure 33 on page 172). A flow switch is required to prevent damage to the cooler caused by the unit operating without adequate liquid flow.
The flow switch used must have gold plated contacts for low voltage/current operation. Paddle type flow switches suitable for 150 psig (10 bar) working pressure and having a 1 in. N.P.T. connection can be obtained from YORK as an accessory for the unit. Alternatively, a differential pressure switch fitted across an orifice plate may be used, preferably of the high/low limit type.
The chilled liquid pump(s) installed in the piping system(s) should discharge directly into the unit cooler section of the system. The pump(s) may be controlled by the chiller controls or external to the unit. For details, see "Electrical Elementary and Connection Diagrams."
34
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Pipework and fittings must be separately supported to prevent any loading on the cooler. Flexible connections are recommended which will also minimize transmission of vibrations to the building. Flexible connections must be used if the unit is mounted on anti-vibration mounts, as some movement of the unit can be expected in normal operation.
Piping and fittings immediately next to the cooler should be readily de-mountable to enable cleaning before operation, and to facilitate visual inspection of the exchanger nozzles.
The cooler must be protected by a strainer, preferably of 40 mesh, fitted as close as possible to the liquid inlet connection, and provided with a means of local isolation.
The cooler must not be exposed to flushing velocities or debris released during flushing. It is recommended that a suitably sized bypass and valve arrangement is installed to allow flushing of the piping system. The bypass can be used during maintenance to isolate the heat exchanger without disrupting flow to other units.
Thermometer and pressure gauge connections should be provided on the inlet and outlet connections of each cooler. Gauges and thermometers are not provided with the unit.
Drain and air vent connections should be provided at all low and high points in the piping to permit drainage of the system and to vent any air in the pipes.
Liquid system lines at risk of freezing, due to low ambient temperatures should be protected using insulation and heater tape and/or a suitable glycol solution. The liquid pump(s) may also be used to ensure liquid is circulated when the ambient temperature approaches freezing point.
Insulation should also be installed around the cooler nozzles. Heater tape of 21 watts per meter under the insulation is recommended, supplied independently and controlled by an ambient temperature thermostat set to switch ON at approximately 4°F, above the freezing temperature of the chilled liquid.
SECTION 4 - INSTALLATION
Evaporator heater mats are installed under the insulation, and are powered from the chiller's control panel. In sub-freezing conditions, unless the evaporator has been drained or an appropriate water-to-glycol concentration is maintained, high voltage power to the chiller must be kept on to ensure the heater mats assist in evaporator freeze protection. If there is a potential for power loss, Johnson Controls recommends that the evaporator is drained or that water in the chilled water circuit be replaced with an appropriate water-to-glycol concentration.
Any debris left in the water piping between
the strainer and cooler could cause seri-
ous damage to the tubes in the cooler and
must be avoided. Be sure the piping is clean before connecting it to the evapora-
4
tor. Keep evaporator nozzles and chilled
liquid piping capped prior to installation
to assure construction debris is not al-
lowed to enter.
The installer/user must also ensure that the quality of the water in circulation is adequate, without any dissolved gases, which can cause oxidation of steel parts within the cooler.
WATER TREATMENT
The unit performance provided in the Design Guide is based on a fouling factor of 0.0001 ft2hr°F/Btu (0.018m2/hr °C/kW). Dirt, scale, grease and certain types of water treatment will adversely affect the heat exchanger surfaces and therefore the unit performance. Foreign matter in the water system(s) can increase the heat exchanger pressure drop, reducing the flow rate and causing potential damage to the heat exchanger tubes.
Aerated, brackish or salt water is not recommended for use in the water system(s). Johnson Controls recommends that a water treatment specialist should be consulted to determine whether the proposed water composition will adversely affect the evaporator materials of carbon steel and copper. The pH value of the water flowing through the evaporator must be kept in a range between 7 and 8.5.
JOHNSON CONTROLS
35
SECTION 4 - INSTALLATION
PIPEWORK ARRANGEMENT The following is a suggested piping arrangement for single unit installations. For multiple unit installations, each unit should be piped as shown in Figure 5 on page 36.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Option Flanges
One of two types of flanges may be fitted depending on the customer or local Pressure Vessel Code requirements. These are grooved adapter flanges, normally supplied loose, or weld flanges, which may be supplied loose or ready-fitted. Grooved adapter and weld flange dimensions are to ISO 7005 - NP10.
-Isolating Valve - Normally Open
-Isolating Valve - Normally Closed
-Flow Regulating Valve
-Flow Measurement Device
-Strainer
-Pressure Tapping
-Flow Switch -Flanged Connection
LD10507
-Pipework
Figure 5 - PIPEWORK ARRANGEMENT
CONNECTION TYPES AND SIZES For connection sizes relevant to individual models see SECTION 6 - TECHNICAL DATA.
COOLER CONNECTIONS Standard chilled liquid connections on all coolers are of the grooved type (See Figure 6 on page 36).
Figure 6 - GROOVED NOZZLE
LD10494
WELD FLANGE
GROOVED ADAPTER
LD29341
Figure 7 - FLANGE ATTACHMENT
REFRIGERANT RELIEF VALVE PIPING
The evaporator is protected against internal refrigerant overpressure by refrigerant relief valves. A pressure relief valve is mounted on each of the main refrigerant lines connecting the cooler to the compressors.
A piece of pipe is fitted to each valve and directed so that when the valve is activated the release of high pressure gas and liquid cannot be a danger or cause injury. For indoor installations, pressure relief valves should be piped to the exterior of the building.
The size of any piping attached to a relief valve must be of sufficient diameter so as not to cause resistance to the operation of the valve. Unless otherwise specified by local regulations. Internal diameter depends on the length of pipe required and is given by the following formula:
D5 = 1.447 x L
Where:
D = minimum pipe internal diameter in cm L = length of pipe in meters
If relief piping is common to more than one valve, its cross-sectional area must be at least the total required by each valve. Valve types should not be mixed on a common pipe. Precautions should be taken to ensure the outlets of relief valves or relief valve vent pipes remain clear of obstructions at all times.
36
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DUCTWORK CONNECTION
General Requirements
The following ductwork recommendations are intended to ensure satisfactory operation of the unit. Failure to follow these recommendations could cause damage to the unit, or loss of performance, and may invalidate the warranty.
When ducting is to be fitted to the fan discharge it is recommended that the duct should be the same crosssectional area as the fan outlet and straight for at least 3 ft (1 m) to obtain static regain from the fan. Ductwork should be suspended with flexible hangers to prevent noise and vibration being transmitted to the structure. A flexible joint is also recommended between the duct attached to the fan and the next section for the same reason. Flexible connectors should not be allowed to concertina.
The unit is not designed to take structural loading. No significant amount of weight should be allowed to rest on the fan outlet flange, deck assemblies or condenser coil module. No more than 3 ft (1 m) of light construction ductwork should be supported by the unit. Where cross winds may occur, any ductwork must be supported to prevent side loading on the unit.
If the ducts from two or more fans are to be combined into a common duct, back-flow dampers should be fitted in the individual fan ducts. This will prevent recirculation of air when only one of the fans is running.
Units are supplied with outlet guards for safety and to prevent damage to the fan blades. If these guards are removed to fit ductwork, adequate alternative precautions must be taken to ensure persons cannot be harmed or put at risk from rotating fan blades.
SECTION 4 - INSTALLATION
ELECTRICAL CONNECTION
The following connection recommendations are intended to ensure safe and satisfactory operation of the unit. Failure to follow these recommendations could cause harm to persons, or damage to the unit, and may invalidate the warranty.
No additional controls (relays, etc.)
should be mounted in the control panel.
Power and control wiring not connected
to the control panel should not be run
through the control panel. If these pre-
cautions are not followed it could lead
to a risk of electrocution. In addition,
electrical noise could cause malfunctions
or damage the unit and its controls.
4
After power wiring connection, do not switch on mains power to the unit. Some internal components are live when the mains are switched on and this must only be done by "Authorized" persons familiar with starting, operating, and troubleshooting this type of equipment.
JOHNSON CONTROLS
37
SECTION 4 - INSTALLATION
POWER WIRING
All electrical wiring should be carried out in accordance with local regulations. Route properly sized cables to cable entries on the unit.
In accordance with local codes, NEC codes and U.L. Standards, it is the responsibility of the user to install over current protection devices between the supply conductors and the power supply terminals on the unit.
To ensure that no eddy currents are set up in the power panel, the cables forming the 3-phase power supply must enter via the same cable entry.
All sources of supply to the unit must be taken via a common point of isolation (not supplied by Johnson Controls).
Copper power wiring only should be used for supplying power to the chiller. This is recommended to avoid safety and reliability issues resulting from connection failure at the power connections to the chiller. Aluminum wiring is not recommended due to thermal characteristics that may cause loose terminations resulting from the contraction and expansion of the wiring. Aluminum oxide may also build up at the termination causing hot spots and eventual failure. If aluminum wiring is used to supply power to the chiller, AL-CU compression fittings should be used to transition from aluminum to copper. This transition should be done in an external box separate to the power panel. Copper conductors can then be run from the box to the chiller.
POWER SUPPLY WIRING
Units require only one 3-phase supply, plus earth ground.
Connect the 3-phase supplies to the terminal block or optional circuit breaker located in the panel using lug sizes detailed in SECTION 6 - TECHNICAL DATA (see Figure 26 on page 165, Figure 32 on page 171 and Figure 33 on page 172.
Connect a ground wire from the chiller panel ground lug to the incoming line supply ground.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
115 VAC CONTROL SUPPLY TRANSFORMER
A 3-wire high voltage to 115 VAC supply transformer is standard in the chiller. This transformer is mounted in the cabinet and steps down the high voltage supply to 115 VAC to be used by the controls, VSD, Feed and Drain Valve Controller, valves, solenoids, heaters, etc.
The high voltage for the transformer primary is taken from the chiller input. Fusing is provided for the transformer.
Removing high voltage power to the chiller will remove the 115 VAC supply voltage to the control panel circuitry and the evaporator heater. In cold weather, this could cause serious damage to the chiller due to evaporator freeze-up. Do not remove power unless alternate means are taken to ensure operation of the evaporator heater.
CONTROL PANEL WIRING
All control wiring utilizing contact closures to the control panel terminal block is nominal 115 VAC and must be run in shielded cable, with the shield grounded at the panel end only, and run in water tight conduit. Run shielded cable separately from mains cable to avoid electrical noise pick-up. Use the control panel cable entry to avoid the power cables.
Voltage free contacts connected to the panel must be suitable for 115 VAC - 10 mA (gold contacts recommended). If the voltage free contacts form part of a relay or contactor, the coil of the device must be suppressed using a standard R/C suppressor. The above precautions must be taken to avoid electrical noise, which could cause a malfunction or damage to the unit and its controls.
38
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
VOLTS FREE CONTACTS
Voltage free contacts are rated at 115 VAC, 100 VA resistive load only. Inductive loads must be suppressed across the coil.
Chilled Liquid Pump Starter
Terminals 23 and 24 on 1TB close to start the chilled liquid pump. This contact can be used as a master start/ stop for the pump in conjunction with the daily start/ stop schedule. Cycle the pumps from the unit panel if the unit will be operational or shut-down during subfreezing conditions. See the Evaporator Pump Control on page 197 for more information on testing the pumps.
Run Contact
Terminals 21 and 22 on 1TB (Figure 32 on page 171 and Figure 33 on page 172) close to indicate that a system is running.
Alarm Contacts
The Systems 1/3 and 2/4 each have a single voltagefree contact, which will operate to signal an alarm condition whenever any system locks out, or there is a power failure. To obtain system alarm signal, connect the alarm circuit to volt free Terminals 25 and 26 (Sys 1/3), Terminals 27 and 28 (Sys 2/4) of 1TB (Figure 32 on page 171 and Figure 33 on page 172).
SYSTEM INPUTS
Flow Switch
A chilled liquid flow switch of suitable type MUST be connected between Terminals 2 and 13 of 1TB (Figure 32 on page 171 and Figure 33 on page 172) to provide protection against loss of liquid flow, which will cause evaporator freeze-up if the chiller is permitted to run. The flow switch circuitry is a 115 VAC circuit. Contacts must be rated for low current (10 mA). Gold contacts should be used.
SECTION 4 - INSTALLATION
Remote Run / Stop
A Remote Run/Stop input is available for each pair of systems (1/3 and 2/4). These inputs require a dry contact to start and stop the system. System 1/3 remote dry contacts are connected between Terminals 2 and 15 of 1TB (Figure 32 on page 171 and Figure 33 on page 172) and System 2/4 dry contacts are connected between Terminals 2 and 16 of 1TB (Figure 32 on page 171 and Figure 33 on page 172). If remote start/stop is not utilized, a jumper must be paced across the terminals to allow the system to run. The remote run/stop circuitry is a 115 VAC circuit. Contacts must be rated for low current (10 mA). Gold contacts should be used.
Remote Print
4
Closure of suitable contacts connected to Terminals 2
and 14 of 1TB (Figure 32 on page 171 and Figure
33 on page 172) will cause a hard copy printout of
Operating Data/Fault History to be made if an optional
printer is connected to the RS-232 port. The remote
print circuitry is a 115 VAC circuit. Contacts must be
rated for low current (10 mA). Gold contacts should
be used.
Optional Remote Setpoint Offset Temperature
A current or voltage signal connected to Terminals 17 and 18 will provide a remote offset function of the chilled liquid setpoint, if required. See Figure 32 on page 171 and Figure 33 on page 172 for the input location and Page 214 for a description of the option.
Optional Remote Setpoint Offset Current
A current or voltage signal connected to Terminals 19 and 20 will provide remote setting of the current limit setpoint, if required. See Figure 32 on page 171 and Figure 33 on page 172 for the input location and Page 216 for a description of the option.
Optional Remote Setpoint Offset Sound Limiting
A current or voltage signal connected to Terminals 40 and 41 will provide remote setting of sound limit setpoint, if required. See Figure 32 on page 171 and Figure 33 on page 172 for the input location and Page 217 for a description of the option.
JOHNSON CONTROLS
39
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
THIS PAGE INTENTIONALLY LEFT BLANK
40
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 5 - COMMISSIONING
PREPARATION
Commissioning of this unit should only be carried out by Johnson Controls Authorized personnel.
type, open them fully (counterclockwise) then close one turn of the stem to ensure operating pressure is fed to pressure transducers. Open the liquid line service valve and oil return line ball valve fully in each system.
Commissioning personnel should be thoroughly familiar with the information contained in this document before starting the unit.
Commission the unit using the detailed checks outlined in the Equipment Pre Start-up and Start-up Checklist on Page 45.
PREPARATION GENERAL The following basic checks should be made with the customer power to the unit switched OFF.
Proper electrical lock out and tag out procedures must be followed.
Inspection Inspect unit for installation damage. If found, take action and/or repair as appropriate.
Refrigerant Charge Packaged units are normally shipped as standard with a full refrigerant operating charge. Check that refrigerant pressure is present in both systems and that no leaks are apparent. If no pressure is present, a leak test must be undertaken, the leak(s) located and repaired. Remote systems and units are supplied with a nitrogen holding charge. These systems must be evacuated with a suitable vacuum pump/recovery unit as appropriate to below 500 microns.
Do not liquid charge with static water in the cooler. Care must also be taken to liquid charge slowly to avoid excessive thermal stress at the charging point. Once the vacuum is broken, charge into the condenser coils with the full operating charge as given in SECTION 6 - TECHNICAL DATA.
Service and Oil Line Valves Open each compressor suction, economizer, and discharge service valve. If valves are of the back-seat
Compressor Oil
To add oil to a circuit - connect a YORK hand oil pump (Part No. 470-10654-000) to the 1/4 in. oil charging valve on the oil separator piping with a length of clean hose or copper line, but do not tighten the flare nut. Using clean oil of the correct type ("L" oil), pump oil until all air has been purged from the hose then tighten the nut. Stroke the oil pump to add oil to the oil system. The oil level should be between the middle of the lower and middle of the upper sight glasses of the oil separator. Approximately 4 gallons to 5 gallons are present in each refrigerant system, with typically
1 gallons to 2 gallons in each oil separator. Oil levels 5
in the oil separators above the top sight glass in either oil separator should be avoided and may cause excessive oil carryover in the system. High oil concentration in the system may cause nuisance trips resulting from incorrect readings on the level sensor and temperature sensors. Temperature sensor errors may result in poor liquid control and resultant liquid overfeed and subsequent damage to the compressor.
Fans
Check that all fans are free to rotate and are not damaged. Ensure blades are at the same height when rotated. Ensure fan guards are securely fixed.
Isolation / Protection
Verify all sources of electrical supply to the unit are taken from a single point of isolation. Check that the maximum recommended fuse sizes given in SECTION 6 - TECHNICAL DATA has not been exceeded.
Control Panel
Check the panel to see that it is free of foreign materials (wire, metal chips, etc.) and clean out if required.
Power Connections
Check that the customer power cables are connected correctly to the terminal blocks or optional circuit breaker. Ensure that connections of power cables within the panels to the circuit breaker or terminal blocks are tight.
JOHNSON CONTROLS
41
SECTION 5 - COMMISSIONING
Grounding
Verify that the unit's protective ground terminal(s) are properly connected to a suitable grounding point. Ensure that all unit internal ground connections are tight.
Water System
Verify the chilled liquid system has been installed correctly, and has been commissioned with the correct direction of water flow through the cooler. The inlet should be at the refrigerant piping connection end of the cooler. Purge air from the top of the cooler using the plugged air vent mounted on the top of the cooler body.
Flow rates and pressure drops must be within the limits given in SECTION 6 - TECHNICAL DATA. Operation outside of these limits is undesirable and could cause damage.
If mains power must be switched OFF for extended maintenance or an extended shutdown period, the compressor suction, discharge and economizer service stop valves should be closed (clockwise). If there is a possibility of liquid freezing due to low ambient temperatures, the coolers should be drained or power should be applied to the chiller. This will allow the cooler heater to protect the cooler from freezing down to - 20°F. Before placing the unit back in service, valves should be opened and power must be switched on (if power is removed for more than 8 hours) for at least 8 hours (24 hours if ambient temperature is below 86°F [30°C]) before the unit is restarted.
Flow Switch
Verify a chilled water flow switch is correctly fitted in the customer's piping on the cooler outlet, and wired into the control panel correctly using shielded cable.
There should be a straight run of at least five pipe diameters on either side of the flow switch. The flow switch should be connected to Terminals 2 and 13 in the panel.
Temperature Sensor(s)
Ensure the leaving liquid temperature sensor is coated with heat conductive compound (Part No. 013-00890000) and is inserted to the bottom of the water outlet sensor well in the evaporator. This sensor is part of the pump control freeze protection operation. It provides some freeze protection and must always be fully inserted in the water outlet sensor well.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Programmed Options Verify that the options factory-programmed into the Micro Panel are in accordance with the customer's order requirements by pressing the OPTIONS key on the keypad and reading the settings from the display.
Programmed Settings Ensure the system cutout and operational settings are in accordance with the operating requirements by pressing the PROGRAM key.
Date and Time Program the date and time by first ensuring that the CLK jumper JP2 on the chiller control board is in the ON position. See Figure 27 on page 166 and Figure 28 on page 167. Then press the DATE/TIME key and set the date and time (see Page 266).
Start/Stop Schedule Program the daily and holiday start/stop by pressing the SCHEDULE key (see Page 266).
Setpoint and Remote Offset Set the required leaving chilled liquid temperature setpoint and Control Range under the SETPOINTS key. The chilled liquid temperature control settings need to be set according to the required operating conditions.
If remote temperature reset (offset) is to be used, the maximum reset required must be programmed by pressing the SETPOINTS key (see Page 258).
FIRST TIME START-UP During the commissioning period there should be sufficient heat load to run the unit under stable full load operation to enable the unit controls, and system operation to be set up correctly, and a commissioning log taken. Be sure that the chiller is properly programmed and the Equipment Pre Start-up and Start-up Checklist (Page 56) is completed.
Interlocks Verify that liquid is flowing through the cooler and that heat load is present. Ensure that any remote run interlocks are in the run position and that the Daily Schedule requires the unit to run or is overridden.
42
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Unit Switch
Place the UNIT switch on the keypad to the ON position.
Start-up
Press the SYSTEM SWITCHES key and place the system switch for System 1 to the ON position. There may be a few seconds delay before the first compressor starts because of the anti-recycle timer). Be ready when each compressor starts, to switch the UNIT switch OFF immediately, if any unusual noises or other adverse conditions develop.
When a compressor is running, the controller monitors oil pressure, motor current, and various other system parameters such as discharge pressure, chilled liquid temperature, etc. Should any problems occur; the control system will immediately take appropriate action and display the nature of the fault.
Oil Pressure
When a compressor starts, press the relevant "System Pressures" key and verify that oil differential pressure (oil pressure-suction pressure) develops immediately. If oil pressure does not develop, the automatic controls will shut down the compressor. Under no circumstances should a restart attempt be made on a compressor, which does not develop oil pressure immediately. Switch the UNIT switch to the OFF position.
Refrigerant Flow
When a compressor starts, a flow of liquid refrigerant will be seen in the liquid line sight glass. After several minutes of operation, and provided a full charge of refrigerant is in the system, the bubbles will disappear and be replaced by a solid column of liquid.
Loading
Once the unit has been started, all operations are fully automatic. After an initial period at minimum capacity, the control system will adjust the unit load depending on the chilled liquid temperature and rate of temperature change. If a high heat load is present, the controller will increase the speed of the compressor(s).
Condenser and Fan Rotation
Once a compressor is running, discharge pressure rises as refrigerant is pumped into the air-cooled condenser coils. This pressure is controlled by stages of fans to ensure maximum unit efficiency while maintaining sufficient pressure for correct operation of the condensers and the lubrication system.
SECTION 5 - COMMISSIONING
As discharge pressure rises, the condenser fans operate in stages to control the pressure. Verify that the fans operate in the correct direction of rotation and operation is correct for the type of unit.
Suction Superheat
Check suction superheat at steady full compressor load only. Measure suction temperature with a thermocouple on the copper line about 6 in. (150 mm) before the compressor suction service valve. Measure suction pressure at the suction transducer access valve or the compressor suction service valve. Superheat should be 10°F to 12°F (5.55°C to 6.67°C) and should be reasonably close to the panel display. Superheat setting is programmable on the control panel, but is not mechanically adjustable. The Flash Tank Drain Valve controller modulates the 2 phase Drain Valve Stepper Motor to control system superheat. Superheat control
is a function of suction pressure and suction tempera- 5
ture measurements from the sensors that are routed to the Chiller Control Board which in turn sends control signals to the Flash Tank Drain and Fill Valve Controller located in the left, back wall of the Chiller Controls Cabinet.
Subcooling
Check liquid subcooling at steady full compressor load only. It is important that all fans are running for the system. Measure liquid line temperature on the copper line at the main liquid line service valve. Measure liquid pressure at the liquid line service valve. Subcooling should be 5°F to 7°F (2.77°C to 3.88°C). YCIV 0157 subcooling should be 10°F (5.55°C). No bubbles should show in the sight glass. If subcooling is out of range, add or remove refrigerant as required to clear the sight glass. Do not overcharge the unit. Subcooling should be checked with a flash tank level of approximately 35% with a clear sight glass.
General Operation
After completion of the above checks for System 1, switch OFF the SYS 1 switch on the keypad and repeat the process for each subsequent system. When all run correctly, stop the unit, switch all applicable switches to the `ON' position and restart the unit.
Assure all checks are completed in the Equipment Pre Start-up and Start-up Checklist (Pages 56 through 61). The chiller is then ready to be placed into operation.
JOHNSON CONTROLS
43
SECTION 5 - COMMISSIONING
Operation in Sub-freezing Conditions The YCIV may be operated in sub-freezing conditions if the following freeze protections are taken :
A. A suction service valve electric actuator is installed. Chiller software will operate the actuator in order to protect against freezing due to evaporator refrigerant migration.
-or-
B. No suction service valve is installed but the water circuit valves are kept open, there is continuous power to the chiller and pump for chilled water pump control, and the pump will operate and circulate water through the evaporator whenever commanded by the chiller. The above operation is only advised if uninterrupted power can be ensured. Unforeseen power interruptions can damage the evaporator in a very short time frame if the temperature falls below freezing.
If there is potential for power loss, Johnson Controls recommends the water in the chilled water circuit be replaced with an appropriate water-to-glycol concentration.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Unit Maintenance and Shutdown in Subfreezing Conditions
If the YCIV is maintained or shut down and will be subjected to sub-freezing conditions, it is critical to protect against evaporator and waterbox freeze damage. Johnson Controls recommends the following options (in order of freeze protection level) be performed on each circuit.
A. Glycol: Replace water with an appropriate water to glycol concentration of antifreeze.
-or-
B. Drain: Remove power to the waterbox heaters. Close the water valves, drain the evaporator, and leave the evaporator drain valves open.
-or-
C. Refrigerant Valve - Off: Close the water valves, close flash tank drain valves, close the suction service valves and leave power to the chiller for evaporator heater mat and waterbox heater operation. For units without a suction service valve, close the discharge and compressor oil valves.
-or-
D. Pump Control: Keep power to the chiller in order to have control over chilled water pumps and heater operation and leave the water circuit valves open. This will enable water to circulate through the evaporator to avoid freezing. Options A and B are the recommended processes for unit maintenance and shutdown. Unforeseen power interruptions can damage the evaporator in a very short time frame if the temperature falls below freezing.
Failure to follow Johnson Controls freeze protection recommendations can void the warranty.
44
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 5 - COMMISSIONING
Equipment Pre Start-up and Start-up Checklist
MODEL YCIV
CHECKLIST
New Release
Form 201.23-CL2 (115)
EQUIPMENT PRE-STARTUP AND STARTUP CHECKLIST
CUSTOMER: ____________________________________
JOB NAME: ____________________________________
ADDRESS: _____________________________________
LOCATION: ____________________________________
PHONE: ________________________________________
CUSTOMER ORDER NO: _________________________
JCI TEL NO: _____________________ JCI ORDER NO: __________________ JCI CONTRACT NO: ______________
CHILLER MODEL NO: ____________________________
UNIT SERIAL NO: _______________________________
The work (as checked below) is in process and will be completed by: _____________ / ____________ / ___________
Month
Day
Year
The following work must be completed in accordance with installation instructions:
5
PRE-STARTUP
UNIT CHECKS (NO POWER)
The following basic checks should be made with the customer power to the unit switched OFF.
WARNING: Proper electrical lock out and tag procedures must be followed.
Check the system 24 hours prior to initial start:
1. Inspect the unit for shipping or installation damage. ..................................................................
2. Ensure that all piping has been completed. ............
3. Assure the unit is properly charged and there are no piping leaks. .......................................................
4. Open each system suction service valve, discharge service valve, economizer service valve, liquid line stop valve, and oil line ball valve. ............
5. The oil separator oil level(s) should be maintained so that an oil level is visible in either of the oil separator sight glasses when a compressor is running at high speeds for 10 to 15 minutes. An oil level may not be visible in the sight glasses when the compressor is off and it may be necessary to run the compressor to obtain a level. In shutdown situations and at some load points, much of the oil may be in the condenser and the level in the separators may fall below the bottom sight glass. ..............................................................
On systems with dual oil separators per compressor, one separator may show a lower level or no level, while the other separator shows a level between the 2 sight glasses. This is normal and a level is only required in one separator. Do not add oil to raise the level in the other oil separator.
Oil levels in single separator systems should not go above the top of the upper sight glass. Dual separator systems should also not show oil levels above the top of one of the sight glasses. In the rare situation where oil levels are high, drain enough oil to lower the level to the bottom of the top sight glass.
Sight glasses will vary in type depending upon the manufacturer of the separator. One type will have balls that float in the sight glasses to indicate level. Another type will have a bulls' eye glass. The bulls' eye glass will tend to appear to lose the lines in the bulls' eye when the level is above the glass. Oil level should not be above the top sight glass. In the rare situation where oil levels are high, drain oil to lower the level to the bottom of the top sight glass.
Oil levels in the oil separators above the top sight glass in either oil separator should be avoided and may cause excessive oil carryover in the system. High oil concentration in the system may cause nuisance trips resulting from incorrect readings on the level sensor and temperature sensors. Temperature sensor errors may result in poor refrigerant control and liquid overfeed to the compressor.
In the unlikely event it is necessary to add oil, connect a YORK oil pump to the charging valve on the oil separator, but do not tighten the flare nut on the delivery tubing. With the bottom (suction end) of the pump submerged in oil to avoid entrance of air, operate the pump until oil drips from the flare nut joint, allowing the air to be expelled, and tighten the flare nut. Open the compressor oil charging valve and pump in oil until it reaches the proper level as described above.
CAUTION: When oil levels are high, adding oil may not visibly increase the level in the separators during operation. This may be an indication the level is already too high and the oil is being pumped out into the system where it will cause heat transfer and control problems.
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SECTION 5 - COMMISSIONING
6. Ensure water pumps are on. Check and adjust water pump flow rate and pressure drop across the cooler. ...............................................................
CAUTION: Excessive flow may cause catastrophic damage to the evaporator.
7. Check the control panel to ensure it is free of foreign material (wires, metal chips, tools, documents, etc.). ............................................................
8. Visually inspect wiring (power and control). Wiring MUST meet N.E.C. and local codes. ......................
9. Check tightness of the incoming power wiring inside the power panel and inside the motor terminal boxes. .....................................................................
10. Check for proper size fuses in control circuits. .......
11. Verify that field wiring matches the 3-phase power requirements of the chiller. (See chiller nameplate) ...........................................
12. Be certain all water temperature sensors are inserted completely in their respective wells and are coated with heat conductive compound. .................
13. Ensure the suction line temperature sensors are strapped onto the suction lines at 4 or 8 O'clock positions. .................................................................
14. Assure the glycol level in the VSD cooling system is 9 to 15 inches (23 to 28 cm) from the top of the fill tube. This check should be performed prior to running the pump. ...................................................
CAUTION: Never run the glycol pump without coolant! Running the glycol pump without coolant may damage the pump seals.
Always fill the system with approved YORK coolant (P/N 013-03344-000) to avoid damage to the pump, cooling system and the chiller.
15. Check to assure the remote start/stop for Sys #1 on Terminals 2 to 15 and Sys #2 on Terminals 2 to 16 are closed on the User Terminal Block 1TB to allow the systems to run. If remote cycling devices are not utilized, place a wire jumper between these terminals. .......................................................
16. Ensure that the CLK jumper JP2 on the is in the ON position. ............................................................
17. Assure a flow switch is connected between Terminals 2 and 13 on the User Terminal Block 1TB in the panel. Throttle back flow to assure the flow switch opens with a loss of flow. It is recommended that auxiliary pump contacts be placed in series with the flow switch for additional protection, if the pump is turned off during chiller operation. Whenever the pump contacts are used, the coil of the pump starter should be suppressed with an RC suppressor (031-00808-000). .................................
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
FORM 201.23-CL2 ISSUE DATE: 1/12/2015
A. START-UP
Panel Checks (Power ON Both System Switches OFF)
WARNING: You are about to turn power on to this machine. SAFETY IS NUMBER ONE! Only qualified individuals are permitted to service this product. The qualified individual furthermore is to be knowledgeable of, and adhere to, all safe work practices as required by NEC, OSHA, and NFPA 70E. Proper personal protection is to be utilized where and when required.
1. Assure the chiller OFF/ON UNIT switch at the bottom of the keypad is OFF. .......................................
2. Apply 3-phase power to the chiller. Turn on the optional panel circuit breaker if supplied. The customer's disconnection devices can now be set to ON. ......................................................................
3. Verify the control panel display is illuminated. ........
4. To prevent the compressors from starting, assure that the system switches under the SYSTEM SWITCHES key are in the OFF position. ................
5. Verify that the voltage supply corresponds to the unit requirement and is within the limits given in the "Technical Data" section. ...................................
6. Ensure the heaters on each compressor are ON using a clamp-on ammeter. Heater current draw is approx. 3A. ..............................................................
7. Verify the "Factory Set" overload potentiometers on the VSD Logic Board are set correctly. Press the VSD DATA key and using the arrow keys, scroll to the compressor overload settings. Verify the "Factory Set" overload potentiometer(s) on the VSD Logic Board are set correctly. In the unlikely event that they are not set correctly, adjust the potentiometers until the desired values are achieved.
WARNING: The VSD is powered up and live. High voltage exists in the area of the circuit board on the bus bars, VSD Pole Assemblies, and wiring to the input inductor.
Adjust the potentiometers, if needed. The potentiometers are Sys 1=R19, Sys 2=R64, Sys 3=R42, and Sys 4=R86.
CAUTION: Incorrect settings of the potentiometers may cause damage to the equipment.
Record the Overload Potentiometer settings below:
Compressor Overload Setting:
System 1 = ______________ Amps
System 2 = ______________ Amps
System 3 = ______________ Amps
System 4 = ______________ Amps
2
JOHNSON CONTROLS
46
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
FORM 201.23-CL2 ISSUE DATE: 1/12/2015
8. Press the STATUS key. If the following message appears, immediately contact Johnson Controls Product Technical Support. The appearance of this message may mean the chiller has lost important factory programmed information. The serial number and other important data may need to be reprogrammed. .......................................................
UNIT WARNING: INVALID SERIAL NUMBER ENTER UNIT SERIAL NUMBER
NOTE: Changing the programming of this feature requires the date and time to be set on the chiller prior to programming. Additional information regarding this message and how to enter the serial number with the factory provided password is outlined in the "Serial Number Programming". If the following message appears when the STATUS key is pressed, immediately contact Johnson Controls Product Technical Support. The appearance of this message indicates the chiller is a High IPLV chiller operating in Standard IPLV control.
UNIT WARNING: OPTIMIZED EFFICIENCY DISABLED CONTACT YORK REPRESENTATIVE
NOTE: Changing the programming of this feature requires the date and time to be set on the chiller prior to programming. Additional information regarding this message is provided in the "Enabling Optimized High IPLV Mode".
9. Program the required options into the Panel for the desired operating requirements. Record the values below:
Display Language = ___________________________
Chilled Liquid Mode = __________________________
Local/Remote Mode = _________________________
Display Units = _______________________________
Lead/Lag Control = ____________________________
Remote Temperature Reset = ___________________
Remote Current Reset = _______________________
SECTION 5 - COMMISSIONING
B. PROGRAMMED VALUES
Program the required operating values into the microprocessor for cutouts, safeties, etc. and record them in the chart below.
Suction Pressure Cutout = ____________ PSIG (kPa)
Low Ambient Cutout = __________________ °F (°C)
Leaving
Chilled
Liquid
Temperature Cutout =__________________ °F (°C)
Motor Current Limit = ___________________% FLA
Pulldown Current Limit Time =______________MIN
Suction Superheat Setpoint = _____________°F (°C)
Remote Unit ID # = ___________________________
Sound Limit Setpoint = ______________________%
C. CHILLED LIQUID SETPOINT
Program the Chilled Liquid Setpoint/Range and record:
Local Cooling Setpoint = _____________ °F (°C)
Local Cooling Range = ______ to ______ °F (°C)
5
Maximum
Remote
Temperature Reset = _______ to ______ °F (°C)
D. DATE/TIME, DAILY SCHEDULE, AND CLOCK JUMPER
1. Set the date and time. .............................................
2. Program the Daily Schedule start and stop times. ...............................................................
3. Place the panel in Service Mode and turn on each fan stage one by one. Ensure the fans rotate in the correct direction, so air flow exits the top of the chiller .......................................................................
4. Remove the cap on the fill tube and run the glycol pump to verify the level in the fill tube. Ensure the glycol level in the VSD cooling system is 9 to15 inches (23 to 28 cm) from the top of the fill tube while running. The pump can be run by placing the chiller in the Service Mode. Be sure to re-install the cap before stopping the glycol pump to avoid overflowing the fill tube when the glycol pump is turned off. The glycol system holds about 3.5 gallons of coolant (P/N 013-03344-000) on the largest chiller model. ...............................................
Remote Sound Limit = __________________________
Low Ambient Cutout = __________________________
CAUTION: Damage to the chiller could result if the options are improperly programmed.
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SECTION 5 - COMMISSIONING
E. INITIAL START-UP
After the control panel has been programmed and the compressor heaters have been energized for at least 8 hours (ambient temperature more than 96ºF (36ºC)) or 24 hours (ambient temperature less than 86ºF (30ºC)), the chiller may be placed in operation.
1. Turn on the UNIT switch and program the system switches on the keypad to the "ON" position. .........
2. If cooling demand permits, the compressor(s) will start and a flow of refrigerant will be noted in the sight glass, after the anti recycle timer times out and the precharge of the DC Bus is completed. After several minutes of operation, the bubbles in the sight glass will disappear and there will be a solid column of liquid when the Drain and Feed Valves stabilize the flash tank level. ........................
3. Allow the compressor to run a short time, being ready to stop it immediately if any unusual noise or adverse conditions develop. Immediately at start-up, the compressor may make sounds different from its normal high-pitched sound. This is due to the compressor coming up to speed and the initial lack of an oil film sealing the clearances in the rotors. This should be of no concern and lasts for only a short time. ...............................................
4. Check the system operating parameters. Do this by selecting various displays such as pressures and temperatures. Compare these to test gauge readings. .................................................................
F. CHECKING SUBCOOLING AND SUPERHEAT
The subcooling should always be checked when charging the system with refrigerant and/or before checking the superheat. The subcooling measurement should always be taken with the system loaded, the economizer solenoid energized, and the level in the flash tank reasonably stable with a level of approximately 35%.
Note: It may be desirable to check subcooling with one compressor running to allow the compressor to operate at full speed for a period of time to stabilize system temperatures and pressures.
When the refrigerant charge is correct, there will be no bubbles in the liquid sight glass with the system operating under full load conditions, and there will be 5 to 7°F (2.77 to 3.78°C) subcooled liquid leaving the condenser. Subcooling should be set at 10°F (5.56°C). An overcharged system should be guarded against. Evidence of overcharge is as follows:
a. If a system is overcharged, the discharge pressure will be higher than normal. Normal discharge/condensing pressure can be found in the refrigerant temperature/pressure chart; use entering air temperature plus 30°F (17°C) for normal condensing temperature.
b. The temperature of the liquid refrigerant out of the condenser should be about 5 to 7°F (2.77 to 3.78°C) less than the condensing temperature (The temperature corresponding to the condensing pressure from the refrigerant temperature/pressure chart).
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
FORM 201.23-CL2 ISSUE DATE: 1/12/2015
The subcooling temperature of each system should be calculated by recording the temperature of the liquid line at the outlet of the condenser and subtracting it from the recorded liquid line pressure at the liquid stop valve, converted to temperature from the temperature/pressure chart.
Subcooling
Example:
Liquid line pressure = 110 PSIG converted to Minus liquid line temp. Subcooling =
93°F (33.9°C) -87°F (30.6°C)
6°F (3.3°C)
The subcooling should be adjusted between 5 and 7 °F (2.77 and 3.78°C)
NOTE: This may be difficult to measure, due to test instrument error and the difficulty generally encountered when measuring subcooling on systems operating with very low condenser subcooling.
Record the liquid line pressure and it's corresponding temperature, liquid line temperature, and subcooling below:
Liq Line Press = Temp = Liq Line Temp = Subcooling =
SYS 1 _____ _____ _____ _____
SYS 2 _____ _____ _____ _____
PSIG (kPa) °F (°C) °F (°C) °F (°C)
Add or remove charge as necessary to obtain a full sight glass fully loaded while keeping subcooling to about 5 to 7°F (2.77 to 3.78°C). After an adjustment is made to the charge, the flash tank level may rise or drop from the approx. 35% point. Before another measurement is made, allow the level to stabilize.
After the subcooling is set, the suction superheat should be checked. The superheat should be checked only after steady state operation of the chiller has been established, and the system is running in a fully loaded, stable condition. Correct superheat for a system is between 8 and 12°F (4.45 and 6.67°C) and should be reasonably close to the system superheat on the chiller display.
The superheat is calculated as the difference between the actual temperature of the returned refrigerant gas in the suction line entering the compressor and the temperature corresponding to the suction pressure as shown in a standard pressure/temperature chart.
4
JOHNSON CONTROLS
48
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
FORM 201.23-CL2 ISSUE DATE: 1/12/2015
Superheat
Example:
Suction Temp = minus Suction Press 30 PSIG converted to Temp
46°F (8°C)
- 35°F (1°C) 11°F (6°C)
The suction temperature should be taken 6" (13 mm) before the compressor suction service valve, and the suction pressure is taken at the compressor suction service valve.
No superheat adjustments are necessary and the electronically controlled Drain Valve need not be adjusted in the field. Ensure that superheat is controlling at 8 to 12°F (4.45 to 6.67°C). The purpose of this check is primarily to verify the transducer and suction temperature sensors in a system are providing reasonably accurate outputs to the chiller controls. It also checks the operation of the Feed and Drain Valves.
Record the suction temperature, suction pressure, suction pressure converted to temperature, and superheat of each system below:
Suction Press = SP to Temp = Suction Temp = Superheat =
SYS 1 _____ _____ _____ _____
SYS 2 _____ _____ _____ _____
PSIG (kPa) °F (°C) °F (°C) °F (°C)
Discharge superheat will typically run approx. 28 to 30°F. This can be checked on the micropanel display. If the suction superheat drops very low or the economizer feeds liquid into the compressor, the superheat will drop sharply to approx. 2 to 3°F.
Leak Checking
Leak check compressors, fittings, and piping to ensure no leaks.
If the chiller is functioning satisfactorily during the initial operating period, no safeties trip and the chiller controls chilled liquid temperature; it is now ready to be placed into service.
SECTION 5 - COMMISSIONING
JOB NAME: _____________________________
SALES ORDER #: ________________________
LOCATION: _____________________________
SOLD BY: ______________________________
INSTALLING CONTRACTOR: _________________________
START-UP TECHNICIAN/ COMPANY: _____________________________
START-UP DATE: ________________________
CHILLER MODEL #: ______________________
SERIAL #: ______________________________
5
COMPRESSOR #1 MODEL#: ______________________________
SERIAL #: ______________________________
COMPRESSOR #2 MODEL#: ______________________________
SERIAL #: ______________________________
COMPRESSOR #3 MODEL#: ______________________________
SERIAL #: ______________________________
COMPRESSOR #4 MODEL#: ______________________________
SERIAL #: ______________________________
JOHNSON CONTROLS JOHNSON CONTROLS
5 49
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
THIS PAGE INTENTIONALLY LEFT BLANK
50
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
WATER PRESSURE DROP CHARTS
ENGLISH UNITS
Pressure Drop Through Two Circuit YCIV Evaporators
60
B
50
A
40
C
30
D
20
Pressure Drop (ft H2O)
6
10
0
0
100
200
300
400
500
600
700
800
900
1000
Water Flow Rate (GPM)
COOLER A B
C
D
MODEL NUMBER YCIV 60 HZ
0157(S/P/H) 0157(E/V) 0177(S/P/H/E/V) 0187(S/P/H/E/V) 0197(E/V) 0207(E/V) 0227(E/V) 0207(S/P/H) 0227(S/P/H) 0247(S/P/H/E/V) 0267(S/P/H)
JOHNSON CONTROLS
Excessive flow, above the max. GPM, will damage the evaporator.
51
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
WATER PRESSURE DROP CHARTS (CONT'D)
SI UNITS
200 180 160 140 120 100
80 60 40 20
0 0
Pressure Drop Through Two Circuit YCIV Evaporators
B
C A
D
5
10
15
20
25
30
35
40
45
50
Water Flow Rate (l/s)
Pressure Drop (kPa)
COOLER A B
C
D
MODEL NUMBER YCIV 60 HZ
0157(S/P/H) 0157(E/V) 0177(S/P/H/E/V) 0187(S/P/H/E/V) 0197(E/V) 0207(E/V) 0227(E/V) 0207(S/P/H) 0227(S/P/H) 0247(S/P/H/E/V) 0267(S/P/H)
52
Excessive flow, above the max. GPM, will damage the evaporator.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
WATER PRESSURE DROP CHARTS (CONT'D)
ENGLISH UNITS
Pressure Drop Through Three Circuit YCIV Evaporators Pressure Drop Through Three Circuit YCIV Evaporators
100
B
Pressure Drop (ft H2O)
10
1 100
EVAP A
B
A
6
Water Flow Rate (GPM)
1000
2000
MODEL NUMBER YCIV 60 HZ
0267EA/VA 0287SA/PA/HA
0287EA/VA 0307SA/PA/HA
0327EA/VA 0357SA/PA/HA
0357EA/VA 0397SA/PA/HA
Excessive flow, above the max. GPM, will damage the evaporator.
JOHNSON CONTROLS
53
Pressure Drop (kPa)
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
WATER PRESSURE DROP CHARTS (CONT'D)
SI UNITS
PPrreessssuurree DDrroopp TThhrroouugghh TThhrreeeeCCirirccuuititYYCCIVIVEEvvaappooraratotorsrs
1000
B
100
10
A
1 10.0
Water Flow Rate (l/s)
100.0
EVAP A
B
MODEL NUMBER YCIV 60 HZ
0267EA/VA 0287SA/PA/HA
0287EA/VA 0307SA/PA/HA
0327EA/VA 0357SA/PA/HA
0357EA/VA 0397SA/PA/HA
Excessive flow, above the max. GPM, will damage the evaporator.
54
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
GLYCOL CORRECTION FACTORS
The cooler is designed in accordance with ARI-5909utthi2porpsaTAnotwhrlaohuRselogehoI1spw-hi5sc5ccrnuh%eo69asro60ouesa.la-nsuel9bldDerro2peorewioaavsdwbpdgesrrdhdoeitofesiihpscotfsie.ihrou4ingndp8aantean-lhetl5slooeid1ipgwn1.wrnicsen5Dravs%eftaeosaeacblurrsuacreramiebeosniorasnddivhnyinraeoopctanwhrptrlcehsee.nesoeaswouswcdnaeraieettuPhesinsdaireggrmnoeapsdavdya6oi3lf-ue
When using glycol solutions, pressure drops are higher thaWn hweinthuwsinatgergl(ysceoel csoorlruetciotinosn, fparcetsosrsurteo dbreopasppalrieed whheinghuesrinthganglwycitohl wsoaltuetrio(snes)e. cSoprerecicatliocnafraecmtourssttobebe takamepnupsnltioebtdetowtaehxkeceneneudnsoitnhtgetogmelyaxcxcoiemlesudomltuhftelioomwnsar)xa. tiSmepauelmlcoiwaflloecwda. re
ratAe =allCoowreredc.tion Factor B = MABe==anCMoTerearmencTpteieomrnaptFuearrecattotuhrrreotuhgrohuCgohoCleoroler C = CCo=ncCeonntrcaetinotrnaWtionIWW/W
GLYCOL CORRECTION FACTORS
ETHYLENE GLYCOL
1.45
1.40
1.35
1.30 A 1.25
1.20 1.15 1.10 1.05
-10 -8 -6 -4 -2 0 2
50% 40% 30% C 20% 10% 4 6 8C
B
PROPYLENE GLYCOL
1.8 1.7
Excessive flow, above the max. GPM, will
1.6
daEmxacgeesstihvee efvloawpo, raabtovr.e the max. GPM, will damage the evaporator.
1.5 A 1.4
1.3 1.2 1.1 1.0
50% 40% 30% C 20% 10%
-10 -8 -6 -4 -2 0 2 4 6 8 C
B
LD10500A
6
JOHNSON CONTROLS
55
SECTION 6 - TECHNICAL DATA
WATER TEMPERATURE AND FLOWS
(ENGLISH UNITS)
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
MODEL NUMBER YCIV
0157(S/P/H) 0157(E/V) 0177(S/P/H) 0177(E/V) 0187(S/P/H) 0187(E/V) 0197(E/V) 0207(S/P/H) 0207(E/V) 0227(S/P/H) 0227(E/V) 0247(S/P/H) 0247(E/V) 0267(S/P/H) 0267(E/V) 0287(S/P/H) 0287(E/V) 0307(S/P/H) 0327(E/V) 0357(S/P/H) 0357(E/V) 0397(S/P/H)
LEAVING WATER TEMPERATURE (°F)
MIN.1
MAX.2
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
40
60
COOLER FLOW (GPM)
MIN.
MAX.
140
675
160
750
160
750
160
750
160
750
160
750
180
750
180
800
180
750
180
800
180
750
180
800
180
800
180
800
250
1200
250
1200
250
1200
300
1200
300
1200
300
1200
300
1200
300
1200
AIR ON CONDENSER (°F)
MIN. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
MAX 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125
NOTES: 1. For leaving brine temperature below 40°F (4.4°C), contact your nearest Johnson Controls office for application requirements. 2. For leaving water temperature higher than 60°F (15.6°C), contact the nearest Johnson Controls office for application guidelines.
56
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
WATER TEMPERATURE AND FLOWS (CONT'D) (SI UNITS)
MODEL NUMBER
YCIV
0157(S/P/H) 0157(E/V) 0177(S/P/H) 0177(E/V) 0187(S/P/H) 0187(E/V) 0197(E/V) 0207(S/P/H) 0207(E/V) 0227(S/P/H) 0227(E/V) 0247(S/P/H) 0247(E/V) 0267(S/P/H) 0267(E/V) 0287(S/P/H) 0287(E/V) 0307(S/P/H) 0327(E/V) 0357(S/P/H) 0357(E/V) 0397(S/P/H)
LEAVING WATER TEMPERATURE (°C)
MIN.1
MAX.2
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
4.4
15.6
COOLER3 FLOW (L/S)
MIN.
MAX.
8.8
42.6
10.1
47.3
10.1
47.3
10.1
47.3
10.1
47.3
10.1
47.3
11.4
47.3
11.4
50.5
11.4
47.3
11.4
50.5
11.4
47.3
11.4
50.5
10.1
47.3
11.4
50.5
11.4
50.5
15.8
75.7
15.8
75.7
18.9
75.7
18.9
75.7
18.9
75.7
18.9
75.7
18.9
75.7
AIR ON CONDENSER (°C)
MIN. -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8 -17.8
MAX
51.7
51.7
51.7
51.7
51.7
51.7
51.7
51.7
51.7
51.7
51.7
51.7
51.7
51.7
51.7
51.7
6
51.7
51.7
51.7
51.7
51.7
51.7
NOTES: 1. For leaving brine temperature below 4.4°C, contact your nearest Johnson Controls office for application requirements. 2. For leaving water temperature higher than 15.6°C, contact the nearest Johnson Controls office for application guidelines.
JOHNSON CONTROLS
57
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
PHYSICAL DATA (ENGLISH - STANDARD EFFICIENCY)
REFRIGERANT R-134a
STANDARD EFFICIENCY MODEL NUMBER (YCIV____ S/P/H)
GENERAL UNIT DATA
60 HZ
0157
0177
0187
0207
0227
Number of Independent Refrigerant Circuits
2
2
2
2
2
Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, lb 162/162 170/170 185/170 192/175 192/192
Oil Charge, Ckt.-1/Ckt.-2, gal
5/5
5/5
5/5
5/5
5/5
Compressors, Semi-hermetic Screw Qty per Chiller
2
2
2
2
2
Condensers, High Efficiency Fin/Tube with Integral Subcooler
Total Chiller Coil Face Area, ft2
235
235
264
264
293
Number of Rows
3
3
3
3
3
Fins per Inch
17
17
17
17
17
Condenser Fans
Number, Ckt.-1/Ckt.-2
4/4
4/4
5/4
5/4
5/5
Low Noise Fans
Fan Motor, hp
2
2
2
2
2
Total Chiller Airflow, cfm
104000 104000 117000 117000 130000
ULTRA QUIET FANS
Fan Motor, HP
2
2
2
2
2
Total Chiller Airflow, cfm
104000 104000 117000 117000 130000
Dual Speed Fans - Normal Speed
Fan Motor, hp
2
2
2
2
2
Total Chiller, CFM
88000 88000 99000 99000 110000
Dual Speed Fans - Lower Speed
Fan Motor, hp
2
2
2
2
2
Total Chiller, CFM
67200 67200 75600 75600 84000
High Static Fans
Fan Motor, hp
5
5
5
5
5
Total Chiller, CFM
104000 104000 117000 117000 130000
Evaporator, Direct Expansion
Water Volume, gal
67.0
95.0
95.0
140.0 140.0
Maximum Water Side Pressure, psig
150
150
150
150
150
Maximum Refrigerant Side Pressure, psig
235
235
235
235
235
Minimum Chilled Water Flow Rate, gpm
140
160
160
180
180
Maximum Chilled Water Flow Rate, gpm
675
750
750
800
800
Water Connections, in.
8
10
10
10
10
0247 2
230/195 5/5 2
323 3 17
6/5
2 143000
2 143000
2 121000
2 92400
5 143000
140.0 150 235 180 800 10
0267 2
230/230 5/5 2
352 3 17
6/6
2 156000
2 156000
2 132000
2 100800
5 156000
140.0 150 235 180 800 10
Contact your nearest Johnson Controls Sales Office for weight data.
58
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
PHYSICAL DATA (ENGLISH - STANDARD EFFICIENCY) (CONT'D)
Refrigerant R-134a
STANDARD EFFICIENCY MODEL NUMBER (YCIV____ S/P/H)
General Unit Data
60 Hz
0287
0307
0357
0397
Number of Independent Refrigerant Circuits
3
3
3
3
Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, lb
185/170/170 185/185/170 185/185/230 230/230/230
Oil Charge, Ckt.-1/Ckt.-2, gal
5/4/4
5/4/4
5/5/5
5/5/5
Glycol Charge (43% concentration), gal
5.4
5.5
6.0
6.3
Comp.s, Semihermetic Screw
Quantity per Chiller
3
3
3
3
Condensers, High Efficiency Fin/Tube with Integral Subcooler
Total Chiller Coil Face Area, ft2
381
411
469
528
Number of Rows
3
3
3
3
Fins per Inch
17
17
17
17
Condenser Fans
Number, Ckt.-1/Ckt.-2
5/4/4
5/4/4
5/5/6
6/6/6
Low Noise Fans
Fan Motor, HP/kWi
2/1.8
2/1.8
2/1.8
2/1.8
Total Chiller Airflow, cfm
169000
182000
208000
234000
Ultra Quiet Fans Fan Motor, HP/kWi
2/1.50
2/1.50
2/1.50
2/1.50
6
Total Chiller Airflow, cfm
169000
182000
208000
234000
Dual Speed Fans - Normal Speed
Fan Motor, hp
2
2
2
2
Total Chiller, cfm
143000
143000
165000
165000
Dual Speed Fans - Lower Speed
Fan Motor, hp
2
2
2
2
Total Chiller, cfm
109200
109200
126000
126000
High Static Fans
Fan Motor, hp
5
5
5
5
Total Chiller, cfm
169000
182000
208000
234000
Evaporator, Direct Expansion
Water Volume, gal
202.0
236.0
236.0
236.0
Maximum Water Side Pressure, psig
150
150
150
150
Maximum Refrigerant Side Pressure, psig
235
235
235
235
Minimum Chilled Water Flow Rate, gpm
250
300
300
300
Maximum Chilled Water Flow Rate, gpm
1200
1200
1200
1200
Water Connections, in.
10
10
10
10
Contact your nearest Johnson Controls Sales Office for weight data.
JOHNSON CONTROLS
59
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
PHYSICAL DATA (ENGLISH - HIGH EFFICIENCY)
Refrigerant R-134a
HIGH EFFICIENCY MODEL NUMBER (YCIV____ E/V)
General Unit Data
60 Hz
0157
0177
0187
0197
0207
Number of Independent Refrigerant Circuits
2
2
2
2
2
Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, lb 170/170 185/170 185/185 192/192 225/192
Oil Charge, Ckt.-1/Ckt.-2, gal
5/5
5/5
5/5
5/5
5/5
Compressors, Semihermetic Screw Qty per Chiller
2
2
2
2
2
Condensers, High Efficiency Fin/Tube with Integral Subcooler
Total Chiller Coil Face Area, ft2
235
264
293
293
323
Number of Rows
3
3
3
3
3
Fins per Inch
17
17
17
17
17
Condenser Fans
Number, Ckt.-1/Ckt.-2
4/4
5/4
5/5
5/5
6/5
Low Noise Fans
Fan Motor, hp
2
2
2
2
2
Total Chiller Airflow, cfm
104000 117000 130000 130000 143000
Ultra Quiet Fans
Fan Motor, hp
2
2
2
2
2
Total Chiller Airflow, cfm
104000 117000 130000 130000 143000
Dual Speed Fans - Normal Speed
Fan Motor, hp
2
2
2
2
2
Total Chiller, cfm
88000 99000 110000 110000 121000
Dual Speed Fans - Lower Speed
Fan Motor, hp
2
2
2
2
2
Total Chiller, cfm
67200 75600 84000 84000 92400
High Static Fans
Fan Motor, hp
5
5
5
5
5
Total Chiller, cfm
104000 117000 130000 130000 143000
Evaporator, Direct Expansion
Water Volume, gal
95.0
95.0
95.0
110.0 110.0
Maximum Water Side Pressure, psig
150
150
150
150
150
Maximum Refrigerant Side Pressure, psig
235
235
235
235
235
Minimum Chilled Water Flow Rate, gpm
160
160
160
180
180
Maximum Chilled Water Flow Rate, gpm
750
750
750
750
750
Water Connections, in.
10
10
10
10
10
0227 2
225/225 5/5 2
352 3 17
6/6
2 156000
2 156000
2 132000
2 100800
5 156000
110.0 150 235 180 750 10
0247 2
230/230 5/5 2
352 3 17
6/6
2 156000
2 156000
2 132000
2 100800
5 156000
140.0 150 235 180 800 10
60
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
PHYSICAL DATA (ENGLISH - HIGH EFFICIENCY) (CONT'D)
Refrigerant R-134a
HIGH EFFICIENCY MODEL NUMBER (YCIV____ E/V)
General Unit Data
60 Hz
0267
0287
0327
0357
Number of Independent Refrigerant Circuits
3
3
3
3
Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, lb
185/185/170 185/185/230 185/185/230 230/230/230
Oil Charge, Ckt.-1/Ckt.-2, gal
5/5/4
5/5/5
5/5/5
5/5/5
Glycol Charge (43% concentration), gal
5.5
5.7
6.0
6.3
Comp.s, Semihermetic Screw
Quantity per Chiller
3
3
3
3
Condensers, High Efficiency Fin/Tube with Integral Subcooler
Total Chiller Coil Face Area, ft2
411
469
469
528
Number of Rows
3
3
3
3
Fins per Inch
17
17
17
17
Condenser Fans
Number, Ckt.-1/Ckt.-2
5/5/4
5/5/6
5/5/6
6/6/6
Low Noise Fans
Fan Motor, HP/kWi
2/1.8
2/1.8
2/1.8
2/1.8
Total Chiller Airflow, cfm
182000
208000
208000
234000
Ultra Quiet Fans
Fan Motor, HP/kWi Total Chiller Airflow, cfm Dual Speed Fans - Normal Speed
2/1.50
2/1.50
2/1.50
2/1.50
182000
208000
208000
234000
6
Fan Motor, hp
2
2
2
2
Total Chiller, cfm
154000
176000
176000
198000
Dual Speed Fans - Lower Speed
Fan Motor, hp
2
2
2
2
Total Chiller, cfm
117600
134400
134400
151200
High Static Fans
Fan Motor, hp
5
5
5
5
Total Chiller, cfm
195000
247000
247000
273000
Evaporator, Direct Expansion
Water Volume, gal
202.0
202.0
236.0
236.0
Maximum Water Side Pressure, psig
150
150
150
150
Maximum Refrigerant Side Pressure, psig
235
235
235
235
Minimum Chilled Water Flow Rate, gpm
250
250
300
300
Maximum Chilled Water Flow Rate, gpm
1200
1200
1200
1200
Water Connections, in.
10
10
10
10
JOHNSON CONTROLS
61
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
PHYSICAL DATA (SI - STANDARD EFFICIENCY)
REFRIGERANT R-134a
STANDARD EFFICIENCY MODEL NUMBER (YCIV____ S/P/H)
GENERAL UNIT DATA
60 HZ
0157
0177
0187
0207
0227
Number of Independent Refrigerant Circuits
2
2
2
2
2
Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, kg
74/74 77/77 84/77 87/80 87/87
Oil Charge, Ckt.-1/Ckt.-2, L
19/19 19/19 19/19 19/19 19/19
Compressors, Semihermetic Screw Qty per Chiller
2
2
2
2
2
Condensers, High Efficiency Fin/Tube with Integral Subcooler
Total Chiller Coil Face Area, m2
21.8
21.8
24.5
24.5
27.2
Number of Rows
3
3
3
3
3
Fins per meter
669
669
669
669
669
Condenser Fans
Number, Ckt.-1/Ckt.-2
4/4
4/4
5/4
5/4
5/5
Low Noise Fans
Fan Motor, HP/kWi
2/1.50 2/1.50 2/1.50 2/1.50 2/1.50
Total Chiller Airflow, L/s
49082 49082 55218 55218 61353
Ultra Quiet Fans
Fan Motor, HP/kWi
2/1.50 2/1.50 2/1.50 2/1.50 2/1.50
Total Chiller Airflow, L/s
49082 49082 55218 55218 61353
Dual Speed Fans - Normal Speed
Fan, KWi
1.5
1.5
1.5
1.5
1.5
Total Chiller, m3/s
42
42
47
47
52
Dual Speed Fans - Lower Speed
Fan, KWi
1.5
1.5
1.5
1.5
1.5
Total Chiller, m3/s
32
32
36
36
40
High Static Fans
Fan, KWi
3.7
3.7
3.7
3.7
3.7
Total Chiller, m3/s
49
49
55
55
61
Evaporator, Direct Expansion
Water Volume, L
253.6 359.6 359.6 529.9 529.9
Maximum Water Side Pressure, bar
10
10
10
10
10
Maximum Refrigerant Side Pressure, bar
16
16
16
16
16
Minimum Chilled Water Flow Rate, L/s
8.8
10.1
10.1
11.4
11.4
Maximum Chilled Water Flow Rate, L/s
42.6
47.3
47.3
50.5
50.5
Water Connections, in.
8
10
10
10
10
0247 2
105/89 19/19
0267 2
105/105 19/19
2
2
30.0
32.7
3
3
669
669
6/5
6/6
2/1.50 67488
2/1.50 73624
2/1.50 67488
2/1.50 73624
1.5
1.5
57
62
1.5
1.5
44
48
3.7
3.7
67
74
529.9 10 16 11.4 50.5 10
529.9 10 16 11.4 50.5 10
62
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
PHYSICAL DATA (SI - STANDARD EFFICIENCY) (CONT'D)
REFRIGERANT R-134a
STANDARD EFFICIENCY MODEL NUMBER (YCIV____ S/P/H)
GENERAL UNIT DATA
60 HZ
0287
0307
0357
0397
Number of Independent Refrigerant Circuits
3
3
3
3
Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, kg
84 / 77 / 77
84 / 84 / 77 84 / 84 / 105 105 / 105 / 105
Oil Charge, Ckt.-1/Ckt.-2, L
19 / 15 / 15
19 / 19 / 15
19 / 19 / 19
19 / 19 / 19
Glycol Charge (43% concentration), L
0
0
0
0
Compressors, Semihermetic Screw
Quantity per Chiller
3
3
3
3
Condensers, High Efficiency Fin/Tube with Integral Subcooler
Total Chiller Coil Face Area, m2
35
38
44
49
Number of Rows
3
3
3
3
Fins per meter
669
669
669
669
Condenser Fans
Number, Ckt.-1/Ckt.-2
5/4/4
5/5/4
5/5/6
6/6/6
Low Noise Fans
Fan Motor, HP/kWi
2/1.50
2/1.50
2/1.50
2/1.50
Total Chiller Airflow, L/s
79768
85904
98176
110448
Ultra Quiet Fans
Fan Motor, HP/kWi Total Chiller Airflow, L/s Dual Speed Fans - Normal Speed
2/1.50 79768
2/1.50 85904
2/1.50 98176
2/1.50
110448
6
Fan, KWi
1.5
1.5
1.5
1.5
Total Chiller, m3/s
67
67
78
78
Dual Speed Fans - Lower Speed
Fan, KWi
1.5
1.5
1.5
1.5
Total Chiller, m3/s
52
52
59
59
High Static Fans
Fan, KWi
3.7
3.7
3.7
3.7
Total Chiller, m3/s
80
86
98
110
Evaporator, Direct Expansion
Water Volume, L
764.6
893.3
893.3
893.3
Maximum Water Side Pressure, bar
10
10
10
10
Maximum Refrigerant Side Pressure, bar
16
16
16
16
Minimum Chilled Water Flow Rate, L/s
16
19
19
19
Maximum Chilled Water Flow Rate, L/s
76
76
76
76
Water Connections, mm
245
245
245
245
JOHNSON CONTROLS
63
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
PHYSICAL DATA (SI - HIGH EFFICIENCY)
REFRIGERANT R-134a
HIGH EFFICIENCY MODEL NUMBER (YCIV____ E/V)
GENERAL UNIT DATA
60 HZ
0157
0177
0187
0197
0207
Number of Independent Refrigerant Circuits
2
2
2
2
2
Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, kg
77/77 84/77 84/84 87/87 102/87
Oil Charge, Ckt.-1/Ckt.-2, L
19/19 19/19 19/19 19/19 19/19
Compressors, Semihermetic Screw Qty per Chiller
2
2
2
2
2
Condensers, High Efficiency Fin/Tube with Integral Subcooler
Total Chiller Coil Face Area, m2
21.8
24.5
27.2
27.2
30.0
Number of Rows
3
3
3
3
3
Fins per meter
669
669
669
669
669
Condenser Fans
Number, Ckt.-1/Ckt.-2
4/4
5/4
5/5
5/5
6/5
Low Sound Fans
Fan Motor, HP/kWi
2/1.50 2/1.50 2/1.50 2/1.50 2/1.50
Total Chiller Airflow, L/s
49082 55218 61353 61353 67488
Ultra Quiet Fans
Fan Motor, HP/kWi
2/1.50 2/1.50 2/1.50 2/1.50 2/1.50
Total Chiller Airflow, L/s
49082 55218 61353 61353 67488
Dual Speed Fans - Normal Speed
Fan, KWi
1.5
1.5
1.5
1.5
1.5
Total Chiller, m3/s
42
47
52
52
57
Dual Speed Fans - Lower Speed
Fan, KWi
1.5
1.5
1.5
1.5
1.5
Total Chiller, m3/s
32
36
40
40
44
High Static Fans
Fan, KWi
3.7
3.7
3.7
3.7
3.7
Total Chiller, m3/s
49
55
61
61
67
Evaporator, Direct Expansion
Water Volume, L
359.6 359.6 359.6 416.4 416.4
Maximum Water Side Pressure, bar
10
10
10
10
10
Maximum Refrigerant Side Pressure, bar
16
16
16
16
16
Minimum Chilled Water Flow Rate, L/s
10.1
10.1
10.1
11.4
11.4
Maximum Chilled Water Flow Rate, L/s
47.3
47.3
47.3
47.3
47.3
Water Connections, in.
10
10
10
10
10
0227 2
102/102 19/19
0247 2
105/105 19/19
2
2
32.7
32.7
3
3
669
669
6/6
6/6
2/1.50 73624
2/1.50 73624
2/1.50 73624
2/1.50 73624
1.5
1.5
62
62
1.5
1.5
48
48
3.7
3.7
74
74
416.4 10 16 11.4 47.3 10
529.9 10 16 11.4 50.5 10
64
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
PHYSICAL DATA (SI - HIGH EFFICIENCY) (CONT'D)
REFRIGERANT R-134a
HIGH EFFICIENCY MODEL NUMBER (YCIV____ E/V)
GENERAL UNIT DATA
60 HZ
0267
0287
0327
0357
Number of Independent Refrigerant Circuits
3
3
3
3
Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, kg
84 / 84 / 77 84 / 84 / 105 84 / 84 / 105 105 / 105 / 105
Oil Charge, Ckt.-1/Ckt.-2, L
19 / 19 / 15
19 / 19 / 19
19 / 19 / 19
19 / 19 / 19
Glycol Charge (43% concentration), L
0
0
0
0
Compressors, Semihermetic Screw
Quantity per Chiller
3
3
3
3
Condensers, High Efficiency Fin/Tube with Integral Subcooler
Total Chiller Coil Face Area, m2
38
44
44
49
Number of Rows
3
3
3
3
Fins per meter
669
669
669
669
Condenser Fans
Number, Ckt.-1/Ckt.-2
05/05/04
05/05/06
05/05/06
06/06/06
Low Noise Fans
Fan Motor, HP/kWi
2/1.50
2/1.50
2/1.50
2/1.50
Total Chiller Airflow, L/s
85904
98176
98176
110448
Ultra Quiet Fans
Fan Motor, HP/kWi Total Chiller Airflow, L/s Dual Speed Fans - Normal Speed
2/1.50 85904
2/1.50 98176
2/1.50 98176
2/1.50
110448
6
Fan, KWi
1.5
1.5
1.5
1.5
Total Chiller, m3/s
73
83
83
93
Dual Speed Fans - Lower Speed
Fan, KWi
1.5
1.5
1.5
1.5
Total Chiller, m3/s
56
63
63
71
High Static Fans
Fan, KWi
3.7
3.7
3.7
3.7
Total Chiller, m3/s
92
117
117
129
Evaporator, Direct Expansion
Water Volume, L
764.6
764.6
893.3
893.3
Maximum Water Side Pressure, bar
10
10
10
10
Maximum Refrigerant Side Pressure, bar
16
16
16
16
Minimum Chilled Water Flow Rate, L/s
16
16
19
19
Maximum Chilled Water Flow Rate, L/s
76
76
76
76
Water Connections, mm
245
245
245
245
JOHNSON CONTROLS
65
SECTION 6 - TECHNICAL DATA
ELECTRICAL DATA 2 Compressor Power Wiring Connections
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
VSD 1
VSD 2
2 COMPRESSOR POWER WIRING CONNECTIONS
VSD CONTROL PANEL
STANDARD CONTROL
TRANSFORMER
UNIT CONTROLS EVAPORATOR HEATER
LINE REACTOR
CIRCUIT BREAKER
FAN CONTACTORS
GRD
See Note 3
FIELD PROVIDED UNIT POWER SUPPLY
Figure 8 - TWO COMPRESSOR WIRING DIAGRAM WITH CIRCUIT BREAKER
VSD 1
VSD 2
2 COMPRESSOR POWER WIRING CONNECTIONS
VSD CONTROL PANEL
STANDARD CONTROL TRANSFORMER
UNIT CONTROLS EVAPORATOR HEATER
LINE REACTOR
FAN CONTACTORS
TERMINAL BLOCK
GRD
See Note 3
FIELD PROVIDED UNIT POWER SUPPLY
Figure 9 - TWO COMPRESSOR WIRING DIAGRAM WITH TERMINAL BLOCK 66
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
ELECTRICAL DATA (CONT'D) 3 Compressor Power Wiring Connections
3 COMPRESSOR POWER WIRING CONNECTIONS
VSD 1
VSD 2
VSD 3
VSD CONTROL PANEL
STANDARD CONTROL TRANSFORMER
UNIT CONTROLS EVAPORATOR HEATER
LINE REACTOR
CIRCUIT BREAKER
FAN CONTACTORS
GRD
See Note 3
FIELD PROVIDED UNIT POWER SUPPLY
6
Figure 10 - THREE COMPRESSOR WIRING DIAGRAM WITH CIRCUIT BREAKER SINGLE POINT
3 COMPRESSOR POWER WIRING CONNECTIONS
VSD 1
VSD 2
VSD 3
VSD CONTROL PANEL
STANDARD CONTROL TRANSFORMER
UNIT CONTROLS EVAPORATOR HEATER
LINE REACTOR
TERMINAL BLOCK
FAN CONTACTORS
GRD
See Note 3
FIELD PROVIDED UNIT POWER SUPPLY
Figure 11 - THREE COMPRESSOR WIRING DIAGRAM WITH TERMINAL BLOCK SINGLE POINT
JOHNSON CONTROLS
67
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
STANDARD EFFICIENCY 2-COMPRESSOR UNITS
One Field Provided Power Supply Circuit. Field Connections to Factory provided Terminal Block (Standard); or Individual System Breakers (Optional).
STANDARD EFFICIENCY YCIV_ _ _ _ S/P/H
SYSTEM 1
MODEL NO./NAMEPLATE
STD. & ULTRA QUIET COND. FANS
HIGH HEAD/STATIC COND. FANS
TWO-SPEED COND. FANS
YCIV S/P/H
INPUT VOLTS
(9)
INPUT FREQ
COMPRESSOR RLA (5)
CONDENSER FANS
COMPRESSOR
CONDENSER FANS
QTY.
FLA (EA)
RLA (5)
QTY.
FLA (EA)
COMPRESSOR RLA (5)
CONDENSER FANS
QTY.
FLA (EA)
0157
460 380
60 60
120 152
4 2.8
4 3.5
152
4 9.3
0177
460 380
60 60
159 201
4 2.8
4 3.5
201
4 9.3
0187
460 380
60 60
162 205
5 2.8
5 3.5
205
5 9.3
0207
460 380
60 60
145 184
5 2.8
5 3.5
184
5 9.3
0227
460 380
60 60
162 205
5 2.8
5 3.5
205
5 9.3
0247
460 380
60 60
193 245
6 2.8
6 3.5
245
6 9.3
0267
460 380
60 60
191 242
6 2.8
6 3.5
242
6 9.3
UNIT SHORT CIRCUIT WITHSTAND (KA)
YCIV S/P/H
CONTROL KVA (7)
TERMINAL BLOCK (STD)
CIRCUIT BREAKER
(OPT)
0157
1.8 1.8
30 30
65 65
0177
1.8 1.8
30 30
65 65
0187
1.8 1.8
30 30
65 65
0207
1.8 1.8
30 30
65 65
0227
1.8 1.8
30 30
65 65
0247
1.8 1.8
30 30
65 65
0267
1.8 1.8
30 30
65 65
See page 92 for Electrical Data footnotes.
MINIMUM CKT.
AMPACITY (MCA) (3)
293 370 326 413 348 440 373 472 392 496 433 547 464 587
FIELD WIRING & PROTECTION STD. & ULTRA QUIET COND. FANS
RECOMMENDED FUSE/CKT.
BREAKER RATING (4)
MAX. INVERSE TIME CKT. BRKR. RATING (2)
MAX DUAL ELEMENT
FUSE SIZE (2)
350
400
400
450
500
500
400
450
450
500
600
600
400
500
500
500
600
600
450
500
500
600
600
600
450
500
500
600
700
700
500
600
600
700
700
700
600
600
600
700
800
800
68
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
STANDARD EFFICIENCY 2-COMPRESSOR UNITS (CONT'D)
One Field Provided Power Supply Circuit. Field Connections to Factory provided Terminal Block (Standard); or Individual System Breakers (Optional).
STANDARD EFFICIENCY YCIV_ _ _ _ S/P/H
STD. & ULTRA QUIET COND. FANS
COMPRESSOR RLA (5)
CONDENSER FANS
QTY.
FLA (EA)
SYSTEM 2
HIGH HEAD/STATIC COND. FANS
COMPRESSOR RLA (5)
CONDENSER FANS
QTY.
FLA (EA)
TWO-SPEED COND. FANS
COMPRESSOR RLA (5)
CONDENSER FANS
QTY.
FLA (EA)
120
4
2.8
152
4
3.5
152
4
9.3
105
4
2.8
133
4
3.5
133
4
9.3
120
4
2.8
152
4
3.5
152
4
9.3
162
4
2.8
206
4
3.5
206
4
9.3
162
5
2.8
205
5
3.5
205
5
9.3
160
5
2.8
203
5
3.5
203
5
9.3
191
6
2.8
242
6
3.5
242
6
9.3
6
FIELD WIRING & PROTECTION
HIGH HEAD/HIGH STATIC FANS
TWO-SPEED COND. FANS
MINIMUM CKT.
AMPACITY (MCA) (3)
RECOMMENDED FUSE/CKT.
BREAKER RATING (4)
MAX. INVERSE TIME CKT. BRKR. RAT-
ING (2)
MAX DUAL ELEMENT
FUSE SIZE (2)
MINIMUM CKT.
AMPACITY (MCA) (3)
RECOMMENDED FUSE/CKT. BREAKER RATING (4)
MAX. INVERSE TIME CKT. BRKR. RAT-
ING (2)
MAX DUAL ELEMENT
FUSE SIZE (2)
417
500
500
500
459
600
600
600
492
600
700
700
525
600
700
700
554
700
700
700
610
700
800
800
657
800
800
800
JOHNSON CONTROLS
69
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
STANDARD EFFICIENCY 2-COMPRESSOR UNITS (CONT'D)
MODEL NO./NAMEPLATE
YCIV S/P/H
INPUT VOLTS
(9)
INPUT FREQ
460
60
0157
380
60
460
60
0177
380
60
460
60
0187
380
60
460
60
0207
380
60
460
60
0227
380
60
460
60
0247
380
60
460
60
0267
380
60
STANDARD EFFICIENCY YCIV_ _ _ _ S/P/H
FIELD WIRING LUGS
STD TERMINAL BLOCK STD., U.Q. & TWO-SPD COND.
FANS
OPT CIRCUIT BREAKER STD.,
U.Q. & 2-SPD COND. FANS
STD TERMINAL BLOCK HIGH HEAD/ HIGH STATIC COND.
FANS
LUGS/ PHASE
(1)
LUG WIRE RANGE
LUGS/ PHASE
(1)
LUG WIRE RANGE
LUGS/ PHASE
(1)
LUG WIRE RANGE
2
#2 - 600 KCM
2
#2/0 - 500 KCM
2
#2 - 600 KCM
2
#2/0 - 500 KCM
3
#2 - 600 KCM
2
#2 - 600 KCM
2
#2/0 - 500 KCM
2
#2 - 600 KCM
2
#2/0 - 500 KCM
3
#2 - 600 KCM
2
#2 - 600 KCM
2
#2/0 - 500 KCM
2
#2 - 600 KCM
2
#2/0 - 500 KCM
3
#2 - 600 KCM
2
#2 - 600 KCM
2
#2/0 - 500 KCM
2
#2 - 600 KCM
2
#2/0 - 500 KCM
3
#2 - 600 KCM
2
#2 - 600 KCM
2
#2/0 - 500 KCM
2
#2 - 600 KCM
2
#2/0 - 500 KCM
3
#2 - 600 KCM
2
#2 - 600 KCM
2
#2/0 - 500 KCM
3
#2 - 600 KCM
3
#3/0 - 400 KCM
3
#2 - 600 KCM
2
#2 - 600 KCM
2
#2/0 - 500 KCM
3
#2 - 600 KCM
3
#3/0 - 400 KCM
3
#2 - 600 KCM
OPT CIRCUIT BREAKER HIGH HEAD/HIGH STATIC
COND. FANS
LUGS/ PHASE
(1)
LUG WIRE RANGE
3
#3/0 - 400 KCM
3
#3/0 - 400 KCM
3
#3/0 - 400 KCM
3
#3/0 - 400 KCM
3
#3/0 - 400 KCM
3
#3/0 - 400 KCM
3
#3/0 - 400 KCM
70
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
THIS PAGE INTENTIONALLY LEFT BLANK
JOHNSON CONTROLS
71
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 4/6/2018
HIGH EFFICIENCY 2-COMPRESSOR UNITS
One Field Provided Power Supply Circuit. Field Connections to Factory provided Terminal Block (Standard); or Individual System Breakers (Optional).
HIGH EFFICIENCY YCIV_ _ _ _ E/V
MODEL NO./NAMEPLATE
STD. & ULTRA QUIET COND. FANS
SYSTEM 1
HIGH HEAD/STATIC COND. FANS
TWO-SPEED COND. FANS
YCIV E/V
INPUT VOLTS
(9)
INPUT FREQ
COMPRESSOR RLA (5)
CONDENSER FANS
QTY.
FLA (EA)
COMPRESSOR RLA (5)
CONDENSER FANS
QTY.
FLA (EA)
COMPRESSOR RLA (5)
CONDENSER FANS
QTY.
FLA (EA)
0157
460 380
60 60
110 139
4
2.8
4
3.5
139
4
9.3
0177
460 380
60 60
111 141
5
2.8
5
3.5
141
5
9.3
0187
460 380
60 60
154 195
5
2.8
5
3.5
195
5
9.3
0197
460 380
60 60
141 179
5
2.8
5
3.5
179
5
9.3
0207
460 380
60 60
141 179
6
2.8
6
3.5
179
6
9.3
0227
460 380
60 60
150 190
6
2.8
6
3.5
190
6
9.3
0247
460 380
60 60
194 245
6
2.8
6
3.5
245
6
9.3
YCIV E/V
CONTROL KVA (7)
UNIT SHORT CIRCUIT WITHSTAND (KA)
TERMINAL BLOCK (STD)
CIRCUIT BREAKER
(OPT)
0157
1.8 1.8
30 30
65 65
0177
1.8 1.8
30 30
65 65
0187
1.8 1.8
30 30
65 65
0197
1.8 1.8
30 30
65 65
0207
1.8 1.8
30 30
65 65
0227
1.8 1.8
30 30
65 65
0247
1.8 1.8
30 30
65 65
See page 92 for Electrical Data footnotes.
FIELD WIRING & PROTECTION STD. & ULTRA QUIET COND. FANS
MINIMUM CKT. AMPACITY (MCA) (3)
RECOMMENDED FUSE/CKT. BREAKER RAT-
ING (4)
MAX. INVERSE TIME CKT. BRKR. RATING (2)
MAX DUAL ELEMENT
FUSE SIZE (2)
270
300
350
350
341
400
450
450
288
350
400
400
365
450
500
500
325
400
450
450
411
500
600
600
345
400
450
450
437
500
600
600
362
450
500
500
458
600
600
600
371
450
500
500
469
600
600
600
424
500
600
600
536
700
700
700
72
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
HIGH EFFICIENCY 2-COMPRESSOR UNITS (CONT'D)
One Field Provided Power Supply Circuit. Field Connections to Factory provided Terminal Block (Standard); or Individual System Breakers (Optional).
HIGH EFFICIENCY YCIV_ _ _ _ E/V
SYSTEM 2
STD. & ULTRA QUIET COND. FANS HIGH HEAD/STATIC COND. FANS
TWO-SPEED COND. FANS
COMPRESSOR
CONDENSER FANS
COMPRESSOR
CONDENSER FANS
COMPRESSOR
CONDENSER FANS
RLA (5)
QTY.
FLA (EA)
RLA (5)
QTY.
FLA (EA)
RLA (5)
QTY.
FLA (EA)
110
4
2.8
139
4
3.5
139
4
9.3
122
4
2.8
154
4
3.5
154
4
9.3
105
5
2.8
132
5
3.5
132
5
9.3
141
5
2.8
179
5
3.5
179
5
9.3
152
5
2.8
193
5
3.5
193
5
9.3
150
6
2.8
190
6
3.5
190
6
9.3
149
6
2.8
6
188
6
3.5
188
6
9.3
MINIMUM CKT.
AMPACITY (MCA) (3)
FIELD WIRING & PROTECTION
HIGH HEAD/HIGH STATIC FANS
TWO-SPEED COND. FANS
RECOMMENDED FUSE/CKT.
BREAKER RATING (4)
MAX. INVERSE TIME CKT. BRKR. RAT-
ING (2)
MAX DUAL ELEMENT
FUSE SIZE (2)
MINIMUM CKT.
AMPACITY (MCA) (3)
RECOMMENDED FUSE/CKT.
BREAKER RATING (4)
MAX. INVERSE TIME CKT.
BRKR. RATING (2)
MAX DUAL ELEMENT
FUSE SIZE (2)
388
450
500
500
417
500
500
500
469
600
600
600
495
600
600
600
522
600
700
700
539
600
700
700
606
700
800
800
JOHNSON CONTROLS
73
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
HIGH EFFICIENCY 2-COMPRESSOR UNITS (CONT'D)
MODEL NO./NAMEPLATE
YCIV E/V
INPUT VOLTS
(9)
INPUT FREQ
460
60
0157
380
60
460
60
0177
380
60
460
60
0187
380
60
460
60
0197
380
60
460
60
0207
380
60
460
60
0227
380
60
460
60
0247
380
60
HIGH EFFICIENCY YCIV_ _ _ _ E/V FIELD WIRING LUGS
STD TERMINAL BLOCK STD.,
U.Q. & TWO-SPD COND. FANS
OPT CIRCUIT BREAKER STD.,
U.Q. & 2-SPD COND. FANS
STD TERMINAL OPT CIRCUIT BLOCK HIGH BREAKER HIGH
HEAD/HIGH STAT- HEAD/HIGH STATIC COND. FANS IC COND. FANS
LUGS/ PHASE
(1) 2 2 2 2 2 2 2 2 2 2 2 2 2 3
LUG WIRE RANGE
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
LUGS/ PHASE
(1) 2 2 2 2 2 2 2 2 2 2 2 2 2 3
LUG WIRE RANGE #2/0 - 500 KCM #2/0 - 500 KCM #2/0 - 500 KCM #2/0 - 500 KCM #2/0 - 500 KCM #2/0 - 500 KCM #2/0 - 500 KCM #2/0 - 500 KCM #2/0 - 500 KCM #2/0 - 500 KCM #2/0 - 500 KCM #2/0 - 500 KCM #2/0 - 500 KCM #3/0 - 400 KCM
LUGS/ PHASE
(1) 3
3
3
3
3
3
3
LUG WIRE RANGE
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
#2 - 600 KCM
LUGS/ LUG PHASE WIRE
(1) RANGE
3
#3/0 400 KCM
3
#3/0 400 KCM
3
#3/0 400 KCM
3
#3/0 400 KCM
3
#3/0 400 KCM
3
#3/0 400 KCM
3
#3/0 400 KCM
74
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
THIS PAGE INTENTIONALLY LEFT BLANK
JOHNSON CONTROLS
75
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
STANDARD EFFICIENCY 3-COMPRESSOR UNITS
One Field Provided Power Supply Circuit. Field Connections to Factory provided Terminal Block (Standard); or Individual System Breakers (Optional).
MODEL NO./NAMEPLATE
YCIV S/P/H
INPUT VOLTS
(9)
INPUT FREQ
STD. & ULTRA QUIET COND. FANS
COMP.
CONDENSER FANS
RLA (5)
QTY.
FLA (EA)
SYSTEM 1
HIGH HEAD/STATIC COND. FANS
COMP.
CONDENSER FANS
RLA (5)
QTY.
FLA (EA)
TWO-SPEED COND. FANS
COMP.
CONDENSER FANS
RLA (5)
QTY.
FLA (EA)
SYSTEM 2
STD. & ULTRA QUIET COND. FANS
COMP.
CONDENSER FANS
RLA (5)
QTY.
FLA (EA)
460
60
146
5
2.8
0287
380
60
184
5
3.5 184
5
9.3
460
60
147
5
2.8
0307
380
60
186
5
3.5 186
5
9.3
460
60
160
5
2.8
0357
380
60
202
5
3.5 202
5
9.3
460
60
191
6
2.8
0397
380
60
241
6
3.5 241
6
9.3
164
4
2.8
207
4
3.5
147
5
2.8
186
5
3.5
160
5
2.8
202
5
3.5
191
6
2.8
241
6
3.5
YCIV S/P/H
CONTROL KVA (7)
UNIT SHORT CIRCUIT WITHSTAND (KA)
FIELD WIRING & PROTECTION
STD. & ULTRA QUIET COND. FANS
HIGH HEAD/HIGH STATIC FANS
TERMINAL BLOCK (STD)
CIRCUIT BREAKER (OPT)
MINIMUM RECOMMEND-
CKT. ED FUSE/CKT.
AMPACITY BREAKER RAT-
(MCA) (3)
ING (4)
MAX. INVERSE
TIME CKT. BRKR. RATING (2)
MAX DUAL ELEMENT FUSE SIZE (2)
MINIMUM CKT.
AMPACITY (MCA) (3)
RECOMMENDED FUSE/CKT.
BREAKER RATING (4)
2.4
30
65
494
600
600
600
0287
2.4
30
65
624
700
800
800
676
800
2.4
30
65
540
600
700
700
0307
2.4
30
65
682
800
800
800
731
800
2.4
30
65
607
0357
2.4
30
65
766
700 1000
800
800
1000
1000
827
1000
2.4
30
65
671
0397
2.4
30
65
847
800 1000
800
800
1000
1000
911
1000
See page 92 for Electrical Data footnotes.
76
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
STANDARD EFFICIENCY 3-COMPRESSOR UNITS (CONT'D)
(One Field Provided Power Supply Circuit. Field Connections to Factory provided Terminal Block (Standard); or Individual System Breakers (Optional).
SYSTEM 2
HIGH HEAD/STATIC COND. FANS
TWO-SPEED COND. FANS
COMP.
CONDENSER FANS
COMP.
CONDENSER FANS
RLA (5)
QTY.
FLA (EA)
RLA (5)
QTY.
FLA (EA)
207
4
9.3
186
5
9.3
202
5
9.3
241
6
9.3
STD. & ULTRA QUIET COND. FANS
COMP.
CONDENSER FANS
RLA (5)
QTY.
FLA (EA)
108
4
2.8
136
4
3.5
165
4
2.8
208
4
3.5
193
6
2.8
244
6
3.5
191
6
2.8
241
6
3.5
SYSTEM 3
HIGH HEAD/STATIC COND. FANS
COMP.
CONDENSER FANS
RLA (5)
QTY.
FLA (EA)
136
4
9.3
208
4
9.3
244
6
9.3
241
6
9.3
TWO-SPEED COND. FANS
COMP.
CONDENSER FANS
RLA (5)
QTY.
FLA (EA)
HIGH HEAD/HIGH STATIC FANS
FIELD WIRING & PROTECTION
TWO-SPEED COND. FANS
FIELD WIRING LUGS
6
MAX. INVERSE TIME CKT.
BRKR. RATING
(2)
MAX DUAL ELEMENT FUSE SIZE (2)
MINIMUM CKT.
AMPACITY (MCA) (3)
RECOMMENDED FUSE/CKT.
BREAKER RATING (4)
MAX. INVERSE TIME CKT.
BRKR. RATING
(2)
MAX DUAL ELEMENT FUSE SIZE (2)
STD TERMINAL BLOCK
LUGS/ LUG PHASE WIRE
(1) RANGE
OPT CIRCUIT BREAKER
LUGS/ LUG PHASE WIRE
(1) RANGE
4
#2 - 600 KCM
4
#4/0 500 KCM
800
800
4
#2 - 600 KCM
4
#4/0 500 KCM
4
#2 - 600 KCM
4
#4/0 500 KCM
800
800
4
#2 - 600 KCM
4
#4/0 500 KCM
4
#2 - 600 KCM
4
#4/0 500 KCM
1000
1000
4
#2 - 600 KCM
4
#4/0 500 KCM
4
#2 - 600 KCM
4
#4/0 500 KCM
1000
1000
4
#2 - 600 KCM
4
#4/0 500 KCM
JOHNSON CONTROLS
77
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
HIGH EFFICIENCY 3-COMPRESSOR UNITS
(One Field Provided Power Supply Circuit. Field Connections to Factory provided Terminal Block (Standard); or Individual System Breakers (Optional).
MODEL NO./NAMEPLATE
STD. & ULTRA QUIET COND. FANS
SYSTEM 1
HIGH HEAD/STATIC COND. FANS
TWO-SPEED COND. FANS
SYSTEM 2
STD. & ULTRA QUIET COND. FANS
YCIV E/V
INPUT VOLTS
(9)
INPUT FREQ
COMP.
RLA (5)
CONDENSER FANS
QTY.
FLA (EA)
COMP.
RLA (5)
CONDENSER FANS
QTY.
FLA (EA)
COMP.
RLA (5)
CONDENSER FANS
QTY.
FLA (EA)
COMP.
RLA (5)
CONDENSER FANS
QTY.
FLA (EA)
0267
460 380
60 60
142 179
5 5
2.8 3.5 179
5
9.3
0287
460 380
60 60
137 173
5 5
2.8 3.5 173
5
9.3
0327
460 380
60 60
152 193
5 5
2.8 3.5 193
5
9.3
0357
460 380
60 60
181 229
6 6
2.8 3.5 229
6
9.3
142
5
2.8
179
4
3.5
137
5
2.8
173
5
3.5
152
5
2.8
193
5
3.5
181
6
2.8
229
6
3.5
Unit Short Circuit Withstand (KA)
Field Wiring & Protection
Std. & Ultra Quiet Cond. Fans
High Head/High Static Fans
YCIV Control S/P/H KVA (7) Terminal Circuit
Block Breaker (STD) (OPT)
Minimum Ckt. Ampacity (MCA) (3)
Recommended Fuse/Ckt.
Breaker Rating (4)
Max. Inverse Time Ckt. Brkr. Rating (2)
Max Dual Element
Fuse Size (2)
Minimum Ckt.
Ampacity (MCA) (3)
Recommended Fuse/Ckt. Breaker Rating (4)
2.4
30
65
463
600
600
600
0287
2.4
30
65
581
700
700
700
632
800
2.4
30
65
486
600
600
600
0307
2.4
30
65
610
700
700
700
659
800
2.4
30
65
528
600
600
600
0357
2.4
30
65
667
800
800
800
728
800
2.4
30
65
598
0397
2.4
30
65
755
700
700
700
800
800
800
818
1000
See page 92 for Electrical Data footnotes.
78
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
HIGH EFFICIENCY 3-COMPRESSOR UNITS (CONT'D)
(One Field Provided Power Supply Circuit. Field Connections to Factory provided Terminal Block (Standard); or Individual System Breakers (Optional).
SYSTEM 2
SYSTEM 3
HIGH HEAD/STATIC TWO-SPEED COND. STD. & ULTRA QUIET HIGH HEAD/STATIC TWO-SPEED COND.
COND. FANS
FANS
COND. FANS
COND. FANS
FANS
COMP.
CONDENSER FANS
COMP.
CONDENSER FANS
COMP.
CONDENSER FANS
COMP.
CONDENSER FANS
COMP.
CONDENSER FANS
RLA (5)
QTY.
FLA (EA)
RLA (5)
QTY.
FLA (EA)
RLA (5)
QTY.
FLA (EA)
RLA (5)
QTY.
FLA (EA)
RLA (5)
QTY.
FLA (EA)
179
4
9.3
173
5
9.3
193
5
9.3
229
6
9.3
105
4
2.8
133
4
3.5 133
4
9.3
137
5
2.8
173
4
3.5 173
4
9.3
141
6
2.8
178
6
3.5 178
6
9.3
139
6
2.8
176
6
3.5 176
6
9.3
Field Wiring & Protection
Field Wiring Lugs
High Head/High Static Fans
Two-Speed Cond. Fans
STD Terminal Block
OPT Circuit Breaker
Max. Inverse Time Ckt. Brkr. Rating (2)
Max Dual Element
Fuse Size (2)
Minimum Ckt.
Ampacity (MCA) (3)
Recommended Fuse/Ckt. Breaker Rating (4)
Max. Inverse Time Ckt. Brkr. Rating (2)
Max Dual Element
Fuse Size (2)
Lugs/ Phase
(1)
Lug Wire Range
Lugs/ Phase
(1)
Lug Wire Range
6
4
#2 - 600 KCM
4
#4/0 - 500 KCM
800
800
4
#2 - 600 KCM
4
#4/0 - 500 KCM
4
#2 - 600 KCM
4
#4/0 - 500 KCM
800
800
4
#2 - 600 KCM
4
#4/0 - 500 KCM
4
#2 - 600 KCM
4
#4/0 - 500 KCM
800
800
4
#2 - 600 KCM
4
#4/0 - 500 KCM
4
#2 - 600 KCM
4
#4/0 - 500 KCM
1000
1000
4
#2 - 600 KCM
4
#4/0 - 500 KCM
JOHNSON CONTROLS
79
SECTION 6 - TECHNICAL DATA
ELECTRICAL NOTES
1. As standard, all units have single point power connection. Contact factory for information regarding dual point power units.
2. Maximum Inverse Time Circuit Breaker or Dual Element Fuse - 225% of the largest compressor RLA plus the sum of all the other loads per NEC 440.22 (A).
3. MCA - Minimum Circuit Ampacity - 125% of the largest compressor RLA plus 100% of the remaining compressor RLA's plus the sum of all condenser fan FLA's per NEC 440.33
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
4. Recommended time delay or dual element fuse size - 150%of the largest compressor RLA plus 100% of the remaining compressor RLA's plus the sum of all condenser fan FLA's.
5. RLA - Rated Load Amps - rated in accordance with UL standard 1995.
6. Local codes may take precedence.
7. Control KVA includes operational controls and evaporator heaters.
8. System inrush current is less than RLA due to the use of York Variable Speed Drive technology.
Table 1 - TYPICAL COMPRESSOR STARTING CURRENT (FIRST FOUR SECONDS OF START-UP)
RATED VOLTAGE 380-400/50/3 380/60/3 460/60/3
Table 2 - VOLTAGE UTILIZATION RANGE
RATED VOLTAGE 380-415/50/3 380/60/3 460/60/3
TYPICAL STARTING CURRENT PER COMPRESSOR 28 A 29 A 23 A
UTILIZATION RANGE 360-440 342-402 414-508
NOTES: 1. U.L. Label is provided on 60 Hz units for these electrical wiring configurations. 2. Dashed Line = Field Provided Wiring. 3. The above recommendations are based on the National Electric Code and using copper conductors only. Field wiring must also comply with
local codes. Group Rated breaker must be HACR type for cUL machines.
Electrical Notes - Legend
C.B. D.E. DISC SW FACT CB FLA HZ MAX MCA MIN MIN NF RLA S.P. WIRE
Circuit Breaker Dual Element Fuse Disconnect Switch Factory-Mounted Circuit Breaker
Full Load AMPS Hertz
Maximum Minimum Circuitry AMPACITY
Minimum Minimum Non Fused Rated Load AMPS Single Point Wiring
80
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
THIS PAGE INTENTIONALLY LEFT BLANK
JOHNSON CONTROLS
81
SECTION 6 - TECHNICAL DATA
ELECTRICAL WIRING DIAGRAMS - 2 COMPRESSOR MODELS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Figure 12 - ELEMENTARY CONTROL WIRING DIAGRAM 2 COMPRESSOR MODELS
LD26907
82
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
035-19905-001 REV K, SHT.1
6
LD26908
FIGURE 12 - ELEMENTARY CONTROL WIRING DIAGRAM 2 COMPRESSOR MODELS (CONT'D)
JOHNSON CONTROLS
83
SECTION 6 - TECHNICAL DATA
Elementary Power Wiring Diagram
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD26909
LD13678
Figure 13 - ELEMENTARY POWER WIRING DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS
84
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
035-19905-002 REV J, SHT.1
6
LD26910
LD13679
FIGURE 13 - ELEMENTARY POWER WIRING DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS (CONT'D)
JOHNSON CONTROLS
85
SECTION 6 - TECHNICAL DATA
Power Wiring Connection Diagram
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD26912
Figure 14 - POWER WIRING CONNECTION DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS
86
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
035-19905-004 REV L, SHT. 1
6
LD26911
FIGURE 14 - POWER WIRING CONNECTION DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS (CONT'D)
JOHNSON CONTROLS
87
SECTION 6 - TECHNICAL DATA
Control Wiring Connection Diagram
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD26913
Figure 15 - CONTROL WIRING CONNECTION DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS
88
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
035-19905-003 REV L, SHT. 1
6
LD26914
FIGURE 15 - CONTROL WIRING CONNECTION DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS (CONT'D)
JOHNSON CONTROLS
89
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
035-19905-003 REV L, SHT. 1
LD26921
FIGURE 15 - CONTROL WIRING CONNECTION DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS (CONT'D)
90
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
Power Elementary Wiring Diagram
6
LD13081
Figure 16 - POWER ELEMENTARY WIRING DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS
JOHNSON CONTROLS
91
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD13082
FIGURE 16 - POWER ELEMENTARY WIRING DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS (CONT'D)
92
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
Location Label - 2 Compressor Models
6
JOHNSON CONTROLS
LD10519
93
SECTION 6 - TECHNICAL DATA
Panel Layout - 2 Compressor Models
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
94
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
THIS PAGE INTENTIONALLY LEFT BLANK
JOHNSON CONTROLS
95
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
ELECTRICAL WIRING DIAGRAMS - 3 COMPRESSOR MODELS
LD26915
Figure 17 - CONTROL ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS
96
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
035-20326-001 REV I, SHT. 1
6
LD26916
FIGURE 17 - CONTROL ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D)
JOHNSON CONTROLS
97
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD26917
FIGURE 17 - CONTROL ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D)
98
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
035-20326-002 REV H, SHT.1
6
LD26918
FIGURE 17 - CONTROL ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D)
JOHNSON CONTROLS
99
SECTION 6 - TECHNICAL DATA
Power Elementary Diagram
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD26919
Figure 18 - POWER ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS
100
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
035-23260-003 REV F, SHT. 1
6
LD26920
FIGURE 18 - POWER ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D)
JOHNSON CONTROLS
101
SECTION 6 - TECHNICAL DATA
Control Wiring Connection Diagram
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD13090
Figure 19 - CONTROL WIRING CONNECTION DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS
102
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
6
LD13091
FIGURE 19 - CONTROL WIRING CONNECTION DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D)
JOHNSON CONTROLS
103
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD13092
FIGURE 19 - CONTROL WIRING CONNECTION DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D)
104
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
THIS PAGE INTENTIONALLY LEFT BLANK
JOHNSON CONTROLS
105
SECTION 6 - TECHNICAL DATA
Power Wiring Connection Diagram
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD26922
Figure 20 - POWER WIRING CONNECTION DIAGRAM - YCIV1050-1500 3 COMPRESSOR MODELS
106
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
035-20326-005 REV H, SHT.1
6
LD26923
FIGURE 20 - POWER WIRING CONNECTION DIAGRAM - YCIV1050-1500 3 COMPRESSOR MODELS (CONT'D)
JOHNSON CONTROLS
107
SECTION 6 - TECHNICAL DATA
Power Elementary Diagram
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD13097
Figure 21 - POWER ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS
108
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
6
LD13098
FIGURE 21 - POWER ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D)
JOHNSON CONTROLS
109
SECTION 6 - TECHNICAL DATA
Location Label - 3 Compressor Models
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
110
LD13096
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
Panel Layout - 3 Compressor Models
6
JOHNSON CONTROLS
LD13099
111
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DIMENSIONS - 2 AND 3 COMPRESSOR SI MODELS YCIV0157E/V AND YCIV0157S/P/H
1 1/2"
CONTROL ENTRY 3" WIDE X 13 1/2" HIGH
PPOOWWEERR EENNTTRRYY
4"
1100""WWIIDDEEXX1133"" HIGH
HIGH
VIEW B-B POWER ENTRY IS ON BOTTOM OF PANEL
1 3/4"
12"
VIEW C-C
C
B
B
C
A
B (EDGE OF UNIT
TO COOLER CONNECTION)
YCIV 0157E/V 0157S/P/H
A 19.1" 17.4"
B 28.1" 29.1"
C 84.5" 90.0"
88 1/8"
VIEW A-A
D 112.8" 110.1"
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance.
112
Johnson Controls unit controls will optimize operation without nuisance highpressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: side to wall 2 m; rear to wall 2 m; control panel to end wall 1.2 m; top no obstructions whatsoever; distance between adjacent units 3 m. No more than one adjacent wall may be higher than the unit.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
DIMENSIONS - 2 AND 3 COMPRESSOR ENGLISH (CONT'D)
CONTROL PANEL
X X
5/8" MOUNTING HOLES (TYP)
CG
Y ORIGIN
1 5/16" (TYP)
60"
14 1/8"
101 5/8"
50"
50 5/16"
9 1/8"
6
VIEW D-D
D 93 15/16"
(3) RIGGING HOLES EACH SIDE (3 X 2)
10" WATER OUTLET
C
80"
POWER: SINGLE POINT WITH TERMINAL BLOCK
10" WATER INLET
D
103 3/8"
230"
A D
45 5/16"
A Z
33 5/16" CG
JOHNSON CONTROLS
113
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DIMENSIONS - 2 AND 3 COMPRESSOR ENGLISH (CONT'D)
Models YCIV0177E/V, YCIV0177S/P/H, YCIV0187E/V and YCIV0187S/P/H
1 1/2"
CONTROL ENTRY 3" WIDE X 13 1/2" HIGH
POWER ENTRY
4"
10" WIDE X 13" HIGH
POWER ENTRY
10" WIDE X 13"
HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL
1 3/4"
12"
VIEW C-C
C
B
B
C
19 1/8"
28 1/8" (EDTGOE1CO9OF-1OU/8LNE" IRT CONNECTION)
28-1/8" (EDGE OF UNIT TO COOLER CONNECTION)
88 1/8" VIEW A-A
YCIV 0177E/V 0177S/P/H 0187E/V 0187S/P/H
A 88.1" 80.0" 88.1" 88.1"
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance.
B 274.0"
230.0"
274.0"
274.0"
Johnson Controls unit controls will optimize operation without nuisance highpressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: side to wall 2 m; rear to wall 2 m; control panel to end wall 1.2 m; top no obstructions whatsoever; distance between adjacent units 3 m. No more than one adjacent wall may be higher than the unit.
114
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
DIMENSIONS - 2 AND 3 COMPRESSOR ENGLISH (CONT'D)
5/8" MOUNTING HOLES (TYP)
CG X
Y
CONTROL PANEL
60"
1 5/16" (TYP)
69 11/16"
D 93 15/16"
14 1/8"
86 5/16"
50"
VIEW D-D
50 5/16"
9 1/8"
6
A D
45 5/16"
(3) RIGGING HOLES EACH SIDE 3 X 2
POWER: SINGLE POINT WITH TERMINAL BLOCK
10" (WATER OUTLET) 84 1/2"
A B
10" (WATER INLET) 112 13/16"
103 5/16"
A
33 5/16" Z
X CG
JOHNSON CONTROLS
115
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
Models YCIV0197E/V, YCIV0207S/P/H, and YCIV0227S/P/H
1 1/2"
CONTROL ENTRY 3" WIDE X 13 1/2" HIGH
PPOWER ENTRY
4"
1100""WWIDIDEEXX1133"" HIGH
HIGH
VIEW B-B POWER ENTRY IS ON BOTTOM OF PANEL
1 3/4"
12"
VIEW C-C
C
B
B
C
A
B (EDGE OF UNIT
TO COOLER CONNECTION)
YCIV 0197E/V 0207S/P/H 0227S/P/H
A 20.4" 22.2" 22.2"
B 28.1" 26.0" 26.0"
88 1/8" VIEW A-A
C 85.6" 79.1" 79.1"
D 112.3" 113.3" 113.3
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance.
116
Johnson Controls unit controls will optimize operation without nuisance highpressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: side to wall 2 m; rear to wall 2 m; control panel to end wall 1.2 m; top no obstructions whatsoever; distance between adjacent units 3 m. No more than one adjacent wall may be higher than the unit.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
5/8" MOUNTING HOLES (TYP)
CG X
Y
CONTROL PANEL
1 5/16" (TYP)
69 11/16"
86 5/16"
50"
VIEW D-D
60"
14 1/8"
50 5/16"
9 1/8"
D 93 15/16"
(3) RIGGING HOLES EACH SIDE 3 X 2
POWER: SINGLE POINT WITH TERMINAL BLOCK
10" (WATER OUTLET)
C
88"
274"
10" (WATER INLET)
D
103 5/16"
A
6
D
45 5/16"
A 33 5/16"
Z X
JOHNSON CONTROLS
117
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
Models YCIV0207E/V and YCIV0227E/V
1 1/2"
COC3N"OTWNRTIDORELOXELNE1T3NRT1Y/R2Y" HIGH 3" WIDE X 13-1/2" HIGH
4"
POWWEERREENNTTRRYY 1100"" WWIIDDEEXX1133" " HIGH
HIGH
VIEW B-B
1 3/4" 12"
POWER ENTRY IS ON BOTTOM OF PANEL
VIEW C-C
C
B
B
C
2020-33/8/8""
28 1/8" (EDGE OF UNIT TO COOLER CONNECTION)
88 1/8" VIEW A-A
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance.
118
Johnson Controls unit controls will optimize operation without nuisance highpressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: side to wall 2 m; rear to wall 2 m; control panel to end wall 1.2 m; top no obstructions whatsoever; distance between adjacent units 3 m. No more than one adjacent wall may be higher than the unit.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
5/8" MOUNTING HOLES (TYP)
X
CG
Y ORIGIN
CONTROL PANEL
1 5/16" (TYP)
60"
49 3/16"
64 3/16"
VIEW D-D
60"
37 13/16" 50 5/16"
14 1/8" 9 1/8"
D 93 15/16"
(4) RIGGING HOLES EACH SIDE 3 X 2
10" (WATER OUTLET) 284 7/8"
POWER: SINGLE POINT WITH TERMINAL BLOCK
10" (WATER INLET)
85 5/8" 180 11/16"
318"
6
A D
45 5/16"
112 5/16" 92 11/16"
A 33 5/16" Z
X
CG
JOHNSON CONTROLS
119
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
Models YCIV0247S/P/H, YCIV0247E/V, and YCIV0267S/P/H
1 1/2"
CONTROL ENTRY 3" WIDE X 13 1/2" HIGH
4"
P1P10O0O"W"WWWEEIIDRDREEEEXNXNTT11RR33""YYHIGH
HIGH
VIEW B-B
1 3/4"
12"
POWER ENTRY IS ON BOTTOM OF PANEL
VIEW C-C
C
B
B
C
22 3/16"
26" (EDGE OF UNIT TO COOLER CONNECTION)
88 1/8" VIEW A-A
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance.
120
Johnson Controls unit controls will optimize operation without nuisance highpressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: side to wall 2 m; rear to wall 2 m; control panel to end wall 1.2 m; top no obstructions whatsoever; distance between adjacent units 3 m. No more than one adjacent wall may be higher than the unit.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
1 5/16" (TYP)
5/8" MOUNTING HOLES (TYP)
APPROX. OPERATING WEIGHT DISTRIBUTING (LB)
X
CG
Y ORIGIN
60"
CONTROL PANEL
60"
49 3/16"
64 3/16"
VIEW D-D
37 13/16" 50 5/16"
14 1/8" 9 1/8"
6
D 93 15/16"
(4) RIGGING HOLES EACH SIDE 3 X 2
10" (WATER OUTLET) 284 7/8"
POWER: SINGLE POINT WITH TERMINAL BLOCK
10" (WATER INLET) 79 1/8" 180 11/16"
318"
A D
45 5/16"
113 5/16" 92 11/16"
A 33 5/16"
Z
X
CG
JOHNSON CONTROLS
121
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
Models YCIV0267E/V, and YCIV0287S/P/H
1 1/2"
CONTROL ENTRY 3" WIDE X 13 1/2" HIGH
4"
P1P1P100OO0O"""WWWWWWEEEIIIDDRRDREEEEEEXXNNXNTT11T1RR33R3""YY"YHHIIGGHH
HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL
1 3/4"
12"
VIEW C-C
C
B
B
C
88 1/8" VIEW A-A
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance.
122
Johnson Controls unit controls will optimize operation without nuisance highpressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: side to wall 2 m; rear to wall 2 m; control panel to end wall 1.2 m; top no obstructions whatsoever; distance between adjacent units 3 m. No more than one adjacent wall may be higher than the unit.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
3/4" MOUNTING HOLES (TYP)
X
CG
Y ORIGIN
CONTROL PANEL
1 5/16" (TYP)
D 93 15/16"
(4) RIGGING HOLES EACH SIDE 3 X 2
83 1/8"
80 3/16"
93 5/8"
10" (WATER INLET) 357"
14 5/8"
10" (WATER OUTLET) 238 5/8"
377 3/16"
70"
9 1/8"
7 5/8"
53"
49"
9 1/8"
6
A D
197 13/16" 141 1/8"
17 5/8"
45 5/16"
29 7/8"
A 33 3/16"
Z
X
CG
LD13668
JOHNSON CONTROLS
123
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
Models YCIV0287E/V
1 1/2"
CONTROL ENTRY 3" WIDE X 13 1/2" HIGH
PPOOWWEERR EENNTTRRYY
4"
1100""WWIIDDEEXX1133"" HIGH
HIGH
VIEW B-B POWER ENTRY IS ON BOTTOM OF PANEL
1 3/4"
12"
VIEW C-C
C
B
B
C
88 1/8" VIEW A-A
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance.
124
Johnson Controls unit controls will optimize operation without nuisance highpressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: side to wall 2 m; rear to wall 2 m; control panel to end wall 1.2 m; top no obstructions whatsoever; distance between adjacent units 3 m. No more than one adjacent wall may be higher than the unit.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
3/4" MOUNTING HOLES (TYP)
X
CG
Y ORIGIN
CONTROL PANEL
1 5/16" (TYP)
53 3/8"
19"
D 93 15/16"
99"
76"
VIEW D-D
(5) RIGGING HOLES EACH SIDE 3 X 2
401"
10" (WATER INLET) 14 5/8"
320 1/2"
10" (WATER OUTLET) 197 13/16"
216 11/16"
421 1/4"
70"
7 5/8"
9 1/8"
50"
50 5/16"
9 1/8"
6
123 11/16"
A D
17 5/8"
45 5/16"
29 7/8"
A
Z
37 3/16" X CG
LD13669
JOHNSON CONTROLS
125
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
Models YCIV0307S/P/H
1 1/2"
CONTROL ENTRY 3" WIDE X 13 1/2" HIGH
4"
P1P10O0O""WWWWEEIIDRDREEEEXNXNT1T1R3R3"Y"YHIGH
HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL
1 3/4"
12"
VIEW C-C
C
B
B
C
88 1/8" VIEW A-A
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance.
126
Johnson Controls unit controls will optimize operation without nuisance highpressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: side to wall 2 m; rear to wall 2 m; control panel to end wall 1.2 m; top no obstructions whatsoever; distance between adjacent units 3 m. No more than one adjacent wall may be higher than the unit.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
3/4" MOUNTING HOLES (TYP)
X
CG
Y ORIGIN
CONTROL PANEL
1 5/16" (TYP)
83 1/8"
80 3/16"
D 93 15/16"
93 5/8"
(4) RIGGING HOLES EACH SIDE 3 X 2
10" (WATER INLET) 357"
10" (WATER OUTLET) 15"
238 5/8"
377 3/16"
70"
9 1/8"
7 5/8"
53"
49"
9 1/8"
6
A D
197 13/16" 141 1/8"
16 3/16"
45 5/16"
26 3/8"
A 33 3/16"
Z
X
CG
LD13670
JOHNSON CONTROLS
127
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
Models YCIV0327E/V and YCIV0357S/P/H
1 1/2"
CONTROL ENTRY 3" WIDE X 13 1/2" HIGH
PPOOWWEERR EENNTTRRYY
4"
1100""WWIIDDEEXX1133"" HIGH
HIGH
VIEW B-B POWER ENTRY IS ON BOTTOM OF PANEL
1 3/4"
12"
VIEW C-C
C
B
B
C
88 1/8" VIEW A-A
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance.
128
Johnson Controls unit controls will optimize operation without nuisance highpressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: side to wall 2 m; rear to wall 2 m; control panel to end wall 1.2 m; top no obstructions whatsoever; distance between adjacent units 3 m. No more than one adjacent wall may be higher than the unit.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
3/4" MOUNTING HOLES (TYP)
X
CG
ORIGIN Y
CONTROL PANEL
1 5/16" (TYP)
53 3/8"
74 1/8"
D 93 15/16"
99"
76"
VIEW D-D
(5) RIGGING HOLES EACH SIDE 3 X 2
401"
10" (WATER INLET) 15"
320 1/2"
10" (WATER OUTLET) 197 13/16"
216 11/16"
421 1/4"
70"
6 7/8"
9 1/8"
50"
50 5/16"
9 1/8"
6
A
D
18 3/16"
45 5/16" 25 1/8"
120 11/16"
A
Z 33 3/16"
X
CG
LD13671
JOHNSON CONTROLS
129
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
Models YCIV0357E/V and YCIV0397S/P/H
1 1/2"
CONTROL ENTRY 3" WIDE X 13 1/2" HIGH
PPOOWWEERR EENNTTRRYY
4"
1100""WWIIDDEEXX1133"" HIGH
HIGH
VIEW B-B POWER ENTRY IS ON BOTTOM OF PANEL
1 3/4"
12"
VIEW C-C
C
B
B
C
88 1/8" VIEW A-A
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance.
130
Johnson Controls unit controls will optimize operation without nuisance highpressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: side to wall 2 m; rear to wall 2 m; control panel to end wall 1.2 m; top no obstructions whatsoever; distance between adjacent units 3 m. No more than one adjacent wall may be higher than the unit.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
DIMENSIONS - 2 & 3 COMPRESSOR ENGLISH (CONT'D)
1 5/16" (TYP)
D 93 15/16"
53 3/8"
19"
(5) RIGGING HOLES EACH SIDE 3 X 2
445"
3/4" MOUNTING HOLES (TYP)
ORIGIN
X
CG
Y
70"
CONTROL PANEL
112 11/16" VIEW D-D
10" (WATER INLET) 15"
328 1/8" 465 3/16"
76"
10" (WATER OUTLET) 217 13/16"
6 7/8"
9 1/8"
50"
50 5/16"
9 1/8"
6
A
D
197 13/16" 120 11/16"
18 3/16"
45 5/16"
28 3/8"
A
33 3/16" Z CG
X
LD13672
JOHNSON CONTROLS
131
SECTION 6 - TECHNICAL DATA
TECHNICAL DATA - CLEARANCES
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
(2 m)
(1.3 m)
NOTES: 1. No obstructions allowed above the unit. 2. Only one adjacent wall may be higher than the unit 3. Adjacent units should be 10 feet (3 meters) apart.
132
(2 m)
(2 m)
LD10506A
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
ISOLATOR INFORMATION FOR UNITS SHIPPED ON OR AFTER JUNE 15, 2008
ISOLATOR SELECTION AND MOUNTING STANDARD EFFICIENCY, ENGLISH
Units shipped on or after June 15, 2008
L1
L2
L3
L4
L5
L6
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - IN. AND POINT LOADS - LB
1
2
3
4
5
6
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (211, 86.8)
Al Fin Coils
1702
1592
1396
1340
Cu Fin Coils
1702
1704
1739
1682
RS&LS1/Al Fin Coils 1881
1770
1396
1340
RS&LS1/Cu Fin Coils 1881
1883
1739
1682
0157S/P/H
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (211, 1.3)
Al Fin Coils
1702
1592
1396
1340
Cu Fin Coils
1702
1704
1739
1682
RS&LS1/Al Fin Coils 1881
1770
1396
1340
RS&LS1/Cu Fin Coils 1881
1883
1739
1682
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (211, 86.8)
Al Fin Coils
1720
1614
1667
1609
Cu Fin Coils
1720
1726
2011
1951
RS&LS1/Al Fin Coils 1898
1792
1667
1609
RS&LS1/Cu Fin Coils 1898
1905
2011
1951
0177S/P/H RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (211, 1.3)
Al Fin Coils
1702
1594
1667
1609
Cu Fin Coils
1702
1706
2011
1951
RS&LS1/Al Fin Coils 1881
1773
1667
1609
RS&LS1/Cu Fin Coils 1881
1885
2011
1951
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (195.7, 86.8) (265.4, 86.8)
Al Fin Coils
1715
1579
1559
1274
774
Cu Fin Coils
1715
1700
1898
1653
935
RS&LS1/Al Fin Coils 1894
1757
1559
1274
774
RS&LS1/Cu Fin Coils 1894
1878
1898
1653
935
0187S/P/H
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (195.7, 1.3) (265.4, 1.3)
Al Fin Coils
1698
1559
1559
1241
664
Cu Fin Coils
1698
1680
1898
1620
825
RS&LS1/Al Fin Coils 1876
1737
1559
1241
664
RS&LS1/Cu Fin Coils 1876
1858
1898
1620
825
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
JOHNSON CONTROLS
7
6
133
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
STANDARD EFFICIENCY, ENGLISH (CONT'D)
L1
L2
L3
L4
L5
L6
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - IN. AND POINT LOADS - LB
1
2
3
4
5
6
7
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (195.7, 86.8) (265.4, 86.8)
Al Fin Coils
1728
1680
1768
1512
915
Cu Fin Coils
1728
1801
2108
1892
1076
RS&LS1/Al Fin Coils 1907
1858
1768
1512
915
RS&LS1/Cu Fin Coils 1907
1980
2108
1892
1076
0207S/P/H
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (195.7, 1.3) (265.4, 1.3)
Al Fin Coils
1728
1676
1764
1475
800
Cu Fin Coils
1728
1797
2108
1854
961
RS&LS1/Al Fin Coils 1907
1854
1764
1475
800
RS&LS1/Cu Fin Coils 1907
1975
2103
1854
961
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (195.7, 86.8) (265.4, 86.8)
Al Fin Coils
1728
1680
1768
1523
959
Cu Fin Coils
1728
1801
2108
1903
1120
RS&LS1/Al Fin Coils 1907
1858
1768
1523
959
RS&LS1/Cu Fin Coils 1907
1980
2108
1903
1120
0277S/P/H RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (195.7, 1.3) (265.4, 1.3)
Al Fin Coils
1728
1676
1764
1519
955
Cu Fin Coils
1728
1797
2103
1898
1116
RS&LS1/Al Fin Coils 1907
1854
1764
1519
955
RS&LS1/Cu Fin Coils 1907
1975
2103
1898
1116
LEFT - L
(9.1, 86.8) (59.4, 86.8) (97.2, 86.8) (161.4, 86.8) (210.6, 86.8) (307.9, 86.8)
Al Fin Coils
1728
1638
1248
1160
1261
959
Cu Fin Coils
1728
1728
1488
1435
1609
1199
RS&LS1/Al Fin Coils 1907
1817
1248
1160
1261
959
RS&LS1/Cu Fin Coils 1907
1907
1488
1435
1609
1199
0247S/P/H
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (97.2, 1.3) (161.4, 1.3) (210.6, 1.3) (307.9, 1.3)
Al Fin Coils
1720
1625
1239
1153
1237
955
Cu Fin Coils
1720
1715
1479
1429
1585
1195
RS&LS1/Al Fin Coils 1898
1803
1239
1153
1237
955
RS&LS1/Cu Fin Coils 1898
1894
1479
1429
1590
1195
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
134
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
STANDARD EFFICIENCY, ENGLISH (CONT'D)
L1
L2
L3
L4
L5
L6
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - IN. AND POINT LOADS - LB
1
2
3
4
5
6
7
LEFT - L
(9.1, 86.8) (59.4, 86.8) (97.2, 86.8) (161.4, 86.8) (210.6, 86.8) (307.9, 86.8)
Al Fin Coils
1728
1638
1248
1160
1265
1005
Cu Fin Coils
1728
1728
1488
1435
1614
1246
RS&LS1/Al Fin Coils 1907
1817
1248
1160
1265
1005
RS&LS1/Cu Fin Coils 1907
1907
1488
1435
1614
1246
0267S/P/H
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (97.2, 1.3) (161.4, 1.3) (210.6, 1.3) (307.9, 1.3)
Al Fin Coils
1728
1638
1248
1160
1265
1005
Cu Fin Coils
1728
1728
1488
1435
1614
1246
RS&LS1/Al Fin Coils 1907
1817
1248
1160
1265
1005
RS&LS1/Cu Fin Coils 1907
1907
1488
1435
1618
1246
LEFT - L
(9.1, 86.8) (58.1, 86.8) (111.1, 86.8) (204.7, 86.8) (284.9, 86.8) (368, 86.8)
Al Fin Coils
1753
1585
1821
1810
2123
1175
6
Cu Fin Coils
1775
1757
2165
2156
2467
1347
RS&LS1/Al Fin Coils 1929
1761
1821
1810
2189
1462
0287S/P/H RS&LS1/Cu Fin Coils 1885
1933
2165
2156
2533
1634
RIGHT - R
(9.1, 1.3) (58.1, 1.3) (111.1, 1.3) (204.7, 1.3) (284.9, 1.3) (368, 1.3)
Al Fin Coils
1753
1596
2407
2414
2635
1179
Cu Fin Coils
1775
1768
2751
2760
2978
1351
RS&LS1/Al Fin Coils 1929
1773
2407
2414
2701
1466
RS&LS1/Cu Fin Coils 1951
1944
2751
2760
3045
1638
LEFT - L
(9.1, 86.8) (58.1, 86.8) (111.1, 86.8) (204.7, 86.8) (284.9, 86.8) (368, 86.8)
Al Fin Coils
1753
1585
1953
1978
2304
1184
Cu Fin Coils
1775
1757
2297
2324
2648
1356
RS&LS1/Al Fin Coils 1929
1761
1953
1978
2370
1470
RS&LS1/Cu Fin Coils 1951
1933
2297
2324
2714
1642
0307S/P/H
RIGHT - R
(9.1, 1.3) (58.1, 1.3) (111.1, 1.3) (204.7, 1.3) (284.9, 1.3) (368, 1.3)
Al Fin Coils
1753
1596
2540
2632
2897
1188
Cu Fin Coils
1775
1768
2884
2978
3241
1338
RS&LS1/Al Fin Coils 1929
1773
2540
2632
2963
1475
RS&LS1/Cu Fin Coils 1951
1944
2884
2978
3307
1647
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
JOHNSON CONTROLS
135
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
STANDARD EFFICIENCY, ENGLISH (CONT'D)
L1
L2
L3
L4
L5
L6
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - IN. AND POINT LOADS - LB
1
2
3
4
5
6
7
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (185.4, 86.8) (284.4, 86.8) (358.5, 86.8)
(411.9, 86.8)
Al Fin Coils
1753
1585
1953
1978
1953
1140
946
Cu Fin Coils
1775
1733
2238
2363
2339
1424
1065
RS&LS1/Al Fin Coils 1929
1761
1953
1978
1953
1316
1122
0357S/P/H RS&LS1/Cu Fin Coils 1951
1909
2238
2363
2339
1601
1241
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (185.4, 1.3) (284.4, 1.3) (358.5, 1.3) (411.9, 1.3)
Al Fin Coils
1753
1596
2540
2632
2540
1151
946
Cu Fin Coils
1775
1715
2824
3018
2926
1435
1065
RS&LS1/Al Fin Coils 1929
1773
2540
2632
2540
1327
1122
RS&LS1/Cu Fin Coils 1951
1892
2824
3018
2926
1612
1241
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (185.4, 86.8) (298.1, 86.8) (375.2, 86.8) (456, 86.8)
Al Fin Coils
1766
1607
1953
1978
2041
1404
1056
Cu Fin Coils
1788
1755
2238
2363
2427
1689
1175
RS&LS1/Al Fin Coils 1942
1784
1953
1978
2041
1581
1232
RS&LS1/Cu Fin Coils 1964
1931
2238
2363
2427
1865
1351
0397S/P/H
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (185.4, 1.3) (298.1, 1.3) (375.2, 1.3) (456, 1.3)
Al Fin Coils
1766
1618
2540
2632
2628
1415
1056
Cu Fin Coils
1788
1737
2824
3018
3014
1700
1175
RS&LS1/Al Fin Coils 1942
1795
2540
2632
2628
1592
1232
RS&LS1/Cu Fin Coils 1964
1914
2824
3018
3014
1876
1351
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
136
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
HIGH EFFICIENCY, ENGLISH
L1
L2
L3
L4
L5
L6
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - IN. AND POINT LOADS - LB
1
2
3
4
5
6
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (211, 86.8)
Al Fin Coils
1702
1594
1667
1609
Cu Fin Coils
1702
1706
2011
1951
RS&LS1/Al Fin Coils 1881
1773
1667
1609
RS&LS1/Cu Fin Coils 1881
1885
2011
1951
0157E/V
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (211, 1.3)
Al Fin Coils
1702
1594
1667
1609
Cu Fin Coils
1702
1706
2011
1951
RS&LS1/Al Fin Coils 1881
1773
1667
1609
RS&LS1/Cu Fin Coils 1881
1885
2011
1951
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (195.7, 86.8) (265.4, 86.8)
Al Fin Coils
1698
1559
1559
1274
774
Cu Fin Coils
1698
1680
1898
1653
935
RS&LS1/Al Fin Coils 1876
1737
1559
1274
774
RS&LS1/Cu Fin Coils 1876
1858
1898
1653
935
0177E/V RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (195.7, 1.3) (265.4, 1.3)
Al Fin Coils
1698
1559
1559
1241
664
Cu Fin Coils
1698
1680
1898
1620
825
RS&LS1/Al Fin Coils 1876
1737
1559
1241
664
RS&LS1/Cu Fin Coils 1876
1858
1898
1620
825
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (195.7, 86.8) (265.4, 86.8)
Al Fin Coils
1715
1581
1676
1287
820
Cu Fin Coils
1715
1702
2015
1667
981
RS&LS1/Al Fin Coils 1894
1759
1676
1287
820
RS&LS1/Cu Fin Coils 1894
1881
2015
1667
981
0187E/V
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (195.7, 1.3) (265.4, 1.3)
Al Fin Coils
1698
1561
1561
1287
820
Cu Fin Coils
1698
1682
1900
1667
981
RS&LS1/Al Fin Coils 1876
1739
1561
1287
820
RS&LS1/Cu Fin Coils 1876
1861
1900
1667
981
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
7
6
JOHNSON CONTROLS
137
SECTION 6 - TECHNICAL DATA
HIGH EFFICIENCY, ENGLISH (CONT'D)
L1
L2
L3
L4
L5
L6
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - IN. AND POINT LOADS - LB
1
2
3
4
5
6
7
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (195.7, 86.8) (265.4, 86.8)
Al Fin Coils
1720
1609
1618
1354
860
Cu Fin Coils
1720
1731
1958
1733
1021
RS&LS1/Al Fin Coils 1898
1788
1618
1354
860
RS&LS1/Cu Fin Coils 1898
1909
1958
1733
1021
0197E/V
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (195.7, 1.3) (265.4, 1.3)
Al Fin Coils
1720
1609
1618
1354
860
Cu Fin Coils
1720
1731
1958
1733
1021
RS&LS1/Al Fin Coils 1898
1788
1618
1354
860
RS&LS1/Cu Fin Coils 1898
1909
1958
1733
1021
LEFT - L
(9.1, 86.8) (59.4, 86.8) (97.2, 86.8) (161.4, 86.8) (210.6, 86.8) (307.9, 86.8)
Al Fin Coils
1720
1614
1082
994
1093
952
Cu Fin Coils
1720
1704
1323
1270
1442
1193
RS&LS1/Al Fin Coils 1898
1792
1082
994
1093
952
RS&LS1/Cu Fin Coils 1898
1883
1323
1270
1442
1193
0207E/V RIGHT - R
(9.1, 1.3) (59.4, 1.3) (97.2, 1.3) (161.4, 1.3) (210.6, 1.3) (307.9, 1.3)
Al Fin Coils
1720
1614
1082
994
1078
955
Cu Fin Coils
1720
1704
1323
1270
1426
1195
RS&LS1/Al Fin Coils 1898
1792
1082
994
1078
955
RS&LS1/Cu Fin Coils 1898
1883
1323
1270
1431
1195
LEFT - L
(9.1, 86.8) (59.4, 86.8) (97.2, 86.8) (161.4, 86.8) (210.6, 86.8) (307.9, 86.8)
Al Fin Coils
1720
1616
1085
999
1102
1003
Cu Fin Coils
1720
1706
1325
1274
1451
1243
RS&LS1/Al Fin Coils 1898
1795
1085
999
1102
1003
RS&LS1/Cu Fin Coils 1898
1885
1325
1274
1451
1243
0227E/V
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (97.2, 1.3) (161.4, 1.3) (210.6, 1.3) (307.9, 1.3)
Al Fin Coils
1720
1616
1085
999
1102
1003
Cu Fin Coils
1720
1706
1325
1274
1451
1243
RS&LS1/Al Fin Coils 1898
1795
1085
999
1102
1003
RS&LS1/Cu Fin Coils 1898
1885
1325
1274
1455
1243
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
138
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
HIGH EFFICIENCY, ENGLISH (CONT'D)
L1
L2
L3
L4
L5
L6
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - IN. AND POINT LOADS - LB
1
2
3
4
5
6
7
LEFT - L
(9.1, 86.8) (59.4, 86.8) (97.2, 86.8) (161.4, 86.8) (210.6, 86.8) (307.9, 86.8)
Al Fin Coils
1728
1638
1248
1160
1265
1005
Cu Fin Coils
1728
1728
1488
1435
1614
1246
RS&LS1/Al Fin Coils 1907
1817
1248
1160
1265
1005
RS&LS1/Cu Fin Coils 1907
1907
1488
1435
1614
1246
0247E/V
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (97.2, 1.3) (161.4, 1.3) (210.6, 1.3) (307.9, 1.3)
Al Fin Coils
1720
1629
1248
1160
1265
1005
Cu Fin Coils
1720
1720
1488
1435
1614
1246
RS&LS1/Al Fin Coils 1898
1808
1248
1160
1265
1005
RS&LS1/Cu Fin Coils 1898
1898
1488
1435
1618
1246
LEFT - L
(9.1, 86.8) (58.1, 86.8) (111.1, 86.8) (204.7, 86.8) (284.9, 86.8) (368, 86.8)
Al Fin Coils
1753
1585
1821
1839
2163
1175
6
Cu Fin Coils
1775
1757
2165
2185
2507
1347
RS&LS1/Al Fin Coils 1929
1761
1821
1839
2229
1396
RS&LS1/Cu Fin Coils 1951
1933
2165
2185
2573
1634
0267E/V RIGHT - R
(9.1, 1.3) (58.1, 1.3) (111.1, 1.3) (204.7, 1.3) (284.9, 1.3) (368, 1.3)
Al Fin Coils
1753
1596
2407
2493
2756
1179
Cu Fin Coils
1775
1768
2751
2840
3100
1351
RS&LS1/Al Fin Coils 1929
1773
2407
2493
2822
1466
RS&LS1/Cu Fin Coils 1951
1944
2751
2840
3166
1638
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (185.4, 86.8) (284.4, 86.8) (358.5, 86.8) (411.9, 86.8)
Al Fin Coils
1753
1585
1847
1870
1574
1049
928
Cu Fin Coils
1775
1733
2132
2255
1960
1334
1047
RS&LS1/Al Fin Coils 1929
1761
1847
1870
1574
1226
1105
RS&LS1/Cu Fin Coils 1885
1909
2132
2255
1960
1510
1224
0287E/V
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (185.4, 1.3) (284.4, 1.3) (358.5, 1.3) (411.9, 1.3)
Al Fin Coils
1753
1596
2434
2524
2344
1120
928
Cu Fin Coils
1775
1715
2718
2910
2729
1404
1047
RS&LS1/Al Fin Coils 1929
1773
2434
2524
2344
1296
1105
RS&LS1/Cu Fin Coils 1951
1892
2718
2910
2729
1581
1224
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
JOHNSON CONTROLS
139
SECTION 6 - TECHNICAL DATA
HIGH EFFICIENCY, ENGLISH (CONT'D)
L1
L2
L3
L4
L5
L6
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - IN. AND POINT LOADS - LB
1
2
3
4
5
6
7
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (185.4, 86.8) (284.4, 86.8) (358.5, 86.8) (411.9, 86.8)
Al Fin Coils
1753
1585
1953
1978
1953
1140
928
Cu Fin Coils
1775
1733
2238
2363
2339
1424
1047
RS&LS1/Al Fin Coils 1929
1761
1953
1978
1953
1316
1105
RS&LS1/Cu Fin Coils 1951
1931
2238
2363
2339
1601
1224
0327E/V
RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (185.4, 1.3) (284.4, 1.3) (358.5, 1.3) (411.9, 1.3)
Al Fin Coils
1753
1596
2540
2632
2540
1151
928
Cu Fin Coils
1775
1715
2824
3018
2926
1435
1047
RS&LS1/Al Fin Coils 1929
1773
2540
2632
2540
1327
1105
RS&LS1/Cu Fin Coils 1951
1892
2824
3018
2926
1612
1224
LEFT - L
(9.1, 86.8) (59.4, 86.8) (109.4, 86.8) (185.4, 86.8) (298.1, 86.8) (375.2, 86.8) (456, 86.8)
Al Fin Coils
1766
1607
1953
1978
2041
1404
1038
Cu Fin Coils
1788
1755
2238
2363
2427
1689
1157
RS&LS1/Al Fin Coils 1942
1784
1953
1978
2041
1581
1215
RS&LS1/Cu Fin Coils 1964
1931
2238
2363
2427
1865
1334
0357E/V RIGHT - R
(9.1, 1.3) (59.4, 1.3) (109.4, 1.3) (185.4, 1.3) (298.1, 1.3) (375.2, 1.3) (456, 1.3)
Al Fin Coils
1766
1618
2540
2632
2628
1415
1038
Cu Fin Coils
1788
1737
2824
3018
3014
1700
1157
RS&LS1/Al Fin Coils 1942
1795
2540
2632
2628
1592
1215
RS&LS1/Cu Fin Coils 1964
1914
2824
3018
3014
1876
1334
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
140
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
STANDARD EFFICIENCY, SI
L1
L2
L3
L4
L5
L6
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - MM. AND POINT LOADS - KG
1
2
3
4
5
6
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (5360, 2204)
Al Fin Coils
772
722
633
608
Cu Fin Coils
772
773
789
763
RS&LS1/Al Fin Coils
853
803
633
608
RS&LS1/Cu Fin Coils 853
854
789
763
0157S/P/H
RIGHT - R
(230, 32) (1510, 32) (2780, 32) (5360, 32)
Al Fin Coils
772
722
633
608
Cu Fin Coils
772
773
789
763
RS&LS1/Al Fin Coils
853
803
633
608
RS&LS1/Cu Fin Coils 853
854
789
763
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (5360, 2204)
Al Fin Coils
780
732
756
730
Cu Fin Coils
780
783
912
885
RS&LS1/Al Fin Coils
861
813
756
730
RS&LS1/Cu Fin Coils 861
864
912
885
0177S/P/H RIGHT - R
(230, 32) (1510, 32) (2780, 32) (5360, 32)
Al Fin Coils
772
723
756
730
Cu Fin Coils
772
774
912
885
RS&LS1/Al Fin Coils
853
804
756
730
RS&LS1/Cu Fin Coils 853
855
912
885
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (4970, 2204) (6740, 2204)
Al Fin Coils
778
716
707
578
351
Cu Fin Coils
778
771
861
750
424
RS&LS1/Al Fin Coils
859
797
707
578
351
RS&LS1/Cu Fin Coils 859
852
861
750
424
0187S/P/H
RIGHT - R
(230, 32) (1510, 32) (2780, 32) (4970, 32) (6740, 32)
Al Fin Coils
770
707
707
563
301
Cu Fin Coils
770
762
861
735
374
RS&LS1/Al Fin Coils
851
788
707
563
301
RS&LS1/Cu Fin Coils 851
843
861
735
374
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
7
6
JOHNSON CONTROLS
141
SECTION 6 - TECHNICAL DATA
STANDARD EFFICIENCY, SI (CONT'D)
L1
L2
L3
L4
L5
L6
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - MM. AND POINT LOADS - KG
1
2
3
4
5
6
7
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (4970, 2204) (6740, 2204)
Al Fin Coils
784
762
802
686
415
Cu Fin Coils
784
817
956
858
488
RS&LS1/Al Fin Coils
865
843
802
686
415
RS&LS1/Cu Fin Coils 865
898
956
858
488
0207S/P/H
RIGHT - R
(230, 32) (1510, 32) (2780, 32) (4970, 32) (6740, 32)
Al Fin Coils
784
760
800
669
363
Cu Fin Coils
784
815
956
841
436
RS&LS1/Al Fin Coils
865
841
800
669
363
RS&LS1/Cu Fin Coils 865
896
954
841
436
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (4970, 2204) (6740, 2204)
Al Fin Coils
784
762
802
691
435
Cu Fin Coils
784
817
956
863
508
RS&LS1/Al Fin Coils
865
843
802
691
435
RS&LS1/Cu Fin Coils 865
898
956
863
508
0277S/P/H RIGHT - R
(230, 32) (1510, 32) (2780, 32) (4970, 32) (6740, 32)
Al Fin Coils
784
760
800
689
433
Cu Fin Coils
784
815
954
861
506
RS&LS1/Al Fin Coils
865
841
800
689
433
RS&LS1/Cu Fin Coils 865
896
954
861
506
LEFT - L
(230, 2204) (1510, 2204) (2470, 2204) (4100, 2204) (5350, 2204) (1820, 2204)
Al Fin Coils
784
743
566
526
572
435
Cu Fin Coils
784
784
675
651
730
544
RS&LS1/Al Fin Coils
865
824
566
526
572
435
RS&LS1/Cu Fin Coils 865
865
675
651
730
544
0247S/P/H
RIGHT - R
(230, 32) (1510, 32) (2470, 32) (4100, 32) (5350, 32) (7820, 32)
Al Fin Coils
780
737
562
523
561
433
Cu Fin Coils
780
778
671
648
719
542
RS&LS1/Al Fin Coils
861
818
562
523
561
433
RS&LS1/Cu Fin Coils 861
859
671
648
721
542
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
142
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
STANDARD EFFICIENCY, SI (CONT'D)
L1
L2
L3
L4
L5
L6
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - MM. AND POINT LOADS - KG
1
2
3
4
5
6
7
LEFT - L
(230, 2204) (1510, 2204) (2470, 2204) (4100, 2204) (5350, 2204) (7820, 2204)
Al Fin Coils
784
743
566
526
574
456
Cu Fin Coils
784
784
675
651
732
565
RS&LS1/Al Fin Coils
865
824
566
526
574
456
RS&LS1/Cu Fin Coils 865
865
675
651
732
565
0267S/P/H
RIGHT - R
(230, 32) (1510, 32) (2470, 32) (4100, 32) (5350, 32) (7820, 32)
Al Fin Coils
784
743
566
526
574
456
Cu Fin Coils
784
784
675
651
732
565
RS&LS1/Al Fin Coils
865
824
566
526
574
456
RS&LS1/Cu Fin Coils 865
865
675
651
734
565
LEFT - L
(230, 2204) (1475, 2204) (2823, 2204) (5199, 2204) (7236, 2204) (9346, 2204)
Al Fin Coils
795
719
826
821
963
533
6
Cu Fin Coils
805
797
982
978
1119
611
RS&LS1/Al Fin Coils
875
799
826
821
993
663
RS&LS1/Cu Fin Coils 855
877
982
978
1149
741
0287S/P/H RIGHT - R
(230, 32) (1475, 32) (2823, 32) (5199, 32) (7236, 32) (9346, 32)
Al Fin Coils
795
724
1092
1095
1195
535
Cu Fin Coils
805
802
1248
1252
1351
613
RS&LS1/Al Fin Coils
875
804
1092
1095
1225
665
RS&LS1/Cu Fin Coils 885
882
1248
1252
1381
743
LEFT - L
(230, 2204) (1475, 2204) (2823, 2204) (5199, 2204) (7236, 2204) (9346, 2204)
Al Fin Coils
795
719
886
897
1045
537
Cu Fin Coils
805
797
1042
1054
1201
615
RS&LS1/Al Fin Coils
875
799
886
897
1075
667
RS&LS1/Cu Fin Coils 885
877
1042
1054
1231
745
0307S/P/H
RIGHT - R
(230, 32) (1475, 32) (2823, 32) (5199, 32) (7236, 32) (9346, 32)
Al Fin Coils
795
724
1152
1194
1314
539
Cu Fin Coils
805
802
1308
1351
1470
607
RS&LS1/Al Fin Coils
875
804
1152
1194
1344
669
RS&LS1/Cu Fin Coils 885
882
1308
1351
1500
747
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
JOHNSON CONTROLS
143
SECTION 6 - TECHNICAL DATA
STANDARD EFFICIENCY, SI (CONT'D)
L1
L2
L3
L4
L5
L6
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - MM. AND POINT LOADS - KG
1
2
3
4
5
6
7
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (4710, 2204) (7225, 2204) (9105, 2204)
(10463, 2204)
Al Fin Coils
795
719
886
897
886
517
429
Cu Fin Coils
805
786
1015
1072
1061
646
483
RS&LS1/Al Fin Coils
875
799
886
897
886
597
509
0357S/P/H RS&LS1/Cu Fin Coils 885
866
1015
1072
1061
726
563
RIGHT - R
(230, 32) (1510, 32) (2780, 32) (4710, 32) (7225, 32) (9105, 32) (10463, 32)
Al Fin Coils
795
724
1152
1194
1152
522
429
Cu Fin Coils
805
778
1281
1369
1327
651
483
RS&LS1/Al Fin Coils
875
804
1152
1194
1152
602
509
RS&LS1/Cu Fin Coils 885
858
1281
1369
1327
731
563
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (4710, 2204) (7572, 2204) (9530, 2204)
(11582, 2204)
Al Fin Coils
801
729
886
897
926
637
479
Cu Fin Coils
811
796
1015
1072
1101
766
533
RS&LS1/Al Fin Coils
881
809
886
897
926
717
559
0397S/P/H RS&LS1/Cu Fin Coils 891
876
1015
1072
1101
846
613
RIGHT - R
(230, 32) (1510, 32) (2780, 32) (4710, 32) (7572, 32) (9530, 32) (11582, 32)
Al Fin Coils
801
734
1152
1194
1192
642
479
Cu Fin Coils
811
788
1281
1369
1367
771
533
RS&LS1/Al Fin Coils
881
814
1152
1194
1192
722
559
RS&LS1/Cu Fin Coils 891
868
1281
1369
1367
851
613
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
144
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
HIGH EFFICIENCY, SI
L1
L2
L3
L4
L5
L6
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - MM. AND POINT LOADS - KG
1
2
3
4
5
6
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (5360, 2204)
Al Fin Coils
772
723
756
730
Cu Fin Coils
772
774
912
885
RS&LS1/Al Fin Coils
853
804
756
730
RS&LS1/Cu Fin Coils 853
855
912
885
0157E/V
RIGHT - R
(230, 32) (1510, 32) (2780, 32) (5360, 32)
Al Fin Coils
772
723
756
730
Cu Fin Coils
772
774
912
885
RS&LS1/Al Fin Coils
853
804
756
730
RS&LS1/Cu Fin Coils 853
855
912
885
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (4970, 2204) (6740, 2204)
Al Fin Coils
770
707
707
578
351
Cu Fin Coils
770
762
861
750
424
RS&LS1/Al Fin Coils
851
788
707
578
351
RS&LS1/Cu Fin Coils 851
843
861
750
424
0177E/V RIGHT - R
(230, 32) (1510, 32) (2780, 32) (4970, 32) (6740, 32)
Al Fin Coils
770
707
707
563
301
Cu Fin Coils
770
762
861
735
374
RS&LS1/Al Fin Coils
851
788
707
563
301
RS&LS1/Cu Fin Coils 851
843
861
735
374
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (4970, 2204) (6740, 2204)
Al Fin Coils
778
717
760
584
372
Cu Fin Coils
778
772
914
756
445
RS&LS1/Al Fin Coils
859
798
760
584
372
RS&LS1/Cu Fin Coils 859
853
914
756
445
0187E/V
RIGHT - R
(230, 32) (1510, 32) (2780, 32) (4970, 32) (6740, 32)
Al Fin Coils
770
708
708
584
372
Cu Fin Coils
770
763
862
756
445
RS&LS1/Al Fin Coils
851
789
708
584
372
RS&LS1/Cu Fin Coils 851
844
862
756
445
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
7
6
JOHNSON CONTROLS
145
SECTION 6 - TECHNICAL DATA
HIGH EFFICIENCY, SI (CONT'D)
L1
L2
L3
L4
L5
L6
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - MM. AND POINT LOADS - KG
1
2
3
4
5
6
7
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (4970, 2204) (6740, 2204)
Al Fin Coils
780
730
734
614
390
Cu Fin Coils
780
785
888
786
463
RS&LS1/Al Fin Coils
861
811
734
614
390
RS&LS1/Cu Fin Coils 861
866
888
786
463
0197E/V
RIGHT - R
(230, 32) (1510, 32) (2780, 32) (4970, 32) (6740, 32)
Al Fin Coils
780
730
734
614
390
Cu Fin Coils
780
785
888
786
463
RS&LS1/Al Fin Coils
861
811
734
614
390
RS&LS1/Cu Fin Coils 861
866
888
786
463
LEFT - L
(230, 2204) (1510, 2204) (2470, 2204) (4100, 2204) (5350, 2204) (7820, 2204)
Al Fin Coils
780
732
491
451
496
432
Cu Fin Coils
780
773
600
576
654
541
RS&LS1/Al Fin Coils
861
813
491
451
496
432
RS&LS1/Cu Fin Coils 861
854
600
576
654
541
0207E/V RIGHT - R
(230, 32) (1510, 32) (2470, 32) (4100, 32) (5350, 32) (7820, 32)
Al Fin Coils
780
732
491
451
489
433
Cu Fin Coils
780
773
600
576
647
542
RS&LS1/Al Fin Coils
861
813
491
451
489
433
RS&LS1/Cu Fin Coils 861
854
600
576
649
542
LEFT - L
(230, 2204) (1510, 2204) (2470, 2204) (4100, 2204) (5350, 2204) (7820, 2204)
Al Fin Coils
780
733
492
453
500
455
Cu Fin Coils
780
774
601
578
658
564
RS&LS1/Al Fin Coils
861
814
492
453
500
455
RS&LS1/Cu Fin Coils 861
855
601
578
658
564
0227E/V
RIGHT - R
(230, 32) (1510, 32) (2470, 32) (4100, 32) (5350, 32) (7820, 32)
Al Fin Coils
780
733
492
453
500
455
Cu Fin Coils
780
774
601
578
658
564
RS&LS1/Al Fin Coils
861
814
492
453
500
455
RS&LS1/Cu Fin Coils 861
855
601
578
660
564
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
146
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
HIGH EFFICIENCY, SI (CONT'D)
L1
L2
L3
L4
L5
L6
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - MM. AND POINT LOADS - KG
1
2
3
4
5
6
7
LEFT - L
(230, 2204) (1510, 2204) (2470, 2204) (4100, 2204) (5350, 2204) (7820, 2204)
Al Fin Coils
784
743
566
526
574
456
Cu Fin Coils
784
784
675
651
732
565
RS&LS1/Al Fin Coils
865
824
566
526
574
456
RS&LS1/Cu Fin Coils 865
865
675
651
732
565
0247E/V
RIGHT - R
(230, 32) (1510, 32) (2470, 32) (4100, 32) (5350, 32) (7820, 32)
Al Fin Coils
780
739
566
526
574
456
Cu Fin Coils
780
780
675
651
732
565
RS&LS1/Al Fin Coils
861
820
566
526
574
456
RS&LS1/Cu Fin Coils 861
861
675
651
734
565
LEFT - L
(230, 2204) (1475, 2204) (2823, 2204) (5199, 2204) (7236, 2204) (9346, 2204)
6
Al Fin Coils
795
719
826
834
981
533
Cu Fin Coils
805
797
982
991
1137
611
RS&LS1/Al Fin Coils
875
799
826
834
1011
633
0267E/V RS&LS1/Cu Fin Coils
885
877
982
991
1167
741
RIGHT - R
(230, 32) (1475, 32) (2823, 32) (5199, 32) (7236, 32) (9346, 32)
Al Fin Coils
795
724
1092
1131
1250
535
Cu Fin Coils
805
802
1248
1288
1406
613
RS&LS1/Al Fin Coils
875
804
1092
1131
1280
665
RS&LS1/Cu Fin Coils 885
882
1248
1288
1436
743
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (4710, 2204) (7225, 2204) (9105, 2204) (10463, 2204)
Al Fin Coils
795
719
838
848
714
476
421
Cu Fin Coils
805
786
967
1023
889
605
475
RS&LS1/Al Fin Coils
875
799
838
848
714
556
501
RS&LS1/Cu Fin Coils 855
866
967
1023
889
685
555
0287E/V
RIGHT - R
(230, 32) (1510, 32) (2780, 32) (4710, 32) (7225, 32) (9105, 32) (10463, 32)
Al Fin Coils
795
724
1104
1145
1063
508
421
Cu Fin Coils
805
778
1233
1320
1238
637
475
RS&LS1/Al Fin Coils
875
804
1104
1145
1063
588
501
RS&LS1/Cu Fin Coils 885
858
1233
1320
1238
717
555
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
JOHNSON CONTROLS
147
SECTION 6 - TECHNICAL DATA
HIGH EFFICIENCY, SI (CONT'D)
L1
L2
L3
L4
L5
L6
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
L7
CONTROL PANEL
y
R1
R2
R3
R4
R5
R6
R7
x
YCIV
ISOLATOR LOCATIONS (X, Y) - MM. AND POINT LOADS - KG
1
2
3
4
5
6
7
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (4710, 2204) (7225, 2204) (9105, 2204) (10463, 2204)
Al Fin Coils
795
719
886
897
886
517
421
Cu Fin Coils
805
786
1015
1072
1061
646
475
RS&LS1/Al Fin Coils
875
799
886
897
886
597
501
RS&LS1/Cu Fin Coils 885
876
1015
1072
1061
726
555
0327E/V
RIGHT - R
(230, 32) (1510, 32) (2780, 32) (4710, 32) (7225, 32) (9105, 32) (10463, 32)
Al Fin Coils
795
724
1152
1194
1152
522
421
Cu Fin Coils
805
778
1281
1369
1327
651
475
RS&LS1/Al Fin Coils
875
804
1152
1194
1152
602
501
RS&LS1/Cu Fin Coils 885
858
1281
1369
1327
731
555
LEFT - L
(230, 2204) (1510, 2204) (2780, 2204) (4710, 2204) (7572, 2204) (9530, 2204) (11582, 2204)
Al Fin Coils
801
729
886
897
926
637
471
Cu Fin Coils
811
796
1015
1072
1101
766
525
RS&LS1/Al Fin Coils
881
809
886
897
926
717
551
0357E/V RS&LS1/Cu Fin Coils
891
876
1015
1072
1101
846
605
163 RIGHT - R
(230, 32) (1510, 32) (2780, 32) (4710, 32) (7572, 32) (9530, 32) (11582, 32)
Al Fin Coils
801
734
1152
1194
1192
642
471
Cu Fin Coils
811
788
1281
1369
1367
771
525
RS&LS1/Al Fin Coils
881
814
1152
1194
1192
722
551
RS&LS1/Cu Fin Coils 891
868
1281
1369
1367
851
605
NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option
148
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
ISOLATOR CROSS REFERENCE
SECTION 6 - TECHNICAL DATA
OLD PART NUMBER
MASON
NEW PART NUMBER
THE VMC
029-24583-002 CIP-B-450 RED
029-25334-002 CP-1D-510 BLACK
029-24583-003 CIP-B-750 WHITE
029-25334-003 CP-1D-900 DK GREEN
029-24583-004 CIP-B-1000 BLUE
029-25334-004 CP-1D-1200 GRAY
029-24583-005 CIP-B-1250 GRAY
029-25334-005 CP-1D-1360 WHITE
029-24583-006 CIP-B-1650 BLACK
029-25334-006 CP-1 D-1785N GRAY IRED
029-24583-007 029-24583-008
CIP-C-1000 BLACK CIP-C-1350 YELLOW
029-25334-008 C2P-1D-1350 DARK PURPLE
029-24583-009
CIP-C-1750 BLACK STRIPE WITH RED
029-25334-009 C2P-1D-1800 DARK GREEN
029-24583-010 029-24583-011
CIP-C-2100 YELLOW WITH RED CIP-C-2385 YELLOW WITH GREEN
029-25334-010
C2P-1D-2400 GRAY
029-24583-012 CIP-C-2650 RED WITH RED
029-25334-012 C2P-1D-2720 WHITE
029-24583-013 CIP-C-2935 RED WITH GREEN
029-25334-013 C2P-1D-3570N GRAY/iRED
029-24584-001 ND-C YELLOW
029-25335-001 RD-3 CHARCOAL-WR
029-24584-002 ND-D YELLOW
029-25335-002 RD-4 BRICK RED-WR
029-24584-004 ND-DS YELLOW
029-25335-004 RD-4 CHARCOAL-WR
029-24585-006 029-24585-007
SLRS-2-C2-420 RED SLRS-2-C2-520 WHITE
029-25336-006 Y2RSI-2D-460 GREEN
029-24585-008 SLRS-2-C2-660 BLACK
029-25336-008 Y2RSI-2D-710 DK BROWN
029-24585-009 SLRS-2-C2-920 BLUE
029-25336-009 Y2RSI-2D-870 RED
029-24585-010 029-24585-011
SLRS-2-C2-1220 GREEN SLRS-2-C2-1760 GRAY
029-25336-010 029-25336-011
Y2RSI-2D-1200N RED/BLACK Y2RSI-2D-1690 PINK
6
029-24585-012 SLRS-2-C2-2420 SILVER
029-25336-012 Y2RSI-2D-2640N PINK/GRAY
029-24585-013 SLRS-2-C2-3080 GRAY WITH RED
029-25336-013
Y2RSI-2D-2870N PINK/GRAY/ORANGE
029-24585-014
SLRS-2-C2-3740 SILVER WITH RED
029-25336-014 Y2RSI-2D-3600 PINK/GRAY/BROWN
JOHNSON CONTROLS
149
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
ONE INCH DEFLECTION SPRING ISOLATORS CROSS-REFERENCE
Units shipped on or after June 15, 2008
RATED EFLECTION
(IN)
1.36 1.2 1.17 1.4 1.13 1.02 1.32 1.02 0.9 0.77 0.88
COLOR CODE
LT. PURPLE DK. YELLOW
DK. BLUE YELLOW
RED BLACK DK. PURPLE DK. GREEN GRAY WHITE GRAY/RED
JCI PART NUMBER
029 25334 002 029 25334 003 029 25334 004 029 25334 005 029 25334 006
Ø1/2"
5/8" H"
RATED
DEFLECTION COLOR CODE
(IN)
1.02
BLACK
1.32
DK. PURPLE
1.02
DK. GREEN
0.9
GRAY
0.77 0.88
WHITE GRAY / RED
JCI PART NUMBER
029 25334 008 029 25334 007 029 25334 009 029 25334 010 029 25334 011 029 25334 012 029 25334 013
T"
D" W"
MOUNT
CGH-PEOS,WINDTEERRCPORAETTTEYPDEP,RSEPARNISNIGY-1P4O. WDEWR COATED (COLOR: SEEDTABLE),
PLATE. OLTING
OR
ANCHOCRPING
MOUNT
TO
SU3PPORT
STRUCTURE
W5/IT8H
A
MIN (2)
ADCFOONRC5R0E%TEOVAENRCC-HTOR2RAPVSE. L.
3
5/8
STALLATION INSTRUCTIONS.
C" B" L"
LD13759
DIMENSION DATA (INCHES)
L
B
C
7 3/4
6 1/2
4 3/4
10 1/2
9 1/4
7 3/4
T 1/2 9/16
H 5 5/8
6
DIMREANTSEIDONCAALPDAACTIATY(IN(FCoHrEuSn)its with all load points less
D
L
B than C1785 lb (81T0 kg) H
5/8 5/8
7-3/4 10-1/2
96*--l11b//42
4-3/4 7-3/4
1/2 9/16
5*-k56g/8
Up to 434
Up to 197
435765
198347
7661020
348463
10211156
464524
11571785
525810
Up to 1148
Up to 521
11491530
522694
15312040
695925
20412312
9261049
23133570
10501619
VENDOR P/N
CP-1D-510 CP-1D-900 CP-1D-1200 CP-1D-1360 CP-1D-1785N C2P-1D-1350 C2P-1D-1800 C2P-1D-2400 C2P-1D-2720 C2P-1D-3570N
COLOR
BLACK DK GREEN
GRAY WHITE GRAY/RED DK PURPLE DK GREEN GRAY WHITE GRAY/RED
YORK P/N
029-25334-002 029-25334-003 029-25334-004 029-25334-005 029-25334-006 029-25334-008 029-25334-009 029-25334-010 029-25334-012 029-25334-013
* Value is de-rated by 15% NOTE: Isolators with 1 in. deflection (Pin 54 = 1) must be of the same class for the entire unit. IE. Must use C2P's at all locations on a se-
lected unit, or all CP's NOTES: 1. All dimensions are in inches per ANSI Y14. 2. Standard finish: H ousing - Powder coated.
Spring - Powder coated. (Color: see Table) Hardware - Zinc electroplate 3. Installation requires bolting or anchoring mount to support structure with a min. (2) 5/8 in. dia. bolt or (2) 1/2 in. dia. concrete anchors. 4. All springs are designed for 50% over-travel. 5. See next page for Installation Instructions.
150
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
ONE INCH DEFLECTION SPRING ISOLATORS INSTALLATION INSTRUCTIONS
UNITS SHIPPED ON OR AFTER JUNE 15, 2008
1. Read instructions in their entirety before beginning installation.
2. Isolators are shipped fully assembled and are to be positioned in accordance with the submittal drawings or as otherwise recommended.
3. Set isolators on floor, housekeeping pad or subbase, ensuring that all isolator centerlines match the equipment mounting holes. The VMC group recommends that the isolator base ("B") be installed on a level surface. Shim or grout as required, leveling all isolator bases to the same elevation (1/4-inch maximum difference can be tolerated).
4. Bolt or anchor all isolators to supporting structure utilizing base slotted holes ("C").
5. Place equipment on top of isolators making sure that mounting holes of the equipment line up with isolator positioning pin ("H").
6. The adjustment process can only begin after the equipment or machine is at its full operating weight.
7. Adjust each isolator in sequence by turning spring adjusting bolt ("D") one full counterclockwise turn at a time. Repeat this procedure on all isolators, one at a time.
8. Continue adjusting each isolator until a minimum of 1/4 in. clearance is achieved between the lower housing and upper housing. (See drawing below).
9. Fine adjust isolators to level equipment.
10. Installation is complete.
6
JOHNSON CONTROLS
151
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DURULENE ISOLATOR CROSS-REFERENCE
Units shipped on or after June 15, 2008
ATED RATED
PACITY DEFLECTION DURO (± 5)
LBS]
[IN]
JCI PART NUMBER
DW
35
0.4
30
45
0.4
40
70
0.4
50
120
0.4
60
RATED
RATED
PACITY DEFLECTION DURO (± 5)
LBS]
[IN]
JCI PART NUMBER
CD
135
0.5
30
170
0.5
40
240
0.5
50
380
0.5
60
HF
550
0.5
70
ATED RATED
PACITY DEFLECTION DURO (± 5)
LBS]
[IN]
JCI PART NUMBER
MOLDED DURULENE
n AD THRU TYP 2 PLACES
250
0.5
40
525
0.5
50
750
0.5
60
BT
100
0.5
70 029 25335 001
ATED
RATED
PACITY DEFLECTION DURO (± 5)
LBS]
[IN]
JCI PART NUMBER
AL L
500
0.5
250
0.5
40
50
029 25335 002
LD13760
000
0.5
60
000
0.5
70
029 25335 004
000
0.5
80
MOUNT
DIMENSION DATA (INCHES)
TYPE L RE IN INCHES, INTERPRET PER ANSI Y14. FOR INSTALLATION INSTRUCTIONS.
W
HF
AL
AD
BT
WEATHER RESISTANT DURULENE COMPOUND AS STANDARD. ALSO AVAILABLE IN OTHER MATERIALS
RUBBER, EXTREMREDH1IG-HWTERMPERATUR3E.S1IL3ICONE, HIGH-1D.A7M5PED SILICONE1, .N2IT5RILE, AND EPD2M.3. 8
LE CENTER TO CENTER SPACING.
OF MOUNT, PRIORRTDO2L-OWADRING. OPERA3TI.N8G8HEIGHT CALC2U.L3A8TED BY THE F1RE.7E5HEIGHT LESS3TH.0E0
N UNDER LOAD. ALL DIMENSIONS FOR REFERENCE ONLY
LECTROPLATED RD3-WR
5.50
3.38
2.88
4.13
DIMENSIONAL DATA [INCHES]
W
HFRD4-WALR AD 6.25 BT
4.63CD
2.75 DW 5.00
0.34 0.34 0.56 0.56
0.19 0.22 0.25 0.38
1.75
1.25
2.38
0.34
0.19 5/16-18 UNC X 3/4
1.25
2.38
1.75
3.00
0.34
0.22
3/8-16 UNC X 1
1.75
3.38
2.88* WEI4G.1H3 T RA0.5N6GE (0L.2B5) 1*/2W-13EUINGC HX 1T RANGE2.5(0KG)
VENDOR P/N
4.63
2.75
5.00
0.56
0.38
1/2-13 UNC X 1
3.00
Up to 825
Up to 374
RD-3 CHARCOAL-WR
W
CD
DW
5/16-18 UNC X 3/4
1.25
3/8-16 UNC X 1
1.75
1/2-13 UNC X 1
2.50
1/2-13 UNC X 1
3.00
COLOR CHARCOAL
YORK P/N 029-25335-001
8261688
375766
RD-4 BRICK RED-WR
BRICK RED
029-25335-002
16894000
7671814
RD-4 CHARCOAL-WR
CHARCOAL
029-25335-004
* Value is de-rated by 25%
NOTES: 1. All dimensions are in inches per ANSI Y14. 2. See next page for Installation Instructions. 3. Mount molded in weather resistant durulene compound as standard; also available in other materials such as natural rubber, extreme high
temperature silicone, high-damped silicone, nitrile and EDPM. 4. AL = Mounting hole center to center spacing. 5. HF = Free height of mount, prior to loading. Operating height calculated by the free height less the static deflection under load.
All dimensions for reference only. 6. Hardware - Zinc electroplate.
152
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
INSTALLATION OF DURULENE VIBRATION ISOLATORS
UNITS SHIPPED ON OR AFTER JUNE 15, 2008
1. Read instructions in their entirety before beginning installation.
2. Isolators are shipped fully assembled and are to be positioned in accordance with the submittal drawings or as otherwise recommended.
3. Set isolators on floor, housekeeping pad, or subbase, ensuring that all isolator centerlines match the equipment mounting holes. The VMC group recommends that the isolator base ("A") be installed on a level surface. Shim or grout as required, leveling all isolator bases to the same elevation (1/32-inch maximum difference can be tolerated).
("B")
4. Bolt or anchor all isolators to supporting structure utilizing base thru holes ("B").
5. Remove top bolt and top washer. Place equipment on top of isolators so that mounting holes in equipment or base line up with threaded hole ("C").
6. Reinstall top bolt and washer and tighten down. 7. Installation is complete.
TOP BOLT TOP WASHER
D
D
("C")
6
("B")
CL
CL
("A")
SECTION D-D
LD13762B
JOHNSON CONTROLS
153
SECTION 6 - TECHNICAL DATA
SEISMIC ISOLATOR CROSS-REFERENCE
Units shipped on or after June 15, 2008
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Y2RS
5" 5/8" 2-3/4"
1-1/8" 2-3/4"
3/8" GAP
Ø3/4" TYP.(4)
12"
5/8-11UNC TYP. (4)
3/4" 7/8"
12-1/4" 14"
1/2" LIMIT
STOP &
NUT
8-3/8"
OPER.
HEIGHT
3-1/2"
3/8"
5"
LD13761A
NOTES:
1. ALL DIMENSIONS ARE IN INCHES, INTERPRET PER ANSI Y14.
* WEIGHT RANGE (L2.B)SHTAARN*DDWWARAEDRIEGFIZHNINITSCHR-:EHALOENCUGTSREINOG(PK-LPAGOT)WE.DER CVOEANTEDDO(CROPLO/NR:BLACK), SPRINGC-POOLWODRER COATED (COLORY:OSEREKT P/N
Up to 391
3. EQUIPMENT MUUpSTtoBE17B7OLTED OR WELDYE2DRTSOI-T2HDE-T4O6P0PLATE TO MEETGALRLEOWEANBLE SEISMIC RA0T2IN9G-2S5. 336-006
4. ALL SPRINGS ARE DESIGNED FOR 50% OVERLOAD CAPACITY WITH EXCEPTION OF THE 2D-3280N & 2D-2870
392604 5. REFER TO PAG1E782F7O4R INSTALLATIONYIN2SRTRSUI-C2TDIO-N7S1.0
DK BROWN
029-25336-008
605740
6. CONSULT FACTORY FOR CONCRETE INSTALLATION.
275336
Y2RSI-2D-870
RED
029-25336-009
7411020
337463
Y2RSI-2D-1200N
RED/BLACK
029-25336-010
10211437
464652
Y2RSI-2D-1690
PINK
029-25336-011
14382244
6531018
Y2RSI-2D-2640N
PINK/GRAY
029-25336-012
22452618
10191188
Y2RSI-2D-2870N PINK/GRAY/ORANGE 029-25336-013
26193740
11891696
Y2RSI-2D-3280N PINK/GRAY/DK BROWN 029-25336-014
* Value is de-rated by 15%
NOTES: 1. All dimensions are in inches, interpret per ANSI Y14. 2. Standard finish: housing-powder coated (color, black), spring-powder coated (color, see table above) hardware - zinc-electroplate. 3. Equipment must be bolted or welded to the top plate to meet allowable seismic ratings. 4. All springs are designed for 50% overload capacity with exception of the 2D-3280N and 2D-2870. 5. See next page for installation instructions. 6. Consult factory for concrete installation.
154
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
SEISMIC ISOLATOR INSTALLATION AND ADJUSTMENT
UNITS SHIPPED ON OR AFTER JUNE 15, 2008
1. Read instructions in their entirety before beginning installation.
2. Isolators are shipped fully assembled and are to be positioned in accordance with the submittal drawings or as otherwise recommended.
3. Set isolators on floor, housekeeping pad, or subbase, ensuring that all isolator centerlines match the equipment mounting holes. The VMC group recommends that the isolator base plates ("B") be installed on a level surface. Shim or grout as required, leveling all isolator base plates to the same elevation (1/4-inch maximum difference can be tolerated).
4. Bolt or anchor all isolators to supporting structure utilizing base plate thru holes ("C") or weld base plate to supporting structure with 3/8 fillet weld 2 in. long @ 4 in. on center around entire base plate or as engineered for specific load and or field conditions.
5. Isolators are shipped to the job site with (2) removable spacer shims ("E") between the top plate and the housing. These shims must be in place when the equipment is positioned over the isolators.
6. With all shims ("E") in place, position equipment on top of plate ("A") of isolator. Bolt equipment securely to top plate of isolator using a minimum
of (2) 5/8 UNC A325 grade 5 SAE bolts or weld equipment or bracket to the top plate ("A") of isolator with a minimum of 3/8 fillet welds 2 in. long @ 3 in. on center for a minimum total weld of 10 in. (All sides of equipment or bracket resting on top plate ("A") must be welded).
7. The adjustment process can only begin after the equipment or machine is at its full operating weight.
8. Back off each of the (4) limit stop lock nuts ("F") on isolators 1/2 in.
9. Adjust each isolator in sequence by turning spring adjusting nuts ("G") one full clockwise turn at a time. Repeat this procedure on all isolators, one at a time. Check the limit stop lock nuts ("F") periodically to ensure that clearance between the washer and rubber grommet is maintained. Stop adjustment of isolator only when the top plate ("A") has risen just above the shim ("E").
6
10. Remove all spacer shims ("E").
11. Fine adjust isolators to level equipment.
12. Adjust all limit stop lock nuts ("F") per isolator, maintaining 1/4 in. to 3/8 in. gap. The limit stop nuts must be kept at this gap to ensure uniform bolt loading during uplift (as the case when equipment is drained).
13. Installation is complete.
("A")
("E") CL
("G")
("E")
GROMMET
("A")
CL
1/4 - 3/8 GAP
WASHER ("F")
("F")
("C") ("B")
("C")
EQUIPMENT ("E")
LD13763B
JOHNSON CONTROLS
155
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
ISOLATOR INFORMATION FOR UNITS SHIPPED BEFORE JUNE 15, 2008
SLRS SEISMIC ISOLATOR SPECIFICATIONS
UNITS SHIPPED BEFORE JUNE 15, 2008
"D" T"Da"pT-ap4-H4oHleolsesuunnlelessss
otherowthiesrewirseeqrueequsetestded.
EE
Vertical Limit Stops-Out of
EE
EE
OVf eCrntoicnoataOlrccLmptoimeDanriautlttrSaiionotncogpptNsedo-Orruamurttaiilonng
EE
Rubber SRnuubbbbinegr ColSlarnubbing Collar
H MBD -Max MBDolBt - Max Bolt DiaDmiaemteetrer
TT
HHCCWW WW
HHCCLL LL
AAddjujusstmtmenet nBtolt Bolt
LLoowweerr EnclEosnecdloSsteeedl
RResetrsatirnaininging HSotueseinlg
NuNtut
Housing
InANAteIccenroonoPtuueapaslsrrtndNiteciaecnaloalepPl raednNPmineaotoodnurew-pnNcSmPeotaoskloasdnnivdie-datesbid-rokdNeePiindniefawr.tNomdoeeepmopclouaordopennservintetdsbieeoneadnerP.eiaf d-
LD10509
PIN 54 = S
*WEIGHT RANGE (LB) *WEIGHT RANGE (KG)
VENDOR P/N
COLOR
YORK P/N
Up to 358 358442 443581 582782 7831037 10381496 14972057 20582618 26193179
Up to 162 162201 201264 264335 335471 471679 679933 9331188 11881442
SLRS-2-C2-420 SLRS-2-C2-520 SLRS-2-C2-660 SLRS-2-C2-920 SLRS-2-C2-1220 SLRS-2-C2-1760 SLRS-2-C2-2420 SLRS-2-C2-3080 SLRS-2-C2-3740
Red White Black Blue Green Gray Silver Gray w/ Red Silver w/ Red
029-24585-006 029-24585-007 029-24585-008 029-24585-009 029-24585-010 029-24585-011 029-24585-012 029-24585-013 029-24585-014
* Value is de-rated by 15% Notes: Illustration above shows a SLRS-4-C2 (4 Springs). SLRS-8-2 and C2 have one spring, and SLRS-2-C2 has two springs.
SLRS-6-C2 has six springs and SLRS-9-C2 has nine springs.
156
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
SLRS SEISMIC ISOLATOR INSTALLATION AND ADJUSTMENT
UNITS SHIPPED BEFORE JUNE 15, 2008
To Install and Adjust Mounts 1. Supports for mountings must be leveled to installation's acceptable tolerances.
2. Mountings not subjected to seismic or wind forces do not require bolting to supports.
3. Mountings subjected to seismic or wind forces must be bolted or welded in position.
4. If mountings are welded in position, remove lower friction pad before welding.
5. Set mountings with top channels held in place by the lower restraining nuts and limit stops.
6. Place equipment on mountings and secure by bolting or welding.
7. Hold lower restraining nut in place and turn vertical limit stop bolt counter-clockwise until there is
a 1/8 in. gap between the bolt head and the steel washer.
8. Turn adjustment bolt 8 turns on each mount.
9. Take one additional complete turn on each adjustment bolt in sequence until the top plate lifts off of the lower restraining nuts. Take no additional turns on that mount. Continue with equal turns on the other mounts until the top plates lift off of the lower restraining nuts of all mounts.
10. Hold the limit stop bolt in place and turn the lower restraining nut clockwise and tighten it against the stanchion. Repeat the same procedure on all mounts.
11. Top plate should remain at a fixed elevation, plus or minus 1/8 in.
"D" Tap - 4 Holes unless otherwise requested
Vertical Limit Stops-Out of contact during normal operation
Rubber Snubbing Collar
MBD -Max Bolt Diameter
LIMIT STOP BOLT
LOWER RESTRAINING BOLTS
1/4"
6
1/8"
Adjustment Bolt
Lower Restraining Nut
Enclosed Steel Housing
Internal Neoprene Acoustical
Pad
Non-Skid Neoprene PadPad can be removed if mounts are welded into position.
SHIPPED & INSTALLED
AFTER ADJUSTMENT
LD10568
JOHNSON CONTROLS
157
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
ND-X NEOPRENE ISOLATOR SPECIFICATIONS
UNITS SHIPPED BEFORE JUNE 15, 2008
"C"CS"SC"ACPaSpCSREcrWew
D SBccootoevrtcSBreteoootoelvrsmteeePtiolrodelmPaNndtl.taoeetNtoceopeo-pp-orrrTorepTeesorovveinpeopennne&net.&t
"MBD" MAXIUM
"MBOBLDT"DMIAaMxE.TBEoRlt Dia.
HH
WW
TT
BBCC LL
LD10569
SIZE ND-C ND-D ND-DS
ND-C ND-D ND-DS
D 2 9/16 3 3/8 3 3/8
65.1 85.7 85.7
H 2 3/4 2 3/4 2 3/4
69.9 69.9 69.9
L 5 1/2 6 1/4 6 1/4
139.7 158.8 158.8
ENGLISH T 1/4
5/16 5/16
SI 6.4 7.9 7.9
W 2 5/16
4 4
58.7 101.6 101.6
**WEIGHT RANGE (LB) Up to 751 7511651 16513226
** Value is de-rated by 15%
PIN 54 = N
**WEIGHT RANGE (KG)
COLOR
Up to 341 341749 7491463
ND-C ND-D ND-E
BC 4 1/8
5 5
101.9 127.0 127.0
CS 1/2-13x1" 1/2-13x1" 1/2-13x1"
1/2-13x1" 1/2-13x1" 1/2-13x1"
MBD 1/2" 1/2" 1/2"
13 13 13
YORK P/N Yellow Yellow Yellow
YORK P/N 029-24584-001 029-24584-002 029-24584-003
Installation of Neoprene Mounts
It is not necessary to bolt the mountings to a concrete pad in most cases. Mountings should always be bolted to the chiller rails. When mountings and the chiller are
installed on steel framing above the ground, the mountings should be bolted to the steel framework. Lower the chiller on to the mountings evenly to avoid placing excessive weight on individual isolators.
158
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
CIP 1" DEFLECTION RESTRAINED MOUNTING SPECIFICATIONS
UNITS SHIPPED BEFORE JUNE 15, 2008
LD10576
PIN 54 = 1 (SEE NOTE BELOW)
FOR UNITS WITH ALL LOAD POINTS LESS THAN 1404 LB (637 KG)
*WEIGHT RANGE (LB)
*WEIGHT RANGE (KG)
VENDOR P/N
COLOR
239384 384639 639851 8511064 10641404
Up to 851 8511149 11491489 14891786 17862028 20282254 23542936 * Value is de-rated by 15%
108174
CIP-B-450
Red
174290
CIP-B-750
White
290386
CIP-B-1000
Blue
386483
CIP-B-1250
Gray
483637
CIP-B-1650
Black
FOR UNITS WITH ANY LOAD POINT ABOVE 1404 LB (637 KG)
Up to 386
CIP-C-1000
Black
386521
CIP-C-1350
Yellow
521675
CIP-C-1750
Black w/ Red
675810
CIP-C-2100
Yellow w/ Red
810920
CIP-C-2385
Yellow w/ Green
9201022
CIP-C-2650
Red w/ Red
10221332
CIP-C-2935
Red w/ Green
JOHNSON CONTROLS
YORK P/N
6
029-24583-002 029-24583-003 029-24583-004 029-24583-005 029-24583-006
029-24583-007 029-24583-008 029-24583-009 029-24583-010 029-24583-011 029-24583-012 029-24583-013
159
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
INSTALLATION OF 1" DEFLECTION MOUNTS
IllustrUatNioITnSsShHowIPsPsEiDngBlEeFsOpRrinEgJUCNIPE-B15o,r2C00IP8-C mount.
EQUIPMENT BASE
A
Dowel Pin is 3/8" dia. for CIP-A & 1/2" thereafter
FERROUS HOUSING
SIDE ACCESS INTERNAL ADJUSTMENT BOLT Turn clockwise to load spring and maintain Free & Operating Height.
NON-SKID NEOPRENE ACOUSTICAL ISOLATION PAD
L
(Bolting to floor is not necessary for
indoor applications)
Mounting may be operated 1/2" above Free & Operating Height.
NOTECIP Mounts are not to be used in seismic or wind load applications.
FREE & OPERATING HEIGHT
T W
Slot Width - SW
SBC HCL
MAX BOLT DIA. - MBD
HCW
All springs have additional travel to solid equal to 50%
of the rated deflection.
BASE PLATE DIMENSIONS
TYPE CIP DIMENSIONS (inches)
Size
CIP-B CIP-C
Free Min A L T W SW HCL HCW MBD SBC Ht. Ht.
53/4 8 1/4 1/2 2 3/4 7/16 61/2 11/2 3/8 7 1/4 61/8 51/4 65/8 8 7/8 9/16 3 1/2 7/16 71/4 13/4 3/8 7 7/8 63/4 63/4
Casting dimensions may vary ±1/8"
LD10577
1. Floor or steel frame should be level and smooth.
2. For pad installations, isolators do not normally require bolting. If necessary, anchor isolators to floor through bolt holes in the base plate. Isolators must be bolted to the substructure and the equipment must be bolted to the isolators when outdoor equipment is exposed to wind forces.
3. Lubricate the threads of adjusting bolt. Loosen the hold down bolts to allow for isolator adjustment.
4. Block the equipment 10 mm (1/4 in.) higher than the specified free height of the isolator. To use the isolator as blocking for the equipment, insert a 10 mm (1/4 in.) shim between the upper load plate and vertical uprights. Lower the equipment on the blocking or shimmed isolators.
5. Complete piping and fill equipment with water, refrigerant, etc.
6. Turn leveling bolt of first isolator four full revolutions and proceed to each mount in turn.
7. Continue turning leveling bolts until the equipment is fully supported by all mountings and the equipment is raised free of the spacer blocks or shims. Remove the blocks or shims.
8. Turn the leveling bolt of all mountings in either direction in order to level the installation.
9. Tighten the resilient washer and underside of channel cap plate.
10. Installation is now complete.
160
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
REFRIGERANT FLOW DIAGRAM
SECTION 6 - TECHNICAL DATA
OIL COOLER COIL
CONDENSOR COIL
S SMV
SMV
FLASH TANK
OIL
6
COMPRESSOR
SEPARATOR
RC2
EVAPORATOR
Low Pressure Liquid Medium Pressure Vapor
SMV Stopper Motor Valve
S
Solenoid Valve Relief Valve Ball Valve
Low Pressure Vapor High Pressure Liquid
High Pressure Vapor Oil
Angle Stop Valve Sight Glass Filter or Dryer
M3S - Air Entering Compressor R-1R3-42a2 - Refrigerant Circuit Number
Economizer (Added to some models)
LD10505
Figure 22 - REFRIGERANT FLOW DIAGRAM
JOHNSON CONTROLS
161
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
PROCESS AND INSTRUMENTATION DIAGRAM
SMV
FT
S SMV
Z
Z
OIL COOLER COIL
CONDENSOR COIL
ZT
AIR FLOW
DV HTC LTC
DV LPC
P
COMP
HTR
PS
T P DV DIF
M
OS P DV
HPC HPL DPF
T
EVAPORATOR
HTR
DV
T
CHT
LTC
FS
CHILLER WATER FLOW
T DV
SYSTEM COMPONENTS
SMV
STEPPER MOTOR VALVE
S
SOLENOID VALVE
BALL VALVE
RELIEF VALVE
STOP VALVE ANGLE, ACCESS
MAJOR COMPONENTS
COMP COMPRESSOR OS OIL SEPARATOR
FT FLASH TANK
M
MUFFLER
P PRESSURE SENSOR T TEMPERATURE SENSOR
REPLACEABLE CORE FILTER/DRYER SIGHT GLASS FS FLOW SWITCH (optional) PS PRESSURE SWITCH HTR ELECTRIC HEATER
PLUG
MICROPROCESSOR CONTROL FUNCTIONS
CHT DP
DPF DV HPL
CHILLED LIQUID THERMOSTAT DIFFERENTIAL PRESSURE CUTOUT DISCHARGE PRESSURE FAN CONTROL DISPLAY VALUE HIGH PRESSURE LOAD LIMITING
HTC LPC LTC
HIGH TEMPERATURE CUTOUT LOW PRESSURE CUTOUT LOW TEMPERATURE CUTOUT
HPC HIGH PRESSURE CUTOUT
HTR HEATER DIF DIFFERENTIAL
LD10589A
Figure 23 - PROCESS AND INSTRUMENTATION DIAGRAM 162
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
COMPONENT LOCATIONS
SECTION 6 - TECHNICAL DATA
KEYPAD/DISPLAY PANEL DOOR
CHILLER & DISPLAY ELECTRICAL PANEL
FANS
CONDENSER COIL
6
MUFFLERS
Figure 24 - COMPONENT LOCATIONS
JOHNSON CONTROLS
FILTER DRIER
COMPRESSOR
LD13121
163
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD10578
Figure 25 - CONTROL AND VSD CABINET COMPONENTS 164
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
MICROGATEWAY (OPTIONAL)
CHILLER CONTROL
BOARD
RELAY BOARD #1
6
OPTIONAL
CIRCUIT BREAKER
RELAY BOARD #2
(Standard Unit will have terminal blocks.Input
power to the chiller will be connected here (see
Figures.-31 and 32)).
LD10579
Figure 26 - CHILLER CONTROL BOARD, RELAY BOARDS, MICROGATEWAY, AND OPTIONAL CIRCUIT BREAKER
JOHNSON CONTROLS
165
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
MICROGATEWAY (OPTIONAL)
CHILLER CONTROL
BOARD
RELAY BOARD #1
CLOCK JUMPER (CLK) JP2
JP4, JP5, & JP6
mA
·
·
·
V
JUMPER POSITION
RELAY BOARD #2 RS-232/485 JUMPER
LD10580
Figure 27 - CHILLER CONTROL BOARD, RELAY BOARDS, AND MICROGATEWAY, 2 COMPRESSOR
166
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
RELAY BOARD #3
CHILLER CONTROL
BOARD
RELAY BOARD #1
6
MICROGATEWAY (OPTIONAL)
JP4, JP5, & JP6
mA
·
·
·
V
JUMPER POSITION
RELAY BOARD #2
50069
Figure 28 - CHILLER CONTROL BOARD, RELAY BOARDS, AND MICROGATEWAY, 3 COMPRESSOR
JOHNSON CONTROLS
167
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
VSD LOGIC BOARD
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SCR TRIGGER BOARD
Figure 29 - VSD LOGIC BOARD 168
LD10582
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
YORK
MADE IN THE USA
R86 (COMPR 4 Over Load Adjust)
R42
(COMPR 3
6
Over Load Adjust)
R64 (COMPR 2 Over Load Adjust)
R19 (COMPR 1 Over Load Adjust)
Figure 30 - VSD LOGIC BOARD (ORIGINAL - OBSOLETE), P/N 031-02477-000
JOHNSON CONTROLS
LD10590
169
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
MADE IN THE USA
Figure 31 - VSD LOGIC BOARD (NEW), P/N 031-02507-XXX 170
R86 (COMPR 4 Over Load Adjust)
R42 (COMPR 3 Over Load Adjust)
R64 (COMPR 2 Over Load Adjust)
R19 (COMPR 1 Over Load Adjust)
LD13119
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
OPTIONAL CIRCUIT BREAKER
(Standard Unit will have terminal blocks)
11T TRANSFORMER
CONTROL AND VSD CABINET COOLING COIL
FLASH TANK FEED AND DRAIN VALVE
CONTROLLER
10CR FAN PUMP CONTROL RELAY
CONTROL AND VSD CABINET COOLING FAN
6
10T TRANSFORMER
INCOMING POWER GROUND LUGS
1TB
TERMINAL BLOCK
INPUT POWER TO THE CHILLER CONNECTS
HERE
4-9FU FUSES and 14-16FU FUSES
17-21 FU FUSES
LD10583
TRANSIENT SUPPRESSOR
1L AC LINE INDUCTOR
Figure 32 - POWER COMPONENTS, 2 COMPRESSOR
JOHNSON CONTROLS
171
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
OPTIONAL CIRCUIT BREAKER
(Standard Unit will have terminal blocks)
11T TRANSFORMER
FLASH TANK DRAIN and FEED
VALVE CONTROLLER
(VG1)
CONTROL AND VSD CABINET COOLING COIL
CONTROL AND VSD CABINET COOLING FANS
1TB TERMINAL
BLOCK (Hidden from
view)
10T TRANSFORMER
FUSES FU4, 5, 6, 7, 8 ,9 14, 15, 16, 22, 23, 24
INPUT POWER TO THE CHILLER CONNECTS
HERE
50076
TRANSIENT SUPPRESSOR
BOARD 11, 12, 13 FU
Figure 33 - POWER COMPONENTS, 3 COMPRESSOR 172
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
FAN CONTACTORS 4CR-9CR
6
LD10584
3T TRANSFORMER (24VAC to SCR Gate Driver Board and VSD Logic Board)
Figure 34 - FAN CONTACTORS AND 3T TRANSFORMER, 2 COMPRESSOR
JOHNSON CONTROLS
173
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
FAN CONTACTORS (4, 5, 6, 7, 8, 9 11, 12, 13CR)
3T TRANSFORMER
50072
Figure 35 - FAN CONTACTORS, 3 COMPRESSOR 174
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
17-21 FU FUSES (17 FU: 2T, 18 FU: VSD Logic /
SCR Trigger Board / Pump Contactor,
19 FU: 10T and 11T, 20 FU: Relay Board #1, 21 FU: Relay Board #2
COOLING FAN
COOLING FAN
TRANSIENT
SUPPRESSOR BOARD
(3-Phase Input)
4-9 FU FUSES and 14-16 FU FUSES (4-6 FU: TB-1-3 SCR
Trigger Board, 7-9 FU: Sys. 1 Fans, 14-16 FU: Sys. 2 Fans)
4-6 CT
CURRENT
TRANSFORMERS
3-8 RES RESISTORS
10 CR FAN PUMP CONTROL RELAY
(Motor Output RC "DV/DT" Network)
6
1L AC LINE INDUCTOR
Figure 36 - VSD COMPONENTS
JOHNSON CONTROLS
3-8 RES RESISTORS (Motor Output RC "DV/DT Network)
LD10585
CAPACITORS C15-C17 (Motor Output RC "DV/DT"
Network)
175
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
COOLING FAN
COMPONENT LOCATIONS (CONT'D)
3T
(VSD LOGIC and
CABINET COOLING
COIL
FAN CONTACTORS
4CR-9CR
SCR TRIGGER BOARD 24 VAC SUPPLY TRANSFORMER)
CURRENT TRANSFORMERS
BUS ISOLATOR
BOARD (FEEDS VSD LOGIC BOARD)
SCR TRIGGER BOARD
SNUBBER CAPS
(C7-C12)
IGBT GATE DRIVER BOARDS
IGBT MODULES
1L LINE INDUCTOR
BUS FILTER CAPACITORS (Behind Panel)
HEATSINK (Water Cooled)
Figure 37 - VSD COMPONENTS, 2 COMPRESSOR
176
1RES AND 2RES BUS CAPACITOR BANK EQUALIZING/
BLEEDER RESISTORS
SCR/DIODE MODULES
LD10586
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
COOLING FAN
CABINET COOLING
COIL
FAN CONTACTORS 4CR-9CR AND 11CR-13 CR)
DC BUS
3T
VOLTAGE
(VSD LOGIC AND
ISOLATION SCR TRIGGER BOARD
BOARD
24 VAC SUPPLY
TRANSFORMER)
CURRENT TRANSFORMERS
SNUBBER CAPS
(C7-C12)
SCR TRIGGER BOARD
IBGT GATE
DRIVER
BOARDS
6
BUS FILTER CAPACITORS (Behind Panel)
HEATSINK (Water Cooled)
1RES AND 2RES BUS CAPACITOR BANK EQUALIZING/
BLEEDER RESISTORS
Figure 38 - VSD COMPONENTS, 3 COMPRESSOR
JOHNSON CONTROLS
IBGT MODULES
SCR/DIODE MODULES
50085
177
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
COOLING FANS
CABINET COOLING
COIL
CURRENT TRANSFORMERS
C13-C17
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
FAN RELAYS
TRANSIENT SUPPRESSOR
BOARD W/ 11FU, 12FU, AND 13 FU FUSES (3 Phase Input)
10CR FAN PUMP
CONTROL RELAY
1L LINE INDUCTOR
Figure 39 - VSD COMPONENTS, 2 COMPRESSOR 178
LD10587
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
TRANSIENT SUPPRESSOR
BOARD W/ 11FU, 12FU, AND 13 FU FUSES (3 Phase Input)
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
CABINET COOLING
COIL
COOLING FAN
CURRENT TRANSFORMERS (C14, C13, 12, 9, 8, 7, 6, 5, 4)
FAN RELAYS
6
2
2 22 2 22
1
1 111 11
LINE INDUCTORS
SNUBBER CAPS 1 c24, 25, 26, 21
22, 23, 18, 19, 20
Figure 40 - VSD COMPONENTS, 3 COMPRESSOR
JOHNSON CONTROLS
50073
SNUBBER RESISTORS 2 res15, 16, 17, 18, 19, 20, 9, 10, 11, 12, 13, 14, 3, 4,
5, 6, 7, 8
179
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
The line inductor will reach operating temperatures of over 300°F. Do not open panel doors during operation. Assure the inductor is cool whenever working near the inductor with power OFF.
LD10588
Figure 41 - INVERTER POWER COMPONENTS, 2 COMPRESSOR 180
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
SCR TRIGGER BOARD
6
50077
Figure 42 - INVERTER POWER COMPONENTS, 3 COMPRESSOR
JOHNSON CONTROLS
181
SECTION 6 - TECHNICAL DATA
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
COMPONENT LOCATIONS (CONT'D)
IGBT's
IGBT's
IGBT's
WATER COOLED HEAT SINK
SCR/DIODE MODULES
SCR/DIODE MODULE
1RES and 2RES BUS CAPACITORS BANK EQUALIZING/BLEEDER RESISTORS
LD10591
LAMINATED BUS
STRUCTURE
IGBT GATE DRIVER
BOARD #2
IGBT GATE DRIVER
BOARD #1
IGBT's Figure 43 - INVERTER POWER COMPONENTS 182
IGBT's
LD10592
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
COMPONENT LOCATIONS (CONT'D)
LAMINATED BUS STRUCTURE
IGBT GATE DRIVER BOARD
BUS FILTER CAPACITORS
WATER COOLED HEAT SINK
IGBT
SCR/DIODE MODULES
IGBT's
IGBT's
LD10593
6
SCR/DIODE MODULES
1RES and 2RES BUS CAPACITORS BANK EQUALIZING/BLEEDER RESISTORS
FIGURE 43 - INVERTER POWER COMPONENTS (CONT'D)
JOHNSON CONTROLS
LD10594
183
SECTION 6 - TECHNICAL DATA
GLYCOL SYSTEM COMPONENTS
REAR OF
VSD PANEL
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SEE DETAIL "B"
SEE DETAIL "C"
DETAIL "A"
TO GLYCOL PUMP (SEE DETAIL "A")
DETAIL "B" TYPICAL 4 PLACES
GLYCOL PUMP (SEE DETAIL "A")
Figure 44 - GLYCOL PUMP AND FILL TUBE LOCATIONS 184
DETAIL "C"
LD13122A
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 6 - TECHNICAL DATA
GLYCOL SYSTEM COMPONENTS (CONT'D)
GLYCOL FILL TUBE
6
Figure 45 - GLYCOL PIPING AND FILL TUBE LOCATION
JOHNSON CONTROLS
LD10597
185
SECTION 6 - TECHNICAL DATA
Figure 46 - COMPRESSOR COMPONENTS 186
SUCTION STRAINER
STATOR KEY
ROTOR
COMPRESSOR COMPONENTS
STATOR MOTOR
TERMINALS
OIL FILTER
MOTOR/ROTOR HOUSING
MALE ROTOR
BEARINGS
DISCHARGE HOUSING
FEMALE ROTOR · SHIMS
BEARINGS SHIMS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD10596
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
CHILLER ELECTRONIC COMPONENTS Keypad An operator keypad allows complete control of the system from a central location. The keypad offers a multitude of command keys on the left and right side of the keypad to access displays, program setpoints, history data, and initiate system commands. Most keys have multiple displays that can be accessed by repetitively pressing the key or by pressing the ,,, and (ARROW) keys. The keypad utilizes an overlay to convert the keypad to various languages.
LD10605
The keypad also contains keys in the center section for data entry in the various program modes. These keys are listed below:
· 0-9 Keys NUMERIC KEYPAD · · PERIOD/DECIMAL · +/- PLUS/MINUS · ENTER · X CANCEL · UP ARROW · DOWN ARROW · LEFT ARROW · RIGHT ARROW The numeric keys allow keying numeric values into memory. The · (PERIOD/DECIMAL) key allows keying a decimal point into numeric values.
SECTION 6 - TECHNICAL DATA
The +/- (PLUS/MINUS) key allows making numeric values negative.
The (ENTER) key stores program changes into memory.
The X (CANCEL) key is used to cancel the data entry operation and returns the programmed value to the original value, before any programming changes were made, when an error is made.
The (UP ARROW) and (DOWN ARROW) keys allow scrolling backward () and forward () through items to be programmed under keys such as the PROGRAM or OPTIONS key.
The (UP ARROW) and (DOWN ARROW) keys also allow scrolling forward () or backwards () through data display keys that have multiple displays under keys such as UNIT DATA, SYSTEM DATA, HISTORY, PROGRAM, OPTIONS, etc. The arrow keys can be used instead of repeatedly pressing the data
key to see the multiple displays under a key. Once the 6
(ARROW) keys are pressed and used for scrolling, pressing the original data key will return to the first display message displayed under the data (UNIT DATA, SYSTEM DATA, etc.) keys.
The (LEFT and RIGHT ARROW) keys allow scrolling between non-numeric program choices under the OPTION, DATE/TIME, and SCHEDULE keys.
The (LEFT ARROW) key allows programming the default value when programming numeric values. For changing numeric values, the (RIGHT ARROW) key has no function.
The (ARROW) keys also allow scrolling sideways between the same displays on different systems. For example, Pressing the (RIGHT ARROW) key while viewing the system #1 suction pressure moves the display to system #2 suction pressure.
Pressing the (LEFT ARROW) key moves the opposite direction. The arrow keys also allow fast scrolling through data under keys such as HISTORY by enabling the operator to move between subgroups of data such as Unit, System, and VSD data.
JOHNSON CONTROLS
187
SECTION 6 - TECHNICAL DATA
Keypad Data Entry Mode For numeric programmable items, the data entry mode is entered by pressing any of the number keys, the decimal point key, or the +/- key. When the data entry mode is entered, the data from the key press will be entered and the cursor will appear under the position where the data is being entered.
For non-numeric programmable items, data entry mode is entered by pressing the or (ARROW) keys. When the data entry mode is entered, the cursor will appear under the first position of the non-numeric string. The programmable choice may be changed by pressing the or (ARROW) keys.
To exit the data entry mode and store the programmed value, the (ENTER) key must be pressed. When the (ENTER) key is pressed, the cursor will disappear.
The data entry mode may also be exited by pressing the X (CANCEL) key. The programmed data will be returned to its original value when the X (CANCEL) key is pressed.
When the data entry mode is exited, the cursor will disappear. If any other key is pressed while in the Data Entry Mode, the following display will appear for 2 seconds indicating the user must choose between accepting or canceling the change:
XXXXXXXXXXX PRESS TO ACCEPT VALUE OR
X TO CANCEL DATA ENTRY
If the (ENTER) key was pressed from the data entry mode and the numeric value entered was out of range, the following message will appear for 2 seconds followed by the original data display.
XXXXXXXXXXX OUT OF RANGE TRY AGAIN! XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
Display The 80 character (2 lines of 40 characters per line) display is a Liquid Crystal Display (LCD) used for displaying unit parameters, system parameters, and operator messages. The display has an LED backlight background for night viewing and is viewable in direct sunlight.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DISPLAY
KEYPAD
UNIT SWITCH
Chiller Control Board
LD10605
RTC
LD10606
The Chiller Control Board is the controller and master decision maker in the control panel. The onboard microprocessor control is capable of controlling up to 4 compressors. System inputs from pressure transducers and temperature sensors are connected directly to the Chiller Control Board. The Chiller Control Board circuitry multiplexes all of the analog inputs, digitizes them, and scans the inputs to keep a constant watch on chiller operating conditions. Based on this information, the Chiller Control Board issues
188
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
commands to the Relay Output Board(s), Drain/Feed Valve Controller, and VSD Logic Board to activate and de-activate contactors, solenoids, control valves, set compressor speeds, etc., for chilled liquid and safety control. Keypad commands are acted upon by the Chiller Control Board microprocessor to change setpoints, cutouts, scheduling, operating requirements, and to provide displays.
The Chiller Control Board contains a Real Time Clock integrated circuit chip with an internal battery backup of 8K x 8 bit RAM. The purpose of the battery backed RAM is to assure any programmed values (setpoints, clock, cutouts, history data etc.) are not lost during a power failure, regardless of the time involved in a power outage or shutdown period.
The Chiller Control (Microprocessor) Board contains an onboard power supply, which provides 5 VDC regulated to sensors, transducers, display, and other circuit boards. The supply also provides +12 VDC to the Relay Output Boards and the +34 VDC to the level sensors.
The Chiller Control Board is capable of directly receiving analog inputs from temperature sensors and transducers. An analog to digital converter (A/D) with an onboard 4 channel multiplexer (MUX) allows up to 48 analog inputs to be read. The A/D Converter converts the analog signals to digital signals, which can be read by the onboard microprocessor. On a 2 system chiller, approximately half of these inputs are utilized.
Three integrated circuits on the microprocessor can be configured for digital inputs or outputs (Digital I/O). As inputs, they can read digital (2 level, on/off) inputs like keypad keys, unit switch, high pressure cut-out, flow switch, etc. As outputs they are used for controls like turning on fans, controlling compressor heaters, controlling chiller valves, or other devices requiring ON/OFF control. Up to 72 Digital I/O will be utilized to control the chiller.
The Chiller Control (Microprocessor) Board contains a dual UART (Universal Asynchronous Receiver Transmitter) for RS-485 and RS-232 communications. UART1 is configured for RCC and ISN communications on the external chiller RS-485 port. Data is sent and received at 4800 baud with 1 start bit, 8 data bits, odd parity, and 1 stop bit. The port is shared with the RS-232 interface and at start-up will be initialized to RS-485 communications. UART2 is configured for
SECTION 6 - TECHNICAL DATA
VSD communications over an internal chiller RS-485 port located within the Control/Power cabinet. UART2 has a higher priority interrupt than UART1. The data is sent and received at a rate of 9600 baud and serves only as the communications between the Chiller Control Board and the VSD Logic Board. Both of these boards are located within the control/power panel.
On power-up, the Chiller Control Board will attempt to initialize communications with the VSD Logic Board. The Chiller Control Board will request the number of compressors select and VSD software version. If for some reason the information is not provided, the request will be made over and over again until it is received. Once the data has been received, the Chiller Control Board will not ask for it again. If the communications is not established, a VSD Loss Of Comms fault message will appear on the STATUS display.
Two 8 channel, 8 bit Digital to Analog Converters
(D/A Converter) on the Chiller Control Board sup-
ply the Feed and Drain Valve Controller signals to al-
low the controller to position the Flash Tank Feed and
Drain Valves. The Feed Valve controls the refrigerant
level in the flash tank while the Drain Valves controls superheat. The control voltage to the Feed and Drain
6
Valve Controller has a range of 0 VDC to 10.28 VDC.
Relay Output Boards
LD10607
Two or three Relay Output Boards are required to operate the chiller. These boards convert 0 VDC to 12 VDC logic levels outputs from the Chiller Control Board to 115 VAC levels used by contactors, relays, solenoid valves, etc., to control system and chiller operation. The common side of all relays on the Relay Output Board is connected to +12 VDC.
JOHNSON CONTROLS
189
SECTION 6 - TECHNICAL DATA
The open collector outputs of the Chiller Control Board energize the DC relays on the Relay Output Board by pulling one side of the relay coil to ground. When not energized, both sides of the relay coils will be at +12 VDC potential.
VSD (Variable Speed Drive) The VSD is a liquid cooled, transistorized, PWM inverter packaged within the Control/Power cabinet. The inverter is composed of four major sections:
· AC to DC rectifier section with precharge circuit. · DC link filter section. · Three phase DC to AC inverter section. · Output RC suppression network.
AC to DC Rectifier The AC to DC Rectifier circuit utilizes a semi-converter made of three SCR/diode modules in a three phase bridge configuration. Each SCR/Diode module contains 1 SCR and 1 diode. The modules are mounted on a liquid cooled heatsink. This circuit rectifies the incoming AC voltage to unfiltered DC, which is filtered by the DC Link Filter.
LD10608
A semi-converter (combination SCR/Diode) configuration allows utilizing a separate pre-charge circuit to limit the current in the DC link filter capacitors when the VSD is first switched on. This is accomplished by slowly turning on the SCR's to initially charge the DC Bus. Once charged, the SCR's remain fully gated on during normal operation. This configuration also provides a fast disconnect from main power when the drive is switched off. When the drive is called to run (leaving chilled liquid temperature is more than the Setpoint plus CR), the SCR/Diode modules are turned on by the SCR trigger Board, allowing the DC link filter capacitors to slowly precharge for a period of 20 seconds.
190
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
The AC incoming line voltage is rectified by the full three phase semi-converter bridge, made up of three SCR/Diode modules, which provides pulsating DC to the DC link Filter in the VSD. SCR Trigger Board The SCR Trigger Board controls the firing (gating) sequence of the Bridge SCR's.
LD10609
Command for the SCR Trigger Board to begin firing the SCR's is initiated by the VSD Logic Board. The SCR Trigger Board also monitors the three phase input voltage to detect the loss of an incoming phase. DC Link Filter The DC Link Filter consists of a bank of electrolytic filter capacitors. The capacitors smooth (filter) ripple voltage resulting from the AC to DC rectification and provides an energy reservoir for the DC to AC inverter. The capacitor filter bank is made up of 2 banks of parallel-connected capacitors wired in series. Series banks of capacitors allow using smaller sized capacitors with lower voltage ratings.
FILTER CAPACITORS
LD10610
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
The capacitor bank in conjunction with the 1L Line Inductor forms a low pass LC Filter and provides further smoothing (filters ripple) to the rectified DC. Equalizing/Bleeder resistors connected across the banks equalize the voltage between the top and bottom capacitors to avoid damaging the capacitors from over voltage. The Equalizing/Bleeder resistors also provide a path for discharge of the capacitors when the drive is switched off. This safely discharges the capacitors in approximately 5 minutes. Always be careful, a bleeder resistor could be open and the bus may be charged.
LD10611
EQUALIZING/BLEEDER RESISTORS
When servicing, always check the DC Bus Voltage across the top and bottom, banks of capacitors with a known functioning voltmeter correctly set to the proper scale before performing service on the inverter. DO NOT rely on the Bleeder Resistors to discharge the capacitor banks without checking for the purpose of safety. NEVER short out a capacitor bank to discharge it during servicing. If a bleeder resistor is open and a capacitor bank will not discharge, immediately contact Johnson Controls Product Technical Support.
1L Line Inductor
SECTION 6 - TECHNICAL DATA
1L LINE INDUCTOR
LD10612
The 5% impedance 1L Line Inductor has multiple
functions. 1L forms a low pass LC filter that filters the
pulsating DC from the AC to DC converter, to smooth
DC voltage. The inductance eliminates notches on the
incoming AC line. The inductance also helps protect
the SCR's from high voltage incoming line transients,
which could damage them. 1L slows down the rate of
rise of current if an internal short circuit occurs, reduc-
ing the potential damage caused by the short. 1L also reduces the input current total harmonic distortion.
6
DC to AC Inverter
The DC to AC Inverter section converts the rectified and filtered DC back to AC at the equivalent magnitude and frequency to run a compressor at a specific speed. Although a common DC Bus links the compressor drive outputs, each compressor has its own inverter output module. Each inverter output module consists of 6 IGBT's (3 modules) and an IGBT Gate Driver Board, which converts DC to a 3 - phase AC output. The IGBT's are mounted to the liquid cooled heatsink designed to take the heat away from the devices and remove it in the condenser. The IGBT Gate Driver Board provides gating pulses to turn the IGBT's ON and OFF.
JOHNSON CONTROLS
IGBT's
IGBT's
LD10613
191
SECTION 6 - TECHNICAL DATA
Laminated Bus Structure
The Laminated Bus Structure is a group of copper plates sandwiched together that connects the SCR/Diode Modules, Bus Filter Capacitors, and IGBT's. The purpose of the Laminated Bus Structure is to reduce the inductance that would be present in wiring or bus bars often used to connect high voltage components in VSD's. Removing inductance in the circuit reduces the voltage spike that occurs when the IGBT's turn off. These voltage spikes can potentially damage the IGBT's.
LAMINATED BUS STRUCTURE
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
RTC
LD10614
VSD Logic Board
The VSD Logic Board controls VSD functions/operations and communicates through a serial communications line with the Chiller Control Board. Safety and shutdown information stored in the RTC (Battery backed RAM) is reported back to the Chiller Control Board via the communications link. The VSD Logic Board converts the speed and run commands from the Chiller Control Board into the necessary voltage and frequency commands to operate the inverter section. The VSD Logic Board also controls the converter section of the VSD (AC to DC conversion) by controlling the pre-charge function.
The VSD Logic Board contains a second microprocessor for motor control, which generates the PWM signals that control the IGBT's in the inverter section of the VSD.
LD13120
Figure 47 - NEW BOARD P/N 031-02507-000 The VSD Logic Board contains an FPGA (Field Programmable Gate Array) which handles the hardware safeties and can shut down the VSD much faster than the software safeties, since they are not dependent upon running program loops in software. The VSD handles all VSD related safeties including high motor current, overload, DC Bus voltage faults, etc.
RTC
LD10615
Figure 48 - OBSOLETE BOARD P/N 031-02477-000
192
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Inputs to the VSD Logic Board are fed through an onboard multiplexer (MUX) before being sent to the A/D converter. These signals allow the VSD Logic Board to monitor DC Bus voltages, compressor motor currents, VSD internal ambient temperature, IGBT baseplate temperatures, and compressor overload settings.
The VSD Logic Board controls the glycol pump and the cabinet cooling fans. Details on the controls are provided in the VSD Operation and Controls on page 219.
Control Panel to VSD Communications
Communication between the VSD Logic Board and the Chiller Control Board is made via a three-wire RS485 opto-coupled data link. Communications between the two boards occurs at the rate of 9600 baud. UART2 of the dual UART located on the Chiller Control Board is dedicated to internal communications and has a higher priority interrupt than the external communications UART1. The Chiller Control Board will control VSD start/stop, selection of which compressors to run, and compressor speed. The VSD Logic Board will run the desired compressors at the speed requested by the Chiller Control Board. The VSD will report back to the Chiller Control Board, shutdown and safety information related to internal VSD operation and the compressor motors.
On power-up, the control panel will attempt to initialize communications with the VSD. The Chiller Control Board will request initialization data from the VSD Logic Board. The initialization data required is the number of compressors and the VSD software version. Once these data points have been received by the control panel, the unit has successfully initialized and will not request them again.
If the Chiller Control Board does not receive initialization data from the VSD Logic Board in 8 seconds or loses communications with the VSD for 8 seconds at any time, the chiller will fault on a communications failure. The Chiller Control Board will continue to send messages to the VSD Logic Board in an attempt to establish communications while the chiller is faulted.
SECTION 6 - TECHNICAL DATA
The VSD Logic Board will also monitor a communications loss. If the VSD Logic Board loses communications with the Chiller Microprocessor Board for 8 seconds at any time, the VSD will shut off all compressors and wait for valid comms from the Chiller Control Board.
Once communications is established, the Chiller Control Board will send a data packet on the data link once every second at 9600 baud. This data packet will include run, stop, and speed commands as well as request operating data from the VSD. Operating data returned by the VSD will include individual motor currents, motor %FLA's, output frequency, compressor motor temperature, and fault information related to internal VSD operating parameters such as DC Bus voltage, IGBT baseplate temperatures, VSD internal ambient, pre-charge relay status, power supply status, run relay status, motor overload, and supply single phase. The Chiller Control Board will poll the VSD Logic Board for information continuously while the chiller is running.
IGBT Gate Driver Boards
6
LD10613
The IGBT Gate Driver Boards provide the ON and OFF gating pulses to the IGBT's. The gating signals originate from the VSD Logic Board and are changed in level by the IGBT Gate Driver Board. The IGBT's in the inverter section of the VSD, change the DC Link voltage to a variable Voltage and Frequency output to the motor, to control the compressor motor speed. The IGBT Gate Driver Boards also provides VCE SAT detection (short circuit detection) to safely turn off the IGBT's during a short circuit condition. When a short circuit occurs, the voltage (VCE SAT) across the IGBT increases as a result of the high current. The IGBT Gate Driver Board is an integral part of the IGBT assembly for each compressor.
JOHNSON CONTROLS
193
SECTION 6 - TECHNICAL DATA
Current Transformers
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Flash Tank Feed and Drain Valve Controller
CURRENT TRANSFORMERS
LD10617
A current transformer on each phase sends current signals proportional to phase current to the VSD Logic Board. The output of each CT is buffered, scaled, and sent to RMS to DC converters. These signals are then sent to an A-D converter, scaled, and sent to the Chiller Control Board for current display and current limiting control.
The highest current is also compared to the setting of the Overload Adjustment Potentiometer on the VSD Logic Board for overload safety sensing.
DV/DT Output Suppression Network
DV/DT RESISTORS
LD10618
DV/DT CAPACITORS
The dV/dT Output Suppression Network limits the rate of rise of voltage and the peak voltage of the PWM pulses applied to the motor windings. This eliminates the possibility of causing a turn-to-turn short in the motor due to winding insulation breakdown. The suppression network is made up of a 3-phase RC network.
194
LD10619
The Flash Tank Feed and Drain Valve Controller is a microprocessor driven controller that operates the Feed and Drain Valves based on commands from the Chiller Control Board. The Feed and Drain Valves control the level of liquid in the flash tank and the superheat to the evaporator. The controller is a stand-alone valve control module in the Control/VSD panel. The flash tank liquid level is controlled by sequencing a stepper motor valve (Feed Valve) on the inlet of the flash tank. The controller opens and closes the Feed Valve to control the liquid level of the refrigerant in the flash tank based on commands from the Chiller Control Board. Superheat is controlled by sequencing a stepper motor valve (Drain Valve) on the outlet of the flash tank. The controller opens and closes the Drain Valve to control flow to the evaporator and ultimately superheat to the compressor based on commands from the Chiller Control Board.
Drain Valve superheat control is controlled by a PI control algorithm based on suction pressure and suction temperature in the Chiller Control Board software.
The control algorithms will attempt to control the level in the flash tank to approx 35% when the economizer is energized. If the level exceeds 87.5%, the system will fault. The normal 35% level may fluctuate appreciably when the economizer is off as the flash tank acts as nothing more than a reservoir as the Drain Valve controls superheat. The level will also vary when the economizer is first energized or a system transient occurs such as fan cycling, etc.
The controller is typically located in the back of the panel behind the power wiring terminal block/circuit breaker or on the wall of the panel on the left side of the cabinet.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DC Bus Voltage Isolation Board
LD10620
The DC Bus Isolation Board allows the VSD Logic Board to read the voltage on the DC BUS without exposing the VSD Logic Board to the high voltage. Instead, the DC Bus Isolation Board contains a resistor network that forms voltage dividers with resistors on the VSD Logic Board, which steps down the voltages so that scaled down voltages proportional to the full and 1/2 bus voltages can be safely fed to the VSD Logic Board. The DC Bus Isolation Board supplies 3 connections to the VSD Logic Board; plus bus, minus bus and half bus. Chiller Circuit Breaker
LD10623
An Optional Circuit Breaker may be supplied on the input of the system. The incoming power will be fed to the terminals on the circuit breaker. If the Circuit Breaker Option is not selected, incoming power will be fed to terminal blocks. The breaker also provides ground fault protection. 2 and 3 compressor chillers utilize one circuit breaker, while 4 compressor chillers utilize 2 breakers.
SECTION 6 - TECHNICAL DATA
CHILLER CONFIGURATION JUMPERS
There are a number of chiller configuration jumpers that are factory wired into wire harnesses or plugs. These jumpers typically never need to be reviewed unless in some unlikely situation, a chiller is incorrectly configured or a loose connection occurs.
Number of Compressors Configuration Jumper
Software packs (EPROM's) are common between
2, 3 and 4 compressor chillers. As a result, the VSD
Logic Board must be configured for the actual num-
ber of compressors. The chiller is configured for the
number compressors through the use of jumpers, fac-
tory plugged into the J1 plug on the VSD Logic Board.
This hard wiring configures the VSD Logic Board
for the number of compressors on the chiller, avoid-
ing mis-programming. The jumpers are only checked
at power-up. If no jumpers are sensed, or an invalid
combination is sensed and communicated to the Chill-
er Control Board, start-up of the unit will be inhibited
and an "INVALID NUMBER OF COMPRESSORS
SELECTED" warning message will be displayed in
the Status display.
6
Table 3 on page 195 shows the chiller number of compressors and the associated location of the jumpers to program the appropriate compressor configuration.
Table 3 - COMPRESSORS AND THE APPROPRIATE JUMPER POSITIONS
# OF COMPRESSORS
VSD LOGIC BOARD JUMPER POSITION
2
J1-10 to J1-9
3
J1-11 to J1-9
4
J1-12 to J1-9
JOHNSON CONTROLS
195
SECTION 6 - TECHNICAL DATA
VSD LOGIC TO CHILLER MICROPROCESSOR BOARD RS-485 COMMUNICATION CONFIGURATION JUMPERS
The Chiller Control Board and the VSD Logic Boards communicate over an RS-485 link. The communications link requires a matching address to be set up at both ends. The VSD Logic Board communications bus is configured through the use of jumpers, factory plugged into the J5 plug on the VSD Logic Board. The VSD Logic Board will only check the jumper positions once at power-up.
Table 4 on page 196 shows the VSD Logic BoardAddress configuration and the associated location of the jumpers. The jumpers will vary according to the number of VSD Logic Boards installed. All chillers utilize a single VSD Logic Board and will use VSD Logic Board Address 1.
Table 4 - VSD LOGIC BOARD ADDRESS JUMPER
VSD LOGIC BOARD'S ADDRESS
VSD LOGIC BOARD JUMPER POSITION
J5-1 to J5-2
1
and
J5-3 to J5-4
2
J5-3 to J5-4
3
J5-1 to J5-2
4
NONE
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
MAXIMUM VSD FREQUENCY/MODEL DESIGNATOR
The model number of the chiller determines the maximum VSD frequency at 100% full speed. The maximum frequency is programmed by factory installed jumpers on the J7 plug of the Chiller Control Board. Three digital inputs determine a binary code, which determines the maximum frequency. The inputs are read as a 0 or low when a jumper is out or a 1 or high when the wire jumper is inserted between the two pins. The jumpers will only be checked once by the Chiller Control Board on power-up.
Table 5 on page 196 shows the Chiller configuration and the associated location of the jumpers.
Table 5 - MAXIMUM FREQUENCY / MODEL DESIGNATOR JUMPER
CHILLER CONTROL
BOARD MAX. VSD FREQUENCY
J7-1 TO J7-2
J7-3 TO J7-4
J7-5 TO
J7-6
YCIV
0157 SA/PA,
0177 EA/VA,
200 Hz
11 0
0187 SA/PA, 0227 SA/PA, 0227 EA/VA, 0247 SA/PA, 0247 EA/VA, 0267 SA/PA, 0357 SA/PA, 0397 SA/PA
196 Hz
11 1
192 Hz
01 0
0187 EA/VA, 0207 EA/VA, 0327 EA/VA, 0357 EA/VA
188 Hz
01 1
0307 SA/PA
0207 SA/PA,
186 Hz
10 0
0157 EA/VA,
0287 SA/PA
182 Hz
00 0
0177 SA/PA, 0197 EA/VA, 0267 EA/VA
178Hz
10 1
0287 EA/VA
178 Hz (Spare)
00 1
196
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 7 - OPERATION
OPERATING CONTROLS
Anti-recycle Timer A typical 5 minute or 10 minute anti-recycle timer is not necessary to allow compressor motor cooling, due to the VSD's ability to provide a low current inrush start. The system does utilize a fixed 120 second anti-recycle timer to prevent short cycling of systems and to allow positioning the Feed and Drain Valves to a zero (closed) position by the Flash Tank Drain and Feed Valve Controller in the event of a power failure.
On power-up of the control panel, the anti-recycle timer for each system will be set to 120 seconds and must time out before a compressor is allowed to start.
Whenever a system starts, the anti-recycle timer for all systems will be set to 120 seconds and will count down from the time the motor starts. The timer must time out before another compressor is allowed to start.
Whenever a system shuts down, the anti-recycle timer for that system will be set to 120 seconds. The timer must time out before the system is allowed to restart.
Evaporator Pump Control The evaporator pump dry contacts are energized when any of the following conditions are true:
· If a Low Leaving Chilled Liquid Fault occurs.
· Whenever a compressor is running.
· The Daily Schedule is ON and the UNIT switch is ON.
Even if one of above is true, the pump will not run if the panel has been powered up for less than 30 seconds or if the pump has run in the last 30 seconds to prevent pump motor overheating.
Evaporator Heater Control The evaporator heater is controlled by ambient air temperature. If no systems are running and the ambient temperature drops below 40°F, the heater is turned on. If no systems are running and the temperature rises above 45°F the heater is turned off. Whenever a system is running, the evaporator heater is turned off. Both evaporator heater outputs will always be turned
on and off together. An under voltage condition will keep the heater off until full voltage is restored to the system.
Pumpdown Control The VSD assures a smooth slow compressor start. As a result of this, neither pumpdown on start-up or pumpdown on shutdown is required. The Drain and Feed Valves will close when a compressor stops. This is a similar to a liquid line solenoid valve closing on a conventional chiller.
Compressor Heater Control Each compressor has its own heater. The purpose of the heater is to assure refrigerant does not condense in the compressor. There is no oil sump, but refrigerant could possibly condense in the rotors or the motor housing. The heater will be off whenever the respective compressor is running. As soon as the compressor shuts off, the heater will turn on as long as all motor temperature sensors in the compressor read less than158°F. The heater will turn off, if any internal compressor motor temperature sensor reads more than160°F.
Alarms
Each system has its own alarm. The Alarm output is ON 7
(dry contact closed) when no fault condition is present and OFF (dry contact open) to indicate an alarm situation. The Alarm should be activated (contact open), if any of the following are true.
· A System is faulted or inhibited from starting for more than 5 seconds.
· The Unit is faulted or inhibited from starting for more than 5 seconds.
· A System is locked out.
· The Unit is locked out.
· Power is removed from the chiller.
Chiller Run Contact The Chiller Run dry contact is closed whenever any system is running. It is open when all systems are shut off.
JOHNSON CONTROLS
197
SECTION 7 - OPERATION
Unit Switch
UNIT SWITCH
LD10605
A double pole single throw ON/OFF rocker switch on the front of the control panel is used to turn the entire chiller on and off. When the switch is placed in the OFF position, the entire unit shuts down immediately. One pole of the UNIT switch contacts is wired to the Sys 1/3 and the other to Sys 2/4 VSD Run Signal input and the Chiller Control Board "UNIT switch X" digital input (X equals System 1 or 2). Separate System Fuses are also wired in series with each set of UNIT switch contacts. If either fuse is pulled or blown, only the system with the good fuse (Input is high) will run. When both inputs are high, the entire chiller will be enabled to run. When both inputs are low, the chiller will be disabled as a UNIT switch OFF Shutdown.
The UNIT switch should never be used to shut down the chiller except in an emergency. When the switch is thrown, the compressors will immediately shut down. Since the compressors are not permitted to come to a controlled stop, the rotors may back-spin, which may result in some unusual compressor noise. The back-spin will not hurt the compressors, but should be avoided.
It is suggested that the System Switches on the keypad be used whenever possible to turn a system off and allow the compressor to complete a controlled shutdown.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
BASIC OPERATING SEQUENCE
Start Sequence and Loading To initiate the start sequence of the chiller, the following conditions must be satisfied before the precharge of the DC Bus will take place:
· SWITCH must be ON.
· At least one System Switch is ON
· Run permissive inputs (Remote Cycling Contacts) must be closed.
· No unit faults exist.
· No unit start inhibits exist.
· At least one system not faulted or inhibited.
· The Daily Schedule is calling for the chiller to run.
· The Flow Switch is closed.
· Leaving Chilled Liquid Setpoint is above the Setpoint plus CR (Setpoint High Limit).
Once the precharge takes place, if the anti-recycle timer is timed out the chiller control system on the Chiller Control Board will select the number of compressors to start and begin operation of the compressors. The compressor(s) speed will be ramped to the minimum start frequency and increase speed as needed in an effort to regulate the leaving chilled liquid temperature to meet the desired Setpoint.
When a compressor starts, the Feed and Drain Valves on the system will immediately begin to control superheat and the liquid level in the flash tank and the Chiller Control Board microprocessor will begin to regulate the speed on the VSD to bring the chilled liquid temperature to within the Control Range (CR). The microprocessor will regulate the speed of the compressor(s) primarily based on temperature offset as the loading timer permits.
198
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 7 - OPERATION
48°F --------------------------------------------------
46°F --------- Setpoint + CR ( Setpoint High Limit) ----------
44°F ----------Setpoint ---------------------------------
Programmed
42°F ----------Setpoint CR (Setpoint Low Limit) ---------- Control (Cooling) Range
40°F --------------------------------------------------
38°F --------------------------------------------------
Figure 49 - CHILLER CONTROL (COOLING) RANGE
LD10625
The Setpoint is the Leaving Chilled Liquid Temperature midpoint of the Control (Cooling) Range. The Setpoint High Limit is the Setpoint plus the Control Range. The Setpoint Low Limit is the Setpoint minus the Control Range. The chiller will attempt to control within the temperature range programmed by the Setpoint plus or minus CR.
Starting and stopping of compressors will be handled by the Standard or High IPLV Capacity Control Routine. Loading and unloading will be controlled by temperature offset and rate by the Fuzzy Logic Control Routine.
A graphical representation of the Setpoint and high and low limit (plus or minus CR) are shown in Figure 49 on page 199.
NUMBER OF COMPRESSORS TO START
General
The number of compressors to start control logic varies between the standard and optional High IPLV chillers. Standard IPLV chiller control utilizes sequential logic that requires the microprocessor to start 1 compressor at a time and only add a compressor when all running compressors reach maximum speed. Optional High IPLV chillers have control algorithms that provide "smart" anticipatory control to determine how many compressors need to be started to satisfy the current load. The "smart" logic is capable of reducing short cycling, and reducing loading time on a hot water start, and starting all compressors at the same time.
Standard IPLV
The Standard IPLV control always starts a single compressor under all circumstances as the first step of loading. The Chiller Control Board does not make de-
cisions on the number of compressors to start based on chilled liquid temperatures and prior compressor operation when starting the chiller. An additional compressor is only started when the lead compressor has reached maximum speed and cooling requirements are not satisfied.
Optional Optimized High IPLV
On optimized IPLV chillers, the Number of
Compressors to Start Logic will be used to determine
how many compressors should be run when the unit
starts from the all compressors stopped state. This rou-
tine will try to run all the compressors unless it is deter-
mined that less will be needed due to light load.
7
The first step in the sequence is for the microprocessor
to set the number of compressors to start equal to the
number of compressors in the chiller. The micropro-
cessor will look at two prior conditions relating to the
compressor operating time the previous time it ran and
how long the last compressor has been off along with
two indicators of chilled liquid load requirements (rate
of change of chilled liquid temperature and deviation
from setpoint). Temperature deviation is the amount of
error compared to the setpoint high limit (Setpoint plus
CR). Based on this information, the microprocessor
will then determine the number of compressors to start.
The flowchart in Figure 50 on page 200 describes the
compressor starting decision process.
It is desirable to run as many compressors as possible for increased efficiency. Optimized logic will keep as many compressors on line and reduce speed in an effort to optimize the use of the entire evaporator tube surface.
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SECTION 7 - OPERATION
NUMBER OF COMPS TO START LOGIC
SET NUM COMPS TO START = NUM COMPS IN UNIT
NO
LAST RUN TIME < 5 MIN ?
NUMBER OF COMPS TO START
REDUCTION TABLE
4 COMPS -> 3 COMPS 3 COMPS -> 2 COMPS 2 COMPS -> 1 COMP
1 COMP -> 1 COMP
NO
OFF TIME < 5 MIN ?
LCHLT RATE < 3 °F/MIN AND LCHLT < CR+5°F?
YES
REDUCE NUM COMPS TO START PER
REDUCTION TABLE
YES
REDUCE NUM COMPS TO START PER
REDUCTION TABLE
YES
REDUCE NUM COMPS
NO
TO START PER
REDUCTION TABLE
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Figure 50 - NUMBER OF COMPRESSORS TO START
CONTINUE
LD10626
MINIMUM VSD COMPRESSOR START / RUN FREQUENCY
Minimum VSD Start Frequency
The Minimum VSD Compressor Start Frequency is based on ambient temperature and determines the frequency (speed) the compressor(s) is ramped to at start. At higher ambients, higher speeds are needed to provide adequate motor cooling. At low ambients, higher motor speeds are needed to develop oil pressure differential at start. The temperature ranges and the associated start frequency follows the guidelines below:
· If the ambient temperature is 25°F or less, the Minimum VSD Start Frequency will be 70 Hz.
· If the ambient temperature is between 26°F and 40°F (-3°C and 4°C), the Minimum VSD Start Frequency is 60 Hz.
· If the ambient temperature is between 41°F and 110°F (5°C and 43°C), the Minimum VSD Start Frequency will be 50 Hz.
· If the ambient is between 110°F and 125°F (43°C and 52°C), the Minimum VSD Start Frequency is scaled according to the following formula:
(3 x Ambient Temperature) - 280°F.
The formula is also represented by the graph in Figure 51 on page 200.
Minimum VSD Frequency (Hz)
100
95
90
85
80
75
70
65
60
55
50
45
40
105
110
115
120
125
130
Ambient Temperature (°F)
NOTE: The graph above also illustrates the scaled frequency:
LD10627
Figure 51 - MINIMUM VSD START FREQUENCY
· Above 125°F, the minimum VSD Start Frequency is 95 Hz.
Minimum VSD Run Frequency
The Minimum VSD Compressor Run Frequency is based on ambient temperature and determines the minimum frequency (speed) the compressor(s) is permitted to run as the system unloads. At high ambients, higher motor speeds are needed to cool the compressor motor. The temperature ranges and the associated start frequency follows the guidelines below:
· If the ambient temperature is less than110°F, the Minimum VSD Run Frequency will be 50 Hz.
200
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
· If the ambient is between 110 and 125°F (43 and 52°C), the Minimum VSD Run Frequency is scaled according to the following formula:
(3 x Ambient Temperature) - 280°F.
The formula is also represented by the graph in Figure 52 on page 201.
Minimum VSD Frequency (Hz)
100
95
90
85
80
75
70
65
60
55
50
45
40
105
110
115
120
125
130
Ambient Temperature (°F)
NOTE: The graph above also illustrates the scaled frequency:
LD10628
Figure 52 - MINIMUM VSD RUN FREQUENCY
· If the ambient temperature is more than 125°F, the Minimum VSD Run Frequency will be 95 Hz.
ACCELERATION / DECELERATION RATE WHEN STARTING / STOPPING COMPRESSORS
VSD Acceleration and Deceleration Rates The acceleration rate changes with frequency and follows the guidelines below:
· Between 0 Hz and 50 Hz, the acceleration is 10 Hz/s.
· Between 50 Hz and 200 Hz, the acceleration is 30.4 Hz/s. Even though the acceleration rate of 30.4 Hz/s is possible up to 200 Hz, the frequency (speed) is limited by the minimum start frequency and the add a compressor frequency calculation performed by the microprocessor when bringing on an additional compressor.
When decelerating, the deceleration rate changes with frequency and follows the guidelines below:
· Between 200 Hz and 100 Hz, the deceleration time is 30.4 Hz/s.
· Between 100 Hz and 0 Hz, the deceleration time is 10 Hz/s.
SECTION 7 - OPERATION
When a compressor stops, back-spin of the compressor will often occur as the pressure differential between discharge and suction equalizes. This should not be a cause of concern.
STANDARD IPLV CAPACITY CONTROL (Loading/Unloading and starting additional compressors)
Standard IPLV Capacity Control is installed in the chiller at the factory using a dedicated EPROM (software), part # 031-02476-001, for "Standard Only" IPLV control. If the LCHLT is more than the programmed Setpoint plus CR, only a single compressor is permitted to start under Standard IPLV control. The compressor will start at the minimum start frequency based on ambient temperature (Page 214). The lead compressor Feed and Drain Valves will immediately begin to control superheat and liquid level in the flash tank.
When a compressor starts, the load and unload timers will be set to 30 seconds. During the first 30 seconds of operation after a compressor reaches the start frequency, loading/unloading is inhibited.
After 30 seconds, the control logic looks at the LCHLT temp, compares it to the Setpoint plus CR, and makes decisions to load or unload.
For precise capacity control, the Chiller Control Board
microprocessor loads and unloads compressors quick- 7
ly, as fast as every 2 seconds, in increments of 0.1 to 1 Hz each time a load or unload change is required. Fixed load and unload timers of 2 sec. are set, after a speed change of 0.11 to 1 Hz, to minimize undershoot and overshoot.
As additional cooling is required (LCHLT more than Setpoint plus CR), the Chiller Control Board microprocessor will increase the speed of the compressor at the rate of 0.1 Hz to 1 Hz every 2 seconds until the load is satisfied. Loading will continue to occur as long as leaving chilled liquid temperature is above the Setpoint plus CR.
If the temperature falls very near or within the Control Range, the Chiller Control Board microprocessor will make decisions regarding speed changes under conditions where the "error" and "rate" conflict. Under these conditions, loading/unloading follows the guidelines described in the Fuzzy Logic Control on page 205.
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SECTION 7 - OPERATION
If the compressor speed exceeds the maximum frequency the compressor is allowed to operate minus 1 hertz for a period of 3 minutes without bringing the leaving chilled liquid temperature to within Setpoint plus CR/2, the chiller control will make a decision to start another compressor. At this point, the first compressor will decelerate to a frequency of 5 Hz. Reducing the frequency of the running compressor to 5 Hz enables the differential between discharge and suction pressure to be reduced to a point where it will not affect motor current when the running compressor is ramped up. It also reduces the possibility of backspin on the running compressor. The next lag compressor will be activated and all compressors will be accelerated to the START FREQ. The START FREQ is specified by the formula:
START FREQ = Current VSD Freq x (Number of Compressor enabled -1) Number of Compressors enabled
For example: Current VSD Freq = max freq of the chiller = 200 Hz. Number of compressors enabled = 2 = Original compressor running, plus the compressor to be added.
In this example, assume a single compressor had been running at the max frequency of 200 Hz without satisfying cooling demand. (2) compressors are now enabled when the second compressor is activated. Placing these values in the formula, the START Frequency equals 200 Hz x (2-1)/2 equals 100 Hz. The compressors will be accelerated to a start frequency of 100 Hz. Load and unload timers will be set to 30 seconds. The anti-recycle timer will bew set to 120 seconds.
If additional cooling is required, after the initial 30 seconds of operation, loading will occur at the rate of 0.1 Hz to 1 Hz every 2 seconds, unless load limiting occurs.
If the cooling capacity exceeds the demand and temperature continues to drop while in the Control Range (CR) with multiple compressors operating, the Chiller Control Board microprocessor will decrease the speed of the compressor(s) at the rate of 0.1 to 1 Hz every 2 seconds until the LCHLT stabilizes within the Control Range. If frequency (speed) drops below the LESS COMP FREQ 20 Hz or the minimum VSD frequency, whichever is higher, the compressors will be decelerated to a speed of 5 Hz, the last compressor disabled, and the remaining compressor(s) restarted minus one lag compressor. The LESS COMP FREQ is designated as:
LESS COMP FREQ = Max VSD Freq x (Number of compressor enabled -1) Number of Compressors enabled For example: 200 Hz = max freq of the chiller.
Number of compressors enabled before shutdown = 2
202
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
In this example, one compressor will be shut down when the speed of the compressors drops to 200 Hz x (2-1)/2 = 100 Hz to 20 Hz = 80 Hz.
The restart frequency for the compressor(s) after removing a lag compressor is the OFF FREQ. The OFF FREQ is designated as:
OFF FREQ = Current VSD Freq x (Number of compressors enabled +1) Number of Compressors enabled
For example: 8 0 Hz = current freq of the chiller in the example above. Number of compressors enabled at shutdown = 1
In the example above, one compressor will restart at 160 Hz as calculated in the formula below:
80 Hz x (1+1) = 160 Hz 1
The load timer will also be set to 30 seconds and the unload timer will be set to 10 seconds.
On 3 and 4 compressor chillers, if frequency (speed) drops below the LESS COMP FREQ 20 Hz or the minimum VSD frequency, whichever is higher, another lag compressor will be shut down using the same guidelines.
When the system is only operating a single (lead) compressor, if temperature continues to stay below the Control Range (Setpoint CR) or continues to drop while in the Control Range, the Chiller Control Board microprocessor will unload the compressor at the rate of 0.1 Hz to 1 Hz every 2 seconds. This will continue until the frequency drops below the Minimum VSD Frequency determined by the ambient temperature. At this point, the lead compressor will be shut down, if temperature is below the Setpoint - CR.
Fuzzy Logic Control The fuzzy logic control in software makes decisions to increase or decrease speed according to the error or deviation from Setpoint, and the rate of change of chilled liquid temperature. Before making a change in speed, the Chiller Control Board microprocessor will look at the load and unload timers to assure they are timed out. It also looks to assure there is no load limiting in effect. Each time a change is made, the incremental change in speed is still between 0.1 and1 Hz, unless temperatures fall near the leaving chilled liquid cutout.
In most situations, when the chilled liquid temperature is above the Setpoint plus CR, the Chiller Control Board microprocessor will continue to increase the speed of the compressor(s) to load the chiller until temperature drops in the general range of the Setpoint
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
High Limit (Setpoint plus CR). If the rate of change is dropping too fast and there is potential for overshoot, the Chiller Control Board microprocessor may elect not to continue to increase speed.
In cases where temperature is dropping too fast when temperature is within the desired Control Range, the microprocessor will be required to make decisions regarding speed changes under conditions where the "error" and "rate" conflict. For example, the microprocessor may elect to decrease the speed of the compressor(s) if the error is "0" (temperature is at Setpoint), while the rate of change of chilled liquid temperature is falling (negative). The Chiller Control Board microprocessor may also elect to hold the speed when error is "positive" (temperature is above Setpoint, but not above Setpoint plus CR) because the rate of change of chilled liquid is "negative" (falling). Table 6 on page 203 illustrates these conditions.
Table 6 - FUZZY LOGIC LOADING/UNLOADING VS. ERROR
NEGATIVE ZERO ER- POSITIVE
ERROR
ROR
ERROR
NEGATIVE RATE
ZERO RATE
POSITIVE RATE
UNLOAD UNLOAD
HOLD
UNLOAD HOLD LOAD
HOLD HOLD LOAD
To avoid overshoot or nuisance trips on the low chilled liquid cutout, when the temperature is below the Setpoint CR/2, the Chiller Control Board microprocessor will reduce the speed of the compressor(s) to unload the chiller by 2.0 Hz every 2 seconds. If temperature drops to within 1.0°F above the Low Chilled Liquid temp Cutout, the Chiller Control Board microprocessor will unload the compressors at the rate of 4.0 Hz every 2 seconds.
As the temperature rises the microprocessor's fuzzy logic will factor in the rate of change before continuing to unload. If the rate of change is rising too fast and there is potential for a positive overshoot, the Chiller Control Board microprocessor may elect not to continue to decrease speed.
In cases where temperature is rising too fast, when temperature is within the desired Control Range, the Chiller Control Board microprocessor will be required to make decisions regarding speed changes under conditions where the "error" and "rate" conflict. For example, the Chiller Control Board microprocessor may
JOHNSON CONTROLS
SECTION 7 - OPERATION
elect to increase the speed of the compressor(s) if the error is "0" (temperature is at Setpoint), while the rate of change of chilled liquid temperature is "positive" (rising). The Chiller Control Board microprocessor may also elect to hold capacity when error is "negative" (temperature is below Setpoint) because the rate of change of chilled liquid is "positive" (rising). Table 6 on page 203 illustrates these conditions and the loading response from the Chiller Control Board microprocessor.
Hot Water Starts
On a hot water start under "best" case conditions, assuming power has not been removed and the 120 second timer does not inhibit starting, the design of the control algorithm for a 2compressor Standard IPLV leaving chilled liquid capacity control allows full loading of a chiller in slightly more than 14 1/2 minutes, regardless of the number of compressors. This time period assumes load limiting does not affect the loading sequence and the ambient is above 40°F.
Lag Compressor Operation in Load Limiting
When a single compressor is operating in current, discharge pressure, suction pressure, VSD internal ambient, or VSD baseplate temperature limiting for more than 5 minutes and chilled liquid temperature is more than Setpoint plus CR, the Chiller Control Board micropro-
cessor will turn on the lag compressor to bring the chilled 7
liquid temperature within the Control Range. After 1 hour the Chiller Control Board microprocessor will shut down the lag compressor and attempt to control temperature with only the lead compressor to satisfy the load.
OPTIONAL HIGH IPLV CAPACITY CONTROL
(Loading/Unloading and starting additional compressors)
Optional High IPLV Capacity Control is installed in the chiller at the factory using a dedicated EPROM (software), part # 031-02476-002, for High IPLV control. Its purpose is to control compressors as effectively as possible, optimizing control of both the compressors and condenser fans. If the LWT is more than the programmed Setpoint plus CR, the Chiller Control Board microprocessor will follow the flow chart (Page 214) to determine the number of compressors to start based on the last run time, time off, and the rate of change of chilled liquid temperature. The compressor(s) will start at the minimum start frequency based on ambient temperature (Page 214). The respective system Feed and Drain Valves will immediately begin to control superheat and liquid level in the flash tank.
203
SECTION 7 - OPERATION
When compressors start, the load and unload timers will be set to 30 seconds. During the first 30 seconds of operation after a compressor reaches the start frequency, loading/unloading is inhibited. After 30 seconds, the control logic looks at the LWT temp, compares it to the Setpoint plus CR, and makes a decision to load or unload.
For precise capacity control, the Chiller Control Board microprocessor loads and unloads compressors quickly, as fast as every 2 seconds, in increments of 0.1 Hz to 1 Hz each time a load or unload change is required. Fixed load and unload timers of 2 seconds are set, after a speed change of 0.1 Hz to 1 Hz, to minimize undershoot and overshoot.
As additional cooling is required (LCHLT more than Setpoint plus CR), the Chiller Control Board microprocessor will increase the speed of the compressor at the rate of 1 Hz every 2 seconds until the load is satisfied. Loading will continue to occur as long as leaving chilled liquid temperature is above the Setpoint plus CR.
The chiller control board will be make decisions regarding speed changes under conditions where the "error" and "rate" conflict. Under these conditions, loading/unloading follows the guidelines described in the Fuzzy Logic Control on page 202.
If chilled liquid temperature is not satisfied and above Setpoint plus CR, the microprocessor looks to see if any of the lag compressors are not running. If any lag compressor(s) is off, the Chiller Control Board microprocessor looks at the VSD output frequency. If the VSD output frequency is greater than the ADD COMPRESSOR FREQUENCY plus 15 Hz or equal to the maximum chiller speed (frequency), the microprocessor starts an additional compressor. The ADD COMPRESSOR FREQUENCY is calculated as:
ADD
= Minimum Start Freq x (Number of Compressors Running +1)
COMPRESSOR
Number of Compressors Running
FREQUENCY
Example - A single compressor had been running without satisfying cooling demands. Assume the minimum VSD start frequency based on ambient is 50 Hz for this example. The number of compressors running in the formula will equal to 1. Placing the values into the formula: 50 Hz x (1+1)/1 = 100 Hz. The add compressor frequency will equal 100 Hz. Since the controls are designed to add a compressor at a frequency 15 Hz above this point, a compressor will be added if the speed reaches 115 Hz.
204
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
When a compressor is to be added, the Chiller Control Board microprocessor decelerates the compressor VSD frequency to 5 Hertz. This enables the differential between discharge and suction pressure to be reduced to a point where it will not affect motor current when the compressor is restarted. It also reduces the chance for backspin on the running compressor. The next lag compressor is activated and all compressors are accelerated to the START FREQUENCY. The START FREQUENCY is calculated as:
START = Current VSD Freq x (Number of Compressors Running 1)
FREQUENCY
Number of Compressors Running
With 2 compressors now running and a current VSD frequency of 115 HZ, the start frequency will be computed as:
115 Hz x (2-1) = 115 = 58 Hz
2
2
When the compressors restart, loading and unloading is inhibited for 30 seconds after the compressor(s) reaches the start frequency, as is the case on any compressor start. The anti-recycle timer will be set to 120 sec.
In a situation where a single compressor on a 2 compressor chiller is running and is in load limiting for any reason, and LCHLT more than Setpoint plus CR for less than 5 minutes, but more than 30 seconds, the microprocessor will reset the load/unload timers to 2 seconds every "potential" load cycle. When LCHLT more than Setpoint plus CR for more than 5 minutes, the microprocessor will enable the lag compressor just as it were not satisfied and determine a second compressor was required to handle the load, since the lead compressor is load limited.
If the cooling capacity exceeds the demand (LCHLT less than Setpoint CR/2) and multiple compressors are operating, the Chiller Control Board microprocessor will decrease the speed of the compressors at the rate of 0.1 to 1 Hz every 2 seconds until the LCHLT rises to within the Control Range. If temp remains below Setpoint CR/2, rate is falling, and speed falls to the minimum VSD frequency as determined by the ambient, the VSD will decelerate all compressors to 5 Hertz. The last lag compressor will be shut down. The remaining compressors will be restarted minus the lag compressor. The lead compressor will restart and accelerate to the STOP COMP FREQ designated as:
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
STOP
= Minimum VSD Freq x (Number of Compressors Running +1)
COMP FREQ
Number of Compressors Running
In this example: Number of compressors running = 1 Minimum VSD Freq.= 50 Hz
In the example above, one compressor will restart at 100 Hz as indicated in the formula below:
50 Hz x (1+1) = 100 Hz 1
The load timer will also be set to 30 seconds and the unload timer will be set to 10 seconds.
On 3 and 4 compressor chillers, if temperature stays below the Setpoint minus the Control Range/2, another lag compressor will be shut down using the same guidelines.
When the system is only operating a single (lead) compressor, if temperature continues to stay below the Control Range (Setpoint minus CR), the Chiller Control Board microprocessor will unload the compressor at the rate of 1 Hz every 2 seconds. This will continue until the frequency drops below the Minimum VSD Frequency determined by the ambient temperature. At this point, the lead compressor will be shut down.
Fuzzy Logic Control
The fuzzy logic control in software makes decisions to load or unload according to the error or deviation from Setpoint, and the rate of change of chilled liquid temperature. Before making a change in speed, the logic will look at the load and unload timers to assure they are timed out. It also looks to assure there is no load limiting in effect. Each time a change is made, the incremental change in speed is still 0.1 to 1 Hz, unless temperatures fall near the leaving chilled liquid cutout.
In most situations, when the chilled liquid temperature is above the Setpoint plus CR, the Chiller Control Board microprocessor will continue to increase the speed of the compressor(s) to load the chiller until temperature drops in the general range of the Setpoint High Limit. As the temperature drops and approaches the Setpoint High Limit (Setpoint plus CR), the microprocessor's fuzzy logic will begin factoring in the rate of change before continuing to load. If the rate of change is dropping too fast and there is potential for overshoot, the Chiller Control Board microprocessor may elect not to continue to increase speed.
SECTION 7 - OPERATION
In cases where temperature is dropping too fast, when temperature is within the desired Control Range, the Chiller Control Board microprocessor will be required to make decisions regarding speed changes under conditions where the "error" and "rate" conflict. For example, the Chiller Control Board microprocessor may elect to reduce the speed of the compressor(s) if the error is "0" (temperature is at Setpoint); while the rate of change of chilled liquid temperature is "negative"(falling). The Chiller Control Board microprocessor may also elect to hold capacity when error is "positive" (temperature is above Setpoint, but not above Setpoint plus CR) because the rate of change of chilled liquid is "negative" (falling). Table 7 on page 205 illustrates these conditions.
Table 7 - FUZZY LOGIC LOADING/UNLOADING VS. ERROR
NEGATIVE ZERO ER- POSITIVE
ERROR
ROR
ERROR
NEGATIVE RATE
ZERO RATE
POSITIVE RATE
UNLOAD UNLOAD
HOLD
UNLOAD HOLD LOAD
HOLD HOLD LOAD
When temperature is significantly below the Setpoint minus CR/2, the Chiller Control Board microprocessor
will reduce the speed of the compressor(s) to unload 7
the chiller by 2.0 Hz every 2 seconds. If temperature drops to within 1.0°F above the Low Chilled Liquid Temperature Cutout, the Chiller Control Board microprocessor will unload at the rate of 4.0 Hz every 2 seconds.
As the temperature rises toward Setpoint minus CR, the Chiller Control Board microprocessor's fuzzy logic will begin factoring in the rate of change before continuing to unload. If the rate of change is rising too fast and there is potential for overshoot, the Chiller Control Board microprocessor may elect not to decrease speed.
In cases where temperature is rising too fast, when temperature is within the desired Control Range, the Chiller Control Board microprocessor will be required to make decisions regarding speed changes under conditions where the "error" and "rate" conflict. For example, the Chiller Control Board microprocessor may elect to increase the speed of the compressor(s) if the error is "0" (temperature is at Setpoint), while the rate
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205
SECTION 7 - OPERATION
of change of chilled liquid temperature is "positive" (rising). The Chiller Control Board microprocessor may also elect to hold capacity when error is "negative" (temperature is below Setpoint) because the rate of change of chilled liquid is "positive" (rising). Table 7 on page 205 illustrates these conditions and the response from the Chiller Control Board microprocessor.
Hot Water Starts
On a hot water start under "best" case conditions, assuming power has not been removed and the 120 sec timer does not inhibit starting, the design of the control algorithm for a 2 compressor High IPLV leaving chilled liquid capacity control allows full loading of a chiller in slightly more than 6 minutes, regardless of the number of compressors, if all the compressors start at the same time. This time period assumes load limiting does not affect the loading sequence and the ambient is above 40°F.
LOAD LIMITING CONTROL
Load Limiting
The Load Limiting Controls are intended to prevent a system from reaching a safety trip level. Load limiting controls prevent loading or unload compressors to prevent tripping on a safety. Limiting controls operate for Motor Current %FLA, Suction Pressure, Discharge Pressure, VSD Baseplate Temperature, and VSD Internal Ambient Temperature.
All running system's load limit control values are checked every 2 seconds. Load limiting prevents a system from loading (no increase even though cooling demand requires loading) when the specific operating parameter is within a specific range of values. If the value is above the range where loading is inhibited, the logic will unload the chiller based on the amount (%) the limit has been exceeded. Load limiting affects all compressors, even though only one system may be affected.
If more than one operating parameter is exceeding the value where unloading is required, the value with the highest amount of unloading will determine the unloading. All load limiting controls are active at startup except suction pressure limiting.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Motor Current Load Limiting/Unloading
Motor current load limiting helps prevent the system from tripping on the motor overload safety. The motor "Current Limit Setpoint" is based on %FLA motor current and is programmable under the PROGRAM key or may be set by a remote device. Motor current load limiting prevents the system from loading even though increased loading may be required when the current is between the "Current Limit Setpoint minus 2%" and the "Current Limit setpoint". Between the "Current Limit Setpoint" and the "Current Limit Setpoint plus 5%", the system will unload every 2 seconds according to the amount current is exceeding the "Current Limit Setpoint". At the "Current limit Setpoint", 0 Hz reduction in speed will take place and at the "Current Limit Setpoint plus 5%", a 10 Hz speed reduction will take place. Between the "Current Limit Setpoint" and "Current Limit Setpoint plus 5%", unloading will occur according to the Table 8 on page 206.
Table 8 - CURRENT LIMIT LOAD LIMITING/ UNLOADING
CURRENT LIMIT SETPOINT
UNLOADING
Current Limit Setpoint -2% to +0% Current Limit Setpoint +1% Current Limit Setpoint +2% Current Limit Setpoint +3% Current Limit Setpoint +4% Current Limit Setpoint +5%
0 Hz 2 Hz 4 Hz 6 Hz 8 Hz 10 Hz
Discharge Pressure Load Limiting/Unloading
Discharge pressure load limiting protects the condenser from experiencing dangerously high pressures. A system is permitted to load normally as long as the discharge pressure is below the High Discharge Pressure Cutout minus 20 psig. Between Cutout minus 20 psig and Cutout minus 15 psig loading is inhibited even though increased loading may be required. Between Cutout minus 15 psig and the Discharge Pressure Cutout, forced unloading is performed every 2 seconds according to Table 9 on page 207. The discharge pressure unload point is fixed at 255 psig.
206
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Table 9 - DISCHARGE PRESSURE LOAD LIMITING/UNLOADING
DISCHARGE PRESSURE
UN-LOADING
Discharge Pressure Cutout- 20 psig &
Discharge Pressure Cutout- 15 psig
0 Hz
Discharge Pressure Cutout- 13.5 psig
1 Hz
Discharge Pressure Cutout- 12 psig Discharge Pressure Cutout- 10.5 psig Discharge Pressure Cutout- 9 psig Discharge Pressure Cutout- 7.5 psig Discharge Pressure Cutout- 6 psig Discharge Pressure Cutout- 4.5 psig Discharge Pressure Cutout- 3 psig Discharge Pressure Cutout- 1.5 psig Discharge Pressure Cutout- 0 psig
2 Hz 3 Hz 4 Hz 5 Hz 6 Hz 7 Hz 8 Hz 9 Hz 10 Hz
Suction Pressure Load Limiting/Unloading
Suction pressure load limiting helps to protect the evaporator from freezing. A system is permitted to load normally as long as the Suction Pressure is above the Suction Pressure Cutout plus 2 psig. Between Cutout plus 2 psig and the Cutout, loading is inhibited, even though increased loading is required. Between the Suction pressure Cutout and Suction Pressure Cutout minus 10 psig, forced unloading is performed every 2 seconds according to Table 10 on page 207. This situation would occur if the suction pressure cutout transient override control is in effect (See "Low Suction Pressure Cutout", Page 247). The suction pressure cutout is programmed under the PROGRAM key. The default Suction Pressure Cutout is set at 24.0 psig.
Table 10 - SUCTION PRESSURE LOAD LIMITING/ UNLOADING
SUCTION PRESSURE
UN-LOADING
Suction Pressure is between Cutout +2 psig & Suction Pressure Cutout Suction Pressure Cutout- 1 psig Suction Pressure Cutout- 2 psig Suction Pressure Cutout- 3 psig Suction Pressure Cutout- 4 psig Suction Pressure Cutout- 5 psig Suction Pressure Cutout- 6 psig Suction Pressure Cutout- 7 psig Suction Pressure Cutout- 8 psig Suction Pressure Cutout- 9 psig Suction Pressure Cutout- 10 psig
0 Hz
1 Hz 2 Hz 3 Hz 4 Hz 5 Hz 6 Hz 7 Hz 8 Hz 9 Hz 10 Hz
SECTION 7 - OPERATION
Suction pressure load limiting is active at start-up, to only prevent loading of the compressors. Suction pressure limit unloading will not occur until the system run time reaches 5 minutes of operation to allow the system to stabilize.
VSD Internal Ambient Temperature Load Limiting
VSD Internal Ambient temperature limiting helps prevent the unit from tripping on the high internal cabinet temperature safety. A system is permitted to load normally as long as the VSD Internal Ambient is below the VSD Internal Ambient Cutout minus 3°F. Between VSD Internal Ambient Cutout minus 3°F and the VSD Internal Ambient Cutout minus 2°F, loading is inhibited, even though increased loading is required. Between the VSD Internal Ambient Cutout minus 2°F and the VSD Internal Ambient Cutout, forced unloading is performed every 2 seconds according to Table 11 on page 207 below. The VSD Internal Ambient Safety Cutout is 158°F.
Table 11 - VSD INTERNAL AMBIENT LOAD LIMITING/UNLOADING
VSD INTERNAL AMBIENT TEMPERATURE
UN-LOADING
Internal Ambient Temp. is between Cutout- 3ºF & Internal Ambient Cutout- 2ºF
0 Hz
Internal Ambient Cutout- 1.8ºF Internal Ambient Cutout- 1.6ºF
1 Hz
7
2 Hz
Internal Ambient Cutout- 1.4ºF
3 Hz
Internal Ambient Cutout- 1.2ºF
4 Hz
Internal Ambient Cutout- 0ºF
5 Hz
Internal Ambient Cutout- 0.8ºF
6 Hz
Internal Ambient Cutout- 0.6ºF
7 Hz
Internal Ambient Cutout- 0.4ºF
8 Hz
Internal Ambient Cutout- 0.2ºF
9 Hz
Internal Ambient Cutout
10 Hz
VSD Baseplate Temperature Load Limiting
VSD Baseplate load limiting helps protect the unit from tripping on the high VSD Baseplate Temp Safety. A system is permitted to load normally as long as the VSD Baseplate temperature is below the VSD Baseplate Temperature Cutout minus 8°F. Between the VSD Baseplate Temperature Cutout minus 8°F and the VSD Baseplate Temperature Cutout minus 4°F, loading is inhibited, even though increased loading is required. Between the VSD Baseplate Temperature Cutout minus 4°F and the cutout, forced unloading is performed every 2 seconds according to Table 12 on page 208.
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SECTION 7 - OPERATION
Table 12 - VSD BASEPLATE TEMPERATURE LOAD LIMITING/UNLOADING
VSD BASEPLATE TEMPERATURE UN-LOADING
Baseplate Temp. is between Cutout- 8ºF & Cutout- 4ºF Baseplate Temp. Cutout- 3.6ºF Baseplate Temp. Cutout- 3.2ºF Baseplate Temp. Cutout- 2.8ºF Baseplate Temp. Cutout- 2.4ºF Baseplate Temp. Cutout- 2.0ºF Baseplate Temp. Cutout- 1.6ºF Baseplate Temp. Cutout- 1.2ºF Baseplate Temp. Cutout- 0.8ºF Baseplate Temp. Cutout- 0.4ºF Baseplate Temp. Cutout
0 Hz
1 Hz 2 Hz 3 Hz 4 Hz 5 Hz 6 Hz 7 Hz 8 Hz 9 Hz 10 Hz
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
FLASH TANK DRAIN AND FEED VALVE CONTROLLER
Valve Controller and Control Algorithm Operation
The Flash Tank Feed and Drain Valve PI Controller(s) plays a dual role of supplying drive signals to control the opening and closing of both the Flash Tank Feed and Drain Valves. These valves control the liquid level in the flash tank and the suction superheat of the compressor. The Flash Tank Feed and Drain Valve Controller receive analog signals from the Chiller Control Board to position the Feed and Drain Valves.
The Chiller Control Board PI (Proportional plus Integral) control algorithm in the Chiller Control Board software determines the open % for the Drain and Feed valves. A D/A converter on the Chiller Control Board converts the 0% to 110.0% signal to an output voltage between 0 VDC and 10.28 VDC and sends it to the Drain and Feed Controller. This voltage is then converted to a valve position by the Drain and Feed Valve Controller and a 2 phase (4 wire), signal drives the Feed Valve open or closed. Power for the Valve Controller comes from a 30 VDC supply from the Chiller Control Board.
Figure 53 - FLASH TANK DRAIN AND FEED VALVE CONTROLLER 208
LD10619
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
The Feed Valve is a stepper motor valve that controls the liquid flow from the condenser to assure the liquid level in the flash tank is maintained at a proper level. The Level Sensor is a rod inserted into the reservoir connected to the side of the flash tank. The sensing rod has an active range of about 12 in.
The control algorithm looks at feedback from the Level Sensor and compares it to the fixed level setpoint in the control algorithm. This control strategy attempts to keep the level in the flash tank to approx 35% of the usable portion of the sensing rod. In reality, this is approximately a 50% level in the flash tank. As the level in the flash tank fluctuates, the control algorithm varies the voltage to the Controller, which in turn sends a 2 phase stepped drive signal to open or close the Feed Valve as needed.
As the flash tank level varies farther from the setpoint, the gain of the control algorithm increases for faster response. In some cases, the Feed Valve will fully open or fully close if the levels become too low or too high. When properly charged, the condenser subcooling will be approx. 5-7°F at design conditions as the Feed Valve controls refrigerant flow into the flash tank.
The Drain Valve is also a stepper motor valve. Like the Feed Valve, the controller receives a 0 VDC to 10.28 VDC signal from the Chiller Control Board. The controller then converts the signal to a valve position and a 2 phase signal drives the Drain valve open or closed.
The Drain Valve, Controller, and Chiller Control Board Algorithm combination functions as an Electronic Expansion Valve (EEV). The controller receives an analog 0 VDC to 10.28 VDC signal sent from the Chiller Control Board, which is based on system suction pressure and suction temperature. These operating parameters are used to compute and control suction superheat according to the Setpoint programmed into the panel under the PROGRAM key. After computing the superheat, the signal to the controller is adjusted and the controller subsequently positions the Drain Valve to control the superheat. The gain of the control algorithm is adjusted to aid in correcting for superheat error.
The Chiller Control Board Algorithm assures the level in the flash tank does not become too high. The level setpoint for control is 35%. Levels normally run 30 to 40% with the economizer solenoid energized (open). With the solenoid closed, levels may vary significantly from the 30% to 40% level. If the level exceeds 85% of the full level, the system will shut down on a fault.
SECTION 7 - OPERATION
The Feed and Drain Valves in a system open and begin to control as soon as a compressor starts. When the compressor shuts down, the valves are driven to their closed position.
MOP Setpoint Control for Hot Water Starts
Maximum Operating Pressure control overrides superheat control of the Drain Valve when the MOP Setpoint is exceeded on hot water starts. The fixed setpoint is 68°F Saturated Suction Temp (SST). When this value is exceeded, the Drain Valve switches superheat control to suction pressure control equal to 68°F SST.
Moderate To High Ambient MOP Setpoint Control.
In moderate to high ambients, the suction line may be warmed by the ambient, contributing to inaccurate suction superheat measurement at start-up. To avoid this situation, the MOP control utilizes suction pressure control at start-up, which overrides superheat control. For the first minute of run time, the MOP Setpoint is set to:
RCHLT - Superheat Setpoint 1.0°F Run Time in Seconds
After the first minute of operation, the MOP Setpoint is ramped from the current calculated value to 68°F over the next minute. At this point, normal superheat control based on the programmed setpoint resumes.
Low Ambient MOP Setpoint Control
7
In low ambient start-ups, suction pressure is erratic and pressure differentials across the compressor may be low, resulting in low oil differential faults. The Low Ambient MOP setpoint control assures adequate differential is developed between discharge and suction to push oil through the oil cooling system and the compressor.
For the first 5 minutes of system run time, the MOP Setpoint is set to the saturated suction temperature equal to 15 psig below discharge pressure, which overrides superheat control. The control algorithm will not allow suction pressure control below the cutout. The low limit of the suction pressure is the low suction pressure cutout. After 5 minutes of system run time, the MOP Setpoint is set at 68°F and superheat control based on the programmed setpoint resumes.
Actual MOP Setpoint
The actual MOP Setpoint used by the controller is the minimum of three calculations; the fixed MOP Setpoint, the moderate to high ambient setpoint, and the low ambient setpoint.
JOHNSON CONTROLS
209
SECTION 7 - OPERATION
Valve Controller LED's The Drain and Feed Valve stepper motor controller is equipped with a pair of LED's on the left side of the module and 10 LED's in the center of the module (Figure 54 on page 210). These LED's may be useful during troubleshooting.
A pair of LED's on the left side of the module (Figure 55 on page 210) indicate when the module is powered. The Power LED should be lit at all times.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Figure 54 - LED LOCATIONS
LD10629
Figure 55 - POWER AND COMMS LED'S
LD10630
A column of 10 LED's runs from top to bottom on the right side module (Figure 56 on page 210).
Figure 56 - POWER, COMMS AND SYSTEM
OPEN/CLOSE LED'S
LD10631
A pair of LED's on the top of the module (Figure 56 on page 210) indicates when the module is powered and when the module is communicating with the Chiller Control Board. The Power LED should be lit at all times.
The Open and Close LED's on each system indicate when the Feed and Drain valves are being driven open or closed in an effort to control flash tank level and suction superheat. These valves will light "momentarily" when the valves are being pulsed. In most cases other than start-up, they may appear to not light at all. The valves that are controlled by the outputs associated with the LED's are decoded as shown below:
1. Open = System #1 or 3 Feed Valve Open
2. Open = System #1 or 3 Drain Valve Open
3. Open = System #2 or 4 Feed Valve Open
4. Open = System #2 or 4 Drain Valve Open
5. Close = System #1 or 3 Feed Valve Close
6. Close = System #1 or 3 Drain Valve Close
7. Close = System #2 or 4 Feed Valve Close
8. Close = System #2 or 4 Drain Valve Close
On 3 and 4 compressor chillers, a second module will control systems #3 and #4.
210
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Due to the short duration of the open and close stepper pulses, LED lighting will be difficult to observe. In rare cases where validation of the controller output and valve movement needs to be checked, the valves can be operated in Service Mode. When operated in Service Mode, visual indication of the LED's lighting will be more obvious. Generally, no audible noise is evident as the valves open and close unless the valve is being run against its stop. It is possible to obtain an indication of valve movement by touch, when a valve is opening or closing.
Manually operating the Feed and Drain Valves in Service Mode can drain or overfill the flash tank. This could cause valve movements and levels in the flash tank to act out of the ordinary when a system first starts, until the Chiller Control Board brings the flash tank level and superheat under control. This may also be evident in the flash tank level and open/close % on the displays. It may also cause the liquid line or flash tank sight glasses to empty or the flash tank sight glass to fill.
Careless use of manual control could cause liquid damage to the compressor when it is started.
ECONOMIZER CONTROL
The Economizer Solenoid controls a vapor feed to the economizer port on the compressor from the top of the flash tank. When the valve is open, refrigerant gases off in the flash tank providing additional subcooling to the liquid in the tank. The subcooled liquid is then fed to the evaporator resulting in additional system capacity and efficiency.
In normal operation, the Economizer Solenoid on a compressor will be turned on whenever the VSD frequency is more than 120 Hz, the flash tank level is less than 75%, motor current less than 80%FLA, motor temperature sensors are all less than less than150°F, and the economizer timer is timed out. Whenever the Economizer Solenoid is turned on, the compressor load timer is set to 35 seconds and economizer timers for every system are set to 30 seconds, unless they are already above 30 seconds.
SECTION 7 - OPERATION
In low ambient temperatures less than 40°F, run time on the respective compressor is less than 5 minutes, and the flash tank level is less than75%, the system Economizer Solenoid is turned on. Under these conditions, the VSD frequency and the motor temp sensor readings are not factors that could overload the compressor. Energizing the Economizer Solenoid also helps start a system in low ambients and prevents low suction pressure and low oil differential faults by increasing the load.
At ambients above 40°F, once on, the Economizer Solenoid will remain energized until the VSD frequency drops below 90 Hz. Below 90 Hz, the solenoid will be turned off, regardless of the time remaining on the economizer timers. Under these conditions, the economizer timers will be set to "0" when the solenoids are de-energized. Below 100 Hz, if the economizer timer has timed out, the Economizer Solenoids will be turned off, the unload timer will be set to 30 seconds, the economizer timer will be set to 30 seconds if less than 30 sec.
If a motor temperature sensor exceeds 240°F, the
Economizer Solenoid will de-energize to avoid over-
heating the hot motor. When the economizer solenoid
is de-energized, the compressor unload timer is set to
30 seconds and the economizer solenoid timer is set
to 60 seconds. All other economizer timers for other
systems are set to 30 seconds, if they are already less than 30 seconds.
7
The Economizer Solenoid timer prevents the solenoid from cycling too often.
Whenever a compressor is to be turned off, all system Economizer Solenoids will be de-energized when the compressor(s) ramp down. The solenoids on the compressors that will be ramped back up, if any, will remain off for 30 seconds before the Chiller Control Board allows the solenoids to re-energize. Once on, the economizer solenoid(s) must remain on for 30 seconds as determined by the economizer timer for each system.
JOHNSON CONTROLS
211
SECTION 7 - OPERATION
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
FAN
FAN
FAN
FAN
FAN
FAN
12
10
8
6
4
2
FAN LOCATIONS
SYS #2 SYS #1
VSD/ CONTROL
PANEL
11 FAN UNITS - OMIT FAN 12 10 FAN UNITS - OMIT FANS 11 & 12 9 FAN UNITS - OMIT FANS 10,11 & 12 8 FAN UNITS - OMIT FANS 9,10,11 & 12
FAN
FAN
FAN
FAN
FAN
FAN
11
9
7
5
3
1
FAN BAFFLES
FAN BAFFLES
Figure 57 - CONDENSER FAN LOCATIONS
FAN BAFFLES
LD10632
CONDENSER FAN CONTROL
Condenser Fan control on each system is based on discharge pressure. There are up to five possible stages of fan control utilizing 3 outputs per system. Depending upon the chiller model, there will be 4, 5, or 6 fans per system. The fan nearest the discharge liquid header will always be the first fan on a system to start. As fan stages increment or decrement, a single fan or pair of fans contained within a pair of fan baffles will be turned on or off. The diagram above shows the location of the fan baffles. These baffles will not change location regardless of the number of fans on a chiller.
The fan control algorithm in the Chiller Control Board software will not skip steps as fan stages are staged up and down. The delay between turning on or off fan stages as discharge pressure rises and falls is 5 seconds. The controller increments or decrements the fan stage by one stage based on discharge pressure and fan delay time.
Table 13 on page 212 shows the fan staging and the outputs for each fan stage on 4, 5, and 6 fan systems. The microprocessor fan outputs and the fan contactors will be the same regardless of the number of fans. The fan wiring will change to permit operation of 4, 5, or 6 fans.
Table 13 - FAN STAGES AND CORRESPONDING OUTPUTS
4 FANS
5 FANS
6 FANS
Stage 1 (1 Fan ON) Sys 1 Fan 1 Sys 2 Fan 2
Stage 1 (1 Fan ON) Sys 1 Fan 1 Sys 2 Fan 2
Stage 2 (2 Fans ON) Sys 1 Fans 1 & 11 Sys 2 Fans 2 & 12)
Stage 2
Stage 2
(2 Fans ON) Sys 1 Fans 3 & 5
(2 Fans ON) Sys 1 Fans 3 & 5
-
Sys 2 Fans 4 & 6
Sys 2 Fans 4 & 6
Stage 3 (3 Fans ON) Sys 1 Fans 1, 3, & 5 Sys 2 Fans 2, 4 & 6
Stage 3 (3 Fans ON) Sys 1 Fans 1, 3, & 5 Sys 2 Fans 2, 4, & 6
Stage 4 (4 Fans ON) Sys 1 Fans 1, 3, 5, & 11 Sys 2 Fans 2, 4, 6, & 12
OUTPUT 1 2
1 and 2
CONTACTORS Sys 1: 4CR Sys 2: 7CR
Sys 1: 5CR Sys 2: 8CR
Sys 1: 4CR & 5CR Sys 2: 7CR & 8CR
Stage 4
-
(4 Fans ON) Sys 1 Fans 3, 5, 7, & 9
-
Sys 2 Fans 4, 6, 8, & 10
2 and 3
Sys 1: 5CR & 6CR Sys 2: 8CR & 9CR
Stage 4 (4 Fans ON) Sys 1 Fans 1, 3, 5, & 7 Sys 2 Fans 2, 4, 6, & 8
Stage 5 (5 Fans ON) Sys 1 Fans 1, 3, 5, 7, & 9 Sys 2 Fans 2, 4, 6, 8, & 10
Stage 6 (6 Fans ON) Sys 1 Fans 1, 3, 5, 7, 9, & 11 Sys 2 Fans 2, 4, 6, 8, 10, & 12
1, 2, and 3
Sys 1: 4CR, 5CR, & 6CR Sys 2: 7CR, 8CR, & 9CR
212
JOHNSON CONTROLS
Discharge Pressure (PSIG) Discharge Pressure (PSIG)
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Fan on and off control points will vary for standard and optional optimized IPLV chillers. Unless controls dictate all fans running due to high VSD ambient temperatures, fans will sequence on when a compressor runs and discharge pressure rises. During compressor ramp up or ramp down when compressors are staged, the current fan stage will be held.
The number of fans is factory programmable under the password protected Unit Setup Mode.
Standard IPLV Fan Control
Fan staging ON and OFF points will be determined by the ambient temperature. The fan stage will be incremented, unless the 5 second timer between fan stages is still timing when the discharge pressure rises above the Fan ON Press. The fan stage is decremented, unless the 5 second timer between fan stages is still timing when the discharge pressure falls below the Fan OFF Press. When a fan stage is incremented, the fan delay timer is set to 5 seconds, and the Fan ON pressure is ramped 20 psig over the original ON point back to the original value over the next 20 seconds. When a fan stage is decremented, the fan delay timer is set to 5 seconds, and the Fan OFF pressure is ramped 20 PSIG below the original Fan OFF point, back to the original value over the next 20 seconds. The ON and OFF points will vary as ambient temperature changes. Figure 58 on page 213 below shows the fan ON and OFF points relative to ambient temperature.
Standard IPLV Fan Control
190 180 170 160 150 140 130 120 110 100
90
75
`
85
95
105
115
125
Ambient Air Temp (°F)
Fan On Press Fan Off Press
LD10633
Figure 58 - STANDARD IPLV FAN CONTROL
Optimized IPLV Fan Control Fan staging ON and OFF points will be determined by the ambient temperature. The fan stage will be incremented, unless the 5 second timer between fan stages is still timing when the discharge pressure rises above the Fan ON Press. The fan stage is decremented, unless the 5 second timer between fan stages is still timing when the discharge pressure falls below the Fan
JOHNSON CONTROLS
SECTION 7 - OPERATION
OFF Press. When a fan stage is incremented, the fan delay timer is set to 5 seconds, and the Fan ON pressure is ramped 20 PSIG over the original ON, point back to the original value over the next 20 seconds. When a fan stage is decremented, the fan delay timer is set to 5 seconds, and the Fan OFF pressure is ramped 20 PSIG below the original Fan OFF point, back to the original value over the next 20 seconds. The ON and OFF points will vary as ambient temperature changes. Figure 59 on page 213 below shows the fan ON and OFF points relative to ambient temperature.
Optimized IPLV Fan Control
155 150 145 140 135 130 125 120 115 110 105 100
95 90
75
`
85
95
105
115
125
Ambient Air Temp (°F)
Fan On Press Fan Off Press
Figure 59 - HIGH IPLV FAN CONTROL
LD10634
High VSD Cabinet Ambient Temperature Fan Operation
All condenser fans on all systems will run when the
chiller is off and enabled to run, if the VSD internal ambient temperature is higher than 5°F below the VSD
7
Cabinet Ambient Temperature Cutout of 158°F (158°F
minus 5°F equals 153°F). When the fans turn on in this
situation, the fan outputs will cycle one at a time with
a 100 ms delay between fan starts. When the VSD in-
ternal ambient falls below the "Restart Temperature"
(158°F Cutout minus 10°F equals 148°F), the fans will
all be turned off without a delay.
VSD TEMPERATURE CONTROL, OPERATION OF THE COOLANT PUMP, AND VSD CABINET COOLING FANS
The Coolant pump and VSD Cabinet Cooling Fans will run to cool the VSD whenever any of the following conditions are met:
· VSD Comp IGBT Baseplate Temperature on a 2 or 4 compressor unit is greater than 10°F (5.6°C) below the cutout (Cutout 218°F [103.3°C] minus 10°F [5.6°C] equals 208°F [97.8°C]). When the VSD internal ambient falls below the restart temperature (Cutout 218°F [103.3°C] minus 15°F [8.3°C] equals 203°F [95°C]), the fans and pump will turned off without a time delay.
213
SECTION 7 - OPERATION
· VSD Comp IGBT Baseplate Temperature on a 3 compressor unit is greater than 10°F (5.6°C) below the cutout (cutout 232°F [111.1°C] minus 10°F (5.6°C) equals 222°F [105.6°C]). When the VSD internal ambient falls below the restart temperature (cutout minus 15°F [8.3°C] equals 217°F [102.8°C]), the fans and pump will be turned off without a time delay.
· Pre-charge Enable 1 from the Chiller Logic Board is ON.
· Pre-charge Enable 2 from the Chiller Logic Board is ON.
· VSD Internal Ambient Temp more than 158°F (70.0°C) (Cutout) 10°F (5.6°C) equals 148°F (64.4°C). When the Internal Ambient Temp falls to less than 158°F (70.0°C) (Cutout) minus 15°F (8.3°C) equals 143°F (61.7°C) the VSD cooling fans and glycol pump will turn off.
· Condenser Fans (as needed) and VSD coolant pump/fans will run whenever a compressor is running. Under these conditions, the condenser fans will run to control discharge pressure and the VSD coolant pump/fans will run to cool the IGBT baseplate and internal cabinet. Additional condenser fans will be brought on, if the IGBT baseplate temperatures or internal cabinet ambient rises to 5°F (2.8°C) below the cutout. Condenser fans will turn off, if the compressor turns off provided VSD cooling is not required. The glycol pump and cabinet fan may continue to run, if VSD cooling is required.
· Glycol Pump and Cabinet Cooling Fans will also run in the Service Mode if the Fan/Pump Run Bit is Set.
REMOTE TEMPERATURE RESET CONTROL
Temperature Reset Control
Temperature Reset Control is used to reset the actual LCHLT (Leaving Chilled Liquid Temperature) setpoint used in capacity control. There are several ways to change the LCHLT setpoint. The first is by re-programming the Local Cooling Setpoint under the SETPOINTS key. This is the value the unit will control the LCHLT to if neither of the other methods is active.
Remote Temperature Limit Reset is only possible if the option is enabled by both the OPTIONS key selection and in the factory programmable password protected Unit Setup Mode.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Remote ISN Setpoint Control
The Remote Leaving Chilled Liquid Setpoint Cooling Setpoint can be set via the ISN comms. The control panel will only accept a remote setpoint from the ISN if the control panel is in Remote Control Mode (under the OPTIONS key). If the control panel is in Local Control Mode, the ISN setpoint will be ignored and the Remote Cooling Setpoint is set to the Local Cooling Setpoint. The minimum and maximum allowable reset values will be the same as the minimum and maximum allowable programmable values for the Local Cooling Setpoint. If these values are exceeded by the ISN, the minimum or maximum value will be used.
Contact a local YORK ISN Representative for details on ISN controls and capabilities.
Remote Temperature Reset
The Remote Leaving Chilled Liquid Cooling Setpoint can be reset via the Remote Temperature Reset analog input. A zero signal input (0% input) equates to a 0°F offset to the Local Cooling Setpoint. A full scale signal input (100% input) equates to a "positive" offset to the Local Cooling setpoint equal to the programmable Maximum Remote Temp Reset. The offset is linear and may be adjusted anywhere between the 0% and 100% points. The maximum setpoint allowed is the maximum programmable Local Cooling Setpoint and will be capped at this value, if the calculated setpoint with temperature offset exceeds this value.
This input may be used either in Local or Remote Control Mode. This feature will only operate if enabled under the UNIT SETUP and the OPTIONS key. The input will be ignored if the Remote Temp Reset is disabled under the OPTIONS key or if there are valid ISN comms while in Remote Control Mode. Once a change to the input is registered, a timer is set to the value of the Remote Inputs Service Time as programmable under the Unit Setup Mode at the factory for the default value of 15 minutes. The low limit is 5 minutes and the high limit is 60 minutes. The Remote input will be ignored until this timer expires. The timer assures that rapid changes in a remote reset signal don't result in poor temperature control or excessive compressor cycling. In most instances, this timer will not need to be changed, since reset more often than 15 minutes will create problems with chilled liquid temperature control. Factory Service should be contacted if a timer change is required.
214
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Control Board jumper JP4 must be positioned correctly to receive either a voltage (0 VDC through 10 VDC or 2 VDC through 10 VDC) or current (0 mA through 20 mA or 4 mA through 20 mA) signal. Place the jumper in the "V" position for a voltage signal or mA for a current signal (See Figure 27 on page 166 and Figure 28 on page 167). The software must be configured under the OPTIONS key for the specific type of input signal to be used.
The maximum temperature reset is achieved at either 10 VDC or 20 mA. Sending the minimum signal (0 VDC, 2 VDC, 0 mA, or 4 mA based on the OPTIONS key setting) causes the setpoint to revert back to its local programmed value. If the setpoint reset causes the setpoint to go over the maximum programmable value, it will be set to the maximum programmable setpoint.
0 VDC through 10 VDC Reset Input
A 0 VDC signal produces a 0°F reset. A 10 VDC signal produces the maximum remote temp reset (programmable under the SETPOINTS key). The setpoint reset is ramped linearly between these limits as the input varies between 0 VDC and 10 VDC. In order for this input to work properly, the Remote Temperature Reset must be programmed for 0 VDC through 10 VDC input (OPTIONS key) and Chiller Control Board jumper JP4 placed in the "V" position.
2 VDC through 10 VDC Reset Input
A 0 VDC to 2 VDC signal produces a 0°F reset. A 10 VDC signal produces the maximum remote temp reset (programmable under the SETPOINTS key). The setpoint reset is ramped linearly between these limits as the input varies between 2 VDC and 10 VDC. In order for this input to work properly, the Remote Temperature Reset must be programmed for 2 through 10 VDC input (OPTIONS key) and Chiller Control Board jumper JP4 placed in the "V" position.
0 mA through 20 mA Reset Input
A 0 mA signal produces a 0°F reset. A 20 mA signal produces the maximum remote temp reset (programmable under the SETPOINTS key). The setpoint reset is ramped linearly between these limits as the input varies between 0 mA and 20 mA. In order for this input to work properly, the Remote Temperature Reset must be programmed for 0 mA through 20 mA input (OPTIONS key) and Chiller Control Board jumper JP4 placed in the "mA" position.
SECTION 7 - OPERATION
4 mA through 20 mA Reset Input
A 0 mA to 4 mA signal produces a 0°F reset. A 20 mA signal produces the maximum remote temp reset (programmable under the SETPOINTS key). The setpoint reset is ramped linearly between these limits as the input varies between 4 mA and 20 mA. In order for this input to work properly, the Remote Temperature Reset must be programmed for 4 mA through 20 mA input (OPTIONS key) and Chiller Control Board jumper JP4 placed in the "mA" position.
Local Current Limit Control
Local Current Limit Control is used to set the actual Current Limit Setpoint. This is accomplished by changing the Local Current Limit Setpoint under the PROGRAM key. This is the value at which the unit will begin to current limit and override capacity control if remote reset is not actively overriding this control. If any other current limit methods are active, the lowest value will be used.
Keep in mind that limiting current may interfere with capacity control, pulling down chilled liquid temperatures on hot water starts, and maintaining chilled liquid setpoints.
Pulldown Current Limit Setpoint
The Pulldown Current Limit Setpoint can be set under
the PROGRAM key. This current limit setpoint is only 7
active on start-up for the time defined by the Pulldown Current Limit Time under the PROGRAM key. After the run time has exceeded this time, the Pulldown Current Limit Setpoint is ignored.
This control is useful in limiting current pulldown demand during peak usage periods where electric costs are highest.
Keep in mind that limiting current may interfere with capacity control, pulling down chilled liquid temperatures on hot water starts, and maintaining chilled liquid setpoints.
REMOTE CURRENT LIMIT RESET CONTROL
Remote Current Limit Reset is used to reset the actual current limit setpoint used in current limit control. There are several ways to change the current limit setpoint. The first is by reprogramming the Local Current Limit Setpoint under the PROGRAM key. This is the value the unit will control the current limit to if neither of the other methods is active.
JOHNSON CONTROLS
215
SECTION 7 - OPERATION
Remote Current Limit Reset is only possible if the option is enabled by both the OPTIONS key selection and in the factory programmable password protected Unit Setup Mode.
Remote ISN Current Limit Setpoint
The ISN Current Limit Setpoint can be set via the ISN comms. The control panel will only accept a Current Limit Setpoint from the ISN if the control panel is in Remote Control Mode (under the OPTIONS key). If the control panel is in Local Control Mode, the ISN setpoint will be ignored. The minimum and maximum allowable values will be the same as the minimum and maximum allowable reset values for the Current Limit Setpoint under the PROGRAM key. If these values are exceeded, the minimum or maximum value will be used.
Contact a local Johnson Controls ISN Representative for details on ISN controls and capabilities.
Remote Current Limit Reset
The Current Limit Setpoint can be set or reset via the Remote Current Limit analog input. A zero signal input (0% input) equates to the maximum current limit setpoint as defined under the PROGRAM key Current Limit Setpoint. A full scale signal input (100% input) equates to the minimum current limit setpoint as defined under the PROGRAM key Current Limit Setpoint. The current limit value is linear and may be adjusted anywhere between the maximum and minimum points of 0% (no offset) and 100% (max. current limiting).
This input may be used either in Local or Remote Control Mode. This input will be ignored if the Remote Current Limit is disabled under the OPTIONS key. Once a change to the input is registered, a timer is set to the value of the Remote Inputs Service Time as programmable under the Unit Setup Mode at the factory for the default value of 15 minutes. The low limit is 5 minutes and the high limit is 60 minutes. The Remote input will be ignored until this timer expires. The timer assures that rapid changes in a remote reset signal don't result in poor temperature control or excessive compressor cycling. In most instances, this timer will not need to be changed, since reset more often than 15 minutes will create problems with chilled liquid temperature control. Factory Service should be contacted if a timer change is required.
Control board jumper JP5 must be positioned correctly to receive either a voltage (0 VDC to 10 VDC or 2
216
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
VDC to 10 VDC) or current (0 mA to 20 mA or 4 mA to 20 mA) signal. Place the jumper in the "V" position for a voltage signal or mA for a current signal (See Figure 27 on page 166 and Figure 28 on page 167). The software must be configured under the OPTIONS key for the type of input signal to be used.
The minimum current limit setpoint is achieved at either 10 VDC or 20 mA. Sending the minimum signal (0 VDC, 2 VDC, 0 mA, or 4 mA based on the OPTIONS key setting) causes the current limit to revert back to its maximum value.
0 VDC through Reset Input
A 0 VDC signal sets the current limit to the maximum value. A 10 VDC signal sets the current limit to the minimum value. The current limit is ramped linearly between these limits as the input varies between 0 VDC and 10 VDC. In order for this input to work properly, the Remote Current Limit must be programmed for 0 VDC through 10 VDC input (OPTIONS key) and Chiller Control Board jumper JP5 placed in the "V" position.
2 VDC through 10 VDC Reset Input
A 0 VDC to 2 VDC signal sets the current limit to the maximum value. A 10 VDC signal sets the current limit to the minimum value. The current limit is ramped linearly between these limits as the input varies between 2 VDC and 10 VDC. In order for this input to work properly, the Remote Current Limit must be programmed for 2 VDC through 10 VDC input (OPTIONS key) and Chiller Control Board jumper JP5 placed in the "V" position.
0 mA through 20 mA Reset Input
A 0 mA signal sets the current limit to the maximum value. A 20 mA signal sets the current limit to the minimum value. The current limit is ramped linearly between these limits as the input varies between 0 mA and 20 mA. In order for this input to work properly, the Remote Current Limit must be programmed for 0 mA through 20 mA input (OPTIONS key) and Chiller Control Board jumper JP5 placed in the "mA" position.
4 mA through 20 mA Reset Input
A 4 mA signal sets the current limit to the maximum value. A 20 mA signal sets the current limit to the minimum value. The current limit is ramped linearly between these limits as the input varies between 4 mA and 20 mA. In order for this input to work properly, the Remote Current Limit must be programmed for 4 mA
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
through 20 mA input (OPTIONS key) and Chiller Control Board jumper JP5 placed in the "mA" position.
SOUND LIMIT CONTROL
(Local and Remote Reset Control)
Sound Limiting and Local Sound Limit Setpoint Sound limit control to reduce overall chiller noise levels at specified times of the day is accomplished by setting a Sound Limit Setpoint. There are several ways to set the Sound Limit Setpoint. The first is by changing the Local Sound Limit Setpoint under the PROGRAM key. This is the value the unit will use for sound limiting, if neither of the other methods is active. If any other sound limit methods are active, the lowest value will be used. A sound limit of 0% will allow the unit to run up to the unit's maximum frequency. A sound limit of 100% will not allow the unit to run above the minimum frequency. All other sound limit values are linear between these 2 points.
A sound limit schedule must be programmed under the SCHEDULE key when sound limiting is utilized. The schedule defines the time period that sound limiting will be active.
Sound Limiting is only possible if the option is enabled by both the OPTIONS key selection and the factory programmable password protected Unit Setup Mode.
If Sound Limiting is disabled under the Unit Setup Mode, nothing relating to Sound Limiting will show up on any display screen or printout.
ISN Sound Limit Setpoint The ISN Sound Limit Setpoint can be set via the ISN II comms. The control panel will only accept a Sound Limit Setpoint from the ISN if the control panel is in Remote Control Mode. If the control panel is in Local Control Mode, the ISN setpoint will be ignored. The minimum and maximum allowable values will be the same as the minimum and maximum allowable values for the Sound Limit Setpoint under the PROGRAM key. If these values are exceeded, the minimum or maximum value will be used.
Contact a local Johnson Controls ISN Representative for details on ISN controls and capabilities.
JOHNSON CONTROLS
SECTION 7 - OPERATION
Remote Sound Limit
The Sound Limit Setpoint can be set via the Remote Sound Limit analog input. A zero signal input (0% input) equates to the minimum sound limit setpoint as defined under the PROGRAM key Sound Limit Setpoint. A full scale signal input (100% input) equates to the maximum sound limit setpoint as defined under the PROGRAM key Sound Limit Setpoint. The input is linear and may be adjusted between 0% (minimum sound limiting) and 100% (maximum sound limiting) points.
This input may be used either in Local or Remote Control Mode. The input will be ignored if the Remote Sound Limit is disabled under the OPTIONS key. Once a change to the input is registered, a timer is set to the value of the Remote Inputs Service Time as programmable under the Unit Setup Mode at the factory for the default value of 15 minutes. The low limit is 5 minutes and the high limit is 60 minutes. The Remote input will be ignored until this timer expires. The timer assures that rapid changes in a remote reset signal don't result in poor temperature control and excessive compressor cycling. In most instances, this timer will not need to be changed, since reset more often than 15 minutes will create problems with chilled liquid temperature control. Factory Service should be contacted if a timer change is required.
Control board jumper JP6 must be positioned correctly
to receive either a voltage (0 VDC to10 VDC or 2 VDC 7
to 10 VDC) or current (0 mA to 20 mA or 4 mA to 20 mA) signal. Place the jumper in the "V" position for a voltage signal or mA for a current signal (See Figure 27 on page 166 and Figure 28 on page 167). The software must be configured under the OPTIONS key for the type of input signal to be used.
The maximum sound limit is achieved at either 10 VDC or 20 mA. Sending the minimum signal (0 VDC, 2 VDC, 0 mA, or 4 mA based on the OPTIONS key setting) causes the sound limit to be set to its minimum (no limiting) value.
0 VDC through 10 VDC Reset Input
A 0 VDC signal produces a 0% sound limit (no change to max VSD freq). A 10 VDC signal produces a 100% sound limit (max VSD freq equals min VSD freq). The sound limit is ramped linearly between these limits as the input varies between 0 VDC and 10 VDC. In order for this input to work properly, the Remote Sound Limit must be programmed for 0 VDC through 10 VDC input (OPTIONS key) and Chiller Control Board jumper JP6 placed in the "V" position.
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SECTION 7 - OPERATION
2 VDC through 10 VDC Reset Input
A 0 VDC through 2 VDC signal produces a 0% sound limit (no change to max VSD freq). A 10 VDC signal produces a 100% sound limit (max VSD freq equals min VSD freq). The sound limit reset is ramped linearly between these limits as the input varies between 2VDC and 10 VDC. In order for this input to work properly, the Remote Sound Limit must be programmed for 2 VDC through 10 VDC input (OPTIONS key) and Chiller Control Board jumper JP6 placed in the "V" position.
0 mA through 20 mA Reset Input
A 0 mA signal produces a 0% sound limit (no change to max VSD freq). A 20 mA signal produces a 100% sound limit (max VSD freq equals min VSD freq). The sound limit reset is ramped linearly between these
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
limits as the input varies between 0 mA and 20 mA. In order for this input to work properly, the Remote Sound Limit must be programmed for 0 mA through 20 mA input (OPTIONS key) and Chiller Control Board jumper JP6 placed in the "mA" position.
4 mA through 20 mA Reset Input A 0 mA through 4 mA signal produces a 0% sound limit (no change to max VSD freq). A 20 mA signal produces a100% sound limit (max VSD freq equals min VSD freq). The sound limit reset is ramped linearly between these limits as the input varies between 4mA and 20 mA. In order for this input to work properly, the Remote Sound Limit must be programmed for 4 mA through 20 mA input (OPTIONS key) and Chiller Control Board jumper JP6 placed in the "mA" position.
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SECTION 8 - MICROPANEL
VSD OPERATION AND CONTROLS
VSD Logic Board
The VSD Logic Board communications with the Chiller Control Board via comms and controls the VSD functions. It converts the frequency and run commands from the Chiller Control Board into the necessary voltage and frequency commands to operate the inverter section. It also controls the converter section of the drive (AC Line to DC Bus conversion) by controlling the pre-charge function.
The VSD Logic Board contains a 2nd microprocessor (motor controller) that generates the PWM signals that control the IGBT outputs in the inverter section of the VSD.
An FPGA handles the hardware safeties that can shut down the VSD much faster than the software safeties. The VSD Logic Board handles all of the VSD related safeties, which includes motor current, BUS voltage, and other safeties.
The VSD Logic Board reports shutdown information back to the Chiller Control Board via the RS-485 communication link.
2, 3 and 4 compressor chillers all use the same software. The microprocessor determines whether the chiller is a 2, 3 or 4 compressor chiller by electronically checking for a factory-installed jumper in the system wiring harness. The microprocessor checks for the jumper located in the J1 plug wiring harness at powerup. If no jumper or more than one jumper is sensed, the microprocessor will inhibit start-up. Details regarding the location of the jumper are provided in Chiller Configuration Jumpers on page 195.
VSD Start/run Initiation
Following a successful precharge of the DC Bus and a run command from the Chiller Control Board, the VSD Logic Board microprocessor will determine the motor output voltage (% modulation) and the output frequency required based on the operating frequency command from the Chiller Control Board. This information will then be sent to the PWM generator located on the VSD Logic Board. On start-up, the output frequency from the VSD to the motor(s) will be increased from 0 Hz to the operating frequency commanded by the Chiller Control Board.
JOHNSON CONTROLS
The rate of change of the frequency will also be controlled by the VSD Logic Board.
The rate of change of the output frequency at start-up, during acceleration is 10 Hz/s between 0 Hz and 50 Hz and 30.4 Hz/s above 50 Hz. The maximum rate of change of the output frequency during deceleration between 200 Hz and 100 Hz is 30.4 Hz/s, and 100 Hz and 0 Hz is 10 Hz/s.
The VSD Logic Board and its PWM generator will receive operating frequency and voltage commands from the Chiller Control Board based on the load.
When a frequency (speed) change is requested from the Chiller Control Board, the chiller microprocessor will send the change to the VSD Logic Board and the VSD Logic Board will acknowledge it accepted the change. Loading and unloading will take place at the rate of 0.1 Hz to 1 Hz every 2 seconds.
PWM Generator Type and Carrier Frequency
The PWM generator is responsible for providing asym-
metrical uniform sampled PWM waveforms to the
compressor motor at a carrier frequency of 3125 Hz by
turning on an off the inverter IGBT's. The waveform
generated is equivalent to a specific V/F ratio at a given
speed based on the voltage and frequency commands
from the Chiller Control Board. The PWM Generator
receives operating frequency and voltage commands
from the VSD Logic Board control processor.
8
Short Circuit Protection Minimum Output Pulse Width and Interlock Delay
The PWM generator is programmed to drop all "on" pulses in less than 10 microseconds (and all matching "off" pulses in the mirrored waveform) to permit time for the IGBT gate drivers to detect and self extinguish an inverter short circuit condition.
Modulating Frequency
The modulating frequency range will range from 0 Hz to 200 Hz. The modulating frequency waveform consists of a sinusoidal waveform summed together with 16.66% of the third harmonic component of the sinusoidal waveform. Utilization of this waveform as the modulating waveform will permit the drive to generate a fundamental line to line voltage equal to the DC Bus voltage divided by 1.414.
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SECTION 8 - MICROPANEL
Maximum VSD Frequency
The maximum VSD frequency will vary for each chiller model. The microprocessor board determines the frequency according to jumpers' factory installed in the wiring on the J7 plug of the microprocessor board. The location of these jumpers' is interpreted as a binary value, which presently allows 7 speed selections plus a default. The maximum frequency may vary from 178 Hz to 200 Hz. If the J7 plug is not installed, the speed will default to 178 Hz. Details on the location of the jumpers' and the associated maximum speed are provided in Chiller Configuration Jumpers on page 195.
VSD % Modulation
The voltage and frequency commands issued by the VSD Logic Board microprocessor are determined by the frequency command from the Chiller Control Board. The VSD output is a PWM signal (Figure 4 on page 21), which has effects on the motor comparable to an AC voltage sinusoidal waveform. To change the speed of an AC motor, the frequency of the AC voltage must be changed. Whenever frequency is changed, the voltage is changed in a linear ratio. Maintaining a relatively constant V/F ratio as speed changes assures motor losses and overheating do not occur.
The output voltage of the VSD is not a sinusoidal waveform. Instead, the PWM generator provides an output that simulates a true AC waveform by repetitively turning on and off the voltage to the motor to create an average voltage that is equal to a lower AC voltage at lower frequencies and a higher voltage at higher frequencies. The PWM generator also changes the % modulation of the waveform to simulate the frequency change to maintain the V/F ratio with motor speed changes.
The PMW generator is programmed to essentially operate a linear volts/Hz ratio over the 0 Hz to 200 Hz frequency range. The complex control algorithm modifies the voltage command to boost the voltage of the V/F ratio at lower speeds to provide additional torque.
The 100% modulation operating point occurs at a fundamental frequency of 189.6 Hz. As the output frequency increases above 189.6 Hz, the drive operates in an over-modulated mode. For example, at 200 Hz fundamental modulating frequency the PWM waveform is over-modulated by approximately 18%. This will yield a fundamental output line to line voltage applied to the motor terminals at maximum output frequency that is equal to the input line to line voltage applied to the drive (provided the DC Bus current remains continuous).
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
VSD Cooling and Cooling Loop
The VSD generates heat in the IGBT power modules and the SCR/Diode assemblies, which must be removed. The heat not only heats the modules but also the Micro/VSD cabinet.
The VSD is cooled by a glycol loop and circulating pump. The glycol cooling loop feeds a liquid cooled heatsink called a chillplate that cools the IGBT's and SCR/Diode modules. The coolant is pumped by a circulator pump through the heatsink where it absorbs heat in several passes of tubes on the lower rows of the inside condenser coils where the condenser fans remove the heat picked up from the modules. The coolant is then pumped back to the modules. The glycol loop also provides cooling for the Micro/VSD cabinet. The baseplates of the power components are mounted to the glycol cooled heatsinks in the cooling loop. The cooling loop also circulates the glycol through a cooling coil in the cabinet. A fan blows air from the cabinet across the cooling coil to cool the electronics in the cabinet.
Never run the glycol pump without coolant! Running the glycol pump without coolant may damage the pump seals
Always fill the system with approved coolant to avoid damage to the pump seals and other components.
Heat transfer characteristics of the coolant are very critical. Substituting coolant or adding water will result in cooling loop performance loss and chiller shutdown.
The glycol coolant level in the VSD cooling system should be maintained between 9 and 15 inches (23 and 38 cm) from the top of the fill tube. This check should be performed prior to running the pump. The pump can be test run by placing the chiller in Service Mode. It is advisable to fill the tube to the required level before starting the glycol pump because it may empty when the pump starts. The level should be topped off as needed while running. Be sure to re-install the cap before stopping the glycol pump to avoid overflowing the fill tube when the glycol pump is turned off.
Glycol coolant has a defined operating life. System coolant should be changed 5 years from date of shipment of the equipment. Mixing other coolants or water with the special glycol will reduce the life of the coolant, and cause VSD overheating and damage.
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
VSD GLYCOL PUMP
SECTION 8 - MICROPANEL
· Pre-charge Enable 2 from the Chiller Logic Board is OFF.
· VSD Internal Ambient Temp less than Cutout minus 15°F.
· No compressors are running.
· Service Mode Fan/Pump is disabled. In some cases, the condenser fans may be turned on by the microprocessor, when no compressors are running, to keep the power components and Control/VSD Cabinet from overheating.
LD10635
The VSD fan and glycol pump will run if any of the following conditions listed below are true, provided the VSD has been powered up for less than 30 seconds and the pump has not run in the last 30 seconds. The 30 second limitations prevent pump motor overheating.
· 2 and 4 Compressor Baseplate temp is more than Cutout (218°F) minus 10°F.
· 3 Compressor IGBT Baseplate temp is more than Cutout (232°F) minus 10°F.
· Pre-charge Enable 1 from the Chiller Logic Board is ON.
· Pre-charge Enable 2 from the Chiller Logic Board is ON.
· VSD Internal Ambient Temp more than Cutout minus 10°F.
· Any compressor is running.
· Service Mode Fan/Pump Run is enabled.
The VSD fan/glycol pump will turn off when ALL of the following conditions are true:
· Compressor 1/3 IGBT Baseplate temp is less than Cutout minus 15°F.
· Compressor 2/4 IGBT Baseplate temp is less than Cutout minus 15°F.
· Pre-charge Enable 1 from the Chiller Logic Board is OFF.
IGBT Module Baseplate Temperature Sensing Each IGBT module has an internal 5Kohm thermistor built in to measure the temperature of the module. Up to 4 thermistors are connected to the VSD Logic Board (one per compressor). The highest module temperature of compressors 1 and 3 are sent to the logic board along with the highest module temperature of compressors 2 and 4. If the temperature exceeds the software trip point, the unit will shut down on a safety. See "High Baseplate Temperature Fault" (Page 241) for details.
LM 34 SENSOR
8
LD10615
ORIGINAL - OBSOLETE P/N 031-02477-000
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SECTION 8 - MICROPANEL
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Following successful completion of the pre-charge interval, the SCR's on the AC to DC semi-converter (SCR/Diode Modules) will be gated fully on by the SCR Trigger Board and the DC Bus will be brought up to its full potential. After pre-charge has been successfully completed, the SCR's will stay fully on until the Chiller Control Board turns off the Pre-Charge Enable via comms.
LM 34 SENSOR
There will be a Unit Pre-charge Enable for 2 and 3 compressor units and separate System Pre-charge Enables for 4 compressor units.
The pre-charge will only take place when all of the following conditions are true, otherwise it is disabled:
LD13123
· Daily Schedule is ON.
NEW BOARD - P/N 031-02507-XXX
· UNIT switch is ON.
VSD Internal Ambient Temperature Sensing
A National LM34 temperature sensor located on the VSD Logic Board is used to measure the internal ambient temperature of the Control Panel/VSD enclosure. It has an output voltage that is linearly proportional to the temperature in degrees Fahrenheit. If the temperature exceeds the software trip point, the unit will shut down on a safety. See "High VSD Ambient Temperature Fault" (Page 241) for details.
Pre-charge
When cooling is required (LCWT is more than SPHL), leaving chilled liquid temp is greater than the setpoint high limit), the chiller Control Board will send a Pre-Charge Enable (2 enables on a 4 comp unit) via comms to the VSD Logic Board. The VSD's DC Bus voltage(s) across the Bus Filter Capacitors will slowly be increased to the proper level (more than 500 VDC) through firing of the SCR Trigger Board(s) and the associated pre-charge enable control signal(s). The precharge time interval is fixed at 20 seconds. The purpose of the precharge is to limit current when charging an uncharged capacitor bank. When uncharged, the capacitor bank looks like an electrical short. The bus is brought up slowly by only turning on the SCR's during the trailing half of the + and portion of the incoming AC sine wave. Following is the status message displayed while the precharge is taking place.
SYS X VSD DC BUS PRECHARGE
· System Switch(es) are ON.
· Run Permissive(s) are Enabled.
· Flow Switch indicates flow.
· LCHLT more than Setpoint High Limit.
· Unit not faulted / locked out.
Run Mode / Unit Restart
In order to initiate a system run, two conditions must be met. At least 1 of the 2 systems run signals from the control panel must be present and at least 1 of the 4 possible Compressor RUN bits must be set in the serial communications link between the VSD Logic Board and the Chiller Control Board. Following successful completion of pre-charge and receipt of the system run signals, the motor output voltage (% modulation) and output frequency commands will be determined by the VSD microprocessor located on the VSD Logic Board. These two parameters will be sent to the PWM generator located on the VSD Logic Board for waveform processing at a rate of once every 10 ms.
The voltage and frequency commands issued by the VSD microprocessor are determined by the operating frequency command received on the communications link from the Chiller Control Board and by the present operating frequency of the drive. Upon receipt of a legitimate run command communication, the VSD's output frequency will be increased from 0 Hz to the operating frequency command from the communications link.
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SECTION 8 - MICROPANEL
DC Bus Voltage Sensing and Scaling
VSD Transmitted Operating Parameters
Full DC Bus voltage and ½ DC Bus voltages are sensed for up to 2 DC Buses. 2 and 3 compressor chillers share a common DC Bus, while 4 compressor chillers utilize 2 DC Buses (1/3 and 2/4). The DC Bus is wired to the DC Bus Isolation Board, the voltage is divided down through a resistance voltage divider, and the reduced voltage is fed to the VSD Logic Board for safety monitoring.
Current Sensing and Scaling
Individual current transformers on each leg sense three phases of output current on each compressor. These signals are buffered, divided by 2, and filtered by an RMS to DC converter. The highest of the currents in the three phases of each compressor leaving the RMS converters is then sent to an A-D converter scaled, monitored by the VSD Logic Board overload and high current protection circuitry, and sent to the Chiller Control Board for display as the compressor current.
In order to set the motor overload level (determined by the setting of the OVERLOAD ADJUST potentiometer on the VSD Logic Board), the voltage level on the wipers of the four OVERLOAD ADJUST potentiometers is continuously sensed by the VSD Logic Board for current protection and sent to the Chiller Control Board for both display purposes and for current limiting control. This parameter is the 105% FLA value.
VSD operating parameters will be transmitted to the Chiller Control Board over the RS-485 communications link between the 2 boards. These values will be displayed on the control panel display. The data and display format are outlined in the Table 14 on page 223.
VSD SAFETIES (FAULTS)
VSD operating conditions are monitored by both software algorithms and hardware circuitry. Both types exist as a result of the need for both extremely fast protection requirements such as a short circuit condition or a slow reacting trip such as a slow rising overload condition. To eliminate nuisance unit trips, the sensor inputs for the VSD's operating parameters are averaged four times before "Software" generated unit/system fault trips from the VSD Logic Board are initiated. These faults cause single compressor or total unit controlled "ramped" shutdown. Other parameters that are not fed to the VSD Logic Board microprocessor are protected by "Hardware" generated fault trips. Hardware trips involve electronic circuitry that measures voltages or currents and activate level sensitive comparators connected to programmable gate arrays on the VSD Logic Board FPGA (Field Programmable Gate Array). These safeties operate extremely fast and provide "immediate" shutdown, because they are not dependent upon software program loops that operate in seconds or fractions of a second. Outputs from the gate arrays provide a digital signal to indicate whether a safety threshold has been reached.
Table 14 - VSD OPERATING DISPLAY PARAMETERS DATA
8
DISPLAY
FORMAT
Highest Phase of Compressor Motor Current in Amperes RMS (per Compressor)
XXX Amps
VSD Output Frequency
XXX.X Hz
Motor Overload Setting (105% FLA potentiometer setting) in amperes RMS (per Compressor)
XXX Amps
DC Bus Voltage in DC Volts (maximum of 2)
XXX Volts
VSD Internal Ambient Temperature
XXX.XºF (or ºC)
IBGT Power Assembly Power Module Highest Baseplate Temperature (maximum of 2)
XXX.XºF (or ºC)
Pre-Charge Enable Signal (maximum of 2)
On or OFF
VSD cooling Fan/Pump
On or OFF
Compressor Run Status (maximum of 4)
On or OFF
Immediate Fault shutdowns are often accompanied by audible motor backspin due to equalizing of the differential between discharge and suction when the compressor is turned off while rotating at high speeds. This should not cause concern and will not damage the chiller.
JOHNSON CONTROLS
Each fault outlined in the descriptions that follow will indicate whether it is a hardware or software generated fault. It will be noted the "ramped" shutdown results in minimal compressor backspin and noise associated with backspin. "Immediate" shutdowns will result in
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SECTION 8 - MICROPANEL
compressor backspin and a higher noise level based upon the differential pressure between discharge and suction.
When a VSD fault occurs, the VSD Logic Board captures VSD data in the onboard battery backed RAM. At the same time, the VSD Board "Fault Relay" will open, signaling the Chiller Control Board microprocessor to save a snapshot of system data. The VSD Logic Board then transmits the fault data to the Chiller Control Board microprocessor on the next comms between the two boards. If the Chiller Control Board receives the comms fault indication before the Fault Relay signal, it will immediately save a snapshot of system data when the comms fault is recognized. This also enables the microprocessor to capture fault data if the Fault relay fails. Both the system and VSD fault data are then stored in the Chiller Control Board history buffers. Any additional faults that may occur during shutdown on the first fault or between the first fault and the next comms will also be stored and transmitted to the Chiller Control Board along with the original fault data. This data will be stored as "ALL FAULT" data.
When the control panel acknowledges a fault (via the fault acknowledge bit in comms) the fault relay will be reset (closed) by the VSD Logic Board and the fault indication flag (in comms) will be reset.
The fault relay will not open when a non-running fault occurs. In this case, the system will be inhibited from running until the fault condition is corrected. An inhibit message will be displayed on the panel display indicating the system is not allowed to run. Examples of this type of fault would be the High Internal Ambient fault and the VSD CT Plug Fault. When the chiller receives the transmitted fault data via comms, it will save a snapshot of system data in the history buffer even though the chiller is not running.
Some faults will be unit faults; other faults will be system (specific compressor or compressor pairs) faults, depending upon the number of compressors in the chiller. Most faults will shut down the unit/ system and allow restart once the fault clears and the 120 seconds anti-recycle timer times out. These faults will allow up to 3 faults in 90 minutes before locking out the unit/ system. Other faults lock out the unit/system after only a single fault. Details on individual faults are provided in the following explanations.
A start inhibit will take place if a VSD fault condition exists and a compressor that is not running is called to
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
start. The start inhibit will be cleared when the fault condition goes away and the compressor will be permitted to start.
Pre-charge Low DC Bus Voltage (Software) Fault The DC Bus voltage must reach at least 50 VDC within four seconds and 500 VDC within 19 seconds after the pre-charge signal has been asserted. If not, the unit/system will shut down on a fault.
This is an auto-restart safety that will lock out on the 3rd fault in 90 minutes. The fault will be a unit fault for 2 or 3 compressor chillers. The Status display fault message is shown below:
UNIT YYYYYYYY PRECHARGE - LOW DC BUS VOLTAGE
The Low DC Bus voltage fault will be a unit fault for 2 and 3 compressor units or a system fault for System 1/3 or 2/4 for 4 compressor units. The reason for this is two inverter power sections with separate DC Bus circuitry for each inverter section is utilized on a 4 compressor unit. One section serves systems 1 and 3 while another serves systems 2 and 4. The Status display fault message is shown below:
SYS X YYYYYYYY PRECHARGE - LOW DC BUS VOLT
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the fault clears or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
Pre-charge DC Bus Voltage Imbalance (Software) Fault The 1/2 DC Bus voltage magnitude must remain within plus or minus 100 VDC of the total DC Bus voltage divided by two during the pre-charge interval. If not, the unit/system shall shut down on a fault. This safety will lock out on the 1st fault. The fault will be a unit fault for 2 or 3 compressor units. The Status display fault message is shown below:
UNIT YYYYYYYY PRECHARGE - DC BUS VOLTAGE IMBALANCE
The fault will be a System 1/3 or 2/4 fault for 4 compressor units. Two key presses of the STATUS key are required to show the fault on both systems. The Status display fault message is displayed below:
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SECTION 8 - MICROPANEL
SYS X YYYYYYYY PRECHARGE-BUS VOLT IMBAL
X indicates the system and YYYYYYY indicates the system is in a "LOCKOUT" condition and will not restart until the operator clears the fault using the keypad.
High DC Bus Voltage (Hardware) Fault The high DC Bus voltage trip level is determined by hardware on the VSD Logic Board and is designed to trip the unit at 766 plus or minus 30 VDC. If the DC Bus exceeds this level, the unit/system will fault and shut down immediately. This safety is an auto-restart safety that will lock out on the 3rd fault in 90 minutes. The fault will be a unit fault for 2 or 3 compressor units. Two key presses of the STATUS KEY are required to show the fault on both systems. Below is the control panel Status display fault message:
UNIT YYYYYYYY HIGH DC BUS VOLTAGE
The fault will be a System 1/3 or 2/4 fault on 4 compressor units. Below is the Status display fault messages for all systems. Two key presses of the STATUS key are required to show the fault on both systems.
SYS X YYYYYYYY HIGH DC BUS VOLTAGE
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the fault clears or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
Low DC Bus Voltage (Software) Fault The low DC Bus voltage trip level is set at 500VDC. If the DC Bus drops below this level the unit/system will fault and immediately shut down.
The low DC Bus voltage cutout is an auto-restart safety that will lock out on the 3rd fault in 90 minutes. The fault is a unit fault for 2 or 3 compressor units. Below is an example of the Status display fault message:
UNIT YYYYYYYY LOW DC BUS VOLTAGE
The low DC Bus voltage cutout is a system fault (1/3 or 2/4) on 4 compressor units. Two key presses of the STATUS key are required to show the fault on both systems. Below is a sample Status display system fault message:
JOHNSON CONTROLS
SYS X YYYYYYYY LOW DC BUS VOLTAGE
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the fault clears or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
DC Bus Voltage Imbalance (Software) Fault The 1/2 DC Bus voltage magnitude must remain within plus or minus 100 VDC of the total DC Bus voltage divided by two. If the 1/2 DC Bus magnitude exceeds the plus or minus 100 VDC tolerances, the unit/system will fault and immediately shut down.
This safety will lock out on the 1st fault. The fault will be a unit fault for 2 or 3 compressor units. Below is the Status display fault message:
UNIT YYYYYYYY DC BUS VOLTAGE IMBALANCE
The fault will be a System 1/3 or 2/4 fault on 4 compressor units. Two key presses of the STATUS key are required to show the fault on both systems. Below is a sample Status display fault message:
SYS X YYYYYYYY DC BUS VOLTAGE IMBALANCE
X indicates the system and YYYYYYY indicates the system is in a "LOCKOUT" condition and will not restart until the operator clears the fault using the keypad.
High Motor Current (Hardware) Fault
The three output lines to each phase of the compres- 8
sor motor are monitored via three current transformers within the VSD. The unit's three phases of instantaneous output current will be compared to a predetermined limit, which is contained in hardware. The nominal peak current trip level is 575.5 A (554 A minimum, 597 A maximum). 380 VAC, 60 Hz and 400 VAC, 50 Hz nominal peak current trip level is 649.5 A (626 A minimum, 674 A maximum). The variation in trip point is the result of component tolerances on the VSD Logic Board. If the peak current limit is exceeded, the unit will fault and shutdown immediately.
This fault is an auto-restart safety that will lock out system on the 3rd fault in 90 minutes. The fault will be an individual system/compressor fault for all units. Following is a sample Status display fault message:
SYS X YYYYYYYY HIGH MOTOR CURRENT
225
SECTION 8 - MICROPANEL
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
Motor Current Overload (Software) Fault The Motor Current Overload will compare the highest of the 3 phases of motor current per compressor to the compressor's 105% FLA ADJUST (overload) potentiometer setting on the VSD Logic Board. If the current exceeds the setting continuously for 20 seconds, the compressor will trip.
This safety will lock out a system on the 1st fault and shut down with a controlled ramped shutdown. The fault will be an individual system/compressor fault for all systems. A sample Status display fault is shown below:
SYS X YYYYYYYY MOTOR CURRENT OVERLOAD
X indicates the system and YYYYYYY indicates the system is in a "LOCKOUT" condition and will not restart until the operator clears the fault using the keypad.
Motor Current Overload (Hardware) Fault The Motor Current Overload will compare the highest of the 3 phases of motor current per compressor to the compressor's overload ADJUST potentiometer setting. If the current exceeds the setting continuously for 30 seconds, all compressors will fault and shut down immediately.
The fault will be a unit fault and will lock out all systems on the first fault. A sample Status display fault is shown below:
UNIT YYYYYYYY MOTOR CURRENT OVERLOAD
YYYYYYYY indicates the unit is in a "Lockout" condition and will not restart until the operator clears the fault using the keypad.
IGBT Gate Driver (Hardware) Fault The unit's phase bank assembly(s) contains one IGBT gate driver control board per compressor. These boards monitor the saturation voltage drop across each of the six IGBT's while gated on. If the IGBT's saturation voltage exceeds the prescribed limit, the gate driver will make the determination that a short circuit is present. This in turn will cause the system to trip. During
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
normal operation, the voltage drop across a saturated IGBT is low. When a short or shoot occurs, the extremely high current causes the voltage across the device to increase. When the electronic hardware on the IGBT Gate Driver Board senses the current rise, it immediately turns off all IGBT's in the module and the system will shut down immediately.
Additionally, if the IGBT's Gate Driver board's power supply voltage falls below the permissible limit, this same fault will be generated.
This is an auto-restart safety that will lock out on the 3rd fault in 90 minutes. The fault will be a system fault for all units. Following is the Status display fault messages for all systems.
SYS X YYYYYYYY GATE DRIVER
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
High Baseplate Temperature (Software) Fault
Each phase bank assembly contains one liquid cooled heatsink to cool both the inverter power modules and the converter SCR/Diode modules. Each compressor's inverter power module (6 IGBT's and Gate Driver Board) contains an internal temperature sensor (5K ohm at 25°C) to monitor the baseplate temperature.
On two compressor chillers, the outputs from System 1 and System 2 sensors are each compared in software to a limit of 218°F. If either sensor exceeds this limit, the unit will fault and shut down with a controlled ramped shutdown.
On 3 compressor chillers, the baseplate temperatures on compressors 1 and 3 are OR'd together and the highest of the two temperatures is compared in software to a limit of 232°F. Compressor #2 will have its individual power module sensor compared in software to a limit of 232°F. If the limit is exceeded by either of the 2 inputs, the unit will fault and shut down with a controlled ramped shutdown.
3 compressor chillers operate at higher baseplate temperature compared to 2 or 4 compressor chillers.
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On 4 compressor chillers, the baseplate temperatures on compressors 1 and 3 are OR'd together and the highest of the two temperatures is compared in software to a limit of 218°F. The baseplate temperatures on compressors 2 and 4 are OR'd together and the highest of the two temperatures compared in software to a limit of 218°F. If the limit is exceeded by either of the 2 inputs, the unit will fault and shut down with a controlled ramped shutdown.
This is an auto-restart safety that will lock out on the 3rd fault in 90 minutes. The fault will be a system fault for all units. Below are the Status display fault messages for all systems.
SYS X YYYYYYYY HIGH VSD BASEPLATE TEMP
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the fault clears or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
After a fault, the fan(s) and water pump will remain energized until the inverter power module base plate temperature(s) falls below 165°F.
The system will be allowed to restart when the inverter power module base plate temperatures drop below this value.
It is possible for an internal sensor to fail and not sense temperature without causing a high baseplate sensor fault.
High VSD Internal Ambient Temperature (Software) Fault The VSD Logic board contains a temperature sensor, which monitors the unit's internal ambient temperature. If the VSD internal ambient temperature rises above the cutout of 158°F, the unit will fault and shut down with a controlled ramped shutdown.
This safety will not cause a lockout. The fault will be a unit fault for all units. Following is the Status display fault message.
UNIT YYYYYYYY HIGH VSD INTERNAL AMBIENT TEMP
The unit will be allowed to restart when the internal ambient temperature drops 10°F below the cutout.
YYYYYYYY indicates the unit is in a "Fault" condition and will restart when the condition clears.
SECTION 8 - MICROPANEL
Single Phase Input (Hardware) Fault The VSD's SCR Trigger Control board contains circuitry that checks the three phase mains for the presence of all three-line voltages. If any of the line voltages are not present, the system will immediately shut down on a fault.
This fault will not cause a lockout. The fault will be a unit fault for 2 or 3 compressor units. Below is the Status display fault message.
UNIT YYYYYYYY SINGLE PHASE INPUT VOLTAGE
The fault will be a system fault 1/3 or 2/4 for 4 compressor units. Two key presses of the STATUS key are required to show the fault on both systems. Below is the fault message for all systems.
SYS X YYYYYYYY SINGLE PHASE INPUT VOLTS
X indicates the system and YYYYYYY indicates the system is "FAULT" and will restart when the single phase condition clears.
Power Supply (Hardware) Fault Various DC power supplies which power the VSD Logic Board are monitored via hardware located on the logic board. If any of these power supplies fall outside their allowable limits, the unit will immediately shut down on a fault.
This is an auto-restart safety that will restart after the
fault clears and lock out on the 3rd fault in 90 minutes. 8
The fault will be a unit fault for all units. Below is the Status display fault message.
UNIT YYYYYYYY VSD LOGIC BOARD POWER SUPPLY
YYYYYYY indicates the system is in a "FAULT" condition and will restart when the fault clears or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
Run Relay (Software) Fault Upon receipt of either of the two types of run commands (hardware and software) a 5 second timer will commence timing. The hardware run signal comes from the SYS X VSD Run Signal to the VSD Logic Board. The software run signal comes through the comms from the Chiller Control Board. If the missing
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SECTION 8 - MICROPANEL
run signal is not asserted within the 5-second window, the system will fault. In addition, if either run signal is disabled while the VSD is running, the remaining run signal must be disabled within 5 seconds after the VSD is shut down or the system will fault. If running, the unit will fault and shut down with a controlled ramped shutdown.
Control Panel Info - This is an auto-restart safety that will autostart after the 120 second anti-recycle timer times out and will lock out on the 3rd fault in 90 minutes. The fault will be a system fault for 2 compressor units. On 3 and 4 compressor units, the fault is combined as a 1/3 or 2/4 system fault. Below are the fault messages for all systems.
SYS X YYYYYYYY VSD RUN RELAY
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the fault clears or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
VSD Logic Board Failure (Software) Fault Upon receipt of the voltage and frequency commands, the PWM generator will acknowledge receipt of the command. If the system microprocessor does not receive the handshake within 1.5 seconds of issuing the command, the unit will trip. This safety is only active during precharge and during running of a compressor. It is not active when all the compressors are shut down and the precharge is disabled. If the VSD Logic Board Fault occurs while the chiller is running, all systems will immediately shut down on a fault.
This is an auto-restart safety that will auto restart after the 120 second anti-recycle timer times out and lock out on the 3rd fault in 90 minutes. The fault is a unit fault for all units. Following is the fault message.
UNIT YYYYYYYY VSD LOGIC BOARD FAILURE
VSD CT Plug (Hardware) Fault Jumpers are installed in each CT plug on the VSD Logic Board to feed back signals to indicate if the plugs are installed or not. If either plug is not installed, a low value is read on the digital input and the unit will immediate shutdown on a fault or will not run if off.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
This is an auto-restart safety that will restart after the 120 second anti-recycle timer times out and lock out on the 3rd fault in 90 minutes. The fault is a unit fault for all units. Following is the fault message.
UNIT YYYYYYYY VSD CT PLUG FAULT
YYYYYYYY indicates the system is in a "FAULT" condition and will restart or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
VSD Fault Data When a fault has occurred, the VSD Logic Board will capture fault data. This data will be stored in the onboard battery backed RAM for safekeeping and transferred to the panel via the communications link as soon as possible.
A fault code will be set for the fault that initiated the system shutdown. This fault will appear as a specific fault in the Status message.
Any faults that occur after the initial fault, which occur within the comms transmission time frame following the inception of the first fault, will be stored and transmitted to the Micro Logic Board together with the first fault data. These faults will appear in the "All Fault" display in the History.
A snapshot of the operating parameters of the VSD is continuously updated in battery-backed memory once every program loop. Upon receipt of a first fault, the snapshot of the operating parameters will be stored in memory and are transmitted to the panel as the fault data.
Fault Relay/Fault Acknowledge Bit Control of the Fault Relay is from the VSD Logic Board. The Fault Relay on the VSD will be closed during a non-fault condition.
When a running or pre-charge fault occurs on the VSD, the fault relay will immediately open. The relay will not open for non-running faults that occur.
When the Chiller Control Board sees the VSD fault relay open, it will immediately take a snapshot of system data and save it to the history buffer.
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
A fault acknowledge bit from the Chiller Control Board is sent to the VSD via comms after receiving valid fault data from the VSD. When the VSD Logic Board receives the fault acknowledge via comms from the panel it will reset (close) the Fault Relay. The fault acknowledge is reset by the Chiller Control Board after the Fault Relay is closed by the VSD Logic Board. VSD Fault Compressor Start Inhibit If a VSD fault condition exists while the compressor is not running or pre-charging, the Chiller Control Board will not try to start the faulted compressor(s). The start inhibit will be automatically cleared when the fault condition goes away. UNIT WARNINGS Unit Warning Operation Unit warnings are caused when a condition is present requiring operator intervention to restart the unit. All setpoints, program values, and options should be checked before operating the unit. Warnings are not logged to the history buffer. If a unit warning is in effect, the message will be displayed to the operator when the STATUS key is pressed.
STATUS KEY
LD10605
SECTION 8 - MICROPANEL
Low Battery Warning
The LOW BATTERY WARNING can only occur at unit power-up. On micropanel power-up, the RTC battery is checked to see if it is still operational. If it is, normal unit operation is allowed. If the battery voltage is determined to be low, the following warning message is displayed indefinitely.
UNIT WARNING: !! LOW BATTERY !! CHECK SETPOINTS/PROGRAM/OPTIONS/TIME
If a low battery condition exists, all programmed setpoints, program values, time, schedule, and history buffers will have been lost. These values will all be reset to their default values, which may not be the desired operating values. Once a bad battery is detected, the unit will be prevented from running until the MANUAL OVERRIDE key is pressed. Once the MANUAL OVERRIDE key is pressed, the anti recycle timers will be set to the programmed default anti recycle time to allow the operator sufficient time to check setpoints, program values, etc.
If a low battery is detected, it should be replaced as soon as possible. The programmed values will all be lost and the unit will be prevented from running on the next power interruption. The RTC/Battery is located on the Chiller Logic Board shown in Figure 60 on page 230.
MICROBOARD (331-03478-XXX)
The 331-03478-xxx microboard was developed as a
direct replacement for the 031-02478-xxx line of mi-
croboards. No adapter harness is required when replacing a 02478 with the new 03478. The 03478 uses the
8
IPUII processor card and provides some new features
for the chillers that the 02478 did not have. The 03478
program resides in flash memory instead of EPROM.
Program updates are accomplished by loading the new
program from an SD card inserted into the SD card
reader/writer. This same SD card reader/writer also al-
lows the user to datalog the operating parameters to an
SD card every 5 seconds. This information is invalu-
able when troubleshooting unit and system problems
since it allows the service technician to view operat-
ing parameters prior to a unit fault. Details on the new
datalogging capability are explained in the OPTIONS
Key area of this manual. A Real Time Clock/BRAM
keeps time and setpoints during power outtages.
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SECTION 8 - MICROPANEL
Power Supplies and LEDs The 03478 has LEDs to indicate various states of operation of the microboard.
STATUS Flashes every ½ second to indicate that the base board processor is running its program.
POWER On solid indicates that the base board +12 V and +5 V power supplies are operational.
TX1 Red LED flashes when transmitting data out Port 1 TB3 (Future native communications BAS port)
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
RX1 Green LED flashes when receiving data in Port 1 TB3 (Future native communications BAS port)
TX2 Red LED that flashes when transmitting data out Port 2 (E-Link TB2 or printer TB1)
RX2 Green LED that flashes when receiving data in Port 2 (E-Link TB2 or printer TB1)
VSD_TX Red LED that flashes when transmitting data out Port 3 to the VSD Logic board
VSD_RX Green LED that flashes when receiving data in Port 3 from the VSD Logic board
TP10 +24 V TP5 +15 V TP4 +12 V TP1 GND
Port 1 Future Native BAS
TP3 +5V TP2 +3.3V
SD Card
JP4 JP5 JP6 Remote Setpoint Jumpers
U5 RTC/ BRAM
Power LED
Figure 60 - MICROBOARD 331-03478-XXX
Status LED
U26 Port 1 RS-485 Driver
Port 2
Power LED
RS-485 to E-Link
U18 VSD RS-485 Driver
VSD RX VSD TX RS-232 to Printer Port 2 RX2 TX2
U23 Port 2 RS-485 Driver
LD19331
24 VAC power is applied to the 331-03478-xxx microboard connector J12 and is then used to create the various DC power sources required by the microboard circuitry. If the chiller control is malfunctioning, the power supply test points should be measured to determine the status of the microboard.
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Power Supply Test Points TP1 GND (Measure TP2, TP3, TP4 and TP5 in reference to this Test Point)
TP2 +3.3 V [3.2 VDC to 3.4 VDC] provides power to the processors
TP3 +5 V [4.8 VDC to 5.2 VDC] power communiaction ports 2,3 and 4 and analog sensors
TP4 +12 V [11.64 VDC to 12.36 VDC] powers the display and backlight and is regulated to become the +5 V
TP5 +15 V [11.3 VDC to 16.6 VDC] powers the analog outputs to the EEV valves
Configuration Jumpers The same configuration jumpers that existed on the 02478 are provided on the 03478.
JP4 Remote Temp Reset jumper position Pins 1 to 2 (left) = 4 mA to 20 mA, Pins 2 to 3 (right) = 0 VDC to 10 VDC
JP5 Remote Current Limit jumper position Pins 1 to 2 (left) = 4 mA to 20 mA, Pins 2 to 3 (right) = 0 VDC to 10 VDC
JP6 Remote Sound Limit jumper position (Pins 1 to 2 (left) = 4 mA to 20 mA, Pins 2 to 3 (right) = 0 VDC to 10 VDC
Communication Ports TB3 Port 1 Native BAS RS-485.
SW1 RS-485 Biasing Switch for Port. Set to ON if Chiller is in an End Of Line position on the network.
U26 is the Port 1 RS-485 Driver Chip. It is socketed to allow field replacement. RX1 and TX1 LEDs illuminate to indicate Port 1 communications activity.
E-Link SW2 RS-485 Biasing Switch for E-link Port 2, should be in the OFF position.
TB2 is the Port 2 RS-485 E-Link Communications Port. RX2 and TX2 LEDs illuminate to indicate the Port 2 communications activity. U23 is the Port 2 RS485 Driver Chip. It is socketed to allow field replacement. J16 provides +12 VDC to power the E-Link.
VSD J2 VSD#1 and J1 VSD#2 connections headers for RS485 communications to the Variable Speed Drive(s). VSD RX and VSD TX LEDs illuminate to indicate the
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SECTION 8 - MICROPANEL
VSD communications activity.U18 is the VSD Port RS-485 Driver Chip. It is socketed to allow field replacement.
PROGRAM UPDATE
The Application software and BACnet database are stored in the IPU II Flash memory. Copying a new version of software and/or database from the SD Flash card changes the IPU II Flash. The new application software must be named SOFTWARE.BIN. The new BACnet database must be named DATABASE.BIN. These files must be located in the root directory of the SD Flash card. The software can be updated without updating the database. In this case, the existing database will be used with the new software. The database cannot be updated without updating the software.
To update the Program:
1. Copy the new software in to the root directory of the SD card.
2. Rename this new program file SOFTWARE.BIN.
3. Turn the Unit Switch OFF.
4. Insert the SD card in to the SD card Reader/Writer slot.
5. Press the OPTIONS Key and then press the Down Arrow Key until FLASH CARD UPDATE DISABLED is displayed.
6. Press the RIGHT ARROW Key to change the DISABLED to ENABLED
7. Press the ENTER Key to start the update. Once the ENTER Key is pressed the message FLASH
8
CARD
8. UPDATING PLEASE WAIT... is displayed until the update has been completed. The keypad and display will not respond during the flash update.
Do not reset or power down the chiller until the update is finished. Interrupting the Flash Update procedure can corrupt the program file and render the control board inoperative.
9. After the software is finished updating, the controller will automatically reboot.
10. If an error occurs during the update, an error message will be displayed where XXXX is the Error Code.
231
SECTION 8 - MICROPANEL
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Table 15 - FLASH CARD UPDATE ERROR XXXXX
FLASH CARD
UPDATE
ERROR CODE
0
Okay
DEFINITION
10
Flash card not found.
11
SOFTWARE.BIN file not found
14
SOFTWARE.BIN file larger than expected.
15
RAM to IPU Flash transfer of DATABASE. BIN failed.
16
RAM to IPU Flash transfer of SOFTWARE.BIN failed.
17
Could not allocate sufficient memory to read or write file.
99
Internal software error.
11. After the update is completed and the controller reboots, the keypad and display will return to full functionality. The SD card may be left in place for datalogging or else replaced with another SD card dedicated for datalogging.
12. To remove the SD card, GENTLY press the card in slightly then release the pressure. The card should then pop out slightly to allow removal.
DATA LOGGING
A 2GB SD card (p/n 031-03466-000) may be inserted into the 03478 IPUII SD card slot to record the chiller operating parameters at 5 second intervals. The data is stored in a folder named RMYYYYMM where YYYY is the year and MM is the month the data was recorded. The controller creates a file for each day within this folder with the format YYYYMMDD.csv where DD equals the day of the month in addition to the Y Year and M Month fields. For example: The folder named RM201503 is a folder created in March of 2015. Within this folder would be a file for each day of that month that the datalogging is running. If a review of the History Report shows that an abnormal event occurred on March 3rd at 2:05pm, the user can import the 20150303.csv file into Excel and look at the system parameter details leading up to the 2:05pm event. Table 16 - DATA LOGGING
Follow all JCI Safety Directives when inserting or removing the SD card since the card is located inside the control cabinet.
To start the Data Logging, insert the SD card into the SD card slot on the 03478 IPUII board. The label on the SD card should be facing outwards.
Once the SD card is inserted and the unit is powered up, press the OPTIONS key. Then press the Down Arrow key to advance to the DATA LOG TO FLASHCARD selection. Next press the Right Arrow key to select ON then press the ENTER key to start the Data Log. A 2GB SD card will hold about 8 months worth of data. A smaller card may be used that will hold less data but should be tested for compatibility. The controller operating system does not support SD cards larger than 2GB. When the SD card becomes full, the oldest date file is automatically deleted and a new day log file is written in its place.
To stop the data logging and retrieve the SD card, press the OPTION key and then the Down Arrow key to display the DATA LOG TO FLASHCARD option and then use the Right Arrow key to select OFF then press the ENTER key.
Again, follow the JCI Safety Directives to stop the chiller, power off the unit and open the control cabiner door to retrieve the SD card.
Once inside the control cabinet, lightly press in on the SD card and then release the pressure. The SD card should pop out slightly to allow removal. You may then copy the files to a PC for analysis or email the file to someone. The files are saved as a CSV format which can be read by Excel. Below is a sample of some of the data imported from a YCIV Chiller. Once the file is read in to Excel, you can hide unrelated columns or plot desired parameters to analyze the data.
HOUR
MIN
SYS 1 SYS 1 SYS SYS 1 SUCT DSCH 1 OIL SUCT SEC PRESS PRESS PRESS TEMP
SYS 1 SAT SUCT TEMP
SYS 1 SUCT SHEAT
SYS 1 MTR CURR FLA
SYS 1 DSCH TEMP
SYS 1 SAT DSCH TEMP
SYS 1 DSCH SHEAT
SYS 1 OIL TEMP
SYS 1 COMP STATUS
SYS 1 ECON
SYS 1 FAN STAGE
SYS 1 MOTOR TEMP1
PSIG PSIG PSIG <?>F <?>F <?>F AMPS <?>F <?>F <?>F <?>F
<?>F
0
0 10 82.6 84.4 84.4 93 77.5 15.5
0
83 78.6 4.4 82 OFF OFF 0 107.9
11 0 15 82.6 84.4 84.4 93 77.5 15.5
0
83 78.6 4.4 82 OFF OFF 0 107.9
11 22 20 82.6 84.4 84.4 93 77.5 15.5
0
83 78.6 4.4 82 OFF OFF 0 107.9
11 22 25 82.6 84.4 84.4 93 77.5 15.5
0
83 78.6 4.4 82 OFF OFF 0 107.9
11 22 30 82.6 84.4 84.4 93 77.5 15.5
0
83 78.6 4.4 82 OFF OFF 0 107.9
11 22 35 82.5 84.4 84.4 93 77.4 15.6
0
83 78.6 4.4 82 OFF OFF 0 107.9
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Invalid Number of Compressors Warning The INVALID NUMBER OF COMPRESSORS SELECTED Warning will occur after the VSD has been initialized, if no "Number of Compressors Select" jumpers are installed or if more than 1 jumper is installed. The following warning message will be displayed indefinitely.
UNIT WARNING: INVALID NUMBER OF COMPRESSSORS SELECTED
To clear this warning, both the control panel and VSD control voltage must be turned off and the jumpers properly installed in the VSD wiring harness (see Page 210 for more details on jumper installation).
These jumpers are factory installed in the wire harness plug and should not require changes.
Invalid Serial Number Warning If the INVALID SERIAL NUMBER message appears, immediately contact Johnson Controls Product Technical Support. The appearance of this message may mean the chiller has lost important factory programmed information. The serial number can be entered using the SERVICE key.
UNIT WARNING: INVALID SERIAL NUMBER ENTER UNIT SERIAL NUMBER
Additionally, when this appears, an Optimized IPLV chiller will only run in Standard IPLV control mode. Optimized IPLV cannot be enabled unless the serial number is programmed into the unit using the special password supplied by Johnson Controls Product Technical Support. Once the password is entered, a second password will be needed to activate the optimized IPLV control (see Page 292).
This status message can be bypassed to view additional messages under the STATUS key by pressing the STATUS key repeatedly to scroll through as many as three STATUS messages that could possibly be displayed at any time.
Optimized Efficiency Disabled If the OPTIMIZED EFFICIENCY DISABLED message appears, immediately contact Johnson Controls Product Technical Support or Johnson Controls ES Commercial.
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The appearance of this message means an optimized chiller is programmed for standard control.
UNIT WARNING: OPTIMIZED EFFICIENCY DISABLED - CONTACT YORK REPRESENATIVE
Optimized IPLV cannot be enabled unless a special password is entered. Once the password is entered and the option is enabled using the SERVICE key, the message will disappear (see Page 292). This status message can be bypassed to view additional messages under the STATUS key by pressing the STATUS key repeatedly to scroll through as many as three STATUS messages that could possibly be displayed at any time. UNIT SAFETIES Unit Safety Operation Unit faults are safeties that cause all running compressors to be shut down, if a safety threshold is exceeded for 3 seconds. Unit faults are recorded in the history buffer along with all data on the unit and system operating conditions. Unit faults are auto reset faults where the unit will be allowed to restart automatically after the fault condition is no longer present. The only exception is any of the VSD related unit faults. If any 3 VSD unit faults occur within 90 minutes, the unit will be locked out on the last fault. A VSD lockout condition requires a manual reset using the system switches. Both system switches must be cycled off and on to clear a VSD unit lockout fault. If a unit safety is in
effect, the message will be displayed to the operator 8
when the STATUS key is pressed. STATUS KEY
LD10605
233
SECTION 8 - MICROPANEL
In the descriptions of the fault displays that follow, the fault message will show a YYYYYYY to indicate that a system is in a "FAULT" condition and will restart when the fault clears or LOCKOUT" and will not restart until the operator clears the fault using the keypad.
If a control panel safety occurs after the VSD fault, but before the fault is reset, the control panel fault is an ALL FAULT of the VSD fault, meaning it will be registered as such in the History because it occurred while the VSD was shutting down or while the systems were shut down. All faults do not store operating data at the time of the fault.
If a "VSD" fault occurs during the fault rampdown or while the systems are shut down, the VSD fault will be registered as a new fault. The reason for this is the belief any VSD fault should be registered with a full account of the systems data at the time of the fault.
High Ambient Temp Fault If the ambient temperature rises above 130°F, the chiller will shut down with a controlled ramped shutdown. Restart will automatically occur, if demand allows, when temperature falls 2°F below the cutout (128°F). This fault cannot cause a lockout. The fault display message will be present only during the time when the ambient temperature is causing a fault condition. A sample display is shown below:
UNIT YYYYYYYY HIGH AMBIENT TEMP
The unit will also be inhibited from starting any time the temperature is above 128°F.
Low Ambient Temp Fault If the ambient temperature falls below the programmable Low Ambient Temp Cutout the chiller will shut down with a controlled ramped shutdown. This fault will only occur if the Low Ambient Cutout is "ENABLED" under the OPTIONS key. Restart can occur, if demand allows, when temperature rises 2°F above the cutout. This fault cannot cause a lockout. The fault display message will be present only during the time when the ambient temperature is causing a fault condition. A sample display is shown below:
UNIT YYYYYYYY LOW AMBIENT TEMP
The unit is also inhibited from starting any time the temperature is below the cutout plus 2°F.
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Low Leaving Chilled Liquid Temp Fault
The Low Leaving Chilled Liquid Temp Cutout helps to protect the chiller from an evaporator freeze-up should the chilled liquid temp drop below the freeze point. This situation could occur under low flow conditions or if the Micro Panel setpoint values are improperly programmed. Any time the leaving chilled liquid temperature (water or brine) drops below the programmable cutout point, the chiller will fault and shutdown with a controlled ramped shutdown. Restart can occur, if demand allows, when chilled liquid temperature rises 4°F above the cutout. This fault cannot cause a lockout. A sample shutdown message is shown below:
UNIT YYYYYYYY LOW LEAVING CHILLED LIQUID TEMP
The unit is inhibited from starting any time the chilled liquid temperature is below the cutout plus 4°F.
VSD Communications Failure Fault
The VSD Communications Failure is to prevent the unit from trying to run, if the Chiller Control Board never initializes communications with the VSD Logic Board. The unit will also shut down with a controlled ramped shutdown if the Chiller Control Board loses communications with the VSD Logic Board while the chiller is operating.
On power-up, the Chiller Microprocessor Board will attempt to initialize communications with the VSD Logic Board. The control panel will request data from the VSD, which includes the number of compressors and the VSD software version. Once these data points have been received by the Chiller Control Board, and have been successfully initialized, the Chiller Control Board will not request them again. If the comms connection fails to occur, the Chiller Control Board will prevent the chiller from operating and a fault message will be displayed.
During normal operation, if the control panel Chiller Control Board receives no valid response to messages for 8 seconds, the unit will shut down all compressors on a Comms fault. The Chiller Control Board will continue to send messages to the VSD while faulted. The unit will be inhibited from starting until communications is established. The fault will automatically reset when the Chiller Control Board receives a valid response from the VSD for a data request. Shown below is an example of a Comms Failure fault message:
UNIT YYYYYYYY VSD COMMUNICATIONS FAILURE
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SYSTEM SAFETIES (FAULTS)
System Safety (Fault) Operation
System safeties are faults that cause individual systems to be shut down if a safety threshold is exceeded for 3 seconds. System faults are auto reset faults in that the system will be allowed to restart automatically after the 120 second anti-recycle timer times out. The only exception is after any 3 faults on the same system occur within 90 minutes, that system will be "locked out" on the last fault. The lockout condition requires a manual reset using the system switch. The respective system switch must be cycled off and on to clear the lockout fault. See Table 21 on page 262 for the programmable limits for many of the cutouts.
When multiple systems are operating and a system fault occurs, the running systems will ramp down and the faulted system will be shut off and the previously operating will restart if required after the fault clears and/or the 120 second anti-recycle timer times out.
In the descriptions of the fault displays that follow, the fault message will show a YYYYYYYY to indicate that a system is in a "FAULT" condition and will restart when the fault clears, or "LOCKOUT" and will not restart until the operator clears the fault using the keypad. If a system safety is in effect, the message will be displayed to the operator when the STATUS key is pressed.
STATUS KEY
SECTION 8 - MICROPANEL
In some cases, a control panel fault will occur after a VSD fault, possibly during system shutdown or at some later time. This is known as an "ALL FAULT" and these faults will be recorded as such under the HISTORY information stored at the instant of the primary fault. In some cases, this information may be valuable in troubleshooting the primary fault. An example of the "ALL FAULT" history message is shown on Page 263 under the HISTORY key. When an "ALL FAULT" occurs, associated history information will not be stored. If an additional fault does not occur, the "ALL FAULTS" display will indicate NONE. In cases where a VSD fault occurs during the rampdown of a control panel fault (i.e.: low suction pressure, low water temp, etc.), the VSD fault will be stored as a new fault with the associated fault information stored at the instant the VSD fault occurred (i.e.: IGBT Gate Drive, Single Phase Input, VSD CT Plug, etc.). The control panel fault that occurred prior to the VSD fault will be stored with the associated complete data related to the fault as a numerically lower numbered history in the history buffers.
High Discharge Pressure Cutout (Software) Fault The High Discharge Pressure Cutout is a software fault. A system will fault and shut down with a controlled ramped shutdown on high discharge pressure when the discharge pressure rises above 274 psig for 0.5 seconds. The system will be allowed to restart
when the discharge pressure falls to 259 psig. The sys- 8
tem will also be inhibited from starting if the pressure is above 259 psig. The fault message for this safety is shown below:
SYS X YYYYYYYY HIGH DISCHARGE PRESSURE
X indicates the system and YYYYYYYY indicates the system is in a "FAULT" condition and will restart when the 120 second anti-recycle timer times out, or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
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SECTION 8 - MICROPANEL
High Discharge Pressure Cutout (HPCO) (Hardware) Fault The mechanical High Pressure Cutout protects the system from experiencing dangerously high discharge pressure. A system will fault and shut down immediately when the mechanical high pressure cutout contacts open. The fault will occur immediately and not wait 3 seconds, which is typical of most system faults. The HPCO is wired in series with the VSD Run Signal and will only be checked by the Chiller Control Board when the system is running.
The mechanical cutout opens at 315 psig plus or minus 8 psig and closes at 230 psig plus or minus 10 psig. The Status display fault message for this system is shown below:
SYS X YYYYYYYY HPCO FAULT
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the 120 second anti-recycle timer times out or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
Low Suction Pressure Cutout (Software) Fault The programmable Low Suction Pressure Cutout is a secondary back-up for the flow switch and protects against operation with low refrigerant charge, which helps protect the chiller from an evaporator freeze-up, should the system attempt to run with a low refrigerant charge. The Status display fault message for this cutout is shown below:
SYS X YYYYYYYY LOW SUCTION PRESSURE
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the 120 second anti-recycle timer times out or "LOCKOUT" and will not restart until the operator clears the fault using the keypad. Typically, the cutout will be set at 24 psig for chilled water applications.
The cutout is ignored for the first 30 seconds of system run time. During the next 3 minutes of run time the cutout point is linearly ramped from 10% of the cutout value up to the programmed cutout point. If at any time during the first 3 minutes of operation the suction pressure falls below the ramped cutout point, the system will shut down with a controlled ramped shutdown.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
The cutout pressure during operating periods of 30 seconds to 210 seconds is ramped and can be calculated by:
Cutout = (Programmed Cutout x Run Time)1.2 psig 200
After the first 3 minutes and 30 seconds of run time, if the suction pressure falls below the cutout as a result of a transient in the system, a transient timer is set at 30 seconds and a linearly ramped cutout is set starting at 10% of the programmed cutout. If over the next 30 seconds, the suction pressure does not stay above the ramped cutout, which ramps between 10% of the cutout and the programmed cutout over the 30 second period, the system will fault on low suction pressure.
Low Motor Current Cutout Fault The Motor Current Cutout shuts the system down with a controlled ramped shutdown when the microprocessor detects the absence of motor current (less than 10% FLA), usually indicating that a compressor is not running. This safety is ignored for the first 10 seconds of operation.
The status display fault message for this safety is shown below:
SYS X YYYYYYYY LOW MOTOR CURRENT
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the 120 second anti-recycle timer times out or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
High Differential Oil Pressure Cutout Fault The High Differential Oil Pressure Cutout protects the compressor from low oil flow and insufficient lubrication, possibly from a dirty oil filter. A system will fault and shut down with a controlled ramped shutdown when its Discharge to Oil Differential Pressure rises above the cutout of 65 psid. This safety is ignored for the first 90 seconds of run time. This safety measures the pressure differential between discharge and oil pressure, which is the pressure drop across the oil filter. The Status display fault message for this safety is shown below:
SYS X YYYYYYYY HIGH DIFF OIL PRESSURE
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the 120 second anti-recycle timer times out or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
Low Differential Oil Pressure Cutout Fault The Low Differential Oil Pressure Cutout protects the compressor from low oil flow and insufficient lubrication. A system will fault and shut down with a controlled ramped shutdown when it's differential between oil and suction pressure falls below the cutout. This safety assures that the compressor is pumping sufficiently to push oil through the oil cooling circuit and through the internal compressor lubrication system. The Status display fault message for this safety is shown below:
SYS X YYYYYYYY LOW DIFF OIL PRESSURE
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the 120 second anti-recycle timer times out or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
The safety is ignored for the first 60 seconds of run time. After the first 60 seconds of operation, the cutout is linearly ramped from 0 psid to 30 psig in 5 minutes to 10 minutes based on ambient temperature. See Table 17 on page 237 for the ramp times for the given ambient temperatures.
Table 17 - LOW DIFFERENTIAL OIL PRESSURE CUTOUT
AMBIENT TEMPERATURE
RAMP TIME
> 50ºF
5 min
> 45ºF
6 min
> 40ºF
7 min
> 35ºF
8 min
> 30ºF
9 min
>=30ºF
10 min
A 30 second safety bypass below 50 Hertz is employed during rampdown. The bypass is primarily needed under conditions where another compressor is being brought on and the running compressor is being ramped down to 5 Hertz to add the additional compressor due to load requirements.
SECTION 8 - MICROPANEL
Under these conditions, the slow speed of the running compressor(s) causes the oil differential to become very low, especially if the water temperature is high and the suction pressure is high. The bypass assures the compressor(s) will not trip on a nuisance low oil differential fault.
High Discharge Temperature Cutout Fault
The High Discharge Temperature Cutout protects the motor and compressor from overheating. A system will fault and shut down with a controlled ramped shutdown when its Discharge Temperature rises above 250°F. A system will also be inhibited from starting if the discharge temperature is above 200°F. The Status display fault message for this safety is shown below:
SYS X YYYYYYYY HIGH DSCHARGE TEMP
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the 120 second anti-recycle timer times out or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
High Oil Temperature Cutout Fault
The High Oil Temperature Cutout protects the compressor from insufficient lubrication. A system will fault and shut down with a controlled ramped shutdown when its oil temperature rises above 225°F. The system will be inhibited from starting if the oil temperature is above 175°F. The Status display fault message for this safety is shown below:
SYS X YYYYYYYY HIGH OIL TEMP
8
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the fault clears or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
Low Suction Superheat Cutout Fault
The Low Suction Superheat Cutout helps protect the compressor from liquid floodback due to low suction superheat. This safety is ignored for the first 30 seconds of compressor operation. Low suction superheat will fault a system when any one of the following conditions occur:
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SECTION 8 - MICROPANEL
· After the first 30 seconds of run time, if the suction superheat falls below 2.0°F, the discharge superheat is less than 15°F, and the run time is less than 5 minutes, the superheat safety will be ignored for the next 30 seconds followed by setting the superheat cutout to 0°F and linearly ramping it up to 2.0°F over the next 60 seconds. If at any time during these 60 seconds the suction superheat falls below the ramped cutout, the system will fault and shut down with a controlled ramped shutdown.
· If the suction superheat less than 2°F, the discharge superheat less than 15°F for 10 seconds, and the run time is equal to or more than 5 minutes, the system will fault and shutdown with a controlled ramped shutdown.
· If the suction superheat less than 0.5°F and discharge superheat is more than 15°F for 60 seconds and run time equal to or more than 5 minutes, the system will fault and shutdown with a controlled ramped shutdown.
· If suction superheat less than 5°F for 10 minutes, the system will fault and shutdown with a controlled ramped shutdown.
The Status display fault message for this safety is shown below:
SYS X YYYYYYYY LOW SUCTION SUPERHEAT
X indicates the system and YYYYYYYY indicates the system is "FAULT" and will restart after the 120 second anti-recycle timer times out or "LOCKOUT" and will not restart until the operator clears the fault.
Low Discharge Superheat Cutout Fault
The Low Discharge Superheat Cutout helps protect the compressor primarily from liquid floodback through the economizer line due to a high flash tank level. It also provides protection from liquid floodback through the suction line in conjunction with the low superheat safety. This safety is ignored for the first 5 minutes of compressor operation.
After the first 5 minutes of run time, if the discharge superheat falls below 10.0°F for 5 minutes, the system will fault and shut down with a controlled ramped shutdown.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
The Status display fault message for this safety is shown below:
SYS X YYYYYYYY LOW DISCHARGE SUPERHEAT
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the 120 second anti-recycle timer times out or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
Sensor Failure Cutout Fault The Sensor Failure Cutout prevents the system from running when a critical sensor (transducer, level sensor, or motor winding temp sensor) is not functioning properly and reading out of range. This safety is checked at start-up and will prevent the system from running if one of the sensors has failed.
The sensor failure safety will also fault and shutdown a system while in operation, if a safety threshold is exceeded or a sensor reads out of range (high or low). Following is the Status display fault message.
SYS X YYYYYYYY SENSOR FAILURE: ZZZZZZZZZZZZ
X indicates the specific system. YYYYYYYY will either indicate the system is in a "FAULT" condition and will restart when the fault clears, or "LOCKOUT" after 3 faults and will not restart until the operator clears the fault using the keypad.
ZZZZZZZZZZZ indicates the failed sensor below:
· SUCT PRESS
· OIL PRESS
· DSCH PRESS
· LEVEL SENSOR
· MOTOR TEMP X *
* The Unit Setup Mode allows a specific motor temperature sensor to be ignored, if it fails.
The start inhibit thresholds for each sensor are shown in Table 18 on page 239.
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Table 18 - START INHIBIT SENSOR THRESHOLDS
SENSOR
LOW THRESH- HIGH THRESH-
OLD
OLD
Suction Transducer
0.3 VDC
4.7 VDC
Oil Transducer
0.3 VDC
4.7 VDC
Discharge Transducer
0.3 VDC
4.7 VDC
Level Sensor
3.0 mA
21.0 mA
Motor Temp. Sensor
0ºF
240ºF
High Motor Temperature Cutout Fault
The High Motor Temperature Cutout prevents a compressor from running when its motor temperature is too high. A system will fault and shut down when any compressor motor temperature sensor rises above 250°F. The system will be inhibited from starting if its motor temperatures sensors indicate temperatures above 240°F. If any single temperature sensor is being ignored under the Unit Set-up Mode, that sensor will not be utilized when evaluating motor temperature.
Below is a sample Status display fault message:
SYS X YYYYYYYY HIGH MOTOR TEMP
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the fault clears or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
High Flash Tank Level Cutout Fault
The Flash tank level Cutout prevents the system from running when the liquid level in the flash tank is too high. The safety will be ignored for the first 15 seconds of system operation.
A fault will occur if the tank level is greater than 85% for 10 seconds.
SECTION 8 - MICROPANEL
Below is a sample Status fault display fault message:
SYS X YYYYYYYY HIGH FLASH TANK LEVEL
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the 120 second anti-recycle timer times out or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
System Control Voltage Cutout Fault The System Control Voltage Cutout alerts the operator the 115 VAC Control voltage to one of the systems is missing. This could be due to a system fuse that has been removed or is blown. The affected system will fault and shut down immediately when the 115 VAC supply is lost.
The safety will "not" shut down a system if the UNIT switch is OFF, which electrically removes the 115 VAC to "all" systems. The safety is only used to indicate a situation where a single system is missing the 115 VAC. The safety will not cause a lockout and the system fault will reset when power is returned. A sample message is shown below:
SYS X YYYYYYYY CONTROL VOLTAGE
X indicates the system and YYYYYYY indicates the system is in a "FAULT" condition and will restart when the fault clears or "LOCKOUT" and will not restart until the operator clears the fault using the keypad.
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SECTION 8 - MICROPANEL
STATUS KEY
STATUS KEY
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LD10605
Status Key Operation
The STATUS key displays the current chiller or system operational status. The messages displayed include running status, cooling demand, system faults, unit faults, VSD faults, unit warnings, external device status, load limiting, anti-recycle timer, status of unit/system switches, and a number of other messages. Pressing the STATUS key will enable the operator to view the current status of the chiller. The display will show one message relating to the "highest priority" information as determined by the microprocessor. The STATUS key must be pressed twice to view both System 1/2 and System 3/4 data. There are three types of status data, which may appear on the display:
· General Status messages
· Unit Safeties
· System Safeties.
When power is first applied to the control panel, the following message displaying YORK International Corporation, the EPROM version, date, and time will be displayed for 2 seconds, followed by the appropriate general status message:
(C)2004 YORK INTERNATIONAL CORPORATION C.XXX.XX.XX 18-SEPT-2005 12:45: AM
Unit status messages occupy 2 lines of the Status message display. If no unit status message applies, individual status messages for each system will be displayed. On 3 and 4 compressor units, the STATUS key must be pressed twice to display the status of all systems.
Any time the STATUS key is pressed or after the EPROM message disappears at power-up, a status display indicating chiller or system status will appear.
Multiple STATUS messages may appear and can be viewed by pressing the STATUS key repeatedly to allow scrolling through as many as three STATUS messages, that could possibly be displayed at any time on a 2 compressor chiller or 4 messages that could be displayed on a 3 or 4 compressor chiller.
Examples of the typical Status messages are shown in the next topic
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General Status Messages
UNIT STATUS MANUAL OVERRIDE
This message indicates the chiller is operating in MANUAL OVERRIDE mode. This message is a priority message and cannot be overridden by any other STATUS message. When in Manual Override, no other status message will ever be present.
UNIT STATUS UNIT SWITCH OFF SHUTDOWN
This message indicates the UNIT SWITCH is in the off position and not allowing the unit to run.
UNIT STATUS DAILY SCHEDULE SHUTDOWN
This message indicates that either the daily or holiday schedule programmed is keeping the chiller from running.
UNIT STATUS REMOTE CONTROLLED SHUTDOWN
This message indicates that either an ISN or RCC has turned the chiller off and is not allowing it to run.
UNIT STATUS FLOW SWITCH SHUTDOWN
This message indicates the flow switch is not allowing the chiller to run. There is a 1 second delay on this safety to assure the flow switch did not momentarily open.
UNIT STATUS VSD COOLING SHUTDOWN
This message indicates the chiller is shutdown, but running all the condenser fans, VSD glycol pump, and VSD fan in an effort to bring the internal VSD ambient temperature down to an acceptable level before allowing the chiller to start.
SYS X REMOTE RUN CONTACT IS OPEN
This message indicates the remote start/stop contact between 2-15 or 2-16 of the 1TB terminal block is open. There is a 1 second delay on this safety to assure the remote contacts did not momentarily open.
SYS X SYSTEM SWITCH IS OFF
SECTION 8 - MICROPANEL
This message indicates the system switch (software via keypad) is turned off. The system will not be allowed to run until the system switch is turned ON via the keypad.
SYS X NOT RUNNING
This message indicates the system is not running because the chilled liquid is below the setpoint or the micro has not loaded the lead system far enough into the loading sequence to bring the lag system on. This message will be displayed on the lag system until the loading sequence is ready for the lag system to start.
SYS X COOLING DEMAND SHUTDOWN
This message is only displayed in the Normal Shutdown History display to indicate a capacity control shutdown.
SYS X COMPRESSOR RUNNING
This message indicates the system is running as a result of cooling demand.
SYS X SHUTTING DOWN
The compressor shutting down message indicates the
respective system is ramping down in speed prior to
shutting off. This message is displayed after the soft-
ware run signal is disabled until the VSD notifies the Chiller Control Board the compressor is no longer run-
8
ning.
SYS X ANTI-RECYCLE TIMER = XXX SEC
This message indicates the amount of time left on the respective system anti-recycle timer and the system is unable to start until the timer times out.
SYS X DISCHARGE PRESSURE LIMITING
The Discharge Pressure Limiting message indicates the discharge pressure load limit or discharge pressure unloading is in effect.
SYS X SUCTION PRESSURE LIMITING
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The Suction Pressure Limiting message indicates the suction pressure load limit or suction pressure unloading is in effect.
SYS X MOTOR TEMP LIMITING
The Motor Temp Limiting message indicates the motor temp load limit or motor temp unloading is in effect.
SYS X MOTOR CURRENT LIMITING
The motor current limiting message indicates the motor current load limit or motor current unloading is in effect.
SYS X PULLDOWN MOTOR CURRENT LIMITING
The pulldown motor current limiting message indicates the pulldown motor current load limit or pulldown motor current unloading is in effect based on the programmed setpoint.
SYS X ISN CURRENT LIMITING
The ISN Current Limiting message indicates the motor current load limit or motor current unloading is in effect through the use of the YORKTalk setpoint.
SYS X REMOTE MOTOR CURRENT LIMITING
The Remote Motor Current Limiting message indicates the motor current load limit or motor current unloading is in effect through the use of the remote setpoint offset. The setpoint may be offset using a remote voltage or a current signal. The remote current limit must be activated for this function to operate.
SYS X VSD BASEPLATE TEMP LIMITING
The VSD Baseplate Temp Limiting message indicates the VSD Baseplate temp is high and load limit or unloading is in effect.
SYS X VSD INTERNAL AMBIENT TEMP LIMITING
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
The VSD Internal Ambient Temp Limiting message indicates the VSD internal ambient temp is high and load limit or unloading is in effect.
SYS X SOUND LIMITING
The sound limiting message indicates the sound load limit is in effect based on the locally programmed sound limit from the keypad. The sound limit must be activated for this function to operate.
SYS X ISN SOUND LIMITING
The ISN sound limiting message indicates the sound load limit is in effect based on the ISN transmitted sound limit setpoint. The sound limit must be activated for this function to operate.
SYS X REMOTE SOUND LIMITING
The Remote sound limiting message indicates the sound load limit is in effect based on the Remote controlled sound limit setpoint. The setpoint may be offset using a remote voltage or current signal. The sound limit option must be activated for this function to operate.
Unit Safety (Fault) Status Messages A complete listing of the unit safeties and the corresponding status messages is provided on Page 245.
System Safety (Fault) Status Messages A complete listing of the system safeties and the corresponding status messages is provided on Page 246.
VSD Safety (Fault) Status Messages A complete listing of VSD safeties and the corresponding status messages is provided on Page 237.
Unit Warning Messages A complete listing of the unit warnings and the corresponding status messages is provided on Page 243.
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UNIT DATA KEY
UNIT DATA KEY
SECTION 8 - MICROPANEL
LD10605
General
The UNIT DATA key provides the user with displays of unit temperatures, and unit related data. Displays can be selected by repeatedly pressing the UNIT DATA key or the or Arrow Keys.
Unit Data Key Operation The first key press displays Evaporator Leaving and Return Chilled Liquid Temps.
UNIT CHILLED LIQUID LEAVING = XXX.X °F ENTERING = XXX.X °F
The next key press of the UNIT DATA key or the (ARROW) key displays the ambient air temperature.
UNIT OUTSIDE AMBIENT AIR TEMP = XXX.X °F
The next key press will display the time remaining on the load and unload timers.
UNIT
LOAD TIMER = XXX SEC
UNLOAD TIMER = XXX SEC
The next key press displays the error in temperature between the actual leaving chilled liquid temperature and the setpoint temperature. The display also shows the rate of change of the chilled liquid temperature.
UNIT
TEMP ERROR = XXX.X °F RATE = XXX.X °F/M
8
The next key press displays the system designated as the lead system and the Flow Switch status (ON or OFF).
UNIT LEAD SYSTEM NUMBER = X FLOW SWITCH = XXX
The next key press displays the status of the evaporator pump and heater, where XXX is either ON or OFF.
UNIT
EVAP PUMP RUN = XXX EVAP HEATER = XXX
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SECTION 8 - MICROPANEL
The next key press displays the status of Active Remote Control.
UNIT ACTIVE REMOTE CONTR0L = XXXXXX TYPE: RCC ISN CURR TEMP SOUND
XXXXX is either ACTIVE or NONE.
If no remote keys are active, the items on the second line are all blanked out. Any remote items that are active will be displayed, while the inactive items will be blanked out.
The types of remote control are listed below:
· NONE - No remote control is actively controlling the chiller; however, remote monitoring by a remote device may still be active.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
· RCC - A Remote Control Center is providing remote control. The chiller is in remote mode.
· ISN - YorkTalk via ISN. The chiller in remote mode.
· CURR - Remote Current Limiting is enabled.
· TEMP - Remote Temperature Reset is enabled.
· SOUND - Remote Sound Limiting is enabled.
The next key press displays the sound limit values as set under the PROGRAM key by the Local, ISN, and the Remote Sound Limit Inputs. Any sound limits that are inactive will display XXX instead of a numeric value.
UNIT SOUND LIMIT ISN = XXX
LOCAL = XXX % REMOTE = XXX %
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SYSTEM DATA KEYS 1 THROUGH 4
SECTION 8 - MICROPANEL
SYSTEM 1 DATA KEY SYSTEM 2 DATA KEY
SYSTEM 3 DATA KEY SYSTEM 4 DATA KEY
LD10605
General
The data keys provide the user with many displays of individual system temperatures, pressures, and other operating data. These keys have multiple displays, which can be seen by repeatedly pressing the SYSTEM DATA or the or (ARROW) keys. An explanation of each key and its messages is provided below.
System 1 Data Key Operation
The SYSTEM 1 DATA key provides the user with access to System 1 operating parameters. The following is a list of the data in the order in which it appears.
The first key press of the SYSTEM X DATA key displays all of the measured system pressures (oil, suction, and discharge).
SYS 1 PRESSURES
OIL = XXXX PSIG
SUCTION = XXXX DISCHARGE = XXXX PSIG
The second key press of the SYSTEM DATA key or the (DOWN ARROW) key displays all of the measured system temperatures (oil, suction, and discharge).
SYS 1 TEMPERATURES OIL = XXX.X °F SUCTION = XXX.X DISCHARGE = XXX.X °F
The next key press displays the suction temperature and all of the calculated suction temperatures (saturated suction and system superheat).
SYS 1 SUCTION
TEMP = XXX.X °F
SUPERHEAT = XXX.X SAT TEMP = XXX.X °F
8
The next key press displays the discharge temperature and all of the calculated discharge temperatures (saturated discharge and discharge superheat).
SYS 1 DISCHARGE
TEMP = XXX.X °F
SUPERHEAT = XXX.X SAT TEMP = XXX.X °F
The next key press displays the System 1 motor thermistor temperatures.
SYS 1 MOTOR TEMPS T2 = XXX.X °F
T1 = XXX.X °F T3 = XXX.X °F
If any motor temp sensor is being ignored, (selectable under Unit Set-up Mode), that sensor's value will be displayed as XXXXX.
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The next key press indicates the % of compressor loading and status of the economizer solenoid as determined by the operating frequency.
SYS 1 COMPRESSOR SPEED = XXX.X % ECONOMIZER SOLENOID = XXX
XXX indicates whether the economizer solenoid is either ON or OFF.
The next keypress displays the liquid level in the flash tank and an indicator of the % the Flash Tank Feed Valve is open.
SYS 1 FLASH TANK LEVEL = XXX.X % FEED VALVE PERCENT OPEN = XXX.X %
The next key press displays the system suction superheat and an indicator of the % the Flash Tank Drain Valve is open.
SYS 1 SUCTION SUPERHEAT = XXX.X °F DRAIN VALVE PERCENT OPEN = XXX.X %
The next key press displays the system fan stage and the status of the compressor heater.
SYS 1 CONDENSER FANS ON = X COMPRESSOR HEATER = XXX
X equals the number of fans ON. XXX indicates either the heater is ON or OFF.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
The next key press displays the system run time in days, hours, minutes, and seconds.
SYS 1 RUN TIME XX DAYS XX HOURS XX MINUTES XX SECONDS
The next key press displays the status of several system signals.
SYS 1 RUN SIGNALS RELAY = XXX RUN PERM = XXX SOFTWARE = XXX
XXX indicates either ON or OFF.
System 2 through 4 Data Key Operation These keys function the same as the SYSTEM 1 DATA key except that it displays data for System 2 through 4. On a 2 compressor system, the SYSTEM 3 and SYSTEM 4 data keys will display the following messages:
SYS 3 DATA NOT AVAILABLE
SYS 4 DATA NOT AVAILABLE
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Sensor Displays Table 19 on page 247 lists all the sensors attached to the control board associated with system data keys. The minimum and maximum values displayed on the micro display are provided.
If values exceed the limits in the table, a < (less than) or > (more than) sign will be display along with the minimum or maximum value.
Table 19 - SENSOR MIN/MAX OUTPUTS
SENSOR
TYPE
Suction Pressure
Transducer
Oil Pressure
Transducer
Discharge Pressure
Transducer
Flash Tank Level
Capacitance
Leaving Chilled Liquid Temp.
3Kohm Thermistor
Return Chilled Liquid Temp.
3Kohm Thermistor
Ambient Air Temp.
10Kohm Thermistor
Suction Temp.
3Kohm Thermistor
Oil Temp.
50Kohm Thermistor
Discharge Temp.
50Kohm Thermistor
Compressor Motor Temp.
10Kohm Thermistor
Remote Temp. Reset
420 mA / 210 VDC 020 mA / 010 VDC
Remote Current Limit
Remote Sound Limit
420 mA / 210 VDC
020 mA / 010 VDC 420 mA / 210 VDC 020 mA / 010 VDC
MINIMUM 0.0 psig 0.0 psig 0.0 psig
0.0% -19.1ºF -19.1ºF -4.6ºF -4.1ºF 40.3ºF 40.3ºF -30.0ºF
0%
0%
0%
SECTION 8 - MICROPANEL
MAXIMUM 125.0 psig 275.0 psig 275.0 psig
100 % 110.2ºF 110.2ºF 137.9ºF 132.8ºF 302.6ºF 302.6ºF
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302.0ºF 100% 100% 100%
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SECTION 8 - MICROPANEL
VSD DATA KEY
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
VSD DATA KEY
LD10605
General
The VSD DATA key provides the user with displays of VSD temperatures, voltages, currents, and other operating data. This key has multiple displays, which can be seen by repeatedly pressing the VSD DATA or the or (ARROW) keys. An explanation of each message is provided below.
VSD Data Key Operation
The first VSD DATA key press displays the actual VSD Output Frequency and Command Frequency.
VSD FREQUENCYACTUAL = XXX.X HZ COMMAND = XXX.X HZ
The second key press of the VSD DATA key or the (ARROW) key displays the compressor % FLA and "calculated" currents in amps for systems 1 and 2. The "calculated" currents are approximate and some error can be expected. Also keep in mind that measuring inverter PWM current is difficult and meter error can be significant.
VSD COMP 1 = XXX AMPS = XXX %FLA COMP 2 = XXX AMPS = XXX %FLA
For 3 and 4 compressor units only, the second key press will display the following message for systems 1 and 3:
VSD COMP 1 = XXX AMPS = XXX %FLA COMP 3 = XXX AMPS = XXX %FLA
For 3 and 4 compressor units only, the next key press displays the compressor %FLA and currents for systems 2 and 4. 3 compressor units will have the 4th compressor information blanked out.
VSD COMP 2 = XXX AMPS COMP 4 = XXX AMPS
= XXX %FLA = XXX %FLA
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
The next key press displays the current limit values set locally on the panel under the PROGRAM key, remotely by an ISN, and remotely by the Current Limit input. Any current limits that are inactive will display "XXX" instead of a numeric value.
VSD CURRENT LIMIT LOCAL = XXX %FLA
ISN = XXX
REMOTE = XXX %FLA
The next key press displays DC Bus voltage for 2 and 3 compressor units. On 4 compressor units, the 2nd message will apply, since two DC Bus voltages are present (Systems 1/3 and 2/4).
VSD
DC BUS VOLTAGE = XXX VDC
VSD DC BUS VOLTAGES BUS 1 = XXX VDC BUS 2 = XXX VDC
The next key press displays the Control Panel/VSD Internal Ambient Temperature and VSD Cooling Pump/ Fan Status. YYY will indicate ON or OFF.
VSD INTERNAL AMBIENT TEMP = XXX.X °F COOLING SYSTEM STATUS = YYY
The next key press displays the IGBT highest baseplate temperature for 2 and 3 compressor units. 4 compressor units display temperatures for Systems 1/3 (T1) and Systems 2/4 (T2).
VSD IGBT BASEPLATE TEMPS T1 = XXX °F T2 = XXX °F
SECTION 8 - MICROPANEL
The next key press displays the state of the Precharge signal, where XXX is either ON or OFF. The first display is for 2 and 3 compressor units, the second display shown is for 4 compressor units where Precharge 1 is for compressors 1 and 3 DC Bus and Precharge 2 is for compressors 2 and 4 DC Bus.
VSD PRECHARGE SIGNAL = XXX
VSD PRECHARGE 1 SIGNAL = XXX VSD PRECHARGE 2 SIGNAL = XXX
The next key press displays the setting of the VSD's 105% FLA overload potentiometer for Compressor #1 and 2. The settings are determined by the adjustment of the overload potentiometers on the VSD Logic Board. These pots are factory set and should not require changing unless the circuit board is replaced. See Table 39 on page 315 for factory settings.
VSD COMP 1 MOTOR OVERLOAD = XXX AMPS COMP 2 MOTOR OVERLOAD = XXX AMPS
The next key press displays the setting of the VSD's 105% FLA potentiometer for Compressor #3 and #4 (3 and 4 compressor units only). The second line will be blanked out on 3 compressor units.
VSD COMP 3 MOTOR OVERLOAD = XXX AMPS COMP 4 MOTOR OVERLOAD = XXX AMPS
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SECTION 8 - MICROPANEL
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
OPERATING HOURS / START COUNTER KEY
OPERATING HOURS/ START COUNTER KEY
Compressor operating hours and compressor starts are displayed with a single key press. The maximum value for both hours and starts is 99,999, at which point they will roll over to 0. A single display is available under this key and is displayed below. On 2 and 3 compressor units, the data and compressor designators for compressors not present are blanked out.
HOURS 1=XXXXX, 2=XXXXX, 3=XXXXX, 4=XXXXX
` START 1=XXXXX, 2=XXXXX, 3=XXXXX, 4=XXXXX
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
HISTORY KEY
SECTION 8 - MICROPANEL
HISTORY KEY
LD10605
History Key Operation
The HISTORY key provides the user access to many unit and system operating parameters captured at the instant a unit or system safety (fault) shutdown occurs. The history buffer will also capture system data at the time of normal shutdowns such as cycling shutdowns. When the HISTORY key is pressed the following screen is displayed:
HISTORY CHOOSE HISTORY TYPE XXXXXXXXXXXXXXXXXXXXXXXXXXXX
The and (ARROW) keys allow choosing between NORMAL SHUTDOWNS and FAULT SHUTDOWNS. "Fault" shutdowns provide information on safety shutdowns, while "Normal" shutdowns provide chiller cycling information on temperature (demand), cycling, remote, system switch, etc., shutdowns that are non-safety related shutdowns. Once the selection is made, the (ENTER) key must be pressed to enter the selection.
Normal Shutdowns History If the NORMAL SHUTDOWNS History is selected, the following screen will be displayed:
NORM HIST XX 18-JUN-20004 10:34:58 AM YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY
XX is the normal shutdown number. The display will
provide date and time of the shutdown and the reason for the cycling shutdown (YYY....).
8
The operator can view any of the stored 20 single display normal shutdown history buffers. History buffer number 1 provides the most recent shutdown information and buffer number 20 is the oldest safety shutdown information saved. The and (ARROW) keys allow scrolling between each of the history buffers. The (ARROW) key scrolls to the next normal history shutdown and the (ARROW) key scrolls to the previous normal history shutdown.
The following display will typically be displayed on a normal shutdown due to shutdown on lack of cooling demand.
NORM HIST XX 18-JUN-20004 10:34:58 AM SYS X COOLING DEMAND SHUTDOWN
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SECTION 8 - MICROPANEL
Fault Shutdowns History
If the FAULT SHUTDOWNS History is selected, the following screen will be displayed:
FAULT HIST XX 18-JUN-20004 10:34:58 AM YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY
XX is the FAULT HISTORY shutdown number. The display will provide the date, time, and a description of the specific type of fault that occurred (YYY....).
The operator can view any of the stored 10 fault history buffers. History buffer number 1 provides the most recent safety shutdown information and buffer number 10 is the oldest safety shutdown information saved. The and arrow keys allow scrolling between each of the FAULT HIST buffers 1 through 10. The (UP) and (DOWN) arrow keys can be used to scroll forwards and backwards through the data in a specific history buffer, once it is displayed.
There is a large amount of data provided under each history. Rather than scroll sequentially through the data in a history, which is possible using the arrow key, the use of a combination of the , , , and arrow keys allows fast scrolling to specific data the user desires to view. To use this feature, the user needs to be aware the and arrow keys allow scrolling to the top of the data subgroups. Once a specific history is selected, the history data is divided under the subgroups of Unit Data, VSD Data, System Data, Hours/ Starts, Setpoints, Options, and Program data. The and arrow keys allow moving to the first display under the next or previous subgroup at any time. Once the first display of a subgroup is displayed, the , and arrow keys allow scrolling though the data in the subgroup. The arrow key allows scrolling though the data from first to last. When the last piece of data is displayed, the next press of the arrow key scrolls to the first piece of data in the next subgroup. The arrow key allows going to the previous display.
Listed below is a description of the fault data displays and their meaning. Data will be displayed in a specific order starting with the Status Display (System Faults only), Fault Display, All Fault Display, Unit Data, VSD Data, System Data, Operating Hours/Starts, Setpoints, Options, and Program Values at the time of the fault.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Status Fault Type
SYS X COMPRESSOR RUNNING SYS X YYYYYYYY HIGH DIFF OIL PRESSURE
This message indicates the type of system fault. This screen is skipped if a UNIT Fault caused the shutdown.
Unit Fault Type
UNIT FAULT LOW AMBIENT TEMP
This message indicates the type of unit fault. This screen is skipped if a SYSTEM Fault caused the shutdown.
All Fault Data
FAULT HIST XX ALL FAULTS ZZ OF WW YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY
The ALL FAULT display indicates whether a fault occurred while the unit is shutting down on another fault.
If a control panel fault occurred while the unit is shutting down on a VSD fault before it is reset, the control panel fault is an ALL FAULT of the VSD fault.
If another VSD fault occurs while the unit is shutting down on a VSD fault, the next VSD fault will be registered as an ALL FAULT of the VSD fault.
If a VSD fault occurs during the ramp down shutdown of a control panel fault, the VSD fault is registered as a new fault, not an ALL FAULT
XX is the history number, YYY is the ALL FAULT description, ZZ is the ALL FAULT number and WW is the total number of All Faults for the current history. Sometimes, multiple faults may occur during the shutdown and multiple displays will be observed when scrolling through the data using the arrow. In most cases, the ALL FAULT display will indicate NONE. The ALL FAULT display will only indicate the cause of the fault. No additional chiller information will be displayed under the ALL FAULT, since a snapshot of all chiller data was taken at the time of the first fault.
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Unit Data
Evaporator Leaving and Return Chilled Liquid Temps
This message indicates the leaving and entering chilled liquid temperatures at the time of the fault.
Ambient Air Temperature
UNIT OUTSIDE AMBIENT AIR TEMP = XXX.X °F
This message indicates the ambient air temperature at the time of the fault.
Load / Unload Timers
UNIT
LOAD TIMER = XXX SEC
UNLOAD TIMER = XXX SEC
This message indicates remaining time on the load and unload timers at the time of the fault.
Chilled Liquid Temperature Error and Rate of Change
UNIT
TEMP ERROR = XXX.X °F
RATE = XXX.X °F/M
This message indicates the temperature error between the actual and the programmed setpoint at the time of the fault and the rate of temperature change.
Programmed Lead System Selection and Flow Switch Status
UNIT LEAD SYSTEM NUMBER = X
FLOW SWITCH = XXX
This message indicates the designated lead system at the time of the fault and whether the flow switch was ON (Closed) or OFF (Open) at the time of the fault.
Evaporator Pump and Evaporator Heater Status
UNIT
EVAP PUMP RUN = XXX
EVAP HEATER = XXX
This message indicates the status of the evaporator pump and the evaporator heater at the time of the fault. XXX indicates ON or OFF.
SECTION 8 - MICROPANEL
Active Remote Control Status
UNIT ACTIVE REMOTE CONTR0L = XXXXXX
This message indicates whether the system was operating under Active Remote Control (RCC, ISN, LOAD, TEMP, or SOUND) or standard control (NONE) at the time of the fault.
UNIT SOUND LIMIT LOCAL = XXX % ISN = XXX REMOTE = XXX %
This message indicates that sound limiting was in effect, the amount, and whether it was local or remotely limited.
VSD Data
VSD Actual and Command Frequency
VSD FREQUENCY ACTUAL = XXX.X HZ COMMAND = XXX.X HZ
This message indicates the VSD actual operating frequency and the command frequency at the time of the fault. Actual and command may not match due to load/ unload timers, limitation of 1 Hz per load/unload increment, and to allowable acceleration/deceleration of the motor.
VSD COMP 1 = XXX AMPS COMP 2 = XXX AMPS
= XXX %FLA = XXX %FLA
Compressor AMPS and %FLA
The message indicates the compressor %FLA and cur-
rents for systems 1 and 2 at the time of the fault.
8
COMP 1 = XXX AMPS
= XXX %FLA
COMP 3 = XXX AMPS
= XXX %FLA
COMP 2 = XXX AMPS COMP 4 = XXX AMPS
= XXX %FLA = XXX %FLA
These messages indicate the compressor %FLA and currents for systems 3 and 4 at the time of the fault. For 3 compressor units, the #4 compressor information is blanked out.
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VSD Current Limit
VSD CURRENT LIMIT LOCAL = XXX %FLA
ISN = XXX
REMOTE = XXX %FLA
This message displays the current limit values as set locally, by an ISN, or a remote current limiting input at the time of the fault.
DC BUS Voltage
VSD
DC BUS VOLTAGE = XXX VDC
DC BUS VOLTAGES BUS 1 = XXX VDC BUS 2 = XXX VDC
This message displays the DC Bus voltage at the time of the fault. On 4 compressor units, the 2nd message will apply since two DC Bus voltages are present (1/3 and 2/4) at the time of the fault.
VSD Internal Ambient Temp
VSD INTERNAL AMBIENT TEMP = XXX.X °F COOLING SYSTEM STATUS = YYY
This message displays the VSD/Microprocessor internal ambient cabinet temperature and the cooling system status (ON or OFF) at the time of the fault.
IGBT Baseplate Temperature
VSD IGBT BASEPLATE TEMPS T1 = XXX °F T2 = XXX °F
This message displays the IGBT highest baseplate temperature for 2 and 3 compressor units at the time of the fault. 4 compressor units display temperatures for 1/3 (T1) and 2/4 (T2).
Precharge Signal Status and VSD Cooling Status
VSD
PRECHARGE SIGNAL = XXX
VSD PRECHARGE 1 SIGNAL = XXX PRECHARGE 2 SIGNAL = XXX
This display provides the state of the precharge signal, where Precharge 1 and Precharge 2 is either ON or OFF at the time of the fault. Precharge 2 is only used on 4 compressor units.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Compressor #1 and #2, 105% FLA Motor Overload Current Setting
VSD COMP 1 MOTOR OVERLOAD = XXX AMPS COMP 2 MOTOR OVERLOAD = XXX AMPS
This message displays the setting of the VSD's 100% FLA potentiometer for Compressor #1 and #2 at the time of the fault.
Compressor #3 and #4, 105% FLA Current Setting
COMP 3 MOTOR OVERLOAD = XXX AMPS COMP 4 MOTOR OVERLOAD = XXX AMPS
This message displays the setting of the
VSD's 100% FLA potentiometer for Compressor #3 and #4 at the time of the fault.
System Data
System #1 Pressures
SYS 1 PRESSURES
OIL = XXXX PSIG
SUCTION = XXXX
DISCHARGE = XXXX PSIG
This message displays all of the measured system pressures (oil, suction, and discharge) at the time of the fault.
System # 1 Measured Temperatures
SYS 1 TEMPERATURES
OIL = XXX.X °F
SUCTION = XXX.X
DISCHARGE = XXX.X °F
This message displays all of the measured system temperatures (oil, suction, and discharge) at the time of the fault.
System #1 Measured Suction Temperature and Calculated SAT Suction Temperature and Superheat
SYS 1 SUCTION
TEMP = XXX.X °F
SUPERHEAT = XXX.X SAT REMP = XXX.X °F
This message displays all of the calculated suction temperatures (saturated suction and system superheat) at the time of the fault as well as measured suction temperature.
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
System #1 Calculated Discharge Temperatures
SYS 1 DISCHARGE
TEMP = XXX.X °F
SUPERHEAT = XXX.X SAT REMP = XXX.X °F
This message displays all of the calculated discharge temperatures (saturated discharge and discharge superheat) at the time of the fault as well as measured discharge temperature.
System #1 Motor Temperatures
SYS 1 MOTOR TEMPS
T1 = XXX.X °F
T2 = XXX.X
T3 = XXX.X °F
This message displays the System 1 motor thermistor temperatures at the time of the fault.
System #1 Compressor Speed and Economizer Solenoid Status
SYS 1 COMPRESSOR
SPEED = XXX.X %
ECONOMIZER SOLENOID = XXX
This message indicates the compressor speed and status of economizer solenoid at the time of the fault. The economizer status will be indicated as either ON or OFF.
System #1 Flash Tank Level and Feed Valve % Open
SYS 1 FLASH TANK
LEVEL = XXX.X %
FEED VALVE PERCENT OPEN = XXX.X %
This message displays the liquid level in the flash tank and indicates the % the Flash Tank Feed Valve is open at the time of the fault.
System #1 Suction Superheat and Flash Tank Drain Valve % Open
SYS 1
SUCTION SUPERHEAT = XXX.X °F
DRAIN VALVE PERCENT OPEN = XXX.X %
This message displays the system suction superheat and indicates the % the Flash Tank Drain Valve is open at the time of the fault.
SECTION 8 - MICROPANEL
System #1 Fan Stage and Compressor Heater Status
SYS 1 CONDENSER FANS ON = XXX
COMPRESSOR HEATER = XXX
This message displays the actual # of system fans on, and the status of the compressor heater at the time of the fault. The fan display will show the number of fans operating while the compressor heater status will indicate either ON or OFF.
Compressor #1 Run Time
SYS 1 RUN TIME XX DAYS XX HOURS XX MINUTES XX SECONDS
This message displays the system run time since the last start in days, hours, minutes, and seconds at the time of the fault.
System #1 Run Signals
SYS 1 RUN SIGNALS RUN PERM = XXX
RELAY = XXX SOFTWARE = XXX
This message displays the System Run Signal Relay (Relay Output Board) status, Run Permissive Input status, and the Internal Software (microprocessor command) ON/OFF Start status. The status of each will indicate either ON or OFF.
System 2 through 4 Data
Data for the remaining systems 2 through 4 at the time
of the fault is displayed in the same sequence as the
system #1 data.
Compressor Operating Hours and Starts
8
HOURS 1=XXXXX, 2=XXXXX, 3=XXXXX, 4=XXXXX START 1=XXXXX, 2=XXXXX, 3=XXXXX, 4=XXXXX
This message displays compressor operating hours and compressor starts at the time of the fault. On 3 and 4 compressor units, the data and compressor designators for compressors not present will be blanked out.
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Chilled Liquid Setpoint Cooling Setpoints
SETPOINTS LOCAL COOLING SETPOINT = XXX.X °F
This message displays the programmed cooling setpoint at the time of the fault.
SETPOINTS LOCAL CONTROL RANGE
= +/- X.X °F
This message displays the programmed Control Range at the time of the fault.
Remote Setpoint and Range
SETPOINTS REMOTE SETPOINT = XXX.X °F REMOTE CONTROL RANGE = +/- X.X °F
This message displays the remote setpoint and Control Range at the time of the fault.
Maximum Remote Temperature Setpoint
SETPOINTS MAXIMUM REMOTE TEMP RESET = XXX.X °F
This message displays the maximum remote reset programmed at the time of the fault.
Options
Display Language
OPTIONS DISPLAY LANGUAGE XXXXXXXXXXXXXXXXXXXX
This message displays the language selected at the time of the fault.
Chilled Liquid Cooling Mode
OPTIONS CHILLED LIQUID COOLING MODE
WATER COOLING
This message displays the chilled liquid temperature mode (water or glycol) selected at the time of the fault.
Local / Remote Control Mode
OPTIONS CHILLED LIQUID COOLING MODE
GLYCOL COOLING
This message indicates whether Local or Remote Control Mode was selected at the time of the fault.
OPTIONS LOCAL / REMOTE CONTROL MODE
XXXXXXXXXXXXXXXXXXXXX
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
When Remote Control Mode is selected, control of the Chilled Liquid Setpoint is from a remote device such as an ISN/BAS controller.
OPTIONS DISPLAY UNITS
XXXXXXXXXXXXXXXXXXXX
Display Units Mode
This message indicates whether SI (°C, barg) or Imperial units (°F, psig) was selected at the time of the fault.
OPTIONS LEAD / LAG CONTROL MODE
XXXXXXXXXXXXXXXXXXXXX
System Lead/Lag Control Mode This message indicates the type of lead lag control selected at the time of the fault. Five choices are available:
· Automatic · Sys 1 Lead · Sys 2 Lead · Sys 3 Lead · Sys 4 Lead. The default mode will be AUTOMATIC.
Remote Temperature Reset
One of the 5 messages below indicates whether remote temperature reset was active or disabled at the chiller keypad at the time of the fault. If active, the type of reset signal selected is indicated. If the option is not factory enabled, the option will not appear.
OPTIONS
REMOTE TEMP RESET INPUT DISABLED
OPTIONS
REMOTE TEMP RESET INPUT 0.0 TO 10.0 VOLTS DC
OPTIONS
REMOTE TEMP RESET INPUT 2.0 TO 10.0 VOLTS DC
OPTIONS
REMOTE TEMP RESET INPUT 0.0 TO 20.0 MILLIAMPS
OPTIONS
REMOTE TEMP RESET INPUT 4.0 TO 20.0 MILLIAMPS
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Low Ambient Temp Cutout
OPTIONS LOW AMBIENT TEMP CUTOUT
XXXXXXXXXXXXXXXXXXXX
This message indicates whether the low ambient cutout was enabled or disabled at the time of the fault.
Remote Current Reset
OPTIONS REMOTE CURRENT LIMIT INPUT
DISABLED
OPTIONS
REMOTE CURRENT LIMIT INPUT 0.0 TO 10.0 VOLTS DC
OPTIONS
REMOTE CURRENT LIMIT INPUT 2.0 TO 10.0 VOLTS DC
OPTIONS
REMOTE CURRENT LIMIT INPUT 0.0 TO 20.0 MILLIAMPS
OPTIONS REMOTE CURRENT LIMIT INPUT
4.0 TO 20.0 MILLIAMPS
This message indicates whether remote current reset was active or disabled at the chiller keypad at the time of the fault and if active, the type of reset signal selected. One of the following messages will be indicated: DISABLED (no signal)
· 0 VDC to 10 VDC
· 2 VDC to 10 VDC
· 0 mA to 20 mA
· 4 mA to 20 mA.
If the option is not factory enabled, the option will not appear.
Program Values
Suction Pressure Cutout
PROGRAM SUCTION PRESSURE CUTOUT = XXX.X PSIG
This message indicates the he suction pressure cutout programmed at the time of the fault.
Low Ambient Cutout
PROGRAM LOW AMBIENT TEMP CUTOUT = XXX.X °F
This message displays the low ambient temp cutout programmed at the time of the fault.
SECTION 8 - MICROPANEL
Low Leaving Chilled Liquid Temp Cutout
PROGRAM LEAVING LIQUID TEMP CUTOUT = XXX.X °F
This message displays the low leaving Chilled liquid temperature cutout programmed at the time of the fault.
Motor Current Limit
PROGRAM MOTOR CURRENT LIMIT= XXX %FLA
This message indicates the motor current limit programmed at the time of the fault.
Pulldown Current Limit
PROGRAM PULLDOWN CURRENT LIMIT= XXX %FLA
This message indicates the pulldown current limit programmed at the time of the fault.
Pulldown Current Limit Time
PROGRAM PULLDOWN CURRENT LIMIT TIME
= XXX MIN
This message indicates the pulldown current limit time programmed at the time of the fault.
Suction Superheat Setpoint
PROGRAM SUCTION SUPERHEAT SETPOINT
= XXX.X °F
This message indicates the suction superheat setpoint
programmed at the time of the fault.
8
Unit ID Number
PROGRAM
REMOTE UNIT ID NUMBER = X
This indicates the unit ID # programmed at the time of the fault.
Sound Limit Setpoint
PROGRAM SOUND LIMIT SETPOINT
= XXX %
This indicates the sound limit setpoint programmed at the time of the fault, if the sound limit option is activated at the factory. If the option is not factory activated, the display will not appear.
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SETPOINTS KEY
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SETPOINTS KEY
LD10605
Setpoints Key Operation
Cooling setpoints and ranges may be programmed by pressing the SETPOINTS key. The first setpoint entry screen will be displayed as shown below. The first line of the display will show the chiller default (DEF), minimum acceptable value (LO) and maximum acceptable value (HI). The second line shows the actual programmed value. Table 20 on page 259 also shows the allowable ranges for the cooling setpoints and Control Ranges. Note that the Imperial units are exact values while the Metric units are only approximate.
SETPOINTS DEF XXXXX LO XXXXX HI XXXXX LOCAL COOLING SETPOINT = XXX.X °F
Pressing the SETPOINTS key a second time or the (ARROW) key will display the leaving chilled liquid Control Range, default, and low/high limits.
SETPOINTS DEF XXXXX LO XXXXX HI XXXXX LOCAL CONTROL RANGE = +/- X.X °F
Pressing the SETPOINTS key or the (ARROW) key a third time will display the remote setpoint and cooling range. This display automatically updates about every 2 seconds. This remote setpoint message is show below:
SETPOINTS REMOTE SETPOINT = XXX.X °F REMOTE CONTROL RANGE = +/- X.X °F
If there is no remote setpoint being utilized, the remote setpoint value will be displayed as XXXXXX and the remote Control Range will display XXX.
Pressing the SETPOINTS key or the Arrow key a fourth time will bring up a screen that allows the Maximum Remote Temperature Reset to be programmed. This message is show below:
SETPOINTS DEF XXXXX LO XXXXX HI XXXXX MAXIMUM REMOTE TEMP RESET = XXX.X °F
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The values displayed under each of the key presses may be changed by keying in new values and pressing the (ENTER) key to store the new value into memory. Where more than one value may be keyed in on a display, a portion of the data that does not need updating may be skipped by pressing the (ENTER) key. The (ENTER) key must also be pressed after the last value in the display to store the data into memory.
SECTION 8 - MICROPANEL
The (ARROW) key allows scrolling back through the setpoints displays.
The minimum, maximum, and default values allowed under the SETPOINTS key are provided in Table 20 on page 259.
Table 20 - SETPOINT LIMITS PROGRAM VALUE
Leaving Chilled Liquid Setpoint
Leaving Chilled Liquid Control Range Max. Remote Temperature Reset
MODE Water Cooling Glycol Cooling
-
-
LOW LIMIT 40.0°F 4.4°C 15.0°F -9.4°C 1.5°F 0.8°C 2°F
1°C
HIGH LIMIT 60.0°F 15.6°C 70.0°F 15.6°C 2.5°F 1.4°C 40°F
22°C
DEFAULT 44.0°F 6.7°C 44.0°F 6.7°C 2.0°F 1.1°C 20°F
11°C
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SECTION 8 - MICROPANEL
PROGRAM KEY
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
PROGRAM KEY
LD10605
Program Key Operation
Various operating parameters are programmable by the user. These are modified by pressing the PROGRAM key and then the (ENTER) key to enter Program Mode. A listing of the limits of the programmable values is found below. Note that the Imperial units are exact values, while Metric units are only approximate.
The and (ARROW) keys are used to scroll through the user programmable values. A value may be changed by keying in the new value and pressing the (ENTER) key to store the new value in memory. The cursor will be displayed on the screen when a number key is pressed. The first line of each message will indicate the chiller default (DEF) value), lowest acceptable programmable value (LO), and highest acceptable programmable value (HI). The user programmable value is programmed on in the second line of the message.
When the PROGRAM key is first pressed, the following display will appear indicating the user is in the program mode:
PROGRAM MODE XXXX PRESS ENTER KEY TO CONTINUE
Pressing the (ENTER) key again will display the first programmable selection.
Suction Pressure Cutout
PROGRAM DEF XXXXX LO XXXXX HI XXXXX SUCTION PRESSURE CUTOUT = XXX.X PSIG
The suction pressure cutout is protects the chiller from a low refrigerant condition. It also helps protect from a freeze-up due to low or no chilled liquid flow. However, it is only a back-up for a flow switch and cannot protect against an evaporator freeze under many conditions. This cutout is programmable and should generally be programmed for 24 psig (1.65 barg) for chilled water cooling.
The cutout is programmable between 24.0 psig and 36.0 psig (1.65 barg and 2.48 barg) in the Water Cooling mode and 5.0 psig and 36.0 psig (0.34 barg and 2.28 barg) in the Glycol Cooling mode. The default value for both modes will be 24.0 psig (1.65 barg).
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Low Ambient Cutout
PROGRAM DEF XXXXX LO XXXXX HI XXXXX LOW AMBIENT TEMP CUTOUT = XXX.X °F
The low ambient temp cutout allows programming the outdoor temperature at which it is desired to shut down the chiller to utilize other methods of cooling.
The cutout is programmable between 2.0°F (-18.9°C) and 50°F (10.0°C) with a 25°F (-3.9°C) default.
Low Leaving Liquid Temp Cutout
PROGRAM DEF XXXXX LO XXXXX HI XXXXX LEAVING LIQUID TEMP CUTOUT = XXX.X °F
The leaving chilled liquid temp cutout is programmed to avoid freezing the evaporator due to excessively low chilled liquid temperatures. The cutout is automatically set at 36°F (2.2°C) in the Water Cooling mode and is programmable in the Glycol Cooling mode. In the Glycol Cooling Mode, the cutout is programmable from 11.0°F to 36.0°F (-11.7°C to 2.2°C) with a default of 36.0°F (2.2°C).
Motor Current Limit
PROGRAM DEF XXXXX LO XXXXX HI XXXXX MOTOR CURRENT LIMIT = XXX % FLA
The motor current limit %FLA is programmable. This allows the microprocessor to limit a system before it faults on high current. Typically, the limit point is set at 100%. The unload point is programmable from 30% to 100% with a default of 100%.
Pulldown Current Limit
PROGRAM DEF XXXXX LO XXXXX HI XXXXX PULLDOWN CURRENT LIMIT = XXX % FLA
The pulldown current limit %FLA is programmable. This allows the microprocessor to limit a system on pulldown limiting for the purpose of peak time energy savings. Typically, the limit point is set at 100%. The pulldown limit point is programmable from 30% to 100% with a default of 100%. Be aware when using pulldown motor current limit, the chiller may not be able to load to satisfy temperature demand
SECTION 8 - MICROPANEL
Pulldown Current Limit Time
PROGRAM DEF XXXXX LO XXXXX HI XXXXX PULLDOWN CURRENT LIMIT TIME = XXX MIN
The pulldown current limit time is programmable. This allows the microprocessor to limit a system on pulldown limiting for a defined period of time for the purpose of peak time energy savings. The pulldown limit point is programmable from 0 to 255 with a default of 0 Min.
Suction Superheat Setpoint
PROGRAM DEF XXXXX LO XXXXX HI XXXXX SUCTION SUPERHEAT SETPOINT = XXX.X °F
The suction superheat setpoint is programmable from 8.0°F to 12.0°F (4.4°C to 8.3°C) with a 10.0°F (5.6°C) default. Typically the superheat control will be programmed for 10.0°F. Higher superheats between 10 and 12°F will reduce the risk of liquid carry over and are preferred by some users.
Unit ID Number
PROGRAM DEF XXXXX LO XXXXX HI XXXXX REMOTE UNIT ID NUMBER = X
For purposes of remote communications, multiple chillers may be connected to an RS-485 communications bus. To allow communications to each chiller, a chiller ID number may be programmed into memory. On a single chiller application, the value will be "0".
8
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SECTION 8 - MICROPANEL
Sound Limit Setpoint
PROGRAM DEF XXXXX LO XXXXX HI XXXXX SOUND LIMIT SETPOINT = XXX %
The sound limit setpoint is programmable from 0% to 100% with a 0% default. 0% allows operating up to the full speed capability of the unit with no sound limiting. Typically the sound limit control setting will be programmed for 0 % unless sound limiting is utilized on the chiller. Sound limiting will only permit the unit to run to a frequency less than the maximum speed capability of the unit. Programming a value of 1% would be the minimum sound limiting that can be programmed and 100% will be the maximum. 100% will only allow the unit speed to operate at the minimum frequency. Usually, the sound limit % will be programmed somewhere between 0% and 100% according the limiting needed to satisfy the sound requirements of the site. Typically, sound limiting will be utilized in areas sensitive to noise during night-time hours. The sound limit display will only be present if the sound limit option is programmed at the factory.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Default Values A listing of the low limits, high limits, and default values for each of the programmable values is noted in each display and can be found in Table 21 on page 262. Note that the Imperial units are exact values while the Metric units are only approximate.
Table 21 - PROGRAMMABLE OPERATING PARAMETERS
PROGRAM VALUE
MODE
Suction Pressure Cutout
Water Cooling
Glycol Cooling
Low Ambient Temp. Cutout
-
Leaving Chilled Liquid Temp. Cutout
Motor Current Limit Pulldown Motor Current Limit Pulldown Motor Current Limit Time
Water Cooling
Glycol Cooling
-
Suction Superheat Setpoint
-
Unit ID Number Sound Limit Setpoint
-
Sound Limit Option Enabled
LOW LIMIT 24.0 psig 1.65 bar 5.0 psig 0.34 bar -2°F -18.9°C 11.0°F -11.7°C 30% 30% 0 min 8.0°F 4.4°C 0
0%
HIGH LIMIT 36.0 psig 2.48 bar 36.0 psig 2.48 bar 50.0°F 10.0°C 36.0°F 2.2°C 103% 100% 255 min 12.0°F 6.6°C 7
100%
DEFAULT 24.0 psig 1.65 bar 24.0 psig 1.65 bar
25.0°F 2.2°C 36.0°F 2.2°C 36.0°F 2.2°C 103% 100% 0 min 10.0°F 5.6°C
0
0%
262
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
OPTIONS KEY
SECTION 8 - MICROPANEL
OPTIONS KEY
LD10605
Options Key Operation
The OPTIONS key provides the user with a display of unit configuration and the capability to modify the configuration. These options can only be viewed under the OPTIONS key. To view the current options settings, press the OPTIONS key. Each press of the OPTIONS key or press of the or (ARROW) keys will scroll to the next option setting. The and (ARROW) keys allow changing the option choices. The (ENTER) key must be pressed after a selection is made to save the change in memory.
An explanation of each option message is provided below.
Display Language Selection
The display language can be selected for English, Dutch, German, Italian, and Chinese
OPTIONS
DISPLAY LANGUAGE XXXXXXXXXXXXXXXXXX
The default language will be English.
Chilled Liquid Cooling Mode Selection
The Chilled liquid cooling mode can be selected for Water Cooling or low temperature Glycol Cooling.
OPTIONS
CHILLED LIQUID COOLING MODE XXXXXXXXXXXXXXXXXX
When Water Cooling is chosen, the chilled liquid tem-
perature setpoint can only be programmed from 40°F to 70°F
8
OPTIONS
CHILLED LIQUID COOLING MODE WATER COOLING
When Glycol Cooling is chosen, the chilled liquid temperature setpoint can be programmed from 10°F to 70°F.
OPTIONS
CHILLED LIQUID COOLING MODE GLYCOL COOLING
The default Chilled Liquid Mode will be WATER.
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263
SECTION 8 - MICROPANEL
Local / Remote Control Mode Selection
Local or Remote Control Mode allows the user to select the chilled liquid temperature control mode.
OPTIONS LOCAL / REMOTE CONTROL MODE
XXXXXXXXXXXXXXXXXX
When LOCAL CONTROL mode is selected, chilled liquid control is from the keypad of the chiller. In local mode, a remote device can read system data, but not reset operating parameters.
OPTIONS LOCAL / REMOTE CONTROL MODE
LOCAL CONTROL
When REMOTE CONTROL mode is selected, control of the chilled liquid setpoint is from a remote device such as an ISN/BAS controller.
OPTIONS LOCAL / REMOTE CONTROL MODE
REMOTE CONTROL
The default mode will be LOCAL.
Display Units Selection
Imperial or SI display units may be selected for data display.
OPTIONS
DISPLAY UNITS XXXXXXXXXXXXXXXXXX
The user may select system operating temperatures and pressures to be displayed in either SI (°C, Barg) or Imperial units (°F, PSIG).
OPTIONS
DISPLAY UNITS IMPERIAL
OPTIONS
DISPLAY UNITS SI
The default mode is IMPERIAL.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
System Lead/Lag Control Mode Selection
The operator may select the type of lead/lag control desired.
OPTIONS
LEAD / LAG CONTROL MODE XXXXXXXXXXXXXXXXXX
In most cases, automatic lead/lag will be selected. When automatic lead/lag is selected, the microprocessor will attempt to balance run time by switching the lead compressor whenever all compressors are shut off. If a compressor is not able to run when the microprocessor attempts a start, the microprocessor will select another compressor in an effort to control chilled liquid temperature. Manual lead/lag allows selecting a specific compressor to be the lead. If #2 is selected as the lead in a 3 compressor chiller, the sequence will be 2, 3, and 1.
OPTIONS
LEAD / LAG CONTROL MODE AUTOMATIC
The default mode will be AUTOMATIC.
Lag selections of individual systems will appear as:
OPTIONS
LEAD / LAG CONTROL MODE MANUAL SYS 1 LEAD
OPTIONS
LEAD / LAG CONTROL MODE MANUAL SYS 2 LEAD
OPTIONS
LEAD / LAG CONTROL MODE MANUAL SYS 3 LEAD
SYSTEM 3 LEAD may be selected only on 3 and 4 compressor units.
OPTIONS
LEAD / LAG CONTROL MODE MANUAL SYS 4 LEAD
SYSTEM 4 LEAD may be selected only on 4 compressor units.
264
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Remote Temperature Reset Selection
Remote temperature reset from an external source may be tied directly into the chiller microprocessor board.
OPTIONS
REMOTE TEMP RESET INPUT XXXXXXXXXXXXXXXXXX
Selections may be made for DISABLED (no signal), 0 VDC to10 VDC, 2 VDC to 10 VDC, 0 mA to 20 mA, and 4 mA to 20 mA.
OPTIONS
REMOTE TEMP RESET INPUT DISABLED
OPTIONS
REMOTE TEMP RESET INPUT 0.0 TO 10.0 VOLTS DC
OPTIONS
REMOTE TEMP RESET INPUT 2.0 TO 10.0 VOLTS DC
OPTIONS
REMOTE TEMP RESET INPUT 0.0 TO 20.0 MILLIAMPS
OPTIONS
REMOTE TEMP RESET INPUT 4.0 TO 20.0 MILLIAMPS
The default setting for Remote Temp Reset is DISABLED. This display will only appear if the remote temp limit option is enabled at the factory.
Remote Current Limit Input Selection
Remote current limit from an external source may be tied directly into the chiller microprocessor board.
OPTIONS
REMOTE CURRENT LIMIT INPUT XXXXXXXXXXXXXXXXXXXXX
Selections may be made for DISABLED (no signal), 0 VDC to 10 VDC, 2 VDC to 10 VDC, 0 mA to 20 mA, and 4 mA to 20 mA.
OPTIONS
REMOTE CURRENT LIMIT INPUT DISABLED
OPTIONS
REMOTE CURRENT LIMIT INPUT 0.0 TO 10.0 VOLTS DC
OPTIONS
REMOTE CURRENT LIMIT INPUT 2.0 TO 10 VOLTS DC
OPTIONS
REMOTE CURRENT LIMIT INPUT 0.0 TO 20.0 MILLIAMPS
OPTIONS
REMOTE CURRENT LIMIT INPUT 4.0 TO 20.0 MILLIAMPS
SECTION 8 - MICROPANEL
The default setting for Remote Current Reset is DISABLED. This display will only appear if the remote current limit option is enabled at the factory.
Remote Sound Limit Selection
Remote sound limit from an external source may be tied directly into the chiller microprocessor board.
OPTIONS
REMOTE SOUND LIMIT INPUT XXXXXXXXXXXXXXXXXXXX
Selections may be made for DISABLED (no signal), 0 VDC to10 VDC, 2 VDC to 10 VDC, 0 mA to 20 mA, and 4 mA to 20 mA.
OPTIONS
REMOTE SOUND LIMIT INPUT DISABLED
OPTIONS
REMOTE SOUND LIMIT INPUT 0.0 TO 10.0 VOLTS DC
OPTIONS
REMOTE SOUND LIMIT INPUT 2.0 TO 10.0 VOLTS DC
OPTIONS
REMOTE SOUND LIMIT INPUT 0.0 TO 20.0 MILLIAMPS
OPTIONS
REMOTE SOUND LIMIT INPUT 4.0 TO 20.0 MILLIAMPS
The default setting for Remote Sound Limit is DISABLED. This display will only appear if the remote sound limit option is enabled at the factory.
Low Ambient Cutout Enable/Disable
8
The low ambient cutout may be enabled or disabled.
When enabled, the chiller will cut off when the low
ambient cutout is reached. When disabled, the chiller
will run at any temperature.
OPTIONS LOW AMBIENT TEMPERATURE CUTOUT
ENABLED
OPTIONS LOW AMBIENT TEMPERATURE CUTOUT
DISABLED
The default setting for the low ambient cutout will be ENABLED.
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SECTION 8 - MICROPANEL
DATE / TIME AND SCHEDULE KEYS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DATE/TIME KEY
SCHEDULE KEY
LD10605
Date/Time Key Operation
When the DATE/TIME key is pressed, the chiller microprocessor will display the date and the time. This feature is useful and required for using the Daily Schedule. It is also a valuable tool for troubleshooting to allow a technician to determine the time of the fault, which is stored in the history memory buffers. When the DATE/TIME key is pressed, the first display screen shown below will be displayed:
CLOCK FRI 18-JUN-2005 10:15:33 AM
DAY OF WEEK
= XXX
Whenever any changes are made, the (ENTER) key must be pressed to store the data.
Pressing the or (ARROW) keys allows scrolling to the next programmed item. Pressing the (DOWN ARROW) key scrolls to the next item that can be programmed and the (UP ARROW) key scrolls to the previous item.
The day of the week is the first display and can be changed by pressing either the or (LEFT OR RIGHT ARROW) key to select the day. After the day is selected, the (ENTER) key must be pressed to store the data.
CLOCK FRI 18-JUN-2005 10:15:33 AM
DAY OF MONTH
= XX
Pressing the (DOWN ARROW) key again scrolls to the day of the month:
CLOCK FRI 18-JUN-2005 10:15:33 AM
DAY OF MONTH
= XX
The day of the month can be selected by keying in the numerical value to select the day. After the day of the month is selected, the (ENTER) key must be pressed to store the data.
A "0" must be typed in to select dates for days of the 1st through the 9th.
Pressing the (DOWN ARROW) key again scrolls to month:
CLOCK FRI 18-JUN-2005 10:15:33 AM
MONTH
= XX
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
The month can be selected by keying in the numerical value to select the day. After the month is selected, the (ENTER) key must be pressed to store the data.
A "0" must be keyed in for months 01 through 09. The panel will automatically provide the abbreviation of the month.
Pressing the (DOWN ARROW) key again scrolls to the year:
CLOCK FRI 18-JUN-2005 10:15:33 AM
YEAR
= XXXX
The year can be selected by keying in the numerical value to select the year. After the year is selected, the (ENTER) key must be pressed to store the data.
Pressing the (DOWN ARROW) key again scrolls to the hour:
CLOCK FRI 18-JUN-2005 10:15:33 AM
HOUR
= XX
The hour can be selected by keying in the numerical value for the hour. After the hour is selected, the (ENTER) key must be pressed to store the data.
One or two "0's" must be keyed in for hours 00-09.
Pressing the (DOWN ARROW) key again scrolls to the minute:
CLOCK FRI 18-JUN-2004 10:15:33 AM
MINUTE
= XX
The minute can be selected by keying in the numerical value for the hour. After the minute is selected, the (ENTER) key must be pressed to store the data.
One or two "0's" must be keyed in for minutes 00 through 09.
SECTION 8 - MICROPANEL
Pressing the (DOWN ARROW) key again scrolls to AM/PM:
CLOCK FRI 18-JUN-2004 10:15:33 AM
AM/PM
= XX
AM/PM can be selected by pressing the or (ARROW) keys. After the meridian is selected, the (ENTER) key must be pressed to store the data.
Pressing the (DOWN ARROW) key again scrolls to the time format selection:
CLOCK FRI 18-JUN-2004 10:15:33 AM
TIME FORMAT
= XXXXXXX
The time format may be displayed in either a 12 hour or 24 hour format. Selection can be changed by pressing the or (ARROW) keys. The (ENTER) key must be pressed to store the data.
Schedule Key Operation
The Daily Schedule must be programmed for the unit start and stop times. To set the schedule, press the SCHEDULE key. The display will provide a message allowing access to 2 types of schedule information:
SCHEDULECHOOSE SCHEDULE TYPE
XXXXXXXXXXXXXXXXXXXXXXXXX
The schedule types are:
· UNIT OPERATING SCHEDULE
· (Default selection)
· SOUND LIMIT SCHEDULE
8
(Only if Sound Limiting is enabled by the factory when the option is installed.)
The schedule type (UNIT OPERATING SCHEDULE or SOUND LIMIT SCHEDULE) may be changed by pressing the (LEFT ARROW) or (RIGHT ARROW) keys followed by the (ENTER) key. The selection must be entered by pressing the (ENTER) key before a schedule display will appear.
JOHNSON CONTROLS
267
SECTION 8 - MICROPANEL
Unit Operating Schedule
The Unit Operating Schedule is used to enable/disable the chiller unit on time of day. The chiller can be enabled and disabled once each day or it can be programmed to run continuously. Any time the daily or holiday schedule shuts the chiller down, the running system(s) will go through a controlled ramped shutdown. If the UNIT OPERATING SCHEDULE is selected under the CHOOSE SCHEDULE display, the following message will appear:
SCHEDULEUNIT OPERATING MON START = 06:00 AM STOP = 10:00 PM
The line under the 0 is the cursor. If the start time is wrong, it can be changed by keying in the new time from the numeric keypad. Once the correct values for the START hour and minute are entered, press the (ENTER) key. The cursor will then move to the AM/ PM selection. The meridian (AM/PM) value may be changed by the (LEFT ARROW) or (RIGHT ARROW) keys and entered by pressing (ENTER) key. Repeat this process for the STOP time. Once a schedule is entered, the schedule for the next day will appear. The start and stop time of each day may be programmed differently. To view the schedule without making a change, simply press the SCHEDULE key until the day you wish to view appears. The (UP ARROW) key will scroll backwards to the previous screen.
If at any time the schedule is changed for Monday, all the other days will change to the new Monday schedule. This means if the Monday times are not applicable for the whole week, then the exceptional days would need to be reprogrammed to the desired schedule.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
To program the chiller for 24 hour operation, program the start and stop times of each day of the week for 00:00.
After the SUN (Sunday) schedule appears on the display, a subsequent press of the SCHEDULE or (UP ARROW) key will display the Holiday schedule. This is a two-part display. The first reads:
SCHEDULEUNIT OPERATING HOL START = 00:00 AMSTOP = 00:00 PM
The holiday times may be set using the same procedure as described above for the days of the week. Be sure to press the (ENTER) key after setting the START and STOP times to save the change in memory. Pressing the SCHEDULE key a second time, the display will show the individual days:
SCHEDULEUNIT OPERATING S M T W T F S HOLIDAY NOTED BY *
The line below the empty space is the cursor and will move to the next or previous empty space when the (LEFT ARROW) or (RIGHT ARROW) keys and pressed. To set a day for the Holiday Schedule, the cursor must be moved to the space following the day of the week. The * key is then pressed and an "*" will appear in the space signifying that day as a holiday. The Holiday schedule must be programmed weekly. If there is no holiday, the "*" key is also used to delete the "*". The (ENTER) key is used to accept the holiday schedule for the entire week.
The HOLIDAY SCHEDULE is a temporary schedule. Once the schedule is executed, the selected holidays will be cleared from memory for the following week.
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Sound Limit Schedule
The SOUND LIMIT SCHEDULE allows setting the day and time when the user desires using the "SILENT NIGHT" factory programmed option to limit chiller loading and fan operation for reduced audible noise in the surrounding area. If the SOUND LIMIT SCHEDULE is selected under the CHOOSE SCHEDULE display, the following message will appear:
SCHEDULE SOUND LIMIT = XXX % MON START = 06:00 AM STOP = 10:00 PM
The Sound Limit option can be enabled and disabled once each day or the chiller can be set to run continuously in this mode for sound limiting whenever the chiller is operating. When sound limiting is enabled, the unit will be limited by the Sound Limit setpoint % as set under the PROGRAM key. XXX in the display above will show the Sound Limit Setpoint % programmed under the PROGRAM key. 0% will cause no speed reduction, while 100% only allows running at minimum speed.
The START Time for a specific day (hour and minute) is entered using the same guidelines used for the start/ stop schedules, and press the (ENTER) key to store it into memory. The cursor will then move to the AM/ PM selection.
SECTION 8 - MICROPANEL
The AM/PM selection may be chosen using the (LEFT ARROW) or (RIGHT ARROW) keys and pressing (ENTER) key to store the value.
This process is repeated for the STOP time.
Once the schedule for a specific day is programmed and entered, the schedule for the next day will appear. The schedule for each day may be programmed the same or differently.
To view the schedule without changing it, simply press the SCHEDULE key or the (DOWN ARROW) key until the desired day is displayed. The (UP ARROW) key will scroll backwards to the previous screen.
If the schedule is changed for Monday, all other days will change to the Monday schedule. Be aware of this when programming.
8
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269
SECTION 8 - MICROPANEL
MANUAL OVERRIDE KEY
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Manual Overrride Key Operation If the MANUAL OVERRIDE key is pressed during a schedule shutdown, the STATUS display will display the message below. This indicates that the Daily Schedule is being ignored and the chiller will start when chilled liquid temperature allows, Remote Contacts, UNIT switch and SYSTEM switches permitting. This is a priority message and cannot be overridden by anti-recycle messages, fault messages, etc. when in the STATUS display mode. Therefore, do not expect to see any other STATUS messages when in the MANUAL OVERRIDE mode. MANUAL OVERRIDE is to only be used in emergencies or for servicing. Manual override mode automatically disables itself after 30 minutes.
MANUAL OVERRIDE
270
MANUAL OVERRIDE KEY
LD10605
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
PRINT KEY
SECTION 8 - MICROPANEL
PRINT KEY
LD10605
Print Key Operation
The PRINT key is used to initiate a printout of current operating data (real time data), a complete history printout of all history (fault) buffers, a printout of all normal shutdowns (compressor cycling, chiller shutdown, etc.) or history (fault) data printout of a specific fault. History Buffer 1 will always be the most recent fault history printout. Printing may also be canceled by selecting the CANCEL PRINTING option. The following message is displayed when the PRINT key is pressed.
PRINT CHOOSE PRINT REPORT XXXXXXXXXXXXXXXXXXXXX
After pressing the PRINT key, the printout type is selected by pressing the (LEFT ARROW) or (RIGHT ARROW) keys until the desired printout is displayed.
Table 22 on page 271 shows the available printout types.
Table 22 - PRINTOUT TYPES
PRINTOUT TYPES
Operating Data
(Default Selection)
All History Buffers
Normal Shutdowns History Buffer 1
8
History Buffer 2
History Buffer 3
History Buffer 4
History Buffer 5
History Buffer 6
History Buffer 7
History Buffer 8
History Buffer 9
History Buffer 10
Cancel Printing
The specific printout is initiated by pressing the (ENTER) key.
JOHNSON CONTROLS
271
SECTION 8 - MICROPANEL
A sample of the operating data printout is shown below. The operating data printout is a snapshot of current system operating conditions when the printout was selected. The sample shows combined printouts of 2, 3, and 4 circuit units. The actual printout will only show data for the appropriate chiller type.
Bold italic text below a line of print is not on the actual printout. Bold italic text indicates information that may not be available on all printouts or is additional information to help explain the difference in a 2/3 or 4-circuit printout.
Operating Data Printout
YORK INTERNATIONAL CORPORATION LATITUDE SCREW CHILLER OPERATING DATA 2:04:14 PM 18 FEB 10
SYS 1 NOT RUNNING SYS 2 COMPRESSOR RUNNING
OPTIONS
CHILLED LIQUID
WATER
LOCAL/REMOTE MODE
REMOTE
LEAD/LAG CONTROL
AUTOMATIC
REMOTE TEMP RESET
DISABLED
REMOTE CURRENT LIMIT
0 TO 10 V
REMOTE SOUND LIMIT
4 TO 20 MA
(if Sound Limiting enabled)
LOW AMBIENT CUTOUT
ENABLED
PROGRAM VALUES
SUCT PRESS CUTOUT
44 PSIG
LOW AMBIENT CUTOUT
25.0 DEGF
LEAVING LIQUID CUTOUT
36.0 DEGF
MOTOR CURRENT LIMIT
100 %FLA
PULLDOWN CURRENT LIMIT
100 %FLA
PULLDOWN LIMIT TIME
0 MIN
SUCTION SUPERHEAT SETP
12.0 DEGF
UNIT ID NUMBER
0
SOUND LIMIT SETPOINT
100%
(if Sound Limiting enabled)
UNIT DATA
LEAVING LIQUID TEMP
49.0 DEGF
RETURN LIQUID TEMP
58.2 DEGF
TEMP RATE
XXX.X DEGF/MIN
COOLING RANGE
42.0+/-2.0 DEGF
REMOTE SETPOINT
44.0 DEGF
AMBIENT AIR TEMP
74.8 DEGF
LEAD SYSTEM
SYS 2
FLOW SWITCH
ON
EVAPORATOR PUMP RUN
ON
EVAPORATOR HEATER
OFF
ACTIVE REMOTE CONTROL
NONE
OPERATING HOURS 1=XXXXX, 2=XXXXX
3=XXXXX
(3 circuit)
272
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
START COUNTER
3=XXXXX, 4=XXXXX 1=XXXXX, 2=XXXXX 3=XXXXX
(3 circuit) 3=XXXXX, 4=XXXXX
(4 circuit)
SOFTWARE VERSION
C.ACS.XX.00
VSD DATA
ACTUAL FREQUENCY
XXX.X HZ
COMMAND FREQUENCY
XXX.X HZ
DC BUS VOLTAGE
XXX VDC
(2 circuit & 3 circuit)
DC BUS VOLTAGES
XXX XXX VDC
(4 circuit)
INTERNAL AMBIENT TEMP XXX.X DEGF
COOLING SYSTEM STATUS XXX
BASEPLATE TEMPS
XXX XXX DEGF
PRECHARGE SIGNAL
XXX
(2 circuit & 3 circuit)
PRECHARGE SIGNALS
XXX XXX
(4 circuit)
MOTOR OVERLOADS 1/2
XXX XXX AMPS
MOTOR OVERLOADS 3/4
XXX XXX AMPS
(3 circuit & 4 circuit)
SOFTWARE VERSION
C.VSD.XX.00
SYSTEM 1 DATA
COMPRESSOR STATUS
OFF
RUN TIME
0- 0- 0- 0 D-H-M-S
MOTOR CURRENT
0AMPS 0 %FLA
SUCTION PRESSURE
125 PSIG
DISCHARGE PRESSURE
131 PSIG
OIL PRESSURE
130 PSIG
SUCTION TEMPERATURE
68.4 DEGF
DISCHARGE TEMPERATURE 68.8 DEGF
OIL TEMPERATURE
68.8 DEGF
SAT SUCTION TEMP
71.8 DEGF
SUCTION SUPERHEAT
3.4 DEGF
SAT DISCHARGE TEMP
74.5 DEGF
DISCHARGE SUPERHEAT
6.3 DEGF
MOTOR TMP XXX.X XXX.X XXX.X DEGF
COMPRESSOR SPEED
XXX.X %
ECONOMIZER SOLENOID
OFF
FLASH TANK LEVEL
XXX.X %
FEED VALVE % OPEN
XXX.X %
DRAIN VALVE % OPEN
XXX.X %
CONDENSER FANS ON
0
COMPRESSOR HEATER
ON
RUN PERMISSIVE
ON
VSD RUN RELAY
OFF
VSD SOFTWARE RUN SIGNAL OFF
SYSTEM 2 DATA
COMPRESSOR STATUS
ON
RUN TIME
0-0-15-26 D-H-M-S
MOTOR CURRENT
104 AMPS 87 %FLA
SUCTION PRESSURE
57 PSIG
DISCHARGE PRESSURE
233 PSIG
OIL PRESSURE
218 PSIG
SUCTION TEMPERATURE
42.9 DEGF
DISCHARGE TEMPERATURE
145.5 DEGF
OIL TEMPERATURE
102.8 DEGF
SAT SUCTION TEMP
31.7 DEGF
SUCTION SUPERHEAT
11.2 DEGF
SAT DISCHARGE TEMP
112.1 DEGF
DISCHARGE SUPERHEAT
33.4 DEGF
MOTOR TMP
XXX.X XXX.X XXX.X DEGF
COMPRESSOR SPEED
XXX.X%
LIQUID LINE SOLENOID
ON
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
FLASH TANK LEVEL
XXX.X %
FEED VALVE % OPEN
XXX.X %
DRAIN VALVE % OPEN
XXX.X %
CONDENSER FANS ON
3
COMPRESSOR HEATER
OFF
RUN PERMISSIVE
ON
VSD RUN RELAY
OFF
VSD SOFTWARE RUN SIGNAL
OFF
UNIT OPERATING SCHEDULE
S M T W T F S
*=HOLIDAY
MON START=00:00AM
STOP=00:00AM
TUE START=00:00AM
STOP=00:00AM
WED START=00:00AM
STOP=00:00AM
THU START=00:00AM
STOP=00:00AM
FRI START=00:00AM
STOP=00:00AM
SAT START=00:00AM
STOP=00:00AM
HOL START=00:00AM
STOP=00:00AM
SOUND LIMIT SCHEDULE
(This section is printed only if the
sound limit schedule is enabled)
MON START=00:00AM
STOP=00:00AM
TUE START=00:00AM
STOP=00:00AM
WED START=00:00AM
STOP=00:00AM
THU START=00:00AM
STOP=00:00AM
FRI START=00:00AM
STOP=00:00AM
SAT START=00:00AM
STOP=00:00AM
HOL START=00:00AM
STOP=00:00AM
SECTION 8 - MICROPANEL
History Data Printout
History printouts, when selected, provide stored data relating to all specific system and chiller operating conditions at the time of the fault, regardless of whether a lockout occurred. History information is stored in battery-backed memory on the Chiller Control Board and is not affected by power failures or resetting of faults. Whenever a fault of any type occurs, all system operating data is stored in battery-backed memory at the instant of the fault. The history printout is similar to the operating data printout except for the change in the header information shown below:
YORK INTERNATIONAL CORPORATION LATITUDE SCREW CHILLER HISTORY NUMBER 1 2:04:14 PM 18 FEB 10
SYS 1 YYYYYYY HIGH DSCH PRESS SHUTDOWN
STATUS AT TIME OF SHUTDOWN SYS 1 XXXXXXXXXXXXXXXXXXXXXXXXXX SYS 2 XXXXXXXXXXXXXXXXXXXXXXXXXX
ALL FAULTS XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
The most recent fault will always be stored as HISTORY BUFFER #1.
8
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SECTION 8 - MICROPANEL
SERVICE KEY
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SERVICE KEY
LD10605
Service Key Operation The SERVICE key allows viewing data related to the internal function of the chiller system electronics. Data such as circuit board output status as controlled by the Chiller Control software while operating can be viewed and compared to actual chiller operation in the event servicing is required. The SERVICE key allows controlling of analog and digital outputs for troubleshooting purposes when the unit is not running. The Unit Serial Number and Optimized IPLV Control mode are also entered using the SERVICE key.
The (ARROW) keys allow scrolling through the displays. The (ARROW) key scrolls through the displays in the forward direction.
When the SERVICE key is pressed, the following message will appear:
SERVICE MODE XXXX PRESS ENTER KEY TO CONTINUE
XXXX will display a password, if a numerical password is entered.
274
Pressing the (ENTER) key allows "view only" Service Mode operation. All control board I/O will be viewable in this mode. No outputs can be changed. For troubleshooting or start-up commissioning purposes, the Chiller Micro Board and some VSD outputs can be toggled or changed by turning off the UNIT SWITCH, pressing the SERVICE key, entering password 9675, and pressing the (ENTER) key. Once the password is entered, the Digital Outputs (DO) can be toggled by pressing the (ENTER) key. The Analog Outputs can be programmed to output a specific value using the keypad and programming in the desired value, which will usually be noted as a % or VDC. If the UNIT SWITCH is turned back on, the chiller will revert to normal viewable only control.
Displays can be viewed by pressing the and (ARROW) keys. The (ARROW) key scrolls through the displays in the forward direction.
The and (ARROW) keys allow jumping from data section to data section to avoid scrolling sequentially through all the data. Once in a data section, the and (ARROW) keys allow scrolling through the data under the section. Pressing the and (ARROW) keys at any time moves to the top of the next data section.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
The data sections are listed below: · Software Versions · Analog Inputs · Digital Inputs · Digital Outputs · Analog Outputs · VSD Logic Digital Output
SERVICESOFTWARE VERSIONS CONTROL = C.AXX.ZZ.YY VSD = C.VXX.ZZ.YY
The software version of the chiller Micro Control Board and the VSD microprocessor are viewable in the first data section.
XX, YY, and ZZ will be filled in with alphanumeric characters.
The second data section displays the Analog Inputs (AI). Displays for 3 and 4 compressor chillers are skipped if the unit does not have those systems. These messages will only be displayed in English. The voltage displayed is referenced to common (return, ground) in the system. J12-3 can also be used as common, as well as chassis ground, or the common terminal point on the Chiller Control Board. See the wiring diagrams.
SERVICE AI J17-11 REMOTE TEMP RESET
X.X VDC
= XXX.X %
SERVICE AI J17-12 REMOTE CURRENT LIMIT
X.X VDC
= XXX.X %
SERVICE AI J17-13 REMOTE SOUND LIMIT
X.X VDC
= XXX.X %
The Remote Temp Reset, Remote Current Limit Reset, and Remote Sound Limit inputs have onboard voltage dividers, if the jumper is set for a voltage input. This will cause the voltage read on the display to be less than the voltage on the board header inputs between TB1-17 and 18, TB1-19 and 20, or TB1-40 and 41). To correct for this when measuring voltage at the remote device supplying voltage to the board header while troubleshooting, use the following calculation:
Voltage = 10 x VDC volts / 4.5
SECTION 8 - MICROPANEL
If the input is programmed for a current input, the voltage read by the MUX is displayed. If the input is disabled under the OPTIONS key, the voltage display will display "DISABLED".
The analog inputs display will continue to sequence as follows. The inputs indicate voltages read between the input terminal to the Chiller Logic Board and the plug GND or Drain.
SERVICE AI J17-14 SPARE ANALOG 1 X.X VDC
SERVICE AI J17-15 SPARE ANALOG 2 X.X VDC
SERVICE AI J18-7 LEAVING LIQUID TEMP
X.X VDC
= XXX.X °F
SERVICE AI J18-8 RETURN LIQUID TEMP
X.X VDC
= XXX.X °F
SERVICE AI J18-9 AMBIENT AIR TEMP
X.X VDC
= XXX.X °F
SERVICE AI J19-1 SYS1 MOTOR TEMP T1
X.X VDC
= XXX.X °F
SERVICE AI J19-2 SYS1 MOTOR TEMP T2
X.X VDC
= XXX.X °F
SERVICE AI J19-3 SYS1 MOTOR TEMP T3
X.X VDC
= XXX.X °F
SERVICE AI J19-6 SYS2 MOTOR TEMP T1
X.X VDC
= XXX.X °F
SERVICE AI J19-7 SYS2 MOTOR TEMP T2
8
X.X VDC
= XXX.X °F
SERVICE AI J19-8 SYS2 MOTOR TEMP T3
X.X VDC
= XXX.X °F
SERVICE AI J20-1 SYS3 MOTOR TEMP T1
X.X VDC
= XXX.X °F
SERVICE AI J20-2 SYS3 MOTOR TEMP T2
X.X VDC
= XXX.X °F
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SECTION 8 - MICROPANEL
SERVICE AI J20-3 SYS3 MOTOR TEMP T3
X.X VDC
= XXX.X °F
SERVICE AI J20-6 SYS4 MOTOR TEMP T1
X.X VDC
= XXX.X °F
SERVICE AI J20-7 SYS4 MOTOR TEMP T2
X.X VDC
= XXX.X °F
SERVICE AI J20-8 SYS4 MOTOR TEMP T3
X.X VDC
= XXX.X °F
SERVICE AI J21-3 SYS1 OIL TEMP
X.X VDC
= XXX.X °F
SERVICE AI J21-6 SYS1 FL TANK LEVEL
X.X VDC
= XXX.X %
SERVICE AI J21-13 SYS1 SUCTION TEMP
X.X VDC
= XXX.X °F
SERVICE AI J21-16 SYS1 DISCHARGE TEMP
X.X VDC
= XXX.X °F
SERVICE AI J21-20 SYS1 SUCTION PRESS
X.X VDC
= XXX.X PSIG
SERVICE AI J21-22 SYS1 OIL PRESS
X.X VDC
= XXX.X PSIG
SERVICE AI J21-24 SYS1 DISCHARGE PRESS
X.X VDC
= XXX.X PSIG
SERVICE AI J22-3 SYS2 OIL TEMP
X.X VDC
= XXX.X °F
SERVICE AI J22-6 SYS2 FL TANK LEVEL
X.X VDC
= XXX.X %
SERVICE AI J22-13 SYS2 SUCTION TEMP
X.X VDC
= XXX.X °F
SERVICE AI J22-16 SYS2 DISCHARGE TEMP
X.X VDC
= XXX.X °F
SERVICE AI J22-20 SYS2 SUCTION PRESS
X.X VDC
= XXX.X PSIG
SERVICE AI J22-22 SYS2 OIL PRESS
X.X VDC
= XXX.X PSIG
276
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SERVICE AI J22-24 SYS2 DISCHARGE PRESS
X.X VDC
= XXX.X PSIG
SERVICE AI J23-3 SYS3 OIL TEMP
X.X VDC
= XXX.X °F
SERVICE AI J23-6 SYS3 FL TANK LEVEL
X.X VDC
= XXX.X %
SERVICE AI J23-13 SYS3 SUCTION TEMP
X.X VDC
= XXX.X °F
SERVICE AI J23-16 SYS3 DISCHARGE TEMP
X.X VDC
= XXX.X °F
SERVICE AI J23-20 SYS3 SUCTION PRESS
X.X VDC
= XXX.X PSIG
SERVICE AI J23-22 SYS3 OIL PRESS
X.X VDC
= XXX.X PSIG
SERVICE AI J23-24 SYS3 DISCHARGE PRESS
X.X VDC
= XXX.X PSIG
SERVICE AI J24-3 SYS4 OIL TEMP
X.X VDC
= XXX.X °F
SERVICE AI J24-6 SYS4 FL TANK LEVEL
X.X VDC
= XXX.X %
SERVICE AI J24-13 SYS4 SUCTION TEMP
X.X VDC
= XXX.X °F
SERVICE AI J24-16 SYS4 DISCHARGE TEMP
X.X VDC
= XXX.X °F
SERVICE AI J24-20 SYS4 SUCTION PRESS
X.X VDC
= XXX.X PSIG
SERVICE AI J24-22 SYS4 OIL PRESS
X.X VDC
= XXX.X PSIG
SERVICE AI J24-24 SYS4 DISCHARGE PRESS
X.X VDC
= XXX.X PSIG
The third data section displays the Digital Inputs (DI) to the Chiller Control Board that can be viewed from the Service Mode. Displays for systems 3 and 4 are skipped if the systems are not present on the chiller. XXX is replaced with ON or OFF in the actual display. These messages will only be displayed in English.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SERVICE DI J4-2 SERVICE DI J4-3
UNIT SWITCH 1 STATUS = XXX
UNIT SWITCH 2 STATUS = XXX
SERVICE DI J4-4
SYS 1 HPCO STATUS = XXX
SERVICE DI J4-5
SYS 2 HPCO STATUS = XXX
SERVICE DI J4-6
VSD FAULT RELAY STATUS = XXX
SERVICE DI J5-1
SYS 3 HPCO STATUS = XXX
SERVICE DI J5-2
SYS 4 HPCO STATUS = XXX
SERVICE DI J5-3
SPARE DIGITAL INPUT 2 STATUS = XXX
J5 is not present on a 2 compressor Chiller Control Board. The displays above are skipped for a 2 compressor chiller:
SERVICE DI J6-2 SERVICE DI J6-3 SERVICE DI J6-4 SERVICE DI J6-5 SERVICE DI J6-6 SERVICE DI J7-2 SERVICE DI J7-4 SERVICE DI J7-6
FLOW SWITCH STATUS = XXX
PRINT STATUS = XXX
SYS 1/3 RUN PERM STATUS = XXX
SYS 2/4 RUN PERM STATUS = XXX
SPARE DIGITAL INPUT 1 STATUS = XXX
CONFIG INPUT 0 STATUS = XXX
CONFIG INPUT 1 STATUS = XXX CONFIG INPUT 2 STATUS = XXX
SECTION 8 - MICROPANEL
SERVICE DI J7-8 SERVICE DI J7-10 SERVICE DI J7-12
CONFIG INPUT 3 STATUS = XXX
CONFIG SPARE INPUT 0 STATUS = XXX
CONFIG SPARE INPUT 1 STATUS = XXX
SERVICE DO J9-1 RB1 TB1-20
SERVICE DO J9-2 RB1 TB1-18
EVAP HEATER STATUS = XXX
SYS 1/3 VSD RUN STATUS = XXX
SERVICE DO J9-3 RB1 TB1-16
SYS 1/3 ALARM STATUS = XXX
SERVICE DO J9-4 RB1 TB1-14
EVAP HEATER 2 STATUS = XXX
SERVICE DO J9-5 RB1 TB1-12
SYS 1 SPARE STATUS = XXX
SERVICE DO J9-6 RB1 TB1-10
SPARE 1 STATUS = XXX
SERVICE DO J9-7 RB1 TB1-8
SPARE 2 STATUS = XXX
SERVICE DO J9-8
SYS 1 COND FAN OUT 1
RB1 TB1-6
STATUS = XXX
SERVICE DO J9-9
SYS 1 COND FAN OUT 2
RB1 TB1-5
STATUS = XXX
8
SERVICE DO J9-10 SYS 1 COND FAN OUT 3
RB1 TB1-4
STATUS = XXX
SERVICE DO J9-11 RB1 TB1-3
SYS 1 COMP HEATER STATUS = XXX
SERVICE DO J9-10 SYS 1 ECON SOL VALVE
RB1 TB1-2
STATUS = XXX
SERVICE DO J10-1 RB1 TB1-20
EVAP PUMP RUN STATUS = XXX
SERVICE DO J10-2 RB1 TB1-18
SYS 2/4 VSD RUN STATUS = XXX
SERVICE DO J10-3 RB1 TB1-16
SYS 2/4 ALARM STATUS = XXX
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SECTION 8 - MICROPANEL
SERVICE DO J10-4 RB1 TB1-14
CHILLER RUN STATUS = XXX
SERVICE DO J10-5 RB1 TB1-12
SYS 2 SPARE STATUS = XXX
SERVICE DO J10-6 RB1 TB1-10
SERVICE DO J10-7 RB1 TB1-8
SPARE 3 STATUS = XXX
SPARE 4 STATUS = XXX
SERVICE DO J10-8SYS COND 2 FAN OUT 1
RB1 TB1-6
STATUS = XXX
SERVICE DO J10-9SYS COND 2 FAN OUT 2
RB1 TB1-5
STATUS = XXX
SERVICE DO J10-10SYS COND 2 FAN OUT 3
RB1 TB1-4
STATUS = XXX
SERVICE DO J10-11SYS 2 COMP HEATER
RB1 TB1-3
STATUS = XXX
SERVICE DO J10-12SYS 2 ECON SOL VALVE
RB1 TB1-2
STATUS = XXX
SERVICE DO J11-1SYS 4 COND FAN OUT 1
RB1 TB1-20
STATUS = XXX
SERVICE DO J11-2SYS 4 COND FAN OUT 2
RB1 TB1-18
STATUS = XXX
SERVICE DO J11-3SYS 4 COND FAN OUT 3
RB1 TB1-16
STATUS = XXX
SERVICE DO J11-4SYS 4 COMP HEATER
RB1 TB1-14
STATUS = XXX
SERVICE DO J11-5SYS 4 ECON SOL VALVE
RB1 TB1-12
STATUS = XXX
SERVICE DO J11-6 RB1 TB1-10
SYS 4 SPARE STATUS = XXX
SERVICE DO J11-7 RB1 TB1-8
SYS 3 SPARE STATUS = XXX
SERVICE DO J11-8SYS 3 COND FAN OUT 1
RB1 TB1-6
STATUS = XXX
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SERVICE DO J11-9SYS 3 COND FAN OUT 2
RB1 TB1-5
STATUS = XXX
SERVICE DO J11-10SYS 3 COND FAN OUT 3
RB1 TB1-4
STATUS = XXX
SERVICE DO J11-11SYS 3 COMP HEATER
RB1 TB1-3
STATUS = XXX
SERVICE DO J11-12SYS 3 ECON SOL VALVE
RB1 TB1-2
STATUS = XXX
The fifth data section displays the Analog Outputs (AO) that can be viewed from the Service Mode. The Analog Output signals are typically referenced to the common (return, ground) in the system. J12-3 can also be used as common, as well as chassis ground, or the common terminal point on the Chiller Control Board. See the wiring diagrams. GND on the plug. Displays for systems 3 and 4 are skipped if the systems are not present on the chiller. XXX is replaced with ON or OFF in the actual display. The state of these outputs is only viewable unless the password 9675 (ENTER) key was entered from the initial Service Mode display with the UNIT switch in the OFF position. The chiller will not be permitted to run when the outputs are made active. The outputs can be programmed for a specific % output by keying in the value and pressing the (ENTER) key. These messages will only be displayed in English.
SERVICE AO J15-1SYS 1 FEED VALVE OUT
XXX.X %
= XX.X VDC
SERVICE AO J15-3SYS 1 DRAIN VALVE OUT
XXX.X %
= XX.X VDC
SERVICE AO J15-5SYS 2 FEED VALVE OUT
XXX.X %
= XX.X VDC
SERVICE AO J15-7SYS 2 DRAIN VALVE OUT
XXX.X %
= XX.X VDC
SERVICE AO J14-1 SYS 3 FEED VALVE OUT
XXX.X %
= XX.X VDC
SERVICE AO J14-2 SYS 3 DRAIN VALVE OUT
XXX.X %
= XX.X VDC
278
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SERVICE AO J14-3 XXX.X %
SYS 4 FEED VALVE OUT = XX.X VDC
SERVICE AO J14-4 SYS 4 DRAIN VALVE OUT
XXX.X %
= XX.X VDC
SERVICE AO J25-1 XXX.X %
SERVICE AO J25-2 XXX.X %
SERVICE AO J25-3 XXX.X %
SYS 1 SPARE = XX.X VDC
SYS 2 SPARE = XX.X VDC
SYS 3 SPARE = XX.X VDC
SERVICE AO J25-4 XXX.X %
SYS 4 SPARE = XX.X VDC
SECTION 8 - MICROPANEL
The sixth data section displays the "VSD" digital outputs (DO) that can be viewed from the Service Mode. The Digital Output signals indicate the status of the output. The 0 VAC to 120 VAC digital outputs are referenced to neutral (Wire 2).
SERVICE DO J10-2 VSD COOLING FAN/PUMP
VSD LOGIC
STATUS = XXX
8
JOHNSON CONTROLS
279
SECTION 8 - MICROPANEL
SYSTEM SWITCHES KEY
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SYSTEM SWITCHES
KEY
LD10605
System Switches Key Operation
The SYSTEM SWITCHES key allows the operator to turn individual systems ON and OFF. Safety lockouts are also reset by selecting the respective system switch RESET. When the SYSTEM SWITCHES key is pressed, the following message will appear:
SYSTEM SWITCHES SYS 1 ON / OFF / RESET
=XXXXXXXXXXXXXXX
The display indicates the respective system and it's on/ off /reset switch status. The (ARROW) keys allow scrolling to the next and previous system switch (System 1, 2, 3, or 4).
SYSTEM SWITCHES
SYS 2 ON / OFF / RESET =XXXXXXXXXXXXXXX
SYSTEM SWITCHES
SYS 3 ON / OFF / RESET =XXXXXXXXXXXXXXX
SYSTEM SWITCHES SYS 4 ON / OFF / RESET
=XXXXXXXXXXXXXXX
The (LEFT ARROW) or (RIGHT ARROW) keys allow scrolling through the choices of:
· SYSTEM OFF (default)
· SYSTEM ON
· RESET (LOCKOUT)
The switch selection is accepted into memory by pressing the (ENTER) key.
When the "RESET" selection is made and accepted, it will not change the position of the switch (either ON or OFF).
Whenever possible, except in emergencies, always use the associated system switch to turn off a compressor, which allows the compressors to go through a controlled shutdown. Avoid using the "UNIT" switch to turn off the compressors.
280
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SERIAL NUMBER PROGRAMMING
When changing a Chiller Control Board, a Chiller Control Board EPROM, or if a situation occurs where a chiller is not programmed from the factory, the chiller serial number will need to be programmed into the chiller. The serial number is the actual serial number displayed on the unit Data Plate. The serial number will be in a format similar to RABM000000, where the first 4 characters are letters and the next 6 are numbers. The lack of a serial number programmed into the panel will not prevent a chiller from operating, but a High IPLV chiller will only operate in the Standard IPLV mode. The STATUS display will inform the operator a serial number problem exists by displaying the following message:
UNIT WARNING: INVALID SERIAL NUMBER ENTER UNIT SERIAL NUMBER
If the following message appears, immediately contact Johnson Controls Product Technical Support. The appearance of this message may also mean the chiller has lost important factory programmed information and may need to be reprogrammed. Additional STATUS messages can be viewed by pressing the STATUS key repetitively to enable the technician to view any other messages that may be preventing the chiller from operating.
Changing the programming of this feature requires the date and time to be set on the chiller prior to programming. The password is also time sensitive and must be used the same day it is received.
Johnson Controls Product Technical Support will provide a factory password to allow programming the serial number into the chiller. You will need to supply Factory Technical Support with the version of the Chiller Control Board EPROM. The version will be written on the EPROM label and typically will be in the format Version C.ACS.XX.XX.
After obtaining the password, the following steps will need to be followed to input the serial number. As the serial number is input, the characters keyed in will appear in the display indicating the panel has recognized the entry.
First press the SERVICE key. The following message will appear:
SECTION 8 - MICROPANEL
SERVICE MODE
XXXXX
PRESS ENTER KEY TO CONTINUE
Key in the 5 digit alphanumeric password provided by Product Technical Support and press the (ENTER) key. The following display will appear:
S/N ENTRYUNIT SERIAL NUMBER POS 1
X
Key in the first letter (A through Z) of the serial number using the and (ARROW) keys and press the (ENTER) key. Press the (DOWN ARROW) key to scroll to position 2 and the following message will
appear:
S/N ENTRYUNIT SERIAL NUMBER POS 2
XX
Key in the second letter (A through N) of the serial number using the and (ARROW) keys and press the (ENTER) key. Press the (DOWN ARROW) key to scroll to position 3 and the following message
will appear:
S/N ENTRYUNIT SERIAL NUMBER POS 3
XXX
Key in the third letter (A through Z) of the serial number using the and (ARROW) keys and press the (ENTER) key. Press the (DOWN ARROW) key to scroll to position 4 and the following message will
appear:
S/N ENTRYUNIT SERIAL NUMBER POS 4
8
XXXX
Key in the fourth letter (A through Z) of the serial number using the and (ARROW) keys and press the (ENTER) key. Press the (DOWN ARROW) key to scroll to positions 5-7 and the following message will appear:
S/N ENTRY UNIT S/N = YYYY XXX ZZZ UNIT SERIAL NUMBER POS 5-7 = XXX
At this point, the letters entered for the YYYY inputs should now appear in the top line of the display and should match the first 4 characters of the serial number on the unit Data Plate. The next three digits of the serial number should now be keyed in. Press the (ENTER) key to store the input. Press the (DOWN ARROW) key to scroll to positions 8 through10 and the following message will appear:
JOHNSON CONTROLS
281
SECTION 8 - MICROPANEL
S/N ENTRY UNIT S/N = YYYY XXX ZZZ UNIT SERIAL NUMBER POS 8-10 = XXX
At this point, the letters entered for the YYYY and XXX inputs should now appear in the top line of the display and should match the first 7 characters of the serial number on the unit Data Plate. The next three digits of the serial number should now be keyed in. Press the (ENTER) key to store the input. The full serial number should now be displayed across the top of the display and the cursor should disappear.
Press the STATUS key to go to the next STATUS display to determine if additional Status messages are preventing the chiller from operating.
ENABLING OPTIMIZED HIGH IPLV MODE
When changing a Chiller Control Board, a Chiller Control Board EPROM, or if a situation occurs where a chiller is not programmed from the factory, the chiller will not be capable of operating High IPLV mode. The serial number of the unit will first need to be programmed into the panel, if the Invalid Serial Number display appears (see Page 292). The Invalid Serial Number message will override the Optimized Efficiency Disabled message. If the chiller was purchased with the High IPLV Option and does not have the High IPLV mode enabled, it will not prevent the chiller from operating, but the chiller will only operate in the Standard IPLV mode. Additional STATUS messages can be viewed by pressing the STATUS key repetitively to enable the technician to view any other messages that may be preventing the chiller from operating.
Changing the programming of this feature requires the date and time to be set on the chiller prior to programming the password. The password is also time sensitive and must be used "immediately" when it is received.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
The STATUS display will inform the operator when a High IPLV chiller is operating with the High IPLV mode disabled by displaying the following STATUS message:
UNIT WARING: OPTIMZED EFFICIENCY DISABLED - CONTACT YORK REPRESENATIVE
If the message above appears, immediately contact Johnson Controls Product Technical Support or Johnson Controls ES Commercial for a password to enable the High IPLV mode. You will need to provide Johnson Controls Product Technical Support or Johnson Controls ES Commercial with the Unit Serial Number located on the chiller nameplate. The date and time will also need to be current on the chiller, and will need to be provided to Johnson Controls Product Technical Support or Johnson Controls ES Commercial. It is essential Johnson Controls Product Technical Support or, Johnson Controls ES Commercial is aware of the "local" time to allow adjustments for time differences from Eastern Standard Time.
After obtaining the password, the following steps will need to be carried out "immediately" to input the serial number. If the password is not immediately input, the panel will not accept it.
To enable HIGH IPLV Mode, first press the SERVICE key. The following message will appear:
SERVICE MODE
XXXXX
PRESS ENTER KEY TO CONTINUE
Key in the 6 digit alphanumeric password provided by Johnson Controls Technical Support or Johnson Controls ES Commercial and press the (ENTER) key. The following display will appear:
IPLV OPTIMZED EFFICIENCY CONTROL XXXXXXXXXXXXXXXXXXXXXXXXX
When the Optimized (High IPLV) is enabled, the dis-
play will indicate, "ENABLED". When not enabled, the display will indicate, "DISABLED". Use the and (ARROW) keys to enable/disable and press the (ENTER) key to store the selection.
282
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 8 - MICROPANEL
UNIT SETUP MODE
Unit Setup Mode will allow the programming all of the programmable values that the user should never change. These will either be programmed at the factory or by service personnel on the job.
This mode may be entered by pressing the PROGRAM key, entering the password 4245, and pressing the (ENTER) key. Table 23 on page 283 lists the values that can be programmed in this mode. Details relating to the actual message follow the table.
Table 23 - UNIT SETUP PROGRAMMABLE VALUES
SETUP MODE VALUE
PROGRAMMABLE RANGE
DEFAULT
Sys 1 Number of Cond Fans Sys 2 Number of Cond Fans Sys 3 Number of Cond Fans Sys 4 Number of Cond Fans Compressor 1 Operating hours Compressor 2 Operating hours Compressor 3 Operating hours Compressor 4 Operating hours
Compressor 1 Starts Compressor 2 Starts Compressor 3 Starts Compressor 4 Starts Clear History Buffers Remote Temp Reset Option Remote Current Limit Option Sound Limit Option Remote Inputs Service Time Sys 1 Motor Sensor to Ignore Sys 2 Motor Sensor to Ignore Sys 3 Motor Sensor to Ignore Sys 4 Motor Sensor to Ignore
4 to 6 4 to 6 4 to 6 4 to 6 0 to 99,999 0 to 99,999 0 to 99,999 0 to 99,999 0 to 99,999 0 to 99,999 0 to 99,999 0 to 99,999 Yes/ No Disabled/Enabled Disabled/Enabled Disabled/Enabled 5 min - 60 min See Below See Below See Below See Below
6 6 6 6 0 0 0 0 0 0 0 0 Disabled Disabled Disabled 15 min None None None None
The following messages will be displayed for the Unit
8
Setup Mode in the order they appear. The first group of
displays relates to setup parameters that relate to unit
configuration and factory setpoints.
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX
SYS 1 NUMBER OF COND FANS
= X
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX
SYS 2 NUMBER OF COND FANS
= X
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX
SYS 3 NUMBER OF COND FANS
= X
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX
SYS 4 NUMBER OF COND FANS
= X
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX COMP 1 OPERATING HOURS = XXXXX
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX COMP 2 OPERATING HOURS = XXXXX
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX COMP 3 OPERATING HOURS = XXXXX
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX COMP 4 OPERATING HOURS = XXXXX
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SECTION 8 - MICROPANEL
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX
COMP 1 STARTS
= XXXXX
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX
COMP 2 STARTS
= XXXXX
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX
COMP 3 STARTS
= XXXXX
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX
COMP 4 STARTS
= XXXXX
The following setup display is selectable as YES or NO using the and (ARROW) keys.
SETUP MODE CLEAR HISTORY BUFFERS? XXXXXXXXXXXXXXXXXXXXXXXX
The following (3) setup OPTION displays are selectable as ENABLED or DISABLED using the and (ARROW) keys according to the options installed on the chiller:
SETUP MODE REMOTE TEMP RESET OPTION XXXXXXXXXXXXXXXXXXXXXXXX
SETUP MODE REMOTE CURRENT LIMIT OPTION XXXXXXXXXXXXXXXXXXXXXXXX
SETUP MODE SOUND LIMIT OPTION XXXXXXXXXXXXXXXXXXXXXXXX
The following setup OPTION display is selectable as ENABLED or DISABLED using the and (ARROW) keys:
SETUP MODE DEF XXXXX LO XXXXX HI XXXXX REMOTE INPUTS SERVICE TIME = XX MIN
The following OPTION displays are selectable as ENABLED or DISABLED using the and (ARROW) keys. The choices are:
· NONE (default) · TEMP SENSOR 1 · TEMP SENSOR 2 · TEMP SENSOR 3
SETUP MODE SYS 1 MOTOR SENSOR TO IGNORE XXXXXXXXXXXXXXXXXXXXXXXXX
SETUP MODE SYS 2 MOTOR SENSOR TO IGNORE XXXXXXXXXXXXXXXXXXXXXXXXX
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SETUP MODE SYS 3 MOTOR SENSOR TO IGNORE XXXXXXXXXXXXXXXXXXXXXXXXX
SETUP MODE SYS 4 MOTOR SENSOR TO IGNORE XXXXXXXXXXXXXXXXXXXXXXXXX
If a motor temperature sensor fails, a single sensor may be ignored by making a program change in the Unit Setup Mode. The default setting is "NONE", indicating all sensors are being monitored.
DEFAULT PROGRAMMABLE VALUES
To quickly program or reset most of the user programmable values to their default values, press PROGRAM, 6140, ENTER. The following message will then be displayed, allowing a choice to reset the operating parameters to their default values.
DEFAULTS SET PROG VALUES TO DEFAULT?
XXX
YES or NO may be selected for XXX using the and (ARROW) keys to change the selection. Following is a list of the operating parameters that will be reset to their default values:
· Suction Pressure Cutout = 24.0 psig · Low Ambient Air Temp Cutout = 25°F · Leaving Chilled Liquid Temp Cutout = 36°F · High Motor Current Limit = 100% · Pulldown Current Limit = 100% · Pulldown Current Limit Time = 0 min · Suction Superheat Setpoint = 10°F · Sound limit Setpoint = 0%
SERIAL PORT CONNECTIONS
Table 24 on page 285 lists the serial ports and the circuit board they are located on. The serial communications lines provide communications to external devices outside the chiller and between microprocessors located in the chiller control panel.
TB2 allows connecting to a remote OptiView RCC or Microgateway. The OptiView RCC option is not yet available. The OptiView RCC and Microgateway option cannot both be used. Only one or the other is permitted to be connected to the chiller.
284
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FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Table 24 - SERIAL PORT CONNECTIONS
BOARD
HEADER
Chiller Control Board Chiller Control Board
VSD Logic Board
TB1 / TB2 J2 / J1 J12
SECTION 8 - MICROPANEL
PORT TYPE RS-232 / RS-485
RS-485 Opto- Coupled RS-485
PORT USE Printer/RCC and ISN Control Panel <-> VSD #1 / #2 VSD <-> Control Panel
ANALOG INPUT CONNECTIONS
Table 25 on page 285 lists the Analog inputs and the circuit board they are located on. Not all of the sensors are installed in every unit, as some of them are optional. The software must read the optional sensors if installed. The Analog input signals are typically referenced to the common (return, ground) in the system.
J12-3 can also be used as common, as well as chassis ground, or the common terminal point on the Chiller Control Board. See the wiring diagrams. The +DC Bus, -DC Bus and ½ DC Bus voltages are measured in reference to one of the other DC Bus points. For example: +DC Bus measured to ½ DC Bus.
Table 25 - ANALOG INPUT CONNECTIONS
BOARD
Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board
HEADER
J17-11 J17-12 J17-13 J17-14 J17-15
J8-7 J8-8 J8-9 J19-1 J19-2 J19-3 J19-6 J19-7 J19-8 J21-13 J21-3 J21-16 J21-6 J21-20 J21-22 J21-24 J22-13 J22-2 J22-16 J22-6 J22-20 J22-22 J22-24 J20-1
ANALOG INPUT
Remote Temperature Reset Remote Current Limit
Spare 1
Spare 2 Spare 3
Leaving Chilled Liquid Temp Sensor
Return Chilled Liquid Temp Sensor Ambient Air Temp Sensor
Comp 1 Motor Temperature 1
Comp 1 Motor Temperature 2 Comp 1 Motor Temperature 3
Comp 2 Motor Temperature 1
Comp 2 Motor Temperature 2
8
Comp 2 Motor Temperature 3
Sys 1 Suction Temperature
Sys 1 Oil Temperature
Sys 1 Discharge Temperature
Sys 1 Flash Tank Level Sensor
Sys 1 Suction Pressure
Sys 1 Oil Pressure
Sys 1 Discharge Pressure
Sys 2 Suction Temperature
Sys 2 Oil Temperature
Sys 2 Discharge Temperature
Sys 2 Flash Tank Level Sensor
Sys 2 Suction Pressure
Sys 2 Oil Pressure
Sys 2 Discharge Pressure
Comp 3 Motor Temperature 1
JOHNSON CONTROLS
285
SECTION 8 - MICROPANEL
TABLE 25 - ANALOG INPUT CONNECTIONS (CONT'D)
BOARD
HEADER
Chiller Control Board
J20-2
Chiller Control Board
J20-3
Chiller Control Board
J20-6
Chiller Control Board
J20-7
Chiller Control Board
J20-8
Chiller Control Board
J23-13
Chiller Control Board
J23-3
Chiller Control Board
J23-16
Chiller Control Board
J23-6
Chiller Control Board
J23-20
Chiller Control Board
J23-22
Chiller Control Board
J23-24
Chiller Control Board
J24-13
Chiller Control Board
J24-3
Chiller Control Board
J24-16
Chiller Control Board
J24-6
Chiller Control Board
J24-20
Chiller Control Board
J24-22
Chiller Control Board
J24-24
VSD Logic Board
J1-1 to J1-2
VSD Logic Board
J1-3 to J3-4
VSD Logic Board
J1-5 to J1-6
VSD Logic Board VSD Logic Board
J1-13 to J1-14 J1-15 to J1-16
VSD Logic Board
J1-17 to J1-18
VSD Logic Board VSD Logic Board
J2-1 to J2-2 J2-3 to J2-4
VSD Logic Board
J2-5 to J2-6
VSD Logic Board VSD Logic Board
J2-9 to J2-10 J2-11 to J2-12
VSD Logic Board
J2-13 to J2-14
VSD Logic Board
J3-1
VSD Logic Board
J3-2
VSD Logic Board
J3-3
VSD Logic Board
J3-4
VSD Logic Board
J3-5
VSD Logic Board
J3-6
VSD Logic Board
J6-8
VSD Logic Board
J7-8
VSD Logic Board
J8-8
VSD Logic Board
J9-8
VSD Logic Board
R19
VSD Logic Board
R42
VSD Logic Board
R64
VSD Logic Board
R86
286
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
ANALOG INPUT Comp 3 Motor Temperature 2 Comp 3 Motor Temperature 3 Comp 4 Motor Temperature 1 Comp 4 Motor Temperature 2 Comp 4 Motor Temperature
Sys 3 Suction Temperature Sys 3 Oil Temperature
Sys 3 Discharge Temperature Sys 3 Flash Tank Level Sensor
Sys 3 Suction Pressure Sys 3 Oil Temperature Sys 3 Discharge Pressure Sys 4 Suction Temperature Sys 4 Oil Temperature Sys 4 Discharge Temperature Sys 4 Flash Tank Level Sensor Sys 4 Suction Pressure
Sys 4 Oil Pressure Sys 4 Discharge Pressure Comp 1 Phase A Motor Current Comp 1 Phase B Motor Current Comp 1 Phase C Motor Current Comp 3 Phase A Motor Current Comp 3 Phase B Motor Current Comp 3 Phase C Motor Current Comp 2 Phase A Motor Current Comp 2 Phase B Motor Current Comp 2 Phase C Motor Current Comp 4 Phase A Motor Current Comp 4 Phase B Motor Current Comp 4 Phase C Motor Current
+DC Bus Voltage 1 1/2 DC Bus Voltage 1
-DC Bus Voltage 1 -DC Bus Voltage 2 1/2 DC Bus Voltage 2 +DC Bus Voltage 2 Comp 1 IGBT Baseplate Temperature Comp 3 IGBT Baseplate Temperature Comp 2 IGBT Baseplate temperature Comp 4 IGBT Baseplate Temperature Comp 1 Overload Adjust Comp 3 Overload Adjust Comp 2 Overload Adjust Comp 4 Overload Adjust
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DIGITAL INTPUT CONNECTIONS
Table 26 on page 287 lists the digital inputs and the circuit board they are located on. The Digital input signals are typically referenced to the common (return, ground) in the system.
SECTION 8 - MICROPANEL
J12-3 can also be used as common, as well as chassis ground, or the common terminal point on the Chiller Control Board. See the wiring diagrams.
Table 26 - DIGITAL INPUT CONNECTIONS
BOARD
HEADER
Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board
VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board VSD Logic Board
J4-2 J4-3 J4-4 J4-5 J4-6 J5-1 J5-2 J5-3 J6-2 J6-3 J6-4 J6-5 J6-6 J7-1 to J7-2 J7-3 to J7-4 J7-5 to J7-6 J7-7 to J7-8 J7-9 to J7-10 J7-11 to J7-12 J1-10 J1-11 J1-12 J5-1 to J5-2 J5-3 to J5-4 J6-2 J6-5 J6-12 J7-2 J7-5 J7-12 J7-2 J7-5 J7-12 J8-2 J8-5 J8-12
VSD Logic Board
J11-2
VSD Logic Board
J11-6
VSD Logic Board
SW1
VSD Logic Board
J10-5 to J10-6
VSD Logic Board
J10-7 to J10-8
ANALOG OUTPUT
Unit Switch 1 Unit Switch 2 Sys 1 HPCO Sys 2 HPCO VSD Fault Relay 1 Sys 3 HPCO Sys 4 HPCO VSD Fault Relay (Unused) Flow Switch
Print Sys 1/3 Run Permissive Sys 2/4 Run Permissive
Spare Config0 Config1 Config2 Config3 Spare 0 Spare 1 2 Compressor Select 3 Compressor Select 4 Compressor Select
8
Comp 1 Phase A Gate Driver Fault Comp 1 Phase C Gate Driver Fault Comp 1 Phase B Gate Driver Fault Comp 3 Phase A Gate Driver Fault Comp 3 Phase C Gate Driver Fault Comp 3 Phase B Gate Driver Fault Comp 2 Phase A Gate Driver Fault Comp 2 Phase C Gate Driver Fault Comp 2 Phase B Gate Driver Fault Comp 4 Phase A Gate Driver Fault Comp 4 Phase C Gate Driver Fault Comp 4 Phase B Gate Driver Fault
Phase Loss Fault 1 Phase Loss Fault 2
Test Pushbutton Comp 1/3 Run (from control panel)
Comp 2/4 (from control panel)
JOHNSON CONTROLS
287
SECTION 8 - MICROPANEL
ANALOG OUTPUT CONNECTIONS Table 27 on page 288 lists the analog outputs and the circuit board they are located on. The analog output signals are feed to the associated control device from the 2 wires in the associated plug.
Table 27 - ANALOG OUTPUT CONNECTIONS
BOARD
HEADER
Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board Chiller Control Board
J15-1 to J15-2 J15-3 to J15-4 J15-5 to J15-6 J15-7 to J15-8 J14-1 to J14-6 J14-2 to J14-7 J14-3 to J14-8 J14-4 to J14-9 J25-1 to J25-5 J25-2 to J25-6 J25-3 to J25-7 J25-4 to J25-8
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
ANALOG OUTPUT Sys 1 Flash Tank Feed Valve Sys 1 Flash tank Drain Valve Sys 2 flash Tank Feed Valve Sys 2 Flash Tank Drain Valve Sys 3 Flash Tank Feed Valve Sys 3 Flash Tank Drain Valve Sys 4 Flash Tank Feed Valve Sys 4 Flash Tank Feed Valve Sys 1 Condenser Fan Speed (Future) Sys 2 Condenser Fan Speed (Future) Sys 3 Condenser Fan Speed (Future) Sys 4 Condenser Fan Speed (Future)
288
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
DIGITAL OUTPUT CONNECTIONS
Table 28 on page 289 lists the digital outputs and the plug/terminals of the circuit board they originate from. Not all of the outputs will be used on every unit. Signal levels may be 12 VDC, 120 VAC, or a dry contact (no voltage) closure). 120 VAC signals typically may show only one connection point; the other will be neutral (Wire 2). Outputs which reference multiple boards, such as "Chiller Control Board / Relay Board 1" indicate the signal originates on the Chiller Control Board as a 0 VDC to 12 VDC digital signal (example: J9-1) that is then fed to the Relay board and output as a dry contact closure between TB1-20 and 19. In this case, outputs from both boards are called out in the table.
SECTION 8 - MICROPANEL
The 0 VAC to 120 VAC single digital outputs from the Relay Output Boards are referenced to neutral (Wire 2). For example, the fan output on TB1-6 is a single 120 VAC output. The 0 VDC to 12 VDC outputs from the Chiller Control Board are referenced to common (return, ground) in the system. J12-3 can also be used as common, as well as chassis ground, or the common terminal point on the Chiller Control Board. See the wiring diagrams. See the wiring diagrams whenever there is a requirement for tracing out these signals.
Table 28 - DIGITAL OUTPUT CONNECTIONS
BOARD
HEADER
ANALOG OUTPUT
Chiller Control / Relay Board 1
J9-1 / TB1-20 and 19
Evaporator Heater
Chiller Control / Relay Board 1
J9-2 / TB1-18 and 17
Sys 1/3 VSD Run
Chiller Control / Relay Board 1
J9-3 / TB1-16 and 15
Sys 1/3 Alarm
Chiller Control / Relay Board 1
J9-4 / TB1-14 and 13
Evaporator Heater 2
Chiller Control / Relay Board 1
J9-5 / TB1-12 and 11
Sys 1 SPARE
Chiller Control / Relay Board 1
J9-6 / TB1-10 and 9
SPARE
Chiller Control / Relay Board 1
J9-7/ TB1-8 and 7
SPARE
Chiller Control / Relay Board 1
J9-8 / TB1-6
Sys 1 Condenser Fans Output 1
Chiller Control / Relay Board 1
J9-9 / TB1-5
Sys 1 Condenser Fans Output 2
Chiller Control / Relay Board 1
J9-10 / TB1-4
Sys 1 Condenser Fans Output 3
Chiller Control / Relay Board 1
J9-11 / TB1-3
Sys 1 Compressor Heater
Chiller Control / Relay Board 1
J9-12 / TB1-2
Sys 1 Economizer Solenoid Valve
Chiller Control / Relay Board 2
J10-1 / TB1- 20 and 19
Evaporator Pump Start
Chiller Control / Relay Board 2
J10-2 / TB1-18 and 17
Sys 2/4 VSD Run
8
Chiller Control / Relay Board 2
J10-3 / TB1-18 and 15
Sys 2/4 Alarm
Chiller Control / Relay Board 2
J10-4 / TB1-16 and 14
Chiller Run
Chiller Control / Relay Board 2
J10-5 / TB1-12 and 11
Sys 2 SPARE
Chiller Control / Relay Board 2
J10-6 / TB1-10 and 9
SPARE
Chiller Control / Relay Board 2
J10-7 / TB1-8 and 7
SPARE
Chiller Control / Relay Board 2
J10-8 / TB1-6
Sys 2 Condenser Fans Output 1
Chiller Control / Relay Board 2
J10-9 / TB1-5
Sys 2 Condenser Fans Output 2
Chiller Control / Relay Board 2
J10-10 / TB1-4
Sys 2 Condenser Fans Output 3
Chiller Control / Relay Board 2
J10-11 / TB1-3
Sys 2 Compressor Heater
Chiller Control / Relay Board 3
J10-12 / TB1-2
Sys 2 Economizer Solenoid Valve
Chiller Control / Relay Board 3
J11-1 / TB1-20 and 19
Sys 4 Condenser Fan Output 1
Chiller Control / Relay Board 3
J11-2 / TB1-18 and 17
Sys 4 Condenser Fan Output 2
Chiller Control / Relay Board 3
J11-3 / TB1-16 and 15
Sys 4 Condenser Fan Output 3
Chiller Control / Relay Board 3
J11-4 / TB1-14 and 13
Sys 4 Compressor Heater
JOHNSON CONTROLS
289
SECTION 8 - MICROPANEL
TABLE 28 - DIGITAL OUTPUT CONNECTIONS (CONT'D)
BOARD
HEADER
Chiller Control / Relay Board 3 Chiller Control / Relay Board 3
J11-5 / TB1-12 and 11 J11-6 / TB1-10 and 9
Chiller Control / Relay Board 3
J11-7 / TB1-8 and 7
Chiller Control / Relay Board 3 Chiller Control / Relay Board 3
J11-8 / TB1-6 J11-9 / TB1-5
Chiller Control / Relay Board 3
J11-10 / TB1-4
Chiller Control / Relay Board 3 Chiller Control / Relay Board 3
J11-11 / TB1-3 J11-12 / TB1-2
VSD Logic Board
J6-1
VSD Logic Board
J6-3
VSD Logic Board
J6-4
VSD Logic Board
J6-10
VSD Logic Board VSD Logic Board
J6-11 J6-13
VSD Logic Board
J6-14
VSD Logic Board
J7-1
VSD Logic Board
J7-3
VSD Logic Board
J7-4
VSD Logic Board
J7-10
VSD Logic Board
J7-11
VSD Logic Board
J7-13
VSD Logic Board
J7-14
VSD Logic Board
J8-1
VSD Logic Board
J8-3
VSD Logic Board
J8-4
VSD Logic Board
J8-10
VSD Logic Board
J8-11
VSD Logic Board
J8-13
VSD Logic Board
J8-14
VSD Logic Board
J9-1
VSD Logic Board
J9-3
VSD Logic Board
J9-4
VSD Logic Board
J9-10
VSD Logic Board
J9-11
VSD Logic Board
J9-13
VSD Logic Board
J9-12
VSD Logic Board
J11-3
VSD Logic Board
J11-7
VSD Logic Board
J10-1 to J10-2
VSD Logic Board
J10-3 to J10-4
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
ANALOG OUTPUT Sys 4 Economizer Solenoid Valve
Sys 4 SPARE Sys 3 SPARE Sys 3 Condenser Fans Output 1 Sys 3 Condenser Fans Output 2 Sys 3 Condenser Fans Output 3 Sys 3 Compressor Heater Sys 3 Economizer Solenoid Valve Comp 1 Phase A+ IGBT Gating Signal Comp 1 Phase B- IGBT Gating Signal Comp 1 Phase C+ IGBT Gating Signal Comp 1 Phase A- IGBT Gating Signal Comp 1 Phase B+ IGBT Gating Signal Comp 1 Phase C- IGBT Gating Signal Comp1 Enable Comp 3 Phase A+ IGBT Gating Signal Comp 3 Phase B- IGBT Gating Signal Comp 3 Phase C+ IGBT Gating Signal Comp 3 Phase A- IGBT Gating Signal Comp 3 Phase B+ IGBT Gating Signal Comp 3 Phase C- IGBT Gating Signal Comp 3 Enable Comp 2 Phase A+ IGBT Gating Signal Comp 2 Phase B- IGBT Gating Signal Comp 2 Phase C+ IGBT Gating Signal Comp 2 Phase A- IGBT Gating Signal Comp 2 Phase B+ IGBT Gating Signal Comp 2 Phase C- IGBT Gating Signal Comp 2 Enable Comp 4 Phase A+ IGBT Gating Signal Comp 4 Phase B- IGBT Gating Signal Comp 4 Phase C+ IGBT Gating Signal Comp 4 Phase A- IGBT Gating Signal Comp 4 Phase B+ IGBT Gating Signal Comp 4 Phase C- IGBT Gating Signal Comp 4 Enable Pre-charge Enable 1 Pre-charge Enable 2 VSD Fan / Pump Run VSD Fault Relay (to control panel)
290
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
BACNET, MODBUS AND YORKTALK 2 COMMUNICATIONS
Data can be read and in some cases modified using a serial communication BACnet, Modbus or YorkTalk 2 network connection. This information allows communications of chiller operating parameters and external control changes to setpoint, load limiting, and start/ stop commands.
BACnet and YorkTalk 2 RS485 networks are wired to the + and - terminals of TB1 for port 1 communications. Modbus network connection has the option of RS232 or RS485 connection for port 2 communications. Modbus network is wired to either TB2 or TB3 as follows:
· RS-485: connect to TB2 - Network (-1) to TB2 (-1); Network (+1) to TB2 (+1)
· RS-232: connect to TB3 - Network (RX) to TB3 (TXD); Network (TX) to TB3 (RXD); Network (GND) to TB3 (GND)
SECTION 8 - MICROPANEL
See Figure 61 on page 292 "Control Board Connections" for TB1, and TB2 locations.
In most cases, communication parameters will need to be modified. Table 30 on page 293 lists the setup parameters for the available protocol. In the 02478 microboard modification is accomplished by pressing the PROGRAM, DOWN ARROW, DOWN ARROW, DOWN ARROW, DOWN ARROW, and ENTER keys in sequence. In the 03478 microboard, press the PROGRAM key then enter the password 5255. The list below shows the displays for the values that may be modified:
DE MODIFIER ADDRESS XXXXX
DE MODIFIER OFFSET XX
P1 PROTOCOL XXXXXX
P1 MANUAL MAC ADDRESS
XXX
P1 BAUD RATE
XXXXX
P1 PARITY
XXXXX
P1 STOP BITS X
P2 PROTOCOL XXXXXXXXXX
P2 MANUAL MAC ADDRESS
XXX
P2 BAUD RATE
XXXXX
P2 PARITY
XXXXX
P2 STOP BITS X
P2 HW SELECT BIT XXXXX
REAL TIME ERROR ## RESET 1 = YES, 0 = NO 0 Note: See TABLE 27 for error descriptions
JOHNSON CONTROLS
8
291
SECTION 8 - MICROPANEL
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Figure 61 - CONTROL BOARD CONNECTIONS
LD10637
The Chiller Control Board contains a dual UART for RS-485 and RS-232 communications. UART1 is dedicated to RCC and ISN communications over an RS485 link. UART2 is dedicated to internal communications within the chiller. The RS-485 port is configured for 4800 baud, 1 start bit, 8 data bits, odd parity, and 1 stop bit.
Connections for ISN communications are on the Chiller Control Board on TB1/TB2. TB2 on the Microgateway is utilized for ISN comms connection. P3 is RS485+, P2 is RS485-, and USHL is the shield.
The table below shows the minimum, maximum, and default values.
Table 29 - MINIMUM, MAXIMUM AND DEFAULT VALUES
DESCRIPTION
MINIMUM
MAXIMUM
DEFAULT
DE MODIFIER ADDRESS
-1
41943
-1
DE MODIFIER OFFSET
-1
99
-1
P1 BAUD RATE
1200
76800
4800
1200, 4800, 9600, 19200, 38400, 76800, AUTO SELECTABLE
P2 BAUD RATE
1200
57600
1200
1200, 4800, 9600, 19200, 38400, 57600 SELECTABLE
P1, P2 MANUAL Mac ADDRESS
-1
127
-1
P1, P2 PARITY
NONE
IGNORE
NONE
NONE, EVEN, ODD, IGNORE SELECTABLE
P1 PROTOCOL
BACNET
API
BACNET
BACNET, API SELECTABLE
P2 PROTOCOL
TERMINAL
MODBUS CLIENT
API
TERMINAL, MODBUS IO, MODBUS SERVER, API, MODBUS CLIENT SELECTABLE
P1, P2 STOP BITS
1
2
1
RESET REAL TIME ERROR
NO
YES
NO
292
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 8 - MICROPANEL
The table below shows set-up requirements for each communication protocol.
Table 30 - VALUES REQUIRED FOR BAS COMMUNICATION
SETTING DESCRIPTION
DE MODIFIER ADDRESS DE MODIFIER OFFSET P1 PROTOCOL P1 MANUAL MAC ADDRESS P1 BAUD RATE P1 PARITY P1 STOP BITS P2 PROTOCOL P2 MANUAL MAC ADDRESS P2 BAUD RATE P2 PARITY P2 STOP BITS P2 HW SELECT BIT RESET REAL TIME ERROR P1 HW SELECT BIT CHILLER ID
BACnet MS/TP 0 to 41943(3) 0 to 99(4) BACNET 0-127(1)
9600 To 76800 or Auto Selectable(1) NONE 1 N/A N/A N/A N/A N/A N/A N/A N/A N/A
Protocol Modbus RTU5 1 0 N/A N/A N/A N/A N/A MODBUS SVR 0-127(1) 19,200(2) NONE(2) 1
RS-485 or RS-232(1) N/A N/A N/A
1 as Required By Network 2 or Other As Required By Network 3 number Is Multiplied By 100, Set As Required By Network 4 number Is Added To De Modifier Address, Set As Required By Network 5 unit Operating Software Version C.Mmc.13.03 Or Later Required For Modbus Protocol
YorkTalk 2 -1 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 0
Table 31 - REAL TIME ERROR NUMBERS
ERROR NUMBER (##)
DESCRIPTION
0
ALL OK
1
DATUM TYPE OK TEST FAILED
2
ENGLISH TEXT TOO LONG
3
FLOATING POINT EXCEPTION
4
GET PACKET FAILED
5
GET TYPE FAILED
6
INVALID UNIT CONVERSION
7
INVALID HARDWARE SELECTION
8
REAL TIME FAULT
9
SPANISH TEXT TOO LONG
10
THREAD EXITED
11
THREAD FAILED
12
THREAD STALLED
13
IO BOARD RESET
14
BRAM INVALID
15
BACNET SETUP FAILED
Reboot required (cycle power) after settings are changed.
8
Table 31 on page 293 shows the real time error numbers that may be encountered during communication setup and a description of each.
JOHNSON CONTROLS
293
SECTION 8 - MICROPANEL
BACnet and Modbus Communications Chiller data that can be read and modified using specific BACnet or Modbus Register Addresses; and the data associated with the addresses, is outlined in the following description:
ANALOG WRITE POINTS
This data can be read and modified using a BACnet or Modbus network connection. The Modbus Register Address for these points is 1025 plus AV #.
BINARY WRITE POINTS
This data can be read and modified using a BACnet or Modbus network connection. The Modbus Register Address for these points is 1537 plus BV #.
ANALOG READ ONLY POINTS
This data can be read using a BACnet or Modbus network connection and can NOT be modified using this connection. The Modbus Register Address for these points is 513 plus AI #.
BINARY MONITOR ONLY POINTS
This data can be read using a BACnet or Modbus network connection and can NOT be modified using this connection. The Modbus Register Address for these points is 1281 plus BI #.
See Table 32 on page 295 for complete list of BACnet and Modbus registers.
The latest data map information is listed on the Johnson Controls Equipment Integration website.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Communications Data Map Notes (See Table 32 on page 295)
1. IPU II based units are configured for Native BACnet MS/TP and Modbus RTU communications. Microgateway or E-Link not required for these two communication protocols.
2. BACnet Object Types: 0= Analog In, 1 = Analog Out, 2= Analog Value, 3= Binary In, 4 = Binary Output, 5= Binary Value, 8= Device, 15 = Alarm Notification (0 through 127 are reserved ASHRAE Objects).
3. WC= Inches of water column; CFM = Cubic Feet per Minute; FPM = Feet per Minute: PSI = Lbs per square inch; Pa = Pascals; kPa = Kilopascals; PPM = Part per Million; kJ/kg = Kilojoules per Kilogram.
4. Water Cooled Scroll units use the same firmware as Air-Cooled Scroll units, ignoring Fan Control.
294
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8/25/2014
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Table 32 - BACNET AND MODBUS COMMUNICATIONS DATA MAP
JOHNSON CONTROLS
YCAV/YCIV 1st, 2nd Systems
Item 1 2 3 4 5 6 7 8 9 10
Version C.A15.14.01 C.A15.15.01 C.A15.14.03 C.A15.15.03 C.A09.14.03 C.A09.15.03 C.A14.14.03 C.A16.15.03
Checksum 13A8 3A9E 98E1 32D7 935C 1D47 98FB n/a
REV K03G
YORK P N 031-02476-001 031-02476-002 031-02476-001 031-02476-002 031-02476-001 031-02476-002 031-02476-001 031-02476-002
SECTION 1
ELINK
YORK TALK 2
Micro Board: 031-02478-xxx
Baud
4800 Std. :
see Elink Installation manual
4800 Opt
4800 Std. :
added p80,p81
4800 Opt
added p80,p81
4800 STD- Foreign langauge enhancements
4800 OPT Foreign langauge enhancements
4800 Std: Add p72 functionality (SCR 796)
4800 Opt: Add p72 functionality (SCR 796)
COMMENTS PN 24-10404-9 for wiring instructions
ENG PAGE
Ref
P03 P04 P05 P06 P07 P08 P09 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 P22 P23 P24 P25 P26 P27 P28 P29 P30 P31 P32 P33 P34 P35 P36 P37 P38 P39 P40 P41 P42
BACnet Object Typ/Ins
AV1 AV2 AV3 AV4 BV1 BV2 BV3 BV4 AV5 AV6 AV7 AV8 AV9 AV10 AV11 AV12 AV13 AV14 AV15 AV16 AV17 AV18 AV19 AV20 AV21 AV22 AV23 AV24 AV25 AV26 AV27 AV28 AV29 BV5 BV6 BV7 BV8 BV9 BV10 BV11
Bacnet Object Name
YT2_ S01_ P03 YT2_ S01_ P04 YT2_ S01_ P05 YT2_ S01_ P06 YT2_ S01_ P07 YT2_ S01_ P08 YT2_ S01_ P09 YT2_ S01_ P10 YT2_ S01_ P11 YT2_ S01_ P12 YT2_ S01_ P13 YT2_ S01_ P14 YT2_ S01_ P15 YT2_ S01_ P16 YT2_ S01_ P17 YT2_ S01_ P18 YT2_ S01_ P19 YT2_ S01_ P20 YT2_ S01_ P21 YT2_ S01_ P22 YT2_ S01_ P23 YT2_ S01_ P24 YT2_ S01_ P25 YT2_ S01_ P26 YT2_ S01_ P27 YT2_ S01_ P28 YT2_ S01_ P29 YT2_ S01_ P30 YT2_ S01_ P31 YT2_ S01_ P32 YT2_ S01_ P33 YT2_ S01_ P34 YT2_ S01_ P35 YT2_ S01_ P36 YT2_ S01_ P37 YT2_ S01_ P38 YT2_ S01_ P39 YT2_ S01_ P40 YT2_ S01_ P41 YT2_ S01_ P42
LON Profile Name
LON SNVT Type
nviYTS01p003 nviYTS01p004 nviYTS01p005 nviYTS01p006 nviYTS01p007 nviYTS01p008 nviYTS01p009 nviYTS01p010 nvoYTS01p011 nvoYTS01p012 nvoYTS01p013 nvoYTS01p014 nvoYTS01p015 nvoYTS01p016 nvoYTS01p017 nvoYTS01p018 nvoYTS01p019 nvoYTS01p020 nvoYTS01p021 nvoYTS01p022 nvoYTS01p023 nvoYTS01p024 nvoYTS01p025 nvoYTS01p026 nvoYTS01p027 nvoYTS01p028 nvoYTS01p029 nvoYTS01p030 nvoYTS01p031 nvoYTS01p032 nvoYTS01p033 nvoYTS01p034 nvoYTS01p035 nvoYTS01p036 nvoYTS01p037 nvoYTS01p038 nvoYTS01p039 nvoYTS01p040 nvoYTS01p041 nvoYTS01p042
SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95)
N2 Metasys
ADF 1 ADF 2 ADF 3 ADF 4 BD 1 BD 2 BD 3 BD 4 ADF 5 ADF 6 ADF 7 ADF 8 ADF 9 ADF 10 ADF 11 ADF 12 ADF 13 ADF 14 ADF 15 ADF 16 ADF 17 ADF 18 ADF 19 ADF 20 ADF 21 ADF 22 ADF 23 ADF 24 ADF 25 ADF 26 ADF 27 ADF 28 ADF 29 BD 5 BD 6 BD 7 BD 8 BD 9 BD 10 BD 11
MODBUS
Address Scale see note 3
0001 Div 10 0002 Div 10 0003 Div 10 0004 Div 10 0061 N/A 0062 N/A 0063 N/A 0064 N/A 0005 X 10 0006 X 10 0007 X 10 0008 X 10 0009 X 10 0010 X10 0011 X10 0012 X10 0013 X10 0014 X10 0015 X10 0016 X1 * 0017 X1 * 0018 X 10 0019 X 10 0020 X 10 0021 X 10 0022 X 10 0023 X 10 0024 X 1 0025 X1 * 0026 X1 * 0027 X1 * 0028 X 1 0029 X 10 0065 N/A 0066 N/A 0067 N/A 0068 N/A 0069 N/A 0070 N/A 0071 N/A
ENG UNITS POINT LIST CODE:
S = STANDARD
Imper SI
POINT LIST DESCRIPTION
O = OPTIONAL
°F °C Setpoint
( Start command must be active to take effect)
% % ISN Current Limit Start command must be active to take effect
% % ISN Sound Limit ( RSL Option must be enabled or this point ignored)
0 / 1 0 / 1 Start / Stop Command
0 / 1 °F °F °F °F °F °F °F PSI PSI PSI % hrs count °F °F °F PSI PSI PSI % hrs count hz % % 0 / 1 0 / 1 0 / 1 0 / 1 0 / 1 0 / 1 0 / 1
0 / 1 History Buffer 1 Request °C Leaving Chilled Liquid Temp °C Return Chilled Liquid Temp °C VSD Internal Ambient Temp °C Sys 1 Suction Temperature °C Sys 1 Discharge Temperature °C Outside Ambient Air Temperature °C Sys 1 Oil Temperature BAR Sys 1 Oil Pressure (gauge) BAR Sys 1 Suction Pressure (gauge) BAR Sys 1 Discharge Pressure (gauge) % Sys 1 Compressor % Full Load Amps hrs Sys 1 Total Run Hours count Sys 1 Total Number of Starts °C Sys 1 Highest Motor Temp °C Sys 2 Highest Motor Temp °C Sys 2 Oil Temperature BAR Sys 2 Oil Pressure (gauge) BAR Sys 2 Suction Pressure (gauge) BAR Sys 2 Discharge Pressure (gauge) % Sys 2 Compressor % Full Load Amps hrs Sys 2 Total Run Hours count Sys 2 Total Number of Starts hz VSD Output Frequency % Sys 1 Flash Tank Feed Valve % Open % Sys 2 Flash Tank Feed Valve % Open 0 / 1 Chiller Run 0 / 1 Chiller Alarm ( 0 = no alarm, 1 = alarm ) 0 / 1 Evaporator Heater Status 0 / 1 Evaporator Pump Status 0 / 1 Sys 1 Compressor Run Status 0 / 1 Sys 2 Compressor Run Status 0 / 1 Sys 1 Economizer Solenoid Valve Status
ENG
N = NOT AVAILABLE
PAGE
1 2 3 4 5 6 7 8 9 10 Ref
SSSSSSSS
P03
SSSSSSSS
P04
SSSSSSSS
P05
P06
SSSSSSSS
P07
P08
P09
SSSSSSSS
P10
SSSSSSSS
P11
SSSSSSSS
P12
SSSSSSSS
P13
SSSSSSSS
P14
SSSSSSSS
P15
SSSSSSSS
P16
SSSSSSSS
P17
SSSSSSSS
P18
SSSSSSSS
P19
SSSSSSSS
P20
SSSSSSSS
P21
SSSSSSSS
P22
SSSSSSSS
P23
SSSSSSSS
P24
SSSSSSSS
P25
SSSSSSSS
P26
SSSSSSSS
P27
SSSSSSSS
P28
SSSSSSSS
P29
SSSSSSSS
P30
SSSSSSSS
P31
SSSSSSSS
P32
SSSSSSSS
P33
OOOOOOOO
P34
OOOOOOOO
P35
SSSSSSSS
P36
SSSSSSSS
P37
SSSSSSSS
P38
SSSSSSSS
P39
SSSSSSSS
P40
SSSSSSSS
P41
SSSSSSSS
P42
SECTION 8 - MICROPANEL
8
295
Revision: YCAV_YCIV BAS (Rev K_03g).xlsx Tab: YCAV and YCIV
Property of Johnson Controls, York, PA
Page: 1
SECTION 8 - MICROPANEL
TABLE 32 - BACNET AND MODBUS COMMUNICATIONS DATA MAP (CONT'D)
296
8/25/2014
ENG PAGE
Ref
BACnet Object Typ/Ins
P43 P44 P45 P46 P47 P48 P49 P50 P51 P52 P53 P54 P55 P56 P57 P58 P59 P60 P61 P62 P63 P64 P65 P66 P67 P68 P69 P70 P71 P72 P73 P74 P75 P76 P77 P78 P79 P80 P81 P82 P83 P84
BV12 BV13 BV14 BV15 BV16 BV17 BV18 BV19 BV20 BV21 BV22 BV23 BV24 MV1 MV2 MV3 MV4 MV5 MV6 MV7 MV8 MV9 MV10 AV30 AV31 AV32 AV33 AV34 AV35 AV36 AV37 AV38 AV39 AV40 AV41 AV42 AV 43 BV25 BV26 BV27 BV28 BV29
Bacnet Object Name
YT2_ S01_ P43 YT2_ S01_ P44 YT2_ S01_ P45 YT2_ S01_ P46 YT2_ S01_ P47 YT2_ S01_ P48 YT2_ S01_ P49 YT2_ S01_ P50 YT2_ S01_ P51 YT2_ S01_ P52 YT2_ S01_ P53 YT2_ S01_ P54 YT2_ S01_ P55 YT2_ S01_ P56 YT2_ S01_ P57 YT2_ S01_ P58 YT2_ S01_ P59 YT2_ S01_ P60 YT2_ S01_ P61 YT2_ S01_ P62 YT2_ S01_ P63 YT2_ S01_ P64 YT2_ S01_ P65 YT2_ S01_ P66 YT2_ S01_ P67 YT2_ S01_ P68 YT2_ S01_ P69 YT2_ S01_ P70 YT2_ S01_ P71 YT2_ S01_ P72 YT2_ S01_ P73 YT2_ S01_ P74 YT2_ S01_ P75 YT2_ S01_ P76 YT2_ S01_ P77 YT2_ S01_ P78 YT2_ S01_ P79 YT2_ S01_ P80 YT2_ S01_ P81 YT2_ S01_ P82 YT2_ S01_ P83 YT2_ S01_ P84
LON Profile Name
LON SNVT Type
nvoYTS01p043 nvoYTS01p044 nvoYTS01p045 nvoYTS01p046 nvoYTS01p047 nvoYTS01p048 nvoYTS01p049 nvoYTS01p050 nvoYTS01p051 nvoYTS01p052 nvoYTS01p053 nvoYTS01p054 nvoYTS01p055 nvoYTS01p056 nvoYTS01p057 nvoYTS01p058 nvoYTS01p059 nvoYTS01p060 nvoYTS01p061 nvoYTS01p062 nvoYTS01p063 nvoYTS01p064 nvoYTS01p065 nvoYTS01p066 nvoYTS01p067 nvoYTS01p068 nvoYTS01p069 nvoYTS01p070 nvoYTS01p071 nvoYTS01p072 nvoYTS01p073 nvoYTS01p074 nvoYTS01p075 nvoYTS01p076 nvoYTS01p077 nvoYTS01p078 nvoYTS01p079 nvoYTS01p080 nvoYTS01p081 nvoYTS01p082 nvoYTS01p083 nvoYTS01p084
SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95)
N2 Metasys
BD 12 BD 13 BD 14 BD 15 BD 16 BD 17 BD 18 BD 19 BD 20 BD 21 BD 22 BD 23 BD 24 ADI 1 ADI 2 ADI 3 ADI 4 ADI 5 ADI 6 ADI 7 ADI 8 ADI 9 ADI 10 ADF 30 ADF 31 ADF 32 ADF 33 ADF 34 ADF 35 ADF 36 ADF 37 ADF 38 ADF 39 ADF 40 ADF 41 ADF 42 ADF 43 BD 25 BD 26 BD 27 BD 28 BD 29
MODBUS
Address Scale see note 3
0072 N/A 0073 N/A 0074 N/A 0075 N/A 0076 N/A 0077 N/A 0078 N/A 0079 N/A 0080 N/A 0081 N/A 0082 N/A 0083 N/A 0084 N/A 0030 X 1 0031 X 1 0032 X 1 0033 X 1 0034 X 1 0035 X 1 0036 X 1 0037 X 1 0038 X 1 0039 X 1 0040 X 1 0041 X 1 0042 X 1 0043 X 1 0044 X 10 0045 X1 * 0046 X1 * 0047 X1 * 0048 X1 * 0049 X1 * 0050 X 1 0051 X 1 0052 X 1 0053 X 1 0085 N/A 0086 N/A 0087 N/A 0088 N/A 0089 N/A
ENG UNITS POINT LIST CODE:
S = STANDARD
Imper SI
POINT LIST DESCRIPTION
Sys 2 Economizer Solenoid Valve Status
O = OPTIONAL
0 / 1 0 / 1 S1-1 Cooling Type: 0=Water, 1=Glycol 0 / 1 0 / 1 Local/Remote Control Mode: 0 = Local, 1 = Remote 0 / 1 0 / 1 Display Units Mode: 0 = Imperial, 1 = SI
enum enum *Sys 1 Operational Code enum enum *Sys 1 Fault Code enum enum *Sys 2 Operational Code enum enum *Sys 2 Fault Code
% % Sys 1 Flash Tank Level (%) count count Sys 1 Condenser Fan Stages Running (0-7) count count Sys 2 Flash Tank Level (%) count count Sys 2 Condenser Fan Stages Running (0-7) count count Lead System Number enum enum Sys 1 & 2 Debug Code ( internal use only)
°F °C Local Leaving Chilled Liquid Setpoint °F °C Low Leaving Chilled Liquid Temp Cutout % % Sys 1 Flash Tank Drain Valve % Open % % Sys 2 Flash Tank Drain Valve % Open PSI BAR Low Suction Pressure Cutout volts volts VSD DC Bus Voltage °F °C Remote Leaving Chilled Liquid Setpoint °F °C Sys 1 Suction Superheat °F °C Cooling Range °F °C Sys 1 Discharge Superheat °F °C Sys 2 Suction Temperature °F °C Sys 2 Discharge Temperature °F °C Sys 2 Suction Superheat °F °C Sys 2 Discharge Superheat 0/1 0/1 Sys 1 Lockout 0/1 0/1 Sys 2 Lockout
N = NOT AVAILABLE
ENG PAGE
1 2 3 4 5 6 7 8 9 10 REF
SSSSSSSS
P43
P44
P45
P46
P47
P48
P49
SSSSSSSS
P50
SSSSSSSS
P51
SSSSSSSS
P52
P53
P54
P55
SSSSSSSS
P56
SSSSSSSS
P57
SSSSSSSS
P58
SSSSSSSS
P59
SSSSSSSS
P60
SSSSSSSS
P61
SSSSSSSS
P62
SSSSSSSS
P63
SSSSSSSS
P64
NNNNNNNN
P65
SSSSSSSS
P66
SSSSSSSS
P67
SSSSSSSS
P68
SSSSSSSS
P69
SSSSSSSS
P70
SSSSSSSS
P71
NNNNNNSS
P72
SSSSSSSS
P73
SSSSSSSS
P74
SSSSSSSS
P75
SSSSSSSS
P76
SSSSSSSS
P77
SSSSSSSS
P78
SSSSSSSS
P79
NNSSSSSS
P80
NNSSSSSS
P81
P82
P83
P84
NOTES
1
LON SNVTS Used: SNVT_count (8), SNVT_lev_percent (81), SNVT_temp_p (105), SNVT_switch (95) , SNVT_time_minute (123) , SNVT_freq_hz (76) , SNVT_amp (01) , SNVT_elec_kwh (13) , SNVT_power_kilo (83) , SNVT_volt (44) , SNVT_volt_ac (138), SNVT_press_p (87)
2
3
MODBUS scaling factors indicated in BOLD with an (*) asterisk are User Configurable, by a field technician if necessary. All Modbus values are of the type SIGNED with the exception of the User Configurabale values that are all UNSIGNED. Modbus Function Types Supported (ENG P03-P06 = Types 03, 06, 16) , ( ENG P07- P10 = 01, 03, 05, 15, 06, 16), (ENG P11-P35, P56-P79) = 03, 04) , (ENG P36-P55, P80 -P84 = 01, 02, 03)
4 BACnet Engineering Units shown with an (*) Asterisk will be assigned a BACnet Eng Unit type of (95) ie NO UNITS.
5 Status Codes: Special Display characters such as (, ), [, ], {, },/,\,%,< and > are not compatible with Elink N2 formats. Substitute text strings , "-", PCT, GTN will be used .
6 Status Codes: Status Code Text string lengths are limited to 60 total characters (including spaces)
7
8
9
10
NOTE: The Appropriate Product Code Listing Summary Should Accompany Document
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
JOHNSON CONTROLS
Revision: YCAV_YCIV BAS (Rev K_03g).xlsx Tab: YCAV and YCIV
Property of Johnson Controls, York, PA
Page: 2
8/25/2014
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
TABLE 32 - BACNET AND MODBUS COMMUNICATIONS DATA MAP (CONT'D)
JOHNSON CONTROLS
YCAV/YCIV 3rd, 4th Systems
SECTION 2
ELINK
YORK TALK 2
ENG PAGE
Ref
P03 P04 P05 P06 P07 P08 P09 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 P22 P23 P24 P25 P26 P27 P28 P29 P30 P31 P32 P33 P34 P35 P36 P37 P38 P39 P40 P41 P42
BACnet Object Typ/Ins
AV101 AV102 AV103 AV104 BV101 BV102 BV103 BV104 AV105 AV106 AV107 AV108 AV109 AV110 AV111 AV112 AV113 AV114 AV115 AV116 AV117 AV118 AV119 AV120 AV121 AV122 AV123 AV124 AV125 AV126 AV127 AV128 AV129 BV105 BV106 BV107 BV108 BV109 BV110 BV111
Bacnet Object Name
YT2_ S02_ P03 YT2_ S02_ P04 YT2_ S02_ P05 YT2_ S02_ P06 YT2_ S02_ P07 YT2_ S02_ P08 YT2_ S02_ P09 YT2_ S02_ P10 YT2_ S02_ P11 YT2_ S02_ P12 YT2_ S02_ P13 YT2_ S02_ P14 YT2_ S02_ P15 YT2_ S02_ P16 YT2_ S02_ P17 YT2_ S02_ P18 YT2_ S02_ P19 YT2_ S02_ P20 YT2_ S02_ P21 YT2_ S02_ P22 YT2_ S02_ P23 YT2_ S02_ P24 YT2_ S02_ P25 YT2_ S02_ P26 YT2_ S02_ P27 YT2_ S02_ P28 YT2_ S02_ P29 YT2_ S02_ P30 YT2_ S02_ P31 YT2_ S02_ P32 YT2_ S02_ P33 YT2_ S02_ P34 YT2_ S02_ P35 YT2_ S02_ P36 YT2_ S02_ P37 YT2_ S02_ P38 YT2_ S02_ P39 YT2_ S02_ P40 YT2_ S02_ P41 YT2_ S02_ P42
LON Profile Name
LON SNVT Type
nviYTS02p003 nviYTS02p004 nviYTS02p005 nviYTS02p006 nviYTS02p007 nviYTS02p008 nviYTS02p009 nviYTS02p010 nvoYTS02p011 nvoYTS02p012 nvoYTS02p013 nvoYTS02p014 nvoYTS02p015 nvoYTS02p016 nvoYTS02p017 nvoYTS02p018 nvoYTS02p019 nvoYTS02p020 nvoYTS02p021 nvoYTS02p022 nvoYTS02p023 nvoYTS02p024 nvoYTS02p025 nvoYTS02p026 nvoYTS02p027 nvoYTS02p028 nvoYTS02p029 nvoYTS02p030 nvoYTS02p031 nvoYTS02p032 nvoYTS02p033 nvoYTS02p034 nvoYTS02p035 nvoYTS02p036 nvoYTS02p037 nvoYTS02p038 nvoYTS02p039 nvoYTS02p040 nvoYTS02p041 nvoYTS02p042
SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95)
N2 Metasys
ADF 44 ADF 45 ADF 46 ADF 47 BD 30 BD 31 BD 32 BD 33 ADF 48 ADF 49 ADF 50 ADF 51 ADF 52 ADF 53 ADF 54 ADF 55 ADF 56 ADF 57 ADF 58 ADF 59 ADF 60 ADF 61 ADF 62 ADF 63 ADF 64 ADF 65 ADF 66 ADF 67 ADF 68 ADF 69 ADF 70 ADF 71 ADF 72 BD 34 BD 35 BD 36 BD 37 BD 38 BD 39 BD 40
MODBUS
ENG UNITS POINT LIST CODE:
S = STANDARD
Address Scale see note 3
0101 Div 10 0102 Div 10 0103 Div 10 0104 Div 10 0161 N/A 0162 N/A 0163 N/A 0164 N/A 0105 X 10 0106 X 10 0107 X 10 0108 X 10 0109 X 10 0110 X10 0111 X10 0112 X10 0113 X10 0114 X10 0115 X10 0116 X1 * 0117 X1 * 0118 X 1 0119 X 1 0120 X 1 0121 X 1 0122 X 1 0123 X 1 0124 X 1 0125 X1 * 0126 X1 * 0127 X1 * 0128 X 1 0129 X 1 0165 N/A 0166 N/A 0167 N/A 0168 N/A 0169 N/A 0170 N/A 0171 N/A
Imper
°F °F °F °F °F
°F PSI PSI PSI % hrs count °F °F °F PSI PSI PSI % hrs count hz % %
0 / 1 0 / 1 0 / 1
SI
POINT LIST DESCRIPTION
°C Leaving Chilled Liquid Temp °C Return Chilled Liquid Temp °C VSD Internal Ambient Temp 2 °C Sys 3 Suction Temperature °C Sys 3 Discharge Temperature
°C Sys 3 Oil Temperature BAR Sys 3 Oil Pressure BAR Sys 3 Suction Pressure BAR Sys 3 Discharge Pressure
% Sys 3 Compressor % Full Load Amps hrs Sys 3 Total Run Hours count Sys 3 Total # of Starts °C Sys 3 Highest Motor Temp °C Sys 4 Highest Motor Temp °C Sys 4 Oil Temperature BAR Sys 4 Oil Pressure BAR Sys 4 Suction Pressure BAR Sys 4 Discharge Pressure % Sys 4 Compressor % Full Load Amps hrs Sys 4 Total Run Hours count Sys 4 Total # of Starts hz VSD Output Frequency 2 % Sys 3 Flask Tank Feed Valve % Open % Sys 4 Flask Tank Feed Valve % Open
Chiller Alarm ( 0 = no alarm, 1 = alarm )
0 / 1 Sys 3 Compressor Run Status 0 / 1 Sys 4 Compressor Run Status 0 / 1 Sys 3 Economizer Solenoid Valve Status
O = OPTIONAL
Micro Board: 031-02478-xxx
N = NOT AVAILABLE
ENG PAGE
Ref
1 2 3 4 5 6 7 8 9 10
P03
P04
P05
P06
P07
P08
P09
P10
SSSSSSSS
P11
SSSSSSSS
P12
SSSSSSSS
P13
SSSSSSSS
P14
SSSSSSSS
P15
P16
SSSSSSSS
P17
SSSSSSSS
P18
SSSSSSSS
P19
SSSSSSSS
P20
SSSSSSSS
P21
SSSSSSSS
P22
SSSSSSSS
P23
SSSSSSSS
P24
SSSSSSSS
P25
SSSSSSSS
P26
SSSSSSSS
P27
SSSSSSSS
P28
SSSSSSSS
P29
SSSSSSSS
P30
SSSSSSSS
P31
SSSSSSSS
P32
SSSSSSSS
P33
OOOOOOOO
P34
OOOOOOOO
P35
P36
P37
P38
P39
SSSSSSSS
P40
SSSSSSSS
P41
SSSSSSSS
P42
SECTION 8 - MICROPANEL
Revision: YCAV_YCIV BAS (Rev K_03g).xlsx Tab: YCAV and YCIV
Property of Johnson Controls, York, PA
Page: 3
8
297
8/25/2014
SECTION 8 - MICROPANEL
TABLE 32 - BACNET AND MODBUS COMMUNICATIONS DATA MAP (CONT'D)
298
ENG PAGE
Ref
BACnet Object Typ/Ins
P43 P44 P45 P46 P47 P48 P49 P50 P51 P52 P53 P54 P55 P56 P57 P58 P59 P60 P61 P62 P63 P64 P65 P66 P67 P68 P69 P70 P71 P72 P73 P74 P75 P76 P77 P78 P79 P80 P81 P82 P83 P84
BV112 BV113 BV114 BV115 BV116 BV117 BV118 BV119 BV120 BV121 BV122 BV123 BV124 MV101 MV102 MV103 MV104 MV105 MV106 MV107 MV108 MV109 MV110 AV130 AV131 AV132 AV133 AV134 AV135 AV136 AV137 AV138 AV139 AV140 AV141 AV142 AV143 BV125 BV126 BV127 BV128 BV129
Bacnet Object Name
YT2_ S02_ P43 YT2_ S02_ P44 YT2_ S02_ P45 YT2_ S02_ P46 YT2_ S02_ P47 YT2_ S02_ P48 YT2_ S02_ P49 YT2_ S02_ P50 YT2_ S02_ P51 YT2_ S02_ P52 YT2_ S02_ P53 YT2_ S02_ P54 YT2_ S02_ P55 YT2_ S02_ P56 YT2_ S02_ P57 YT2_ S02_ P58 YT2_ S02_ P59 YT2_ S02_ P60 YT2_ S02_ P61 YT2_ S02_ P62 YT2_ S02_ P63 YT2_ S02_ P64 YT2_ S02_ P65 YT2_ S02_ P66 YT2_ S02_ P67 YT2_ S02_ P68 YT2_ S02_ P69 YT2_ S02_ P70 YT2_ S02_ P71 YT2_ S02_ P72 YT2_ S02_ P73 YT2_ S02_ P74 YT2_ S02_ P75 YT2_ S02_ P76 YT2_ S02_ P77 YT2_ S02_ P78 YT2_ S02_ P79 YT2_ S02_ P80 YT2_ S02_ P81 YT2_ S02_ P82 YT2_ S02_ P83 YT2_ S02_ P84
LON Profile Name
LON SNVT Type
nvoYTS02p043 nvoYTS02p044 nvoYTS02p045 nvoYTS02p046 nvoYTS02p047 nvoYTS02p048 nvoYTS02p049 nvoYTS02p050 nvoYTS02p051 nvoYTS02p052 nvoYTS02p053 nvoYTS02p054 nvoYTS02p055 nvoYTS02p056 nvoYTS02p057 nvoYTS02p058 nvoYTS02p059 nvoYTS02p060 nvoYTS02p061 nvoYTS02p062 nvoYTS02p063 nvoYTS02p064 nvoYTS02p065 nvoYTS02p066 nvoYTS02p067 nvoYTS02p068 nvoYTS02p069 nvoYTS02p070 nvoYTS02p071 nvoYTS02p072 nvoYTS02p073 nvoYTS02p074 nvoYTS02p075 nvoYTS02p076 nvoYTS02p077 nvoYTS02p078 nvoYTS02p079 nvoYTS02p080 nvoYTS02p081 nvoYTS02p082 nvoYTS02p083 nvoYTS02p084
SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_count_f (51) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95) SNVT_switch (95)
N2 Metasys
BD 41 BD 42 BD 43 BD 44 BD 45 BD 46 BD 47 BD 48 BD 49 BD 50 BD 51 BD 52 BD 53 ADI 11 ADI 12 ADI 13 ADI 14 ADI 15 ADI 16 ADI 17 ADI 18 ADI 19 ADI 20 ADF 73 ADF 74 ADF 75 ADF 76 ADF 77 ADF 78 ADF 79 ADF 80 ADF 81 ADF 82 ADF 83 ADF 84 ADF 85 ADF 86 BD 54 BD 55 BD 56 BD 57 BD 58
MODBUS
Address Scale see note 3
0172 N/A 0173 N/A 0174 N/A 0175 N/A 0176 N/A 0177 N/A 0178 N/A 0179 N/A 0180 N/A 0181 N/A 0182 N/A 0183 N/A 0184 N/A 0130 X 1 0131 X 1 0132 X 1 0133 X 1 0134 X 1 0135 X 1 0136 X 1 0137 X 1 0138 X 1 0139 X 1 0140 X 1 0141 X 1 0142 X 1 0143 X 1 0144 X 10 0145 X1 * 0146 X1 * 0147 X1 * 0148 X1 * 0149 X1 * 0150 X 1 0151 X 1 0152 X 1 0153 X 1 0185 N/A 0186 N/A 0187 N/A 0188 N/A 0189 N/A
ENG UNITS POINT LIST CODE:
S = STANDARD
Imper SI
POINT LIST DESCRIPTION
0 / 1 0 / 1 Sys 4 Economizer Solenoid Valve Status
enum enum enum enum
% count count count
enum Sys 3 Operational Code enum Sys 3 Fault Code enum Sys 4 Operational Code enum Sys 4 Fault Code
% Sys 3 Flash Tank Level % count Sys 3 Condenser Fan Stage ( 0-7 ) count Sys 4 Flash Tank Level % count Sys 4 Condenser Fan Stage ( 0-7)
enum enum Sys 3 & 4 Debug Code
% % PSI volts
% Sys 3 Flash Tank Drain Valve % Open % Sys 4 Flash Tank Drain Valve % Open BAR volts VSD DC Bus Voltage 2
°F °C Sys 3 Suction Superheat
°F °C Sys 3 Discharge Superheat °F °C Sys 4 Suction Temperature °F °C Sys 4 Discharge Temperature °F °C Sys 4 Suction Superheat °F °C Sys 4 Discharge Superheat 0/1 0/1 Sys 3 Lockout 0/1 0/1 Sys 4 Lockout
O = OPTIONAL
N = NOT AVAILABLE
ENG PAGE
1 2 3 4 5 6 7 8 9 10 REF
SSSSSSSS
P43
P44
P45
P46
P47
P48
P49
P50
P51
P52
P53
P54
P55
SSSSSSSS
P56
SSSSSSSS
P57
SSSSSSSS
P58
SSSSSSSS
P59
SSSSSSSS
P60
SSSSSSSS
P61
SSSSSSSS
P62
SSSSSSSS
P63
P64
SSSSSSSS
P65
P66
P67
SSSSSSSS
P68
SSSSSSSS
P69
P70
SSSSSSSS
P71
P72
SSSSSSSS
P73
P74
SSSSSSSS
P75
SSSSSSSS
P76
SSSSSSSS
P77
SSSSSSSS
P78
SSSSSSSS
P79
NNSSNNSS
P80
NNSSNNSS
P81
P82
P83
P84
NOTES
1
LON SNVTS Used: SNVT_count (8), SNVT_lev_percent (81), SNVT_temp_p (105), SNVT_switch (95) , SNVT_time_minute (123) , SNVT_freq_hz (76) , SNVT_amp (01) , SNVT_elec_kwh (13) , SNVT_power_kilo (83) , SNVT_volt (44) , SNVT_volt_ac (138), SNVT_press_p (87)
2
3
MODBUS scaling factors indicated in BOLD with an (*) asterisk are User Configurable, by a field technician if necessary. All Modbus values are of the type SIGNED with the exception of the User Configurabale values that are all UNSIGNED. Modbus Function Types Supported (ENG P03-P06 = Types 03, 06, 16) , ( ENG P07- P10 = 01, 03, 05, 15, 06, 16), (ENG P11-P35, P56-P79) = 03, 04) , (ENG P36-P55, P80 -P84 = 01, 02, 03)
4 BACnet Engineering Units shown with an (*) Asterisk will be assigned a BACnet Eng Unit type of (95) ie NO UNITS.
5 Status Codes: Special Display characters such as (, ), [, ], {, },/,\,%,< and > are not compatible with Elink N2 formats. Substitute text strings , "-", PCT, GTN will be used .
6 Status Codes: Status Code Text string lengths are limited to 60 total characters (including spaces)
7
8
9
10
NOTE: The Appropriate Product Code Listing Summary Should Accompany Document
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
JOHNSON CONTROLS
Revision: YCAV_YCIV BAS (Rev K_03g).xlsx Tab: YCAV and YCIV
Property of Johnson Controls, York, PA
Page: 4
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
TABLE 32 - BACNET AND MODBUS COMMUNICATIONS DATA MAP (CONT'D)
JOHNSON CONTROLS
ENG
PAGE P56,58
63 64 65 66 67 68 69 70 71 72 73 74
75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Operational Code
C_OPER.CODE Manual Override Daily Schedule Shutdown Unit Switch OFF Remote Controlled Shutdown Loss of External Communications Flow Switch Shutdown VSD Cooling Shutdown Serial Number Shutdown SPARE SPARE SPARE No Run Permissive
Anti-Recycle Timer Active System Switch OFF System Not Running System Running Discharge Pressure Limiting Suction Pressure Limiting Motor Current Limiting Motor Temperature Limiting ISN Motor Current Limiting Remote Motor Current Limiting System Pumping Down VSD PreCharging VSD Baseplate Temp Limiting VSD Internal Ambient Temp Limiting Sound Limiting ISN Sound Limiting Remote Sound Limiting Pulldown Motor Current Limiting Cooling Demand Shutdown Reserved 94 Reserved 95 Reserved 96
ENG
PAGE P57,59
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
Fault/Inhibit Code
C_FAULT.CODE Low Ambient Temperature High Ambient Temperature Low Chilled Liquid Temperature SPARE0 Low RTC Battery Voltage Invalid Number of Comp ressors Selected VSD Communications Failure Pre-charge Low DC Bus Voltage Pre-charge DC Bus Voltage Imbalance Bus Voltage High DC Bus Voltage Low DC Voltage Imbalance DC Bus
High VSD Ambient Temperature Single Phase Input VSD Power Supply Fault VSD Logic Board Fault Motor Current Overload (Hardware) CT Plug Fault Reserved 19 Reserved 20 Reserved 21 Reserved 22 Reserved 23 Reserved 24 Reserved 25 Reserved 26 High Discharge Pressure (Software) High Differential Oil Pressure Low Differential Oil Pressure Low Suction Pressure High Discharge Temperature High Oil Temperature Low Suction Superheat Sensor Failure Low Motor Current High Motor Temperature Pre-charge Low DC Bus Voltage Pre-charge DC Bus Voltage Imbalance High DC Bus Voltage Low DC Bus Voltage DC Bus Voltage Imbalance High Motor Current Motor Current Overload (Software) IGBT Gate Driver Fault High Baseplate Temperature Single Phase Input VSD Run Signal Fault High Discharge Press (Hardware HPCO) High Flash Tank Level Control Voltage Fault Low Discharge Superheat
8/25/2014
ENG
PAGE P57,59
52 53 54 55 56 57 58 59 60 61 62
Fault/Inhibit Code (cont)
C_FAULT.CODE Reserved 52 Reserved 53 Reserved 54 Reserved 55 Reserved 56 Reserved 57 Reserved 58 Reserved 59 Reserved 60 Reserved 61 Reserved 62
SECTION 8 - MICROPANEL
8
299
Revision: YCAV_YCIV BAS (Rev K_03g).xlsx Tab: YCAV and YCIV
Property of Johnson Controls, York, PA
Page: 5
SECTION 8 - MICROPANEL
Yorktalk 2 Communications
Received Data (Control Data)
The unit receives eight data values from the MicroGateway or E-Link. The first four are analog values and the last four are digital values. These eight data values are used as control parameters when in REMOTE mode. When the unit is in LOCAL mode, these eight values are ignored. If the unit receives no valid YorkTalk 2 transmission for 5 minutes it will revert back to all local control values. Table 33 on page 301 "Yorktalk 2 Communications Data Map" lists the control parameters. These values are found under feature 54 in the MicroGateway or E-Link.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Transmitted Data
After receiving a valid transmission from the MicroGateway or E-Link, the unit will transmit either operational data or history buffer data depending on the "History Buffer Request" on ENG PAGE 10. Data must be transmitted for every page under feature 54. If there is no value to be sent to a particular page, a zero will be sent. Table 33 on page 301 "Yorktalk 2 Communications Data Map" shows the data values and page listings for this unit.
The latest point map information is listed on the Johnson Controls Equipment Integration website.
300
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Table 33 - YORKTALK 2 COMMUNICATIONS DATA MAP
JOHNSON CONTROLS
02/17/2017
YCAV YCIV
Item
Version
Y.ACS.14.03, Y.ACS.15.03, Y.ACS.16.03, Y.ACS.17.03,
1 Y.ACS.18.03, Y.ACS.19.03, Z.ACS.14.04, Z.ACS.15.03M,
Z.ACS.17.03, Z.ACS.19.04, Z.ACS.31.03
2
3
4
5
6
7
8
9
10
York P/N 031-03476-001, -002, -003, 004, -005, -202, -101, -210, 104, -AGR, -225
Item Ref Num
BACnet Name
BACnet Object Instance
Modbus Address
Modbus Data Type Modbus
Supported
Scaling (See
Note 5)
N2 Metasys
ANALOG WRITE POINTS
1 REM_SETP
AV1
2 DMD_LIMIT
AV2
3 SND_LIMIT
AV3
4 SPARE AV1
AV4
BINARY WRITE POINTS
5 START_STOP
BV1
6 SPARE_BV1
BV2
7 SPARE_BV2
BV3
8 SPARE_BV3
BV3
ANALOG READ ONLY POINTS
9 LCHLT
AI1
10 ECHLT
AI2
11 VSD_IA_TEMP
AI3
12 S1_SUCT_TEMP
AI4
13 S2_SUCT_TEMP
AI5
14 S3_SUCT_TEMP
AI6
15 S4_SUCT_TEMP
AI7
16 S1_DSCH_TEMP
AI8
17 S2_DSCH_TEMP
AI9
18 S3_DSCH_TEMP
AI10
19 S4_DSCH_TEMP
AI11
20 OAT
AI12
21 S1_OIL_TEMP
AI13
22 S2_OIL_TEMP
AI14
23 S3_OIL_TEMP
AI15
24 S4_OIL_TEMP
AI16
25 S1_OIL_PRESS
AI17
26 S2_OIL_PRESS
AI18
27 S3_OIL_PRESS
AI19
28 S4_OIL_PRESS
AI20
29 S1_SUCT_PRES
AI21
30 S2_SUCT_PRES
AI22
31 S3_SUCT_PRES
AI23
1026 1027 1028 1029
1538 1539 1540 1541
514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536
03,06,16 03,06,16 03,06,16 03,06,16
01,03,05,06,15 01,03,05,06,15 01,03,05,06,15 01,03,05,06,15
03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04
Div 10 Div 10 Div 10 Div 10
N/A N/A N/A N/A
x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10
ADF 1 ADF 2 ADF 3 ADF 4
BD 1 BD 2 BD 3 BD 3
ADF 5 ADF 6 ADF 7 ADF 8 ADF 9 ADF 10 ADF 11 ADF 12 ADF 13 ADF 14 ADF 15 ADF 16 ADF 17 ADF 18 ADF 19 ADF 20 ADF 21 ADF 22 ADF 23 ADF 24 ADF 25 ADF 26 ADF 27
Modbus, BACnet MS/TP, N2 Data Map New
Comments
Board: 031-03478
Engineering Units Point List Code: S = Standard O = Optional N = Not Available
Imperial SI
Point List Description
1 2 3 4 5 6 7 8 9 10
°F
°C Remote Setpoint
S
% FLA % FLA Remote Current Limit Setpoint
S
%
% Remote Sound Limit
S
None None Spare
N
0/1
0/1 Remote Start / Stop Command [0=Stop, 1=Run]
S
0/1
0/1 Spare
N
0/1
0/1 Spare
N
0/1
0/1 Spare
N
°F
°C Leaving Chilled Liquid Temperature
S
°F
°C Entering Chilled Liquid Temperature
S
°F
°C VSD Internal Ambient Temperature
S
°F
°C Sys 1 Suction Temperature
S
°F
°C Sys 2 Suction Temperature
S
°F
°C Sys 3 Suction Temperature
S
°F
°C Sys 4 Suction Temperature
S
°F
°C Sys 1 Discharge Temperature
S
°F
°C Sys 2 Discharge Temperature
S
°F
°C Sys 3 Discharge Temperature
S
°F
°C Sys 4 Discharge Temperature
S
°F
°C Ambient Air Temperature
S
°F
°C Sys 1 Oil Temperature
S
°F
°C Sys 2 Oil Temperature
S
°F
°C Sys 3 Oil Temperature
S
°F
°C Sys 4 Oil Temperature
S
PSI
BAR Sys 1 Oil Pressure
S
PSI
BAR Sys 2 Oil Pressure
S
PSI
BAR Sys 3 Oil Pressure
S
PSI
BAR Sys 4 Oil Pressure
S
PSI
BAR Sys 1 Suction Pressure
S
PSI
BAR Sys 2 Suction Pressure
S
PSI
BAR Sys 3 Suction Pressure
S
SECTION 8 - MICROPANEL
8
301
YCAV and YCIV Native
Property of Johnson Controls, Inc. Subject to change without notice.
1 of 4
SECTION 8 - MICROPANEL
TABLE 33 - YORKTALK 2 COMMUNICATIONS DATA MAP (CONT'D)
302
02/17/2017
Item Ref BACnet Name Num 32 S4_SUCT_PRES 33 S1_DSCH_PRES 34 S2_DSCH_PRES 35 S3_DSCH_PRES 36 S4_DSCH_PRES 37 S1_MC_FLA 38 S2_MC_FLA 39 S3_MC_FLA 40 S4_MC_FLA 41 S1_OP_HRS 42 S2_OP_HRS 43 S3_OP_HRS 44 S4_OP_HRS 45 S1_COMP_ST 46 S2_COMP_ST 47 S3_COMP_ST 48 S4_COMP_ST 49 S1_HI_MTR_T 50 S2_HI_MTR_T 51 S3_HI_MTR_T 52 S4_HI_MTR_T 53 VSD_OUT_FR 54 S1_FEED 55 S2_FEED 56 S3_FEED 57 S4_FEED 58 S1_OP_CODE 59 S2_OP_CODE 60 S3_OP_CODE 61 S4_OP_CODE 62 S1_FTL_CODE 63 S2_FLT_CODE 64 S3_FTL_CODE 65 S4_FLT_CODE 66 S1_LEVEL 67 S2_LEVEL 68 S3_LEVEL 69 S4_LEVEL 70 S1_FAN_STG 71 S2_FAN_STG 72 S3_FAN_STG 73 S4_FAN_STG 74 LEAD 75 LCHLT_SETP 76 LCHLT_CUTOUT 77 S1_DRAIN 78 S2_DRAIN 79 S3_DRAIN 80 S4_DRAIN 81 SUCT_PRS_CUT 82 VSD_DCB_V_13
BACnet Object Instance
AI24 AI25 AI26 AI27 AI28 AI29 AI30 AI31 AI32 AI33 AI34 AI35 AI36 AI37 AI38 AI39 AI40 AI41 AI42 AI43 AI44 AI45 AI46 AI47 AI48 AI49 AI50 AI51 AI52 AI53 AI54 AI55 AI56 AI57 AI58 AI59 AI60 AI61 AI62 AI63 AI64 AI65 AI66 AI67 AI68 AI69 AI70 AI71 AI72 AI73 AI74
Modbus Address
537 538 539 540 541 542 543 544 545 546 547 548 549 550 551 552 553 554 555 556 557 558 559 560 561 562 563 564 565 566 567 568 569 570 571 572 573 574 575 576 577 578 579 580 581 582 583 584 585 586 587
Modbus Data Type Supported
03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04
Modbus Scaling (See
Note 5)
x10 x10 x10 x10 x10 x10 x10 x10 x10 x1 x1 x1 x1 x1 x1 x1 x1 x10 x10 x10 x10 x10 x10 x10 x10 x10 x1 x1 x1 x1 x1 x1 x1 x1 x10 x10 x10 x10 x1 x1 x1 x1 x1 x10 x10 x10 x10 x10 x10 x10 x1
N2 Metasys
ADF 28 ADF 29 ADF 30 ADF 31 ADF 32 ADF 33 ADF 34 ADF 35 ADF 36 ADF 37 ADF 38 ADF 39 ADF 40 ADF 41 ADF 42 ADF 43 ADF 44 ADF 45 ADF 46 ADF 47 ADF 48 ADF 49 ADF 50 ADF 51 ADF 52 ADF 53 ADF 54 ADF 55 ADF 56 ADF 57 ADF 58 ADF 59 ADF 60 ADF 61 ADF 62 ADF 63 ADF 64 ADF 65 ADF 66 ADF 67 ADF 68 ADF 69 ADF 70 ADF 71 ADF 72 ADF 73 ADF 74 ADF 75 ADF 76 ADF 77 ADF 78
Engineering Units Point List Code: S = Standard O = Optional N = Not Available
Imperial PSI PSI PSI PSI PSI % % % % None None None None None None None None °F °F °F °F Hz % % % % None None None None None None None None % % % % None None None None None °F °F % % % % PSI Volts
SI BAR BAR BAR BAR BAR
% % % % None None None None None None None None °C °C °C °C Hz % % % % None None None None None None None None % % % % None None None None None °C °C % % % % BAR Volts
Point List Description Sys 4 Suction Pressure Sys 1 Discharge Pressure Sys 2 Discharge Pressure Sys 3 Discharge Pressure Sys 4 Discharge Pressure Sys 1 Motor Current FLA Sys 2 Motor Current FLA Sys 3 Motor Current FLA Sys 4 Motor Current FLA Sys 1 Operating Hours Sys 2 Operating Hours Sys 3 Operating Hours Sys 4 Operating Hours Sys 1 Compressor Starts Sys 2 Compressor Starts Sys 3 Compressor Starts Sys 4 Compressor Starts Sys 1 Highest Motor Temperature Sys 2 Highest Motor Temperature Sys 3 Highest Motor Temperature Sys 4 Highest Motor Temperature VSD Output Frequency Sys 1 Flash Tank Feed Valve % Sys 2 Flash Tank Feed Valve % Sys 3 Flash Tank Feed Valve % Sys 4 Flash Tank Feed Valve % Sys 1 Operational Code Sys 2 Operational Code Sys 3 Operational Code Sys 4 Operational Code Sys 1 Fault Code Sys 2 Fault Code Sys 3 Fault Code Sys 4 Fault Code Sys 1 Flash Tank Level % Sys 2 Flash Tank Level % Sys 3 Flash Tank Level % Sys 4 Flash Tank Level % Sys 1 Condenser Fan Stage Sys 2 Condenser Fan Stage Sys 3 Condenser Fan Stage Sys 4 Condenser Fan Stage Lead System Leaving Chilled Liquid Setpoint Leaving Chilled Liquid Cutout Sys 1 Flash Tank Drain Valve % Sys 2 Flash Tank Drain Valve % Sys 3 Flash Tank Drain Valve % Sys 4 Flash Tank Drain Valve % Suction Pressure Cutout VSD DC Bus Voltage Sys 1/3
1 2 3 4 5 6 7 8 9 10 S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
JOHNSON CONTROLS
YCAV and YCIV Native
Property of Johnson Controls, Inc. Subject to change without notice.
2 of 4
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
TABLE 33 - YORKTALK 2 COMMUNICATIONS DATA MAP (CONT'D)
JOHNSON CONTROLS
02/17/2017
Item Ref BACnet Name Num 83 VSD_DCB_V_24 84 REM_SETPOINT 85 S1_SUC_SHEAT 86 S2_SUC_SHEAT 87 S3_SUC_SHEAT 88 S4_SUC_SHEAT 89 COOLING_RNG 90 S1_DSC_SHEAT 91 S2_DSC_SHEAT 92 S3_DSC_SHEAT 93 S4_DSC_SHEAT
94 S1_SYS_STATE
BACnet Object Instance
AI75 AI76 AI77 AI78 AI79 AI80 AI81 AI82 AI83 AI84 AI85
AI86
95 S2_SYS_STATE
AI87
96 S3_SYS_STATE
AI88
97 S4_SYS_STATE
AI89
98 S1_MTR_OVER
AI90
99 S2_MTR_OVER
AI91
100 S3_MTR_OVER
AI92
101 S4_MTR_OVER
AI93
BINARY READ ONLY POINTS
102 S13_ALARM
BI1
103 S24_ALARM
BI2
104 EVAP_HEATER
BI3
105 EVAP_PUMP
BI4
106 S1_COMP_RUN
BI5
107 S2_COMP_RUN
BI6
108 S3_COMP_RUN
BI7
109 S4_COMP_RUN
BI8
110 S1_ECON_SV
BI9
111 S2_ECON_SV
BI10
112 S3_ECON_SV
BI11
113 S4_ECON_SV
BI12
114 WATER_GLYCOL BI13
115 LOCAL_REMOTE BI14
116 DISP_UNITS
BI15
Modbus Address
588 589 590 591 592 593 594 595 596 597 598
599
Modbus Data Type Supported
03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04 03,04
Modbus Scaling (See
Note 5)
x1 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10
03,04
x1
N2 Metasys
ADF 79 ADF 80 ADF 81 ADF 82 ADF 83 ADF 84 ADF 85 ADF 86 ADF 87 ADF 88 ADF 89
ADF 90
600
03,04
x1
ADF 91
601
03,04
x1
ADF 92
602
03,04
603
03,04
604
03,04
605
03,04
606
03,04
x1
ADF 93
x1
ADF 94
x1
ADF 95
x1
ADF 96
x1
ADF 97
1282
01,02,03
N/A
BD5
1283
01,02,03
N/A
BD6
1284
01,02,03
N/A
BD7
1285
01,02,03
N/A
BD8
1286
01,02,03
N/A
BD9
1287
01,02,03
N/A
BD10
1288
01,02,03
N/A
BD11
1289
01,02,03
N/A
BD12
1290
01,02,03
N/A
BD13
1291
01,02,03
N/A
BD14
1292
01,02,03
N/A
BD15
1293
01,02,03
N/A
BD16
1294
01,02,03
N/A
BD17
1295
01,02,03
N/A
BD18
1296
01,02,03
N/A
BD19
Engineering Units Point List Code: S = Standard O = Optional N = Not Available
Imperial Volts °F
°F (diff) °F (diff) °F (diff) °F (diff)
°F °F (diff) °F (diff) °F (diff) °F (diff)
None
None
None
None
Amps Amps Amps Amps
SI Volts
°C °C (diff) °C (diff) °C (diff) °C (diff)
°C °C (diff) °C (diff) °C (diff) °C (diff)
None
None
None
None
Amps Amps Amps Amps
Point List Description VSD DC Bus Voltage Sys 2/4 Remote Leaving Chilled Liquid Setpoint Sys 1 Suction Superheat Sys 2 Suction Superheat Sys 3 Suction Superheat Sys 4 Suction Superheat Cooling Range Sys 1 Discharge Superheat Sys 2 Discharge Superheat Sys 3 Discharge Superheat Sys 4 Discharge Superheat Sys 1 System State [0=Stopped, 1=Running, 2=Faulted, 4=Locked Out, 5=Pre-Run Sys 2 System State [0=Stopped, 1=Running, 2=Faulted, 4=Locked Out, 5=Pre-Run Sys 3 System State [0=Stopped, 1=Running, 2=Faulted, 4=Locked Out, 5=Pre-Run Sys 4 System State [0=Stopped, 1=Running, 2=Faulted, 4=Locked Out, 5=Pre-Run Sys 1 Motor Current Overload Setting Sys 2 Motor Current Overload Setting Sys 3 Motor Current Overload Setting Sys 4 Motor Current Overload Setting
1 2 3 4 5 6 7 8 9 10 S S S S S S S S S S S
S
S
S
S
S S S S
0/1
0/1 Sys 1/3 Alarm [0=No Alarm, 1=Alarm]
S
0/1
0/1 Sys 2/4 Alarm [0=No Alarm, 1=Alarm]
S
0/1
0/1 Evaporator Heater Status
S
0/1
0/1 Evaporator Pump Status
S
0/1
0/1 Sys 1 Compressor Run Status
S
0/1
0/1 Sys 2 Compressor Run Status
S
0/1
0/1 Sys 3 Compressor Run Status
S
0/1
0/1 Sys 4 Compressor Run Status
S
0/1
0/1 Sys 1 Economizer Solenoid Valve Status
S
0/1
0/1 Sys 2 Economizer Solenoid Valve Status
S
0/1
0/1 Sys 3 Economizer Solenoid Valve Status
S
0/1
0/1 Sys 4 Economizer Solenoid Valve Status
S
0/1
0/1 Cooling Type [0=Water, 1=Glycol]
S
0/1
0/1 Local Remote Control Mode [0=Local, 1=Remote]
S
0/1
0/1 Display Units [0=Imperial, 1=SI]
S
NOTES
1 Units have Native BACnet MS/TP, Modbus RTU, and N2 communications. No external Gateway is required for these interfaces unless the customer is using Connected Services. 2 BACnet Object Types: 0 = Analog In, 1 = Analog Out, 2 = Analog Value, 3 = Binary In, 4 = Binary Out, 8 = Device, 15 = Alarm Notification (0-127 are reserved ASHRAE Objects) 3 WC = Inches of water Column, CFM = Cubic Feet per Minute, FPM = Feet Per Minute, PSI = Pounds per Square Inch, Pa = Pascals, kPa = kiloPascals, PPM = Parts Per Million, kJ/kg = kiloJoules per kilogram 4 Values that are not applicable due to unit configuration and options will be sent as zero (0). 5 Modbus values are all of type signed. Scaling values in x10 (Bold) indicate scaling in metric is x100. Scaling and signing may not be modified in the field. 6 7 8 9 10
SECTION 8 - MICROPANEL
8
303
YCAV and YCIV Native
Property of Johnson Controls, Inc. Subject to change without notice.
3 of 4
JOHNSON CONTROLS
304
Code Value 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114
Operational Code Manual Override Daily Schedule Shutdown Unit Switch OFF Remote Controlled Shutdown Loss Of External Communications Flow Switch Shutdown VSD Cooling Shutdown Serial Number Shutdown Password Shutdown (AGR)
No Run Permissive Anti-Recycle Timer Active System Switch OFF System Not Running System Running Discharge Pressure Limiting Suction Pressure Limiting Motor Current Limiting
ISN/BAS Motor Current Limiting Remote Motor Current Limiting System Shutting Down VSD Pre-Charging VSD Baseplate Temp Limiting VSD Internal Ambient Temp Limiting Sound Limiting ISN Sound Limiting Remote Sound Limiting Pulldown Motor Current Limiting Cooling Demand Shutdown System HPCO (Fan Special)
YCAV and YCIV Native
Code Value 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
Fault/Inhibit Code No Fault Code Low Ambient Temperature High Ambient Temperature Low Chilled Liquid Temperature
Low RTC Battery Voltage Invalid Number of Compressors Selected VSD Communications Failure Pre-charge Low DC Bus Voltage (Unit) Pre-charge DC Bus Voltage Imbalance (Unit) High DC Bus Voltage (Unit) Low DC Bus Voltage (Unit) DC Bus Voltage Imbalance (Unit) High VSD Ambient Temperature Single Phase Input (Unit) VSD Power Supply Fault VSD Logic Board Fault Motor Current Overload (Hardware) CT Plug Fault
High Discharge Pressure (Software) High Differential Oil Pressure Low Differential Oil Pressure Low Suction Pressure High Discharge Temperature High Oil Temperature Low Suction Superheat Sensor Failure Low Motor Current High Motor Temperature Pre-charge Low DC Bus Voltage (System 1/3, 2/4) Pre-charge DC Bus Voltage Imbalance (System 1/3, 2/4) High DC Bus Voltage (System 1/3, 2/4) Low DC Bus Voltage (System 1/3, 2/4) DC Bus Voltage Imbalance (System 1/3, 2/4) High Motor Current Motor Current Overload (Software) IGBT Gate Driver Fault High Baseplate Temperature Single Phase Input (System 1/3, 2/4) VSD Run Signal Fault High Discharge Pressure (Hardware - HPCO) High Flash Tank Level Control Voltage Fault Low Discharge Superheat
Property of Johnson Controls, Inc. Subject to change without notice.
02/17/2017
4 of 4
SECTION 8 - MICROPANEL
TABLE 33 - YORKTALK 2 COMMUNICATIONS DATA MAP (CONT'D)
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 9 - MAINTENANCE
GENERAL REQUIREMENTS The units have been designed to operate continuously, provided they are regularly maintained and operated within the limitations given in this manual. Each unit should be included in a routine schedule of daily maintenance checks by the operator/customer, backed up by regular service inspection and maintenance visits by a suitably qualified Service Engineer.
It is entirely the responsibility of the owner to provide for these regular maintenance requirements and/ or enter into a maintenance agreement with a Johnson Controls service organization to protect the operation of the unit. If damage or a system failure occurs due to improper maintenance during the warranty period, Johnson Controls shall not be liable for costs incurred to return the unit to satisfactory condition.
Section 9 - Maintenance on page 305 applies to the basic unit only and may, on individual contracts, be supplemented by additional requirements to cover any modifications or ancillary equipment as applicable.
Section 1 - General Chiller Information and Safety on page 11 of this manual should be read carefully before attempting any maintenance operations on the unit.
Daily Maintenance The following maintenance checks should be carried out on a daily basis by the operator/customer. Note that the units are not generally user serviceable and no attempt should be made to rectify faults or problems found during daily checks unless competent and equipped to do so. If in any doubt, contact your local Johnson Controls Service Agent.
Unit Status Press the `STATUS' key on the keypad and ensure no fault messages are displayed.
JOHNSON CONTROLS
Refrigerant Leaks
Visually check the heat exchangers, compressors and pipework for damage and gas leaks.
Operating Conditions
Read the operating pressures and temperatures at the control panel using the display keys and check that these are within the operating limitations given in the manual.
Compressor Oil Level
Check the compressor oil level after the compressor has been operating on `FULL LOAD' for approximately half an hour. The oil level should be between the upper and lower sight glasses on the oil separators.
Refrigerant Charge
When a system starts up, or sometimes after a change of capacity, a flow of bubbles will be seen in the liquid line sight glass. After a few minutes of stable operation, the bubbles should clear leaving just liquid refrigerant showing in the sight glass.
Scheduled Maintenance
The maintenance operations detailed in the following
table should be carried out on a regular basis by a suit-
ably qualified Service Engineer. It should be noted that
the interval necessary between each `minor' and `ma-
jor' service can vary depending on, for instance, appli-
cation, site conditions and expected operating sched-
ule. Normally a `minor' service should be carried out
every three to six months and a `major' service once a
year. It is recommended that your local Johnson Con-
trols Service Center is contacted for recommendations
for individual sites.
9
Chiller / Compressor Operating Log
A Chiller/Compressor Operating Log is supplied on Page 329 for logging compressor and chiller operating data.
EVACUATING A SYSTEM
If a system or a portion of a system needs to be evacuated, it should be evacuated to a minimum of 500 microns. The system should then be able to hold the vacuum for 10 minutes with a maximum rise of 50 microns. If the system is not able to hold a vacuum, recheck the system for leaks.
305
SECTION 9 - MAINTENANCE
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
R-134a CONVERSION TABLES
The following table can be used for converting R-134a pressures to their equivalent saturated temperatures.
Table 34 - R-134a PRESSURE TO SATURATED TEMPERATURE CONVERSION
PRESSURE PSIG (BAR)
DEW POINT TEMP. ºF (ºC)
PRESSURE PSIG (BAR)
DEW POINT TEMP. ºF (ºC)
PRESSURE PSIG (BAR)
0.0 (0)
-14.9 (-26.1)
135.0 (9.31)
105.0 (40.6)
270.0 (18.62)
5.0 (.34)
-3.0 (-19.4)
140.0 (9.65)
107.2 (41.8)
275.0 (18.96)
10.0 (.69)
6.7 (-14.1)
145.0 (10.0)
109.4 (43)
280.0 (19.31)
15.0 (1.03)
14.9 (-9.5)
150.0 (10.34)
111.5 (44.2)
285.0 (19.65)
20.0 (1.38)
22.2 (-5.4)
155.0 (10.69)
113.6 (45.3)
290.0 (19.99)
25.0 (1.72)
28.7 (-1.8)
160.0 (11.03)
115.6 (46.4)
295.0 (20.34)
30.0 (2.07)
34.6 (1.4)
165.0 (11.38)
117.6 (47.6)
300.0 (20.68)
35.0 (2.41)
40.0 (4.4 )
170.0 (11.72)
119.6 (48.7)
305.0 (21.03)
40.0 (2.76)
45.0 (7.2)
175.0 (12.07)
121.5 (49.7)
310.0 (21.37)
45.0 (3.10)
49.6 (9.8)
180.0 (12.41)
123.3 (50.7)
315.0 (21.72)
50.0 (3.45)
54.0 ( 12.2)
185.0 (12.76)
125.2 (51.8)
320.0 (22.06)
55.0 (3.79)
58.1 (14.5)
190.0 (13.10)
126.9 (52.7)
325.0 (22.41)
60.0 (4.14)
62.0 (16.7)
195.0 (13.44)
128.7 (53.7)
330.0 (22.75)
65.0 (4.48)
65.7 (18.7)
200.0 (13.79)
130.4 (54.7)
335.0 (23.10)
70.0 (4.83)
69.2 (20.7)
205.0 (14.13)
132.1 (55.6)
340.0 (23.44)
75.0 (5.17)
72.6 (22.6)
210.0 (14.48)
133.8 (56.6)
345.0 (23.79)
80.0 (5.52)
75.9 (24.4)
215.0 (14.82)
135.5 (57.5)
350.0 (24.13)
85.0 (5.86)
79.0 (26.1)
220.0 (15.17)
137.1 (58.4)
355.0 (24.48)
90.0 (6.21)
82.0 (27.8)
225.0 (15.51)
138.7 (59.3)
360.0 (24.82)
95.0 (6.55)
84.9 (29.4)
230.0 (15.86)
140.2 (60.1)
365.0 (25.17)
100.0 (6.89)
87.7 (30.9)
235.0 (16.20)
141.8 (61)
370.0 (25.51)
105.0 (7.24)
90.4 (32.4)
240.0 (16.55)
143.3 (61.8)
375.0 (25.86)
110.0 (7.58)
93.0 (33.9)
245.0 (16.89)
144.8 (62.3)
380.0 (26.20)
115.0 (7.93)
95.5 (35.3)
250.0 (17.24)
146.3 (63.5)
385.0 (26.54)
120.0 (8.27)
98.0 (36.7)
255.0 (17.58)
147.7 (64.3)
390.0 (26.89)
125.0 (8.62)
100.4 (38)
260.0 (17.93)
149.2 (65.1)
395.0 (27.23)
130.0 (8.96)
102.7 (39.3)
265.0 (18.27)
150.6 (65.9)
400.0 (27.58)
DEW POINT TEMP. ºF (ºC) 152.0 (66.7) 153.4 (67.4) 154.7 (68.2) 156.1 (68.9) 157.4 (69.7) 158.7 (70.4) 160.0 (71.1) 161.3 (71.8) 162.5 (72.5) 163.8 (73.2) 165.0 (73.9) 166.2 (74.6) 167.4 (75.2) 168.6 (75.9) 169.8 (76.6) 171.0 (77.2) 172.1 (77.8) 173.3 (78.5) 174.4 (79.1) 175.5 (79.7) 176.6 (80.3) 177.7 (80.9) 178.8 (81.6) 179.9 (82.2) 180.9 (82.7) 182.0 (83.3) 183.0 (83.9)
306
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 9 - MAINTENANCE
MAINTENANCE REQUIREMENTS FOR YCIV CHILLERS
PROCEDURE
Check Oil Level in Oil Separator Sight Glass.
WEEKLY
QUARTERLY
SEMIANNUALLY
ANNUALLY
EVERY 5 YEARS
EVERY * HOURS
X
Check Liquid Line Sight Glass/ Moisture Indicator.
X
Record System Operating Temperatures & Pressures.
X
Check Condenser Coils for dirt / debris and clean as necessary.
X
Check Programmable Operating
Setpoints and Safety Cutouts. Assure
X
they are correct for the application.
Check Compressor and Evaporator Heater operation.
X
Check for dirt in the Panel. Check Door Gasket sealing integrity.
X
**Check Superheat on the Evaporator
and the Economizer feed to the Compres-
X
sor.
**Check Condenser Subcooling.
X
**Leak check the Chiller.
X
**Sample Compressor Oil, check for Acid, and replace if necessary.
**Disconnect Power Source and Lock Out. Check tightness of Power Wiring connections.
Check Glycol concentration on Low Temp. or other applications where freezing may be a problem.
VSD Glycol Change.
X
9
X
X X
* Reserved for customer use for any special site requirements. **This procedure must be performed at the specific time by an industry certified technician who has been
trained and qualified to work on this type of equipment. A record of this procedure be successfully carried out should be maintained on file by the equipment owner should proof of adequate maintenance be required at a later date for warranty purposes.
JOHNSON CONTROLS
307
SECTION 9 - MAINTENANCE
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
TROUBLESHOOTING GUIDE
(Always remove power to the chiller and assure the DC Bus voltage has bled off)
PROBLEM
POSSIBLE CAUSE
ACTION
High Voltage to the Chiller is missing.
Supply to the Panel is missing.
No Display On Control Panel. Unit Will Not Run. Line Fuse is blown.
Chiller Control Board is defective.
Check 1FU, 2FU, 4FU, 5FU, 17FU, or 19FU. Check 2T or 10T Transformer. Check Fuses. Replace Chiller Control Board
Display Board defective.
Replace Display Board
SCR Diode Module is defective.
Check SCR/Diode Module.
IBGT Module is defective. Line Fuse Blows.
VSD Logic Board is defective.
Check IBGT Module. Replace VSD Logic Board.
SCR Trigger Board is defective
Replace SCR Trigger Board.
Chiller Fault: Low Ambient Temperature
Chiller Fault: High Ambient Temperature
Chiller Fault: Low Leaving Chilled Liquid
System Fault: Control Voltage
Ambient temperature is lower than the programmed operating limit.
Check the programmed cutout and determine if it is programmed correctly
Ambient Sensor is defective.
Check the panel against the thermometer reading of ambient temperature
Ambient Temperature is above the maximum operating limit.
Check outside air temperature.
Ambient Sensor is defective.
Check the Panel Display against Thermometer reading of Ambient Temperature at the sensor.
Check for restricted flow.
Leaving chilled liquid temperature drops faster than the Check for rapid flow changes.
unit can unload.
Water loop is too small.
Flow is below minimum for chiller.
Chilled Water Sensor is defective.
Check Sensor against Temp. Gauge in water line.
Check Sensor for intermittent operation.
Check Wiring for shorts or opens.
System Fuse is blown.
Check respective system Fuse 20FU or 21FU.
System Fault: High Oil Temperature
Oil Temperature Sensor is defective.
Check Sensor with infrared to determine if reading is reasonable.
Condenser Fans NOT operating or running backwards. Check Fans.
Coils dirty.
Check and clean Coils.
Coils dirty.
Check and clean coils.
System Fault: High Discharge Pressure
Coils are damaged. Fans NOT operating.
Comb out fins. Check fan fuses. Check fan rotation. Check fan motor/blade.
System is overcharged.
Remove charge and check subcooling.
308
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 9 - MAINTENANCE
PROBLEM
POSSIBLE CAUSE
ACTION
Discharge Temperature Sensor is defective.
Check Sensor.
System Fault: High Discharge Temperature
Condenser Fans NOT operating or are running backwards. Coils dirty.
High Superheat.
Check Fans.
Check and clean Coils. Measure Superheat with gauges and thermocouple. Determine cause.
Refrigerant charge low. Check subcooling.
System Fault: High Motor Temperature
High Motor temperature input from one of the sensors
Excess charge in system, High discharge pressure. Check subcooling.
High Superheat. Drain/Feed Valves NOT controlling. Isolate cause.
Motor Sensor reading incorrectly. Program panel to ignore a single sensor.
Economizer Solenoid energized at low speeds. Valve is leaking through.
Low charge.
Check subcooling.
Transducer reads incorrectly.
Check transducer against a gauge.
System Fault: Low Suction Pressure
Suction Temp. Sensor reads incorrectly. Low flow. Feed or Drain Valve NOT operating
Feed or Drain Valve defective.
Check sensor against a thermocouple.
Check flow.
Check Feed and Drain Valve operation. Check superheat. Check Feed and Drain Valve operation. Check superheat.
Discharge Transducer is defective.
Check transducer against a gauge.
System Fault: Discharge Pressure Limiting
Ambient Temp. very high.
Fans NOT operating. Remote or local discharge pressure load limiting is programmed.
Normal operation. Check fan operation. Normal operation.
Ambient temperature is high, normal response from controller
System Fault: Motor Current Limiting
High motor current has activated current limiting
Remote or panel limiting is in
9
effect, Normal response.
Excess charge in system, adjust charge.
Condenser coils dirty, Clean condenser.
Fans NOT operating, Check fans.
Vsd Fault: High Baseplate Temperature
Coolant level low. Glycol Pump is defective. VSD Board is defective IBGT Module is defective.
Add coolant. Replace Glycol Pump. Replace VSD Logic Board. Check defective IGBT Module.
Vsd Fault: Low Dc Bus Voltage
SCR / Diode Module is defective. SCR Trigger Board is defective.
Check SCR / Diode Module. Check SCR Trigger Board.
JOHNSON CONTROLS
309
SECTION 9 - MAINTENANCE
LIMITED WARRANTY
Warranty on New Equipment Johnson Controls warrants all equipment and associated factory supplied materials, or start-up services performed by Johnson Controls in connection therewith, against defects in workmanship and material for a period of eighteen (18) months from date of shipment. Subject to the exclusions listed below, Johnson Controls, at its option, will repair or replace, FOB point of shipment, such YORK products or components as it finds defective.
Exclusions - Unless specifically agreed to in the contract documents, this warranty does not include the following costs and expenses:
1. Labor to remove or reinstall any equipment, materials, or components.
2. Shipping, handling, or transportation charges.
3. Cost of refrigerants.
No warranty repairs or replacements will be made until payment for all equipment, materials, or components has been received by Johnson Controls.
Warranty on Reconditioned or Replacement Materials Except for reciprocating compressors, which Johnson Controls warrants for a period of one year from date of shipment, Johnson Controls warrants reconditioned or replacement materials, or start-up services performed by Johnson Controls in connection therewith, against defects in workmanship or material for a period of ninety (90) days from date of shipment. Subject to the exclusions listed below, Johnson Controls, at its option, will repair or replace, FOB point of shipment, such materials or parts as Johnson Controls finds defective. However, where reconditioned or replacement materials or parts are placed on equipment still under the original new equipment warranty, then such reconditioned or replacement parts are warranted only until the expiration of such original new equipment warranty.
Exclusions - Unless specifically agreed to in the contract documents, this warranty does not include the following costs and expenses:
1. Labor to remove or reinstall any equipment, materials, or components.
2. Shipping, handling, or transportation charges.
3. Cost of refrigerant.
310
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
No warranty repairs or replacements will be made until payment for all equipment, materials, or components has been received by Johnson Controls.
All Warranties and Guarantees Are Void If:
1. Equipment is used with refrigerants, oil, or antifreeze agents other than those authorized by Johnson Controls.
2. Equipment is used with any material or any equipment such as evaporators, tubing, other low side equipment, or refrigerant controls not approved by Johnson Controls.
3. Equipment has been damaged by freezing because it is not properly protected during cold weather, or damaged by fire or any other conditions not ordinarily encountered.
4. Equipment is not installed, operated, maintained and serviced in accordance with instructions issued by Johnson Controls.
5. Equipment is damaged due to dirt, air, moisture, or other foreign matter entering the refrigerant system.
6. Equipment is not properly stored, protected or inspected by the customer during the period from date of shipment to date of initial start.
7. Equipment is damaged due to acts of GOD, abuse, neglect, sabotage, or acts of terrorism.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES AND LIABILITIES, EXPRESS OR IMPLIED IN LAW OR IN FACT, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE WARRANTIES CONTAINED HEREIN SET FORTH BUYER'S SOLE AND EXCLUSIVE REMEDY IN THE EVENT OF A DEFECT IN WORKMANSHIP OR MATERIALS. IN NO EVENT SHALL JOHNSON CONTROLS LIABILITY FOR DIRECT OR COMPENSATORY DAMAGES EXCEED THE PAYMENTS RECEIVED BY JOHNSON CONTROLS FROM BUYER FOR THE MATERIALS OR EQUIPMENT INVOLVED. NOR SHALL JOHNSON CONTROLS BE LIABLE FOR ANY SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. THESE LIMITATIONS ON LIABILITY AND DAMAGES SHALL APPLY UNDER ALL THEORIES OF LIABILITY OR CAUSES OF ACTION, INCLUDING, BUT NOT LIMITED TO, CONTRACT, WARRANTY, TORT (INCLUDING NEGLIGENCE) OR STRICT LIABILITY. THE ABOVE LIMITATIONS SHALL INURE TO THE BENEFIT OF JOHNSON CONTROLS SUPPLIERS AND SUBCONTRACTORS.
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 9 - MAINTENANCE
CHILLED LIQUID AND SUCTION TEMPERATURE SENSOR INPUT VOLTAGE
Table 35 - TEMPERATURE INPUT VOLTAGE SENSOR (MEASURED SIGNAL TO SHIELD AT THE SENSOR)
TEMP. (ºF)
VOLTAGE
TEMP. (ºF)
VOLTAGE
TEMP. (ºF)
VOLTAGE
16.1
1.52
35.9
2.19
55.6
2.85
16.7
1.54
36.5
2.21
56.3
2.87
17.3
1.56
37.0
2.23
56.9
2.89
17.9
1.58
37.6
2.25
57.5
2.91
18.5
1.60
38.2
2.27
58.1
2.93
19.1
1.62
38.7
2.29
58.7
2.95
19.7
1.64
39.3
2.30
59.4
2.97
20.3
1.66
39.9
2.32
60.0
2.99
20.9
1.68
40.4
2.34
60.6
3.01
21.5
1.70
41.0
2.36
61.3
3.03
22.1
1.72
41.6
2.38
61.9
3.05
22.7
1.74
42.1
2.40
62.5
3.07
23.3
1.76
42.7
2.42
63.2
3.09
23.9
1.78
43.3
2.44
63.8
3.11
24.5
1.80
43.9
2.46
64.5
3.13
25.0
1.82
44.4
2.48
65.1
3.14
25.6
1.84
45.0
2.50
65.8
3.16
26.2
1.86
45.6
2.52
66.5
3.18
26.8
1.88
46.2
2.54
67.1
3.20
27.3
1.90
46.7
2.56
67.8
3.22
27.9
1.91
47.3
2.58
68.5
3.24
28.5
1.93
47.9
2.60
69.2
3.26
29.0
1.95
48.5
2.62
69.9
3.28
29.6
1.97
49.1
2.64
70.6
3.30
30.2
1.99
49.7
2.66
71.3
3.32
9
30.8
2.01
50.3
2.68
72.0
3.34
31.3
2.03
50.8
2.70
72.7
3.36
31.9
2.05
51.4
2.71
73.4
3.38
32.5
2.07
52.0
2.73
74.2
3.40
33.0
2.09
52.6
2.75
74.9
3.42
33.6
2.11
53.2
2.77
34.2
2.13
53.8
2.79
34.8
2.15
54.5
2.81
35.3
2.17
55.0
2.83
JOHNSON CONTROLS
311
SECTION 9 - MAINTENANCE
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Table 36 - OUTSIDE AIR TEMPERATURE SENSOR INPUT VOLTAGE (MEASURED SIGNAL TO SHIELD AT THE SENSOR)
TEMP. (ºF)
VOLTAGE
TEMP. (ºF)
VOLTAGE
TEMP. (ºF)
VOLTAGE
0.24
0.68
49.8
2.00
93.3
3.31
1.79
0.71
50.7
2.03
94.4
3.34
3.30
0.74
51.6
2.06
65.6
3.37
4.76
0.77
52.5
2.09
96.8
3.40
6.19
0.80
53.4
2.11
98.0
3.43
7.58
0.83
54.3
2.14
99.2
3.46
8.94
0.85
55.3
2.17
100.4
3.49
10.3
0.88
56.2
2.20
101.6
3.52
11.6
0.91
57.1
2.23
102.9
3.55
12.8
0.94
58.0
2.26
104.2
3.57
14.1
0.97
58.9
2.29
105.5
3.60
15.3
1.00
59.8
2.32
106.8
3.63
16.5
1.03
60.7
2.35
108.1
3.66
17.7
1.06
61.6
2.38
109.5
3.69
18.9
1.09
62.6
2.41
110.9
3.72
20.0
1.12
63.5
2.44
112.3
3.75
21.2
1.15
64.4
2.47
113.8
3.78
22.3
1.18
65.3
2.50
115.2
3.81
23.4
1.21
66.3
2.52
116.7
3.84
24.4
1.24
67.2
2.55
118.3
3.87
25.5
1.26
68.1
2.58
119.9
3.90
26.6
1.26
69.1
2.61
121.5
3.93
27.6
1.32
70.0
2.64
123.2
3.96
28.7
1.35
70.9
2.67
124.9
3.98
29.7
1.38
71.9
2.70
126.6
4.01
30.7
1.41
72.8
2.73
128.4
4.04
31.7
1.44
73.8
2.76
130.3
4.07
32.7
1.47
74.8
2.76
33.7
1.50
75.8
2.82
34.7
1.53
76.7
2.85
35.7
1.56
77.7
2.88
36.7
1.59
78.7
2.91
37.6
1.62
79.7
2.93
38.6
1.65
80.7
2.96
39.6
1.67
81.7
2.99
40.5
1.70
82.7
3.02
41.4
1.73
83.6
3.05
42.4
1.76
84.6
3.08
43.3
1.79
85.7
3.11
44.3
1.82
86.7
3.13
45.2
1.85
87.8
3.16
46.1
1.88
88.9
3.19
47.0
1.91
90.1
3.22
48.0
1.94
91.1
3.25
48.9
1.97
92.2
3.28
312
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 9 - MAINTENANCE
Table 37 - PRESSURE TRANSDUCER OUTPUT VOLTAGE (MEASURED SIGNAL TO RETURN AT THE TRANSDUCER)
SUCTION PRESSURE TRANSDUCER (125 PSIG)
DISCHARGE PRESSURE TRANSDUCER (275 PSIG)
DISCHARGE PRESSURE TRANSDUCER (275 PSIG)
PRESSURE
VOLTAGE
PRESSURE
VOLTAGE
PRESSURE
VOLTAGE
0
0.50
0
0.50
140
2.54
5
0.66
5
0.57
145
2.61
10
0.82
10
0.65
150
2.68
15
0.98
15
0.72
155
2.75
20
1.14
20
0.79
160
2.83
25
1.30
25
0.86
165
2.90
30
1.46
30
0.94
170
2.97
35
1.62
35
1.01
175
3.05
40
1.78
40
1.08
180
3.12
45
1.94
45
1.15
185
3.19
50
2.10
50
1.23
190
3.26
55
2.26
55
1.30
195
3.34
60
2.42
60
1.37
200
3.41
65
2.58
65
1.45
205
3.48
70
2.74
70
1.52
210
3.55
75
2.90
75
1.59
215
3.63
80
3.06
80
1.66
220
3.70
85
3.22
85
1.74
225
3.77
90
3.38
90
1.81
230
3.85
95
3.54
95
1.88
235
3.92
100
3.70
100
1.95
240
3.99
105
3.86
105
2.03
245
4.06
110
4.02
110
2.10
250
4.14
115
4.18
115
2.17
255
4.21
120
4.34
120
2.25
260
4.28
125
4.50
125
2.32
265
4.35
130
2.39
270
4.43
135
2.46
275
4.50
9
JOHNSON CONTROLS
313
SECTION 9 - MAINTENANCE
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Table 38 - MOTOR TEMPERATURE SENSOR RESISTANCE (CHECK AT THE MOTOR)
TEMP. (ºC)
RNOMINAL (OHM)
RTOL (± %)
RMIN (OHM)
-20
97,062
5.00
92,209
-15
77,941
4.60
69,586
-10
55,391
4.20
52,996
-5
42,324
3.85
40,695
0
32,654
3.50
31,511
5
25,396
3.15
24,596
10
19,903
2.80
19,346
15
15,713
2.50
15,321
20
12,493
2.20
12,218
25
10,000
2.00
9,800
30
8,056
2.40
7,863
35
6,531
2.70
6,354
40
5,326
3.00
5,166
45
4,368
3.25
4,226
50
3,602
3.50
3,476
55
2,986
3.75
2,874
60
2,488
4.00
2,389
65
2,083
4.25
1,995
70
1,753
4.50
1,674
75
1,481
4.75
1,411
80
1,257
5.00
1,194
85
1,071
5.20
1,016
90
916.9
5.40
867.4
95
787.7
5.60
743.6
100
679.3
5.80
639.9
105
587.9
6.00
552.6
110
510.6
6.20
479.9
115
445.0
6.40
416.5
120
389.0
6.60
363.4
125
341.2
6.70
318.4
130
300.2
6.90
279.5
135
264.9
7.10
246.1
140
234.4
7.30
217.3
145
208.0
7.40
192.6
150
185.0
7.50
171.1
RMAX (OHM) 101,915 76,296 57,643 43,954 33,797 26,196 20,461 16,106 12,768 10,200 8,250 6,707 5,485 4,510 3,728 3,098 2,588 2,172 1,832 1,551 1,321 1,127 966.4 831.9 718.7 623.2 542.3 473.5 414.7 364.1 320.9 283.7 251.5 223.3 198.9
314
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 9 - MAINTENANCE
Table 39 - COMPRESSOR MOTOR OVERLOAD SETTINGS AND MAX. VSD FREQUENCY
2 COMP CHILLER MODELS WITH STANDARD (PIN 52 = X) AND ULTRA QUIET FANS (PIN 52 = L)
CHILLER MODEL (2 COMP)
W/ STD & UQ FANS
CHILLER NAMEPLATE VOLTAGE
(VAC)
COMPRESSOR 1
COMPRESSOR 2
OVERLOAD SETTING OVERLOAD SETTING
(A)
(A)
MAXIMUM VSD FREQUENCY (HZ)
YCIV0157EA/VA
380
269
269
186
YCIV0157EA/VA
460
192
192
186
YCIV0157SA/PA/HA
380
273
273
200
YCIV0157SA/PA/HA
460
196
196
200
YCIV0177EA/VA
380
262
275
200
YCIV0177EA/VA
460
184
197
200
YCIV0177SA/PA/HA
380
289
267
182
YCIV0177SA/PA/HA
460
270
191
182
YCIV0187EA/VA
380
289
259
192
YCIV0187EA/VA
460
250
183
192
YCIV0187SA/PA/HA
380
289
275
200
YCIV0187SA/PA/HA
460
254
198
200
YCIV0197EA/VA
380
289
289
182
YCIV0197EA/VA
460
244
244
182
YCIV0207EA/VA
380
289
289
192
YCIV0207EA/VA
460
234
250
192
YCIV0207SA/PA/HA
380
289
289
186
YCIV0207SA/PA/HA
460
247
273
186
YCIV0227EA/VA
380
289
289
200
YCIV0227EA/VA
460
238
238
200
YCIV0227SA/PA/HA
380
289
289
200
YCIV0227SA/PA/HA
460
255
255
200
YCIV0247EA/VA
380
345
314
200
YCIV0247EA/VA
460
289
238
200
YCIV0247SA/PA/HA
380
345
331
200
YCIV0247SA/PA/HA
460
289
254
200
YCIV0267SA/PA/HA
380
345
345
200
YCIV0267SA/PA/HA
460
289
289
200
NOTE: Overload settings are based on Chiller Model and Condenser Fan Option
9
JOHNSON CONTROLS
315
SECTION 9 - MAINTENANCE
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
TABLE 39 - COMPRESSOR MOTOR OVERLOAD SETTINGS AND MAX. VSD FREQUENCY (CONT'D)
2 COMP CHILLER MODELS WITH HIGH HEAD/HIGH STATIC FANS (PIN 52 = H)
CHILLER MODEL (2 COMP) W/ HH/HS FANS
CHILLER NAMEPLATE VOLTAGE
(VAC)
COMPRESSOR 1
COMPRESSOR 2
OVERLOAD SETTING OVERLOAD SETTING
(A)
(A)
MAXIMUM VSD FREQUENCY (HZ)
YCIV0157EA/VA
380
269
269
186
YCIV0157EA/VA
460
192
192
186
YCIV0157SA/PA/HA
380
273
273
200
YCIV0157SA/PA/HA
460
196
196
200
YCIV0177EA/VA
380
262
275
200
YCIV0177EA/VA
460
184
197
200
YCIV0177SA/PA/HA
380
289
267
182
YCIV0177SA/PA/HA
460
270
191
182
YCIV0187EA/VA
380
289
259
192
YCIV0187EA/VA
460
250
183
192
YCIV0187SA/PA/HA
380
289
275
200
YCIV0187SA/PA/HA
460
254
198
200
YCIV0197EA/VA
380
289
289
182
YCIV0197EA/VA
460
244
244
182
YCIV0207EA/VA
380
289
289
192
YCIV0207EA/VA
460
234
250
192
YCIV0207SA/PA/HA
380
289
289
186
YCIV0207SA/PA/HA
460
247
273
186
YCIV0227EA/VA
380
289
289
200
YCIV0227EA/VA
460
238
238
200
YCIV0227SA/PA/HA
380
289
289
200
YCIV0227SA/PA/HA
460
255
255
200
YCIV0247EA/VA
380
345
314
200
YCIV0247EA/VA
460
289
238
200
YCIV0247SA/PA/HA
380
345
331
200
YCIV0247SA/PA/HA
460
289
254
200
YCIV0267SA/PA/HA
380
345
345
200
YCIV0267SA/PA/HA
460
289
289
200
NOTE: Overload settings are based on Chiller Model and Condenser Fan Option
316
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 9 - MAINTENANCE
TABLE 39 - COMPRESSOR MOTOR OVERLOAD SETTINGS AND MAX. VSD FREQUENCY (CONT'D)
3 COMP CHILLER MODELS WITH STANDARD (PIN 52 = X) AND ULTRA QUIET FANS (PIN 52 = L)
CHILLER MODEL (3 COMP)
W/ STD & UQ FANS
CHILLER NAMEPLATE VOLTAGE
(VAC)
COMPRESSOR 1 OVERLOAD SET-
TING (A)
COMPRESSOR 2 OVERLOAD SET-
TING (A)
COMPRESSOR 3 OVERLOAD
SETTING (A)
MAXIMUM VSD FREQUENCY (HZ)
YCIV0267EA/VA
380
289
289
267
182
YCIV0267EA/VA
460
244
244
191
182
YCIV0287EA/VA
380
289
289
289
178
YCIV0287EA/VA
460
242
242
242
178
YCIV0287SA/PA/HA
380
289
289
268
186
YCIV0287SA/PA/HA
460
246
273
192
186
YCIV0307SA/PA/HA
380
289
289
289
188
YCIV0307SA/PA/HA
460
248
248
274
188
YCIV0327EA/VA
380
289
289
289
192
YCIV0327EA/VA
460
250
250
234
192
YCIV0357EA/VA
380
338
338
309
192
YCIV0357EA/VA
460
289
289
232
192
YCIV0357SA/PA/HA
380
331
331
338
200
YCIV0357SA/PA/HA
460
254
254
289
200
YCIV0397SA/PA/HA
380
338
338
338
200
YCIV0397SA/PA/HA
460
289
289
289
200
3 COMP CHILLER MODELS WITH HIGH HEAD/HIGH STATIC FANS (PIN 52 = H)
CHILLER MODEL (3 COMP)
W/ HH/HS FANS
CHILLER NAMEPLATE VOLTAGE
(VAC)
COMPRESSOR 1 OVERLOAD SET-
TING (A)
COMPRESSOR 2 OVERLOAD SET-
TING (A)
COMPRESSOR 3 OVERLOAD SET-
TING (A)
MAXIMUM VSD FREQUENCY
(HZ)
YCIV0267EA/VA
380
289
289
267
182
YCIV0267EA/VA
460
244
244
191
182
YCIV0287EA/VA
380
289
289
289
178
YCIV0287EA/VA
460
242
242
242
178
YCIV0287SA/PA/HA
380
289
289
268
186
YCIV0287SA/PA/HA
460
246
273
192
186
YCIV0307SA/PA/HA
380
YCIV0307SA/PA/HA
460
289 248
289 248
289 274
188 188
9
YCIV0327EA/VA
380
289
289
289
192
YCIV0327EA/VA
460
250
250
234
192
YCIV0357EA/VA
380
338
338
309
192
YCIV0357EA/VA
460
289
289
232
192
YCIV0357SA/PA/HA
380
331
331
338
200
YCIV0357SA/PA/HA
460
254
254
289
200
YCIV0397SA/PA/HA
380
338
338
338
200
YCIV0397SA/PA/HA
460
289
289
289
200
NOTE: Overload settings are based on Chiller Model and Condenser Fan Option
JOHNSON CONTROLS
317
SECTION 9 - MAINTENANCE
PRINTER WIRING A "serial" printer may be connected to the TB1 connector on the Chiller Logic Board for the purposes of logging data and troubleshooting. Weightronix Imp-2600, Seiko DPU-414, and Okidata Microline 184 printers or equivalents may be used.
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Printer designs change rapidly. The user should use the printer manual for the respective printer for set-up and wiring.
Data from the chiller is transmitted at 1200 baud. Wiring diagrams for cables are shown below:
OKIDATA MICROLINE 184
25 pin RS-232 (DB-25P)
11
CTS
TB1 Chiller Control Board
RS-232
DSR
TB1-2
3
RD
7
GND
TXD GND
TB1-3 TB1-5
SEIKO DPU-414
9 pin RS-232 (DB-9)
TB1 Chiller Control Board
8
CTS
3
RD
5
GND
DSR
TB1-2
TXD GND
TB1-3 TB1-5
WEIGHTRONIX IMP-24, MODEL 2600
25 pin RS-232 (DB-25P)
TB1 Chiller Control Board
5
CTS
2
RD
7
GND
DSR
TB1-2
TXD GND
TB1-3 TB1-5
ld10638
Figure 62 - PRINT CABLE - CHILLER TO SERIAL PRINTER 318
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
Printer Cables Printer cables should be shielded coaxial, #18AWG, stranded wire cables, not to exceed 50 ft in length. On long cable runs or whenever permanent installation is required, the shield of the coax should be tied to the chassis ground at the chiller only, not at the printer.
Printer Setup The following information may be useful for quick set up of a printer. Specific printer manuals should be utilized, if problems occur, since functions often change as new versions of printers are introduced with enhancements requiring control code, signal programming, and wiring changes.
Okidata 184 Control Board Switch Settings
SW1 ON: Unslashed 0 2 OFF: Unslashed 0 3 OFF: Unslashed 0 4 OFF: Form Length 11 in. 5 ON: Form Length 11 in. 6 OFF: Auto Line feed OFF 7 ON: 8 bit data 8 OFF: Enable front panel
With Super Speed Serial Board SW1-1 ON: Odd or even parity 1-2 ON: No parity 1-3 ON: 8 bit data 1-4 ON: Protocol ready/busy 1-5 ON: Test select 1-6 ON: Print mode 1-7 OFF: SDD(-) pin 11 1-8 ON: SDD(-) pin 11 2-1 ON: 1200 baud 2-2 ON: 1200 baud 2-3 OFF: 1200 baud 2-4 OFF: DSR active 2-5 ON: Buffer threshold 32 bytes 2-6 ON: Busy signal 200ms 2-7 ON: DTR space after power on 2-8 not used
JOHNSON CONTROLS
SECTION 9 - MAINTENANCE
With High Speed Serial Board SW1 OFF: (-) Low when busy 2 OFF: 1200 baud 3 OFF: 1200 baud 4 ON: 1200 baud 5 not used 6 OFF: no parity 7 OFF: Pin 20 and pin 11 act as busy line
Weigh-tronix IMP 24 Model 2600 SW1 OFF: 1200 baud 2 ON: 1200 baud
Seiko
DipSW1-1 OFF: Input -Serial
1-2 ON: Printing speed high
1-3 ON: Auto loading - ON
1-4 OFF: Auto LF - OFFF
1-5 ON: Setting Command - Enable
1-6 OFF: Printing density - 100%
1-7 ON: Printing density - 100%
1-8 ON: Printing density - 100%
DipSW2-1 ON: Printing Columns - 40
2-2 ON: User Font Back-up - ON
2-3 ON: Character Select - normal
2-4 OFF: Zero - slash
2-5 ON: International character setAmerican
2-6 ON: International character set American
2-7 ON: International character set -
9
American
2-8 OFF: International character set American
DipSW3-1 ON: Data length - bits
3-2 ON: Parity Setting - no
3-3 ON: Parity condition - odd
3-4 ON: Busy control H/W busy
3-5 ON: Baud rate select - 1200
3-6 OFF: Baud rate select - 1200
3-7 ON: Baud rate select - 1200
3-8 OFF: Baud rate select - 1200
319
SECTION 9 - MAINTENANCE
JOB NAME:
OPERATING LOG SHEET SITE AND CHILLER INFORMATION
START DATE:
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
LOCATION:
COMPRESSOR # 1 - MODEL #:
SALES ORDER #: TECHNICIAN NAME: CHILLER MODEL #: SERIAL #:
COMPRESSOR # 2 - MODEL #: COMPRESSOR # 3 - MODEL #: COMPRESSOR # 4 - MODEL #: SERIAL #:
CHILLED LIQUID SETPOINT Setpoint = Range = +/Display Language = Chilled Liquid Mode = Local/Remote Mode = Display Units = Lead/Lag Control = Remote Temperature Reset = Remote Current Reset =
PROGRAMMED VALUES
PROGRAMMED CUTOUTS
ºF(ºC) Suction Pressure Cutout =
PSIG (kPa)
ºF(ºC) Low Ambient Cutout = ºF(ºC)
Leaving Chilled Liquid Temp. Cutout =
ºF(ºC)
High Motor Current Unload = %FLA
320
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
SECTION 9 - MAINTENANCE
UNIT OPERATING TEMPERATURES AND PRESSURES
CHILLED LIQUID TEMPERATURES
Entering Temp. =
ºF(ºC)
VSD BUS VOLTAGE Bus 1 =
Leaving Temp. =
ºF(ºC)
Bus 2 =
OUTDOOR AMBIENT TEMPERATURES
OAT =
ºF(ºC)
VSD INTERNAL AMBIENT TEMPERATURE
Ambient Temp. =
ºF(ºC)
VSD FREQUENCY Actual =
VSD COOLING SYSTEM STATUS ON OFF
Command =
VSD IGBT BASEPLATE TEMPS T1 =
ºF(ºC)
T2 =
ºF(ºC)
SYSTEM OPERATING TEMPERATURES, PRESSURES AND CURRENTS
SYSTEM PRESSURES SYS 1 SYS 2 SYS 3 SYS 4
MOTOR TEMPERATURES SYS 1 SYS 2 SYS 3 SYS 4
Oil
PSIG (kPa)
T1
ºF(ºC)
Suction
PSIG (kPa)
T2
ºF(ºC)
Discharge
PSIG (kPa)
T3
ºF(ºC)
SYSTEM TEMPERATURES
COMPRESSOR SPEED
SYS 1 SYS 2 SYS 3 SYS 4
SYS 1 SYS 2 SYS 3 SYS 4
Oil Suction Discharge SAT Suction SAT Superht SAT Discharge
ºF(ºC) Speed
%
9
ºF(ºC) SYSTEM CURRENT
ºF(ºC) ºF(ºC) ºF(ºC)
SYS 1 SYS 2 SYS 3 SYS 4
Current
AMPS
SYS 1 SYS 2 SYS 3 SYS 4
Current
%FLA
ºF(ºC)
Dsch Superht
ºF(ºC)
JOHNSON CONTROLS
321
SECTION 9 - MAINTENANCE
SYSTEM OPERATING CONDITIONS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
ECONOMIZER SOLENOID STATUS
SYS 1 SYS 2 SYS 3 SYS 4
Economizer (ON/OFF)
FEED/DRAIN VALVE % OPEN SYS 1 SYS 2 SYS 3 SYS 4
Feed Valve Drain Valve
FLASH TANK LEVEL
SYS 1 SYS 2 SYS 3 SYS 4
Flash Tank
%
Level
CONDENSER FAN STAGE (0-6) SYS 1 SYS 2 SYS 3 SYS 4
Fan Stage
COMPRESSOR HEATER (ON/OFF) SYS 1 SYS 2 SYS 3 SYS 4
Comp Heater
SYSTEM RUN TIME Days Hours Mins Sec
System 1 System 2 System 3 System 4
SYSTEM STARTS STARTS
SYSTEM 1 SYSTEM 2 SYSTEM 3 SYSTEM 4
OIL SEPARATOR LEVEL
Check Oil Separator Oil Levels
SYS 1
Separator
#1 #2
Oil Level Top Glass
Oil Level Bot Glass
SYS 3
Separator
#1 #2
Oil Level Top Glass
Oil Level Bot Glass
SYS 2 #3 #4
SYS 4 #3 #4
Oil Separator level should be maintained so that an oil level is between the upper and lower sight glasses.
322
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
WATER SYSTEM CONDITIONS
EVAPORATOR FLOW
Flow Rate
GPM
Evap Pressure Drop
FT / LBS (Circle One)
Glycol Freeze Point
ºF (ºC)
SECTION 9 - MAINTENANCE
CONDENSER CONDITIONS
AIR TEMPERATURE
Air ON Temperature
ºF (ºC)
Air OFF Temperature
ºF (ºC)
JOHNSON CONTROLS
9
323
SECTION 9 - MAINTENANCE
RECOMMENDED SPARE PARTS
DESCRIPTION
MODEL NUMBER YCIV
Fan Motor
-40
(Standard Low Noise)
-46
Fan Motor
-40
(Optional Ultra Low Noise)
-46
Fan Blade (Standard Low Noise)
ALL
Fan Blade (Optional Ultra Low Noise)
ALL
Core, Dehydrator
ALL
Oil, Compressor (Type "L")
R-134a
Sensor, Outside Air Temperature
ALL
Transducer, Pressure (0-275 psig)
ALL
High Pressure Cutout (297 psig)
ALL
Transducer, Suction Pressure (0-125 psig)
ALL
Sensor, EWT, LWT
ALL
Relay Output Board
ALL
VSD Logic Board Kit
ALL
Controller, Valve
ALL
SCR Trigger Board
60 HZ YCIV
Chiller Control Board
ALL
Level Sensor
ALL
Feed Drain Valve
ALL
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
PART NUMBER 024-27322-004 024-27322-007 024-34980-005 024-34980-001 026-41594-000 026-41942-000 026-37450-000 011-00592-000 026-28663-001 025-29139-003 025-39456-000 025-29583-001 025-40334-000 031-02479-002 031-02507-601 031-02742-000 031-02060-001 031-02478-002 025-40274-000 025-41565-000
324
JOHNSON CONTROLS
FORM 201.23-NM2 ISSUE DATE: 09/30/2019
NOTES
JOHNSON CONTROLS
325
5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 Copyright © by Johnson Controls 2019
Form 201.23-NM2 (919) Issue Date: September 30, 2019 Supersedes: 201.23-NM2 (418)
1-800-524-1330 www.johnsoncontrols.com
Subject to change without notice. Printed in USA ALL RIGHTS RESERVED
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