Johnson Controls YORK OPTIVIEW YK Series Service Instructions Manual
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Johnson Controls YORK OPTIVIEW YK Series Service Instructions Manual

Centrifugal liquid chillers with optiview control center
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CENTRIFUGAL LIQUID CHILLERS
WITH OPTIVIEW™ CONTROL CENTER
SERVICE INSTRUCTIONS
Supersedes: 160.54-M1
Form 160.54-M1
OPTIVIEW™ CONTROL CENTER
MODEL YK (THROUGH STYLE G)
00614VIP

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  • Page 1 CENTRIFUGAL LIQUID CHILLERS WITH OPTIVIEW™ CONTROL CENTER SERVICE INSTRUCTIONS Supersedes: 160.54-M1 Form 160.54-M1 OPTIVIEW™ CONTROL CENTER MODEL YK (THROUGH STYLE G) 00614VIP...
  • Page 2 All wiring must be in accordance with Johnson Controls’ published specifications and must be performed only by a qualified electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of improper control signals.
  • Page 3 FORM 160.54-M1 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls’ policy for con- these documents, the technician should verify whether tinuous product improvement, the information con- the equipment has been modified and if current litera- tained in this document is subject to change without ture is available from the owner of the equipment prior notice.

  • Page 4: Table 1 - Control Panel Applications

    -111 Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications and VGD, no J7 compressor – CE -112 Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications and VGD, J7 compressor – NEMA 1 JOHNSON CONTROLS...

  • Page 5: Table Of Contents

    Modbus Protocol Configuration ........................124 SECTION 14 - PROXIMITY PROBE ........................131 SECTION 15 - HIGH SPEED THRUST BEARING LIMIT SWITCH ..............137 SECTION 16 - REFRIGERANT LEVEL CONTROL .....................139 Automatic Operation ............................. 139 Manual Operation ............................141 Actuators ..............................141 JOHNSON CONTROLS...
  • Page 6 Stall Detector Board ............................ 201 SECTION 26 - LARGE TONNAGE CHILLER (LTC) I/O BOARD ...............205 Digital Inputs ..............................205 Digital Outputs .............................. 207 Analog Inputs ............................... 208 Analog Outputs ............................. 209 Auto Detection ............................. 210 Diagnostic Screen ............................210 JOHNSON CONTROLS...
  • Page 7 High Condenser Pressure Warning Threshold ..................... 257 Brine Low Evaporator Pressure Cutout ......................258 Leaving Chilled Liquid Temperature Control Sensitivity ................258 Drop Leg Refrigerant Temperature ....................... 258 Smart Freeze Protection ..........................259 Evaporator Refrigerant Temperature ......................259 Hot Gas Bypass Control ..........................259 JOHNSON CONTROLS...
  • Page 8 SI0212 - Software Enhancements (Ver 21) Effective June 2009 ..............333 SI0224 - Software Enhancements (Ver 22) Effective April 2010 ..............338 SI0252 - Software Enhancements (Ver 23) Effective May 2011 ..............339 SI0265 - Software Enhancements (Ver 24) Effective May 2012 ..............342 JOHNSON CONTROLS...
  • Page 9 FIGURE 38 - Display Interface Board 031-02887-000 ....................92 FIGURE 39 - Display Backlight Inverter Board (Sharp LQ10D367/368 (031-01774-000) and LG Semicon LP104V2-W (031-02046-000))..................94 FIGURE 40 - Display Backlight Inverter Board – Sharp LQ104V1DG61 Display 031-02886-000 ......95 FIGURE 41 - Keypad...............................98 JOHNSON CONTROLS...
  • Page 10 FIGURE 79 - Triac Outputs ...........................207 FIGURE 80 - Open Collector ..........................208 FIGURE 81 - Analog Inputs ...........................208 FIGURE 82 - Analog Outputs ..........................209 FIGURE 83 - I/O Board (031-02895-XXX) ......................210 FIGURE 84 - Heat Recovery Block Diagram......................212 JOHNSON CONTROLS...
  • Page 11 FIGURE 105 - Serial Inputs / Outputs Test Screen ....................289 FIGURE 106 - Microboard - COM 5 Serial Data Port ....................290 FIGURE 107 - Digital inputs / Outputs Test Screen ....................291 FIGURE 108 - Analog Inputs Test Screen ......................294 JOHNSON CONTROLS...
  • Page 12 TABLE 27 - Flash Memory Card Version C.MLM.01.08.105A and C.MLM.01.08.206A (and later) ...... 265 TABLE 28 - Software Version C.MLM.01.10B.XXX (and later) or C.OPT.01.10B.XXX (and later) ...... 265 TABLE 29 - Software Version C.OPT.01.16.XXX (and later) ................266 TABLE 30 - Loop Back Connections ........................341 TABLE 31 - SI Metric Conversion .........................345 JOHNSON CONTROLS...

  • Page 13: Section 1 - Introduction

    OptiView™ Control Cen- lem through the system. Use the Diagnostic Routines ter keypad, how to enter setpoints and explains all the where appropriate. messages displayed on the OptiView™ Control Cen- JOHNSON CONTROLS...
  • Page 14 FORM 160.54-M1 SECTION 1 - INTRODUCTION THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 15: Section 2 - System Architecture

    Typical output voltage range of both is ure 8 on Page 27 and Figure 9 on Page 28 0.5 to 4.5VDC. These are Analog Inputs to the OptiV- are Operation Sequence timing diagrams of the iew™ Control Center. different starter applications. JOHNSON CONTROLS...
  • Page 16 Since the newer versions microboard are backward Refer to SECTION 25 - VARIABLE GEOMETRY DIF- compatible to earlier vintage OptiView™ Control Cen- FUSER. ters, earlier chillers could be equipped with a later ver- sion microboard due to service replacement. JOHNSON CONTROLS...
  • Page 17 Figure 15 on Page 45. and condenser. These are electronic thermal-type sen- sors. Flash memory card version C.MLM.01.07.xxx and C.MLM.01.07A.xxx automatically selects the flow sensor input, either digital or analog per the chiller style/compressor setpoint selection. JOHNSON CONTROLS...
  • Page 18 B LCSSS (after mid 2008) use Modbus protocol (re- quires software version C.OPT.01.18.307 or later). Stall may occur at low load conditions with high head. A mechanical ring, located in the compressor diffuser passage is operated to open or close the diffuser gap. JOHNSON CONTROLS...
  • Page 19 If the chiller is provided with a compressor motor VSD conditions. Software version C.OPT.01.22.307 (and or the optional hot gas bypass, the PRV potentiometer later) is required for this feature. for those features is used. Otherwise, a PRV potenti- ometer is provided interfaced to the microboard. JOHNSON CONTROLS...

  • Page 20: Figure 1 - Optiview™ Control Center - Electro-Mechanical Starter Applications

    FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE FIGURE 1 - OPTIVIEW™ CONTROL CENTER - ELECTRO-MECHANICAL STARTER APPLICATIONS JOHNSON CONTROLS...

  • Page 21: Figure 2 - Optiview™ Control Center - Mod A Solid State Starter Applications

    FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE FIGURE 2 - OPTIVIEW™ CONTROL CENTER - MOD A SOLID STATE STARTER APPLICATIONS JOHNSON CONTROLS...

  • Page 22: Figure 3 - Optiview™ Control Center - Mod B Solid State Starter Applications

    FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE FIGURE 3 - OPTIVIEW™ CONTROL CENTER - MOD B SOLID STATE STARTER APPLICATIONS JOHNSON CONTROLS...

  • Page 23: Figure 4 - Optiview™ Control Center - Medium Voltage Solid State Starter Applications

    FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE FIGURE 4 - OPTIVIEW™ CONTROL CENTER - MEDIUM VOLTAGE SOLID STATE STARTER APPLICATIONS JOHNSON CONTROLS...

  • Page 24: Figure 5 - Optiview™ Control Center - Compressor Motor Variable Speed Drive (York Serial Communications Protocol)

    FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE FIGURE 5 - OPTIVIEW™ CONTROL CENTER - COMPRESSOR MOTOR VARIABLE SPEED DRIVE (YORK SERIAL COMMUNICATIONS PROTOCOL) JOHNSON CONTROLS...

  • Page 25: Figure 6 - Optiview™ Control Center - Compressor Motor Variable Speed Drive

    FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE FIGURE 6 - OPTIVIEW™ CONTROL CENTER - COMPRESSOR MOTOR VARIABLE SPEED DRIVE (MODBUS SERIAL COMMUNICATIONS PROTOCOL) JOHNSON CONTROLS...

  • Page 26: Figure 7 - Optiview™ Control Center - Compressor Motor Medium Voltage Variable Speed Drive

    FORM 160.54-M1 SECTION 2 - SYSTEM ARCHITECTURE FIGURE 7 - OPTIVIEW™ CONTROL CENTER - COMPRESSOR MOTOR MEDIUM VOLTAGE VARIABLE SPEED DRIVE JOHNSON CONTROLS...

  • Page 27: Figure 8 - Operation Sequence Timing Diagram (Electro-Mechanical And Solid State Starter Applications)

    BYPASS 150 SEC. SWITCH (2.5 MIN) 1800 VANES VANES (0.17) (0.22) (0.75) (0.83) (1.83) (30) START START CLOSED RESTART CLOSE TIME IN SECONDS (MINUTES) LD06502 FIGURE 8 - OPERATION SEQUENCE TIMING DIAGRAM (ELECTRO-MECHANICAL AND SOLID STATE STARTER APPLICATIONS) JOHNSON CONTROLS...

  • Page 28: Figure 9 - Operation Sequence Timing Diagram (Compressor Motor Variable Speed Drive Applications)

    (1.83) (10) START START CLOSED RESTART RESTART (IF FIVE SUCCESSIVE CLOSE (ONLY AFTER FIFTH RESTARTS HAVE NOT TIME IN SECONDS (MINUTES) SUCCESSIVE RESTART) OCCURED) LD06504 FIGURE 9 - OPERATION SEQUENCE TIMING DIAGRAM (COMPRESSOR MOTOR VARIABLE SPEED DRIVE APPLICATIONS) JOHNSON CONTROLS...

  • Page 29: Section 3 - Microboard 031-01730-000

    Refer to YORK Renewal and revision level. The version is printed on a label ad- Parts - OptiView™ Control Center (Form hered to the memory card’s surface. The version code 160.54-RP1) and Service Replacement is as follows: paragraph in this manual. JOHNSON CONTROLS...
  • Page 30 The watchdog circuit also assures that all the program instructions are being performed and that the Program has not latched-up, bypassing important safety thresh- olds. If the Program has latched-up, the microproces- sor initiates a safety shutdown and displays WATCH- DOG – SOFTWARE REBOOT message. JOHNSON CONTROLS...

  • Page 31: Boot-Up Step And Description

    LED Indicators When power is applied to the OptiView™ Control Cen- ter, both the red (CR18 - Fail) and green (CR17 - Pass) LED's simultaneously illuminate for 1 second, then the Boot-up process begins in the following sequence: JOHNSON CONTROLS...

  • Page 32: Table 3 - Addresses And Associated Data

    (CM-2 Current Board for Electromechani- Peak Motor Current cal starter or Style A Solid State Starter Logic Board). phase A, B, C line voltage Refer to the appropriate section of this manual for detailed explanation of each board. JOHNSON CONTROLS...
  • Page 33 I/O Board is converted to a logic low (less than 1VDC). A 0VAC input to the I/O Board is converted to a logic high (more than 4VDC). Refer to SECTION 5 - I/O Board of this manual for details of the I/O Board. JOHNSON CONTROLS...
  • Page 34 2 of the flow sensor. Then connect a voltmeter from • CR15 TX3 – COM3 serial port transmit data. Microboard J7-14 (evaporator) or J7-16 (condenser) to • CR14 RX3 – COM3 serial port receive data. Microboard TP1(ground). JOHNSON CONTROLS...
  • Page 35 031-02430-001 lists the required program jumper con- figuration for each display. Also, a label attached to the display mounting plate lists the required program jumper configuration for that display. The position of program jumper JP2 determines whether the supply voltage is +5VDC or +3.3VDC. JOHNSON CONTROLS...

  • Page 36: Power Supply

    JP24 to accept these inputs in either 0 to 10VDC, 2 to 10VDC, 0 to 20mA or 4 to 20mA form. Refer to Pro- gram Jumper configurations and SECTION 21 - RE- MOTE SETPOINTS of this manual for details of the Remote setpoints. JOHNSON CONTROLS...
  • Page 37 FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 LD07776 FIGURE 10 - MICROBOARD 031-01730-000 JOHNSON CONTROLS...

  • Page 38: Figure 11 - Flash Memory Card

    WRITE PROTECT SWITCH (OPTIONAL) (MUST BE IN "ENABLED POSITION") PAD 60 PAD 31 PAD 30 PAD 1 CINS CINS 3V/5V ALIGNMENT NOTCH LD04049 MEMORY CARD - SIDE VIEW WRITE ENABLED WRITE DISABLED LD04050 FIGURE 11 - FLASH MEMORY CARD JOHNSON CONTROLS...

  • Page 39: Figure 12 - Microboard (031-01730-000) Power Supply Test Points

    SECTION 3 - MICROBOARD 031-01730-000 + 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...

  • Page 40: Program Jumpers

    JP5 - Display backlight power. Determines the power input on J22-1. supply voltage applied to the Display Backlight Pins 1-2: Allows a 0 to 20mA or 4 to 20mA Inverter Board. input on J22-2. Pins 2-3: Not Used. JOHNSON CONTROLS...
  • Page 41 IN: Mod A - Old style with Logic Board mount- microboard adjacent to the program jumper. ed in OptiView™ Control Center. Not used on YK Chiller applications. OUT: Mod B - New style with integrated Log- ic/Trigger Board mounted Starter cabinet. JOHNSON CONTROLS...

  • Page 42: Program Switches

    OFF: Disables anti-recycle timer. Chiller TB1-34 Liquid Line, TB1-61 Oil Return and can be started at the completion of System Vent Line connected in parallel, TB1-62 High Coastdown, regardless of how long the chiller Speed Thrust. had been running. JOHNSON CONTROLS...

  • Page 43: Figure 13 - Microboard Lamp Dimmer Circuit

    2. The position of Program Jumpers JP7 and JP8 determine the output at J6-7; In = Variable Voltage; Out = Variable Resistance. Refer to Program Jumper Listing for applications. 3. Potentiometer is actually an integrated circuit that is the electrical equivalent of a 10KΩ potentiometer. FIGURE 13 - MICROBOARD LAMP DIMMER CIRCUIT JOHNSON CONTROLS...

  • Page 44: Figure 14 - Microboard Serial Data Communications Ports

    1. Microboard Program Jumper JP27 determines whether COM 4A or 4B can be used. 1 and 2 - 4A, 2 and 3, 4B. 2. J15-4 Loop-Around Test IN. J15-5 Loop-Around Test OUT. Refer to FIGURE 88 for details. FIGURE 14 - MICROBOARD SERIAL DATA COMMUNICATIONS PORTS JOHNSON CONTROLS...

  • Page 45: Figure 15 - Configurable Analog And Remote Setpoint Inputs

    2. Applies to Flash memory card version C.MLM.01.07.xxx and later. Program Jumpers JP21 and JP22 must be on pins 2-3 on style F and later chillers equipped with factory-mounted thermal-type flow sensors. FIGURE 15 - CONFIGURABLE ANALOG AND REMOTE SETPOINT INPUTS JOHNSON CONTROLS...
  • Page 46 FORM 160.54-M1 SECTION 3 - MICROBOARD 031-01730-000 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 47: Section 4 - Microboard 031-02430-000 And 031-02430-001

    TP3. It is applied to a +3.3VDC regula- OptiView™ Control Cente tor, +2.5VDC regulator and used directly by the mi- Commercial chiller croboard circuits as the Vcc voltage. The outputs of these regulators are applied to Microboard circuits and JOHNSON CONTROLS...

  • Page 48: Table 4 - Diagnostic Display Codes

    It contains the Safety and Cycling memory storage device that is programmed with the shutdown thresholds (non-changeable) and display chiller operating program. The program card part num- screen messages and graphics. ber for YK chillers is 031-02474-001 and is available JOHNSON CONTROLS...
  • Page 49 28-pin socket. Program Jumper JP14 trol revision level. The version is as follows: is a non-removable (soldered) wire jumper that con- nects DC power to the appropriate pin on the BRAM for 32KB operation. JOHNSON CONTROLS...
  • Page 50 The The Program Switches are miniature switches that are Watchdog circuit is a timer that times-out if not given placed in either the ON or OFF position. a reset pulse within its time-out period (1 to 2.25 sec- JOHNSON CONTROLS...

  • Page 51: Table 5 - Multiplexer Channels

    Motor Current (%FLA) Starter model/ Current Phase C Phase B Phase A Phase A Phase B STYLE A Phase C SOLID STATE voltmeter limit motor motor motor line line line voltage STARTER current current voltage voltage range command current JOHNSON CONTROLS...
  • Page 52 J15-2. Between June 2006 and March 2007, new production VSD communicate with Microboard 031- Refer to Figure 21 on Page 67 and SECTION 13 - 02430-001 using the same interface/protocol. ADAPTIVE CAPACITY CONTROL Board for details of the variable speed drive interface. JOHNSON CONTROLS...
  • Page 53 Refer to SECTION Refer to SECTION 18 - COMMUNICATIONS of this 20 - TEMPERATURE THERMISTORS of this manual. manual. Included are tables to convert the expected output volt- age for any temperature applied to the thermistor. JOHNSON CONTROLS...
  • Page 54 A green RX LED illuminates as data is received from another device. The RS-232 voltages are industry standard +5 to +25VDC and -5VDC to -25VDC logic levels. The RS-485 voltages are indus- JOHNSON CONTROLS...
  • Page 55 The Lamp Dimmer is an integrated circuit that the drive signals are accompanied by a clock and hori- is the electrical equivalent of a 10K ohm potentiometer zontal and vertical sync signals. JOHNSON CONTROLS...

  • Page 56: Configuration/Setup

    1. Standard – Contacts open at completion of System Coastdown after all shutdowns except LEAVING CHILLED LIQUID – LOW TEMPERATURE. On this shutdown, they remain closed, causing the pump to continue to run while the chiller is shutdown. JOHNSON CONTROLS...
  • Page 57 Fixed Speed Oil Pump. A de- Variable Speed Drive applications, used when the scription of the two Oil Pumps is as follows: microboard is interfaced to the VSD via the ACC Board. On Style B Liquid Cooled Solid State JOHNSON CONTROLS...
  • Page 58 Motor Node ID setpoint. Then set the Mod- sition will be shown on respective screens when En- bus Address of the Logic/Trigger Board 031-02505 abled; not shown when Disabled. to 1 by setting Switch SW1 Position 1 to ON with all other positions OFF. JOHNSON CONTROLS...
  • Page 59 C.OPT.01.23.307 and later) – Allows the • Style B Liquid Cooled Solid State Starter (LC- Heat Pump Duty to be enabled or disabled. SSS) Modbus applications. A summary of the differences between 031-02430-000 and 031-02430-001 Microboards are shown in the fol- lowing table: JOHNSON CONTROLS...

  • Page 60: Figure 16 - Bram Socket

    When transferring a 32KB BRAM from 031-02430– Program cards can be re-programmed with the latest 000 Board to 031-02430–001 board - applications program version. other than MV SSS, MV VSD and VSD Modbus ap- JOHNSON CONTROLS...

  • Page 61: Downloading A Program From Aprogram Card

    Download the program as follows: cedure, “Er” displayed. During the Programming procedure, “Pr” is displayed. During the Verifying 1. Remove power to OptiView™ Control Center. procedure, “Ch” is displayed. 2. Remove protective cover from Microboard con- nector U33. JOHNSON CONTROLS...

  • Page 62: Program Jumpers

    JP4 – Display Backlight enable signal logic levels. De- JP12 – Factory mounted thermal flow sensor – heating termines the logic levels of the Backlight Enable condenser water. Heat Recovery chillers. signal. Pins 1-2: not used. Pins 1-2: +12VDC/0VDC – not used. Pins 2-3: Heat Recovery chillers. JOHNSON CONTROLS...

  • Page 63: Program Switches

    OFF – Disables diagnostics. Enables normal Pins 2-3: Factory mounted condenser Thermal chiller operation. type flow sensor (new production chillers prior to June 2009). SW1-4 – Not used. JP23 – Remote Current Limit setpoint (J22) type. Configures Analog Input for 0 to 10VDC, 2 to 10VDC, 0 to 20mA or 4 to 20mA. JOHNSON CONTROLS...

  • Page 64: Figure 17 - Microboard 031-02430-000 And 031-02430-001

    FORM 160.54-M1 SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001 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 JOHNSON CONTROLS...

  • Page 65: Figure 18 - Program Card 031-02474-001

    + 5 VDC (Analog) VOLTAGE (For Transducer and Thermistors) + 5 VDC (VCC) 2.5 VDC VOLTAGE 2.5 VDC J1-1 + 5 VDC 3.3 VDC 3.3 VDC VOLTAGE J1-2 LD09255A FIGURE 19 - MICROBOARD (031-02430-000 AND 031-02430-001) DC POWER SUPPLY TEST POINTS JOHNSON CONTROLS...

  • Page 66: Figure 20 - Microboard Lamp Dimmer Circuit

    2. The position of Program Jumpers JP7 and JP8 determine the output at J6-7; In = Variable Voltage; Out = Variable Resistance. Refer to Program Jumper Listing for applications. 3. Potentiometer is actually an integrated circuit that is the electrical equivalent of a 10KΩ potentiometer. FIGURE 20 - MICROBOARD LAMP DIMMER CIRCUIT JOHNSON CONTROLS...

  • Page 67: Figure 21 - Microboard Serial Data Communications Ports

    JP17 as follows: On pins 1 and 2 for RS-485 operation. On Pins 2 and 3 for RS-232 operation. The COM 2 RS-485 port is not present on 031-02430-000 Microboard. FIGURE 21 - MICROBOARD SERIAL DATA COMMUNICATIONS PORTS JOHNSON CONTROLS...

  • Page 68: Figure 22 - Configurable Analog And Remote Setpoint Inputs

    3. Factory mounted evaporator Thermal type flow sensor (new production chillers prior to June 2009) or Leaving Chilled Liquid Temperature Thermistor (chillers equipped with the optional Heat Pump Duty.feature) FIGURE 22 - CONFIGURABLE ANALOG AND REMOTE SETPOINT INPUTS JOHNSON CONTROLS...

  • Page 69: Figure 23 - Configurable Analog And Remote Setpoint Inputs (Heat Pump Duty)

    2-10 VDC TEMP SETPOINT 0-20 mA / 4-20 mA JP24 REMOTE SETPOINT GND CONNECTIONS LD15436 NOTE: 1. Program Jumper JP21 must be positioned on pins 2-3. FIGURE 23 - CONFIGURABLE ANALOG AND REMOTE SETPOINT INPUTS (HEAT PUMP DUTY) JOHNSON CONTROLS...

  • Page 70: Figure 24 - Low Voltage Digital Inputs

    Jumpers JP10 through JP12 must be positioned on pins 2-3 and software version C.OPT.01.21.307 (and later) is required. On new production chillers prior to June 2009, the Thermal type flow sensors are connected to Microboard J7 (Refer to Figure 22). FIGURE 24 - LOW VOLTAGE DIGITAL INPUTS JOHNSON CONTROLS...

  • Page 71: Section 5 - I/O Board

    Variable Speed Drive applications. The High Pres- sure safety switch “HP”, must be closed and the RUN The coils of these devices operate on 115VAC and Switch “1SS” must be in the Run position. therefore cannot be directly connected to the mi- JOHNSON CONTROLS...

  • Page 72: Triacs

    This actuator operates from remain closed during shutdown, when a chiller restart 24VAC. As described previously in this section, Triacs JOHNSON CONTROLS...
  • Page 73 C.MLM.01.07.xxx or keypad COMPRESSOR switch is placed in the Stop - later version)) (TB1-64/17) Reset (O) position. On cycling shutdowns, the contacts will close when the cycling condition clears. On safety Contacts operate the same as K15. JOHNSON CONTROLS...
  • Page 74 K18 - Compressor Motor Starter (TB5-22/25) K13 - Compressor Motor Starter (start) Run Status (TB2-35/36) (TB1-6/16) Contacts operate the same as K14. Contacts close coincident with the beginning of Sys- tem run. They remain closed for 0.2 seconds and then open. JOHNSON CONTROLS...

  • Page 75: Figure 25 - I/O Board

    FORM 160.54-M1 SECTION 5 - I/O BOARD LD04055 FIGURE 25 - I/O BOARD JOHNSON CONTROLS...

  • Page 76: Figure 26 - I/O Board Digital Inputs

    CONDENSER WATER FLOW SWITCH TB4 - 82 J1 -19 NOT USED TB4 - 1 115VAC TB4 - 95 J1 -20 NOT USED TB4 - 1 115VAC TB3 - 1 115VAC LD09566 FIGURE 26 - I/O BOARD DIGITAL INPUTS JOHNSON CONTROLS...

  • Page 77: Figure 27 - I/O Board Typical Opto-Coupler Circuit

    FIGURE 27 - I/O BOARD TYPICAL OPTO-COUPLER CIRCUIT TB4 - X OPTO- J1 - Y COUPLER 115VAC TB4 - 1 TB3 - 1 FIELD SUPPLIED DRY CONTACTS (RATED 5MA @ 115VAC) LD04058 FIGURE 28 - I/O BOARD TYPICAL FIELD CONNECTIONS JOHNSON CONTROLS...

  • Page 78: Figure 29 - J1 I/O Board Digital Outputs

    TB1- 61 OIL RETURN SOLENOID (ALL STYLES) (LIQUID LINE SOLENOID - TB1 - 1 (Style D and later chillers) J-COMPRESSOR ONLY) VENT LINE SOLENOID (Style C and earlier chillers) LD09042 FIGURE 29 - J1 I/O BOARD DIGITAL OUTPUTS JOHNSON CONTROLS...
  • Page 79 Drive Applications). 3. Chillers equipped with P compressors and all style "F" and later chillers use a different High Pres- sure (HP) Switch and associated interface than other compressor applications. FIGURE 29 - J1 I/O BOARD DIGITAL OUTPUTS (CONT'D) JOHNSON CONTROLS...
  • Page 80 CLOSE TB1-163 FIELD 115VAC REFRIGERANT TB1-161 LEVEL CONTROL ACTUATOR (BELIMO) REFRIGERANT J1-29 TRIAC LEVEL CONTROL DRIVER OPEN TB1-162 24VAC REFRIGERANT J1-28 TRIAC LEVEL CONTROL DRIVER CLOSE TB1-163 115VAC LD09567 FIGURE 29 - J1 I/O BOARD DIGITAL OUTPUTS (CONT'D) JOHNSON CONTROLS...

  • Page 81: Section 6 - Liquid Crystal Display

    Imbedded in each window of the pixel is a transistor, is approximately 16 milliseconds. The next VSYNC the conduction of which determines the amount of light pulse causes the above cycle to repeat. that will pass through the window. The conduction of JOHNSON CONTROLS...
  • Page 82 Displays stocked for Service replacement are a Microboard section and the Display Interface Board result of that same agreement. Therefore, the Display section that follows. received for service replacement may be by a differ- JOHNSON CONTROLS...

  • Page 83: Backlight Lamp Replacement

    4. Using small Phillips screwdriver, remove lamp wires to the display with power applied retaining screw. will damage the display!!! 5. Grasp lamp AC power connector and gently pull until lamp housing is completely removed from the Display. JOHNSON CONTROLS...

  • Page 84: Figure 30 - Display Mounting

    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. Connect lamp AC power connector to Backlight Inverter Board. 4. Apply AC power to OptiView™ Control Center. LD04062 FIGURE 30 - DISPLAY MOUNTING JOHNSON CONTROLS...

  • Page 85: Figure 31 - Liquid Crystal Display Assembly - Sharp Lq10D367/368 (031-01774-000) Display

    2. 025-33752-000 (prior to October 2002) 025-40317-000 (after October 2002) FIGURE 31 - LIQUID CRYSTAL DISPLAY ASSEMBLY – SHARP LQ10D367/368 (031-01774-000) DISPLAY NOTE: LD14074 1. Configure Microboard Program Jumpers per label. FIGURE 32 - LIQUID CRYSTAL DISPLAY ASSEMBLY – SHARP LQ104V1DG61 (031-02886-000) DISPLAY JOHNSON CONTROLS...

  • Page 86: Figure 33 - Liquid Crystal Display Assembly - Lg Semicon Lp104V2-W (031-02046-000)

    ENABLE PERIOD PERIOD PERIOD 39.72 NS 640 CLKS NOTES: (25.18 1. BP = Back Porch = 4-48 CLKS MHz) 2. FP = Front Porch = 2-16 CLKS LD04066 FIGURE 34 - LIQUID CRYSTAL DISPLAY TYPICAL CONTROL SIGNAL TIMING JOHNSON CONTROLS...

  • Page 87: Figure 35 - Display (Sharp Lq10D367/368) Lamp Replacement

    (white/GND side) HOLE LOCKING TAB WIRE (pink/HOT side) DIRECTION A DIRECTION B DIRECTION C LD04067 FIGURE 35 - DISPLAY (SHARP LQ10D367/368) LAMP REPLACEMENT SCREW FOR LAMP REMOVAL LD14075 FIGURE 36 - DISPLAY (SHARP LQ104V1DG61 (031-02886-000) AND LG LP104V2-W (031-02046-000)) JOHNSON CONTROLS...
  • Page 88 FORM 160.54-M1 SECTION 6 - LIQUID CRYSTAL DISPLAY THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 89: Section 7 - Display Interface Board

    LG Semicon LP104V2-W (031-02046-000) • Display Interface Board 031-01765-001 PID0 – IN (GND) Display Applicability: PID1 – OUT (VCC) LG Semicon LP104V2-W (031-02046-000) PID2 – OUT (VCC) P30 – OUT (Open) PID3 – OUT (VCC) P31 – OUT (Open) JOHNSON CONTROLS...
  • Page 90 • Display Interface Board 031-02887-000 face Board. The value of VCC is either +5VDC or Display Applicability: +3.3VDC, as determined by the position of Program Jumper JP2 on the microboard. SHARP LQ104V1DG61 (031-02886-000) J1-30 – (VCC) J1-31 – (GND) JOHNSON CONTROLS...

  • Page 91: Figure 37 - Display Interface Board 031-01765-001 And 031-01765-002

    FORM 160.54-M1 SECTION 7 - DISPLAY INTERFACE BOARD FIGURE 37 - DISPLAY INTERFACE BOARD 031-01765-001 AND 031-01765-002 JOHNSON CONTROLS...

  • Page 92: Figure 38 - Display Interface Board 031-02887-000

    FORM 160.54-M1 SECTION 7 - DISPLAY INTERFACE BOARD FIGURE 38 - DISPLAY INTERFACE BOARD 031-02887-000 JOHNSON CONTROLS...

  • Page 93: Section 8 - Display Backlight Inverter Board

    When the Backlight Enable signal is +5VDC, the high croboard provides the Backlight Enable signal. This voltage signal is applied to the lamp. When the Enable signal turns the lamp ON and OFF. Some manufactur- is 0VDC, the high voltage is removed from the lamp. JOHNSON CONTROLS...

  • Page 94: Figure 39 - Display Backlight Inverter Board (Sharp Lq10D367/368 (031-01774-000) And

    BRIGHTNESS CONTROL (NOTE 2) MICRO BOARD N.C. N.C. BACKLIGHT ENABLE (NOTE 1) N.C. N.C. + 12 VDC (NOTE 3) INVERTER CABLE 031-01770-003 LD09568a FIGURE 39 - DISPLAY BACKLIGHT INVERTER BOARD (SHARP LQ10D367/368 (031-01774-000) AND LG SEMICON LP104V2-W (031-02046-000)) JOHNSON CONTROLS...

  • Page 95: Figure 40 - Display Backlight Inverter Board - Sharp Lq104V1Dg61 Display 031-02886-000

    2. 0- + 3.0 VDC. 0VDC = MAX (100%) brightness. +3VDC = MIN (0%) brightness. Refer to Microboard Program Jumpers JP7 and JP8. 3. Refer to Microboard Program Jumper JP5. 4. N.C. = No Connection. FIGURE 40 - DISPLAY BACKLIGHT INVERTER BOARD – SHARP LQ104V1DG61 DISPLAY 031-02886-000 JOHNSON CONTROLS...
  • Page 96 FORM 160.54-M1 SECTION 8 - DISPLAY BACKLIGHT INVERTER BOARD THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 97: Section 9 - Keypad

    Display and rocker switch openings and a key in that column and row is pressed. For example, apply the keypad to the door. if at the time row 4 is being driven low, if column 3 JOHNSON CONTROLS...

  • Page 98: Figure 41 - Keypad

    FORM 160.54-M1 SECTION 9 - KEYPAD LD04074 CONNECTOR FIGURE 41 - KEYPAD JOHNSON CONTROLS...

  • Page 99: Figure 42 - Keypad

    FORM 160.54-M1 SECTION 9 - KEYPAD LD04075 LD04076 FIGURE 42 - KEYPAD JOHNSON CONTROLS...
  • Page 100 FORM 160.54-M1 SECTION 9 - KEYPAD THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 101: Section 10 - Power Supply

    Analog circuits and is labeled as the +5VDC (Analog) supply. It is also routed to all Pressure Trans- ducers, Temperature Thermistors, Proximity probe and Motor Controller Board (CM-2, Mod A Solid State Starter Logic Board or VSD ACC Board). JOHNSON CONTROLS...

  • Page 102: Figure 44 - Power Supply - Dc Power Distribution (Refer To Optiview™ Control Center Wiring Diagram For Wire Connections)

    FORM 160.54-M1 SECTION 10 - POWER SUPPLY FIGURE 44 - POWER SUPPLY – DC POWER DISTRIBUTION (REFER TO OPTIVIEW™ CONTROL CENTER WIRING DIAGRAM FOR WIRE CONNECTIONS) JOHNSON CONTROLS...

  • Page 103: Section 11 - Current Module (Cm-2)

    Electro-Mechanical Starter present; UP for plied to potentiometer R8. This is factory adjusted Y-delta or 57% Autotransformer starters, DOWN for (field adjusted on service replacements) to illuminate all other starters. the 105% CURR indicator (CR6) when the compressor JOHNSON CONTROLS...

  • Page 104: Table 8 - Mux Address

    FLA, the microboard applies a close signal to the PRV calibrated on CM-2 until the motor current decreases to 102% FLA. While board to be +4.0VDC Current Limit is in effect, MOTOR - HIGH CUR- at 100% FLA. RENT LIMIT is displayed. JOHNSON CONTROLS...

  • Page 105: Figure 45 - Cm-2 Current Module (Electro-Mechanical Starter Application)

    FORM 160.54-M1 SECTION 11 - CURRENT MODULE (CM-2) LD04079 FIGURE 45 - CM-2 CURRENT MODULE (ELECTRO-MECHANICAL STARTER APPLICATION) LD04080 FIGURE 46 - CM-2 CURRENT MODULE (ELECTRO-MECHANICAL STARTER APPLICATIONS) JOHNSON CONTROLS...

  • Page 106: Figure 47 - Cm-2 Current Module - Interface, Current Transformers And Variable Resistors

    R = 0.247 (CT RATIO) 11-18 200:1 R = 0.370 (CT RATIO) 19-37 200:1 2300-4160 38-123 200:1 R = 0.740 (CT RATIO) 124-264 350:1 265-518 700:1 LD04082 FIGURE 47 - CM-2 CURRENT MODULE – INTERFACE, CURRENT TRANSFORMERS AND VARIABLE RESISTORS JOHNSON CONTROLS...

  • Page 107: Section 12 - Solid State Starters

    Microboard 031-02430-001, equipped with the 128K displays LCSSS INITIALIZATION FAILED on the BRAM and software C.OPT.01.15.xxx (or later) is re- System Details line of the OptiView™ Control Center quired for this application. Microboard Program Jump- display. The microboard will continue to establish com- JOHNSON CONTROLS...
  • Page 108 On new production chillers after mid 2008, Microboard under LAST TEN FAULTS. Refer to Operation Manual 031-02430-001 COM 2 (J13) serial port communicates (Form 160.54-O1) for description of all Cycling and with Logic/Trigger Board 031-02505 (J14) using RS- Safety shutdown messages. JOHNSON CONTROLS...
  • Page 109 Full Load Amps (FLA) of the chiller, as listed Logic/Trigger Board initiates a cycling shutdown and on the SALES ORDER Screen. Each starter mod- displays LCSSS - HIGH SUPPLY LINE VOLTAGE or el has a permissible range over which this setpoint can be programmed as follows: JOHNSON CONTROLS...
  • Page 110 Logic/Trigger Board, by the value decreases to less than or equal to 98% of the Current programmed for the Full Load Amps setpoint. The Limit setpoint. message % FULL LOAD AMPS is displayed on the JOHNSON CONTROLS...

  • Page 111: Figure 48 - Style B Liquid Cooled Solid State Starter (Lcsss) - Interface (York Protocol)

    START / STOP STARTER (MOTOR CONTROLLER) INITIATED SHUTDOWN BOARD STOP CONTACTS NOTES: LD04648B – “CONDOR” Power Supply; 13 – “POWER ONE” Power Supply FIGURE 49 - STYLE B LIQUID COOLED SOLID STATE STARTER (LCSSS) – INTERFACE (YORK PROTOCOL) JOHNSON CONTROLS...

  • Page 112: Figure 50 - Style B Liquid Cooled Solid State Starter (Lcsss) - Interface (Modbus Protocol)

    JUMPER BETWEEN NO. 7 AND 8 PINS LOGIC P1 / J1 Board PLUG INDICATOR CONN. LED’S 24672A R3 R2 R1 START OVERLOAD RESET RESISTORS CURRENT POT CURRENT POT PUSHBUTTON (SWI) FIGURE 51 - SOLID STATE STARTER LOGIC BOARD JOHNSON CONTROLS...
  • Page 113 Table 9 on Page 114. Rotation/Loss or Trigger Board Out of Lock (OOL) LED illuminates and remains illuminated until manu- ally reset with the S1 RESET switch. The chiller will automatically restart when the contacts close. JOHNSON CONTROLS...

  • Page 114: Table 9 - Microboard Multiplex Channels

    Phase A Compressor Motor Current. 0 to +5VDC spanning range in address 0 above. Phase B Compressor Motor Current. 0 to +5VDC spanning range in address 0 above. Phase “C” Compressor Motor Current. 0 to +5VDC spanning range in address 0 above. JOHNSON CONTROLS...

  • Page 115: Figure 52 - Mod A Liquid Cooled Solid State Starter (Lcsss) - Interface

    FORM 160.54-M1 SECTION 12 - SOLID STATE STARTERS FIGURE 52 - MOD A LIQUID COOLED SOLID STATE STARTER (LCSSS) – INTERFACE JOHNSON CONTROLS...
  • Page 116 FORM 160.54-M1 SECTION 12 - SOLID STATE STARTERS THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 117: Section 13 - Adaptive Capacity Control Board

    Condenser Pressure Differential (head) that exists bus. If Modbus is selected, the Motor Node ID setpoint when each surge occurs. must be set to match the setting of the VSD Logic Board Modbus Address Switch SW3. They must be both set to “1”. JOHNSON CONTROLS...
  • Page 118 Board. The ACC Board returns both the VSD Logic each of these commands. If a response is not received Board’s response and the Harmonic Filter’s response to to 10 consecutive commands, a cycling shutdown is the microboard. performed and VSD – SERIAL COMMUNICATIONS JOHNSON CONTROLS...
  • Page 119 • Pre-rotation Vanes position • Input Power KW • Surge count • KWH The compressor motor speed can be controlled either • 100% Job FLA manually in Manual Mode or automatically in Auto • DC Link Voltage Mode. JOHNSON CONTROLS...
  • Page 120 80% but less than 98%FLA. OptiView™ display as 0% when fully closed, 100 • 0.2Hz every 19 seconds if none of the above con- % when fully open and whole percentage points ditions are present. in between. JOHNSON CONTROLS...
  • Page 121 Surge Detected by the Delta P method must have all of bility by comparing the Leaving Chilled Liquid the following conditions occur within 5 seconds to be Temperature to the Leaving Chilled Liquid Tem- considered a valid surge: perature setpoint to arrive at a rate of change value. JOHNSON CONTROLS...
  • Page 122 1.0Hz but the surge is not plotted on the Surge Map fied Service technicians as a method of plotting a surge since these conditions would produce an erroneous JOHNSON CONTROLS...
  • Page 123 0 to 5VDC form. LED’s YM XMT (CR7) • TPD: Harmonic Filter Logic Board 0 to +5VDC and YM RCV (CR6) LED’s illuminate during serial 1200 baud serial data. communications with the OptiView™ Control Center • TPE: Harmonic Filter Logic Board Frame pulse. JOHNSON CONTROLS...

  • Page 124: Modbus Protocol Configuration

    This logic shall be in tarily illuminates and the “ACC Surge Count” incre- effect during the entire initial ramp and take action as ments (The “Surge Avoidance Surge Detected” LED is many times as necessary. shown for reference only. It momentarily illuminates JOHNSON CONTROLS...
  • Page 125 ACC current limiting shall not be allowed to de- way to clear it is to clear the BRAM. To prevent this crease the frequency below the mapped point. from happening, this value is no longer programmable. It is now always set to 7000. JOHNSON CONTROLS...

  • Page 126: Figure 53 - Compressor Motor Variable Speed Drive (Vsd) Adaptive Capacity Control (Acc) Board

    MICROBOARD RECEIVE LED TRANSMIT (POWER FAIL) RECEIVE MICRO BOARD TRANSMIT MANUAL SURGE POINT SWITCH SURGE MICRO VALID SURGE POINT (GND) LD04084 BRAM EPROM (+5VDC) FIGURE 53 - COMPRESSOR MOTOR VARIABLE SPEED DRIVE (VSD) ADAPTIVE CAPACITY CONTROL (ACC) BOARD JOHNSON CONTROLS...

  • Page 127: Figure 54 - Serial Communications Interface - York Protocol

    FIGURE 54 - SERIAL COMMUNICATIONS INTERFACE – YORK PROTOCOL ADAPTIVE CAPACITY MICROBOARD VSD LOGIC BOARD CONTROL BOARD 031-02430-001 031-01782 031-01433 COND PRESSURE 031-02077 031-02506 EVAP PRESSURE COM 5 OPTO-COUPLE COM 2 RS-485 POSITION LD12568 FIGURE 55 - SERIAL COMMUNICATIONS INTERFACE – YORK PROTOCOL JOHNSON CONTROLS...

  • Page 128: Figure 56 - Serial Communications Interface - Modbus Protocol

    FORM 160.54-M1 SECTION 13 - ADAPTIVE CAPACITY CONTROL BOARD MICROBAORD VSD LOGIC BOARD 031-02430-001 031-02506 COM 5 OPTO-COUPLE COM 2 RS-485 +12 VDC 22 10 POSITION LD12569 FIGURE 56 - SERIAL COMMUNICATIONS INTERFACE – MODBUS PROTOCOL JOHNSON CONTROLS...

  • Page 129: Figure 57 - Adaptive Capacity Control (Acc) Board

    FORM 160.54-M1 SECTION 13 - ADAPTIVE CAPACITY CONTROL BOARD FIGURE 57 - ADAPTIVE CAPACITY CONTROL (ACC) BOARD JOHNSON CONTROLS...
  • Page 130 FORM 160.54-M1 SECTION 13 - ADAPTIVE CAPACITY CONTROL BOARD THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 131: Section 14 - Proximity Probe

    This value remains the Reference Position until the compressor is rebuilt, whereupon the calibration proce- dure must be repeated to establish a new Reference Posi- tion. Since this Reference Position value is stored in the BRAM (U52) memory device on the microboard, field JOHNSON CONTROLS...
  • Page 132 Probes. The Probe differences vary with the vin- tage. The differences are listed in Table 10 on Page 133. For service replacement, refer to part number listed in Renewal Parts – OptiView™ Control Center (Form 160.54-RP1) or the unit renewal parts manual. JOHNSON CONTROLS...

  • Page 133: Table 10 - Proximity Probes

    The probe is connected to the electronics module with a coaxial cable. Refer to Figure 60 on Page 135 for parts breakout of probe assembly 025-40496-000. JOHNSON CONTROLS...

  • Page 134: Figure 58 - Proximity Probe Interface - Probe Part Number 025-30961-000

    1. +24VDC Reference for “Proximity probe - Low Supply Voltage” Cycling Shutdown. 2. CM-2 Board, Solid State Starter Logic Board or Adaptive Capacity Control Board as determined by the Starter Application. FIGURE 59 - PROXIMITY PROBE INTERFACE – PROBE PART NUMBER 025-35900-000 AND 025-35900-001 JOHNSON CONTROLS...

  • Page 135: Figure 60 - Proximity Probe Interface - Probe Part Number 025-40496-000

    5. When replacing previous probe versions with this probe, use the existing cable and retrofit kit 364-51806-000, consisting of: 025-40496-000 probe assembly (Refer to note 4) 025-37805-000 DIN connector 028-12209-000 O-ring 035-21458-000 instruction drawing FIGURE 60 - PROXIMITY PROBE INTERFACE – PROBE PART NUMBER 025-40496-000 JOHNSON CONTROLS...
  • Page 136 FORM 160.54-M1 SECTION 14 - PROXIMITY PROBE 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 61 - PROXIMITY PROBE JOHNSON CONTROLS...

  • Page 137: Section 15 - High Speed Thrust Bearing Limit Switch

    15 to 25 PSIG. One side of these con- CONTROL CENTER COMPRESSOR BOARD LD06866 FIGURE 62 - HIGH SPEED THRUST BEARING LIMIT SWITCH – INTERFACE JOHNSON CONTROLS...

  • Page 138: Figure 63 - High Speed Thrust Bearing Limit Switch

    FORM 160.54-M1 SECTION 15 - HIGH SPEED THRUST BEARING LIMIT SWITCH PRESSURE SWITCH GRD PIN (GRN/YEL) PINS 1 AND 2 (BLK) BREAK-AWAY PROBE GRN/YEL LD06860 FIGURE 63 - HIGH SPEED THRUST BEARING LIMIT SWITCH JOHNSON CONTROLS...

  • Page 139: Section 16 - Refrigerant Level Control

    Some sensors are equipped with Upon entering chiller Pre-lube, the Refrigerant adjustable potentiometers, while others are equipped Level close output is energized for the length of with pushbuttons that are used to calibrate the sensor. JOHNSON CONTROLS...
  • Page 140 Level setpoint in a recurring period of time called • ZONE 2 a Level Control Period. At the end of each Level Con- trol Period, the Proportion error and Rate of Change • ZONE CONTROL OFF (if chiller shutdown) JOHNSON CONTROLS...

  • Page 141: Manual Operation

    Page 143. The description of the operation of both ac- ror is to the Limit; close yields larger influence, further tuators is in the SECTION 5 - I/O Board of this manual. yields smaller influence. To establish the response to the JOHNSON CONTROLS...

  • Page 142: Figure 64 - Refrigerant Liquid Level Sensor

    FORM 160.54-M1 SECTION 16 - REFRIGERANT LEVEL CONTROL 1 2 3 F/UP E/DN LD09256 FIGURE 64 - REFRIGERANT LIQUID LEVEL SENSOR JOHNSON CONTROLS...

  • Page 143: Figure 65 - Refrigerant Liquid Level Control - Interface

    FORM 160.54-M1 SECTION 16 - REFRIGERANT LEVEL CONTROL FIGURE 65 - REFRIGERANT LIQUID LEVEL CONTROL – INTERFACE JOHNSON CONTROLS...
  • Page 144 FORM 160.54-M1 SECTION 16 - REFRIGERANT LEVEL CONTROL THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 145: Section 17 - Oil Pump Variable Speed Drive

    Coastdown period, it operates it over the same frequen- during the last 10 seconds of system pre-lube cy range to maintain the pressure to the programmed or during the first 15 seconds of system run. oil pressure setpoint. JOHNSON CONTROLS...

  • Page 146: Manual Operation

    Oil Pressure setpoint and the actual be used to monitor the actual oil pressure and the speed oil pressure is less than plus or minus 6 PSID, the fre- command. quency is increased or decreased 0.5Hz to increase or JOHNSON CONTROLS...

  • Page 147: Oil Heater Operation

    To prevent overheating the oil in the event of an OptiV- all Style "F" (and later) chillers iew™ Control Center failure, thermostat 1HTR opens at 180°F. OIL PUMP VSD 28782A FIGURE 66 - OIL PUMP VARIABLE SPEED DRIVE (VSD) JOHNSON CONTROLS...

  • Page 148: Figure 67 - Oil Pump Vsd / Oil Heater Control - Interface

    0.7 SEC +12VDC 0VDC 25.0 Hz +12VDC 0VDC 33.5 Hz 0.17 SEC 42.5 Hz 0.35 SEC 51.0 Hz 0.52 SEC 60.0 Hz +12VDC "OFF TIME" 0VDC "ON TIME" LD04094 FIGURE 68 - OIL PUMP VSD SPEED CONTROL SIGNAL JOHNSON CONTROLS...

  • Page 149: Section 18 - Communications

    COM 4B communications port. Refer to SECTION 33 - DIAGNOSTICS AND TROUBLE- SHOOTING of this manual. E-LINK GATEWAY G TX G RX TO BAS + 12VDC RS-485 LD06511 MICROBOARD FIGURE 69 - E-LINK GATEWAY INTERFACE BLOCK DIAGRAM JOHNSON CONTROLS...
  • Page 150 FORM 160.54-M1 SECTION 18 - COMMUNICATIONS THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 151: Section 19 - Pressure Transducers

    The differential between the sump and TROUBLESHOOTING of this manual. pump oil pressure transducer outputs during a 3 second period beginning 10 seconds after the start of the Sys- tem Pre-lube period are compared to determine the off- JOHNSON CONTROLS...

  • Page 152: Figure 70 - Pressure Transducers

    P = (17 x V) - 2.5 P + 37.5 P = (75 x V) - 37.5 V = VOLTS DC P = PRESSURE (PSIG) LD09969A V = VOLTS DC P = PRESSURE (PSIG) LD09569a FIGURE 70 - PRESSURE TRANSDUCERS JOHNSON CONTROLS...

  • Page 153: Table 11 - Pressure Transducer Applications

    Evaporator 025-28678-104 Evaporator 025-28678-115 Evaporator (Heat Pump Duty) 025-39464-000 Stall Detection 025-40088-000 * Note: Transducers 025-28678-001, -004, -102 and -103, 104 have NPTF threads. Transducers 025-28678-006, -112, -113, -114 and 025-39464-000 and 025-40088-000 have straight threads with O-rings. JOHNSON CONTROLS...
  • Page 154 FORM 160.54-M1 SECTION 19 - PRESSURE TRANSDUCERS THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 155: Section 20 - Temperature Thermistors

    If any of the displayed pressures do not appear to be this voltage at the input to the microboard and converts correct, refer to SECTION 33 - DIAGNOSTICS AND it to a temperature value. TROUBLESHOOTING of this manual. JOHNSON CONTROLS...

  • Page 156: Table 12 - Leaving Chilled Liquid Temperature

    -4.09 1.9158 14.76 -9.58 1.5835 19.81 -6.77 1.7512 24.73 -4.04 1.9189 14.85 -9.53 1.5865 19.90 -6.72 1.7542 24.82 -3.99 1.9219 14.95 -9.47 1.5896 19.99 -6.67 1.7573 24.91 -3.94 1.9250 15.04 -9.42 1.5926 20.08 -6.62 1.7603 24.99 -3.89 1.9280 JOHNSON CONTROLS...
  • Page 157 3.96 2.4189 29.57 1.35 2.0866 34.38 1.32 2.2543 39.22 4.01 2.4220 34.47 1.37 2.2573 29.66 -1.30 2.0896 39.30 4.06 2.4250 29.75 -1.25 2.0927 34.56 1.42 2.2604 39.39 4.11 2.4281 34.64 1.47 2.2634 29.83 -1.21 2.0957 39.48 4.16 2.4311 JOHNSON CONTROLS...
  • Page 158 9.45 2.7543 54.27 12.37 2.9251 44.10 6.72 2.5897 49.11 9.51 2.7574 54.36 12.42 2.9281 44.19 6.77 2.5927 49.20 9.56 2.7604 54.46 12.48 2.9312 44.28 6.82 2.5958 49.29 9.61 2.7635 54.55 12.53 2.9342 44.37 6.87 2.5988 49.38 9.66 2.7665 JOHNSON CONTROLS...
  • Page 159 21.81 3.4251 65.32 18.51 3.2605 71.37 21.87 3.4282 59.65 15.36 3.0928 65.43 18.57 3.2635 71.49 21.94 3.4312 59.75 15.42 3.0958 65.53 18.63 3.2666 71.60 22.00 3.4343 59.85 15.47 3.0989 65.64 18.69 3.2696 71.72 22.07 3.4373 59.95 15.53 3.1019 JOHNSON CONTROLS...
  • Page 160 27.72 3.6904 74.75 23.75 3.5166 78.30 25.72 3.6050 82.02 27.79 3.6935 74.87 23.82 3.5197 78.42 25.79 3.6081 82.15 27.86 3.6965 74.99 23.89 3.5227 78.55 25.86 3.6111 82.28 27.94 3.6996 75.11 23.95 3.5258 78.67 25.93 3.6142 82.41 28.01 3.7026 JOHNSON CONTROLS...
  • Page 161 44.18 4.1357 28.40 -2.00 1.8701 63.74 17.64 3.0420 116.76 47.09 4.2139 30.71 -0.72 1.9482 66.35 19.08 3.1201 122.56 50.31 4.2920 33.01 0.56 2.0264 69.02 20.57 3.1982 129.02 53.90 4.3701 35.30 1.83 2.1045 71.78 22.10 3.2764 136.37 57.98 4.4482 JOHNSON CONTROLS...

  • Page 162: Table 14 - Return Chilled Liquid Temperature

    3.22 2.3730 22.45 -5.31 1.8408 30.22 -0.99 2.1094 37.94 3.30 2.3779 22.60 -5.22 1.8457 30.36 -0.91 2.1143 38.08 3.38 2.3828 22.74 -5.14 1.8506 30.50 -0.83 2.1191 38.22 3.46 2.3877 22.88 -5.07 1.8555 30.64 -0.76 2.1240 38.36 3.53 2.3926 JOHNSON CONTROLS...
  • Page 163 16.95 3.1787 45.79 7.66 2.6465 53.95 12.20 2.0150 62.67 17.04 3.1836 45.93 7.74 2.6514 54.11 12.28 2.9199 62.84 17.13 3.1885 46.08 7.82 2.6563 54.26 12.37 2.9248 63.01 17.23 3.1934 46.22 7.90 2.6611 54.41 12.45 2.9297 63.17 17.32 3.1882 JOHNSON CONTROLS...
  • Page 164 23.84 3.5205 81.93 27.74 3.6914 68.66 20.37 3.3545 75.10 23.95 3.5254 82.14 27.86 3.6963 68.83 20.46 3.3594 75.29 24.05 3.5303 82.35 27.97 3.7012 69.01 20.56 3.3643 75.48 24.16 3.5352 82.56 28.09 3.7061 69.19 20.66 3.3691 75.68 24.27 3.5400 JOHNSON CONTROLS...
  • Page 165 -4.08 1.9165 113.26 45.14 4.2603 62.1 16.72 3.1665 26.92 -2.82 1.9946 119.3 48.50 4.3384 64.77 18.21 3.2446 29.17 -1.57 2.0728 126.1 52.28 4.4165 67.51 19.73 3.3228 31.41 -0.33 2.1509 133.93 56.63 4.4946 70.35 21.31 3.4009 33.66 0.92 2.229 JOHNSON CONTROLS...

  • Page 166: Table 16 - Return And Leaving Condensing Water

    17.90 2.6221 47.79 8.77 2.0898 56.01 13.34 2.3584 64.36 17.98 2.6270 47.94 8.86 2.0947 56.16 13.42 2.3633 64.52 18.07 2.6318 48.09 8.94 2.0996 56.31 13.51 2.3682 64.52 18.07 2.6367 48.24 9.02 2.1045 56.46 13.59 2.3730 64.83 18.24 2.6416 JOHNSON CONTROLS...
  • Page 167 33.51 3.4277 73.05 22.81 2.8955 82.33 27.96 3.1641 92.52 33.62 3.4326 73.22 22.90 2.9004 82.51 28.06 3.1689 92.72 33.74 3.4375 73.38 22.99 2.9053 82.69 28.16 3.1738 92.91 33.84 3.4424 73.54 23.08 2.9102 82.86 28.26 3.1787 93.11 33.95 3.4473 JOHNSON CONTROLS...
  • Page 168 45.06 3.8818 98.86 37.15 3.5840 105.73 40.96 3.7354 113.37 45.21 3.8867 99.07 37.26 3.5889 105.96 41.09 3.7402 113.63 45.35 3.8916 99.29 37.39 3.5938 106.20 41.23 3.7451 113.88 45.49 3.8965 99.50 37.50 3.5986 106.44 41.36 3.7500 114.14 45.64 3.9014 JOHNSON CONTROLS...

  • Page 169: Table 17 - Oil And Discharge Temperature

    24.12 0.7910 89.20 31.78 1.0547 58.06 14.48 0.5273 75.70 24.28 0.7959 89.43 31.91 1.0596 58.43 14.68 0.5322 58.81 14.90 0.5371 75.98 24.44 0.8008 89.67 32.04 1.0645 59.18 15.10 0.5420 76.25 24.59 0.8057 59.54 15.30 0.5469 76.53 24.74 0.8105 JOHNSON CONTROLS...
  • Page 170 50.16 1.8506 101.09 38.39 1.3184 112.09 44.50 1.5869 122.47 50.27 1.8555 101.29 38.50 1.3232 112.28 44.60 1.5918 122.65 50.37 1.8604 101.50 38.61 1.3281 112.48 44.71 1.5967 122.84 50.47 1.8652 101.71 38.73 1.3330 112.67 44.82 1.6016 123.02 50.57 1.8701 JOHNSON CONTROLS...
  • Page 171 67.03 2.6563 132.54 55.86 2.1240 142.59 61.44 2.3926 152.84 67.14 2.6611 132.73 55.97 2.1289 142.77 61.54 2.3975 153.03 67.24 2.6660 132.91 56.07 2.1338 142.95 61.64 2.4023 153.22 67.35 2.6709 133.09 56.17 2.1387 143.14 61.75 2.4072 153.41 67.46 2.6758 JOHNSON CONTROLS...
  • Page 172 86.38 3.4619 163.55 73.09 2.9297 175.04 79.47 3.1982 187.73 86.52 3.4668 163.75 73.20 2.9346 175.26 79.60 3.2031 187.97 86.66 3.4717 163.96 73.32 2.9395 175.48 79.72 3.2080 188.22 86.80 3.4766 164.16 73.43 2.9443 175.70 79.84 3.2129 188.46 86.93 3.4814 JOHNSON CONTROLS...
  • Page 173 104.09 3.9990 196.97 91.66 3.6426 207.57 97.55 3.8232 219.70 104.29 4.0039 197.24 91.81 3.6475 207.87 97.71 3.8281 220.06 104.49 4.0088 197.51 91.96 3.6523 208.17 97.88 3.8330 197.78 92.11 3.6572 208.48 98.05 3.8379 198.06 92.26 3.6621 208.79 98.22 3.8428 JOHNSON CONTROLS...

  • Page 174: Table 18 - Drop Leg Refrigerant Sensor

    34.49 3.949 101.50 38.61 3.644 98.31 36.84 4.027 105.10 40.61 3.722 102.87 39.38 4.105 108.90 42.73 3.801 107.81 42.12 4.183 112.92 44.96 3.879 113.26 45.15 4.261 117.17 47.32 3.957 119.30 48.50 4.339 121.76 49.87 4.035 126.10 52.28 4.418 JOHNSON CONTROLS...

  • Page 175: Table 20 - Leaving And Return Heating Condenser Water Temperature Sensor

    16.26 2.651 66.23 19.01 2.807 71.36 21.86 2.963 76.70 24.61 3.120 82.32 27.955 3.276 88.31 31.28 3.432 94.74 34.85 3.588 101.8 38.77 3.745 109.6 43.11 3.901 118.5 48.05 4.057 128.9 53.83 4.213 141.7 60.94 4.370 158.2 70.11 4.526 JOHNSON CONTROLS...
  • Page 176 FORM 160.54-M1 SECTION 20 - TEMPERATURE THERMISTORS THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 177: Section 21 - Remote Setpoints

    Current Limit setpoint setpoint varies linearly from 100% to 30% FLA as the to 100% and the Leaving Chilled Liquid Temperature input varies from 0 to l0VDC. This input will only be setpoint to the locally programmed Local BASE value. JOHNSON CONTROLS...
  • Page 178 This input will only be accepted in Digital various inputs as follows: Remote Mode. Calculate the setpoint for various pulse widths as follows: Setpoint (%) = 100 – (mA x 3.5) Setpoint (%) = 100 – [(pulse width in seconds – 1) x 7] JOHNSON CONTROLS...

  • Page 179: Leaving Chilled Liquid Temperature

    Reset Temperature Range setpoint is programmed is not used as a “base” in this application. for 10°F and the Local Leaving Chilled Liquid Tem- perature setpoint is programmed for 40°F, the setpoint would be set to 45°F as follows: JOHNSON CONTROLS...
  • Page 180 = 43.8°F Offset (°F) = (mA–4)(Remote Reset Temp Range) 0 to 20mA As shown in Figure 15 on Page 45, connect input to Setpoint (°F) = Local Setpoint + Offset Microboard J22-4 (signal) and J22-5 (GND). A 0mA JOHNSON CONTROLS...

  • Page 181: Leaving Condenser Liquid Temperature (Heat Pump Mode)

    10°F and the Local Leaving Chilled for the Leaving Chilled Liquid Temperature setpoint Liquid Temperature setpoint is programmed for 40°F, inputs as explained above. The Leaving Condenser the setpoint would be set to 44°F as follows: JOHNSON CONTROLS...
  • Page 182 As shown in Figure 12, the input is connected to Range setpoint). Select Digital Remote Mode. The re- Microboard J22-3 (signal) and J2-5 (GND). A 2VDC lay contact closure should occur at least once every 30 signal produces a 0°F offset. A 10VDC signal produces JOHNSON CONTROLS...
  • Page 183 E-Link Gateway. Select ISN Remote Mode. not to exceed once every 70 seconds. The setpoint is calculated as follows: Offset(°F) = (PW – 1)(Remote Reset Temp Range) Where PW = Pulse Width in seconds Setpoint (°F) = Local Setpoint - Offset JOHNSON CONTROLS...
  • Page 184 FORM 160.54-M1 SECTION 21 - REMOTE SETPOINTS THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 185: Section 22 - Hot Gas Bypass

    “Temperature Differential (Leaving will be closed at 10 minute intervals after the Hold Chilled Liquid Temperature minus setpoint)” on the Period has elapsed. Refer to Hold Period above. hot gas screen. The surge events it reacts to are detect- JOHNSON CONTROLS...

  • Page 186: Operation

    • If Hot gas valve position is greater than 50%, it is as it does in a standard YK chiller without Heat Pump driven open another 10%. There will be no valve ability. However, in Heating Mode, Hot gas operation response to surge events in the next 2 minutes. JOHNSON CONTROLS...

  • Page 187: Hot Gas Operation With Variable Geometry Diffuser (Vgd)

    Manual control has priority over Minimum Load serial port using Opto-22 protocol. It is compatible Override, Variable Speed Drive Override and Auto- with Microboard 031-01730-000 and 031-02430-000/- matic Control. 001, equipped with any software version. Refer to Fig- ure 71 on Page 189. JOHNSON CONTROLS...

  • Page 188: Pre-Rotation Vanes Potentiometer

    Service Replacement present, it is connected to this board at P1. If I/O Replace the defective board with the same part number Board 031-02895-000 is present, it is connected board. This prevents any compatibility issues. to the microboard J7. JOHNSON CONTROLS...

  • Page 189: Figure 71 - Interface, Hot Gas Bypass (Analog I/O Board 371-02514-000)

    FORM 160.54-M1 SECTION 22 - HOT GAS BYPASS FIGURE 71 - INTERFACE, HOT GAS BYPASS (ANALOG I/O BOARD 371-02514-000) JOHNSON CONTROLS...

  • Page 190: Figure 72 - Interface, Hot Gas Bypass (I/O Board 031-02895-000)

    FORM 160.54-M1 SECTION 22 - HOT GAS BYPASS FIGURE 72 - INTERFACE, HOT GAS BYPASS (I/O BOARD 031-02895-000) JOHNSON CONTROLS...

  • Page 191: Section 23 - Smart Freeze Protection

    Pre-Rotation Vanes Load Inhibit still oc- Low Evaporator Pressure Safety thresholds (R22 – 54.3 curs at the same thresholds as with normal operation; PSIG, 29.6°F) (R-134a – 25.0 PSIG, 28.7°F) are used. inhibit at 56.2 PSIG (R22) and 27.0 PSIG (R-134a). As JOHNSON CONTROLS...
  • Page 192 • Minimum Leaving Chilled Liquid setpoint - 36.0°F Note 1: The freeze threshold evaporation saturation • If the Leaving Chilled Liquid Temperature temperature is 32.0°F on Flash memory card version setpoint is greater than or equal to 38.0°F: C.MLM.01.01 (and earlier). JOHNSON CONTROLS...

  • Page 193: Section 24 - Surge Protection

    The parameters displayed drive is running at maximum frequency). If equipped on this screen vary according to the software version with software version C.OPT.01.18.307 or earlier, the and compressor motor type as noted below. JOHNSON CONTROLS...

  • Page 194: Excess Surge Detection

    SURGE PROTECTION continue to run under the same conditions displaying – EXCESS SURGE is displayed. WARNING – EXCESS SURGE DETECTED. This message will be displayed until manually reset with the WARNING RESET key in OPERATOR access level. JOHNSON CONTROLS...

  • Page 195: Hot Gas Bypass/Compressor Motor Variable Speed Drive (Vsd) Applications

    VSD output frequency is at maximum. Software version C.MLM.01.09.xxx (and later) or C.OPT.09.301 (and later) – The Extended Run Mode, Shutdown Mode and EXCESS SURGE WARNING message will not be implemented unless the VSD out- put frequency is at maximum. JOHNSON CONTROLS...
  • Page 196 FORM 160.54-M1 SECTION 24 - SURGE PROTECTION THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 197: Section 25 - Variable Geometry Diffuser

    Hot gas valve closure. The VGD is held in last posi- VOLTAGE and is input to the microboard where it is tion until one of the following occurs: compared to the Low Limit and High Limit setpoint JOHNSON CONTROLS...
  • Page 198 VGD is closing. count can be reset using an ADMIN access level. The ac- cumulated time the Stall Detector Board output voltage is greater than the HIGH LIMIT threshold is displayed on the VGD Screen as VGD TIME. JOHNSON CONTROLS...

  • Page 199: Stall Sensor Validation

    Control Status displays PRV POSITION played. The VGD is held in the open position until the OVERRIDE. warning is manually cleared. It can be cleared after the Stall Detector Voltage returns to less than two times the JOHNSON CONTROLS...

  • Page 200: Manual Operation

    Probe Wait setpoint RIDE is displayed as Control Status. interval. • Probe Wait (0.5-15 minutes; default 10) – Speci- fies how long the VGD control remains in the Stall Waiting or Surge Waiting states before enter- ing the Probing state. JOHNSON CONTROLS...

  • Page 201: Pre-Rotation Vanes Position

    Check outputs an analog voltage (displayed as STALL the part number of the replacement transducer and make DETECTOR VOLTAGE on the VGD Screen) connections at the transducer connector as follows: that represents the magnitude of stall noise pres- JOHNSON CONTROLS...

  • Page 202: Figure 73 - Variable Geometry Diffuser Block Diagram

    +5 Vdc OUTPUT Open Close +5 Vdc STALL SEE NOTE 1 TRANSDUCER OUTPUT NOTE: Requires I/O Board 031-01743-002 * Refer to PIN Connections above LD09467b NOTES: 1. Requires I/O Board 031-01743-002 FIGURE 73 - VARIABLE GEOMETRY DIFFUSER BLOCK DIAGRAM JOHNSON CONTROLS...

  • Page 203: Figure 74 - Variable Geometry Diffuser State Diagram

    Hot Gas Valve Open Detect Stall Hot Gas Valve Open HOT GAS OVERRIDE Action Arrow Legend Hold VGD Stall Surge Hot Gas Valve LD15438 NOTES: 1. Software version C.OPT.01.23.307 (and later), FIGURE 74 - VARIABLE GEOMETRY DIFFUSER STATE DIAGRAM JOHNSON CONTROLS...
  • Page 204 FORM 160.54-M1 SECTION 25 - VARIABLE GEOMETRY DIFFUSER THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 205: Section 26 - Large Tonnage Chiller (Ltc) I/O Board

    The respective LED illuminates when the 120VAC at the microboard, the microboard’s RX3 (CR16) il- input is present. Otherwise, it is extinguished. The -000 luminates. board is component populated for 2 inputs. The -001 board is populated for 6 inputs. JOHNSON CONTROLS...

  • Page 206: Figure 75 - Ltc I/O Board Basic Block Diagram

    OPTO COUPLER TB19-1(+) CR22 DI1- -2(-) (-001 board only) TB19-3(+) CR23 LD14233 -4(-) (-001 board only) FIGURE 76 - 120VAC DIGITAL INPUT TB18-1(+) CR24 -2(-) (-001 board only) TB18-3(+) CR25 -4(-) (-001 board only) 5VDC TTL TB21 +5VDC JOHNSON CONTROLS...

  • Page 207: Digital Outputs

    TB13-1 Ret TB21 -2 DO7 +5VDC TB12-1 Ret OPEN COLLECTOR -2 DO8 TB11 TRIAC OUTPUTS 5.1K +5VDC +12V +12VDC TB15 PULL UP SELECT FROM PROCESSOR LD14233 LD14234 FIGURE 79 - TRIAC OUTPUTS FIGURE 77 - +5VDC DIGITAL INPUT JOHNSON CONTROLS...

  • Page 208: Analog Inputs

    LD14234 FIGURE 80 - OPEN COLLECTOR ANALOG INPUTS +5VDC +5VDC 11.5K .33/UF LOAD RESISTOR SELECT FROM PROCESSOR (see notes below) Resistor (Ohms) 0-5VDC, TRANSDUCER, THERMISTOR 0-10VDC 10K-11.5K THERMISTOR 4-20mA LD14235A FIGURE 81 - ANALOG INPUTS JOHNSON CONTROLS...

  • Page 209: Analog Outputs

    -15 Ret AI14 J11-16 +5VDC (-001 board only) -17 AI14 LD14236 -18 Ret FIGURE 82 - ANALOG OUTPUTS AI15 J11-19 +5VDC (-001 board only) -20 AI15 -21 Ret AI16 J11-22 +5VDC (001 board only) -23 AI16 -24 Ret JOHNSON CONTROLS...

  • Page 210: Auto Detection

    I/O Board and key to select the desired output, then use the numeric transmitted to the microboard, is displayed as ANA- keys to set it to the desired value. LOG INPUTS. LD14349 FIGURE 83 - I/O BOARD (031-02895-XXX) JOHNSON CONTROLS...

  • Page 211: Section 27 - Heat Recovery

    If Head Pressure Control is played on this screen as described below. also enabled, the Head Pressure parameters appear on the HEAT RECOVERY Screen (there is no separate HEAD PRESSURE CONTROL screen in this configu- ration). JOHNSON CONTROLS...

  • Page 212: Figure 84 - Heat Recovery Block Diagram

    NO water flow in the heating condenser, valve control will automatically switch over to the Head Pressure Control. 2. The chiller could be equipped with either paddle/differential pressure (120VAC) type or Thermal Type (+5VDC) flow switches. Each Type must be connected as shown. LD14238 FIGURE 84 - HEAT RECOVERY BLOCK DIAGRAM JOHNSON CONTROLS...

  • Page 213: Figure 85 - Pid Controller Diagram

    Hot Water Setpoint Analog PID Control Analog Output Error Control Output Output Conditioning (0-10V, Leaving Heating (0.0–100.0%) 10-0V, Condenser Water 4-20mA [2-10V], Temperature 20-4mA [10-2V]) Type Output (0-10V, (Direct, (PID Gains) 4-20mA) Reverse) FIGURE 85 - PID CONTROLLER DIAGRAM JOHNSON CONTROLS...

  • Page 214: Figure 86 - Heat Recovery Flow Diagram

    Not Active Not Active Head Pressure Head Control Active Pressure Control PID Control Mode Enabled? is Head Pressure Head Pressure Control Not Active PID Control Mode is Inactive Valve Output = 0% FIGURE 86 - HEAT RECOVERY FLOW DIAGRAM JOHNSON CONTROLS...

  • Page 215: Remote Hot Water Setpoint

    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 JOHNSON CONTROLS...
  • Page 216 FORM 160.54-M1 SECTION 27 - HEAT RECOVERY THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 217: Section 28 - Head Pressure Control

    MICROBOARD 031-02430-000 BOARD 031-02430-001 031-02895-000 SERIAL COMMS 4/12 RS-485 COM 3 3/11 VALVE POSITIONING HEAD PRESSURE 18 21 CONTROL VALVE 0-10VDC or 4-20mA EVAPORATOR TRANSDUCER CONDENSER TRANSDUCER LD14237 FIGURE 87 - HEAD PRESSURE CONTROL BLOCK DIAGRAM JOHNSON CONTROLS...

  • Page 218: Control

    Setpoint Analog PID Control Analog Output Error Control Output Output Conditioning (0-10V, (0.0–100.0%) Head Pressure 10-0V, (Delta P) 4-20mA [2-10V], 20-4mA [10-2V]) Type Output (0-10V, (Direct, (PID Gains) 4-20mA) Reverse) FIGURE 88 - HEAD PRESSURE CONTROL FLOW DIAGRAM JOHNSON CONTROLS...

  • Page 219: Operation When Equipped With Both Heat Recovery And Head Pressure Control

    Reverse chart in SECTION 27 - HEAT RECOVERY . 4 to 20mA Direct 4mA (2V) 20mA (10V) 4 to 20mA Reverse 20mA (10V) 4mA (2V) Remote Head Pressure Setpoint This setpoint cannot be set from a remote input. JOHNSON CONTROLS...
  • Page 220 FORM 160.54-M1 SECTION 28 - HEAD PRESSURE CONTROL THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 221: Section 29 - Quick Start

    OptiView™ reboot time. This provides the access level. However, once disabled, it requires an fastest possible ability to start or restart after generator ADMIN password to enable it again, as explained above. or utility power is restored. JOHNSON CONTROLS...
  • Page 222 • VSD Start Frequency (60Hz units with quick start enabled equals 30Hz to 45Hz; default 45Hz) (50Hz equals 25Hz to 37.5Hz; default 37.5Hz) - JOHNSON CONTROLS...

  • Page 223: Operation

    30 seconds after coastdown has completed, the fol- begins. No Pre-lube occurs. lowing control returns to standard control: • Oil Pressure more than 25PSID • Chilled Liquid Pump control returns to standard • VSD has completed Precharge • PRV control returns to standard JOHNSON CONTROLS...

  • Page 224: Table 22 - Compare A Normal Start, Quick Normal Start And A Quick Restart

    Standard when LCHLT less than Ac- Slow Ramp-up of Speed Setpoint + Quick Pulldown Setpoint tive LCHLT Setpoint + Quick Pulldown Offset OR when Run Time more than Setpoint Offset OR when Run Time > Pulldown Override Time Pulldown Override Time JOHNSON CONTROLS...
  • Page 225 This fault is currently only Normal operation turns the chilled liquid pump off at active during pre-lube and run. It shall not cause a shut- the end of coastdown. When Quick Start is ENABLED down during coastdown or while not running. JOHNSON CONTROLS...
  • Page 226 • LCHLT less than Active LCHLT setpoint + Quick TB5-23 to TB5-22. Pulldown Setpoint Offset • Command Frequency equals Maximum VSD Fre- quency • Run Time more than Pulldown Override Time Once one of these conditions is met, ACC control shall return to standard. JOHNSON CONTROLS...

  • Page 227: Section 30 - Heat Pump Duty

    HEAT PUMP Screen is accessible from Sets the range over which an analog signal (0 to 20mA, the CONDENSER Screen. 4 to 20mA, 0 to 10VDC or 2 to 10VDC) in Analog Re- mote Mode or a PWM signal (1-11 seconds) in Digital JOHNSON CONTROLS...

  • Page 228: Control

    Chilled Liquid Temperature in Heating Mode, if the Heat Pump restart until the heating load has increased. Leaving Chilled Liquid Temperature decreases to the Requires OPERATOR or higher access level. JOHNSON CONTROLS...

  • Page 229: Hot Gas Bypass Control

    0% when this temperature falls back to 105°F. All other aspects of Hot gas control remain unchanged in Heat- ing Mode. Refer to SECTION 22 - Hot gas bypass in this manual for details of the hot gas bypass operation. JOHNSON CONTROLS...

  • Page 230: Figure 89 - Heat Pump Duty Block Diagram

    3. Input resets Leaving Chilled Setpoint when heat pump operational mode setpoint is set to "Cooling" Input resets Leaving Condenser Setpoint when heat pump operational mode setpoint are set to "Heating". FIGURE 89 - HEAT PUMP DUTY BLOCK DIAGRAM JOHNSON CONTROLS...

  • Page 231: Section 31 - Motor Monitoring

    Motor Monitoring Board (Refer to Figure 90 on Page 231). LD14241 FIGURE 90 - MOTOR MONITORING BOARD (031-02893-000/001) JOHNSON CONTROLS...

  • Page 232: Figure 91 - Motor Monitoring Board Basic Block Diagram

    FORM 160.54-M1 SECTION 31 - MOTOR MONITORING MOTOR MONITORING Board BASIC BLOCK DIAGRAM LD15001 FIGURE 91 - MOTOR MONITORING BOARD BASIC BLOCK DIAGRAM JOHNSON CONTROLS...

  • Page 233: Motor Monitoring Board

    The board is shown in Figure 90 on Page 231. 4=Off 8=Off The board does not contain a separate program stor- age device. The boards are programmed at the time of manufacture, and the program cannot be changed in the field. JOHNSON CONTROLS...

  • Page 234: Figure 92 - Motor Monitoring Block Diagram

    6. When thermistors are used for Winding Temperatures, they can be connected to the Motor Monitoring Board TB1 (see Note 1) or the VSD and the temperature values transmitted via existing VSD to Microboard Serial Communications. LD15000 FIGURE 92 - MOTOR MONITORING BLOCK DIAGRAM JOHNSON CONTROLS...
  • Page 235 TOR SETPOINTS Screen. Program Jumper JP1 configuration, the input is low when the input must always be removed. It is only installed for switch is open; high when closed. Both of these manufacturing testing. inputs have an LED (DI1 and DI2) that illumi- JOHNSON CONTROLS...

  • Page 236: Winding Temperatures

    This is the default setting. The Motor Moni- Ohm Thermistor. CONFIGURABLE ANALOG INPUTS +5VDC LOAD RESISTOR SELECT FROM PROCESSOR NOTES Phase A thermistor connection shown. Typical of all thermistor inputs. LD15004 FIGURE 93 - WINDING TEMPERATURE – THERMISTORS JOHNSON CONTROLS...
  • Page 237 266 320°F Refer to Table 23 on Page 243 for RTD resistance/ (default 311). The WINDING HOTSPOT ALLOW- voltage table. Refer to Table 24 on Page 243 for ANCE safety shutdown threshold is programmable over Thermistor resistance/voltage table. JOHNSON CONTROLS...

  • Page 238: Bearing Temperatures

    Monitoring Board to read the sensor inputs at the respective data boxes on the MOTOR SETPOINTS following points: Screen. RTD ANALOG INPUTS NOTES Phase A RTD connection shown. Typical of all RTD inputs. LD15005 FIGURE 94 - WINDING AND BEARING TEMPERATURE – RTD JOHNSON CONTROLS...

  • Page 239: Vibration

    Once set, the mi- VIBRATION ANALOG INPUTS GAIN 1:1, 11:1, 21:1 GAIN SELECT FROM PROCESSOR NOTES Shaft end connection shown. Typical of opposite shaft end input. LD15006 FIGURE 95 - BEARING VIBRATION SENSOR JOHNSON CONTROLS...
  • Page 240 If Vibra- ues manually entered with the VIBRATION SETUP tion Baseline values are established after thresholds SETPOINT key. Normally, the Baseline derived values have been entered with the Vibration Setup setpoint, JOHNSON CONTROLS...

  • Page 241: Cooling Coil Leak Detection

    Stop-Reset (O) position. This safety shutdown does not sor inputs. occur when the Motor Vibration Protection setpoint is Digital inputs +24VDC OPT0 COUPLER CLOSE = OK OPEN = TRIP LD15002 FIGURE 96 - MOTOR COOLING COIL LEAK DETECTOR – FLOAT SENSOR JOHNSON CONTROLS...

  • Page 242: Figure 97 - Motor Cooling Coil Leak Detector - Optical Sensor

    The optical sensor contains a switch that is connected leak sensor no longer indicates a leak and the COM- between TB7-5 (input) and TB7-6 (GND). With no PRESSOR switch is placed in the Stop-Reset position. leak being detected, the switch closes producing a less JOHNSON CONTROLS...

  • Page 243: Table 23 - Rtd Resistance/Temperature Chart

    158.87 147.971 298.35 7864 72.433 162.38 153.267 307.88 7367 74.375 165.87 159.219 318.59 6907 76.313 169.36 166.021 330.84 6480 78.251 172.85 173.966 345.14 6082 80.192 176.35 183.518 362.33 5711 82.142 179.86 195.478 383.86 5364 84.103 183.39 211.400 412.52 JOHNSON CONTROLS...
  • Page 244 FORM 160.54-M1 SECTION 31 - MOTOR MONITORING THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 245: Section 32 - System Calibration, Service Setpoints And Reset Procedures

    This password is obtained by contacting the local is displayed momentarily. Johnson Controls Service Office. When requesting this Some safety shutdowns will not permit the chiller to password, supply the “Controls” version of software (available on the DIAGNOSTIC Screen) and the cal- start until a special reset procedure is performed.

  • Page 246: Solid State Starter Applications

    RES required to “SSS-Mod A”, “SSS-Mod B” or “MV SSS”, achieve this voltage. Adjust both resistors equally as appropriate. such that the combined resistance equals the cal- culated value. 6. Press ENTER () key. JOHNSON CONTROLS...
  • Page 247 4 - Microboard 031-02430-000 AND 031-02430- 2. Use ◄ and ► keys to scroll to desired value. 001. Used when the microboard is interfaced to LCSSS Logic/Trigger Board 031-02505 (J14). 3. Press ENTER () key. Microboard can be equipped with either 32K BRAM (031-02431-000) or 128K BRAM (031- 02565-000). JOHNSON CONTROLS...
  • Page 248 Logic Board is field replaced, field calibration is neces- sary. Logic Board Program Jumper JP5 (300V/600V) 1. Press VOLTAGE RANGE key. must be placed in the appropriate position per the com- 2. Use ◄ and ► keys to scroll to desired value. pressor motor AC power line. 3. Press ENTER () key. JOHNSON CONTROLS...
  • Page 249 Select COMPRESSOR Screen. on Solid State Starter Logic Board until the 105% FLA LED illuminates. Clockwise in- b. Run chiller and monitor Compressor Motor creases signal level; Counterclockwise de- current on the COMPRESSOR Screen. creases signal level. Tighten locking nut. JOHNSON CONTROLS...

  • Page 250: Compressor Motor Variable Speed Drive Applications

    Vari- 1. At the keypad, log in at SERVICE access level able Speed Drive Logic Board. In order to select (unless otherwise noted) using password 1 3 8 0. Modbus, Microboard 031-02430-001 is required JOHNSON CONTROLS...
  • Page 251 This is the Full Load Amps (FLA) of the chiller as played when the clearing has completed. IM- listed on the SALES ORDER Screen. The microboard PORTANT! – This should not be performed uses the programmed value to perform Current Lim- unless advised by YORK factory Service. JOHNSON CONTROLS...
  • Page 252 Programmable over the range of AMT (increment amount) key. 0.5°F to 20.0°F (default 1.0°F), 0.5°F to Each press of this key increases the frequency 4.0°F (software version C.OPT.01.22.307 by the programmed Amount (0.1 to 10.0Hz). (and earlier)). JOHNSON CONTROLS...

  • Page 253: Proximity Probe

    OptiView™ Control Center door. Using numeric anyone other than a qualified Service technician. keypad keys, enter this value. Only values be- tween 37 and 79 mils will be accepted. 6. Press ENTER () key. JOHNSON CONTROLS...

  • Page 254: High Speed Thrust Bearing Limit Switch

    1 3 8 0. the procedure below. 3. After Coastdown is complete, select Proximity The refrigerant Level Sensor, located in the Condenser, probe CALIBRATE Screen from COMPRES- must be properly calibrated to accurately detect the re- SOR Screen. JOHNSON CONTROLS...
  • Page 255 Rate Limit Open - 10% to 50% (10%) Screen from the CONDENSER Screen. 5% to 50% (10%) (Flash memory card 3. Press the appropriate key to select the setpoint to version C.MLM.01.06.xxx and later or be programmed. C.MLM.04.02.xxx). JOHNSON CONTROLS...

  • Page 256: Oil Pump Variable Speed Drive

    3. The speed can be increased and decreased in 0.5Hz increments using the RAISE and LOWER Enable/Disable keys. Each time the key is pressed, the frequency is changed 0.5Hz. The Oil Pump Variable Speed Drive Program opera- tion must be enabled. JOHNSON CONTROLS...

  • Page 257: Oil Return Min

    Oil when the pressure decreases to 5 PSIG below the pro- Pump for 2 minutes every 24 hours if the chiller has grammed value. Proceed as follows to enter this value: JOHNSON CONTROLS...

  • Page 258: Brine Low Evaporator Pressure Cutout

    Longest allowed pulse is 18 seconds in duration. This selection will ture sensor in the drop leg between the condenser and provide proper operation in most applications. evaporator. If ENABLED with the procedure below, JOHNSON CONTROLS...

  • Page 259: Smart Freeze Protection

    The Default value is the recommended value TOR PRESSURE safety shutdown threshold calculation, and should provide proper operation in most applica- as explained in SECTION 23 - SMART FREEZE PRO- tions. However, the setpoint can be programmed to oth- TECTION of this manual. JOHNSON CONTROLS...

  • Page 260: Chiller Starts And Operating Hours Reset

    Field 1 – Regional phone number label. Default value 1. At the keypad, log in at SERVICE access level is “Johnson Controls North American Parts using password 1 3 8 0. Center Toll Free Number”. 2. Select Hot gas bypass Screen from the COM- Field 2 –...

  • Page 261: Surge Protection

    1. At the keypad, log in at ADMIN access level. Ob- only applicable to chillers equipped with Flash tain ADMIN password from local service office. memory card Version C.MLM.01.01 and later. This password changes daily. 2. Select SURGE PROTECTION Screen from COMPRESSOR Screen. 3. Press CLEAR SURGE COUNT key. JOHNSON CONTROLS...

  • Page 262: Custom User Id And Passwords

    3. Press CHANGE USER ATTRIBUTES key. The first changeable area is outlined in a green selec- can be used to forward space. tion box. 8. Press ENTER () key. ◄ ► ▲ ▼ 4. Use the keys to move the green selection box to the desired value to be changed. JOHNSON CONTROLS...

  • Page 263: Record Setpoint Changes

    • Date and time of change chiller style/compressor combinations are equipped • Access Level and User ID used to make the change differently and have different control requirements. • Old Value Variables include the following: • New Value JOHNSON CONTROLS...

  • Page 264: Table 25 - Flash Memory Card Version C.mlm.01.07.Xxx And C.mlm.01.07A.xxx

    35 PSID (Thermal Type) Analog “Style F/J Compr” Probe TB1-64 3.5 sec 35 PSID (Thermal Type) Analog “Style F/P, Compr” Limit Switch TB1-64 10.0 sec 25 PSID (Thermal Type) * Not applicable to Style C (and earlier) chillers. JOHNSON CONTROLS...

  • Page 265: Table 26 - Flash Memory Card Version C.mlm.01.08.Xxx

    TB1-64 3.5 sec 35 PSID (Analog or Digital) Programmable 35 PSID “Style F/J, H3 Compr” Probe TB1-64 3.5 sec (Analog or Digital) “Style F/P, Q LH9 Programmable Limit Switch TB1-64 10.0 sec 35 PSID (Analog or Digital) Compr” JOHNSON CONTROLS...

  • Page 266: Flow Switch

    After the selection is made, the program will read the vided connected to the microboard J14 (Refer to Fig- flow sensor input at the selected connection point and ure 23 on Page 69). ignore the other connection points. JOHNSON CONTROLS...

  • Page 267: Microboard 031-02430-000/-001 Setup/Configuration

    • Motor Monitoring - enable/disable (software ver- Enable/Disable sion C.OPT.01.22.307 and later). If the compressor is equipped with the VGD, it must • Heat recovery-enable/disable (software version be enabled. Otherwise it must be disabled. Use the fol- C.OPT.01.21.307 and later). lowing procedure: JOHNSON CONTROLS...
  • Page 268 PRV position is 0.3VDC with software version C.OPT.01.22 (and earlier)) to 0.7VDC. Press the START CALIBRATION (Software version C.MLM.01.14.xxx (and later) key to initiate the calibration. The CALIBRA- or C.OPT.01.14.306 (and later)) TION IN PROGRESS and PRV OPENING LED JOHNSON CONTROLS...

  • Page 269: High Condenser Pressure Fault While Shutdown - Reset Procedure

    CONDENSER – HIGH PRES- the MOTOR Screen in any access level, displays infor- SURE - STOPPED is displayed. The chiller can be mation applicable to this feature. started after the Condenser Pressure decreases to less JOHNSON CONTROLS...
  • Page 270 DOWN key. recorded when the operator enters his/her initials, name 7. Use the ◄ and ► keys to select Enable or Disable or User ID with the MOTOR LUBE ACKNOWLEDGE as desired per above. key in the above procedure. However, if it is necessary 8. Press ENTER () key. JOHNSON CONTROLS...

  • Page 271: Quick Start

    6. Use left/right arrow keys to select the desired set- 7. Press the  key. ting. Once enabled, the Quick Start setpoints can be changed 7. Press  key. using the following procedure. 1. At the keypad, login at SERVICE access level us- ing access code 1380. JOHNSON CONTROLS...

  • Page 272: Motor Monitoring Software (Version C.opt.01.22.307 And Later)

    The default setting is line over a 1 hour period while the chiller is running. Disabled. To Enable or Disable the Motor Bearing Vi- To access the MOTOR DETAILS screen: bration Protection feature: JOHNSON CONTROLS...

  • Page 273: Motor Setpoints Screen

    This setpoint allows the individual winding tempera- 7. Press ENTER () key. A dialog box appears giv- ture sensors to be enabled or disabled. A sensor can ing the range of values. be disabled if it is defective or for service reasons. JOHNSON CONTROLS...
  • Page 274 Motor Bearings 6. Press ENTER () key. A dialog box appears with High Vibration shutdown and High Vibration Warning the range of allowed values. data boxes on this MOTOR SETPOINTS Screen. The JOHNSON CONTROLS...
  • Page 275 ADMIN access level and Mo- value. tor Vibration Protection setpoint on the MOTOR DE- 8. Press ENTER () key. TAILS Screen is not set to disabled. To enter desired values: 9. Press CANCEL (X) key to exit. JOHNSON CONTROLS...
  • Page 276 FORM 160.54-M1 SECTION 32 - SYSTEM CALIBRATION, SERVICE SETPOINTS AND RESET PROCEDURES THIS PAGE INTENTIONALY LEFT BLANK JOHNSON CONTROLS...

  • Page 277: Section 33 - Diagnostics And Troubleshooting

    1. Shown in Figure 90 on Page 231 through Figure Digital I/O states to be monitored. These screens 99 on Page 279. These screens are used during are preceded by a general screen that provides the the diagnostics and troubleshooting process. They installed software versions. JOHNSON CONTROLS...

  • Page 278: Diagnostics Screen

    Modbus UI - Motor Monitoring – Software in Mo- tor Monitoring Board (only displayed with Microboard Kernel – software that is part of flash memory. software version C.OPT.01.22.307 and later). GUI – Software that is part of the flash memory. JOHNSON CONTROLS...

  • Page 279: Main Diagnostics Screen

    Main Screen The ADVANCED SECURITY key is used during the - Monitor Monitoring Board (software version manufacturing process and has no field service use. C.OPT.01.22.307 and later) - I/O Board (software version C.OPT.01.21.307 and later) - Keypad test JOHNSON CONTROLS...

  • Page 280: Motor Monitoring Board Diagnostic Screen

    TB3-4 Motor Bearing Opposite Shaft End Vibration (accelerometer) TB1-8 Motor Winding Phase C Temperature (50K Ohm thermistor) TB3-6 Not used TB2-11 Not used TB3-8 Not used TB2-8 Not used TB2-5 Not used TB2-2 Not used TB1-11 Not used JOHNSON CONTROLS...
  • Page 281 TB7-2 Not used 7. Use ◄ and ► keys to select desired value. TB8-5,6 Motor Cooling Coil 8. Press ENTER () key. Leak Detector (float switch) 9. Press CANCEL (X) key to exit. TB8-2,3 Not used JOHNSON CONTROLS...

  • Page 282: I/O Board (031-02895-000) Diagnostic Screen

    The voltage value and the current value are directly 4. Using the keypad keys, enter the desired voltage scaled over their respective ranges of 0 to 10VDC and value. 0 to 20mA. For example, when the voltage output (ter- JOHNSON CONTROLS...
  • Page 283 I/O Board opens this circuit. When Diagnos- tic Mode is exited (DIP Switch 3 is set back to the OFF • Timeout Faults position), outputs revert to Program control. Press the RESET ERROR COUNTERS key to reset these counters to zero. JOHNSON CONTROLS...

  • Page 284: Keypad Test

    If the keypad and ribbon ca- b. Identify row/column coordinate of the key to ble check OK per the above procedures, the mi- be tested. Refer to Figure 42 on Page 99. croboard is most likely the cause of the problem. JOHNSON CONTROLS...

  • Page 285: Display Test Main Screen

    Re- dark blue, light blue and yellow, outlined by a red fer to description of “All Red” test above. border are displayed. If the vertical bars are not stable or straight, or the red border is not com- JOHNSON CONTROLS...
  • Page 286 • All Black - This test verifies the display’s ability to turn off all pixels to display a completely black screen. Any pixel that does not turn off will ap- pear as a red, green, blue or white dot. Refer to description “All Red” test above. JOHNSON CONTROLS...

  • Page 287: Bit Patterns Test Screen

    1. Display Ribbon Cable should be greater than 3.0VDC. If not, the microboard is defective. Using an Ohmmeter, perform a continuity test on all conductors in the ribbon cable. An open circuit would indicate the ribbon cable is defective. JOHNSON CONTROLS...
  • Page 288 With the “All Black” test selected, the volt- age at Microboard J5-6 through J5-11, J5-13 through J5-18 and J5-20 through J5-25 should be greater than 1.0VDC. If not, the microboard is defective. JOHNSON CONTROLS...

  • Page 289: Serial Inputs / Outputs Test Screen

    Failure to install the loop-back connection From or configure the microboard Program Jumper as COM 4b J2-7 (GTX) J2-6 (GRX) noted will result in a FAIL outcome for the test. Microboard Program Jumper JP27 must be installed in position 2 and 3. JOHNSON CONTROLS...

  • Page 290: Figure 106 - Microboard - Com 5 Serial Data Port

    DIAGNOSTICS key to return to the MAIN DIAGNOSTICS Screen. TRANSMIT COMMON RECEIVE +5VDC LOOP-AROUND DIAGNOSTIC CONNECTOR YORK PIN 025-33778-000 INSTALL TO PERFORM DIAGNOSTIC +5VDC LOOP-AROUND TEST LD04250 FIGURE 106 - MICROBOARD - COM 5 SERIAL DATA PORT JOHNSON CONTROLS...

  • Page 291: Digital Inputs / Outputs Test Screen

    1. The Digital inputs are listed on this screen accord- 6. If a Program Switch (DIP) is in the ON position, the ing to: applicable LED should be illuminated. If the LED is not illuminated, the microboard is defective. JOHNSON CONTROLS...
  • Page 292 If it is not extinguished, replace the mi- is selected, it will turn off, de-energizing the de- croboard. vice it is connected to. If relay does not de-ener- gize or triac does not turn off, perform appropriate troubleshooting procedure below. JOHNSON CONTROLS...
  • Page 293 10VAC. If not closed, replace the I/O Board. the Triac is turned off, the voltage will be greater than 100VAC (Slide Valve Actuator) or greater than 20VAC (PRV, Hot gas or Refrigerant Level Control Actuator). JOHNSON CONTROLS...

  • Page 294: Analog Inputs Test Screen

    13 - Proximity probe DC Voltage Reference 16 - REFRIGERANT LEVEL CONTROL, SECTION 19 (Not applicable to P compressors and style "F" - PRESSURE TRANSDUCERS, AND SECTION 20 - and later chillers with “G, Q” and “H5-8” com- TEMPERATURE THERMISTORS. pressors) JOHNSON CONTROLS...
  • Page 295 All inputs except chan- with the value displayed on the ANALOG IN- nel 0, 15 through 22, 27 and 28 are sensors that PUTS Screen for that value. connect directly to the microboard via shielded JOHNSON CONTROLS...
  • Page 296 An open circuit would indicate the cable is defective. 3. If steps are OK, problem most likely is in the re- mote device that supplies the remote signal. JOHNSON CONTROLS...

  • Page 297: Section 34 - System Commissioning Checklist

    ____ Brine Low Evaporator Pressure Cutout ____ Head Pressure Control – P Threshold* (160.54-M1) ____ Smart Freeze Protection ON/OFF ____ Head Pressure Control – I (160.54-M1) ____ Head Pressure Control - D ____ Refrigerant Temp Sensor Enable/Disable (160.54-M1) JOHNSON CONTROLS...
  • Page 298 (Software ver- sion C.MLM.01.07.xxx (and later) or ture C.OPT.01.14.xxx (and later)) ____ Enable/Disable Extended Run feature ____ Ramp-up Time (Software ver- ____ Count Window sion C.MLM.01.07.xxx (and later) or ____ Count Limit C.OPT.01.14.xxx (and later)) ____ Surge Sensitivity JOHNSON CONTROLS...
  • Page 299 VSD DETAILS Screen (VSD) Verify the following setpoints were programmed: ____ Set chiller Full Load Amps (FLA) value by adjusting potentiometer on VSD logic board ____ Full Load Amps* (R34 on logic board 031-02506; R28 on all others) ____ Start Current* JOHNSON CONTROLS...
  • Page 300 ____ Motor Cooling Coil Leak Protection ____ Motor Drive Type ____ Manual Baseline or Auto Baseline ____ Anti-Recycle MOTOR SETPOINTS SCREEN (Software version ____ Power Failure Restart C.OPT.01.22.307 and later) ____ Coastdown ____ Temperature Disable ____ Pre-run ____ Winding Setup JOHNSON CONTROLS...
  • Page 301 ____ Quick Start Pulldown Setpoint Offset ____ Report type; Status, Setpoints, Schedule or ____ Pulldown Override Time Sales Order ____ VSD Start Frequency SALES ORDER Screen ____ Mapping Enable ____ Enter system commissioning date ____ Quick Ramp Current Threshold JOHNSON CONTROLS...
  • Page 302 ____ Enter local phone number (Flash memory card version C.MLM.01.05.xxx and later) ____ Enter Chiller Style/Compressor (Flash memory card version C.MLM.01.07.xxx and later) ____ Enter Flow Sensor type (Flash memory card version C.MLM.01.08.xxx and later). JOHNSON CONTROLS...

  • Page 303: Section 35 - Software Enhancements

    If stop is selected, data collection will begin when manually initiated, and will stop when all triggers have been sat- isfied and any selected trigger delay has elapsed. JOHNSON CONTROLS...
  • Page 304 In previous flash memory card versions, the oil pump VSD starts at 25Hz when turned on during System Pre- lube. In this version, the VSD starts at 45Hz, which provides greater reliability in achieving the required 45 PSID target oil pressure at chiller start. JOHNSON CONTROLS...

  • Page 305: Si0019 - Software Enhancements Effective March 2002

    • Access Level and User ID used to make the change mediately enter a normal coastdown period: • Old Value • Leaving Chilled Liquid – Low Temperature • New Value • Remote Stop • Multi-unit Cycling – Contacts Open JOHNSON CONTROLS...
  • Page 306 • The message WARNING – REFRIGERANT The hot gas valve position is now animated on the Hot LEVEL OUT OF RANGE and the associated gas bypass screen. lower signal that opens the valve until the level is within range was eliminated. JOHNSON CONTROLS...

  • Page 307: Si0034 - Software Enhancements Effective August 2002

    Variables include the following: • High Speed Thrust Bearing proximity sensing – Proximity probe or Limit Switch • Flow Sensor – Paddle type (115VAC Digital Input) or factory mounted thermal type sensor (+5VDC Analog Input) JOHNSON CONTROLS...
  • Page 308 (pin 4) is connected to a Microboard Analog Evaporator: Input. From Sensor pin 2 Microboard J7-1 (+5VDC) pin 4 J7-14 (input to Microboard ) Condenser: From Sensor pin 2 Microboard J7-15 (+5VDC) pin 4 J7-16 (input to Microboard) JOHNSON CONTROLS...
  • Page 309 Setting the valve preset time to 0 seconds disables this pre-positioning feature. Set- ting the valve preset time to a value greater than 50 seconds has no effect on the pre-lube time. JOHNSON CONTROLS...

  • Page 310: Si0058 - Software Enhancements Effective February 2003

    If digital is selected, the VSD – LOW PHASE B INVERTER BASEPLATE program reads the paddle-type sensor inputs at the I/O TEMPERATURE board digital inputs TB4-12 (evaporator) and TB4-11 Same as Phase A above. (condenser) and ignores the analog inputs. JOHNSON CONTROLS...
  • Page 311 Same as Phase A above. SECURITY LOG Screen VSD – HIGH PHASE C INVERTER In previous flash card versions, some setpoint changes BASEPLATE TEMPERATURE were not logged in metric mode. All setpoint changes Same as Phase A above. are now logged. JOHNSON CONTROLS...

  • Page 312: Si0062 - Software Enhancements Effective March 2003

    Probe TB1-64 3.5 sec 35 PSID J and H3 Compr (Analog or Digital) Style F/ Programmable Limit Switch TB1-64 10.0 sec 25 PSID P, Q Compr (Analog or Digital) * Not applicable to Style "C" (and earlier) chillers JOHNSON CONTROLS...

  • Page 313: Si0080 - Software Enhancements Effective January 2004

    Also, if the endpoints are not established within 10 minutes, PRV CALIBRATION UN- • The hot gas valve position must be at 100% AND SUCCESSFUL is displayed. the VSD output frequency must be at maximum before the above surge features are performed. JOHNSON CONTROLS...
  • Page 314 This compressor motor VSD setpoint default is now 7000 (was 4500). E-LINK GATEWAY INDUCED REBOOTS With previous flash memory card versions, E-Link Gate- way communications could cause the microboard to ran- domly reboot was corrected in this version. JOHNSON CONTROLS...

  • Page 315: Si0089 - Software Enhancements Effective May 2004

    COMPRESSOR screen. A dialog box displays A, B or C as appropriate) ENTER PASSWORD TO CLEAR FAULT. Diagnostics Screen 5. Enter 1 3 9 7 and press the  key (). The communications error counters now count up to 65535 (was 255). JOHNSON CONTROLS...
  • Page 316 MOTOR – HIGH CURRENT LIMIT was corrected in this version. History Data Storage The data capture has been modified to assure that all data is that which is valid at the instant of the event. JOHNSON CONTROLS...

  • Page 317: Software Enhancements Effective March 2005

    20 minutes), the VGD is driven to the full open po- sition and WARNING – CONDITIONS OVERRIDE VGD is displayed until the stall detector voltage re- turns to less than two times the high limit setpoint and the warning is manually cleared. JOHNSON CONTROLS...
  • Page 318 15% FLA motor cur- rent is detected while the chiller is shutdown. Previ- ously, it was not put into effect until the invalid motor current was present for at least 10 seconds. JOHNSON CONTROLS...

  • Page 319: Si0148 - Software Enhancements Effective June 2006

    02430-000 or 031-02430-001). However, this ver- shutdown is performed. sion (or later versions) is required for microboard • VSD-LOW DC BUS VOLTAGE (P/N 031-02430-001). If the DC Link Voltage falls below 600VDC while running, this shutdown is performed. JOHNSON CONTROLS...

  • Page 320: Si0158 - Software Enhancements Effective October 2006

    The version and part number for both NEMA 1-4 and CE chillers is C.OPT.01.15A.307 (031-02474-001). LANGUAGES Version C.OPT.01.15.011 was released as English only. This version allows display in English, Chinese Traditional, Chinese Simplified, French, Spanish, Ital- ian, German or Hungarian. JOHNSON CONTROLS...

  • Page 321: Si0164 - Software Enhancements Effective April 2007

    In this version, LOAD CONTROL MODE is displayed the chiller is running or failed to close during the pre- instead of MOTOR – HIGH CURRENT LIMIT under lube period. The chiller will automatically restart when this condition. the flow switch closes. JOHNSON CONTROLS...
  • Page 322 Therefore, when the automatic lubri- shutdowns. Report contains only motor run state, PRV cation hardware is present, the auto lube setpoint must position and MV VSD fault code. be enabled. With this setting, no lubrication warnings or shutdown will occur. JOHNSON CONTROLS...
  • Page 323 This screen displays the fol- NEW SETPOINTS lowing Modbus communications error counters: The following new setpoints are programmed on the Panel to VSD SETUP Screen. VSD to Panel FTR to VSD (if IEE 519 filter present and enabled) JOHNSON CONTROLS...

  • Page 324: Si0186 - Software Enhancements Effective October 2006

    R-22 and the oil pump package (SETUP Screen) is Current Limit setpoint inputs. This stabilizes these re- set to VARIABLE SPEED, the OIL-VARIABLE SPEED mote setpoint values under noisy conditions and when PUMP-SETPOINT NOT ACHIEVED safety shutdown the inputs are unstable. is not performed. JOHNSON CONTROLS...
  • Page 325 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. JOHNSON CONTROLS...

  • Page 326: Si0201 - Software Enhancements (Ver 19) Effective October 2008

    Motor Communications Protocol setpoint must be set to Modbus in this configuration. This configuration is referred to below as “Modbus Protocol configuration”. All MV VSD applications use Modbus protocol. Due to service parts replacement, early production chillers could be in the Modbus configuration. JOHNSON CONTROLS...
  • Page 327 ACC function in ACC Board and it increments when any surge is the microboard, while the drive is running at less detected by the ACC Board, whether running at than maximum frequency. maximum or less than maximum frequency. JOHNSON CONTROLS...
  • Page 328 OptiView™ Control Panel – Operation (Form 160.54- selected while a print is in process. The PAGE UP and O1) FIGURE 18 shows this screen in Modbus protocol PAGE DOWN keys are used to scroll to the previous configuration. or next listing. JOHNSON CONTROLS...
  • Page 329 ACC function increases the VSD or MV VSD Modbus protocol configuration) or MV VSD, these are output frequency, the frequency increase is limited by the surges that are detected while the drive is running the motor current as follows: at maximum frequency. JOHNSON CONTROLS...
  • Page 330 • Warning – High Pressure Limit – Maximum al- lowable value is 193.0 PSIG, with no change to the default value. • Condenser – High Pressure – Trip/Reset thresh- old is 200/140 PSIG. JOHNSON CONTROLS...

  • Page 331: Si0210 - Software Enhancements (Ver 20) Effective June 2009

    186 A 1750 392 A 274 A 217 A 2000 438 A 312 A 248 A 2250 494 A 345 A 274 A 2500 561 A 391 A 310 A Max. Job/Rated 100% FLA (A) (Programmed Drive Current) JOHNSON CONTROLS...
  • Page 332 Toll Free Phone Number The label for the toll free number was changed from YORK International North American Toll Free Num- ber to Johnson Controls North America Parts Center. Japanese Language Japanese was added to the selection of languages. Variable Speed Drive Low Frequency Fault In previous software versions, the VSD –...

  • Page 333: Si0212 - Software Enhancements (Ver 21) Effective June 2009

    PRV potentiometer, the software reads the potentiometer input at microboard input J7-10. In previous software versions, the initial ramp is com- plete when either of the following conditions occur: JOHNSON CONTROLS...
  • Page 334 P, Q FREQUENCY COMMAND MOTOR and H9 compressor chillers, while the chiller is running. INCREASE CURRENT More than 90 %FLA 1.5Hz More than 75 %FLA More than 60 %FLA Less than or equal to 60 %FLA JOHNSON CONTROLS...
  • Page 335 This option uses two tube bundles in the condenser. The lower bundle is the standard condenser bundle and is piped to the cooling tower water source. The upper tube bundle is used to recover heat waste heat rejection for use in a closed loop heating circuit. JOHNSON CONTROLS...
  • Page 336 UPS, which prevents a reboot of both on a pow- er failure and keeps communications between them ac- tive throughout the utility power failure. This provides the fastest possible ability to start or restart after gen- erator or utility power is restored. JOHNSON CONTROLS...
  • Page 337 QUICK START screen, accessible from the SETPOINTS screen when logged in at SERVICE access level. A complete explanation of this feature is contained in Service Manual (Form 160.54-M1), SECTION 29 - QUICK START. JOHNSON CONTROLS...

  • Page 338: Si0224 - Software Enhancements (Ver 22) Effective April 2010

    OptiView™ Control Panel – Operation (Form 160.54-O1). The motor monitoring feature must be enabled. Once enabled, the MOTOR DETAILS and MOTOR SETPOINTS screens are available, where all informa- tion pertinent to the feature are displayed. JOHNSON CONTROLS...

  • Page 339: Si0252 - Software Enhancements (Ver 23) Effective May 2011

    • The ACC MAPPING ENABLE setpoint pro- • The VGD high limit setpoint default changed grammable range increased from 0.5 to 4.0°F to from 0.8V to 0.6V. 0.5 to 20.0°F. • The VGD low limit setpoint default changed from 0.6V to 0.5V. JOHNSON CONTROLS...
  • Page 340 Temperature Differential (LCHLT – Setpoint) is now occurs, the contacts remain closed into and throughout displayed on the surge map screen. the pre-lube period and the transducer auto-zeroing is not performed (the values from the last auto-zeroing are used). JOHNSON CONTROLS...

  • Page 341: Table 30 - Loop Back Connections

    Change the format using the new DATE FOR- MAT setpoint on the USER screen, which can be done at the operator access level. The selectable formats are: • DD MMM YYYY (default) • DD.MM.YYYY, or • YYYY-MM-DD JOHNSON CONTROLS...

  • Page 342: Si0265 - Software Enhancements (Ver 24) Effective May 2012

    “Warning – Condenser was changed to conform to the JCI standard "York – Freeze Threat From Low Pressure”. by Johnson Controls". The new BIOS eprom is P/N 031-02429-002. This warning will automatically reset whenever the chiller is running or the Saturated Condenser 2.
  • Page 343 Fault. This start inhibit feature has been corrected to function properly. 2. Condenser Screen – Corrected the font sizing Heat Pump Duty The Heat Pump Duty enable on the Setup Screen is selectable in Test Op Access Level and above when the refrigerant is R134a. JOHNSON CONTROLS...
  • Page 344 FORM 160.54-M1 NOTES JOHNSON CONTROLS...

  • Page 345: Table 31 - Si Metric Conversion

    (°C), subtract 32° and multiply by 5/9 or 0.5556. Example: (45.0°F - 32°) x 0.5556 = 27.2°C To convert a temperature range (i.e., a range of 10°F) from Fahrenheit to Celsius, multiply by 5/9 or 0.5556. Example: 10.0°F range x 0.5556 = 5.6°C range JOHNSON CONTROLS...
  • Page 346 P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2011 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 160.54-M1 SUPERSEDES 160.54-M1...

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