Page 1 AIR-COOLED SCREW LIQUID CHILLERS INSTALLATION, OPERATION, MAINTENANCE Supersedes: 201.23-NM2 (610) Form 201.23-NM2 (315) 035-21506-101 YCIV STYLE A MODELS YCIV0157-0397, 60 HZ (150-260 TONS) AIR-COOLED SCREW LIQUID CHILLERS E/V HIGH EFFICIENCY AND S/P STANDARD EFFICIENCY R134A Issue Date: March 9, 2015...
Page 2 All wiring must be in accor- dance with Johnson Controls’ published specifications and must be performed only by a qualified electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of improper control signals.
Page 3 FORM 201.23-NM2 ISSUE DATE: 3/9/2015 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 MODEL NUMBER UNIT DESIGNATOR UNIT DESIGNATOR VOLTAGE CODE E- High Efficiency with Standard IPLV 17=200-3-60 S- Standard Efficiency with Standard IPLV 28=230-3-60 P- Standard Efficiency with Optimized IPLV 40=380-3-60 V- High Efficiency with Optimized IPLV 46=460-3-60 50=380/400/415-3-50 58=575-3-60 JOHNSON CONTROLS...
Page 5: Table Of Contents
Variable Speed Drive (VSD) ........................29 Accessories and Options ..........................30 Sound Reduction Options ........................30 Condenser Coil Protection ........................31 Protective Chiller Panels ........................31 Evaporator Options ..........................32 General Options ............................32 Vibration Isolation ..........................32 Complete Pin Number Description ......................... 34 JOHNSON CONTROLS...
Page 6 System Inputs ..............................49 Flow Switch ............................49 Remote Run / Stop ..........................49 Remote Print ............................49 Optional Remote Setpoint Offset – Temperature................... 49 Optional Remote Setpoint Offset – Current ................... 49 Optional Remote Setpoint Offset – Sound Limiting ................49 JOHNSON CONTROLS...
Page 7 Start-up ..............................53 Oil Pressure ............................53 Refrigerant Flow ............................53 Loading ..............................53 Condenser and Fan Rotation ........................ 53 Suction Superheat ..........................53 Subcooling .............................53 General Operation ..........................53 Operation in Sub-freezing Conditions ....................54 Unit Maintenance and Shutdown in Sub-freezing Conditions .............. 54 JOHNSON CONTROLS...
Page 8 ND-X Neoprene Isolator Specifications ....................170 Installation of Neoprene Mounts ......................170 CIP 1" Deflection Restrained Mounting Specifications ................ 171 Installation of 1" Deflection Mounts ..................... 172 Refrigerant Flow Diagram ..........................173 Process and Instrumentation Diagram ......................174 JOHNSON CONTROLS...
Page 9 Minimum VSD Compressor Start / Run Frequency ..................212 Minimum VSD Start Frequency ......................212 Minimum VSD Run Frequency ......................212 Acceleration / Deceleration Rate when Starting / Stopping Compressors ........... 213 VSD Acceleration and Deceleration Rates ..................213 JOHNSON CONTROLS...
Page 10 Remote Current Limit Reset Control ......................227 Remote ISN Current Limit Setpoint ..................... 228 Remote Current Limit Reset ........................ 228 Sound Limit Control ............................229 Sound Limiting and Local Sound Limit Setpoint .................. 229 ISN Sound Limit Setpoint ........................229 Remote Sound Limit ..........................229 JOHNSON CONTROLS...
Page 11 Invalid Serial Number Warning ......................242 Optimized Efficiency Disabled ......................242 Unit Safeties ..............................243 Unit Safety Operation ..........................243 High Ambient Temp Fault ........................243 Low Ambient Temp Fault ........................243 Low Leaving Chilled Liquid Temp Fault ....................243 VSD Communications Failure Fault ....................244 JOHNSON CONTROLS...
Page 12 All Fault Data ............................261 Unit Data .............................262 VSD Data ............................262 System Data ............................263 Compressor Operating Hours and Starts .................... 264 Chilled Liquid Setpoint Cooling Setpoints ................... 265 Options ..............................265 Remote Temperature Reset ........................ 265 Program Values ...........................266 Pulldown Current Limit ........................266 JOHNSON CONTROLS...
Page 13 Enabling Optimized High IPLV Mode ......................291 Unit Setup Mode ............................292 Default Programmable Values ........................293 Serial Port Connections ..........................293 Analog Input Connections ..........................294 Digital Intput Connections ..........................296 Analog Output Connections ......................... 297 Digital Output Connections ........................... 298 JOHNSON CONTROLS...
Page 14 Weigh-tronix IMP 24 Model 2600 ......................327 Seiko ..............................327 Operating Log Sheet ............................ 328 Site and Chiller Information .........................328 Programmed Values ..........................328 System Operating Conditions ......................330 Water System Conditions ........................331 Condenser Conditions .........................331 Recommended Spare Parts ......................... 332 JOHNSON CONTROLS...
Page 15 FIGURE 40 - VSD Components, 3 Compressor ....................191 FIGURE 41 - Inverter Power Components, 2 Compressor ...................192 FIGURE 42 - Inverter Power Components, 3 Compressor ...................193 FIGURE 43 - Inverter Power Components ......................194 FIGURE 44 - Glycol Pump and Fill Tube Locations ....................196 JOHNSON CONTROLS...
Page 16 FIGURE 57 - Condenser Fan Locations........................224 FIGURE 58 - Standard IPLV Fan Control ......................225 FIGURE 59 - High IPLV Fan Control ........................225 FIGURE 60 - Control Board Connections......................301 FIGURE 61 - Print Cable - Chiller to Serial Printer ....................326 JOHNSON CONTROLS...
Page 17 TABLE 33 - Pressure Transducer Output Voltage (Measured Signal to Return at the Transducer) ..... 321 TABLE 34 - Motor Temperature Sensor Resistance (Check at the Motor) ............322 TABLE 35 - Compressor Motor Overload Settings and Max. VSD Frequency ............. 323 JOHNSON CONTROLS...
Page 18 FORM 201.23-NM2 SAFETY SYMBOLS ISSUE DATE: 3/9/2015 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 19: Section 1 - General Chiller Information And Safety
WARRANTY The chillers comply with the applicable sections of the Johnson Controls warrants all equipment and materials following Standards and Codes: against defects in workmanship and materials for a pe- riod of eighteen months from date of shipment, unless • ANSI/ASHRAE Standard 15, Safety Code for...
Page 20: Responsibility For Safety
This manual and any other document supplied with cept Low-Rise Residential Buildings. the unit are the property of Johnson Controls which re- serves all rights. They may not be reproduced, in whole • ARI 370 Sound Rating of Large Outdoor Refrig- or in part, without prior written authorization from an eration and Air Conditioning Equipment.
Page 21: Pressure Systems
Reasonable care should be taken when trical supply from the inverter system, thus shutting working in contact with the coils to avoid the risk of down the unit. minor abrasions and lacerations. The use of gloves is recommended. JOHNSON CONTROLS...
Page 22 FORM 201.23-NM2 SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY ISSUE DATE: 3/9/2015 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 23: Section 2 - Product Description
405 PSIG design working pressure. Oil cooling is accomplished by rout- ing oil from the oil separator through several rows of tubes in the air cooled condenser. JOHNSON CONTROLS...
Page 24: Compressor
The compressor is a positive displacement type characterized by two helically grooved rotors, LD10482 which are manufactured from forged steel. The 4 pole motor operates at speeds up to 6000 RPM to direct FIGURE 2 - COMPRESSOR JOHNSON CONTROLS...
Page 25: Evaporator
6-pole, 3-phase, Class- “F,” current overload protected, totally enclosed (TEAO) type with double- The cooler is equipped with a thermostatically con- sealed, permanently lubricated ball bearings. trolled heater for protection to -20°F (-29°C) ambient and insulated with 3/4" (19 mm) flexible closed-cell insulation. JOHNSON CONTROLS...
Page 26: Flash Tank Feed Valve/Drain Valves
OFF, the liquid level will vary tank and a 250 PSIG relief valve is located on the suc- greatly as the Drain and Feed Valves directly affect the tion line of the compressor near the evaporator. level as they open and close. JOHNSON CONTROLS...
Page 27: Oil Cooling
115VAC points. control transformer, VSD, fan contactors, ON/OFF unit switch, microcomputer keypad and display, Chill- er Control and VSD Logic Boards, and relay boards. JOHNSON CONTROLS...
Page 28: Keypad
Unit Switch • Up to 10 fault shutdown histories. A master UNIT switch allows activation or de-activa- tion of the chiller system. Separate system switches for controlling each system are provided as part of the chiller control panel keypad. JOHNSON CONTROLS...
Page 29: Variable Speed Drive (Vsd)
VSD is powered off, “bleeder” resistors (1RES and 2RES) are connected across the capacitor banks. LD10480 FIGURE 4 - PWM VOLTAGE WAVEFORM JOHNSON CONTROLS...
Page 30: Accessories And Options
Board. The Bus Isolator board utilizes three resistors eas, hotels, or hospitals etc., where background noise on the board to provide a “safe” impedance (resis- is limited. When paired with the Two-Speed Fan op- JOHNSON CONTROLS...
Page 31: Condenser Coil Protection
Heavy design parameters and related environmental factors. gauge, welded wire-mesh, coated to resist corrosion, (Factory-mounted) around base of machine to restrict unauthorized access. (Factory-mounted) JOHNSON CONTROLS...
Page 32: Evaporator Options
Service Isolation Valve minimum 1.0g accelerated force in all directions up to Service suction isolation valve added to unit for each 2" (51mm). The deflection may vary slightly by ap- refrigerant circuit. (Factory-mounted) plication. They are level adjustable. (Field-mounted) JOHNSON CONTROLS...
Page 33 MODEL NUMBER UNIT DESIGNATOR UNIT DESIGNATOR VOLTAGE CODE E- High Efficiency with Standard IPLV 17=200-3-60 S- Standard Efficiency with Standard IPLV 28=230-3-60 P- Standard Efficiency with Optimized IPLV 40=380-3-60 V- High Efficiency with Optimized IPLV 46=460-3-60 50=380/400/415-3-50 58=575-3-60 JOHNSON CONTROLS...
Page 34: Complete Pin Number Description
Special Power Option Control Transformer required Control Transformer TRANS (PIN 18) Special Transformer or Power Strip required No Option Required Convenience Outlet Convenience Outlet, 115V GFI (PIN 19) (Customer Powered) Special quote No option required PIN 20 Special quote JOHNSON CONTROLS...
Page 35 Valves (PIN 32) Special Optional Valves required No option required HGBP PIN 33 Special quote No option required GAUGE PIN 34 Special quote No option required OVERLOAD PIN 35 Special quote No option required PIN36 PIN 36 Special quote JOHNSON CONTROLS...
Page 36 Wire/Louvered Encl Panels (factory) Wire/Louvered Encl Panels (field) PANEL Enclosure Panels (PIN 48) Louvered (cond only) Encl Panels (factory) Louvered (cond only) Encl Panels (field) Louvered (full unit) Encl Panels (factory) Louvered (full unit) Encl Panels (field) Special Enclosure Panels required JOHNSON CONTROLS...
Page 37 Special quote No option required PIN60 PIN 60 Special quote Plant of Mfg (PIN 61) Plant of Manufacture - Monterrey Monterrey Mfg Location San Antonio YorkWorks configuration version {cv} YorkWorks Version YorkWorks upload version {uv} Special Quote Special quote JOHNSON CONTROLS...
Page 38 FORM 201.23-NM2 ISSUE DATE: 3/9/2015 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 39: Section 3 - Rigging, Handling And Storage
• Do not store where exposed to ambient air tem- Major damage must be reported immediately to your peratures exceeding 43°C (110°F). local Johnson Controls representative. JOHNSON CONTROLS...
Page 40: Moving The Chiller
5. Attach lifting rigging from the crane and slowly the top rails. Use only the lifting holes provided. complete the removal from the container then lift up and away. Lifting Instructions are placed on a label on the chiller and on the shipping bag. LD19197a JOHNSON CONTROLS...
Page 41 NOTE: Weights and approximate center of gravity location shown for base unit. Any options selected may add weight to the unit and affect the center of gravity. Locate the center of gravity through trial lifts to account for possible variations in unit configuration. Contact your nearest Johnson Controls Sales Office for weight data. JOHNSON CONTROLS...
Page 42 FORM 201.23-NM2 ISSUE DATE: 3/9/2015 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 43: Section 4 - Installation
This will allow vibration tion, the same requirement of static pressure loss ap- isolators to be fitted if required. Isolators are recom- plies as for ducts and attenuators stated above. mended for rooftop locations. JOHNSON CONTROLS...
Page 44: Vibration Isolators
June 15, 2008 by the chiller controls or external to the unit. For de- and Pages 170 through 174 for units tails, refer to “Electrical Elementary and Connection shipped before June 15, 2008. Diagrams.” JOHNSON CONTROLS...
Page 45: Water Treatment
If there is a potential for power loss, Johnson Controls recommends that the Piping and fittings immediately next to the cooler evaporator is drained or that water in the chilled water...
Page 46: Pipework Arrangement
Valve types should not be mixed on a common pipe. Precautions should be taken to ensure the outlets of relief valves or relief valve vent pipes remain clear of obstructions at all times. JOHNSON CONTROLS...
Page 47: Ductwork Connection
Units are supplied with outlet guards for safety and to prevent damage to the fan blades. If these guards are removed to fit ductwork, adequate alternative precau- tions must be taken to ensure persons cannot be harmed or put at risk from rotating fan blades. JOHNSON CONTROLS...
Page 48: Power Wiring
In cold weather, taken via a common point of isolation (not this could cause serious damage to the supplied by Johnson Controls). chiller due to evaporator freeze-up. Do not remove power unless alternate means are taken to ensure operation of the evaporator heater.
Page 49: Volts Free Contacts
Remote Run / Stop 229 for a description of the option. A Remote Run/Stop input is available for each pair of systems (1/3 and 2/4). These inputs require a dry con- tact to start and stop the system. System 1/3 remote JOHNSON CONTROLS...
Page 50 FORM 201.23-NM2 ISSUE DATE: 3/9/2015 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 51 Service and Oil Line Valves Commissioning of this unit should only Open each compressor suction, economizer, and dis- be carried out by Johnson Controls Au- charge service valve. If valves are of the back-seat thorized personnel. type, open them fully (counterclockwise) then close one turn of the stem to ensure operating pressure is fed to pressure transducers.
Page 52 It provides locks are in the run position and that the Daily Sched- some freeze protection and must always be fully in- ule requires the unit to run or is overridden. serted in the water outlet sensor well. JOHNSON CONTROLS...
Page 53 This pressure is controlled by stages of fans to 61). The chiller is then ready to be placed into opera- ensure maximum unit efficiency while maintaining tion. sufficient pressure for correct operation of the con- densers and the lubrication system. JOHNSON CONTROLS...
Page 54 For units without a suction service valve, If there is potential for power loss, Johnson Controls close the discharge and compressor oil valves. recommends the water in the chilled water circuit be...
Page 55 This is normal and a level is only required in high and the oil is being pumped out into the system one separator. Do not add oil to raise the level in the where it will cause heat transfer and control problems. other oil separator. JOHNSON CONTROLS JOHNSON CONTROLS...
Page 56 When- ever the pump contacts are used, the coil of the pump starter should be suppressed with an RC System 3 = ______________ Amps suppressor (031-00808-000)........System 4 = ______________ Amps JOHNSON CONTROLS JOHNSON CONTROLS...
Page 57 If the following message appears when the STATUS key Sound Limit Setpoint = ______________________% is pressed, immediately contact Johnson Controls Product Technical Support. The appearance of this message indi- cates the chiller is a High IPLV chiller operating in Standard C.
Page 58 The temperature of the liquid refrigerant out of the condenser should be about 5 to 7°F (2.77 3.78°C) less than the condensing temperature (The temperature corresponding to the con- densing pressure from the refrigerant tempera- ture/pressure chart). JOHNSON CONTROLS JOHNSON CONTROLS...
Page 59 If the chiller is functioning satisfactorily during the initial op- SERIAL #: ______________________________ erating period, no safeties trip and the chiller controls chilled liquid temperature; it is now ready to be placed into service. COMPRESSOR #4 MODEL#: ______________________________ SERIAL #: ______________________________ JOHNSON CONTROLS JOHNSON CONTROLS...
Page 60 FORM 201.23-NM2 SECTION 5 - COMMISSIONING ISSUE DATE: 3/9/2015 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 61: Section 6 - Technical Data
Pressure Drop Through Two Circuit YCIV Evaporators 1000 Water Flow Rate (GPM) Excessive flow, above the max. GPM, will MODEL NUMBER YCIV COOLER damage the evaporator. 60HZ 0157(S/P) 0157(E/V) 0177(S/P/E/V) 0187(S/P/E/V) 0197(E/V) 0207(E/V) 0227(E/V) 0207(S/P) 0227(S/P) 0247(S/P/E/V) 0267(S/P) JOHNSON CONTROLS...
Page 62 SI UNITS Pressure Drop Through Two Circuit YCIV Evaporators Water Flow Rate (l/s) Excessive flow, above the max. GPM, will MODEL NUMBER YCIV COOLER damage the evaporator. 60HZ 0157(S/P) 0157(E/V) 0177(S/P/E/V) 0187(S/P/E/V) 0197(E/V) 0207(E/V) 0227(E/V) 0207(S/P) 0227(S/P) 0247(S/P/E/V) 0267(S/P) JOHNSON CONTROLS...
Page 63 Pressure Drop Through Three Circuit YCIV Evaporators Pressure Drop Through Three Circuit YCIV Evaporators 1000 2000 Water Flow Rate (GPM) Excessive flow, above the max. GPM, will MODEL NUMBER YCIV EVAP damage the evaporator. 60HZ 0267EA/VA 0287SA/PA 0287EA/VA 0307SA/PA 0327EA/VA 0357SA/PA 0357EA/VA 0397SA/PA JOHNSON CONTROLS...
Page 64 Pressure Drop Through Three Circuit YCIV Evaporators Pressure Drop Through Three Circuit YCIV Evaporators 1000 10.0 100.0 Water Flow Rate (l/s) Excessive flow, above the max. GPM, will MODEL NUMBER YCIV EVAP damage the evaporator. 60HZ 0267EA/VA 0287SA/PA 0287EA/VA 0307SA/PA 0327EA/VA 0357SA/PA 0357EA/VA 0397SA/PA JOHNSON CONTROLS...
Page 65: Glycol Correction Factors
B = Mean Temperature through Cooler PROPYLENE GLYCOL B= Mean Temperature through Cooler C= Concentration W/W C = Concentration WIW Excessive flow, above the max. GPM, will Excessive flow, above the max. GPM, damage the evaporator. will damage the evaporator. LD10500A JOHNSON CONTROLS...
Page 66: Water Temperature And Flows
0397(S/P) 1200 NOTES: 1. For leaving brine temperature below 40°F (4.4°C), contact your nearest Johnson Controls office for application requirements. 2. For leaving water temperature higher than 60°F (15.6°C), contact the nearest Johnson Controls office for application guidelines. JOHNSON CONTROLS...
Page 67 18.9 75.7 -17.8 51.7 NOTES: 1. For leaving brine temperature below 4.4°C, contact your nearest Johnson Controls office for application requirements. 2. For leaving water temperature higher than 15.6°C, contact the nearest Johnson Controls office for application guidelines. JOHNSON CONTROLS...
Page 68: Physical Data (English - Standard Efficiency)
140.0 140.0 140.0 Maximum Water Side Pressure, PSIG Maximum Refrigerant Side Pressure, PSIG Minimum Chilled Water Flow Rate, gpm Maximum Chilled Water Flow Rate, gpm Water Connections, inches Contact your nearest Johnson Controls Sales Office for weight data. JOHNSON CONTROLS...
Page 69 Maximum Water Side Pressure, PSIG Maximum Refrigerant Side Pressure, PSIG Minimum Chilled Water Flow Rate, gpm Maximum Chilled Water Flow Rate, gpm 1200 1200 1200 1200 Water Connections, inches Contact your nearest Johnson Controls Sales Office for weight data. JOHNSON CONTROLS...
Page 70: Physical Data (English - High Efficiency)
Evaporator, Direct Expansion Water Volume, gals. 95.0 95.0 95.0 110.0 110.0 110.0 140.0 Maximum Water Side Pressure, PSIG Maximum Refrigerant Side Pressure, PSIG Minimum Chilled Water Flow Rate, gpm Maximum Chilled Water Flow Rate, gpm Water Connections, inches JOHNSON CONTROLS...
Page 71 Evaporator, Direct Expansion Water Volume, gals. 202.0 202.0 236.0 236.0 Maximum Water Side Pressure, PSIG Maximum Refrigerant Side Pressure, PSIG Minimum Chilled Water Flow Rate, gpm Maximum Chilled Water Flow Rate, gpm 1200 1200 1200 1200 Water Connections, inches JOHNSON CONTROLS...
Page 72: Physical Data (Si - Standard Efficiency)
Maximum Water Side Pressure, Bar Maximum Refrigerant Side Pressure, Bar Minimum Chilled Water Flow Rate, l/sec. 10.1 10.1 11.4 11.4 11.4 11.4 Maximum Chilled Water Flow Rate, l/sec. 42.6 47.3 47.3 50.5 50.5 50.5 50.5 Water Connections, inches JOHNSON CONTROLS...
Page 73 Total Chiller, m3/s Evaporator, Direct Expansion Water Volume, liters 764.6 893.3 893.3 893.3 Maximum Water Side Pressure, Bar Maximum Refrigerant Side Pressure, Bar Minimum Chilled Water Flow Rate, l/sec. Maximum Chilled Water Flow Rate, l/sec. Water Connections, mm JOHNSON CONTROLS...
Page 74: Physical Data (Si - High Efficiency)
Maximum Water Side Pressure, Bar1 Maximum Refrigerant Side Pressure, Bar Minimum Chilled Water Flow Rate, l/sec. 10.1 10.1 10.1 11.4 11.4 11.4 11.4 Maximum Chilled Water Flow Rate, l/sec. 47.3 47.3 47.3 47.3 47.3 47.3 50.5 Water Connections, inches JOHNSON CONTROLS...
Page 75 Total Chiller, m3/s Evaporator, Direct Expansion Water Volume, liters 764.6 764.6 893.3 893.3 Maximum Water Side Pressure, Bar Maximum Refrigerant Side Pressure, Bar Minimum Chilled Water Flow Rate, l/sec. Maximum Chilled Water Flow Rate, l/sec. Water Connections, mm JOHNSON CONTROLS...
Page 76: Electrical Data
2 COMPRESSOR POWER WIRING CONNECTIONS VSD CONTROL PANEL STANDARD UNIT CONTROLS CONTROL TRANSFORMER EVAPORATOR HEATER CONTACTORS LINE REACTOR TERMINAL BLOCK See Note 3 FIELD PROVIDED UNIT POWER SUPPLY FIGURE 9 - TWO COMPRESSOR WIRING DIAGRAM WITH TERMINAL BLOCK JOHNSON CONTROLS...
Page 77: Compressor Power Wiring Connections
FIGURE 10 - THREE COMPRESSOR WIRING DIAGRAM WITH CIRCUIT BREAKER – SINGLE POINT 3 COMPRESSOR POWER WIRING CONNECTIONS VSD CONTROL PANEL STANDARD UNIT CONTROLS CONTROL TRANSFORMER EVAPORATOR EATER CONTACTORS LINE REACTOR TERMINAL FIELD PROVIDED UNIT POWER SUPPL FIGURE 11 - THREE COMPRESSOR WIRING DIAGRAM WITH TERMINAL BLOCK – SINGLE POINT JOHNSON CONTROLS...
Page 78: Standard Efficiency 2-Compressor Units
65KA 30KA 65KA 0177 30KA 65KA 30KA 65KA 0187 30KA 65KA 30KA 65KA 0207 30KA 65KA 30KA 65KA 0227 30KA 65KA 30KA 65KA 0247 30KA 65KA 30KA 65KA 0267 30KA 65KA See page 92 for Electrical Data footnotes. JOHNSON CONTROLS...
Page 79 INVERSE CKT. FUSE/CKT. ELEMENT CKT. FUSE/CKT. ELEMENT TIME CKT. TIME CKT. AMPACITY BREAKER RAT- FUSE AMPACITY BREAKER FUSE BRKR. RAT- BRKR. RAT- (MCA) (3) ING (4) SIZE (2) (MCA) (3) RATING (4) SIZE (2) ING (2) ING (2) JOHNSON CONTROLS...
Page 80 #2 - 600 #2/0 - 500 0247 #2 - 600 #3/0 - 400 #2 - 600 #3/0 - 400 #2 - 600 #2/0 - 500 0267 #2 - 600 #3/0 - 400 #2 - 600 #3/0 - 400 JOHNSON CONTROLS...
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Page 82: High Efficiency 2-Compressor Units
65KA 30KA 65KA 0177 30KA 65KA 30KA 65KA 0187 30KA 65KA 30KA 65KA 0197 30KA 65KA 30KA 65KA 0207 30KA 65KA 30KA 65KA 0227 30KA 65KA 30KA 65KA 0247 30KA 65KA See page 92 for Electrical Data footnotes. JOHNSON CONTROLS...
Page 83 INVERSE CKT. FUSE/CKT. ELEMENT CKT. FUSE/CKT. ELEMENT TIME CKT. TIME CKT. AMPACITY BREAKER RAT- FUSE AMPACITY BREAKER RAT- FUSE BRKR. RAT- BRKR. (MCA) (3) ING (4) SIZE (2) (MCA) (3) ING (4) SIZE (2) ING (2) RATING (2) JOHNSON CONTROLS...
Page 84 #2/0 - 500 KCM 0227 #2 - 600 #2 - 600 #3/0 - #2/0 - 500 KCM 400 KCM #2 - 600 #2/0 - 500 KCM 0247 #2 - 600 #2 - 600 #3/0 - #3/0 - 400 KCM 400 KCM JOHNSON CONTROLS...
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Page 86: Standard Efficiency 3-Compressor Units
RATING SIZE (2) 30KA 65KA 0287 30KA 65KA 30KA 65KA 0307 30KA 65KA 30KA 65KA 0357 30KA 65KA 1000 1000 1000 1000 30KA 65KA 0397 30KA 65KA 1000 1000 1000 1000 See page 92 for Electrical Data footnotes. JOHNSON CONTROLS...
Page 87 #2 - 600 #4/0 - 500 KCM #2 - 600 #4/0 - 500 KCM #2 - 600 #4/0 - 1000 1000 500 KCM #2 - 600 #4/0 - 500 KCM #2 - 600 #4/0 - 1000 1000 500 KCM JOHNSON CONTROLS...
Page 88: High Efficiency 3-Compressor Units
Rating (4) Size (2) (MCA) (3) Rating (4) ing (2) 30KA 65KA 0287 30KA 65KA 30KA 65KA 0307 30KA 65KA 30KA 65KA 0357 30KA 65KA 30KA 65KA 0397 30KA 65KA 1000 See page 92 for Electrical Data footnotes. JOHNSON CONTROLS...
Page 89 #2 - 600 #4/0 - 500 #2 - 600 #4/0 - 500 #2 - 600 #4/0 - 500 #2 - 600 #4/0 - 500 #2 - 600 #4/0 - 500 #2 - 600 #4/0 - 500 1000 1000 JOHNSON CONTROLS...
Page 90: Electrical Notes
2. –– –– –– –– –– –– Dashed Line = Field Provided Wiring. 3. The above recommendations are based on the National Electric Code and using copper conductors only. Field wiring must also comply with local codes. Group Rated breaker must be HACR type for cUL machines. JOHNSON CONTROLS...
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Page 92: Electrical Wiring Diagrams - 2 Compressor Models
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 ELECTRICAL WIRING DIAGRAMS - 2 COMPRESSOR MODELS LD13071 FIGURE 12 - ELEMENTARY CONTROL WIRING DIAGRAM 2 COMPRESSOR MODELS JOHNSON CONTROLS...
Page 93 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13072 FIGURE 12 - ELEMENTARY CONTROL WIRING DIAGRAM 2 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 94: Elementary Power Wiring Diagram
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 Elementary Power Wiring Diagram LD13678 FIGURE 13 - ELEMENTARY POWER WIRING DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS JOHNSON CONTROLS...
Page 95 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13679 FIGURE 13 - ELEMENTARY POWER WIRING DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 96: Power Wiring Connection Diagram
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 Power Wiring Connection Diagram LD13676 FIGURE 14 - POWER WIRING CONNECTION DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS JOHNSON CONTROLS...
Page 97 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13677 FIGURE 14 - POWER WIRING CONNECTION DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 98: Control Wiring Connection Diagram
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 Control Wiring Connection Diagram LD13673 FIGURE 15 - CONTROL WIRING CONNECTION DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS JOHNSON CONTROLS...
Page 99 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13674 FIGURE 15 - CONTROL WIRING CONNECTION DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 100 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13675 FIGURE 15 - CONTROL WIRING CONNECTION DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 101: Power Elementary Wiring Diagram
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 Power Elementary Wiring Diagram LD13081 FIGURE 16 - POWER ELEMENTARY WIRING DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS JOHNSON CONTROLS...
Page 102 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13082 FIGURE 16 - POWER ELEMENTARY WIRING DIAGRAM - YCIV0157-0267 2 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 103: Location Label - 2 Compressor Models
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 Location Label - 2 Compressor Models LD10519 JOHNSON CONTROLS...
Page 104: Panel Layout - 2 Compressor Models
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 Panel Layout - 2 Compressor Models JOHNSON CONTROLS...
Page 105 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 106: Electrical Wiring Diagrams - 3 Compressor Models
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 ELECTRICAL WIRING DIAGRAMS - 3 COMPRESSOR MODELS LD13084 FIGURE 17 - CONTROL ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS JOHNSON CONTROLS...
Page 107 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13085 FIGURE 17 - CONTROL ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 108 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13086 FIGURE 18 - CONTROL ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 109 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13087 FIGURE 18 - CONTROL ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 110: Power Elementary Diagram
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 Power Elementary Diagram LD13088 FIGURE 18 - POWER ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS JOHNSON CONTROLS...
Page 111 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13089 FIGURE 19 - POWER ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 112: Control Wiring Connection Diagram
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 Control Wiring Connection Diagram LD13090 FIGURE 19 - CONTROL WIRING CONNECTION DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS JOHNSON CONTROLS...
Page 113 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13091 FIGURE 19 - CONTROL WIRING CONNECTION DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 114 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13092 FIGURE 19 - CONTROL WIRING CONNECTION DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 115 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 116: Power Wiring Connection Diagram
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 Power Wiring Connection Diagram FIGURE 20 - POWER WIRING CONNECTION DIAGRAM - YCIV1050-1500 3 COMPRESSOR MODELS JOHNSON CONTROLS...
Page 117 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 FIGURE 20 - POWER WIRING CONNECTION DIAGRAM - YCIV1050-1500 3 COMPRESSOR MODELS(CONT'D) JOHNSON CONTROLS...
Page 118 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 FIGURE 20 - POWER WIRING CONNECTION DIAGRAM - YCIV1050-1500 3 COMPRESSOR MODELS(CONT'D) JOHNSON CONTROLS...
Page 119 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 120: Power Elementary Diagram
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 Power Elementary Diagram LD13097 FIGURE 21 - POWER ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS JOHNSON CONTROLS...
Page 121 FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 LD13098 FIGURE 21 - POWER ELEMENTARY DIAGRAM - YCIV0257-0397 3 COMPRESSOR MODELS (CONT'D) JOHNSON CONTROLS...
Page 122: Location Label - 3 Compressor Models
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 Location Label - 3 Compressor Models LD13096 JOHNSON CONTROLS...
Page 123: Panel Layout - 3 Compressor Models
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 Panel Layout - 3 Compressor Models LD13099 JOHNSON CONTROLS...
Page 124: Dimensions - 2 And 3 Compressor Si
– 1.2m; top – no obstructions whatsoever; distance between patterns and possible diminished performance. Johnson Controls adjacent units – 3m. No more than one adjacent wall may be higher unit controls will optimize operation without nuisance high-pressure than the unit.
Page 125 101 5/8" 50" 50 5/16" 9 1/8" VIEW D-D 93 15/16" 45 5/16" 10" 10" WATER OUTLET WATER INLET (3) RIGGING HOLES EACH SIDE (3 X 2) 80" 103 3/8" 33 5/16" 230" POWER: SINGLE POINT WITH TERMINAL BLOCK JOHNSON CONTROLS...
Page 126 – 1.2m; top – no obstructions whatsoever; distance between patterns and possible diminished performance. Johnson Controls adjacent units – 3m. No more than one adjacent wall may be higher unit controls will optimize operation without nuisance high-pressure than the unit.
Page 127 50 5/16" 9 1/8" VIEW D-D 93 15/16" 45 5/16" 10" (WATER INLET) 10" (WATER OUTLET) (3) RIGGING HOLES EACH SIDE 3 X 2 84 1/2" 112 13/16" 103 5/16" 33 5/16" POWER: SINGLE POINT WITH TERMINAL BLOCK JOHNSON CONTROLS...
Page 128 – 1.2m; top – no obstructions whatsoever; distance between patterns and possible diminished performance. Johnson Controls adjacent units – 3m. No more than one adjacent wall may be higher unit controls will optimize operation without nuisance high-pressure than the unit.
Page 129 86 5/16" 50" 50 5/16" 9 1/8" VIEW D-D 93 15/16" 45 5/16" 10" (WATER INLET) 10" (WATER OUTLET) (3) RIGGING HOLES EACH SIDE 3 X 2 88" 103 5/16" 33 5/16" 274" POWER: SINGLE POINT WITH TERMINAL BLOCK JOHNSON CONTROLS...
Page 130 – 1.2m; top – no obstructions whatsoever; distance between patterns and possible diminished performance. Johnson Controls adjacent units – 3m. No more than one adjacent wall may be higher unit controls will optimize operation without nuisance high-pressure than the unit.
Page 131 VIEW D-D 93 15/16" 45 5/16" 10" (WATER INLET) 10" (WATER OUTLET) (4) RIGGING HOLES 112 5/16" 85 5/8" EACH SIDE 3 X 2 92 11/16" 284 7/8" 180 11/16" 33 5/16" 318" POWER: SINGLE POINT WITH TERMINAL BLOCK JOHNSON CONTROLS...
Page 132 – 1.2m; top – no obstructions whatsoever; distance between patterns and possible diminished performance. Johnson Controls adjacent units – 3m. No more than one adjacent wall may be higher unit controls will optimize operation without nuisance high-pressure than the unit.
Page 133 VIEW D-D 93 15/16" 45 5/16" 10" (WATER INLET) 10" (WATER OUTLET) (4) RIGGING HOLES 79 1/8" 113 5/16" EACH SIDE 3 X 2 284 7/8" 180 11/16" 92 11/16" 33 5/16" 318" POWER: SINGLE POINT WITH TERMINAL BLOCK JOHNSON CONTROLS...
Page 134 – 1.2m; top – no obstructions whatsoever; distance between patterns and possible diminished performance. Johnson Controls adjacent units – 3m. No more than one adjacent wall may be higher unit controls will optimize operation without nuisance high-pressure than the unit.
Page 135 9 1/8" 93 15/16" 17 5/8" 45 5/16" 29 7/8" 10" (WATER INLET) 10" (WATER OUTLET) (4) RIGGING HOLES 14 5/8" 197 13/16" EACH SIDE 3 X 2 357" 238 5/8" 141 1/8" 33 3/16" 377 3/16" LD13668 JOHNSON CONTROLS...
Page 136 – 1.2m; top – no obstructions whatsoever; distance between patterns and possible diminished performance. Johnson Controls adjacent units – 3m. No more than one adjacent wall may be higher unit controls will optimize operation without nuisance high-pressure than the unit.
Page 137 93 15/16" 17 5/8" 45 5/16" 29 7/8" (5) RIGGING HOLES 10" (WATER INLET) 10" (WATER OUTLET) EACH SIDE 3 X 2 197 13/16" 14 5/8" 401" 320 1/2" 216 11/16" 123 11/16" 37 3/16" 421 1/4" LD13669 JOHNSON CONTROLS...
Page 138 – 1.2m; top – no obstructions whatsoever; distance between patterns and possible diminished performance. Johnson Controls adjacent units – 3m. No more than one adjacent wall may be higher unit controls will optimize operation without nuisance high-pressure than the unit.
Page 139 49" 9 1/8" 93 15/16" 16 3/16" 45 5/16" 26 3/8" 10" (WATER OUTLET) 10" (WATER INLET) (4) RIGGING HOLES 15" 197 13/16" EACH SIDE 3 X 2 141 1/8" 33 3/16" 357" 238 5/8" 377 3/16" LD13670 JOHNSON CONTROLS...
Page 140 – 1.2m; top – no obstructions whatsoever; distance between patterns and possible diminished performance. Johnson Controls adjacent units – 3m. No more than one adjacent wall may be higher unit controls will optimize operation without nuisance high-pressure than the unit.
Page 141 VIEW D-D 93 15/16" 18 3/16" 45 5/16" 25 1/8" (5) RIGGING HOLES EACH SIDE 3 X 2 10" (WATER INLET) 10" (WATER OUTLET) 15" 197 13/16" 216 11/16" 120 11/16" 33 3/16" 401" 320 1/2" 421 1/4" LD13671 JOHNSON CONTROLS...
Page 142 – 1.2m; top – no obstructions whatsoever; distance between patterns and possible diminished performance. Johnson Controls adjacent units – 3m. No more than one adjacent wall may be higher unit controls will optimize operation without nuisance high-pressure than the unit.
Page 143 VIEW D-D 93 15/16" 18 3/16" 45 5/16" 28 3/8" (5) RIGGING HOLES 10" (WATER OUTLET) 10" (WATER INLET) EACH SIDE 3 X 2 197 13/16" 15" 445" 328 1/8" 217 13/16" 120 11/16" 33 3/16" 465 3/16" LD13672 JOHNSON CONTROLS...
Page 144: Technical Data - Clearances
TECHNICAL DATA - CLEARANCES (1.3 m) (2 m) LD10506A NOTES: 1. No obstructions allowed above the unit. 2. Only one adjacent wall may be higher than the unit 3. Adjacent units should be 10 feet (3 Meters) apart. JOHNSON CONTROLS...
Page 145: Isolator Selection And Mounting
Al Fin Coils 1698 1559 1559 1241 Cu Fin Coils 1698 1680 1898 1620 RS&LS1/Al Fin Coils 1876 1737 1559 1241 RS&LS1/Cu Fin Coils 1876 1858 1898 1620 NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 146 1237 Cu Fin Coils 1720 1715 1479 1429 1585 1195 RS&LS1/Al Fin Coils 1898 1803 1239 1153 1237 RS&LS1/Cu Fin Coils 1898 1894 1479 1429 1590 1195 NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 147 Cu Fin Coils 1775 1768 2884 2978 3241 1338 RS&LS1/Al Fin Coils 1929 1773 2540 2632 2963 1475 RS&LS1/Cu Fin Coils 1951 1944 2884 2978 3307 1647 NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 148 1788 1737 2824 3018 3014 1700 1175 RS&LS1/Al Fin Coils 1942 1795 2540 2632 2628 1592 1232 RS&LS1/Cu Fin Coils 1964 1914 2824 3018 3014 1876 1351 NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 149 Al Fin Coils 1698 1561 1561 1287 Cu Fin Coils 1698 1682 1900 1667 RS&LS1/Al Fin Coils 1876 1739 1561 1287 RS&LS1/Cu Fin Coils 1876 1861 1900 1667 NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 150 1003 Cu Fin Coils 1720 1706 1325 1274 1451 1243 RS&LS1/Al Fin Coils 1898 1795 1085 1102 1003 RS&LS1/Cu Fin Coils 1898 1885 1325 1274 1455 1243 NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 151 1775 1715 2718 2910 2729 1404 1047 RS&LS1/Al Fin Coils 1929 1773 2434 2524 2344 1296 1105 RS&LS1/Cu Fin Coils 1951 1892 2718 2910 2729 1581 1224 NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 152 1788 1737 2824 3018 3014 1700 1157 RS&LS1/Al Fin Coils 1942 1795 2540 2632 2628 1592 1215 RS&LS1/Cu Fin Coils 1964 1914 2824 3018 3014 1876 1334 NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 153 RS&LS1/Cu Fin Coils 0187S/P RIGHT - R (230, 32) (1510, 32) (2780, 32) (4970, 32) (6740, 32) Al Fin Coils Cu Fin Coils RS&LS1/Al Fin Coils RS&LS1/Cu Fin Coils NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 154 RIGHT - R (230, 32) (1510, 32) (2470, 32) (4100, 32) (5350, 32) (7820, 32) Al Fin Coils Cu Fin Coils RS&LS1/Al Fin Coils RS&LS1/Cu Fin Coils NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 155 (7236, 32) (9346, 32) Al Fin Coils 1152 1194 1314 Cu Fin Coils 1308 1351 1470 RS&LS1/Al Fin Coils 1152 1194 1344 RS&LS1/Cu Fin Coils 1308 1351 1500 NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 156 (9530, 32) (11582, 32) Al Fin Coils 1152 1194 1192 Cu Fin Coils 1281 1369 1367 RS&LS1/Al Fin Coils 1152 1194 1192 RS&LS1/Cu Fin Coils 1281 1369 1367 NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 157 RS&LS1/Cu Fin Coils 0187E/V RIGHT - R (230, 32) (1510, 32) (2780, 32) (4970, 32) (6740, 32) Al Fin Coils Cu Fin Coils RS&LS1/Al Fin Coils RS&LS1/Cu Fin Coils NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 158 RIGHT - R (230, 32) (1510, 32) (2470, 32) (4100, 32) (5350, 32) (7820, 32) Al Fin Coils Cu Fin Coils RS&LS1/Al Fin Coils RS&LS1/Cu Fin Coils NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 159 (9105, 32) (10463, 32) Al Fin Coils 1104 1145 1063 Cu Fin Coils 1233 1320 1238 RS&LS1/Al Fin Coils 1104 1145 1063 RS&LS1/Cu Fin Coils 1233 1320 1238 NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 160 (9530, 32) (11582, 32) Al Fin Coils 1152 1194 1192 Cu Fin Coils 1281 1369 1367 RS&LS1/Al Fin Coils 1152 1194 1192 RS&LS1/Cu Fin Coils 1281 1369 1367 NOTES:1. RS = Reduced Sound Option, LS = Low Sound Option JOHNSON CONTROLS...
Page 161 SLRS-2-C2-920 BLUE 029-25336-009 Y2RSI-2D-870 RED 029-24585-010 SLRS-2-C2-1220 GREEN 029-25336-010 Y2RSI-2D-1200N RED/BLACK 029-24585-011 SLRS-2-C2-1760 GRAY 029-25336-011 Y2RSI-2D-1690 PINK 029-24585-012 SLRS-2-C2-2420 SILVER 029-25336-012 Y2RSI-2D-2640N PINK/GRAY Y2RSI-2D-2870N PINK/GRAY/OR- 029-24585-013 SLRS-2-C2-3080 GRAY WITH RED 029-25336-013 ANGE SLRS-2-C2-3740 SILVER WITH 029-24585-014 029-25336-014 Y2RSI-2D-3600 PINK/GRAY/BROWN JOHNSON CONTROLS...
Page 162: One Inch Deflection Spring Isolators Cross-Reference
3. Installation requires bolting or anchoring mount to support structure with a min. (2) 5/8" dia. bolt or (2) 1/2" dia. concrete anchors. 4. All springs are designed for 50 % over-travel. 5. Refer to next page for Installation Instructions. JOHNSON CONTROLS...
Page 163: One Inch Deflection Spring Isolators Installation Instructions
1/4" clearance is achieved between the lower tolerated). housing and upper housing. (See drawing below). 4. Bolt or anchor all isolators to supporting structure 9. Fine adjust isolators to level equipment. utilizing base slotted holes (“C”). 10. Installation is complete. JOHNSON CONTROLS...
Page 164: Durulene Isolator Cross-Reference
4. AL = Mounting hole center to center spacing. 5. HF = Free height of mount, prior to loading. Operating height calculated by the free height less the static deflection under load. All dimensions for reference only. 6. Hardware - Zinc electroplate. JOHNSON CONTROLS...
Page 165: Installation Of Durulene Vibration Isolators
(“A”) be in- stalled on a level surface. Shim or grout as re- quired, leveling all isolator bases to the same elevation (1/32-inch maximum difference can be tolerated). TOP BOLT ("B") TOP WASHER ("C") ("B") ("A") SECTION D-D LD13762B JOHNSON CONTROLS...
Page 166: Seismic Isolator Cross-Reference
3. Equipment must be bolted or welded to the top plate to meet allowable seismic ratings. 4. All springs are designed for 50% overload capacity with exception of the 2D-3280N and 2D-2870. 5. Refer to next page for installation instructions. 6. Consult factory for concrete installation. JOHNSON CONTROLS...
Page 167: Seismic Isolator Installation And Adjustment
(“A”) of isolator. Bolt equipment ment is drained). securely to top plate of isolator using a minimum 13. Installation is complete. ("G") ("E") ("A") ("A") ("E") GROMMET 1/4 - 3/8 GAP EQUIPMENT ("F") WASHER ("E") ("F") ("C") ("C") ("B") LD13763B JOHNSON CONTROLS...
Page 168: Isolator Information For Units Shipped Before June 15, 2008
Silver w/ Red 029-24585-014 * Value is de-rated by 15% Notes: Illustration above shows a SLRS-4-C2 (4 Springs). SLRS-8-2 and C2 have one spring, and SLRS-2-C2 has two springs. SLRS-6-C2 has six springs and SLRS-9-C2 has nine springs. JOHNSON CONTROLS...
Page 169: Slrs Seismic Isolator Installation And Adjustment
LO ER Rubber RESTRAININ Snubbing BOLTS Collar 4" Adjustment Bolt Non-Skid Neoprene Pad- Internal Lower Pad can be removed if Enclosed Neoprene SHIPPED INSTALLED A TER AD STMENT Restraining mounts are welded Steel Acoustical into position. Housing LD10568 JOHNSON CONTROLS...
Page 170: Nd-X Neoprene Isolator Specifications
Mountings should always be bolted excessive weight on individual isolators. to the chiller rails. When mountings and the chiller are installed on steel framing above the ground, the mount- JOHNSON CONTROLS...
Page 171: Cip 1" Deflection Restrained Mounting Specifications
1786-2028 LBS 810 to 920 kg CIP-C-2385 Yellow w/ Green 029-24583-011 2028-2254 LBS 920 to 1022 kg CIP-C-2650 Red w/ Red 029-24583-012 2354-2936 lbs 1022 to 1332 kg CIP-C-2935 Red w/ Green 029-24583-013 * Value is de-rated by 15% JOHNSON CONTROLS...
Page 172: Installation Of 1" Deflection Mounts
To use the 10. Installation is now complete. isolator as blocking for the equipment, insert a 10mm (1/4") shim between the upper load plate and vertical uprights. Lower the equipment on the blocking or shimmed isolators. JOHNSON CONTROLS...
Page 173: Refrigerant Flow Diagram
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 REFRIGERANT FLOW DIAGRAM R134a - R 22 LD10505 FIGURE 22 - REFRIGERANT FLOW DIAGRAM JOHNSON CONTROLS...
Page 174: Process And Instrumentation Diagram
HIGH TEMPERATURE CUTOUT PRESSURE SENSOR LOW PRESSURE CUTOUT TEMPERATURE SENSOR REPLACEABLE CORE FILTER/DRYER LOW TEMPERATURE CUTOUT SIGHT GLASS HIGH PRESSURE CUTOUT FLOW SWITCH (optional) HEATER PRESSURE SWITCH DIFFERENTIAL ELECTRIC HEATER PLUG LD10589A FIGURE 23 - PROCESS AND INSTRUMENTATION DIAGRAM JOHNSON CONTROLS...
Page 175: Component Locations
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 COMPONENT LOCATIONS CHILLER & DISPLAY ELECTRICAL PANEL FANS KEYPAD/DISPLAY PANEL DOOR CONDENSER COIL FILTER DRIER COMPRESSOR MUFFLERS LD13121 FIGURE 24 - COMPONENT LOCATIONS JOHNSON CONTROLS...
Page 176: Figure 25 - Control And Vsd Cabinet Components
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 COMPONENT LOCATIONS (CONT'D) LD10578 FIGURE 25 - CONTROL AND VSD CABINET COMPONENTS JOHNSON CONTROLS...
Page 177: Figure 26 - Chiller Control Board, Relay Boards, Microgateway, And Optional Circuit Breaker
LD10579 OPTIONAL RELAY BOARD #2 CIRCUIT BREAKER (Standard Unit will have terminal blocks.Input power to the chiller will be connected here (see Figures.-31 and 32)). FIGURE 26 - CHILLER CONTROL BOARD, RELAY BOARDS, MICROGATEWAY, AND OPTIONAL CIRCUIT BREAKER JOHNSON CONTROLS...
Page 178: Figure 27 - Chiller Control Board, Relay Boards, And Microgateway, 2 Compressor
RELAY BOARD #1 BOARD CLOCK JUMPER (CLK) RELAY BOARD #2 RS-232/485 JUMPER JP4, JP5, & JP6 LD10580 ▼ ▼ • • • ▲ ▲ JUMPER POSITION FIGURE 27 - CHILLER CONTROL BOARD, RELAY BOARDS, AND MICROGATEWAY, 2 COMPRESSOR JOHNSON CONTROLS...
Page 179: Figure 28 - Chiller Control Board, Relay Boards, And Microgateway, 3 Compressor
BOARD RELAY BOARD #3 RELAY BOARD #1 RELAY BOARD #2 JP4, JP5, & JP6 MICROGATEWAY 50069 (OPTIONAL) ▼ ▼ • • • ▲ ▲ JUMPER POSITION FIGURE 28 - CHILLER CONTROL BOARD, RELAY BOARDS, AND MICROGATEWAY, 3 COMPRESSOR JOHNSON CONTROLS...
Page 180: Figure 29 - Vsd Logic Board
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 COMPONENT LOCATIONS (CONT'D) LOGIC BOARD SCR TRIGGER BOARD LD10582 FIGURE 29 - VSD LOGIC BOARD JOHNSON CONTROLS...
Page 181: Figure 30 - Vsd Logic Board (Original - Obsolete), P/N 031-02477-000
COMPONENT LOCATIONS (CONT'D) (COMPR 4 Over Load Adjust) (COMPR 3 Over Load Adjust) (COMPR 2 Over Load Adjust) (COMPR 1 Over Load Adjust) YORK MADE IN THE USA LD10590 FIGURE 30 - VSD LOGIC BOARD (ORIGINAL - OBSOLETE), P/N 031-02477-000 JOHNSON CONTROLS...
Page 182: Figure 31 - Vsd Logic Board (New), P/N 031-02507-Xxx
SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 COMPONENT LOCATIONS (CONT'D) (COMPR 4 Over Load Adjust) (COMPR 3 Over Load Adjust) (COMPR 2 Over Load Adjust) (COMPR 1 Over Load Adjust) LD13119 FIGURE 31 - VSD LOGIC BOARD (NEW), P/N 031-02507-XXX JOHNSON CONTROLS...
Page 183: Figure 32 - Power Components, 2 Compressor
TRANSFORMER CONTROLLER LD10583 4-9FU FUSES and 14-16FU FUSES INCOMING POWER TRANSIENT GROUND LUGS TRANSFORMER 17-21 FU SUPPRESSOR FUSES TERMINAL INPUT POWER TO BLOCK THE CHILLER CONNECTS 1L AC LINE HERE INDUCTOR FIGURE 32 - POWER COMPONENTS, 2 COMPRESSOR JOHNSON CONTROLS...
Page 184: Figure 33 - Power Components, 3 Compressor
(Hidden from view) 50076 FUSES FU4, 5, 6, 7, 8 ,9 14, 15, 16, 22, 23, 24 TRANSIENT SUPPRESSOR BOARD INPUT POWER TO 11, 12, 13 FU TRANSFORMER THE CHILLER CONNECTS HERE FIGURE 33 - POWER COMPONENTS, 3 COMPRESSOR JOHNSON CONTROLS...
Page 185: Figure 34 - Fan Contactors And 3T Transformer, 2 Compressor
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 COMPONENT LOCATIONS (CONT'D) FAN CONTACTORS 4CR-9CR LD10584 3T TRANSFORMER (24VAC to SCR Gate Driver Board and VSD Logic Board) FIGURE 34 - FAN CONTACTORS AND 3T TRANSFORMER, 2 COMPRESSOR JOHNSON CONTROLS...
Page 186: Figure 35 - Fan Contactors, 3 Compressor
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 COMPONENT LOCATIONS (CONT'D) CONTACTORS (4, 5, 6, 7, 8, 9 11, 12, 13CR) TRANSFORMER 50072 FIGURE 35 - FAN CONTACTORS, 3 COMPRESSOR JOHNSON CONTROLS...
Page 187: Figure 36 - Vsd Components
7-9 FU: Sys. 1 Fans, “DV/DT” Network) COOLING COOLING CONTROL RELAY 14-16 FU: Sys. 2 Fans) LD10585 3-8 RES RESISTORS 1L AC LINE (Motor Output RC INDUCTOR CAPACITORS C15-C17 "DV/DT Network) (Motor Output RC “DV/DT” Network) FIGURE 36 - VSD COMPONENTS JOHNSON CONTROLS...
Page 188: Figure 37 - Vsd Components, 2 Compressor
IGBT GATE SNUBBER DRIVER CAPS BOARDS (C7-C12) IGBT MODULES SCR/DIODE MODULES 1RES AND 2RES LD10586 1L LINE BUS CAPACITOR BUS FILTER INDUCTOR BANK EQUALIZING/ CAPACITORS BLEEDER HEATSINK (Behind Panel) RESISTORS (Water Cooled) FIGURE 37 - VSD COMPONENTS, 2 COMPRESSOR JOHNSON CONTROLS...
Page 189: Figure 38 - Vsd Components, 3 Compressor
TRIGGER BOARD IBGT GATE SNUBBER DRIVER CAPS BOARDS (C7-C12) IBGT MODULES SCR/DIODE MODULES BUS FILTER CAPACITORS 50085 (Behind Panel) 1RES AND 2RES BUS CAPACITOR HEATSINK BANK EQUALIZING/ (Water Cooled) BLEEDER RESISTORS FIGURE 38 - VSD COMPONENTS, 3 COMPRESSOR JOHNSON CONTROLS...
Page 190: Figure 39 - Vsd Components, 2 Compressor
CURRENT CABINET TRANSFORMERS COOLING C13-C17 COIL COOLING FANS RELAYS TRANSIENT SUPPRESSOR BOARD W/ 11FU, 12FU, AND 13 FU FUSES (3 Phase Input) 10CR FAN PUMP CONTROL RELAY LD10587 1L LINE INDUCTOR FIGURE 39 - VSD COMPONENTS, 2 COMPRESSOR JOHNSON CONTROLS...
Page 191: Figure 40 - Vsd Components, 3 Compressor
SNUBBER RESISTORS c24, 25, 26, 21 res15, 16, 17, 18, 19, 20, LINE 22, 23, 18, 19, 20 9, 10, 11, 12, 13, 14, 3, 4, INDUCTORS 5, 6, 7, 8 FIGURE 40 - VSD COMPONENTS, 3 COMPRESSOR JOHNSON CONTROLS...
Page 192: Figure 41 - Inverter Power Components, 2 Compressor
The line inductor will reach operating temperatures of LD10588 over 300° F. Do not open panel doors during operation. Assure the inductor is cool whenever working near the inductor with power OFF. FIGURE 41 - INVERTER POWER COMPONENTS, 2 COMPRESSOR JOHNSON CONTROLS...
Page 193: Figure 42 - Inverter Power Components, 3 Compressor
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 COMPONENT LOCATIONS (CONT'D) TRIGGER BOARD 50077 FIGURE 42 - INVERTER POWER COMPONENTS, 3 COMPRESSOR JOHNSON CONTROLS...
Page 194: Figure 43 - Inverter Power Components
IGBT's IGBT's HEAT SINK SCR/DIODE MODULES SCR/DIODE MODULE LD10591 1RES and 2RES BUS CAPACITORS BANK EQUALIZING/BLEEDER RESISTORS LAMINATED STRUCTURE IGBT GATE DRIVER IGBT GATE BOARD #1 DRIVER BOARD #2 LD10592 IGBT's IGBT's FIGURE 43 - INVERTER POWER COMPONENTS JOHNSON CONTROLS...
Page 195 IGBT GATE DRIVER BOARD WATER COOLED LAMINATED BUS FILTER HEAT SINK BUS STRUCTURE CAPACITORS IGBT LD10593 IGBT's IGBT's SCR/DIODE MODULES SCR/DIODE MODULES LD10594 1RES and 2RES BUS CAPACITORS BANK EQUALIZING/BLEEDER RESISTORS FIGURE 43 - INVERTER POWER COMPONENTS (CONT'D) JOHNSON CONTROLS...
Page 196: Glycol System Components
GLYCOL SYSTEM COMPONENTS REAR VSD PANEL DETAIL "B" DETAIL "C" DETAIL "A" TO GLYCOL PUMP (SEE DETAIL "A") DETAIL "B" TYPICAL 4 PLACES GLYCOL PUMP (SEE DETAIL "A") DETAIL "C" LD13122A FIGURE 44 - GLYCOL PUMP AND FILL TUBE LOCATIONS JOHNSON CONTROLS...
Page 197: Figure 45 - Glycol Piping And Fill Tube Location
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 GLYCOL SYSTEM COMPONENTS (CONT'D) GLYCOL FILL TUBE LD10597 FIGURE 45 - GLYCOL PIPING AND FILL TUBE LOCATION JOHNSON CONTROLS...
Page 198: Compressor Components
FORM 201.23-NM2 SECTION 6 - TECHNICAL DATA ISSUE DATE: 3/9/2015 COMPRESSOR COMPONENTS LD10596 FIGURE 46 - COMPRESSOR COMPONENTS JOHNSON CONTROLS...
Page 199: Chiller Electronic Components
• ► RIGHT ARROW of data such as Unit, System, and VSD data. The numeric keys allow keying numeric values into memory. The • (PERIOD/DECIMAL) key allows keying a decimal point into numeric values. JOHNSON CONTROLS...
Page 200: Keypad Data Entry Mode
The display has an LED backlight inputs, digitizes them, and scans the inputs to keep a background for night viewing and is viewable in direct constant watch on chiller operating conditions. Based sunlight. on this information, the Chiller Control Board issues JOHNSON CONTROLS...
Page 201: Relay Output Boards
RS-232 interface and at start-up will be initialized to The common side of all relays on the Relay Output RS-485 communications. UART2 is configured for Board is connected to +12VDC. VSD communications over an internal chiller RS-485 JOHNSON CONTROLS...
Page 202: Vsd (Variable Speed Drive)
When the drive is called to run (leaving chilled liquid temperature is more than the Setpoint plus CR), the SCR/Diode modules are turned on by the SCR trigger Board, allowing the DC link filter capacitors to slowly precharge for a period of 20 seconds. LD10610 FILTER CAPACITORS JOHNSON CONTROLS...
Page 203: 1L Line Inductor
IGBT’s ON and OFF. discharge it during servicing. If a bleeder resistor is open and a capacitor bank will not discharge, immediately contact John- son Controls Product Technical Support. LD10613 IGBT's IGBT's JOHNSON CONTROLS...
Page 204: Laminated Bus Structure
The VSD Logic Board contains a second microproces- LD10615 sor for motor control, which generates the PWM sig- nals that control the IGBT’s in the inverter section of FIGURE 48 - OBSOLETE BOARD P/N 031-02477-000 the VSD. JOHNSON CONTROLS...
Page 205: Control Panel To Vsd Communications
(VCE SAT) across the IGBT increases as a result of the high current. The IGBT Gate Driver Board is an integral part of the IGBT assembly for each compressor. JOHNSON CONTROLS...
Page 206: Current Transformers
This eliminates the cabinet. the possibility of causing a turn-to-turn short in the mo- tor due to winding insulation breakdown. The suppres- sion network is made up of a 3-phase RC network. JOHNSON CONTROLS...
Page 207: Dc Bus Voltage Isolation Board
If the Circuit Breaker Option is not selected, incoming power will be fed to terminal blocks. The breaker also provides ground fault protection. 2 and 3 compressor chillers utilize one circuit breaker, while 4 compressor chillers utilize 2 breakers. JOHNSON CONTROLS...
Page 208: Vsd Logic To Chiller Microprocessor Board Rs-485 Communication Configuration Jumpers
196 Hz 0187 EA/VA, 0207 EA/VA, 192 Hz 0327 EA/VA, 0357 EA/VA 188 Hz 0307 SA/PA 0207 SA/PA, 186 Hz 0157 EA/VA, 0287 SA/PA 0177 SA/PA, 182 Hz 0197 EA/VA, 0267 EA/VA 178Hz 0287 EA/VA 178 Hz (Spare) JOHNSON CONTROLS...
Page 209: Section 7 - Operation
It is open when all systems are shut ture rises above 45°F the heater is turned off. Whenever off. a system is running, the evaporator heater is turned off. Both evaporator heater outputs will always be turned JOHNSON CONTROLS...
Page 210: Unit Switch
It is suggested that the System Switches on the keypad be used whenever possible to turn a system off and allow the com- pressor to complete a controlled shut- down. JOHNSON CONTROLS...
Page 211: Number Of Compressors To Start
Standard IPLV fort to optimize the use of the entire evaporator tube The Standard IPLV control always starts a single com- surface. pressor under all circumstances as the first step of JOHNSON CONTROLS...
Page 212: Minimum Vsd Compressor Start / Run Frequency
The temperature ranges and the associated start The formula is also represented by the graph in Figure frequency follows the guidelines below: 51 on page 212. • If the ambient temperature is less than110°F, the Minimum VSD Run Frequency will be 50 Hz. JOHNSON CONTROLS...
Page 213: Acceleration / Deceleration Rate When Starting / Stopping Compressors
• Between 200 and 100 Hz, the deceleration time is described in the Fuzzy Logic Control on page 217. 30.4 Hz/sec. • Between 100 and 0 Hz, the deceleration time is 10 Hz/sec. JOHNSON CONTROLS...
Page 214: Fuzzy Logic Control
Number of Compressors enabled the speed of the compressor(s) to load the chiller until For example: 200 Hz = max freq of the chiller. temperature drops in the general range of the Setpoint Number of compressors enabled before shutdown = 2 JOHNSON CONTROLS...
Page 215: Hot Water Starts
Drain Valves will immediately begin to control su- ditions where the “error” and “rate” conflict. For ex- perheat and liquid level in the flash tank. ample, the Chiller Control Board microprocessor may JOHNSON CONTROLS...
Page 216 STOP COMP FREQ designated as: frequency will equal 100 Hz. Since the controls are de- signed to add a compressor at a frequency 15 Hz above this point, a compressor will be added if the speed reaches 115 Hz. JOHNSON CONTROLS...
Page 217: Fuzzy Logic Control
Chiller Control Board microprocessor may is potential for overshoot, the Chiller Control Board elect to increase the speed of the compressor(s) if the microprocessor may elect not to continue to increase error is “0” (temperature is at Setpoint), while the rate speed. JOHNSON CONTROLS...
Page 218: Hot Water Starts
255 PSIG. the highest amount of unloading will determine the unloading. All load limiting controls are active at start- up except suction pressure limiting. JOHNSON CONTROLS...
Page 219: Suction Pressure Load Limiting/Unloading
Between the VSD Baseplate Temperature Cutout mi- nus 4°F and the cutout, forced unloading is performed Suction Pressure Cutout- 9 PSIG 9 Hz every 2 seconds according to Table 10 on page 220. Suction Pressure Cutout- 10 PSIG 10 Hz JOHNSON CONTROLS...
Page 220: Flash Tank Drain And Feed Valve Controller
2 phase (4 wire), signal drives the Feed Valve open or closed. Power for the Valve Controller comes from a 30VDC supply from the Chiller Control Board. LD10619 FIGURE 53 - FLASH TANK DRAIN AND FEED VALVE CONTROLLER JOHNSON CONTROLS...
Page 221: Mop Setpoint Control For Hot Water Starts
MOP from the 30 to 40% level. If the level exceeds 85% of Setpoint, the moderate to high ambient setpoint, and the full level, the system will shut down on a fault. the low ambient setpoint. JOHNSON CONTROLS...
Page 222: Valve Controller Led's
A column of 10 LED’s runs from top to bottom on the right side module (Figure 56 on page 222). 8. Close = System #2 or 4 Drain Valve Close On 3 and 4 compressor chillers, a second module will control systems #3 and #4. JOHNSON CONTROLS...
Page 223: Economizer Control
Whenever the system. Economizer Solenoid is turned on, the compressor load timer is set to 35 seconds and economizer timers for every system are set to 30 seconds, unless they are al- ready above 30 seconds. JOHNSON CONTROLS...
Page 224: Condenser Fan Control
Sys 1 Fans 1, 3, 5, 7, 9, & 11 Sys 2: 7CR, 8CR, & 9CR Sys 2 Fans 2, 4, 6, & 8 Sys 2 Fans 2, 4, 6, 8, & 10 Sys 2 Fans 2, 4, 6, 8, 10, & 12 JOHNSON CONTROLS...
Page 225: Standard Iplv Fan Control
(Cutout 218°F [103.3°C] minus 15°F unless the 5 second timer between fan stages is still [8.3°C] equals 203°F [95°C]), the fans and pump timing when the discharge pressure falls below the Fan will turned off without a time delay. JOHNSON CONTROLS...
Page 226: Remote Temperature Reset Control
Factory Service should be contacted if a timer Remote Temperature Limit Reset is only possible if the change is required. option is enabled by both the OPTIONS key selection and in the factory programmable password protected Unit Setup Mode. JOHNSON CONTROLS...
Page 227: Local Current Limit Control
Limit Setpoint under the PROGRAM key. This is key) and Chiller Control Board jumper JP4 placed in the value the unit will control the current limit to if the “mA” position. neither of the other methods is active. JOHNSON CONTROLS...
Page 228: Remote Isn Current Limit Setpoint
The current limit is ramped linearly used. between these limits as the input varies between 0VDC Contact a local Johnson Controls ISN Representative and 10VDC. In order for this input to work properly, for details on ISN controls and capabilities.
Page 229: Sound Limit Control
VSD freq). A 10VDC signal produces a 100% sound limit (max VSD freq equals min VSD freq). The Contact a local Johnson Controls ISN Representative sound limit is ramped linearly between these limits as for details on ISN controls and capabilities.
Page 230 VSD freq). A 20mA signal produces a 100% through 20mA input (OPTIONS key) and Chiller Con- sound limit (max VSD freq equals min VSD freq). The trol Board jumper JP6 placed in the “mA” position. sound limit reset is ramped linearly between these lim- JOHNSON CONTROLS...
Page 231: Section 8 - Micropanel
On start-up, the output frequency from the VSD to the modulating waveform will permit the drive to generate motor(s) will be increased from 0 Hz to the operating a fundamental line to line voltage equal to the DC Bus voltage divided by 1.414. JOHNSON CONTROLS...
Page 232: Maximum Vsd Frequency
Be sure to re-install the cap over-modulated by approximately 18%. This will yield before stopping the glycol pump to avoid overflowing a fundamental output line to line voltage applied to the the fill tube when the glycol pump is turned off. JOHNSON CONTROLS...
Page 233: Igbt Module Baseplate Temperature Sensing
The VSD fan/glycol pump will turn off when ALL of the following conditions are true: • Compressor 1/3 IGBT Baseplate temp is less than Cutout minus 15°F. • Compressor 2/4 IGBT Baseplate temp is less than Cutout minus 15°F. JOHNSON CONTROLS...
Page 234: Vsd Internal Ambient Temperature Sensing
VSD’s played while the precharge is taking place. output frequency will be increased from 0 Hz to the operating frequency command from the communica- S YS X VSD DC BUS PRECHARGE tions link. JOHNSON CONTROLS...
Page 235: Dc Bus Voltage Sensing And Scaling
IBGT Power Assembly Power Module Highest Baseplate Temperature (maximum of 2) XXX.XºF (or ºC) Pre-Charge Enable Signal (maximum of 2) On or OFF VSD cooling Fan/Pump On or OFF Compressor Run Status (maximum of 4) On or OFF JOHNSON CONTROLS...
Page 236: Pre-Charge Low Dc Bus Voltage (Software) Fault
High Internal Ambient fault and the VSD CT Plug Fault. When the chiller re- ceives the transmitted fault data via comms, it will save a snapshot of system data in the history buffer even though the chiller is not running. JOHNSON CONTROLS...
Page 237: Pre-Charge Dc Bus Voltage Imbalance (Software) Fault
X indicates the system and YYYYYYY indicates the system is in a “FAULT” condition and will restart when the fault clears or “LOCKOUT” and will not restart un- til the operator clears the fault using the keypad. JOHNSON CONTROLS...
Page 238: High Motor Current (Hardware) Fault
X indicates the system and YYYYYYY indicates the system is in a “FAULT” condition and will restart or “LOCKOUT” and will not restart until the operator clears the fault using the keypad. JOHNSON CONTROLS...
Page 239: High Baseplate Temperature (Software) Fault
X indicates the system and YYYYYYY indicates the system is “FAULT” and will restart when the single After a fault, the fan(s) and water pump will remain phase condition clears. energized until the inverter power module base plate JOHNSON CONTROLS...
Page 240: Power Supply (Hardware) Fault
A fault code will be set for the fault that initiated the the fault clears or “LOCKOUT” and will not restart un- system shutdown. This fault will appear as a specific til the operator clears the fault using the keypad. fault in the Status message. JOHNSON CONTROLS...
Page 241: Fault Relay/Fault Acknowledge Bit
AL OVERRIDE key is pressed. Once the MANUAL OVERRIDE key is pressed, the anti recycle timers will be set to the programmed default anti recycle time to allow the operator sufficient time to check setpoints, program values, etc. JOHNSON CONTROLS...
Page 242: Invalid Number Of Compressors Warning
Optimized IPLV cannot be enabled unless the serial BATTERY number is programmed into the unit using the special password supplied by Johnson Controls Product Tech- nical Support. Once the password is entered, a second password will be needed to activate the optimized IPLV control (see Page 292).
Page 243: Unit Safeties
All faults do not store operating data at the with a controlled ramped shutdown. Restart can occur, time of the fault. if demand allows, when chilled liquid temperature rises 4°F above the cutout. This fault cannot cause a lockout. A sample shutdown message is shown below: JOHNSON CONTROLS...
Page 244: Vsd Communications Failure Fault
(i.e.: low suction pressure, low wa- the last fault. The lockout condition requires a manual ter temp, etc.), the VSD fault will be stored as a new reset using the system switch. The respective system JOHNSON CONTROLS...
Page 245: High Discharge Pressure Cutout (Software) Fault
This safety is ignored for the first 10 seconds of system is in a “FAULT” condition and will restart when operation. the 120 second anti-recycle timer times out or “LOCK- OUT” and will not restart until the operator clears the fault using the keypad. JOHNSON CONTROLS...
Page 246: High Differential Oil Pressure Cutout Fault
The High Oil Temperature Cutout protects the com- OUT” and will not restart until the operator clears the pressor from insufficient lubrication. A system will fault using the keypad. fault and shut down with a controlled ramped shutdown JOHNSON CONTROLS...
Page 247: Low Suction Superheat Cutout Fault
SYS X YYYYYYYY LOW SUCTION SUPERHEAT X indicates the system and YYYYYYYY indicates the system is “FAULT” and will restart after the 120 sec- ond anti-recycle timer times out or “LOCKOUT” and will not restart until the operator clears the fault. JOHNSON CONTROLS...
Page 248: High Motor Temperature Cutout Fault
X indicates the system and YYYYYYY indicates the system is in a “FAULT” condition and will restart when the fault clears or “LOCKOUT” and will not restart un- til the operator clears the fault using the keypad. JOHNSON CONTROLS...
Page 249: Status Key
When power is first applied to the control panel, the Examples of the typical Status messages are shown in following message displaying YORK International the next topic Corporation, the EPROM version, date, and time will be displayed for 2 seconds, followed by the appropriate general status message: JOHNSON CONTROLS...
Page 250: General Status Messages
2-15 or 2-16 of the 1TB terminal block is open. There is a 1 second delay on this safety to assure the remote contacts did not momentarily open. The Discharge Pressure Limiting message indicates the discharge pressure load limit or discharge pressure unloading is in effect. JOHNSON CONTROLS...
Page 251: Unit Safety (Fault) Status Messages
The VSD Baseplate Temp Limiting message indicates A complete listing of the unit warnings and the cor- the VSD Baseplate temp is high and load limit or un- responding status messages is provided on Page 243. loading is in effect. JOHNSON CONTROLS...
Page 252: Unit Data Key
EVAP PUMP RUN = XXX OUTSIDE AMBIENT AIR TEMP = XXX.X °F EVAP HEATER = XXX The next key press will display the time remaining on the load and unload timers. UNIT LOAD TIMER = XXX SEC UNLOAD TIMER = XXX SEC JOHNSON CONTROLS...
Page 253 • NONE - No remote control is actively controlling value. the chiller; however, remote monitoring by a re- UNIT SOUND LIMIT LOCAL = XXX % mote device may still be active. ISN = XXX REMOTE = XXX % JOHNSON CONTROLS...
Page 254: System Data Keys 1 Through 4
The second key press of the SYSTEM DATA key or the that sensor’s value will be displayed as ▼ (DOWN ARROW) key displays all of the measured XXXXX. system temperatures (oil, suction, and discharge). SYS 1 TEMPERATURES OIL = XXX.X °F SUCTION = XXX.X DISCHARGE = XXX.X °F JOHNSON CONTROLS...
Page 255: System 2 Through 4 Data Key Operation
SYS 4 DATA NOT AVAILABLE the status of the compressor heater. SYS 1 CONDENSER FANS ON = X COMPRESSOR HEATER = XXX X equals the number of fans ON. XXX indicates either the heater is ON or OFF. JOHNSON CONTROLS...
Page 256: Sensor Displays
Oil Temp. 40.3ºF 302.6ºF Thermistor Discharge 50Kohm 40.3ºF 302.6ºF Temp. Thermistor Compressor 10Kohm -30.0ºF 302.0ºF Motor Temp. Thermistor 4-20mA/2-10VDC Remote Temp. 100 % Reset 0-20mA/0-10VDC 4-20mA/2-10VDC Remote 100 % Current Limit 0-20mA/0-10VDC 4-20mA/2-10VDC Remote 100 % Sound Limit 0-20mA/0-10VDC JOHNSON CONTROLS...
Page 257: Vsd Data Key
“calculated” currents in amps for systems 1 and 2. The “calculated” currents are approximate and some error can be expected. Also keep in mind that measuring in- verter PWM current is difficult and meter error can be significant. JOHNSON CONTROLS...
Page 258 Systems 1/3 (T1) VSD COMP 3 MOTOR OVERLOAD = XXX AMPS and Systems 2/4 (T2). COMP 4 MOTOR OVERLOAD = XXX AMPS VSD IGBT BASEPLATE TEMPS T1 = XXX °F T2 = XXX °F JOHNSON CONTROLS...
Page 259: Operating Hours / Start Counter Key
0. A single display is available under this key and is displayed below. On 2 and 3 compres- sor units, the data and compressor designators for com- pressors not present are blanked out. HOURS 1=XXXXX, 2=XXXXX, 3=XXXXX, 4=XXXXX START 1=XXXXX, 2=XXXXX, 3=XXXXX, 4=XXXXX JOHNSON CONTROLS...
Page 260: History Key
 (ENTER) key must be pressed to enter the selection. The following display will typically be displayed on a normal shutdown due to shutdown on lack of cooling demand. NORM HIST XX 18-JUN-20004 10:34:58 AM SYS X COOLING DEMAND SHUTDOWN JOHNSON CONTROLS...
Page 261: Fault Shutdowns History
Status Display (System Faults only), Fault Display, All Fault Display, Unit Data, VSD Data, System Data, Operating Hours/Starts, Setpoints, Options, and Program Values at the time of the fault. JOHNSON CONTROLS...
Page 262: Unit Data
EVAP HEATER = XXX 3 compressor units, the #4 compressor information is blanked out. This message indicates the status of the evaporator pump and the evaporator heater at the time of the fault. XXX indicates ON or OFF. JOHNSON CONTROLS...
Page 263: System Data
This display provides the state of the precharge sig- perature. nal, where Precharge 1 and Precharge 2 is either ON or OFF at the time of the fault. Precharge 2 is only used on 4 compressor units. JOHNSON CONTROLS...
Page 264: Compressor Operating Hours And Starts
This message displays the system suction superheat for compressors not present will be blanked out. and indicates the % the Flash Tank Drain Valve is open at the time of the fault. JOHNSON CONTROLS...
Page 265: Chilled Liquid Setpoint Cooling Setpoints
This message indicates whether Local or Remote Con- trol Mode was selected at the time of the fault. OPTIONS REMOTE TEMP RESET INPUT ◄ ► 0.0 TO 20.0 MILLIAMPS OPTIONS REMOTE TEMP RESET INPUT ◄ ► 4.0 TO 20.0 MILLIAMPS JOHNSON CONTROLS...
Page 266: Program Values
LOW AMBIENT TEMP CUTOUT = XXX.X °F ed at the factory. If the option is not factory activated, the display will not appear. This message displays the low ambient temp cutout programmed at the time of the fault. JOHNSON CONTROLS...
Page 267: Setpoints Key
(ARROW) key will display the leaving chilled liquid SETPOINTS ◄DEF XXXXX LO XXXXX HI XXXXX Control Range, default, and low/high limits. MAXIMUM REMOTE TEMP RESET = XXX.X °F SETPOINTS ◄DEF XXXXX LO XXXXX HI XXXXX LOCAL CONTROL RANGE = +/- X.X °F JOHNSON CONTROLS...
Page 268: Table 16 - Setpoint Limits
Water Cooling 4.4°C 15.6°C 6.7°C Leaving Chilled Liquid Setpoint 15.0°F 70.0°F 44.0°F Glycol Cooling -9.4°C 15.6°C 6.7°C 1.5°F 2.5°F 2.0°F Leaving Chilled Liquid Control Range 0.8°C 1.4°C 1.1°C 2°F 40°F 20°F Max. Remote Temperature Reset 1°C 22°C 11°C JOHNSON CONTROLS...
Page 269: Program Key
When the PROGRAM key is first pressed, the follow- Cooling mode. The default value for both modes will ing display will appear indicating the user is in the pro- be 24.0 PSIG (1.65 Barg) PSIG. gram mode: PROGRAM MODE XXXX PRESS ENTER KEY TO CONTINUE JOHNSON CONTROLS...
Page 270: Low Ambient Cutout
Typically, the limit point is set at 100%. The pulldown limit point is programmable from 30 to 100% with a default of 100%. Be aware when using pulldown motor current limit, the chiller may not be able to load to satisfy temperature demand JOHNSON CONTROLS...
Page 271: Sound Limit Setpoint
103% Pulldown Motor Current Limit 100% 100% Pulldown Motor Current Limit Time 0 Min 255 Min 0 Min 8.0°F 12.0°F 10.0°F Suction Superheat Setpoint 4.4°C 6.6°C 5.6°C Unit ID Number Sound Limit Sound Limit Setpoint 100% Option Enabled JOHNSON CONTROLS...
Page 272: Options Key
The display language can be selected for English, OPTIONS CHILLED LIQUID COOLING MODE Dutch, German, Italian, and Chinese ◄ ► GLYCOL COOLING OPTIONS DISPLAY LANGUAGE The default Chilled Liquid Mode will be WATER. ◄ ► XXXXXXXXXXXXXXXXXX The default language will be English. JOHNSON CONTROLS...
Page 273: Local / Remote Control Mode Selection
◄ ► IMPERIAL OPTIONS LEAD / LAG CONTROL MODE OPTIONS DISPLAY UNITS ◄ ► MANUAL SYS 4 LEAD ◄ ► SYSTEM 4 LEAD may be selected only on 4 compres- The default mode is IMPERIAL. sor units. JOHNSON CONTROLS...
Page 274: Remote Temperature Reset Selection
The default setting for the low ambient cutout will be ◄ ► 2.0 TO 10 VOLTS DC ENABLED. OPTIONS REMOTE CURRENT LIMIT INPUT ◄ ► 0.0 TO 20.0 MILLIAMPS OPTIONS REMOTE CURRENT LIMIT INPUT ◄ ► 4.0 TO 20.0 MILLIAMPS JOHNSON CONTROLS...
Page 275: Date / Time And Schedule Keys
◄ or ► (LEFT OR MONTH ◄ ► = XX RIGHT ARROW) key to select the day. After the day is selected, the  (ENTER) key must be pressed to store the data. JOHNSON CONTROLS...
Page 276: Schedule Key Operation
 (ENTER) (ENTER) key must be pressed to store the data. key before a schedule display will appear. One or two “0’s” must be keyed in for minutes 00 through 09. JOHNSON CONTROLS...
Page 277: Unit Operating Schedule
Once the schedule is the Monday times are not applicable for executed, the selected holidays will be the whole week, then the exceptional days cleared from memory for the following would need to be reprogrammed to the week. desired schedule. JOHNSON CONTROLS...
Page 278: Sound Limit Schedule
The START Time for a specific day (hour and minute) is entered using the same guidelines used for the start/ stop schedules, and press the  (ENTER) key to store it into memory. The cursor will then move to the AM/ PM selection. JOHNSON CONTROLS...
Page 279: Manual Override Key
STATUS display mode. Therefore, do not expect to see any other STATUS messages when in the MANUAL OVERRIDE mode. MANUAL OVERRIDE is to only be used in emergencies or for servicing. Manual over- ride mode automatically disables itself after 30 min- utes. MANUAL OVERRIDE JOHNSON CONTROLS...
Page 280: Print Key
History Buffer 9 (RIGHT ARROW) keys until the desired printout is History Buffer 10 displayed. Cancel Printing Table 18 on page 280 shows the available printout The specific printout is initiated by pressing the  types. (ENTER) key. JOHNSON CONTROLS...
Page 281: Operating Data Printout
EVAPORATOR HEATER SUCTION SUPERHEAT 11.2 DEGF ACTIVE REMOTE CONTROL NONE SAT DISCHARGE TEMP 112.1 DEGF OPERATING HOURS 1=XXXXX, 2=XXXXX DISCHARGE SUPERHEAT 33.4 DEGF 3=XXXXX MOTOR TMP XXX.X XXX.X XXX.X DEGF (3 circuit) COMPRESSOR SPEED XXX.X% LIQUID LINE SOLENOID JOHNSON CONTROLS...
Page 282: History Data Printout
SYS 1 XXXXXXXXXXXXXXXXXXXXXXXXXX WED START=00:00AM STOP=00:00AM SYS 2 XXXXXXXXXXXXXXXXXXXXXXXXXX THU START=00:00AM STOP=00:00AM FRI START=00:00AM STOP=00:00AM ALL FAULTS SAT START=00:00AM STOP=00:00AM XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX HOL START=00:00AM STOP=00:00AM XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX The most recent fault will always be stored as HIS- TORY BUFFER #1. JOHNSON CONTROLS...
Page 283: Service Key
Once in a data section, the word is entered. ▲and ▼ (ARROW) keys allow scrolling through the data under the section. Pressing the ◄ ► (AR- ROW) keys at any time moves to the top of the next data section. JOHNSON CONTROLS...
Page 284 SERVICE AI J20-2 SYS3 MOTOR TEMP T2 correct for this when measuring voltage at the remote X.X VDC = XXX.X °F device supplying voltage to the board header while troubleshooting, use the following calculation: Voltage = 10 x VDC volts / 4.5 JOHNSON CONTROLS...
Page 285 SERVICE AI J24-22 SYS4 OIL PRESS X.X VDC = XXX.X °F X.X VDC = XXX.X PSIG SERVICE AI J22-20 SYS2 SUCTION PRESS SERVICE AI J24-24 SYS4 DISCHARGE PRESS X.X VDC = XXX.X PSIG X.X VDC = XXX.X PSIG JOHNSON CONTROLS...
Page 286 SERVICE DO J9-11 SYS 1 COMP HEATER STATUS = XXX RB1 TB1-3 STATUS = XXX SERVICE DI J6-6 SPARE DIGITAL INPUT 1 SERVICE DO J9-10 SYS 1 ECON SOL VALVE STATUS = XXX RB1 TB1-2 STATUS = XXX JOHNSON CONTROLS...
Page 287 SERVICE DO J11-4 SYS 4 COMP HEATER RB1 TB1-14 STATUS = XXX XXX.X % = XX.X VDC SERVICE DO J11-5 SYS 4 ECON SOL VALVE SERVICE AO J15-7 SYS 2 DRAIN VALVE OUT XXX.X % = XX.X VDC RB1 TB1-12 STATUS = XXX JOHNSON CONTROLS...
Page 288 (DO) that can be viewed from the Service Mode. The Digital Output signals indicate the status of the output. The 0 to 120VAC digital outputs are referenced to neutral (Wire 2). SERVICE DO J10-2 VSD COOLING FAN/PUMP VSD LOGIC STATUS = XXX JOHNSON CONTROLS...
Page 289: System Switches Key
SYSTEM SWITCHES SYS 3 ON / OFF / RESET a controlled shutdown. Avoid using the ◄ ► =XXXXXXXXXXXXXXX "UNIT" switch to turn off the compres- sors. SYSTEM SWITCHES SYS 4 ON / OFF / RESET ◄ ► =XXXXXXXXXXXXXXX JOHNSON CONTROLS...
Page 290: Serial Number Programming
(ARROW) keys and press If the following message appears, immediately contact (ENTER) key. Press the ▼(DOWN ARROW) Johnson Controls Product Technical Support. The ap-  key to scroll to position 3 and the following message pearance of this message may also mean the chiller has...
Page 291: Enabling Optimized High Iplv Mode
Johnson Controls Product Technical ENABLING OPTIMIZED HIGH IPLV MODE Support or Johnson Controls ES Commercial. It is es- When changing a Chiller Control Board, a Chiller sential Johnson Controls Product Technical Support...
Page 292: Unit Setup Mode
= XXXXX SYS 3 NUMBER OF COND FANS SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX COMP 4 OPERATING HOURS = XXXXX SYS 4 NUMBER OF COND FANS JOHNSON CONTROLS...
Page 293: Default Programmable Values
◄ ► XXXXXXXXXXXXXXXXXXXXXXXXX available. The OptiView RCC and Microgateway op- tion cannot both be used. Only one or the other is per- SETUP MODE SYS 2 MOTOR SENSOR TO IGNORE mitted to be connected to the chiller. ◄ ► XXXXXXXXXXXXXXXXXXXXXXXXX JOHNSON CONTROLS...
Page 294: Analog Input Connections
Sys 2 Flash Tank Level Sensor Chiller Control Board J22-20 Sys 2 Suction Pressure Chiller Control Board J22-22 Sys 2 Oil Pressure Chiller Control Board J22-24 Sys 2 Discharge Pressure Chiller Control Board J20-1 Comp 3 Motor Temperature 1 JOHNSON CONTROLS...
Page 295 Comp 2 IGBT Baseplate temperature VSD Logic Board J9-8 Comp 4 IGBT Baseplate Temperature VSD Logic Board Comp 1 Overload Adjust VSD Logic Board Comp 3 Overload Adjust VSD Logic Board Comp 2 Overload Adjust VSD Logic Board Comp 4 Overload Adjust JOHNSON CONTROLS...
Page 296: Digital Intput Connections
Phase Loss Fault 1 VSD Logic Board J11-6 Phase Loss Fault 2 VSD Logic Board Test Pushbutton VSD Logic Board J10-5 to J10-6 Comp 1/3 Run (from control panel) VSD Logic Board J10-7 to J10-8 Comp 2/4 (from control panel) JOHNSON CONTROLS...
Page 297: Analog Output Connections
Sys 1 Condenser Fan Speed (Future) Chiller Control Board J25-2 to J25-6 Sys 2 Condenser Fan Speed (Future) Chiller Control Board J25-3 to J25-7 Sys 3 Condenser Fan Speed (Future) Chiller Control Board J25-4 to J25-8 Sys 4 Condenser Fan Speed (Future) JOHNSON CONTROLS...
Page 298: Digital Output Connections
Sys 4 Condenser Fan Output 2 Chiller Control / Relay Board 3 J11-3 / TB1-16 and 15 Sys 4 Condenser Fan Output 3 Chiller Control / Relay Board 3 J11-4 / TB1-14 and 13 Sys 4 Compressor Heater JOHNSON CONTROLS...
Page 299 Comp 4 Enable VSD Logic Board J11-3 Pre-charge Enable 1 VSD Logic Board J11-7 Pre-charge Enable 2 VSD Logic Board J10-1 to J10-2 VSD Fan / Pump Run VSD Logic Board J10-3 to J10-4 VSD Fault Relay (to control panel) JOHNSON CONTROLS...
Page 300: Bacnet, Modbus And Yorktalk 2 Communications
XXXXX ADDRESS P2 STOP BITS P1 BAUD RATE XXXXX P2 HW SELECT BIT P1 PARITY XXXXX XXXXX REAL TIME ERROR P1 STOP BITS RESET 1 = YES, 0 = NO 0 Note: See TABLE 27 for error descriptions JOHNSON CONTROLS...
Page 301: Figure 60 - Control Board Connections
P1, P2 PARITY NONE IGNORE NONE NONE, EVEN, ODD, IGNORE SELECTABLE P1 PROTOCOL BACNET BACNET BACNET, API SELECTABLE P2 PROTOCOL TERMINAL MODBUS CLIENT TERMINAL, MODBUS IO, MODBUS SERVER, API, MODBUS CLIENT SELECTABLE P1, P2 STOP BITS RESET REAL TIME ERROR JOHNSON CONTROLS...
Page 302: Table 26 - Values Required For Bas Communication
GET PACKET FAILED setup and a description of each. GET TYPE FAILED INVALID UNIT CONVERSION INVALID HARDWARE SELECTION REAL TIME FAULT SPANISH TEXT TOO LONG THREAD EXITED THREAD FAILED THREAD STALLED IO BOARD RESET BRAM INVALID BACNET SETUP FAILED JOHNSON CONTROLS...
Page 303: Bacnet And Modbus Communications
The Modbus Register Address for these points is 1281 plus BI #. Refer to Table 28 on page 304 for complete list of BACnet and Modbus registers. The latest data map information is listed on the Johnson Controls Equipment In- tegration website. JOHNSON CONTROLS...
Page 304: Table 28 - Bacnet And Modbus Communications Data Map
FORM 201.23-NM2 SECTION 8 - MICROPANEL ISSUE DATE: 3/9/2015 TABLE 28 - BACNET AND MODBUS COMMUNICATIONS DATA MAP JOHNSON CONTROLS...
Page 305 FORM 201.23-NM2 SECTION 8 - MICROPANEL ISSUE DATE: 3/9/2015 TABLE 28 - BACNET AND MODBUS COMMUNICATIONS DATA MAP (CONT’D) JOHNSON CONTROLS...
Page 306 FORM 201.23-NM2 SECTION 8 - MICROPANEL ISSUE DATE: 3/9/2015 TABLE 28 - BACNET AND MODBUS COMMUNICATIONS DATA MAP (CONT’D) JOHNSON CONTROLS...
Page 307 FORM 201.23-NM2 SECTION 8 - MICROPANEL ISSUE DATE: 3/9/2015 TABLE 28 - BACNET AND MODBUS COMMUNICATIONS DATA MAP (CONT’D) JOHNSON CONTROLS...
Page 308 FORM 201.23-NM2 SECTION 8 - MICROPANEL ISSUE DATE: 3/9/2015 TABLE 28 - BACNET AND MODBUS COMMUNICATIONS DATA MAP (CONT’D) JOHNSON CONTROLS...
Page 309: Yorktalk 2 Communications
Table 29 on page 310 The latest point map information is listed “Yorktalk 2 Communications Data Map” lists the con- on the Johnson Controls Equipment In- trol parameters. These values are found under feature tegration website.
Page 310: Table 29 - Yorktalk 2 Communications Data Map
FORM 201.23-NM2 SECTION 8 - MICROPANEL ISSUE DATE: 3/9/2015 TABLE 29 - YORKTALK 2 COMMUNICATIONS DATA MAP JOHNSON CONTROLS...
Page 311 FORM 201.23-NM2 SECTION 8 - MICROPANEL ISSUE DATE: 3/9/2015 TABLE 29 - YORKTALK 2 COMMUNICATIONS DATA MAP (CONT’D) JOHNSON CONTROLS...
Page 312 FORM 201.23-NM2 SECTION 8 - MICROPANEL ISSUE DATE: 3/9/2015 TABLE 29 - YORKTALK 2 COMMUNICATIONS DATA MAP (CONT’D) JOHNSON CONTROLS...
Page 313: Section 9 - Maintenance
The oil level should be between the to improper maintenance during the warranty period, upper and lower sight glasses on the oil separators. Johnson Controls shall not be liable for costs incurred to return the unit to satisfactory condition. Refrigerant Charge...
Page 314: R-134A Conversion Tables
179.9 (82.2) 120.0 (8.27) 98.0 (36.7) 255.0 (17.58) 147.7 (64.3) 390.0 (26.89) 180.9 (82.7) 125.0 (8.62) 100.4 (38) 260.0 (17.93) 149.2 (65.1) 395.0 (27.23) 182.0 (83.3) 130.0 (8.96) 102.7 (39.3) 265.0 (18.27) 150.6 (65.9) 400.0 (27.58) 183.0 (83.9) JOHNSON CONTROLS...
Page 315: Maintenance Requirements For Yciv Chillers
A record of this procedure be successfully carried out should be maintained on file by the equipment owner should proof of adequate maintenance be required at a later date for warranty purposes. JOHNSON CONTROLS...
Page 316: Troubleshooting Guide
Check and clean Coils. Coils dirty. Check and clean coils. Coils are damaged. Comb out fins. System Fault: Check fan fuses. High Discharge Fans NOT operating. Check fan rotation. Pressure Check fan motor/blade. System is overcharged. Remove charge and check subcooling. JOHNSON CONTROLS...
Page 317 Replace VSD Logic Board. Temperature IBGT Module is defective. Check defective IGBT Module. Vsd Fault: SCR / Diode Module is defective. Check SCR / Diode Module. Low Dc SCR Trigger Board is defective. Check SCR Trigger Board. Bus Voltage JOHNSON CONTROLS...
Page 318: Limited Warranty
AND EXCLUSIVE REMEDY IN THE EVENT OF A tion, will repair or replace, FOB point of shipment, DEFECT IN WORKMANSHIP OR MATERIALS. IN such materials or parts as Johnson Controls finds de- NO EVENT SHALL JOHNSON CONTROLS LIABIL- fective. However, where reconditioned or replacement...
Page 319: Chilled Liquid And Suction Temperature Sensor Input Voltage
50.8 2.70 72.7 3.36 31.9 2.05 51.4 2.71 73.4 3.38 32.5 2.07 52.0 2.73 74.2 3.40 33.0 2.09 52.6 2.75 74.9 3.42 33.6 2.11 53.2 2.77 34.2 2.13 53.8 2.79 34.8 2.15 54.5 2.81 35.3 2.17 55.0 2.83 JOHNSON CONTROLS...
Page 320: Table 32 - Outside Air Temperature Sensor Input Voltage (Measured Signal To Shield At The Sensor)
82.7 3.02 41.4 1.73 83.6 3.05 42.4 1.76 84.6 3.08 43.3 1.79 85.7 3.11 44.3 1.82 86.7 3.13 45.2 1.85 87.8 3.16 46.1 1.88 88.9 3.19 47.0 1.91 90.1 3.22 48.0 1.94 91.1 3.25 48.9 1.97 92.2 3.28 JOHNSON CONTROLS...
Page 321: Table 33 - Pressure Transducer Output Voltage (Measured Signal To Return At The Transducer)
3.55 2.90 1.59 3.63 3.06 1.66 3.70 3.22 1.74 3.77 3.38 1.81 3.85 3.54 1.88 3.92 3.70 1.95 3.99 3.86 2.03 4.06 4.02 2.10 4.14 4.18 2.17 4.21 4.34 2.25 4.28 4.50 2.32 4.35 2.39 4.43 2.46 4.50 JOHNSON CONTROLS...
Page 322: Table 34 - Motor Temperature Sensor Resistance (Check At The Motor)
552.6 623.2 510.6 6.20 479.9 542.3 445.0 6.40 416.5 473.5 389.0 6.60 363.4 414.7 341.2 6.70 318.4 364.1 300.2 6.90 279.5 320.9 264.9 7.10 246.1 283.7 234.4 7.30 217.3 251.5 208.0 7.40 192.6 223.3 185.0 7.50 171.1 198.9 JOHNSON CONTROLS...
Page 323: Table 35 - Compressor Motor Overload Settings And Max. Vsd Frequency
YCIV0157SA/PA YCIV0157SA/PA YCIV0177EA/VA YCIV0177EA/VA YCIV0177SA/PA YCIV0177SA/PA YCIV0187EA/VA YCIV0187EA/VA YCIV0187SA/PA YCIV0187SA/PA YCIV0197EA/VA YCIV0197EA/VA YCIV0207EA/VA YCIV0207EA/VA YCIV0207SA/PA YCIV0207SA/PA YCIV0227EA/VA YCIV0227EA/VA YCIV0227SA/PA YCIV0227SA/PA YCIV0247EA/VA YCIV0247EA/VA YCIV0247SA/PA YCIV0247SA/PA YCIV0267SA/PA YCIV0267SA/PA NOTE: Overload settings are based on Chiller Model and Condenser Fan Option JOHNSON CONTROLS...
Page 324 YCIV0157SA/PA YCIV0157SA/PA YCIV0177EA/VA YCIV0177EA/VA YCIV0177SA/PA YCIV0177SA/PA YCIV0187EA/VA YCIV0187EA/VA YCIV0187SA/PA YCIV0187SA/PA YCIV0197EA/VA YCIV0197EA/VA YCIV0207EA/VA YCIV0207EA/VA YCIV0207SA/PA YCIV0207SA/PA YCIV0227EA/VA YCIV0227EA/VA YCIV0227SA/PA YCIV0227SA/PA YCIV0247EA/VA YCIV0247EA/VA YCIV0247SA/PA YCIV0247SA/PA YCIV0267SA/PA YCIV0267SA/PA NOTE: Overload settings are based on Chiller Model and Condenser Fan Option JOHNSON CONTROLS...
Page 325 TING TING W/ HH/HS FANS (VAC) (HZ) (AMPS) (AMPS) (AMPS) YCIV0267EA/VA YCIV0267EA/VA YCIV0287EA/VA YCIV0287EA/VA YCIV0287SA/PA YCIV0287SA/PA YCIV0307SA/PA YCIV0307SA/PA YCIV0327EA/VA YCIV0327EA/VA YCIV0357EA/VA YCIV0357EA/VA YCIV0357SA/PA YCIV0357SA/PA YCIV0397SA/PA YCIV0397SA/PA NOTE: Overload settings are based on Chiller Model and Condenser Fan Option JOHNSON CONTROLS...
Page 326: Printer Wiring
SEIKO DPU-414 9 pin RS-232 (DB-9) TB1 Chiller Control Board TB1-2 TB1-3 TB1-5 WEIGHTRONIX IMP-24, MODEL 2600 TB1 Chiller Control Board 25 pin RS-232 (DB-25P) TB1-2 TB1-3 TB1-5 ld10638 FIGURE 61 - PRINT CABLE - CHILLER TO SERIAL PRINTER JOHNSON CONTROLS...
Page 327: Printer Cables
2-6 – ON: Busy signal 200ms 3-6 – OFF: Baud rate select - 1200 2-7 – ON: DTR space after power on 3-7 – ON: Baud rate select - 1200 2-8 – not used 3-8 – OFF: Baud rate select - 1200 JOHNSON CONTROLS...
Page 328: Operating Log Sheet
ºF(ºC) Leaving Chilled Liquid Temp. Cutout = Display Language = ºF(ºC) Chilled Liquid Mode = High Motor Current Unload = %FLA Local/Remote Mode = Display Units = Lead/Lag Control = Remote Temperature Reset = Remote Current Reset = JOHNSON CONTROLS...
Page 329 SYSTEM CURRENT Suction ºF(ºC) SYS 1 SYS 2 SYS 3 SYS 4 Discharge ºF(ºC) Current AMPS SAT Suction ºF(ºC) SYS 1 SYS 2 SYS 3 SYS 4 SAT Superht ºF(ºC) Current %FLA SAT Discharge ºF(ºC) Dsch Superht ºF(ºC) JOHNSON CONTROLS...
Page 330: System Operating Conditions
SYS 1 SYS 2 SYS 3 SYS 4 so that an oil level is between the upper and lower sight glasses. Comp Heater SYSTEM RUN TIME Days Hours Mins Sec System 1 System 2 System 3 System 4 JOHNSON CONTROLS...
Page 331: Water System Conditions
SECTION 9 - MAINTENANCE ISSUE DATE: 3/9/2015 WATER SYSTEM CONDITIONS CONDENSER CONDITIONS EVAPORATOR FLOW AIR TEMPERATURE Flow Rate Air ON Temperature ºF (ºC) Air OFF Temperature Evap Pressure Drop FT / LBS ºF (ºC) (Circle One) Glycol Freeze Point ºF (ºC) JOHNSON CONTROLS...
Page 332: Recommended Spare Parts
Transducer, Suction Pressure (0-125 psig) 025-29583-001 Sensor, EWT, LWT 025-40334-000 Relay Output Board 031-02479-002 VSD Logic Board Kit 031-02507-601 Controller, Valve 031-02742-000 SCR Trigger Board 60 HZ YCIV 031-02060-001 Chiller Control Board 031-02478-002 Level Sensor 025-40274-000 Feed Drain Valve 025-41565-000 JOHNSON CONTROLS...
Page 333 FORM 201.23-NM2 ISSUE DATE: 3/9/2015 NOTES JOHNSON CONTROLS...
Page 334 P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2015 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 201.23-NM2 (315) Issue Date: March9, 2015 Supersedes: 201.23-NM2 (610)

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Johnson Controls York YCIV A Series Installation Operation & Maintenance

Section 1 - General Chiller Information and Safety

Section 2 - Product Description

Section 3 - Rigging, Handling and Storage

Section 4 - Installation

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