Page 1 CENTRIFUGAL LIQUID CHILLERS WITH OPTIVIEW CONTROL CENTER SERVICE INSTRUCTIONS Supersedes: 160.54-M1 (319) Form 160.54-M1 (1019) 4/6/2020 OPTIVIEW CONTROL CENTER MODEL YK (THROUGH STYLE G) Issue Date: October 25, 2019 This is a company confidential document and is for Johnson Controls eyes only.
Page 2 FORM 160.54-M1 ISSUE DATE: 10/25/2019 IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or During rigging, installation, operation, maintenance, death to themselves and people at the site. or service, individuals may be exposed to certain com- This document is intended for use by owner-authorized ponents or conditions including, but not limited to:...
Page 3 FORM 160.54-M1 ISSUE DATE: 10/25/2019 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls’ policy for con- regarding the applicability of these documents, rig- tinuous product improvement, the information con- ging, lifting, and operating/service personnel should tained in this document is subject to change without verify whether the equipment has been modified and notice.
Page 4: Table 1 - Control Panel Applications
FORM 160.54-M1 ISSUE DATE: 10/25/2019 NOMENCLATURE – STYLE (Design Level) MOTOR CODE POWER SUPPLY – for 60Hz 5 for 50Hz COMPRESSOR CODE* CONDENSER CODE* EVAPORATOR CODE* * Refer to YK Engineering Guide (Form 160.75-EG1) for MODEL* Shell/Motor/Compressor combinations. TABLE 1 - CONTROL PANEL APPLICATIONS PART NUMBER DESCRIPTION 371-02264-101...
Page 5: Table Of Contents
SECTION 13 - SOLID STATE STARTERS ......................133 Solid State Starters ............................133 Medium Voltage Solid State Starter ......................133 SECTION 14 - ADAPTIVE CAPACITY CONTROL BOARD ................143 YORK Protocol Configuration ........................143 Modbus Protocol Configuration ........................149 SECTION 15 - PROXIMITY PROBE ........................157 JOHNSON CONTROLS...
Page 6 FORM 160.54-M1 ISSUE DATE: 10/25/2019 TABLE OF CONTENTS (CONT'D) SECTION 16 - HIGH SPEED THRUST BEARING LIMIT SWITCH ..............163 SECTION 17 - REFRIGERANT LEVEL CONTROL .....................165 Automatic Operation ............................. 165 Manual Operation ............................167 Actuators ..............................167 SECTION 18 - OIL PUMP VARIABLE SPEED DRIVE ..................171 Automatic Operation .............................
Page 7 FORM 160.54-M1 ISSUE DATE: 10/25/2019 TABLE OF CONTENTS (CONT'D) SECTION 27 - LARGE TONNAGE CHILLER (LTC) I/O BOARD 031-02895-000/001 ........231 Digital Inputs ..............................231 Digital Outputs .............................. 233 Analog Inputs ............................... 234 Analog Outputs ............................. 235 Auto Detection ............................. 236 Diagnostic Screen ............................
Page 8 FORM 160.54-M1 ISSUE DATE: 10/25/2019 TABLE OF CONTENTS (CONT'D) Oil Return Min .............................. 283 Standby Lubrication ............................283 High Condenser Pressure Warning Threshold ..................... 283 Brine Low Evaporator Pressure Cutout ......................284 Leaving Chilled Liquid Temperature Control Sensitivity ................284 Drop Leg Refrigerant Temperature .......................
Page 9 FORM 160.54-M1 ISSUE DATE: 10/25/2019 TABLE OF CONTENTS (CONT'D) SI0058 - Software Enhancements Effective February 2003 ................ 340 SI0062 - Software Enhancements Effective March 2003 ................342 SI0080 - Software Enhancements Effective January 2004 ................343 SI0089 - Software Enhancements Effective May 2004 ................345 SI0148 - Software Enhancements Effective June 2006 ................
Page 10 FIGURE 4 - OptiView Control Center - Medium Voltage Solid State Starter Applications ........25 FIGURE 5 - OptiView Control Center - Compressor Motor Variable Speed Drive (YORK Serial Communications Protocol) ....................26 FIGURE 6 - OptiView Control Center - Compressor Motor Variable Speed Drive (Modbus Serial Communications Protocol) ..................27...
Page 11 FIGURE 57 - Style B Liquid Cooled Solid State Starter (LCSSS) – Interface (YORK Protocol) ........137 FIGURE 58 - Style B Liquid Cooled Solid State Starter (LCSSS) – Interface (YORK Protocol) ......137 FIGURE 59 - Style B Liquid Cooled Solid State Starter (LCSSS) – Interface (Modbus Protocol) ........138 FIGURE 60 - Solid State Starter Logic Board .......................138...
Page 12 FORM 160.54-M1 ISSUE DATE: 10/25/2019 LIST OF FIGURES (CONT'D) FIGURE 104 - Motor Cooling Coil Leak Detector – Float Sensor .................267 FIGURE 105 - Motor Cooling Coil Leak Detector – Optical Sensor ..............268 FIGURE 106 - Diagnostics Screen ........................306 FIGURE 107 - Serial/SD Screen ...........................307 FIGURE 108 - Main Diagnostics ...........................308 FIGURE 109 - Motor Monitoring Board Diagnostic Screen ...................309 FIGURE 110 - I/O Board Diagnostic Screen ......................
Page 13 FORM 160.54-M1 ISSUE DATE: 10/25/2019 LIST OF TABLES TABLE 1 - Control Panel Applications ........................4 TABLE 2 - Boot-up LED Indicators .........................33 TABLE 3 - Addresses and Associated Data ......................34 TABLE 4 - Diagnostic Display Codes ........................50 TABLE 5 - Multiplexer Channels ..........................53 TABLE 6 - Summary of Differences ........................62 TABLE 7 - Microboard .............................62 TABLE 8 - Diagnostic Display Codes ........................74...
Page 14 FORM 160.54-M1 ISSUE DATE: 03/11/2019 THIS PAGE INTENTIONALLY LEFT BLANK JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS...
Page 15: Section 1 - Introduction
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 1 - INTRODUCTION This document explains the operation of the printed cir- display. The appropriate diagrams for each chiller are cuit boards and major components of the OptiView™ shown in the associated literature table in the front Control Center to a level that allows a service technician of this manual.
Page 16 FORM 160.54-M1 ISSUE DATE: 03/11/2019 THIS PAGE INTENTIONALLY LEFT BLANK JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS...
Page 17: Section 2 - System Architecture
Each starter type requires a differ- Electromechanical Starters, Solid State Starters ent board as follows: and YORK Variable Speed Drives. • Electromechanical Starter – CM-2 Current Module. The OptiView Control Center is a microprocessor based control system that receives analog, digital and •...
Page 18 FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE ISSUE DATE: 10/25/2019 The microprocessor and all supporting logic circuits, The software versions (C.MLM.01.xx.yzz, C.OPT.01. along with the memory devices containing the operat- xx.yzz) or Y.OPT.01.xx.yzz are alphanumeric codes ing program, reside on the microboard. All chiller op- that are interpreted as follows.
Page 19 FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE ISSUE DATE: 10/25/2019 A front panel-mounted keypad allows operator and ser- The operating principle of the sensor is thermal con- vice technician user interface. Membrane keys are used ductivity. It uses the cooling effect of a flowing liquid to display chiller and system parameters, enter set- to sense flow.
Page 20 C.OPT.01.16.xxx (or later). When the compressor motor is driven by a YORK solid Serial data interface to the Building Automation Sys- state starter, one of three different starters could be ap- tem (BAS) is through the optional E-Link Gateway.
Page 21 FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE ISSUE DATE: 10/25/2019 Stall noise is detected as gas pressure pulsations. A After July 2009, chillers that are equipped for the hot stall pressure transducer, mounted in the discharge gas bypass, heat recovery or head pressure control op- scroll of the compressor, detects the gas pressure pul- tions are equipped with a Large Tonnage Chiller (LTC) sations and outputs DC voltage pulsations to the stall...
Page 22: Figure 1 - Optiview Control Center - Electromechanical Starter Applications
FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE ISSUE DATE: 10/25/2019 FIGURE 1 - OPTIVIEW CONTROL CENTER - ELECTROMECHANICAL STARTER APPLICATIONS JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 23: Figure 2 - Optiview Control Center - Mod A Solid State Starter Applications
FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE ISSUE DATE: 10/25/2019 FIGURE 2 - OPTIVIEW CONTROL CENTER - MOD A SOLID STATE STARTER APPLICATIONS JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 24: Figure 3 - Optiview Control Center - Mod B Solid State Starter Applications
FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE ISSUE DATE: 10/25/2019 FIGURE 3 - OPTIVIEW CONTROL CENTER - MOD B SOLID STATE STARTER APPLICATIONS JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 25: Figure 4 - Optiview Control Center - Medium Voltage Solid State Starter Applications
FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE ISSUE DATE: 10/25/2019 FIGURE 4 - OPTIVIEW CONTROL CENTER - MEDIUM VOLTAGE SOLID STATE STARTER APPLICATIONS JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 26: Figure 5 - Optiview Control Center - Compressor Motor Variable Speed Drive (York Serial Communications Protocol)
FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE ISSUE DATE: 10/25/2019 FIGURE 5 - OPTIVIEW CONTROL CENTER - COMPRESSOR MOTOR VARIABLE SPEED DRIVE (YORK SERIAL COMMUNICATIONS PROTOCOL) JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 27: Figure 6 - Optiview Control Center - Compressor Motor Variable Speed Drive
FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE ISSUE DATE: 10/25/2019 FIGURE 6 - OPTIVIEW CONTROL CENTER - COMPRESSOR MOTOR VARIABLE SPEED DRIVE (MODBUS SERIAL COMMUNICATIONS PROTOCOL) JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 28: Figure 7 - Optiview Control Center - Compressor Motor Medium Voltage Variable Speed Drive
FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE ISSUE DATE: 10/25/2019 FIGURE 7 - OPTIVIEW CONTROL CENTER - COMPRESSOR MOTOR MEDIUM VOLTAGE VARIABLE SPEED DRIVE JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 29: Figure 8 - Operation Sequence Timing Diagram (Electromechanical And Solid State Starter Applications)
FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE ISSUE DATE: 10/25/2019 TIMING DIAGRAM – CHILLERS EQUIPPED WITH FIXED SPEED OIL PUMP (STYLE C) DISPLAY AUTO ZEROING DIFFERENTIAL MESSAGE OIL PRESSURE TRANSDUCERS "SYSTEM RUN" ENERGIZE (OPEN) HIGH SPEED THRUST SOLENOID ENERGIZE (OPEN) LIQUID LINE, VENT LINE "SYSTEM PRELUBE"...
Page 30: Figure 9 - Operation Sequence Timing Diagram (Compressor Motor Variable Speed Drive Applications)
FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE ISSUE DATE: 10/25/2019 TIMING DIAGRAM – CHILLERS EQUIPPED WITH FIXED SPEED OIL PUMP (STYLE C) DISPLAY AUTO ZEROING DIFFERENTIAL MESSAGE OIL PRESSURE TRANSDUCERS "SYSTEM RUN" ENERGIZE (OPEN) HIGH SPEED THRUST SOLENOID ENERGIZE (OPEN) LIQUID LINE*, VENT LINE "SYSTEM PRELUBE"...
Page 31: Section 3 - Microboard 031-01730-000
Card, which is a type of non-volatile memory that can be read from or written to, but requires the locations to * Refer to YORK Renewal Parts List 160.54-RP1 for available languages. be erased before they are written to. With the exception...
Page 32 U45. This EPROM is replace- Each time they are revised, a Service Information Bul- able. Refer to YORK Renewal Parts - OptiView Control letin is issued that describes the new features. Those Center (Form 160.54-RP1). The EPROM version is an...
Page 33: Boot-Up Step And Description
It is a replaceable The Flash memory card checksum is calculated part. Refer to YORK Renewal Parts - OptiView Con- and compared to the checksum value that is stored trol Center (Form 160.54-RP1). It is located in socket in the Card at the time the Card was initially pro- location U52.
Page 34: Table 3 - Addresses And Associated Data
The Solid State Starter Logic Board returns a value YORK factory. Some jumpers are plastic sleeves with more than 0.41 VDC to +5 VDC. If the value is less metal inserts that are inserted over 2-prong or 3-prong than 0.4 VDC, it indicates the starter is an Electro-...
Page 35 FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 ISSUE DATE: 10/25/2019 Style B Solid State Starter or Variable Speed Digital Outputs Drive Interface The microboard controls 115 VAC relays and solenoids If equipped with either of these drives, the drive is in- via the I/O Board (via J19).
Page 36 FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 ISSUE DATE: 10/25/2019 Style F (and later) chillers are supplied with factory- Software version C.MLM.01.08.xxx (and later) allows mounted flow sensors on the evaporator and condenser either the Thermal-Type sensors connected to the mi- (Software version C.MLM.01.07.xxx (and later) is re- croboard Analog Inputs or the Paddle-Type sensor con- quired for this feature.
Page 37 FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 ISSUE DATE: 10/25/2019 • CR11 RX2 – COM2 serial port receive data. The microboard controls the Display Backlight via J6. The Display Backlight is the light source for the • CR16 TX2 – COM2 serial port transmit data. display.
Page 38: Power Supply
FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 ISSUE DATE: 10/25/2019 POWER SUPPLY The Lamp Dimmer is an integrated circuit that is the electrical equivalent of a 10K ohm potentiometer with The microboard receives 3 supply voltages (Microboard 100 positions or steps (See Figure 20 on page 68). J1) from the Power Supply;...
Page 39 FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 ISSUE DATE: 10/25/2019 LD07776 FIGURE 10 - MICROBOARD 031-01730-000 JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 40: Figure 11 - Flash Memory Card
FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 ISSUE DATE: 10/25/2019 MEMORY CARD SOCKET MEMORY CARD - ELASTOMERIC CONNECTOR TOP SURFACE AUGAT LD06855 TOP SURFACE MEMORY CARD PRESS DOWN LD04047 RETAINER CLIP TO RELEASE CARD MEMORY CARD - BOTTOM SURFACE WRITE PROTECT SWITCH (OPTIONAL) (MUST BE IN "ENABLED POSITION") PAD 60 PAD 31...
Page 41: Figure 12 - Microboard (031-01730-000) Power Supply Test Points
FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 ISSUE DATE: 10/25/2019 + 12VDC + 12VDC VOLTAGE + 5VDC (ANALOG) FROM POWER + 5VDC (DIGITAL) SUPPLY + 5VDC VOLTAGE + 3.3VDC *REV "E" and later boards only. -12 VDC LD09564 FIGURE 12 - MICROBOARD (031-01730-000) POWER SUPPLY TEST POINTS JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 42: Program Jumpers
FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 ISSUE DATE: 10/25/2019 PROGRAM JUMPERS JP1 - Watchdog enable/disable. The position of this Pins 1-2: +12 VDC. SHARP LQ10D367/368 jumper, in conjunction with Program switch and LQ10D421, NEC NL6448AC33-24 and SW 1 position 12 enables or disables the pro- LG Semicon LP104V2-W displays.
Page 43 FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 ISSUE DATE: 10/25/2019 JP33 - PC-104 Port DMA acknowledge assignment. JP24 - Remote Leaving Chilled Liquid Temp setpoint (J22) type. Configures Analog Input for 0 to 10 Assigns selected PC-104 DMA acknowledge VDC, 2 to 10 VDC, 0-20mA or 4 to 20mA. to PDACK1 on the microprocessor.
Page 44: Program Switches
FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 ISSUE DATE: 10/25/2019 JP40 - Not used. Prerun - Determines the duration of the system pre-lube period. JP43, JP44 – Display Controller (U29) type (rev E ON: Extended prerun system pre-lube period is (and later) boards only)).
Page 45: Figure 13 - Microboard Lamp Dimmer Circuit
Severe compressor or chiller damage MULTIUNIT CYCLING - CONTACTS OPEN could result. The ability to disable the AND SYSTEM CYCLING - CONTACTS watchdog protection is provided for YORK OPEN. factory testing only. OFF: Standard operation. Contacts open at completion of System Coastdown after all ON: Watchdog protection enabled.
Page 46: Figure 14 - Microboard Serial Data Communications Ports
FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 ISSUE DATE: 10/25/2019 TX RX CR3 CR2 RS-232 MICRO COM 1 PRINTER COM 4B (NOTE 1) MICRO- GATEWAY TX RX CR12 CR13 RS-485 COM 4A JP27 (NOTE 1) NOT USED + 5VDC SHIELD TX RX CR16 CR11 RS-232...
Page 47: Figure 15 - Configurable Analog And Remote Setpoint Inputs
FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 ISSUE DATE: 10/25/2019 FACTORY MOUNTED EVAPORATOR 71.5 K THERMAL-TYPE FLOW SENSOR (style F and later chillers) (note 2) JP21 7.5 K 24 VAC FACTORY MOUNTED CONDENSER THERMAL-TYPE FLOW SENSOR (style F and later chillers) (note 2) JP22 24 VAC REMOTE CURRENT...
Page 48 FORM 160.54-M1 ISSUE DATE: 03/11/2019 THIS PAGE INTENTIONALLY LEFT BLANK. JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS...
Page 49: Section 4 - Microboard 031-02430-000 And 031-02430-001
These upgrades are The BIOS (Basic Input Output System) EPROM (U37) necessary for the following applications that require contains the boot-up program. The YORK part number RS-485 Modbus communications to the microboard: is 031-02429-001 and is used in both the 031-02430- •...
Page 50: Table 4 - Diagnostic Display Codes
FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 TABLE 4 - DIAGNOSTIC DISPLAY CODES PASS DISPLAY ON TEST FAIL ACTION WHITE SCREEN CODE First init table complete watchdog will cause reboot SDRAM Regs. Configured watchdog will cause reboot Switch to Protected Mode watchdog will cause reboot Jump to 32-bit code...
Page 51 Time of Day and Calendar Data is stored here. The • Storage temperature range is -20 to 65°C (-4 to YORK Part number is printed on a label adhered to 149°F) the surface of the BRAM. It is available from the Bal- A label adhered to the Program card contains the version timore Parts Distribution Center as a replacement part.
Page 52 PANEL – POWER FAILURE is displayed. components and thus are determined by the YORK fac- The Watchdog Circuit also ensures that the entire pro- tory. The jumpers are plastic sleeves with metal inserts gram is being executed and that the program has not that are inserted over 2-prong or 3-prong conductors.
Page 53: Table 5 - Multiplexer Channels
FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 Keypad Interface The keypad is read via J18. The keypad is a matrix of multiplexer. A 0 to 5 VDC analog value is returned conductors arranged in rows and columns (See Figure from each channel.
Page 54 After March 2007, new production Variable Speed nicate with Microboard 031-02430-000 via the Opto- Drives communicate with Microboard 031-02430-001 coupled COM5 serial data port (J15) using YORK pro- via COM2 serial data port (J13) using RS-485 Modbus prietary protocol. The serial data is represented by +5 protocol.
Page 55 FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 Digital inputs Medium Voltage Solid State Starter (MV SSS) and Medium Voltage Variable Speed Drive The I/O Board converts the 115 VAC inputs to logic Interface (MV VSD) level inputs for the microboard at J19.
Page 56 FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 Style "F" (and later) chillers are supplied with factory- The software accommodates either the Paddle type mounted Flow Sensors on the evaporator and condenser. sensors connected to the TB4 of the I/O Board or the These are electronic thermal-type sensors.
Page 57 FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 try standard 0 VDC and +1.5 to +5 VDC logic levels. During the boot-up, the program in the BIOS EPROM COM5 logic levels are 0 VDC and +5 VDC. A diag- reads wire jumpers PID0 through PID3 on the Display nostic test can be performed on each serial port to con- Interface Board to determine the manufacturer of the...
Page 58: Configuration And Setup
44/45) operation when chiller shuts down on cycling The Anti-recycle timer must never be shutdowns. Selections are: disabled unless advised by YORK factory. 1. Standard – Contacts open at completion of System Coastdown after all shutdowns except LEAVING CHILLED LIQUID – LOW TEMPERATURE.
Page 59 Drive Oil Pump have a Program controlled Oil Heater and a different complement of solenoid valves than 1. YORK – Enables COM 5 (J15) serial port. On chillers equipped with a Fixed Speed Oil Pump. A de- Variable Speed Drive applications, used when the...
Page 60 FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 Starter applications, used when the microboard Coastdown Time (software version C.OPT.01.16.307 is interfaced to the LCSSS Logic/Trigger Board and later) – Only appears when STANDARD is select- TB2. ed for the Coastdown setpoint.
Page 61 If the microboard is replaced within the warranty pe- is enabled on the OPERATIONS Screen or Motor riod, the defective board must be returned to YORK Drive Type setpoint is set to VSD or MVVSD. The per the warranty return procedure. Use the return in-...
Page 62: Figure 16 - Bram Socket
FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 a 031-02430-000 board can be transferred to a 031- TABLE 6 - SUMMARY OF DIFFERENCES 02430-001 board. This can be useful when it is desired 031-02430-000 031-02430-001 to transfer a BRAM from one board to another to save stored setpoint, History or Sales Order data.
Page 63: Downloading A Program From Aprogram Card
FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 DOWNLOADING A PROGRAM FROM A PROGRAM CARD The Program card Write Protect Switch 3. Reposition Microboard Program Jumper JP6 to must be in the “Write Protect” position! pins 2 and 3 (left-hand pins). 4.
Page 64: Program Jumpers
FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 At the completion of the re-programming process, Pins 2-3: VDC/0 SHARP if it is successful, “Flash Has Been Successfully LQ10D367/368 (031-01774-000), SHARP Programmed” is displayed and “Operation Suc- LQ104V1DG61 (031-02886-000) and LG Semi- cessful”...
Page 65: Program Switches
FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 JP13 – Watchdog Enable/Disable. Soldered wire OUT: Allows 0 to 10 VDC or 2 to 10 VDC in- jumper. put on J22-1. Pins 1-2: Allows a 0 to 20mA or 4 to 20mA Never disable the watchdog protection.
Page 66: Figure 17 - Microboard 031-02430-000 And 031-02430-001
FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 BRAM BIOS EPROM PROGRAM SWITCHES PROGRAM DOWNLOAD CONNECTOR BOOT-UP LED STATUS DISPLAY = Jumpers = Test Points = L.E.D. = Switches LD09254a FIGURE 17 - MICROBOARD 031-02430-000 AND 031-02430-001 JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 67: Figure 18 - Program Card 031-02474-001
FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 SWITCH IN "WRITE" POSITION END OF CARD 031-02474-001 SWITCH IN "WRITE PROTECT" POSITION FIGURE 18 - PROGRAM CARD 031-02474-001 J1-8 Not Used - 12 VDC J1-4 + 12 VDC TP10 2.5 VDC J1-3...
Page 68: Figure 20 - Microboard Lamp Dimmer Circuit
FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 5.0 VDC BRIGHTNESS CONTROL (+) OR (N.C.) BACKLIGHT 10 K BRIGHTNESS CONTROL (WIPER) INVERTER BOARD BRIGHTNESS CONTROL (-) LD04054 NOTES: 1. J6-6 not connected (N.C.) to Backlight Inverter Board when display is manufactured by Sharp or NEC. 2.
Page 69: Figure 21 - Microboard Serial Data Communications Ports
HOT GAS BYPASS COM 3 + 5VDC HEAT RECOVERY HEAD PRESSURE CONTROL SHIELD MOTOR MONITORING CR20 CR19 TX5 RX5 OPTO-COUPLE YORK PROTOCOL- COM 5 COMMON VSD ADAPTIVE CAPACITY NOTE 2 CONTROL BOARD OR NOTE 2 STYLE B LCSSS LD15644 NOTES: 1.
Page 70: Figure 22 - Configurable Analog And Remote Setpoint Inputs
FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 FACTORY MOUNTED EVAPORATOR 71.5 K THERMAL-TYPE FLOW SENSOR (note 2) (note 3) (style F and later chillers) (note 2) JP21 7.5 K 24 VAC FACTORY MOUNTED CONDENSER THERMAL-TYPE FLOW SENSOR (note 2) (style F and later chillers) (note 2) JP22...
Page 71: Figure 23 - Configurable Analog And Remote Setpoint Inputs (Heat Pump Duty)
FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 71.5 K LEAVING CHILLED LIQUID TEMPRERATURE JP21 THERMISTOR See Note 1 7.5 K JP22 REMOTE CURRENT 0-10 VDC / LIMIT SETPOINT 2-10 VDC 0-20 mA / 4-20 mA JP23 REMOTE LEAVING 0-10 VDC /...
Page 72: Figure 24 - Low Voltage Digital Inputs
FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 ISSUE DATE: 10/25/2019 Factory Mounted Evaporator Thermal-Type Flow Sensor (note 1) 24VAC Factory Mounted Condenser Thermal-Type Flow Sensor (note 1) 24VAC Factory Mounted Heating Condenser Thermal-Type Flow Sensor (note 1) 24VAC LD12827a NOTE: 1.
Page 73: Section 5 - Microboard 031-03630-001
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 5 - MICROBOARD 031-03630-001 Microboard 031-03630-001 is supplied in new produc- The +12 VDC (fused by F2) can be monitored at TP5 tion YK chillers starting in June of 2015. Although and TP4 in reference to TP1 GND. It is applied to a +5 this board uses a different microprocessor and sup- VDC regulator and the output of the regulator is the +5 porting components, the chiller control and operator...
Page 74: Chiller Operating Program
DIP 4 ON - Boot from SD card Failed NOTE: If the display stops at a 01 display, this may be an indication that the SD card reader is defective. If the display stops at the YORK logo with a white screen, this indicates that the board has no program to boot from.
Page 75 FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 Parts Distribution Center (PDC). There is a Program C.OPT . nn.nn .nnn card for each chiller type (YT, YK, YS, YR, YD, etc) Language Package revision level and each has a unique part number. A label affixed to (00,01,etc) the Program card contains the part number and ver- Language Package (0=English...
Page 76 Watchdog circuit every time the complete of components and thus are determined by the YORK program has been executed. Since it takes less than 1 factory. The jumpers are plastic sleeves with metal in-...
Page 77: Program Jumpers
FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 PROGRAM JUMPERS JP10* – Factory mounted thermal flow senor – evapo- When replacing a 02430 microboard with a 03630, use the same jumper positions for rator. Heat recovery chillers and new produc- the jumpers marked with an *. tion chillers after June 2009.
Page 78: Program Switches
FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 JP21* – Factory mounted evaporator thermal-type JP29 – Applies a pull-down voltage to the COM5B - flow sensor. terminal. Pins 1-2: Not used. IN: Not used. Pins 2-3: Factory mounted evaporator Ther- OUT: Normal position.
Page 79: Table 9 - Multiplexer Channels
FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 Keypad Interface A 0 to 5 VDC analog value is returned from each chan- The keypad is read via J18. The keypad is a matrix of nel. The function of each is in Table 9 on page 79. conductors arranged in rows and columns (See Figure 50 on page 124 and Figure 51 on page 125).
Page 80 Opto-coupled COM5 serial data port (J15) us- Motor Communications Protocol setpoint. The selec- ing YORK proprietary protocol. The serial data is rep- tions are Modbus or “York”. When Modbus is select- resented by +5 VDC and 0 VDC logic levels. TX data ed, the Motor Node ID setpoint must be set to match to the starter is at J15-1.
Page 81 FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 Bits, Parity and Stop Bits must be programmed on the Board. It turns it OFF by applying a logic high (greater COMMS Screen. Other printer setup is performed on than 4 VDC). See SECTION 6 - I/O BOARD of this the Printer Screen.
Page 82 FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 relay output is turned OFF, resulting in no conduction try standard o VDC and +1.5 VDC to +5 VDC logic through the load resistor. This applies less than 1 VDC levels.
Page 83 FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 During the boot-up, the program in the FeRAM reads voltage to vary the brightness; others require a variable wire jumpers PID0 through PID3 on the Display In- resistance. Program Jumpers JP7 and JP8 must be con- terface Board to determine the manufacturer of the figured to enable the appropriate technique.
Page 84: Configuration And Setup
AND RESET PROCEDURES of this manual. been running. The Anti-recycle timer must never be Chilled Liquid Pump Operation – Determines disabled unless advised by YORK factory. Chilled Liquid Pump control contacts (I/O Board TB2- 44/45) operation when chiller shuts down on cycling shutdowns. Selections are: 1.
Page 85 Chiller Style/Compressor setpoint on the OPERATIONS Screen. Refer to the Chiller 1. YORK – Enables COM 5 (J15) serial port. On Style/Compressor setpoint. Variable Speed Drive applications, used when the...
Page 86 If the microboard is replaced within the warranty pe- Vanes potentiometer, regardless of other options. This riod, the defective board must be returned to YORK setpoint allows the software to be used in all YK chill- per the warranty return procedure. Use the return in- ers, whether equipped with the potentiometer or not.
Page 87 FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 Microboard 031-03630-001 is supplied as replacement site of where it was on the 02430 board. It is now part after June 2015. This board is backwards compat- on the left side of J20. Connect the White wire to ible to YK chillers presently using the 031-01730-000, terminal 1 of J20, the Red to terminal 2 and the 031-02430-000 or 031-02430-001 Microboards.
Page 88: Downloading A Program From Aprogram Card
FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 DOWNLOADING A PROGRAM FROM A PROGRAM CARD There are 3 steps to the re-programming 4. Restore power to OptiView Control Center. A process: Erase, Program and Verification. white screen appears displaying “Flash Check- Once the re-programming process is initi- sum Test”...
Page 89 FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 At the completion of the re-programming pro- 9. Remove Program card from Microboard connec- cess, if it is successful, “Flash Has Been Success- tor J26 by lightly pushing the SD card in and then fully Programmed”...
Page 90: Figure 25 - Microboard 031-03630-001
FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 SD CARD SLOT From Power Supply TP35 TP14 TP33 TP32 TP12 CR61 +12V Power Out -12V +12V +24V Smarc Module +3.3V RED (J9) E-Link Power COM3 BLK (J9) TP11 -12V +12V +24V CR53...
Page 91: Figure 26 - Program Card 031-03601-001
FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 031-03601-001 Y.OPT.01.01.308 FIGURE 26 - PROGRAM CARD 031-03601-001 +5.0V Load to Switch Baseboard Measure the power supply voltages with a Digital Volt Meter in reference to Ground at TP1 or TP11. TEST VOLTAGE VOLTAGE RANGE...
Page 92: Figure 28 - Microboard Lamp Dimmer Circuit
FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 5.0 VDC BRIGHTNESS CONTROL (+) OR (N.C.) BACKLIGHT 10 K BRIGHTNESS CONTROL (WIPER) INVERTER BOARD BRIGHTNESS CONTROL (-) LD04054 NOTES: 1. J6-6 not connected (N.C.) to Backlight Inverter Board when display is manufactured by Sharp or NEC. 2.
Page 93: Figure 29 - Microboard Serial Data Communication Ports
COM 3 + 5VDC HEAT RECOVERY HEAD PRESSURE CONTROL SHIELD MOTOR MONITORING CR45 CR47 TX5 RX5 OPTO-COUPLE YORK PROTOCOL- COM 5 COMMON VSD ADAPTIVE CAPACITY NOTE 2 CONTROL BOARD OR NOTE 2 STYLE B LCSSS LD19556 FIGURE 29 - MICROBOARD SERIAL DATA COMMUNICATION PORTS...
Page 94: Figure 30 - Configurable Analog And Remote Setpoint Inputs
FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 FACTORY MOUNTED EVAPORATOR 71.5 K THERMAL-TYPE FLOW SENSOR (style F and later chillers) (note 2) JP21 7.5 K 24 VAC FACTORY MOUNTED CONDENSER THERMAL-TYPE FLOW SENSOR (style F and later chillers) (note 2) JP22 24 VAC REMOTE CURRENT...
Page 95: Figure 31 - Configurable Analog And Remote Setpoint Inputs (Heat Pump Duty)
FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 71.5 K LEAVING CHILLED LIQUID TEMPRERATURE JP21 THERMISTOR 7.5 K JP22 REMOTE CURRENT 0-10 VDC / LIMIT SETPOINT 2-10 VDC 0-20 mA / 4-20 mA JP23 REMOTE LEAVING 0-10 VDC / CHILLED LIQUID 2-10 VDC TEMP SETPOINT...
Page 96: Figure 32 - Low Voltage Digital Inputs
FORM 160.54-M1 SECTION 5 - MICROBOARD 031-03630-001 ISSUE DATE: 10/25/2019 NOT USED Factory Mounted Evaporator Thermal-Type Flow Sensor (note 1) 24VAC Factory Mounted Condenser Thermal-Type Flow Sensor (note 1) 24VAC Factory Mounted Heating Condenser Thermal-Type Flow Sensor (note 1) 24VAC LD12827b NOTE: 1.
Page 97: Section 6 - I/O Board
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 6 - I/O BOARD I/O BOARD The I/O (input/output) Board conditions the Digi- croboard. The Digital Outputs section of the I/O Board tal inputs for the microboard and conditions the mi- contains +12 VDC coil relays that are driven by the croboard’s Digital Outputs for application to other microboard’s logic level outputs.
Page 98: Triacs
FORM 160.54-M1 SECTION 6 - I/O BOARD ISSUE DATE: 10/25/2019 TRIACS 24 VAC. As described previously in this section, Triacs Triacs are used to control the Pre-rotation Vanes ac- are turned ON to allow current to flow through the ap- tuator, Refrigerant Level Variable Orifice actuator and propriate winding to produce the desired rotation.
Page 99 FORM 160.54-M1 SECTION 6 - I/O BOARD ISSUE DATE: 10/25/2019 With software version C.OPT.01.23.307 (and later), on will close when the cycling condition clears. On safety those chiller shutdowns as per above where the contacts shutdowns, the contacts will close only after the Safety remain closed during shutdown, when a chiller restart condition clears.
Page 100 FORM 160.54-M1 SECTION 6 - I/O BOARD ISSUE DATE: 10/25/2019 K11 - Oil Pump Starter (TB 1-29/1) (Style "C" K14 - Compressor Motor Stop (stop) and earlier chillers) (TB 1-6/16) In automatic operation, contacts close 13 seconds after Contacts close coincident with the beginning of Sys- System Pre-lube is initiated.
Page 101: Figure 33 - I/O Board
FORM 160.54-M1 SECTION 6 - I/O BOARD ISSUE DATE: 10/25/2019 LD04055 FIGURE 33 - I/O BOARD JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 102: Figure 34 - I/O Board Digital Inputs
FORM 160.54-M1 SECTION 6 - I/O BOARD ISSUE DATE: 10/25/2019 TB3 - 32 OPTO- HIGH PRESSURE SAFETY COUPLER J2 - 1 MOTOR CONTROLLER SHUTDOWN TB3 - 30 STOP SWITCH (LOCAL) TB3 - 28 START SWITCH (LOCAL) VGD LIMIT SWITCH TB3 - 71 (If equipped with Variable Geometry Diffuser) TB3 - 70 OIL PUMP VSD CYCLING SHUTDOWN...
Page 103: Figure 35 - I/O Board Typical Optocoupler Circuit
FORM 160.54-M1 SECTION 6 - I/O BOARD ISSUE DATE: 10/25/2019 OPTO-COUPLER +5VDC TYPICAL (20 CKTS) J19 - 21 TB4 - X TB3 - X JI - Y NEUTRAL TB3 - 2 JI - 22/23 LD04057 FIGURE 35 - I/O BOARD TYPICAL OPTOCOUPLER CIRCUIT TB4 - X OPTO- J1 - Y...
Page 104: Figure 37 - J1 I/O Board Digital Outputs
FORM 160.54-M1 SECTION 6 - I/O BOARD ISSUE DATE: 10/25/2019 + 12 VDC + 12 VDC TB2 - 44 CHILLED WATER PUMP STARTER TB2 - 45 TB2 - 55 ANTICIPATORY ALARM TB2 - 56 TB2 - 26 REMOTE MODE READY TO START TB2 - 27 TB2 - 42 SAFETY SHUTDOWN...
Page 105 FORM 160.54-M1 SECTION 6 - I/O BOARD ISSUE DATE: 10/25/2019 (Not applicable to "P" compressors or style F and later chillers)(See Note 3) (See inset below for all others) TO I/O BOARD TB3-32 COMPRESSOR MOTOR STARTER (START) START TB1-6 COMPRESSOR MOTOR STARTER (STOP) TB1-16 OIL HEATER ON/OFF (STYLE D/E - ALL...
Page 106 FORM 160.54-M1 SECTION 6 - I/O BOARD ISSUE DATE: 10/25/2019 VARIABLE GEOMETRY DIFFUSER ACTUATOR TB1-158 (BARBER-COLEMAN) VARIABLE J1-31 GEOMETRY TRIAC DIFFUSER DRIVER OPEN TB1-159 VARIABLE GEOMETRY J1-30 TRIAC DIFFUSER DRIVER TB1-160 CLOSE FIELD * Triacs Q3 and Q4 are present on I/O Board 031-01743-002 only. 115VAC REFRIGERANT LEVEL CONTROL...
Page 107: Section 7 - Liquid Crystal Display
Although there are variations in control signal timing INVERTER BOARD that follow this section. Displays between different display manufacturers, Figure 38 on that could be provided from YORK in new chillers or page 110 depicts typical control signals. Since these as replacement parts are: control signals occur at rates greater than can be read •...
Page 108 2 to 16 CLKS before the next HSYNC pulse. Some displays use one lamp. Others use two lamps. All YORK applications operate in the Display Enable Lamps are replaceable, but not interchangeable be- Mode. The state of the ENABLE (Display Interface tween different displays.
Page 109: Backlight Lamp Replacement
The Lamp slides into the Display from left to right and light Ribbon Cable, replacement Displays are ordered is secured with a locking tab. See Figure 39 on page and supplied as a Display Replacement Kit (YORK 111. Part Number 331-01771-000) to ensure component compatibility.
Page 110: Figure 38 - Display Mounting
FORM 160.54-M1 SECTION 7 - LIQUID CRYSTAL DISPLAY ISSUE DATE: 10/25/2019 Installation New lamps may be installed as follows: 1. Slide new lamp into Display from left to right un- til lamp housing is fully inserted. 2. Secure lamp with lamp retaining screw. 3.
Page 111: Figure 39 - Liquid Crystal Display Assembly - Sharp Lq10D367/368 (031-01774-000) Display
FORM 160.54-M1 SECTION 7 - LIQUID CRYSTAL DISPLAY ISSUE DATE: 10/25/2019 BACKLIGHT BULB MOUNTING DISPLAY INTERFACE 025-40317-000 LIQUID CRYSTAL DISPLAY PLATE BOARD 031-01765-002 SHARP LQ10D368 LABEL BACKLIGHT INVERTER BOARD 031-01789-000 DISPLAY CABLE INVERTER CABLE 031-01769-000 NOTE: 031-01770-003 LD05526b 1. Configure Microboard Program Jumpers per label. 2.
Page 112: Figure 41 - Liquid Crystal Display Assembly - Lg Semicon Lp104V2-W (031-02046-000)
FORM 160.54-M1 SECTION 7 - LIQUID CRYSTAL DISPLAY ISSUE DATE: 10/25/2019 BACKLIGHT BULB MOUNTING DISPLAY INTERFACE LIQUID CRYSTAL DISPLAY 025-34564-000 PLATE BOARD 031-01765-001 LG SEMICON LP104V2-W LABEL 4564 BACKLIGHT INVERTER BOARD 031-01789-000 DISPLAY CABLE INVERTER CABLE 031-01769-000 031-01770-003 LD05525 NOTE: 1.
Page 113: Figure 43 - Liquid Crystal Display Typical Control Signal Timing
FORM 160.54-M1 SECTION 7 - LIQUID CRYSTAL DISPLAY ISSUE DATE: 10/25/2019 480 ROWS 16MS VSYNC 31US HSYNC ROW 1 ROW 2 ROW 480 COLUMNS DISPLAY DISPLAY DISPLAY ENABLE PERIOD PERIOD PERIOD 39.72 NS 640 CLKS NOTES: (25.18 1. BP = Back Porch = 4-48 CLKS MHz) 2.
Page 114: Figure 45 - Display (Sharp Lq104V1Dg61 (031-02886-000) And Lg Lp104V2-W (031-02046-000))
FORM 160.54-M1 SECTION 7 - LIQUID CRYSTAL DISPLAY ISSUE DATE: 10/25/2019 SCREW FOR LAMP REMOVAL LD14075 FIGURE 45 - DISPLAY (SHARP LQ104V1DG61 (031-02886-000) AND LG LP104V2-W (031-02046-000)) JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 115: Section 8 - Display Interface Board
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 8 - DISPLAY INTERFACE BOARD The Display Interface Board is located on the Liquid • Display Interface Board 031-01765-002 Crystal Display and is part of the microboard interface Display Applicability: to the Display. It permits the use of displays by differ- ent manufacturers, by providing the microboard with SHARP LQ10D367/368 (031-01774-000) a means of automatically determining which Display...
Page 116 FORM 160.54-M1 SECTION 8 - DISPLAY INTERFACE BOARD ISSUE DATE: 10/25/2019 • Display Interface Board 031-01765-002 Display Interface Boards are available individually for service replacement. The part number of the Display Display Applicability: Interface Board for the installed display is listed on a label attached to the display mounting plate.
Page 117: Figure 46 - Display Interface Board 031-01765-001 And 031-01765-002
FORM 160.54-M1 SECTION 8 - DISPLAY INTERFACE BOARD ISSUE DATE: 10/25/2019 FIGURE 46 - DISPLAY INTERFACE BOARD 031-01765-001 AND 031-01765-002 JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 118: Figure 47 - Display Interface Board 031-02887-000
FORM 160.54-M1 SECTION 8 - DISPLAY INTERFACE BOARD ISSUE DATE: 10/25/2019 FIGURE 47 - DISPLAY INTERFACE BOARD 031-02887-000 JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 119: Section 9 - Display Backlight Inverter Board
Jumper configuration for that particular display. Refer to the display mounting plate). However, service re- to required Program Jumper configurations for the var- placement Displays are provided in a kit (YORK P/N ious Display applications. 331-01771-000) that includes the appropriate Back-...
Page 120: Figure 48 - Display Backlight Inverter Board (Sharp Lq10D367/368 (031-01774-000) And Lg Semicon Lp104V2-W (031-02046-000))
FORM 160.54-M1 SECTION 9 - DISPLAY BACKLIGHT INVERTER BOARD ISSUE DATE: 10/25/2019 The lamp brightness is controlled by a variable volt- age signal, developed by the Lamp Dimmer circuit (See Figure 20 on page 68) on the microboard and ap- plied to the Inverter Board.
Page 121: Figure 49 - Display Backlight Inverter Board - Sharp Lq104V1Dg61 Display 031-02886-000
FORM 160.54-M1 SECTION 9 - DISPLAY BACKLIGHT INVERTER BOARD ISSUE DATE: 10/25/2019 DISPLAY BACKLIGHT INVERTER BOARD PART NUMBER: 031-02889-000 FOR: SHARP LQ104V1DG6 (031-02886-000) DISPLAYS 500 - 1400 VAC BACKLIGHT LAMP 1 RETURN 500 - 1400 VAC BACKLIGHT INVERTER LAMP 2 RETURN BOARD MICRO...
Page 122 FORM 160.54-M1 ISSUE DATE: 03/11/2019 THIS PAGE INTENTIONALLY LEFT BLANK JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS...
Page 123: Section 10 - Keypad
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 10 - KEYPAD The keypad contains touch-sensitive keys that allow the column 3 is low, then the microprocessor concludes the operator to interface with the OptiView Control Cen- key at coordinate of row 4 and column 3 is pressed. ter.
Page 124: Figure 50 - Keypad Interface
FORM 160.54-M1 SECTION 10 - KEYPAD ISSUE DATE: 10/25/2019 LD04074 CONNECTOR FIGURE 50 - KEYPAD INTERFACE JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 125: Figure 51 - Keypad
FORM 160.54-M1 SECTION 10 - KEYPAD ISSUE DATE: 10/25/2019 LD04075 LD04076 FIGURE 51 - KEYPAD JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 126 FORM 160.54-M1 ISSUE DATE: 03/11/2019 THIS PAGE INTENTIONALLY LEFT BLANK JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS...
Page 127: Section 11 - Power Supply
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 11 - POWER SUPPLY The Power Supply provides the DC power for the LCD Display and all the printed circuit boards in the OptiView Control Center. It receives a 102 VAC to 132 VAC input from an external power source and provides the following DC outputs: •...
Page 128: Figure 53 - Power Supply - Dc Power Distribution (Refer To Optiview Control Center Wiring Diagram For Wire Connections)
FORM 160.54-M1 SECTION 11 - POWER SUPPLY ISSUE DATE: 10/25/2019 FIGURE 53 - POWER SUPPLY – DC POWER DISTRIBUTION (REFER TO OPTIVIEW CONTROL CENTER WIRING DIAGRAM FOR WIRE CONNECTIONS) JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 129: Section 12 - Current Module (Cm-2)
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 12 - CURRENT MODULE (CM-2) On applications where the Compressor Motor is con- motor current reaches 105% FLA. This calibrated volt- trolled by an Electromechanical Starter, the OptiView age is applied to the Power Fault detector, Overload Control Center is equipped with a current module.
Page 130: Table 10 - Mux Address
FORM 160.54-M1 SECTION 12 - CURRENT MODULE (CM-2) ISSUE DATE: 10/25/2019 The Multiplexer (MUX) is an electronic switch with 8 As detailed in the SECTION 33 - SYSTEM CALIBRA- inputs and 1 output. The address applied to it determines TION, SERVICE SETPOINTS, AND RESET PROCE- DURES of this manual, to field calibrate potentiometer the position of the switch (i.e., which input is routed to the output).
Page 131: Figure 54 - Cm-2 Current Module (Electromechanical Starter Application)
FORM 160.54-M1 SECTION 12 - CURRENT MODULE (CM-2) ISSUE DATE: 10/25/2019 LD04079 FIGURE 54 - CM-2 CURRENT MODULE (ELECTROMECHANICAL STARTER APPLICATION) LD04080 FIGURE 55 - CM-2 CURRENT MODULE (ELECTROMECHANICAL STARTER APPLICATIONS) JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 132: Figure 56 - Cm-2 Current Module - Interface, Current Transformers, And Variable Resistors
FORM 160.54-M1 SECTION 12 - CURRENT MODULE (CM-2) ISSUE DATE: 10/25/2019 LD04081 NOTES: MOTOR (OHMS) A. Requires passing motor lead through current transformer (CT) VOLTAGE RATIO once before connecting to power supply. 65-111 200:1 B. Requires passing motor lead through CT twice before connect- R = 1.282 (CT RATIO) 112-224 350:1...
Page 133: Section 13 - Solid State Starters
Medium Voltage Solid State Starter – Service (Form 160.00-M5). • Early vintage boards use an opto-coupled inter- face with YORK protocol. Style B Serial Interface LCSSS • Later vintage boards (after mid 2008) use an RS- A complete description, theory of operation and trou- 485 interface with Modbus protocol.
Page 134 Starter Logic/Trigger Board 031-02001 (TB2) us- long as the condition exists. The open STOP contacts ing YORK protocol. See Figure 57 on page 137. interrupt the circuit to 1R causing it to de-energize, re- moving the run signal to the LCSSS. Simultaneously,...
Page 135 • Three phase line-to-line motor supply voltage tection must never be disabled unless advised by • Input Power (KW) the YORK factory. • Three phase SCR module temperature • Kilowatt Hours (KWH) Reset - This allows the accumulated KWH to be set to a desired starting •...
Page 136 FORM 160.54-M1 SECTION 13 - SOLID STATE STARTERS ISSUE DATE: 10/25/2019 lished with the Supply Line Voltage Range setpoint. received from the Logic/Trigger Board, by the value Each supply voltage application has an allowable up- programmed for the Full Load Amps setpoint. The per and lower limit.
Page 137: Figure 57 - Style B Liquid Cooled Solid State Starter (Lcsss) - Interface (York Protocol)
STOP CONTACTS 115VAC NOTES: LD04648D – “CONDOR” Power Supply; 13 – “POWER ONE” Power Supply FIGURE 57 - STYLE B LIQUID COOLED SOLID STATE STARTER (LCSSS) – INTERFACE (YORK PROTOCOL) SOLID STATE STARTER CONTROL CENTER J30 / P30 POWER +24 VDC...
Page 138: Figure 59 - Style B Liquid Cooled Solid State Starter (Lcsss) - Interface (Modbus Protocol)
FORM 160.54-M1 SECTION 13 - SOLID STATE STARTERS ISSUE DATE: 10/25/2019 SOLID STATE STARTER CONTROL CENTER J30 / P30 POWER +24 VDC SUPPLY +12 VDC MICRO BOARD 031-02430-001 031-03630-001 LCSSS LOGIC / TRIGGER BOARD RS-485 031-02505 SERIAL COMMUNICATIONS MODBUS PROTOCOL –...
Page 139 FORM 160.54-M1 SECTION 13 - SOLID STATE STARTERS ISSUE DATE: 10/25/2019 This board provides Overload, Power Fault, Fault Cur- The Starter Trigger Board monitors the Starter’s Sili- rent, Phase Rotation/Loss, and Half Phase Protection con Controlled Rectifier (SCR) Heat sink temperature. for the Compressor Motor.
Page 140: Table 11 - Microboard Multiplex Channels
FORM 160.54-M1 SECTION 13 - SOLID STATE STARTERS ISSUE DATE: 10/25/2019 Mod A Multiplexed Data Interface LCSSS A complete description, theory of operation and trou- bleshooting instructions of this LCSSS are contained in Solid State Starter (Mod A) – Operation and Main- tenance (Form 160.46-OM3.1).
Page 141: Figure 61 - Mod A Liquid Cooled Solid State Starter (Lcsss) - Interface
FORM 160.54-M1 SECTION 13 - SOLID STATE STARTERS ISSUE DATE: 10/25/2019 FIGURE 61 - MOD A LIQUID COOLED SOLID STATE STARTER (LCSSS) – INTERFACE JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 142 FORM 160.54-M1 ISSUE DATE: 03/11/2019 THIS PAGE INTENTIONALLY LEFT BLANK JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS...
Page 143: Section 14 - Adaptive Capacity Control Board
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 14 - ADAPTIVE CAPACITY CONTROL BOARD The optional YORK Variable Speed Drive (refer to Vari- Logic Board Modbus Address Switch SW3. They must able Speed Drive – Service Instructions [Form 160.00- be both set to “1”.
Page 144 FORM 160.54-M1 SECTION 14 - ADAPTIVE CAPACITY CONTROL BOARD ISSUE DATE: 10/25/2019 The VSD consists of a Power Electronics Section, There are three different commands issued from the mi- Logic Board and an optional Harmonic Filter with croboard: Harmonic Filter Logic Board, all mounted in a cabi- •...
Page 145 FORM 160.54-M1 SECTION 14 - ADAPTIVE CAPACITY CONTROL BOARD ISSUE DATE: 10/25/2019 is displayed. The VSD Logic and Harmonic Filter • DC Link Current Boards send the data listed below to the ACC Board • Internal Ambient Temperature and the ACC Board adds its data to it and returns all the •...
Page 146 ACC Board • 0.2 Hz every second if Leaving Chilled Liquid is used. In YORK Protocol configuration, it is Temperature greater than 0.2°F below the setpoint connected to the ACC Board (Figure 62 on page and motor current is less than 80%FLA.
Page 147 The Surge Map must never be cleared un- When the chiller is started, the speed is brought to 60Hz. less advised by the YORK factory. After it has been running for greater than 2 minutes and the Leaving Chilled Liquid Temperature is within +0.3 and –0.6°F of the Leaving Chilled Liquid Temperature...
Page 148 FORM 160.54-M1 SECTION 14 - ADAPTIVE CAPACITY CONTROL BOARD ISSUE DATE: 10/25/2019 • Delta P must make a negative transition and ex- value. Valid Point LED CR8 is illuminated as a visual ceed 3.4 psig for 100 milliseconds. indication that one or both of these conditions are in effect.
Page 149 FORM 160.54-M1 SECTION 14 - ADAPTIVE CAPACITY CONTROL BOARD ISSUE DATE: 10/25/2019 event that the ACC Board does not find on its own. At Similarly, VS XMT (CR5) and VS RCV (CR4) LED’s the instant the condition is identified as a surge event, illuminate during serial communications with the Surge LED CR9 illuminates for 2 seconds.
Page 150: Modbus Protocol Configuration
C.OPT.01.22.307 and earlier) allows the Service tech- erally, the serial communications and data transfer nician to set the Delta T (Leaving Chilled Liquid Tem- and shutdown status is as described in YORK Protocol perature minus setpoint) needed to be met to enable Configuration on page 143.
Page 151 VSD stop contacts on the VSD logic board, notifying With software version C.OPT.01.19.307 (and later), the microboard as described in YORK Protocol Con- to ensure that frequency increases do not cause exces- figuration on page 143. sive motor current resulting in overload shutdowns,...
Page 152: Figure 62 - Compressor Motor Variable Speed Drive (Vsd) Adaptive Capacity Control (Acc) Board
FORM 160.54-M1 SECTION 14 - ADAPTIVE CAPACITY CONTROL BOARD ISSUE DATE: 10/25/2019 MICROBOARD RECEIVE LED TRANSMIT (POWER FAIL) RECEIVE MICRO BOARD TRANSMIT MANUAL SURGE POINT SWITCH SURGE MICRO VALID SURGE POINT (GND) LD04084 BRAM EPROM (+5 VDC) FIGURE 62 - COMPRESSOR MOTOR VARIABLE SPEED DRIVE (VSD) ADAPTIVE CAPACITY CONTROL (ACC) BOARD JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 153: Figure 63 - Serial Communications Interface - York Protocol
ISSUE DATE: 10/25/2019 ADAPTIVE CAPACITY MICROBOARD VSD LOGIC BOARD CONTROL BOARD 031-02430-000 031-01782 031-01730-000 031-01433 COND PRESSURE 031-02077 031-02506 EVAP PRESSURE COM 5 OPTO-COUPLE POSITION LD12567 FIGURE 63 - SERIAL COMMUNICATIONS INTERFACE – YORK PROTOCOL JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 154: Figure 64 - Serial Communications Interface - Modbus Protocol
FORM 160.54-M1 SECTION 14 - ADAPTIVE CAPACITY CONTROL BOARD ISSUE DATE: 10/25/2019 MICROBAORD VSD LOGIC BOARD 031-03630-001 031-02506 031-02430-001 COM 5 OPTO-COUPLE COM 2 RS-485 +12 VDC 22 10 POSITION LD12569 FIGURE 64 - SERIAL COMMUNICATIONS INTERFACE – MODBUS PROTOCOL JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 155: Figure 65 - Adaptive Capacity Control (Acc) Board
FORM 160.54-M1 SECTION 14 - ADAPTIVE CAPACITY CONTROL BOARD ISSUE DATE: 10/25/2019 FIGURE 65 - ADAPTIVE CAPACITY CONTROL (ACC) BOARD JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 156 FORM 160.54-M1 ISSUE DATE: 10/25/2019 THIS PAGE INTENTIONALLY LEFT BLANK. JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 157: Section 15 - Proximity Probe
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 15 - PROXIMITY PROBE The following applies to all applications except P com- tion. Since this Reference Position value is stored in the pressors and style F (and later) chillers with “G, Q” or BRAM (U52) memory device on the microboard, field “H5-8”...
Page 158 FORM 160.54-M1 SECTION 15 - PROXIMITY PROBE ISSUE DATE: 10/25/2019 On chillers equipped with Probe 025-30961-000 and For Microboard 031-01730-000, Microboard program Flash memory card version C.MLM.01.02 (and ear- jumpers JP41 and JP42 must be positioned appropri- lier), if the Drain Line Temperature increases to greater ately to provide proper operation of actual probe in- than or equal to 250.0°F (121.1°C), a safety shutdown stalled.
Page 159: Table 12 - Proximity Probes
FORM 160.54-M1 SECTION 15 - PROXIMITY PROBE ISSUE DATE: 10/25/2019 TABLE 12 - PROXIMITY PROBES PART NUMBER SUPPLY VOLTAGE DESCRIPTION Production until April 2000. Senses Proximity. Also senses High Speed Drain Line Oil Temperature unless equipped with Flash memory card 025-30961-000 +24 VDC, +5 VDC version C.MLM.01.03 or later.
Page 160: Figure 66 - Proximity Probe Interface - Probe Part Number 025-30961-000
FORM 160.54-M1 SECTION 15 - PROXIMITY PROBE ISSUE DATE: 10/25/2019 PROXIMITY / TEMP PROBE +5VDC (DRAIN LINE TEMP) DRAIN TEMP PROXIMITY +24VDC MICRO BOARD +24VDC NOTE 1 NOTE 2 +5VDC +24VDC POWER SUPPLY NOTES: 1. +24 VDC Reference for “Proximity probe - Low Supply Voltage” Cycling Shutdown. LD04090 2.
Page 161: Figure 68 - Proximity Probe Interface - Probe Part Number 025-40496-000
FORM 160.54-M1 SECTION 15 - PROXIMITY PROBE ISSUE DATE: 10/25/2019 PROXIMITY PROBE ELECTRONICS MODULE PROXIMITY PROBE PROXIMITY +24VDC MICRO BOARD +24VDC NOTE 1 NOTE 2 +24VDC POWER SUPPLY PROXIMITY PROBE TIP (025-40496-001) LD05532A ELECTRONICS MODULE W/PVC BUSHING DIN CONNECTOR (025-40496-002) (025-37805-000) PROXIMITY PROBE TIP "O RING"...
Page 162: Figure 69 - Proximity Probe
FORM 160.54-M1 SECTION 15 - PROXIMITY PROBE ISSUE DATE: 10/25/2019 2.0" + 24VDC PROBE LD06510 YORK PART NUMBER 025-30961-000 025-30961-000 2.0" + 24VDC PROBE LD05529a YORK PART NUMBER 025-35900-000 025-35900-000 and 025-35900-001 FIGURE 69 - PROXIMITY PROBE JCI COMPANY CONFIDENTIAL...
Page 163: Section 16 - High Speed Thrust Bearing Limit Switch
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 16 - HIGH SPEED THRUST BEARING LIMIT SWITCH is connected to 115 VAC. The other side connects to Chillers that are equipped with P compressors and style I/O Board TB3-81. The microboard reads the state of "F"...
Page 164: Figure 71 - High Speed Thrust Bearing Limit Switch
FORM 160.54-M1 SECTION 16 - HIGH SPEED THRUST BEARING LIMIT SWITCH ISSUE DATE: 10/25/2019 PRESSURE SWITCH GRD PIN (GRN/YEL) PINS 1 AND 2 (BLK) BREAK-AWAY PROBE GRN/YEL LD06860 FIGURE 71 - HIGH SPEED THRUST BEARING LIMIT SWITCH JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 165: Section 17 - Refrigerant Level Control
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 17 - REFRIGERANT LEVEL CONTROL The chiller can be provided with an optional Condenser The desired refrigerant level to be maintained in the Refrigerant Level Control. A Variable Orifice, located condenser is the Refrigerant Level setpoint and is in the refrigerant liquid line between the Evaporator displayed as REFRIGERANT LEVEL SETPOINT and Condenser, is used to control the refrigerant level...
Page 166 FORM 160.54-M1 SECTION 17 - REFRIGERANT LEVEL CONTROL ISSUE DATE: 10/25/2019 the programmable Valve Preset Time setpoint (0 are compared to control thresholds Proportion Limit to 100 seconds; default 50). After pre-positioning, Close, Proportion Limit Open and Rate Limit Close the valve is held in this position until the first 3 and Rate Limit Open.
Page 167: Manual Operation
FORM 160.54-M1 SECTION 17 - REFRIGERANT LEVEL CONTROL ISSUE DATE: 10/25/2019 When transitioning from Zone 2 to Zone 1, ZONE 2 rate of change, the amount of change in the Level within TO ZONE 1 is displayed and the ZONE CONTROL the Level Control Period is compared to the Rate Limit TIME REMAINING status box displays the amount Close (if level less than setpoint) and Rate Limit Open...
Page 168: Figure 72 - Refrigerant Liquid Level Sensor
FORM 160.54-M1 SECTION 17 - REFRIGERANT LEVEL CONTROL ISSUE DATE: 10/25/2019 1 2 3 F/UP E/DN LD09256 FIGURE 72 - REFRIGERANT LIQUID LEVEL SENSOR JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 169: Figure 73 - Refrigerant Liquid Level Control - Interface
FORM 160.54-M1 SECTION 17 - REFRIGERANT LEVEL CONTROL ISSUE DATE: 10/25/2019 FIGURE 73 - REFRIGERANT LIQUID LEVEL CONTROL – INTERFACE JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
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Page 171: Section 18 - Oil Pump Variable Speed Drive
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 18 - OIL PUMP VARIABLE SPEED DRIVE On Style D (and later) chillers, the oil pump is driven When the chiller is started, 13 seconds after the Sys- by a Variable Speed Drive (VSD) (Refer to Variable tem Pre-lube is initiated, the microboard (J20-3) Speed Oil Pump Drive (Form 160.52-M2) for details of starts the oil pump by driving the EN (enable) input...
Page 172: Manual Operation
FORM 160.54-M1 SECTION 18 - OIL PUMP VARIABLE SPEED DRIVE ISSUE DATE: 10/25/2019 b. If the oil pressure is less than the programmed crease or decrease the oil pressure. However, if the er- oil pressure setpoint and the speed command ror is greater than plus or minus 6 psid, the value pro- is at 60Hz for 5 continuous seconds, any time grammed for Control Period setpoint determines the...
Page 173: Oil Heater Operation
FORM 160.54-M1 SECTION 18 - OIL PUMP VARIABLE SPEED DRIVE ISSUE DATE: 10/25/2019 OIL HEATER OPERATION When the oil pump is not operating, the heater is turned On chillers equipped with the Oil Pump VSD, the Oil ON and OFF to maintain a target value of 50°F above Heater is controlled by the microboard via I/O Board the Condenser Saturation Temperature.
Page 174: Figure 75 - Oil Pump Vsd / Oil Heater Control - Interface
FORM 160.54-M1 SECTION 18 - OIL PUMP VARIABLE SPEED DRIVE ISSUE DATE: 10/25/2019 BOARD 1HTR HEATER SPEED COMMAND +12VDC PUMP MICRO START / STOP BOARD LD04093A STATUS FIGURE 75 - OIL PUMP VSD / OIL HEATER CONTROL – INTERFACE 0.7 SEC +12VDC 0VDC 25.0 Hz...
Page 175: Section 19 - Communications
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 19 - COMMUNICATIONS The complete description of the E-Link Gateway In- If the remote device that is connected to the E-Link stallation Instructions are available in form P/N 24- Gateway is going to provide remote Start/Stop signals, 10404-9 II.
Page 176 FORM 160.54-M1 ISSUE DATE: 03/11/2019 THIS PAGE INTENTIONALLY LEFT BLANK JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS...
Page 177: Section 20 - Pressure Transducers
Each transducer has a ple, if the Pump transducer indicates 1.0 psig greater different YORK part number. Figure 78 on page 178 than the Sump transducer during the Auto-zeroing pe- lists the transducers and the application of each one.
Page 178: Figure 78 - Pressure Transducers
NOMINAL OUTPUT VOLTAGE OIL PRESSURE (LOW SIDE) EVAPORATOR TRANSDUCER (R22 WATER AND BRINE APPLICATIONS) (R22 WATER APPLICATIONS) YORK PART NO. 025-28678-004 YORK PART NO. 025-28678-102 025-28678-113 P + 4.375 V = (P x 4) - 162.5 P = (75 x V) + 162.5 P = (58.75 x V) - 4.375...
Page 179: Table 13 - Pressure Transducer Applications
NOMIAL OUTPUT 0.500 4.500 VOLTAGE PRESSURE (PSIG) NOMINAL OUTPUT VOLTAGE EVAPORATOR TRANSDUCER YORK PART NO. 025-28678-115 V = P + 15.63 P = (31.25 x V) - 15.63 31.25 V = VOLTS DC P = PRESSURE (PSIG) LD15644 FIGURE 78 - PRESSURE TRANSDUCERS (CONT'D)
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Page 181: Section 21 - Temperature Thermistors
One wire supplies the +5 VDC voltage and ous system temperatures. Each type has its own YORK the other is the output of the thermistor. This output part number. Part numbers are listed in YORK Renewal voltage can be measured with a Voltmeter.
Page 182: Table 14 - Leaving Chilled Liquid Temperature
FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 14 - LEAVING CHILLED LIQUID TEMPERATURE TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 9.90 -12.28 1.4280 15.13 -9.37 1.5957 20.17 -6.57 1.7634 10.00 -12.22 1.4310 15.22 -9.32...
Page 183 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 14 - LEAVING CHILLED LIQUID TEMPERATURE (CONT’D) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 29.92 -1.16 2.0988 34.73 1.52 2.2665 25.08 -3.84 1.9311 30.01 -1.11 2.1018 34.82...
Page 184 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 14 - LEAVING CHILLED LIQUID TEMPERATURE (CONT’D) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 49.48 9.71 2.7696 39.57 4.21 2.4342 44.46 6.92 2.6019 49.57 9.76 2.7726 39.66...
Page 185 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 14 - LEAVING CHILLED LIQUID TEMPERATURE (CONT’D) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 60.05 15.58 3.1050 65.75 18.75 3.2727 54.65 12.58 2.9373 60.15 15.64 3.1080 54.74...
Page 186 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 14 - LEAVING CHILLED LIQUID TEMPERATURE (CONT’D) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 71.83 22.13 3.4404 75.23 24.02 3.5288 78.80 26.00 3.6172 71.95 22.20 3.4434 75.35...
Page 187 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 15 - LEAVING CHILLED LIQUID TEMPERATURE (HEAT PUMP APPLICATIONS) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 0.04 -17.76 1.0107 37.58 3.10 2.1826 74.62 23.68 3.3545 3.02 -16.10...
Page 188: Table 16 - Return Chilled Liquid Temperature
FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 16 - RETURN CHILLED LIQUID TEMPERATURE TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 15.01 -9.44 1.5918 23.03 -4.98 1.8604 30.78 -0.68 2.1289 15.16 -9.36 1.5967 23.17 -4.91...
Page 189 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 16 – RETURN CHILLED LIQUID TEMPERATURE (CONT’D) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 38.51 3.62 2.3975 46.37 7.98 2.6660 54.56 12.53 2.9346 38.65 3.69 2.4023 46.51...
Page 190 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 16 – RETURN CHILLED LIQUID TEMPERATURE (CONT’D) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 63.34 17.41 3.2031 69.36 20.76 3.3740 75.87 24.37 3.5449 63.51 17.51 3.2080 69.54...
Page 191 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 17 - RETURN CHILLED LIQUID TEMPERATURE (HEAT PUMP APPLICATIONS) TEMP TEMP TEMP TEMP TEMP TEMP (°F) (°C) (°F) (°C) (°F) (°C) 35.9 2.17 2.3071 0.04 -17.76 1.1353 73.29 22.94 3.479 38.15 3.42...
Page 192: Table 18 - Return And Leaving Condensing Water
FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 18 - RETURN AND LEAVING CONDENSING WATER TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 40.12 4.51 1.8408 48.39 9.11 2.1094 56.61 13.67 2.3779 40.27 4.59 1.8457 48.54...
Page 193 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 18 - RETURN AND LEAVING CONDENSING WATER (CONT’D) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 64.98 18.32 2.6465 73.71 23.17 2.9150 83.04 28.36 3.1836 65.14 18.41 2.6514...
Page 194 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 18 - RETURN AND LEAVING CONDENSING WATER (CONT’D) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 93.31 34.06 3.4521 99.71 37.62 3.6035 106.67 41.49 3.7549 93.51 34.17 3.4570...
Page 195: Table 19 - Oil And Discharge Temperature
FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 19 - OIL AND DISCHARGE TEMPERATURE TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 31.99 -0.01 0.2637 59.90 15.50 0.5518 76.81 24.90 0.8154 32.63 0.35 0.2686 60.26 15.70...
Page 196 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 19 - OIL AND DISCHARGE TEMPERATURE (CONT’D) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 89.90 32.17 1.0693 101.92 38.85 1.3379 112.86 44.93 1.6064 90.13 32.30 1.0742 102.13...
Page 197 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 19 - OIL AND DISCHARGE TEMPERATURE (CONT’D) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 123.21 50.68 1.8750 133.27 56.27 2.1436 143.32 61.85 2.4121 123.39 50.78 1.8799 133.46...
Page 198 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 19 - OIL AND DISCHARGE TEMPERATURE (CONT’D) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 153.60 67.56 2.6807 164.36 73.54 2.9492 175.92 79.96 3.2178 153.79 67.67 2.6855 164.56...
Page 199 FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 19 - OIL AND DISCHARGE TEMPERATURE (CONT’D) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 188.71 87.07 3.4863 198.33 92.41 3.6670 209.10 98.40 3.8477 188.96 87.21 3.4912 198.61...
Page 200: Table 20 - Drop Leg Refrigerant Sensor
FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 20 - DROP LEG REFRIGERANT SENSOR TABLE 21 - EVAPORATOR REFRIGERANT SENSOR TEMP (°F) TEMP (°C) TEMP (°F) TEMP (°C) 0.01 -17.77 0.753 0.04 -17.76 1.135 3.72 -15.71 0.831 2.79 -16.23 1.214...
Page 201: Table 22 - Leaving And Return Heating Condenser Water Temperature Sensor
FORM 160.54-M1 SECTION 21 - TEMPERATURE THERMISTORS ISSUE DATE: 10/25/2019 TABLE 22 - LEAVING AND RETURN HEATING CONDENSER WATER TEMPERATURE SENSOR TEMP (°F) TEMP (°C) 32.63 0.35 1.713 37.47 3.03 1.870 42.23 5.68 2.026 46.96 9.97 2.182 51.68 10.93 2.338 56.44 13.57 2.495...
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Page 203: Section 22 - Remote Setpoints
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 22 - REMOTE SETPOINTS REMOTE OPERATING MODES ISN(BAS) Remote Mode ISN Remote Mode uses RS-232 serial port via E-Link There are three different Remote operating Modes that Gateway. can be selected at the keypad: Analog Remote Mode, Digital Remote Mode or ISN(BAS) Remote Mode.
Page 204 FORM 160.54-M1 SECTION 22 - REMOTE SETPOINTS ISSUE DATE: 10/25/2019 • If Analog Remote Mode is selected, the Remote For example, if the input is 5 VDC, the setpoint would Analog Input Range setpoint must be set to 0 to 10 be set to 74% as follows: VDC or 2 to 10 VDC as detailed below, regardless Setpoint (%)
Page 205: Leaving Chilled Liquid Temperature
FORM 160.54-M1 SECTION 22 - REMOTE SETPOINTS ISSUE DATE: 10/25/2019 The Pulse Width Modulation input is in the form of a The Remote Input Signal changes the setpoint by cre- 1 to 11 second relay contact closure that applies 115 ating an offset above the locally programmed Leaving VAC to the I/O Board TB4-20 for 1 to 11 seconds.
Page 206 FORM 160.54-M1 SECTION 22 - REMOTE SETPOINTS ISSUE DATE: 10/25/2019 0 to 10 VDC For example, if the input is 5 VDC and the Remote As shown in Figure 30 on page 94, connect input to Reset Temperature Range setpoint is programmed Microboard J22-3 (signal) and J22-5 (GND).
Page 207: Leaving Condenser Liquid Temperature (Heat Pump Mode)
FORM 160.54-M1 SECTION 22 - REMOTE SETPOINTS ISSUE DATE: 10/25/2019 4 to 20mA a 1 to 11 second closure is not received within 30 min- As shown in Figure 30 on page 94, connect input to utes of the last closure, the setpoint is defaulted to the Microboard J22-4 (signal) and J22-5 (GND).
Page 208 FORM 160.54-M1 SECTION 22 - REMOTE SETPOINTS ISSUE DATE: 10/25/2019 uid Temperature setpoint. These two setpoints share a 0 to 10 VDC single remote input that resets the appropriate setpoint As shown in Figure 30 on page 94, the input is con- based on the Heat Pump Operational Mode.
Page 209 FORM 160.54-M1 SECTION 22 - REMOTE SETPOINTS ISSUE DATE: 10/25/2019 perature Range setpoint). Select Analog Remote Mode. Remote Mode. The relay contact closure should occur The Remote Analog Input Range setpoint must be set at least once every 30 minutes to maintain the setpoint to 2 to 10 VDC and Microboard JP24 must be placed to the desired value.
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Page 211: Section 23 - Hot Gas Bypass
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 23 - HOT GAS BYPASS tected by the surge protection feature (See SECTION With the optional hot gas bypass feature, the control center modulates a valve located in the hot gas bypass 25 - SURGE PROTECTION). For reference, surge de- connection between the condenser and the evaporator tect indicators and the total surge count are displayed to control the flow of gas to the evaporator.
Page 212: Operation
FORM 160.54-M1 SECTION 23 - HOT GAS BYPASS ISSUE DATE: 10/25/2019 • Minimum Load (0°F to 4°F; default 0°F) – This is the same as Cooling Mode except for the operation sets the Minimum Load override threshold. It is during low load conditions, which is as follows. the offset below the Leaving Chilled Liquid Tem- When the Leaving Condenser Liquid Temperature ex- perature Setpoint at which the Hot gas bypass...
Page 213: Hot Gas Operation With Variable Geometry Diffuser (Vgd)
FORM 160.54-M1 SECTION 23 - HOT GAS BYPASS ISSUE DATE: 10/25/2019 After the chiller has not surged for the period of time When the OPEN or CLOSE key is pressed, the valve programmed as the Hold Period setpoint, the valve is position will be increased or decreased by 5% to a driven toward the closed position at 10 minute inter- maximum of 100% or minimum of 0%.
Page 214: Pre-Rotation Vanes Potentiometer
FORM 160.54-M1 SECTION 23 - HOT GAS BYPASS ISSUE DATE: 10/25/2019 This board must be configured properly for the Hot gas PRE-ROTATION VANES POTENTIOMETER control. The on-board Program Jumpers must be con- A 2.5K ohm potentiometer, mounted on the Pre-rota- figured as follows: tion Vanes control arm, provides a 0 to 5 VDC voltage that represents a PRV position of 0% (fully closed) to...
Page 215: Figure 79 - Interface, Hot Gas Bypass (Analog I/O Board 371-02514-000)
FORM 160.54-M1 SECTION 23 - HOT GAS BYPASS ISSUE DATE: 10/25/2019 FIGURE 79 - INTERFACE, HOT GAS BYPASS (ANALOG I/O BOARD 371-02514-000) JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL...
Page 216: Figure 80 - Interface, Hot Gas Bypass (I/O Board 031-02895-000)
FORM 160.54-M1 SECTION 23 - HOT GAS BYPASS ISSUE DATE: 10/25/2019 FIGURE 80 - INTERFACE, HOT GAS BYPASS (I/O BOARD 031-02895-000) JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 217: Section 24 - Smart Freeze Protection
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 24 - SMART FREEZE PROTECTION The smart freeze feature prevents nuisance chiller Smart Freeze protection is activated only when the fea- shutdowns due to brief periods of chilled liquid flow ture is enabled AND the Leaving Chilled Liquid Tem- fluctuations or other brief operating conditions that perature setpoint is less than 38°F.
Page 218 FORM 160.54-M1 SECTION 24 - SMART FREEZE PROTECTION ISSUE DATE: 10/25/2019 in normal operation, loading will be allowed when the 1. The Low Leaving Chilled Liquid Tem- pressure increases to 57.5 psig (R22) and 28.0 psig perature cycling shutdown threshold is 1 to (R-134a).
Page 219: Section 25 - Surge Protection
ACC surge detection are performed by the ACC Board ACC DETAILS Screen. The Surge Sensitivity setpoint (this is called the YORK Protocol configuration). In on that screen adjusts the sensitivity of the ACC Surge new production chillers after March 2007, the ACC...
Page 220: Excess Surge Detection
FORM 160.54-M1 SECTION 25 - SURGE PROTECTION ISSUE DATE: 10/25/2019 indicator is labeled Surge Detected and it illuminates SURGE PROTECTION whenever a Surge Detected, regardless of VSD operat- The Control Center can be configured to take the fol- ing frequency. lowing courses of action when an excess surge condi- tion has been detected.
Page 221: Hot Gas Bypass/Compressor Motor Variable Speed Drive (Vsd) Applications
FORM 160.54-M1 SECTION 25 - SURGE PROTECTION ISSUE DATE: 10/25/2019 HOT GAS BYPASS/COMPRESSOR Equipped With Both Hot gas and VSD MOTOR VARIABLE SPEED DRIVE (VSD) Software version C.MLM.01.08.xxx (and earlier) or APPLICATIONS C.OPT.08A.300 – The Extended Run Mode will not be implemented unless the Hot gas valve position is 100% Equipped With Hot gas and the VSD output frequency is at maximum.
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Page 223: Section 26 - Variable Geometry Diffuser
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 26 - VARIABLE GEOMETRY DIFFUSER Certain YORK compressors are equipped with a Vari- thresholds to determine if the stall noise is acceptable able Geometry Diffuser (VGD). It is used to reduce ro- or unacceptable. In a typical YK chiller, a signal below tating stall conditions and associated stall noise.
Page 224 FORM 160.54-M1 SECTION 26 - VARIABLE GEOMETRY DIFFUSER ISSUE DATE: 10/25/2019 • The PROBE WAIT time period (0.5 to 15 minutes; Stall Reacting default 10; as programmed with the Probe Wait If a stall is detected from the Probing, Stall Waiting or Time setpoint) expires.
Page 225: Stall Sensor Validation
FORM 160.54-M1 SECTION 26 - VARIABLE GEOMETRY DIFFUSER ISSUE DATE: 10/25/2019 Surge Waiting STALL SENSOR VALIDATION The VGD is held in last position for a wait time, de- (Software version C.MLM.01.14.xxx (and later) or fined by the Probe Wait Time setpoint (0.5 to 15 min- C.OPT.01.14.306 (and later)).
Page 226: Manual Operation
FORM 160.54-M1 SECTION 26 - VARIABLE GEOMETRY DIFFUSER ISSUE DATE: 10/25/2019 HIGH LIMIT Setpoint. Press the WARNING RESET • Open Pulse (1-9 seconds; default 2) – Specifies key in SERVICE access level to clear. After it is cleared, the length of the open pulse applied to the VGD the VGD returns to normal operation.
Page 227: Pre-Rotation Vanes Position
FORM 160.54-M1 SECTION 26 - VARIABLE GEOMETRY DIFFUSER ISSUE DATE: 10/25/2019 PRE-ROTATION VANES POSITION The Pre-rotation Vanes position, as used by the VGD Transducer 025-39464-000 control, is provided by a potentiometer mounted to the pin 1 - signal out - WHT PRV control arm.
Page 228: Figure 81 - Variable Geometry Diffuser Block Diagram
FORM 160.54-M1 SECTION 26 - VARIABLE GEOMETRY DIFFUSER ISSUE DATE: 10/25/2019 of stall noise present. When it reaches the value before surge. Also, since the PRV Position – VGD programmed as the High Limit setpoint (typically Inhibit Setpoint was the original vehicle to avoid set to 0.8 VDC), the VGD closes until the voltage VGD reaction to high gas flow/low head condi- decreases to the Low Limit setpoint (typically set...
Page 229: Figure 82 - Variable Geometry Diffuser State Diagram
FORM 160.54-M1 SECTION 26 - VARIABLE GEOMETRY DIFFUSER ISSUE DATE: 10/25/2019 Variable Geometry Diffuser (VGD) STATE DIAGRAM Chiller Stop CHILLER OFF PRELUBE VGD Open PROBING Pulse VGD Open Until Stall Signal > High Limit (0.5 to 1.2 V, Default 0.8) Pulse Open time (1-5 Sec., Default 2) Detect...
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Page 231: Section 27 - Large Tonnage Chiller (Ltc) I/O Board 031-02895-000/001
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 27 - LARGE TONNAGE CHILLER (LTC) I/O BOARD 031-02895-000/001 Beginning August 2009, new chillers equipped for Hot Each read/write request from the microboard contains gas bypass, Heat Recovery and/or Head Pressure Con- a Modbus Net address. In order for the I/O Board to trol options will be equipped with Input/Output Board respond to the microboard’s requests, the Modbus Net 031-02895-000.
Page 232: Figure 83 - Ltc I/O Board Basic Block Diagram
FORM 160.54-M1 SECTION 27 - LARGE TONNAGE CHILLER (LTC) I/O BOARD 031-02895-000/001 ISSUE DATE: 10/25/2019 POWER J9-7/15 +5VDC +12VDC 5VDC J9-5/13 12V RET TB8-2 24V RET VOLTAGE DIVIDER +5V REF DIGITAL INPUTS CR20-25 STATUS TB8-1 OPTO TB18-TB20 +24VDC COUPLER 120VAC (see FIG 84) INPUTS J9-3/11...
Page 233: Digital Outputs
FORM 160.54-M1 SECTION 27 - LARGE TONNAGE CHILLER (LTC) I/O BOARD 031-02895-000/001 ISSUE DATE: 10/25/2019 +5 VDC Digital inputs (-001 Board only) DIGITAL OUTPUTS There are 2 each +5 VDC TTL inputs. Figure 85 on Relay Outputs (-001 Board only) page 233 is a detail of an input and is representative There are 2 each 120/240 VAC relay contact outputs.
Page 234: Analog Inputs
FORM 160.54-M1 SECTION 27 - LARGE TONNAGE CHILLER (LTC) I/O BOARD 031-02895-000/001 ISSUE DATE: 10/25/2019 Open Collector Outputs (-001 Board only) ANALOG INPUTS There are 2 each open collector outputs. Figure 88 on There are 8 each Analog Inputs on the -000 board and page 234 is a detail of an output and is representa- 16 each on the -001 board.
Page 235: Analog Outputs
FORM 160.54-M1 SECTION 27 - LARGE TONNAGE CHILLER (LTC) I/O BOARD 031-02895-000/001 ISSUE DATE: 10/25/2019 INPUT CONNECTION ANALOG OUTPUTS J10-1 +5 VDC There are five analog outputs on the -000 board and -2 AI1 seven on the -001 board. Figure 90 on page 235 is -3 Ret a detail of this input and is representative of all these J10-4 +5 VDC...
Page 236: Auto Detection
FORM 160.54-M1 SECTION 27 - LARGE TONNAGE CHILLER (LTC) I/O BOARD 031-02895-000/001 ISSUE DATE: 10/25/2019 AUTO DETECTION The voltage value sent from the microboard to the I/O Earlier vintage chillers use Analog I/O Board 371- board for analog output displays as ANALOG OUTPUTS. 02514-000 for the ht gas bypass feature.
Page 237: Section 28 - Heat Recovery
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 28 - HEAT RECOVERY (SOFTWARE VERSION C.OPT.01.21.307 AND LATER) This option uses two tube bundles in the condenser. The heat recovery feature cannot be used with the Heat Pump feature. If HEAT The lower bundle is the standard condenser bundle and is piped to the cooling tower water source.
Page 238: Figure 92 - Heat Recovery Block Diagram
FORM 160.54-M1 SECTION 28 - HEAT RECOVERY ISSUE DATE: 10/25/2019 Setpoints • Hot Water Control setpoint – (Extended temp range equals 65.0°F to 125.0°F; default 95.0) (Standard temp range equals 65.0°F to 112°F; default 95.0) Sets the temperature that the Leav- ing Heating Condenser Water Temperature will be controlled to Displayed as Active Hot Water setpoint.
Page 239: Figure 93 - Pid Controller Diagram
FORM 160.54-M1 SECTION 28 - HEAT RECOVERY ISSUE DATE: 10/25/2019 • Control Valve Output Settings: • Remote Input Type – Configures the LTC I/O Board input (TB9-3/4) to accept either a 0-10 a. TYPE – Makes the control signal to the Heat VDC or 4 to 20mA input signal type for the Re- Recovery Control Valve either 0 to 10 VDC mote Hot Water setpoint input.
Page 240: Figure 94 - Heat Recovery Flow Diagram
FORM 160.54-M1 SECTION 28 - HEAT RECOVERY ISSUE DATE: 10/25/2019 The Control Valve Output Settings keys are used to config- If the chiller is equipped with both Heat Recovery and Head Pressure Control (See SECTION 29 - HEAD ure the output signal to the Heat recovery Control Valve. PRESSURE CONTROL) and both are enabled, there is The Type setpoint is used to make the control signal ei- ther 0 to 10 VDC or 4 to 20mA.
Page 241: Remote Hot Water Setpoint
Heat Recovery Hot Water Setpoint Local and Digital Locally programmed value Screen Remote value via communications Remote Hot Water YORK Talk III Comms Setpoint (GPIC List) Offset added to local Hot Water Setpoint Remote Hot Water Analog Analog Input 0V = -0°F offset, 10V = -20°F offset Setpoint Offset 4mA = -0°F offset, 20mA = -20°F offset...
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Page 243: Section 29 - Head Pressure Control
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 29 - HEAD PRESSURE CONTROL (SOFTWARE VERSION C.OPT.01.21.307 AND LATER) YK chillers are capable of operation within a wide If the chiller is equipped for Head Pressure Control, range of condenser water temperatures. However, a the feature must be ENABLED on the SETUP Screen minimum condenser water temperature, as specified using the Head Pressure Control setpoint.
Page 244: Control
FORM 160.54-M1 SECTION 29 - HEAD PRESSURE CONTROL ISSUE DATE: 10/25/2019 The evaporator and condenser transducers are connect- SET – Is used to manually set the Head Pres- ed to the microboard as shown in Figure 95 on page sure Control Valve to any position between 243.
Page 245: Operation When Equipped With Both Heat Recovery And Head Pressure Control
FORM 160.54-M1 SECTION 29 - HEAD PRESSURE CONTROL ISSUE DATE: 10/25/2019 The Control Valve Output Settings keys are used to OPERATION WHEN EQUIPPED WITH BOTH configure the output signal to the Heat Recovery Con- HEAT RECOVERY AND HEAD PRESSURE trol Valve. The Type setpoint is used to make the con- CONTROL trol signal either 0 to 10 VDC or 4 to 20mA.
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Page 247: Section 30 - Quick Start
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 30 - QUICK START (SOFTWARE VERSION C.OPT.01.21.307 AND LATER) The Quick Start feature is useful in data center and pro- The quick start feature must be enabled per the proce- cess control applications where it is desirable to re-estab- dure below to make it operational.
Page 248 • The Motor Communications Protocol is changed • ACC Mapping Enable (0.5°F to 4.0°F; default to YORK. 1.0°F) - This is the same setpoint as shown on the ACC DETAILS Screen. It can be programmed • The Heat Pump Duty (if enabled) Operational on either the ACC Screen or the QUICK START setpoint is set to Heating Mode.
Page 249: Operation
FORM 160.54-M1 SECTION 30 - QUICK START ISSUE DATE: 10/25/2019 OPERATION When Quick Start Mode is enabled, there are several • Chiller start signal (local or remote) is present operational enhancements common to both Quick Re- • No faults/inhibits present start and Quick Normal Start to decrease time between starts as follows: •...
Page 250: Table 24 - Compare A Normal Start, Quick Normal Start, And A Quick Restart
FORM 160.54-M1 SECTION 30 - QUICK START ISSUE DATE: 10/25/2019 • Variable Orifice control returns to standard and is In Effect” LED on the QUICK START Screen illumi- opened nates while the Quick Pulldown is in effect. The speed command programmed as the VSD Start Frequency • Oil Pump control is returned to standard and turns setpoint is sent to the VSD.
Page 251 FORM 160.54-M1 SECTION 30 - QUICK START ISSUE DATE: 10/25/2019 The following topics detail how the individual func- the chilled liquid pump is kept on for 30 seconds after tions are changed for Quick Restarts and Quick Nor- coastdown is completed. If a quick restart is not initi- mal Starts: ated within 30 seconds of the end of coastdown, the pump is returned to normal control.
Page 252 FORM 160.54-M1 SECTION 30 - QUICK START ISSUE DATE: 10/25/2019 Normal operation turns the oil pump off at the end of Hot gas Control coastdown. When Quick Start is ENABLED the oil When Quick Start is enabled the hot gas output shall be pump shall be kept running through coastdown until 30 set to the programmed Maximum Open value during seconds after the end of coastdown and into the restart.
Page 253: Section 31 - Heat Pump Duty
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 31 - HEAT PUMP DUTY (SOFTWARE VERSION C.OPT.01.23.307 AND LATER) Heat Pump is an available option for certain models Operational Mode of YK chillers. On a Heat Pump equipped chiller, Sets the Heat Pump operation to either COOLING with Heat Pump Duty enabled, the chiller control can (default) or HEATING operation.
Page 254: Control
FORM 160.54-M1 SECTION 31 - HEAT PUMP DUTY ISSUE DATE: 10/25/2019 Remote Mode, can reset the Leaving Condenser Liquid Heating LCHLT (Leaving Chilled Liquid Temperature Setpoint below the operator programmed Temperature) Shutdown Local setpoint (see above) while the Heat Pump is in In Heating Mode, the existing “Leaving Chilled Liquid HEATING Mode.
Page 255: Hot Gas Bypass Control
FORM 160.54-M1 SECTION 31 - HEAT PUMP DUTY ISSUE DATE: 10/25/2019 Heating LCHLT (Leaving Chilled Liquid Tempera- HEAT RECOVERY AND HEAD PRESSURE ture) Shutdown threshold, a cycling shutdown is per- CONTROL formed and “Leaving Chilled Liquid – Low Tempera- When Heat Pump Duty is enabled, Heat Recovery and ture”...
Page 256: Figure 97 - Heat Pump Duty Block Diagram
FORM 160.54-M1 SECTION 31 - HEAT PUMP DUTY ISSUE DATE: 10/25/2019 MICRO BOARD I/O BOARD 031-02430-001 031-01743-002 031-03630-001 6 IN LEAVING CONDENSER WATER THERMISTOR 16 +5VDC PRE - ROTATION OPEN VANES CLOSE ACTUATOR 14 IN (NOTE 1) LEAVING CHILLED WATER THERMISTOR 15 +5VDC REMOTE LEAVING NOTE 2...
Page 257: Section 32 - Motor Monitoring
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 32 - MOTOR MONITORING (SOFTWARE VERSION C.OPT.01.22.307 AND LATER) The optional Motor Monitoring feature allows moni- The motor could be equipped with different types of toring of the compressor motor windings temperatures, sensors for this monitoring. Either RTD’s or thermistors bearing temperatures, bearing vibration and motor could be applied for winding and bearing temperature cooling coil leak detection.
Page 258: Figure 99 - Motor Monitoring Board Basic Block Diagram
FORM 160.54-M1 SECTION 32 - MOTOR MONITORING ISSUE DATE: 10/25/2019 MOTOR MONITORING BOARD BASIC BLOCK DIAGRAM LD15001 FIGURE 99 - MOTOR MONITORING BOARD BASIC BLOCK DIAGRAM JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 259: Motor Monitoring Board
FORM 160.54-M1 SECTION 32 - MOTOR MONITORING ISSUE DATE: 10/25/2019 This board resides in an enclosure that is mounted The board accepts both analog and Digital inputs from separately from the OptiView Control Center. The Mo- motor sensing devices (See Figure 99 on page 258). tor Monitoring Board receives the outputs of the sen- It transmits the data to the microboard using Modbus sors and transmits the sensor values to the microboard...
Page 260: Figure 100 - Motor Monitoring Block Diagram
FORM 160.54-M1 SECTION 32 - MOTOR MONITORING ISSUE DATE: 10/25/2019 MOTOR MONITORING BLOCK DIAGRAM MOTOR MONITORING BOARD 031-02893-(NOTES) MICROBOARD 031-02430-000 031-02430-001 WINDING TEMPERATURES (NOTE 1) (RTD OR THERMISTORS) COM3 RS-485 BEARING TEMPERATURES (NOTE 2) (RTD) MODBUS SERIAL COMMS COM2 BEARING VIBRATIONS (NOTE 3) RS-485 (ACCELEROMETERS)
Page 261 FORM 160.54-M1 SECTION 32 - MOTOR MONITORING ISSUE DATE: 10/25/2019 The Motor Monitoring Board (See Figure 100 on page luminates when the input is high. Each input is 260) has up to 4 different sections of inputs (depend- configured by a command from the microboard ing on the board part number) as follows: via serial communications.
Page 262: Winding Temperatures
FORM 160.54-M1 SECTION 32 - MOTOR MONITORING ISSUE DATE: 10/25/2019 WINDING TEMPERATURES toring Board is commanded to not read any of its The motor windings temperatures can be monitored winding temperature sensor inputs. The winding with either RTD’s or thermistors. When RTD’s are displays can be individually disabled using the used, there are 6 (2 per phase) RTD’s and the -001 Temperature Disable setpoint (ADMIN access...
Page 263 FORM 160.54-M1 SECTION 32 - MOTOR MONITORING ISSUE DATE: 10/25/2019 Motor Winding Phase the range of 0 18°F (default 0). The values programmed for these safety thresholds are displayed in the respec- TB1-1,2 A Temperature tive data boxes on the MOTOR SETPOINTS Screen. TB1-4,5 B Temperature When any of the enabled winding temperatures ex-...
Page 264: Bearing Temperatures
FORM 160.54-M1 SECTION 32 - MOTOR MONITORING ISSUE DATE: 10/25/2019 BEARING TEMPERATURES The motor bearing temperatures can be monitored with TB5-7,8,9 Motor Bearing Opposite either RTD’s or thermistors. Both the shaft end bearings Shaft End Temperature and opposite shaft end bearings are monitored. There- TB5-10,11,12 Motor Bearing Shaft End fore, 2 RTD’s or thermistors are used.
Page 265: Vibration
FORM 160.54-M1 SECTION 32 - MOTOR MONITORING ISSUE DATE: 10/25/2019 When either of the enabled motor bearing temperatures croboard via serial communications, commands the exceeds the programmed High Bearing Temperature Motor Monitoring Board to read the appropriate sen- Warning for 3 continuous seconds, Warning Motor sor inputs and it also sends configuration commands as High Bearing Temperature is displayed.
Page 266 FORM 160.54-M1 SECTION 32 - MOTOR MONITORING ISSUE DATE: 10/25/2019 TB3-1,2 Motor Bearing Shaft are used but they can be overridden by manual entry. End Vibration The actual thresholds that the software is using are dis- played in the Motor Bearings High Vibration Warning TB3-3,4 Motor Bearing Opposite and High Vibration Warning data boxes on the MO-...
Page 267: Cooling Coil Leak Detection
FORM 160.54-M1 SECTION 32 - MOTOR MONITORING ISSUE DATE: 10/25/2019 the baseline derived Shutdown and Warning thresh- set to disabled on the MOTOR DETAILS Screen or olds override the thresholds entered with the Vibration while the Warning Motor Bearing Vibration Baseline Setup setpoint.
Page 268: Figure 105 - Motor Cooling Coil Leak Detector - Optical Sensor
FORM 160.54-M1 SECTION 32 - MOTOR MONITORING ISSUE DATE: 10/25/2019 Digital inputs (CONTINUED) +5VDC +5VDC CLOSE = OK OPEN = TRIP PULL UP SELECT FROM PROCESSOR LD15003 FIGURE 105 - MOTOR COOLING COIL LEAK DETECTOR – OPTICAL SENSOR than 1 VDC input at TB7-5, as measured to TB7-6. •...
Page 269: Table 25 - Rtd Resistance/Temperature Chart
FORM 160.54-M1 SECTION 32 - MOTOR MONITORING ISSUE DATE: 10/25/2019 TABLE 25 - RTD RESISTANCE/TEMPERATURE CHART RESISTANCE (OHMS) °C °F RESISTANCE (OHMS) °C °F 100.0 0.00 32.00 141.7 108.43 227.18 105.9 15.13 59.23 147.6 124.07 255.32 111.9 30.59 87.06 153.6 140.04 284.08 117.8...
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Page 271: Section 33 - System Calibration, Service Setpoints, And Reset Procedures
Although they have been entered at the ELECTROMECHANICAL STARTER YORK factory, they can be changed by a field Service APPLICATIONS technician. If the BRAM battery backed memory de-...
Page 272: Solid State Starter Applications
105% FLA as indicated by the clamp-on Ammeter. The 105% When the compressor motor is driven by a YORK Solid LED on the CM-2 Module should illuminate. State Starter, one of three different Starters could be ap- plied.
Page 273 LCSSS – • YORK - Enables COM 5 (J15) serial port. Used HIGH SUPPLY LINE VOLTAGE and LCSSS – LOW when the microboard is interfaced to the LCSSS SUPPLY LINE VOLTAGE cycling shutdowns as de- Logic/Trigger Board TB2.
Page 274 5. Press  key. A dialog box will appear with 220/230/240 VAC applications. the range of settings. Use ◄► keys to select Setpoints “YORK” or Modbus, as appropriate. 1. At the keypad, log in at SERVICE access level 6. Press ENTER () key. using access code 1 3 8 0.
Page 275 FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 Current Unbalance Check Enable/Disable While the chiller is running, if the compressor Motor c. Manually operate the Pre-rotation Vanes current in phase A, B and C becomes unbalanced, a by pressing the OPEN, CLOSE and HOLD safety shutdown is performed.
Page 276: Compressor Motor Variable Speed Drive Applications
“VSD-60Hz” or “VSD-50Hz”. The Ser- vice technician must enable the appropriate serial com- When the compressor motor is driven by a YORK Vari- munications port for communications to the Variable able Speed Drive, there could be a Variable Speed Drive Speed Drive (VSD).
Page 277 PORTANT! – This should not be performed This is the Full Load Amps (FLA) of the chiller as unless advised by YORK factory Service. listed on the SALES ORDER Screen. The microboard uses the programmed value to perform Current Lim- it functions and display compressor motor current in terms of %FLA.
Page 278 FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 b. Surge Map Print – Prints the entire array of 3. Select SURGE MAP Screen (software version stored surge points to a printer connected to C.OPT.01.19.307 (and later);...
Page 279: Proximity Probe
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 e. Lower – Places frequency Control in Manual Calibration Mode. Decreases the VSD frequency by 0.1 Perform this procedure at the time of manufacture or if to 10.0Hz, as programmed with the INCR the compressor is rebuilt in the field.
Page 280: High Speed Thrust Bearing Limit Switch
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 Safety Shutdown Reset/Inspection Procedure As explained above, to prevent possible compressor dam- 4. Press FAULT ACKNOWLEDGE key. ENTER age, the chiller should not be restarted after a THRUST PASSWORD TO CLEAR FAULT is displayed in BEARING safety shutdown until the shutdown has been a dialog box.
Page 281 FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 The refrigerant Level Sensor, located in the Condenser, e. Rate Limit Open - 10% to 50% (10%) must be properly calibrated to accurately detect the re- 5% to 50% (10%) (Flash memory card frigerant level in the Condenser.
Page 282: Oil Pump Variable Speed Drive
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 1. At the keypad, login at SERVICE access level tion must be ENABLED and the setpoints programmed using access code 1 3 8 0. using the procedures below. Also, the Oil Pump Speed can be manually controlled using the procedure below.
Page 283: Oil Return Min
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 2. Select OIL SUMP Screen. STANDBY LUBRICATION To maintain oil seal integrity while the chiller is shut- 3. The speed can be increased and decreased in down, a feature can be enabled that turns on the Oil 0.5Hz increments using the RAISE and LOWER Pump for 2 minutes every 24 hours if the chiller has...
Page 284: Brine Low Evaporator Pressure Cutout
This selection available with percentage of Brine solution determines this threshold. Flash memory card version C.MLM.01.06. It is calculated at the YORK factory and programmed xxx and later or C.MLM.04.02.xxx). at the time of manufacture. If the BRAM memory de- Flash memory card version C.MLM.01.06.xxx and...
Page 285: Smart Freeze Protection
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 evaporator. If ENABLED with the procedure below, Use the following procedure to Enable or Disable this this temperature is displayed on the CONDENSER feature: Screen as the “Drop Leg Temperature”. It is subtracted 1.
Page 286: Chiller Starts And Operating Hours Reset
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 er values to compensate for local operating conditions. 4. Using numeric keypad keys, enter desired number. There are two different setpoint sets used depending 5. Press ENTER () key. upon the software vintage.
Page 287: Surge Protection
All of the Sales Order Data, except the “Chiller Com- Continue this process until all desired values have missioning Date” is entered at the YORK factory at been entered. the time of chiller manufacture. The Service techni- cian must enter the Chiller Commissioning Date and 7.
Page 288: Custom User Id And Passwords
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 When using this password to enter data 9. Use ▲ and ▼ keys to select another value to be into a new blank BRAM, the FINISH changed within the same category or press CAN- PANEL SETUP procedure (listed at the CEL (X) key to exit and allow selection of another end of the entry procedure below) must be category.
Page 289: Record Setpoint Changes
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 The following setpoint changes are not logged: 5. Press the ENTER () key. 6. Using numeric Keypad keys, enter desired param- • Clock Mode eter as follows: •...
Page 290: Table 27 - Flash Memory Card Version C.mlm.01.07.Xxx And C.mlm.01.07A.xxx
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 • High Speed Thrust Bearing proximity sensing Flash memory card version C.MLM.01.07.xxx and – Proximity probe input at Microboard J8-15 or later are applicable and backward compatible to all YK Limit Switch input at I/O Board TB3-81.
Page 291: Table 28 - Flash Memory Card Version C.mlm.01.08.Xxx
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 TABLE 28 - FLASH MEMORY CARD VERSION C.MLM.01.08.XXX LEVEL OIL-VARIABLE SPEED PUMP CHILLER STYLE/ PROXIMITY CONTROL FLOW HEATER PRESSURE SETPOINT NOT COMPRESSOR SENSE PERIOD SWITCH OUTPUT* ACHIEVED THRESHOLD* DEFAULT...
Page 292: Flow Switch
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 TABLE 31 - SOFTWARE VERSION C.OPT.01.16.XXX (AND LATER) OIL-VARIABLE LEVEL SPEED PUMP STANDARD CHILLER STYLE/ PROXIMITY CONTROL FLOW PRESSURE HEATER COASTDOWN COMPRESSOR SENSE PERIOD SWITCH SETPOINT NOT OUTPUT* TIME...
Page 293: Microboard 031-02430-000-001 And 031-03630-001 Setup/Configuration
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 Enter the applicable flow sensor type as follows: • Head Pressure Control-enable/disable (software version C.OPT.01.21.307 and later). 1. Select SETPOINTS/SETUP/OPERATIONS Screen. • Heat Pump Duty – enable/disable (software ver- 2.
Page 294 FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 1. Shutdown chiller and place COMPRESSOR start/ Use the following procedure: Stop Switch in the Stop-Reset position. 1. At the keypad, log in at SERVICE access level 2.
Page 295: High Condenser Pressure Fault While Shutdown - Reset Procedure
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 will illuminate and an open signal is applied to the than 160.0 (R-134a), 240.0 psig (R22) and a special PRV. After a 60 second delay, the program begins reset procedure is performed as follows: evaluating the feedback voltage from the PRV 1.
Page 296 FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 The MOTOR LUBRICATION Screen, accessible from Motor Lube Date the MOTOR Screen in any access level, displays infor- Normally, the Date of Last Lubrication is automatically mation applicable to this feature.
Page 297 FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 6. If Disable is selected in step 4, press the SHUT- Motor Lubrication. This entry also resets the Operating DOWN key. Hours Since Last Lubrication to zero. 7.
Page 298: Quick Start
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 Change Lube Type QUICK START When logged on at the service level, the technician can (Software version C.OPT.01.21.307 and later) set the type of lubricant to use by pressing the Change The Quick Start feature is useful in data center and Lube Type key.
Page 299: Heat Pump Duty
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 2. Select QUICK START from the SETPOINTS Setpoints Screen. Refer to the HEAT PUMP Screen section in Operation Manual 160.54-O1 and enter the following setpoints: 3.
Page 300 FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 1. At the keypad, login at SERVICE access level us- 1. Press MOTOR VIBRATION PROTECTION key. ing password 1 3 8 0. 2. A dialog box appears with the selections. 2.
Page 301: Motor Setpoints Screen
FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 8. Using numeric keypad keys, enter desired value. Otherwise, it should be enabled. The respective tem- perature data box on this screen reflects enabled or dis- 9.
Page 302 FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 7. Using numeric keypad keys, enter the desired data boxes on this MOTOR SETPOINTS Screen. The value. Vibration Baseline values from which the Vibration Shutdown and Warning thresholds are derived, are dis- 8.
Page 303 FORM 160.54-M1 SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES ISSUE DATE: 10/25/2019 Bearing Setup This setpoint is used to enter the High Bearing Temper- ature Shutdown safety threshold (149 to 212°F; default 203) and High Bearing Temperature Warning thresh- old (140 to 194°F;...
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Page 305: Section 34 - Diagnostics And Troubleshooting
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING The problems that could be encountered in the OptiV- allow output states to be changed. Access the DI- iew Control Center are in the following categories: AGNOSTICS MAIN Screen as follows: a.
Page 306: Diagnostics Screen
FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 DIAGNOSTICS SCREEN LD22790 FIGURE 106 - DIAGNOSTICS SCREEN This screen shows the software that is loaded onto the in unstable control. Note that some versions of soft- microboard and the motor starter connected to the mi- ware also have a Default Setpoints button on the Ca- croboard via serial communications.
Page 307: Serial/Sd Screen
FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 SERIAL/SD SCREEN LD22791 FIGURE 107 - SERIAL/SD SCREEN This screen shows the SD card status and enables Sys- Eject SD Card – Pressing this button before remov- tem Backup & Restore along with data logging. ing the SD card prevents it from being corrupted which could happen if the card is removed during a write event and this button was not pressed.
Page 308: Main Diagnostics Screen
FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 MAIN DIAGNOSTICS SCREEN LD14328a FIGURE 108 - MAIN DIAGNOSTICS Each of the Diagnostics is accessed from this screen. - Display test Press the appropriate key to select the desired diagnos- - Bit patterns test tic.
Page 309: Motor Monitoring Board Diagnostic Screen
FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 MOTOR MONITORING BOARD DIAGNOSTIC SCREEN (SOFTWARE VERSION C.OPT.01.22.307 AND LATER) LD14330 FIGURE 109 - MOTOR MONITORING BOARD DIAGNOSTIC SCREEN This diagnostic screen is used to analyze the analog and VIBRATION INPUTS Digital inputs of the Motor Monitoring Board.
Page 310 FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 RTD INPUTS MODBUS COMMUNICATION COUNTERS The voltage level of each RTD at the indicated input The following error counts are displayed. Pressing the terminals is displayed as X.XX VDC. An LED illumi- RESET COUNTERS key resets them to zero.
Page 311: I/O Board (031-02895-000) Diagnostic Screen
FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 I/O BOARD (031-02895-000) DIAGNOSTIC SCREEN (SOFTWARE VERSION C.OPT.01.21.307 AND LATER) LD14329 FIGURE 110 - I/O BOARD DIAGNOSTIC SCREEN minal 2) is at 0 VDC, the current output (terminal 1) is This diagnostic screen is used to analyze the analog at 0mA.
Page 312 FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 To manually set the output: 5. Press the ENTER () key. The entered voltage value and corresponding current value will be 1. Press SELECT DIGITAL OUTPUT key. A yellow shown in the selected output box.
Page 313: Keypad Test
FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 KEYPAD TEST 00336VIP FIGURE 111 - KEYPAD TEST SCREEN This diagnostic is used to verify Keypad operation and c. In the keypad connector, locate the pins of the microboard’s ability to respond to a pressed key. the row/column coordinate of the key of the See the description of Keypad operation in SECTION key to be tested.
Page 314: Display Test Main Screen
FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 DISPLAY TEST MAIN SCREEN 00337VIP FIGURE 112 - DISPLAY TEST MAIN SCREEN border are displayed. If the vertical bars are not Each display diagnostic is accessed from this screen. stable or straight, or the red border is not com- After each diagnostic is performed, return to this pletely visible, then either the microboard Pro-...
Page 315 FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 • All Blue - This test verifies the operation of all of the blue pixels. All of the blue pixels are turned on to create a completely blue screen. See the de- scription of the All Red test above. •...
Page 316: Bit Patterns Test Screen
FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 BIT PATTERNS TEST SCREEN 00338VIP FIGURE 113 - BIT PATTERNS TEST SCREEN TROUBLESHOOTING 2. Display Interface Board If any of the tests from the previous screen do not per- form correctly as described, perform the applicable pro- Using an Ohmmeter, perform a continuity test on cedure below:...
Page 317 FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 4. Display d. With the “All White” test selected, the volt- age at Microboard J5-6 through J5-11, J5-13 If the Display Ribbon Cable, Display Interface through J5-18 and J5-20 through J5-25 Board and Microboard check OK per the above should be greater than 3.0 VDC.
Page 318: Serial Inputs/Outputs Test Screen
FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 SERIAL INPUTS/OUTPUTS TEST SCREEN LD15435 FIGURE 114 - SERIAL INPUTS/OUTPUTS TEST SCREEN From This diagnostic is used to verify correct operation of the Serial Data Ports. There is a test for each of the six COM 1 J2-4 (TX) J2-3 (RX)
Page 319: Figure 115 - Microboard - Com 5 Serial Data Port
DSR (J13-2) and DCD (J13-1). RTS (J13-4) is set to a Logic High and read at CTS (J13-6) and Make individual wire connections or use YORK loop- R1 (J13-8). If any test fails, COM 2 tests are ter- around diagnostic connector 025-33778-000 as de- minated.
Page 320: Digital Inputs/Outputs Test Screen
FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 DIGITAL INPUTS/OUTPUTS TEST SCREEN 00340VIP FIGURE 116 - DIGITAL INPUTS/OUTPUTS TEST SCREEN This diagnostic is used to analyze the Digital inputs a. Terminal number on the I/O Board. and outputs of the microboard. See description of I/O b.
Page 321 FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 7. If the Program Switch (DIP) is in the OFF posi- 7. When all desired tests have been performed, press tion, the applicable LED should be extinguished. DIAGNOSTICS key to return to the MAIN DI- If the LED is not extinguished, the microboard is AGNOSTICS Screen.
Page 322 FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 Digital Outputs Troubleshooting If any of the Digital Outputs tests fail to perform as b. If a Triac is selected as the output, the Triac described above, perform the following steps in se- should be turned on.
Page 323: Analog Inputs Test Screen
FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 ANALOG INPUTS TEST SCREEN 00341VIP FIGURE 117 - ANALOG INPUTS TEST SCREEN This diagnostic is used to analyze the Analog Inputs to Channel the microboard. The voltage level of each Analog In- 0 - +2.5 VDC Analog supply voltage reference.
Page 324 FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 14 - Proximity probe Position (Not applicable to P cable. Channel 0 is a reference voltage for the compressors and style "F" and later chillers with Analog circuits on the microboard. Channels 15 “G, Q”...
Page 325 FORM 160.54-M1 SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ISSUE DATE: 10/25/2019 4. If the measured value is not within plus or mi- Channels 15 - 22 nus 15% of the displayed value, replace the mi- 1. Disconnect both ends of the ribbon cable connected croboard.
Page 326 FORM 160.54-M1 ISSUE DATE: 03/11/2019 THIS PAGE INTENTIONALLY LEFT BLANK JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS...
Page 327: Section 35 - System Commissioning Checklist
Panel – Operation (Form 160.54-O1). Thresholds, ____ Remote Input Type values and calibrations of items marked with an aster- isk (*) were determined and entered/set at the YORK ____ Control Valve Output Settings - Type factory at the time of manufacture.
Page 328 FORM 160.54-M1 SECTION 35 - SYSTEM COMMISSIONING CHECKLIST ISSUE DATE: 10/25/2019 6. HEAT PUMP DUTY Screen ____ Rate Limit (Software version C.MLM.01.14. xxx (and later) or C.OPT.01.14.306 (and (Software version C.OPT.01.23.307 and later) later)) ____ Heating Sensitivity 8. COMPRESSOR Screen (160.54-M1) ____ Operational Mode ____ Select Pre-rotation Vanes Manual or Auto control...
Page 329 FORM 160.54-M1 SECTION 35 - SYSTEM COMMISSIONING CHECKLIST ISSUE DATE: 10/25/2019 11. VARIABLE GEOMETRY DIFFUSER Screen ____ Supply Voltage Range* (160.54-M1) ____ Enable Open SCR Detection If compressor is equipped with the Variable Ge- ____ Enable Shorted SCR Detection (Flash mem- ometry Diffuser (VGD), enable operation on the ory card version C.MLM.01.04.xxx and OPERATIONS screen and enter the following...
Page 330 FORM 160.54-M1 SECTION 35 - SYSTEM COMMISSIONING CHECKLIST ISSUE DATE: 10/25/2019 MOTOR Screen (MV VSD) ____ Vibration Setup ____ Vibration Gain ____ Full Load Amps ____ Bearing Setup ADAPTIVE CAPACITY CONTROL (ACC) DETAILS Screen 14. SETPOINTS Screen (160.54-O1) ____ Surge Map Clear With the exception of the “Remote Analog Input Range”, the setpoints listed on the SETPOINTS ____ Surge Map Print...
Page 331 FORM 160.54-M1 SECTION 35 - SYSTEM COMMISSIONING CHECKLIST ISSUE DATE: 10/25/2019 SCHEDULE Screen ____ Oil Pump Package ____ Motor Communications Protocol (soft- ____ Enable or disable daily start/stop schedule ware version C.OPT.01.16.xxx (or later) as required. for VSD applications; software version ____ Enter Chiller Start/Stop...
Page 332 FORM 160.54-M1 SECTION 35 - SYSTEM COMMISSIONING CHECKLIST ISSUE DATE: 10/25/2019 OPERATIONS Screen (160.54-M1) ____ Select desired Control Source (Operating Mode); Local, ISN Remote, Digital Remote or Analog Remote ____ Refrigerant Level Control operation Enable/ Disable ____ Hot gas bypass Control (optional) Enable/ Disable ____ Variable Geometry Diffuser (Enable/Disable) (Chillers equipped with Variable Geometry...
Page 333: Section 36 - Software Enhancements
FORM 160.54-M1 ISSUE DATE: 10/25/2019 SECTION 36 - SOFTWARE ENHANCEMENTS SI0006 - SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2001 GENERAL Beginning May 2001, an enhanced flash memory card This feature is a valuable troubleshooting tool for Ser- will be supplied with new production NEMA 1-4 and vice technicians.
Page 334 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0006 - SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2001 (CONT'D) COMPRESSOR MOTOR VARIABLE SPEED DRIVE 1. The compressor motor Variable Speed Drive (VSD) Phase A, B and C output current to the mo- tor is now displayed on the VSD TUNING screen.
Page 335: Si0019 - Software Enhancements Effective March 2002
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0019 - SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2002 GENERAL Beginning March 2002, an enhanced flash memory card • System Cycling – Contacts Open will be supplied in new production YK NEMA 1-4 and •...
Page 336 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0019 - SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2002 (CONT'D) The following setpoint changes are not logged: • The ramp-up feature is now only executed imme- diately after chiller start. Subsequent ramp func- •...
Page 337: Si0034 - Software Enhancements Effective August 2002
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0034 - SOFTWARE ENHANCEMENTS EFFECTIVE AUGUST 2002 Flash Memory card Beginning August 2002, an enhanced flash memory • Oil Heater Outputs – Either TB1-34 or TB1-64 on card will be supplied in new production YK chill- I/O Board ers.
Page 338 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0034 - SOFTWARE ENHANCEMENTS EFFECTIVE AUGUST 2002 (CONT'D) LEVEL OIL-VARIABLE SPEED CHILLER MOD – PROXIMITY CONTROL PUMP PRESSURE SETPOINT HEATER FLOW SWITCH COMPRESSOR SENSE PERIOD NOT ACHIEVED OUTPUT* DEFAULT THRESHOLD* Mod C, D, E –...
Page 339 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0034 - SOFTWARE ENHANCEMENTS EFFECTIVE AUGUST 2002 (CONT'D) Microboard Program Jumpers JP21 and JP22 must be • After three minutes of run time, if the refriger- placed in the positions 2 and 3. ant level is less than the control setpoint, a lin- early increasing ramp limit, called the refrigerant Proximity probe/LIMIT SWITCH...
Page 340: Si0058 - Software Enhancements Effective February 2003
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0058 - SOFTWARE ENHANCEMENTS EFFECTIVE FEBRUARY 2003 GENERAL Beginning February 2003, an enhanced Flash memory Enter the applicable flow sensor type as follows: card will be supplied in all new production YK chillers. 1.
Page 341 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0058 - SOFTWARE ENHANCEMENTS EFFECTIVE FEBRUARY 2003 (CONT'D) VSD – LOW PHASE C INVERTER BASEPLATE HARMONIC FILTER – HIGH BASEPLATE TEMPERATURE TEMPERATURE Same as Phase A above. The chiller has shutdown because the baseplate tem- perature has increased to greater than 194°F.
Page 342: Si0062 - Software Enhancements Effective March 2003
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0062 - SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2003 GENERAL Chiller Style/Compressor Setpoint Beginning March 2003, an enhanced flash memory In previous flash memory card version, this setpoint card will be supplied in all new production YK chillers. key (located on OPERATIONS Screen), was labeled These cards are backward compatible to all previous CHILLER MOD.
Page 343: Si0080 - Software Enhancements Effective January 2004
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0080 - SOFTWARE ENHANCEMENTS EFFECTIVE JANUARY 2004 GENERAL For all applications, the count Window setpoint default Beginning January 2004, enhanced software will be is now three minutes (was five minutes). The count supplied in all new production YK chillers.
Page 344 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0080 - SOFTWARE ENHANCEMENTS EFFECTIVE JANUARY 2004 (CONT'D) The calibration procedure can be termi- nated at any time during the procedure by pressing the CANCEL CALIB key. If the PRVs were previously calibrated successfully, they will revert to using the previous calibration values.
Page 345: Si0089 - Software Enhancements Effective May 2004
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0089 - SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2004 GENERAL Beginning May 2004, enhanced software will be sup- This anticipatory fault is only performed while the plied in all new production YK chillers. It is backward chiller is stopped.
Page 346 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0089 - SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2004 (CONT'D) Variable Speed Oil Pump In previous fash memory card versions, the manual frequency could be changed only when the pump was running. The manual frequency can now be changed whether the pump is running or not.
Page 347 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2005 GENERAL VGD INHIBIT SETPOINT Beginning March 2005, enhanced software will be A new setpoint, PRV VGD Inhibit, was added to the supplied in new production YK chillers. It is backward VGD operation.
Page 348 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2005 (CONT'D) CONDENSER REFRIGERANT LEVEL VSD – FREQUENCY > 0HZ CONTROL This new start inhibit is set whenever the chiller is shut- In previous software versions, all control thresholds down and a compressor motor VSD output rrequency were programmable.
Page 349: Si0148 - Software Enhancements Effective June 2006
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0148 - SOFTWARE ENHANCEMENTS EFFECTIVE JUNE 2006 GENERAL • VSD-DC BUS VOLTAGE IMBALANCE Beginning June 2006, enhanced software will be sup- plied in new production YK chillers. It is backward If the half DC link Voltage does not remain within compatible to all previous YK chillers equipped with plus or minus 106 VDC of the DC Link Voltage...
Page 350: Si0158 - Software Enhancements Effective October 2006
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0158 - SOFTWARE ENHANCEMENTS EFFECTIVE OCTOBER 2006 GENERAL Beginning October 2006, enhanced software will be supplied in new production YK chillers. It is backward compatible to all previous YK chillers equipped with microboard (P/N 031-02430-000 or 031-02430-0001).
Page 351: Si0164 - Software Enhancements Effective April 2007
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0164 - SOFTWARE ENHANCEMENTS EFFECTIVE APRIL 2007 GENERAL Beginning April 2007, enhanced software will be sup- Condenser – Flow Switch Open – The condenser plied in new production YK chillers and replacement flow switch has remained open for 30 continuous sec- Microboard kit 331-02430-601.
Page 352 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0164 - SOFTWARE ENHANCEMENTS EFFECTIVE APRIL 2007 (CONT'D) The compressor motor VSD has not yet reached full If the auto lube setpoint is disabled, as it should be speed after having been commanded to do so in manual when not equipped with the automatic motor lubri- speed control.
Page 353 VSD. En- chillers, the ACC functionality is contained in the mi- tered as YORK to enable COM5 (J15) or Modbus to croboard and the ACC board is not present. On these enable COM2 (J13). Selection is based on hardware chillers, the VSD logic board communicates directly and interface.
Page 354: Si0186 - Software Enhancements Effective October 2006
When SSS-MOD B is selected as the motor drive type setpoint, the motor communications protocol setpoint • 34°F (water with smart freeze enabled) is used to select either YORK or Modbus protocol, as • 6°F (brine). appropriate. The appropriate selection depends on the actual hardware/interface that is present.
Page 355 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0186 - SOFTWARE ENHANCEMENTS EFFECTIVE OCTOBER 2006 (CONT'D) REMOTE RESET TEMPERATURE RANGE SETPOINT In previous software versions, this setpoint could be set to 10°F or 20°F. In this version it can be set to 10°F, 20°F, 30°F, or 40°F.
Page 356: Si0201 - Software Enhancements (Ver 19) Effective October 2008
Communications Protocol setpoint on the SETUP When these surges are detected, the ACC Surge Screen. It is set to either YORK or Modbus, as deter- Count is incremented. This surge detection is used mined by the existing hardware/interface. The correct to determine if the VSD can reduce speed.
Page 357 • Speed Decrease Inhibit – Surge Map Point – eration (Form 160.54-O1) FIGURE 35, the ACC DE- Illuminates when the ACC function in the mi- TAILS Screen in YORK Protocol configuration. The croboard is unable to reduce speed due to a following data boxes are added: mapped surge point.
Page 358 If equipped with a VSD (YORK or Modbus pro- * will be replaced by an O. To view the details of any tocol configuration) or MV VSD, this feature only mapped point, position the green box (□) over the de-...
Page 359 The Italian translations of the following messages were when a surge is detected by the surge protection fea- corrected in this software version: ture. If equipped with a VSD (YORK or Modbus pro- • Condenser-Pressure Transducer Out of Range tocol configuration) or MV VSD, this feature only detects surges that occur while the drive is running at •...
Page 360 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0201 - SOFTWARE ENHANCEMENTS (VER 19) EFFECTIVE OCTOBER 2008 (CONT'D) • When motor current less than or equal to 80% • Condenser – High Pressure – Stopped – Trip/ FLA - No Limiting Reset threshold is 170 psig.
Page 361: Si0210 - Software Enhancements (Ver 20) Effective June 2009
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0210 - SOFTWARE ENHANCEMENTS (VER 20) EFFECTIVE JUNE 2009 GENERAL Mobus Beginning June 2009, enhanced software will be sup- plied in new production YK chillers and replacement Address Name Scale microboard kit (P/N 331-02430-601).
Page 362 The label for the toll free number was changed from full load amps setpoint on the MV VSD screen is now YORK International North American Toll Free Num- set to the programmed drive current (Modbus Address ber to Johnson Controls North America Parts Center.
Page 363: Si0212 - Software Enhancements (Ver 21) Effective June 2009
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0212 - SOFTWARE ENHANCEMENTS (VER 21) EFFECTIVE JUNE 2009 GENERAL VSD ADAPTIVE CAPACITY CONTROL ENHANCEMENTS Beginning August 2009, enhanced software will be supplied in new production YK chillers and replace- The following enhancements were added.
Page 364 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0212 - SOFTWARE ENHANCEMENTS (VER 21) EFFECTIVE JUNE 2009 (CONT'D) In previous software versions, the initial ramp is com- FREQUENCY COMMAND MOTOR plete when either of the following conditions occur: INCREASE CURRENT 1.0 Hz...
Page 365 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0212 - SOFTWARE ENHANCEMENTS (VER 21) EFFECTIVE JUNE 2009 (CONT'D) In this version, to avoid an OIL – LOW TEMPERATURE Heat Recovery DIFFERENTIAL condition from preventing a chiller This software supports the new heat recovery option. start after running at low load conditions for extended This option uses two tube bundles in the condenser.
Page 366 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0212 - SOFTWARE ENHANCEMENTS (VER 21) EFFECTIVE JUNE 2009 (CONT'D) Head Pressure Control Quick Start Mode YK chillers are capable of operation within a wide The quick start feature is useful in data center and pro- range of condenser water temperatures.
Page 367 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0212 - SOFTWARE ENHANCEMENTS (VER 21) EFFECTIVE JUNE 2009 (CONT'D) This feature can only be enabled if the motor drive type setpoint is set to MV VSD or VSD (and the motor communications protocol setpoint is set to Modbus).
Page 368: Si0224 - Software Enhancements (Ver 22) Effective April 2010
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0224 - SOFTWARE ENHANCEMENTS (VER 22) EFFECTIVE APRIL 2010 GENERAL Beginning April 2010, enhanced software will be sup- The hardware involved in this feature consists of motor plied in new production YK chillers and replacement temperature sensors, vibration sensors, a cooling coil microboard kit (P/N 331-02430-601).
Page 369: Si0252 - Software Enhancements (Ver 23) Effective May 2011
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0252 - SOFTWARE ENHANCEMENTS (VER 23) EFFECTIVE MAY 2011 GENERAL Beginning May 2011, enhanced software will be sup- • The PRV VGD inhibit setpoint default changed plied in new production YK chillers and replacement from 95% to 100%.
Page 370 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0252 - SOFTWARE ENHANCEMENTS (VER 23) EFFECTIVE MAY 2011 (CONT'D) FAULTS HISTORY SCREEN If the VSD – HIGH PHASE (X) INSTANTANEOUS The following enhancements were made: FAULT CYCLING fault occurs three times in 10 min- •...
Page 371: Table 32 - Loop Back Connections
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0252 - SOFTWARE ENHANCEMENTS (VER 23) EFFECTIVE MAY 2011 (CONT'D) SECURITY LOG – MANUAL RESET DIAGNOSTICS WARNINGS COM2 RS-485 Port In previous software versions, a generic message In previous software versions, there was no serial port WARNING RESET was added to the security log loopback test for COM2 RS-485.
Page 372: Si0265 - Software Enhancements (Ver 24) Effective May 2012
If the chiller is stopped and the Saturated Con- logo was changed to conform to the JCI standard denser Temperature falls below 35.0 °F, the panel "YORK by Johnson Controls". The new BIOS will display the message: “Warning – Condenser eprom is P/N 031-02429-002.
Page 373 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0265 - SOFTWARE ENHANCEMENTS (VER 24) EFFECTIVE MAY 2012 (CONT'D) This warning will automatically reset whenever Graphics Library - Selection Box Wraparound the chiller is running or the Saturated Condenser An enhancement has been added to allow the green se- Temperature is >...
Page 374: Si0271 - Software Enhancements (Ver 25) Effective August 2013
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0271 - SOFTWARE ENHANCEMENTS (VER 25) EFFECTIVE AUGUST 2013 GENERAL Leaving Chilled Liquid Shutdown Temperature Beginning May 2013, enhanced software will be sup- plied in new production YK chillers and replacement The past logic that set the Shutdown Temperature to microboard kit 331-02430-601.
Page 375 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0271 - SOFTWARE ENHANCEMENTS (VER 25) EFFECTIVE AUGUST 2013 (CONT'D) On startup the Shutdown Temperature is set to the cal- tion is above 95% and released when the PRV position culated value.
Page 376 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0271 - SOFTWARE ENHANCEMENTS (VER 25) EFFECTIVE AUGUST 2013 (CONT'D) This warning requires a manual reset when the above Isolation Valve Configuration conditions are no longer true. The message “Loss of Subcooler Liquid Seal Warning Reset”...
Page 377: Figure 118 - Diagnostic Screen
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0271 - SOFTWARE ENHANCEMENTS (VER 25) EFFECTIVE AUGUST 2013 (CONT'D) If the Isolation Valves option is disabled: Data Logging Control When Data Logging is enabled, data values are seri- • Isolation Valves Open output is energized. ally transmitted to the RS-232 port at an interval de- •...
Page 378: Table 33 - Data Logging
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0271 - SOFTWARE ENHANCEMENTS (VER 25) EFFECTIVE AUGUST 2013 (CONT'D) TABLE 33 - DATA LOGGING NUMBER DATA VALUE HEADING TEXT CHILLER DATA Date (DD/MM/YYYY format) Date Time (24 Hour format) Time Elapsed Time (seconds since data logging started) Elapsed Time...
Page 379 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0271 - SOFTWARE ENHANCEMENTS (VER 25) EFFECTIVE AUGUST 2013 (CONT'D) TABLE 33 - DATA LOGGING (CONT'D) NUMBER DATA VALUE HEADING TEXT Oil Sump Pressure Oil Sump Oil Differential Pressure Oil Diff Pressure Oil Pump Command Frequency Oil Pump Cmd Freq Oil Pump Pressure Setpoint...
Page 380 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0271 - SOFTWARE ENHANCEMENTS (VER 25) EFFECTIVE AUGUST 2013 (CONT'D) TABLE 33 - DATA LOGGING (CONT'D) NUMBER DATA VALUE HEADING TEXT Filter L3 RMS Filter Current Filter L3 Filter Cur Filter L1 RMS Supply Current Filter L1 Supply Cur Filter L2 RMS Supply Current...
Page 381: Figure 119 - Head Pressure Control Screen
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0283 - SOFTWARE ENHANCEMENTS (VER 26) EFFECTIVE APRIL 2014 GENERAL Both settings have a minimum limit of 0% and a maxi- Beginning in April 2014, enhanced software will be mum limit of 100% with an initial default position supplied in new production YK chillers and replace- of 0%.
Page 382: Figure 120 - Power Fault Recovery Screen
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0283 - SOFTWARE ENHANCEMENTS (VER 26) EFFECTIVE APRIL 2014 (CONT'D) The following settings are displayed on the Power Fault Recovery Screen: PROGRAM HIGH SCREEN MODE DEFAULT SETTING LIMIT LIMIT Power Fault VSD Low Frequency Recovery - 60 sec...
Page 383 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0283 - SOFTWARE ENHANCEMENTS (VER 26) EFFECTIVE APRIL 2014 (CONT'D) 5. On heat pump-equipped YK chillers with a LC- 11. The Unit Operating Code number 14 = “Unit SSS, the condenser loop liquid is typically too hot Starting –...
Page 384: Si0300 - Software Enhancements (Ver 27) Effective June 2015
FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0300 - SOFTWARE ENHANCEMENTS (VER 27) EFFECTIVE JUNE 2015 GENERAL QUICK START – OIL HEATER CONTROL Beginning June 2015, enhanced software will be To prevent overloading of the three phase transformer supplied in new production YK chillers and the re- that powers the oil pump and oil heater, the Quick Start placement microboard kit 331-02430-601.
Page 385 When an ACC board is installed and the VSD commu- • Saturated Condenser Temperature is > 36.0 °F nications must therefore be YORK Protocol, the PRV calibration voltage is monitored in the ACC board and Warning - Condenser – Freeze Threat – Flow not communicated to the microboard.
Page 386 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0300 - SOFTWARE ENHANCEMENTS (VER 27) EFFECTIVE JUNE 2015 (CONT'D) P203 Auto-Lubrication System A new version of the ISOLATION VALVES auto-luber, the Lincoln P203 allows the OptiView pan- The control of Isolation Valves is changed to the fol- el to control the lubrication timing which allows the lowing LTC I/O board locations.
Page 387 FORM 160.54-M1 SECTION 36 - SOFTWARE ENHANCEMENTS ISSUE DATE: 10/25/2019 SI0300 - SOFTWARE ENHANCEMENTS (VER 27) EFFECTIVE JUNE 2015 (CONT'D) E-LINK CODE ADDITIONS LANGUAGES The following new code definitions have been added in The panel now supports Turkish. this software release and is compatible with the E-Link LCHWT REMOTE RESET data table for YK OptiView BAS (Rev K_04a).
Page 388 FORM 160.54-M1 ISSUE DATE: 10/25/2019 NOTES JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS...
Page 389: Table 34 - Si Metric Conversion
FORM 160.54-M1 ISSUE DATE: 10/25/2019 The following factors can be used to convert from English to the most common SI Metric values. TABLE 34 - SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW) Power...
Page 390 5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 1-800-524-1330 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2019 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 160.54-M1 (1019) Issue Date: October 25, 2019 Supersedes: 160.54-M1 (319) Johnson Controls Company Confidential...

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