Page 1 COMPOUND YK CENTRIFUGAL LIQUID CHILLER OPERATION AND MAINTENANCE Supersedes: 160.82-OM1 (611) Form 160.82-OM1 (813) MODEL CYK CENTRIFUGAL CHILLER / HEAT PUMP SYSTEM WITH QUANTUM™ LX CONTROLS LD15345 R-134a Issue Date: August 30, 2013...
Page 2: Read Before Proceeding
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: Change Bars
FORM 160.82-OM1 ISSUE DATE: 8/30/2013 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls’ policy for contin- these documents, the technician should verify whether uous product improvement, the information contained the equipment has been modified and if current litera- in this document is subject to change without notice.
Page 4 ISSUE DATE: 8/30/2013 NOMENCLATURE — Special Features Model Design Level Cooler Code High Stage Motor Code Condenser Code Low Stage Motor Code Low Stage Compressor Code Power Supply High Stage Compressor Code - for 60 Hz 5 for 50 Hz JOHNSON CONTROLS...
Page 5: Table Of Contents
History Screen .............................. 126 Freeze Screen ............................127 Trending Screen ............................128 Trending Setup Screen ..........................130 Custom Display Screen ..........................131 SECTION 4 - SOFTWARE UPDATE PROCEDURE ....................133 SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING ...............137 SECTION 6 - TROUBLESHOOTING ........................181 JOHNSON CONTROLS...
Page 6 FIGURE 49 - Liquid Cooled Solid State Starter (Optional) ..................93 FIGURE 50 - Chiller Mode............................96 FIGURE 51 - Heat Pump Mode ..........................97 FIGURE 52 - Manual Auto Station (Capacity Controls) Screen ................98 FIGURE 53 - PID Tuning Screen...........................100 FIGURE 54 - Overrides Screen ..........................102 JOHNSON CONTROLS...
Page 7 FIGURE 93 - BACnet IP Over Ethernet .........................151 FIGURE 94 - BACnet MSTP Over RS-485 ......................152 FIGURE 95 - RJ-45 Connector..........................152 FIGURE 96 - MODBUS RTU or AB DF1 Over RS-485 ..................153 FIGURE 97 - Create Your Own ..........................153 JOHNSON CONTROLS...
Page 8 TABLE 11 - Ethernet Component Recommendations ...................140 TABLE 12 - Serial Communication Setup ......................146 TABLE 13 - Communications Board ........................147 TABLE 14 - Quantum LX for CYK Protocol List ....................155 TABLE 15 - List Alarm Codes ..........................175 TABLE 16 - SI Metric Conversion .........................183 JOHNSON CONTROLS...
Page 9: Section 1 - Description Of System
The system is also • Operator interaction is provided through the key- accessible across an Ethernet LAN through a standard pad, as well as informational status to the dis- web browser. play. Interaction to the outside world is provided JOHNSON CONTROLS...
Page 10: General Information
VAC and CAN CAUSE INJURY OR keypad. The display is used to show the operator, DEATH. via a graphical interface, the actual status of all compressor values. Warnings and shutdowns (and JOHNSON CONTROLS...
Page 11: What To Do Before Calling For Service
• Bad Backlight Fluorescent Tube • The ACT (Active) LED will blink on the Keypad • Wrong Combination of Display, Cable, Inverter, Interface Board. or Software • The boot sequence will show the CMOS boot in- • Faulty CPU Board formation briefly on the display. JOHNSON CONTROLS...
Page 12 Software Maintenance section of this manual. • NOTE: This information will be replaced by factory default values, so any setpoint and calibration data values that need to be cus- tomized must be reentered. JOHNSON CONTROLS...
Page 13: Figure 1 - Main Controller Board And Peripherals
SERIAL PORT TOUCHSCREEN CABLE COM-1 TOUCHSCREEN INTERFACE BOARD CABLE INTERFACE COM 2 RS-232 SERIAL INTERFACE KEYBOARD BOARD SLAVE COMMUNICATION BOARD POWER STATUS PORTS POWER PORT TO PROTOCOL LIGHTS GATEWAY LD15224 FIGURE 1 - MAIN CONTROLLER BOARD AND PERIPHERALS JOHNSON CONTROLS...
Page 14: Figure 2 - Quantum™ Lx Jumper Settings
To replace the battery, ensure that the Control Power switch has been turned OFF. Locate the Battery socket, as shown on the following drawing: LD15322 FIGURE 3 - QUANTUM™ LX 5 MOTHERBOARD POWER CONNECTOR PINOUT LD17439 JOHNSON CONTROLS...
Page 15: Figure 4 - Quantum Lx Interface Board
RS-422 RS-485 RS-485 1 - 2 Closed +TX/+RX -TX/-RX High Speed Target 1 - 2 Closed COMM-1 Default (P10) NOTE: The triangle symbol ( ) denotes Pin 1 on connectors. LD17440 FIGURE 4 - QUANTUM LX INTERFACE BOARD JOHNSON CONTROLS...
Page 16: Figure 5 - Quantum Lx Interconnections
All other Intercon- nection harness ends share the same pinout at both ends. LD17441 FIGURE 5 - QUANTUM LX INTERCONNECTIONS JOHNSON CONTROLS...
Page 17: Figure 6 - Power Supplies
Adjusting the supplies requires the use of a turned ON, wait until the Operating Screen appears. small Philips screwdriver inserted into the supply to This is because the graphics required to create this access an adjusting potentiometer. JOHNSON CONTROLS...
Page 18: Power Supply Replacement
If any of the power supplies are found to be bad, or not capable of acceptable adjustment, the failing supply will need replacing. Refer to the Recommended Spare LD17443 Parts list for the appropriate part number. FIGURE 7 - POTENTIOMETER ADJUSTMENT JOHNSON CONTROLS...
Page 19: Digital Board Description
Quantum™ LX can con- only be plugged into one of these connectors. Take the trol them, they must be interconnected with a wiring red (positive) probe of the DVM and carefully insert harness that provides all of the necessary D.C. voltage JOHNSON CONTROLS...
Page 20: Figure 8 - Digital Input Modules
OUT position for an Output module. ated Output channel. For instance, if a control voltage JOHNSON CONTROLS...
Page 21: Checking The Digital Inputs And Outputs
10. If the LED is not on when it should be and there is no operating condition preventing it, contact the 5. Power on the panel. Service Department. 6. Check the LED on the tester. If the LED is lit, the fuse is OK. 7. Power off the panel. JOHNSON CONTROLS...
Page 22 6. If you are receiving an Alarm or Shutdown from a 4. Install the modified replacement board in the panel. digital input in which the adjacent LED indicator light is on, check the Service Screen to see if that channel is turning on and off. If so, replace the input module. JOHNSON CONTROLS...
Page 23: Figure 10 - Digital Board #1
FORM 160.82-OM1 SECTION 1 - DESCRIPTION OF SYSTEM ISSUE DATE: 8/30/2013 DIGITAL BOARD #1 INSTALL FUSES AND MODULES AS SHOWN Black = Output, Yellow=Input 120v, White=Input 24VDC LD15299 FIGURE 10 - DIGITAL BOARD #1 JOHNSON CONTROLS...
Page 24: Figure 11 - Digital Board #2
FORM 160.82-OM1 SECTION 1 - DESCRIPTION OF SYSTEM ISSUE DATE: 8/30/2013 DIGITAL BOARD #2 INSTALL FUSES AND MODULES AS SHOWN Black = Output, Yellow=Input 120v, White=Input 24VDC LD15300 FIGURE 11 - DIGITAL BOARD #2 JOHNSON CONTROLS...
Page 25: Table 1 - Communications Settings
The following table is to be used to set the digital board addresses. If there is only one board installed, it should be set as board #1, if there are two boards they each need to be set according to the wiring diagrams. Board #1 Board #2 JOHNSON CONTROLS...
Page 26: Communications Led's
Quan- tum™ LX provide all of the necessary D.C. voltage that LD17443 is required (+5 VDC, -12 VDC, +12 VDC, and Return FIGURE 12 - POTENTIOMETER ADJUSTMENT or Common). The voltages are passed through the con- JOHNSON CONTROLS...
Page 27: Active Led
NOTE: Enhanced Analog Board 2 can utilize channels 17 through 24 for PhD if Analog Board 1 is of the old style. Refer to the section on Software Configuration for specific information on the procedure to set these channels. JOHNSON CONTROLS...
Page 28: Figure 13 - Analog Outputs
This selection provides a method to detect all con- tion for the proper transducer type and range, and each nected Analog and Digital boards. If a board has transducer must be calibrated through the appropriate JOHNSON CONTROLS...
Page 29: Figure 14 - Motor Amps
CH. 16 Current Transformer (CT) connection - Standard direct connection, 0 - 5 amp input (Install LK2) CH. 16 Motor Amps - Alternate external signal connection, 0 - 20mA input (Remove LK2) LD15286 FIGURE 14 - MOTOR AMPS JOHNSON CONTROLS...
Page 30: Figure 15 - Enhanced Analog Board Diagram
CH. 7 Input CH. 5 Input CH. 4 Input CH. 2 Input CH. 3 Input D1 - +5VDC Power CH. 1 Input +5 VDC +Tx/+Rx +12 VDC -Tx/-Rx -12 VDC LD15287 FIGURE 15 - ENHANCED ANALOG BOARD DIAGRAM JOHNSON CONTROLS...
Page 31: Table 4 - Communications
Resides in Flash Memory (Version 5.xx) Service Dates June 2003 - Present ANALOG ANALOG ANALOG ANALOG REPLACEMENT PART NUMBERS BOARD 1 BOARD 2 BOARD 1 BOARD 2 Baltimore Parts Replacement 640C0026G01 640C0026G02 640C0057G01 640C0057G02 Field Installation Kit 640C0057G11 640C0057G12 JOHNSON CONTROLS...
Page 32 FORM 160.82-OM1 SECTION 1 - DESCRIPTION OF SYSTEM ISSUE DATE: 8/30/2013 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 33: Section 2 - Fundamentals Of Operation
LED to flash each time a key is pressed. caused by a bad fluorescent tube, inverter or harness. Keypad Replacement 1. Shut off control power. 2. Unplug the defective keypad from the Quantum™ Display Replacement 3. The keypad is affixed to the controller door with a double-sided tape film. Start by lifting the key- JOHNSON CONTROLS...
Page 34: Figure 17 - Quantum™ Lx Basic Panel Layout
5. Take the new keypad, and feed the flat cable through the slotted opening at the bottom of the display area. 6. Remove the paper backing of the keypad to ex- pose the double-backed tape underneath. LD15289 FIGURE 17 - QUANTUM™ LX BASIC PANEL LAYOUT JOHNSON CONTROLS...
Page 35: Figure 18 - General Operating Sequence
The R1 relay is hardwired in series with the high-pressure cutout and • The economizer valve is partially open. the emergency stop to shut down the main • The economizer bypass valve is partially motors in the most extreme danger. open. JOHNSON CONTROLS...
Page 36: Figure 19 - System Status
The LCV-116 will maintain must be configured on the Evaporator Screen. the economizer level until shutdown. This This will be covered in this section. refrigerant inventory management procedure insures that vast quantities of refrigerant LD15240 FIGURE 19 - SYSTEM STATUS JOHNSON CONTROLS...
Page 37 “DEMAND LIMITER” or the “EVAP started its pre-lube process only seconds after the LOW PRESS. OVERRIDE” control signal is being Low stage pre-lube process had started. used to control the capacity of the chiller. JOHNSON CONTROLS...
Page 38: System Shutdown
The compressor pre-rotation vanes are to move to whatever positions are required to maintain closed to minimize back flow of gas through the chilled water at setpoint and provide stable com- the compressor. The hot gas valve is opened pressor operation. JOHNSON CONTROLS...
Page 39 The Capacity Controls algorithm automatically seeks minutes. out the most efficient operation of the CYK chiller. The pre-rotation vanes are automated to obey the tempera- Any additional starts would be considered hot ture controller to maintain process water production. starts. JOHNSON CONTROLS...
Page 40: Figure 20 - Control Model
LESS THAN (DOES NOT UNLOAD SELECTOR LESS THAN ANTI-SURGE) > ANTISURGE VANE RATIO CONTROLLER GREATER POSITION FOR A = 100-(100*LESS THAN THAN GIVEN LIFT SELECTOR)/ANTISURGE) SELECTOR CONDTION COMPRESSOR HOT GAS PRE-ROTATION RECYCLE VANES VALVE FIGURE 20 - CONTROL MODEL JOHNSON CONTROLS...
Page 41: Heat Pump Applications
Heat without aerodynamic instability; therefore the hot gas Pump will unload based on low water temperature or bypass is used to supplement mass flow. This supple- high discharge pressure. mental mass flow creates a source of inefficiency in JOHNSON CONTROLS...
Page 42: Compressor Pre-Rotation Vanes
JOHNSON CONTROLS...
Page 43: Hot Gas Bypass Valve
• On a brine application this valve is closed at shutdown to allow the pressures to drop slowly. Allowing low-pressure cold refrigerant from the evaporator to migrate into the condenser would create a freezing hazard for the condenser water. JOHNSON CONTROLS...
Page 44: Figure 21 - Valve Locations
Quantum LX is a digital output through a double pole relay. The valve will be fully closed at low signal and open at high signal. LCV-116 LCV-117 LCV-114 PVC-116 TCV-100B LD15239 FIGURE 21 - VALVE LOCATIONS JOHNSON CONTROLS...
Page 45 This power override control function uses the motor sor surge curve. power input signals to limit capacity. When one of the motor powers exceeds the setpoint, the control puts out a decreasing signal. The LSR-2, LSR-3 and LSR-4 will JOHNSON CONTROLS...
Page 46: Figure 22 - System Anti-Surge
Anti-surge override acts at HSR-1 on the capacity con- a surge condition. The anti-surge system supplements trols diagram. LD15298 FIGURE 23 - PARAMETERS FOR ANTI-SURGE JOHNSON CONTROLS...
Page 47: Figure 24 - Stage Operations
FORM 160.82-OM1 SECTION 2 - FUNDAMENTALS OF OPERATION ISSUE DATE: 8/30/2013 Single Stage Operation Two Stage Operation LD15278 FIGURE 24 - STAGE OPERATIONS JOHNSON CONTROLS...
Page 48 Low Head (40 psid), Y% = (40-40) x (38-12) / (92-40) + 12 = 12% will move the anti-surge line right and left on the map. Listen for a surge, and move the anti-surge line right several percent, to increase refrigerant flow, by supplementing hot gas. JOHNSON CONTROLS...
Page 49: Tuning Parameters
I = Integral Gain / Reset Time (Minutes/Repeat) , and D are the contributions to the out- D = Derivative Gain / Rate (Minutes) put from the PID controller from each of the three terms, as defined below. JOHNSON CONTROLS...
Page 50 The integral term is given by: term, and can cause a process to become unstable if the ⌠ noise and the derivative gain are sufficiently large. e(τ) dτ ⌡ JOHNSON CONTROLS...
Page 51: Figure 25 - Capacity Control Diagrams
FORM 160.82-OM1 SECTION 2 - FUNDAMENTALS OF OPERATION ISSUE DATE: 8/30/2013 LD15290 FIGURE 25 - CAPACITY CONTROL DIAGRAMS JOHNSON CONTROLS...
Page 52 FORM 160.82-OM1 SECTION 2 - FUNDAMENTALS OF OPERATION ISSUE DATE: 8/30/2013 LD15291 FIGURE 23 - CAPACITY CONTROL DIAGRAMS (CONT'D) JOHNSON CONTROLS...
Page 53 FORM 160.82-OM1 SECTION 2 - FUNDAMENTALS OF OPERATION ISSUE DATE: 8/30/2013 LD15292 FIGURE 23 - CAPACITY CONTROL DIAGRAMS (CONT'D) JOHNSON CONTROLS...
Page 54 FORM 160.82-OM1 SECTION 2 - FUNDAMENTALS OF OPERATION ISSUE DATE: 8/30/2013 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 55: Section 3 - Quantum Lx Control Panel
System (BAS), YORK Chillers not only work well in- information is recorded in memory and is preserved dividually, but also as a team. This new protocol al- even through a power failure condition. The user may lows increased remote control of the chiller, as well JOHNSON CONTROLS...
Page 56: Navigating The Control Panel
SUBMIT - After changing a setpoint value, START - When in Manual Mode, this key use this key to enter (submit) the change. places the compressor unit into the Start MENU - Calibrate Touch Screen Mode for running. UNLOAD VALUE - Not Used JOHNSON CONTROLS...
Page 57: Screen Selection
Press the OK depicted graphically while others, such as setpoints, appear as entry fields in which the operator may enter touch key to acknowledge the error message. Re- enter a correct value. values directly. LD15326 FIGURE 27 - ALLOWABLE RANGE JOHNSON CONTROLS...
Page 58: User Login
System adjustments should be performed only by a qualified service person. Read The Shutdown Trip indicator will remain in the alarm all instructions carefully before making state until the RESET pushbutton is pressed after the adjustments conditions have returned to normal. JOHNSON CONTROLS...
Page 59: Figure 28 - Manual Automatic Stations
Home screen will attempt to reset any alarms or trips. unit. The leftmost top SYSTEM STATUS area describes the operational mode. The right portion of this block states whether the capacity controls are configured for CHILLER operation or HEAT PUMP operation. EXAMPLE 1 LD15327 EXAMPLE 2 LD15328 JOHNSON CONTROLS...
Page 60: Table 8 - System Details
[Submit] button on to 5 seconds, which means that the display will update the panel keypad. all values shown every 5 seconds. Depending on the network connection speed, this updating may interfere JOHNSON CONTROLS...
Page 61: Figure 29 - Control Center
DISPLAY ONLY Values in this group are read-only parameters of infor- mation about the chiller operation. This type of infor- mation may be represented by a numerical value, a text string, or an LED image. JOHNSON CONTROLS...
Page 62: Manual Controls
Auxiliary Analog Configuration Screen (page 119) Auxiliary Analog Calibration Screen (page 121) Retransmitting Outputs Screen (page 123) Economizer Screen (page 124) History Screen (page 126) Freeze Screen (page 127) Trending Screen (page 128) Trending Setup Screen (page 130) Custom Display Screen (page 131) JOHNSON CONTROLS...
Page 63: Home Screen
Condenser Flow / Evaporator Flow position potentiometer. The red LED symbol will be on if there is water flow detected across the heat exchanger vessel. HS Motor Load Percent of High Stage rated motor load as transmitted from the motor protection relay. JOHNSON CONTROLS...
Page 64 I/O configuration, Communications Setup, Software maintenance outside of the normal control routine. Maintenance, Trending, and diagnostics. Economizer History Access Level Required: OPERATOR This screen provides access to a Time stamped Record Returns the display to the Economizer Screen. of shutdown conditions. JOHNSON CONTROLS...
Page 65: System Screen
Displays the differential pressure across the system. Used to provide additional Home information. HS Load Evaporator Displays the motor percent amp load. A detailed view of all evaporator parameters, including the programmable Leaving Chilled Liquid Setpoints. LS Load Displays the motor percent amp load. JOHNSON CONTROLS...
Page 66 This screen displays data about the Low Stage Com- Maintenance, Trending, and diagnostics. pressor. Return High Stage Compressor Returns the display to the previous screen. This screen Displays data about the High Stage Com- pressor. Capacity Controls Returns the display to view the Capacity Controls Screen. JOHNSON CONTROLS...
Page 67: Evaporator Screen
This button toggles between a Locally initiated start evaporator. from the chiller control panel START button, and a re- mote start from an external source. Leaving Chilled Temperature Setpoint Displays the present setpoint to which the chiller is op- erating, whether controlled locally or remotely. JOHNSON CONTROLS...
Page 68 This button toggles between the source of the remote setpoint. It can either be sourced from A-B N102:98 or Modbus 47299 across the network, or from a remote analog signal shown on the wiring diagram. Remember that analog values are times 10. JOHNSON CONTROLS...
Page 69: Condenser Screen
“PRV RAMP HOLD – BUILDING ECONO- Displays the water temperature as it enters the con- MIZER LEVEL”. This will stay illuminated until the denser. level is established. Leaving Condenser Water Temperature Displays the water temperature as it leaves the con- denser. JOHNSON CONTROLS...
Page 70 Returns the display to the Subcooler Screen. Hot Gas Returns the display to the Hot Gas Screen. Economizer Returns the display to the Economizer Screen. Capacity Controls Returns the display to view the Capacity Controls Screen. Return Returns the display to the previous screen. JOHNSON CONTROLS...
Page 71: Subcooler Screen
Pressing the AUTO Displays the current temperature of the condenser re- button when in manual adjustment mode toggles back frigerant. to automatic control. Subcooler Temperature Displays the temperature of the refrigerant in the subcooler. JOHNSON CONTROLS...
Page 72 This screen provides access to a Time stamped Record entering 10% will define a 10% band around the of shutdown conditions. setpoint where the steady state Zone 1 gains will be used. • SUBCOOLER RAMP RATE in %/sec – When the chiller is powered on, the subcooler valve at- tempts to fill the subcooler at the designated rate. JOHNSON CONTROLS...
Page 73: Hot Gas Screen
Displays the position of the pre-rotation vanes in per- cent. HS Discharge Temperature Displays the compressor discharge temperature. LS Discharge Temperature Displays the compressor discharge temperature. Discharge Superheat Displays the temperature expressed as a differential between the discharge temperature and the condenser saturation temperature. JOHNSON CONTROLS...
Page 74 Pressing the AUTO button while in manual adjustment mode to toggle back to automatic control will only be Return accepted if the manual setting is within 5% of the au- Returns the display to the previous screen. tomatic setting. JOHNSON CONTROLS...
Page 75: Low Stage Compressor Screen
(LOP) transducer outputs. During this time, ture (TE-112). the transducers should be sensing the same pressure. LS PRV Position However, due to accuracy tolerances in transducer de- sign, differences may exist in these pressure readings. Displays the Compressors PRV open position percent- age. JOHNSON CONTROLS...
Page 76 Returns the display to view the LS VGD Screen. Compressor Head Displays the Compressors head pressure calculated as Capacity Controls condenser pressure minus economizer pressure. Returns the display to view the Capacity Controls Screen. Return Returns the display to the previous screen. JOHNSON CONTROLS...
Page 77: Ls Proximitor Calibration (Low And High Stages) Screen
TRIP DISPLAY is produced, the compressor should be evaluated for thrust bearing damage. High Speed Thrust Bearing Proximity Position High Speed Thrust Bearing Proximity Reference Oil Supply Pressure Displays available oil pressure to the compressor. JOHNSON CONTROLS...
Page 78 History Warning and Shutdown limits. This screen provides access to a Time stamped Record of shutdown conditions. NAVIGATION Home Used to provide additional Home information. Low Stage Compressor This screen displays data about the Low Stage Com- pressor. JOHNSON CONTROLS...
Page 79: Prv Calibration Screen
INPUT percentage reads between 10% and 20%. 4. After this reading is obtained, tighten the Allen Set Screw on the coupling, and the proceed to the calibration procedure as described below. LD14879a FIGURE 39 - PRV POSITION SENSOR JOHNSON CONTROLS...
Page 80 [END CAL] Selecting this button accepts the automated vane cali- bration or cancels the calibration procedure. When START CALIBRATION is selected, a mes- sage “Vane motor stroking please wait” appears. Press [END CAL] to accept calibration. JOHNSON CONTROLS...
Page 81: Oil Sump (Unified Sump Pressure) Screen
The bar graph on the right shows the actual position of the valve or vane. The automatic bar Indicates the operational status of the oil heater. graph shows where the automatic control system wants LS Oil Return Solenoid the device to be. JOHNSON CONTROLS...
Page 82 This screen Displays data about the High Stage Com- This key allows the service technician to set the deriva- pressor. tive gain of the primary and economizer oil pumps. History This screen provides access to a Time stamped Record of shutdown conditions. JOHNSON CONTROLS...
Page 83: Oil Sump (Ice Thermal Storage) Screen
This can be Oil Pump Run used for testing the oil lubrication circuit. This button can also be used when jogging the motors for direction. Indicates the operational status of the oil pump. JOHNSON CONTROLS...
Page 84: Figure 42 - Low Stage Oil Return Eductor
Oil Return System Operation Centrifugal chillers will lose a small amount of oil into the refrigeration system. Over time, this oil will accu- LEVEL SENSOR SUMP AT EVAPORATOR PRESSURE LD15293 FIGURE 42 - LOW STAGE OIL RETURN EDUCTOR JOHNSON CONTROLS...
Page 85: Figure 43 - High Stage Oil Return Eductor
The high stage compressor has a separate oil SUMP AT INTERMEDIATE TO LOW PRESSURE STAGE SUMP TRANSFER PUMP 0.2 GPM 1750 RPM LD15294a FIGURE 43 - HIGH STAGE OIL RETURN EDUCTOR JOHNSON CONTROLS...
Page 86: Figure 44 - Oil Level Sensor
(Pump Isolation Valve) closes and prevents oil from si- phoning out of the sump and filling the gearbox with oil. PUMP ISOLATION SCAVENGE VALVE OIL LEVEL SENSOR DRAIN BLOCK TO LOW STAGE SUMP AT SUMP INTERMEDIATE PRESSURE LD15294a FIGURE 45 - HIGH STAGE OIL SUMP JOHNSON CONTROLS...
Page 87: Ls Variable Geometry Diffuser Screen
Detector board detects the acoustic signal and provides a 0 to 5 vdc signal (PV) to the microboard. This Stall Detector Voltage is compared to the Stall Detector Voltage setpoint (SP) to determine the operating state of the VGD. JOHNSON CONTROLS...
Page 88 70 to 90% range. The maximum and minimum travel of the VGD ring is limited by the MaxCV and MinCV limit settings. The values of these settings should be set at MaxCV = 100, MinCV= 0. JOHNSON CONTROLS...
Page 89: High Stage Compressor Screen
Displays the position of the pre-rotation vanes in per- saturation temperature. cent. System Head Vane Motor Switch Displays the chiller head pressure calculated as (con- Indicates the status of the vane motor switch. denser pressure – evaporator pressure). JOHNSON CONTROLS...
Page 90 Pressing the MANUAL button while in manual control HS VGD mode toggles back to automatic control. Returns the display to view the HS VGD Screen. Capacity Controls Returns the display to view the Capacity Controls Screen. Return Returns the display to the previous screen. JOHNSON CONTROLS...
Page 91: Hs Proximitor Calibration Screen
Access Level Required: FACTORY Illuminates when the primary compressor is currently This button allows the tecnician to reset a tripped pri- performing a proximitor calibration. mary compressor proximitor probe under the direction from the Factory Technical Support Team. JOHNSON CONTROLS...
Page 92 Low Stage Compressor This screen displays data about the Low Stage Com- pressor. HS Prox Calibration This screen Displays data about the HS Prox Calibra- tion. History This screen provides access to a Time stamped Record of shutdown conditions. JOHNSON CONTROLS...
Page 93: Liquid Cooled Solid State Starter (Optional)
The Logic/Trigger Board is powered by +24VDC from the Quantum™ LX industrial control center Power Starter OK (LED) Supply. The Quantum™ LX Motherboard COM 3 Indicates when the LCSSS has confirmed a no fault communicates with this board via a 19.2K baud Mod- condition. JOHNSON CONTROLS...
Page 94: Table 9 - Full Load Amps
Starter Open SCR safety detection. This must never Defines the maximum amps at which the motor can be disabled unless under advisement of the YORK operate. This value is viewable when logged in at Op- Factory. erator or View access level. JOHNSON CONTROLS...
Page 95 Access Level Required: SERVICE Allows the user to reset the cumulative Kilowatt Hours. NAVIGATION Low Stage Compressor This screen displays data about the Low Stage Com- pressor. History This screen provides access to a Time stamped Record of shutdown conditions. JOHNSON CONTROLS...
Page 96: Capacity Controls Screen
Displays the current interstage pressure. tempt to generate the desired process temperature. Interstage High Pressure Setpoint Displays the system high condenser pressure setpoint, at which the chiller will be unloaded if the condenser pressure goes above this threshold. JOHNSON CONTROLS...
Page 97: Figure 51 - Heat Pump Mode
PRV Target Displays the control system intended position of the pre-rotation vanes. Refer to the table of contents for the explanation of the operation of the Capacity Controls System. LD15247 FIGURE 51 - HEAT PUMP MODE JOHNSON CONTROLS...
Page 98: Manual Auto Station (Capacity Controls) Screen
The manual value must be increased above Access Level Required: OPERATOR Refer to Figure 40 on page 81 for operational use. anti-surge to transition back to automatic operation. JOHNSON CONTROLS...
Page 99 I/O configuration, Communications Setup, Software the programmable Leaving Chilled Liquid Setpoints. Maintenance, Trending, and diagnostics. Condenser Return A detailed view of all condenser parameters, including Returns the display to the previous screen. control of the liquid level functions. JOHNSON CONTROLS...
Page 100: Pid Tuning Screen
Integral Gain (Reset) TC-100 has a setpoint ramp rate in Degrees Tempera- Derivative Gain ture per Second for both Single Stage and Two Stage operation respectively indicated by a 1 and 2. JOHNSON CONTROLS...
Page 101 This screen provides access to a Time stamped Record Stage compressor operation, then this demand of shutdown conditions. limiter PID takes its setpoint from the HS Limit setpoint block below the SP= value. HS LIMIT is displayed in this case. JOHNSON CONTROLS...
Page 102: Overrides Screen
XC-149 controller goes back to sired setpoint, from a standby state, the demand limit a zero output. is slowly allowed to increase. This prevents a sudden change of demand limit and also keeps the system from overload during and ice-building start up. JOHNSON CONTROLS...
Page 103: Figure 55 - Temperature-Based Demand Limiter Function
CYK is started. If the difference in tempera- ture is above this programmable setpoint, the CYK will Demand Limit % FLA Pulldown Limit Demand Degrees Pulldown Temperature Temperature Temperature LD15234 FIGURE 55 - TEMPERATURE-BASED DEMAND LIMITER FUNCTION JOHNSON CONTROLS...
Page 104: Anti-Surge Screen
Values shipped with the unit are only default. An “X” on the plot shows the current Low Stage Vane operating point. Refer to Anti-Surge Tuning on Page 48 for details on anti-surge control line operation and tuning. JOHNSON CONTROLS...
Page 105 PID Tuning Returns the display to view the Capacity Controls Tun- ing Parameters. Overrides Returns the display to view the Capacity Override Tun- ing Parameters. Capacity Controls Returns the display to view the Capacity Controls Screen. JOHNSON CONTROLS...
Page 106: Setup Screen
Resets the anti-recycle (restricted access). Runtime Last Start Chiller Mode / Heat Pump Mode Shows the days, hours and minutes of the last motor Access Level Required: OPERATOR run interval. Toggles between Chilling Operation and Heat Pump operation. JOHNSON CONTROLS...
Page 107 Setup This screen provides a single location to program the most common system setpoints. It is also the gateway to many of the general system setup parameters such as I/O configuration, Communications Setup, Software Maintenance, Trending, and diagnostics. JOHNSON CONTROLS...
Page 108: Test Outputs Screen
I/O configuration, Communications Setup, Software Maintenance, Trending, and diagnostics. Pressing the corresponding button will engage the out- put for two seconds for test purposes. For slow valves the output will be engaged for a longer time delay. JOHNSON CONTROLS...
Page 109: Setpoints 1 Screen
Returns the display to view the Saturation Calc Screen. ing to change any safety setpoints. These thresholds protect the CYK chiller from operations outside its design parameters. Safe operation of the chiller, and war- ranty claims, will be compromised by unauthorized changes. JOHNSON CONTROLS...
Page 110: Setpoints 2 Screen
(current limit) controller is active and will This method is not ideal when the compressors are se- override the offset function if the demand on the HS lected to operate more efficiently with disproportionate motor is too high. sharing of compression ratios. JOHNSON CONTROLS...
Page 111: Figure 61 - Hs Prv Offset Control Scale Function
STOP button is pressed. PD1 from System Antisurge Chiller Head PD2 from System Antisurge Low Head Offset High Head Offset % Vane Position LD15235 FIGURE 61 - HS PRV OFFSET CONTROL SCALE FUNCTION JOHNSON CONTROLS...
Page 112: Miscellaneous Settings
This value is ignored after Returns the display to view the Setpoint 1 Screen. the economizer level setpoint is met. LCV-114 Open On Start On chiller start, the LCV-114 valve is forced to preset to this percentage. JOHNSON CONTROLS...
Page 113: Pressure Calibration Screen
I/O configuration, Communications Setup, Software Each channel should be calibrated for zero and span bit Maintenance, Trending, and diagnostics. counts for the highest accuracy. DISPLAY Displays and controls the instrument scaling of each Pressure transducer on the chiller. JOHNSON CONTROLS...
Page 114: Temperature Calibration Screen
Setup This screen provides a single location to program the most common system setpoints. It is also the gateway to many of the general system setup parameters such as I/O configuration, Communications Setup, Software Maintenance, Trending, and diagnostics. JOHNSON CONTROLS...
Page 115: Miscellaneous Calibration Screen
CT ratio from the Sales Order. The FLA to many of the general system setup parameters such should be entered with the full load amps of the motors as I/O configuration, Communications Setup, Software from the Sales Order. Maintenance, Trending, and diagnostics. JOHNSON CONTROLS...
Page 116: Figure 65 - Flow Instruments Wiring
0%. the IN/OUT or an AVERAGE of the water box nozzle CHANNEL 11 Chilled Brine Flow 0-2000 gpm Inlet, Ethylene Glycol, CHANNEL 12 Condenser Water Flow 0-3000 gpm Inlet, Water, 0% LD16095 FIGURE 65 - FLOW INSTRUMENTS WIRING JOHNSON CONTROLS...
Page 117: Digital Input Configuration Screen
FIGURE 66 - DIGITAL INPUT CONFIGURATION SCREEN OVERVIEW The Digital Input Configuration Screen allows a user with sufficient privilege to assign digital inputs to the correct Board and Channel. This should only be changed under direction of the fac- tory. JOHNSON CONTROLS...
Page 118: Digital Output Configuration Screen
FIGURE 67 - DIGITAL OUTPUT CONFIGURATION SCREEN OVERVIEW The Digital Output Configuration Screen allows a user with sufficient privilege to assign digital outputs to the correct Board and Channel. This should only be changed under direction of the fac- tory. JOHNSON CONTROLS...
Page 119: Auxiliary Analog Configuration Screen
FORM 160.82-OM1 SECTION 3 - QUANTUM LX CONTROL PANEL ISSUE DATE: 8/30/2013 AUXILIARY ANALOG CONFIGURATION SCREEN LD16103 FIGURE 68 - AUXILIARY ANALOG CONFIGURATION SCREEN LD15279 FIGURE 69 - AUXILIARY ANALOG INPUT SAFETIES SCREEN JOHNSON CONTROLS...
Page 120 Low Shutdown threshold. In the event that the associ- ated auxiliary analog input falls below this value for a period of time exceeding the Low Shutdown Delay, an Auxiliary Low Shutdown will be issued, and the com- pressor will stop. JOHNSON CONTROLS...
Page 121: Auxiliary Analog Calibration Screen
Press the [^] (up arrow) button. • Low This will cause the screen to be replaced with an • High Alpha/Numeric key pad entry screen. JOHNSON CONTROLS...
Page 122: Auxiliary Analog Calibration Screen
• None A drop down menu box exists for each of the displayed • Pressure auxiliary readings: • Temperature • Other Units if Type is Other - Up to 5 characters may be entered here. JOHNSON CONTROLS...
Page 123: Retransmitting Outputs Screen
"Input Channel To Retransmit". Then select a spare IO Board and IO channel to re-transmit the data on. This channel will likely need to be calibrated. Navigate to the Analog Output Calibration and perform a cali- bration on the newly assigned channel. JOHNSON CONTROLS...
Page 124: Economizer Screen
The reverse flow of gas through the sideload line. LCV-116 level control is available with two sets of tun- ing parameters, since running in single stage mode and two-stage mode present different running characteris- tics. JOHNSON CONTROLS...
Page 125 Automatic operation transfer. PROGRAMMABLE LCV-114 Auto Access Level Required: OPERATOR Refer to Figure 26 on page 55 for operational use. LCV-116 Auto Access Level Required: OPERATOR Refer to Figure 26 on page 55 for operational use. JOHNSON CONTROLS...
Page 126: History Screen
Press the ENTER key when an alarm is highlighted to ticular alarm was acknowledged. view the frozen data capture at the time that this alarm occured. This display as described in the next section is the “Freeze Screen”. NAVIGATION Return Returns the display to the previous screen. JOHNSON CONTROLS...
Page 127: Freeze Screen
I/O configuration, Communications Setup, Software Record desired data prior to updating the Maintenance, Trending, and diagnostics. Quantum™ LX software. History This screen provides access to a Time stamped Record of shutdown conditions. JOHNSON CONTROLS...
Page 128: Trending Screen
It is also the gateway analyzed further. to many of the general system setup parameters such as I/O configuration, Communications Setup, Software Maintenance, Trending, and diagnostics. JOHNSON CONTROLS...
Page 129: Figure 77 - Real Time Trending Screen
Flash memory is non-volatile and all information is retained even if the power to the panel is lost. The interval at which the data is saved can be adjusted. The events that can be logged are set using the Trending Setup screen. JOHNSON CONTROLS...
Page 130: Trending Setup Screen
Pens 1 – 8. When a pen has been selected, use the UP and DOWN arrow keys on the keypad to assign the desired sensor to that Pen. Press ENTER to confirm the selection. JOHNSON CONTROLS...
Page 131: Custom Display Screen
The Custom Display page allows access from the View level to set a list of custom analog display items which would not normally be viewable all in one location. Press the Enable User Defined Status # and then select from the list and press SUBMIT. JOHNSON CONTROLS...
Page 132 FORM 160.82-OM1 SECTION 3 - QUANTUM LX CONTROL PANEL ISSUE DATE: 8/30/2013 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 133: Section 4 - Software Update Procedure
7. When the message appears in the DOS box that since it would rewrite my system with the image you may “Press Any Key to Continue”, do so and file. Be very careful to select the correct drive then remove the USB flash drive safely from the name spec before going any further. computer. JOHNSON CONTROLS...
Page 134: Delete Partition
>> NEW PARTITION. a. Reply with YES 11. A popup wizard will appear, select NEXT, and then select NEXT again to confirm the PRIMARY 11. After the System Update remove the USB thumb PARTITION, then select again to confirm the de- drive as instructed and cycle the control panel fault size. power. JOHNSON CONTROLS...
Page 135: Figure 80 - Usb Flash Drive
15. Re-highlight the removable disk in the bottom of Your USB flash drive is now ready to use with the Disk Management window and notice that it is Windows again. “FAT23 and Healthy”. 16. From the menu select ACTION >> ALL TASKS >> FORMAT JOHNSON CONTROLS...
Page 136 FORM 160.82-OM1 SECTION 4 - SOFTWARE UPDATE PROCEDURE ISSUE DATE: 8/30/2013 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...
Page 137: Section 5 - System Communication And Networking
Ethernet level. the necessary point of connection for one end (branch) of the connection (a home computer for instance). CONNECT TO LAN 1 FOR ETHERNET COMMUNICATIONS Bottom view of Quantum™ LX controller board LD15274a FIGURE 81 - ETHERNET CONNECTION JOHNSON CONTROLS...
Page 138: Figure 82 - Typical Rj-45 Connector
FIGURE 82 - TYPICAL RJ-45 CONNECTOR • Do keep the cable as far away as possible from EMI sources (motors, transformers, solenoids, When looking at this connector, pin 1 is at the left, and lighting, etc.) pin 8 is at the right. JOHNSON CONTROLS...
Page 139: Figure 83 - Crossover Cable
Switch can connect four computers, an eight-port two you need a Switch. Switch can connect up to eight computers and so on. Refer to the following pictorial to construct a crossover cable: BOTH ENDS OF A CROSSOVER CABLE LD15275 FIGURE 83 - CROSSOVER CABLE JOHNSON CONTROLS...
Page 140: Table 11 - Ethernet Component Recommendations
Complete Cable I/O Qualification Tester Fluke 5 RJ-45 port SFN-5TX Phoenix Switches 7 RJ-45 Port and 1 ST Fiber Optic Port SFN-7TX/FX ST Phoenix 8 RJ-45 port SFN-8TX Phoenix *STP = Shielded Twisted Pair **UTP = Unshielded Twisted Pair JOHNSON CONTROLS...
Page 141: Figure 85 - Ethernet Setup
DHCP (Dynamic) – Dynamic Host Configuration Pro- tocol permits autoassignment of temporary IP address- es for new devices connecting to the network. HOME --> SETUP --> ETHERNET LD15258a FIGURE 85 - ETHERNET SETUP JOHNSON CONTROLS...
Page 142 When you set up an email client, you must specify an then Evap1 could be the name of a work group. An- outgoing server (sometimes called an SMTP server). other three units may be Heat Pump Units, this work JOHNSON CONTROLS...
Page 143: Serial Communications
RS-232 is by far the most common (and oldest) serial pair cable), much greater noise immunity than RS-232. communications hardware protocol, as almost all laptop RS-422/RS-485 signals cannot be connected directly and desktop computers will have at least one RS-232 to an RS-232 device. JOHNSON CONTROLS...
Page 144: Figure 86 - Serial Port Locations
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING ISSUE DATE: 8/30/2013 ETHERNET PORT COM-4 RS-485 I/O SERIAL PORT COM-3 (OPTIONAL) LCSSS COMMUNICATIONS SERIAL PORT COM 1 LD15224 COM 2 RS-232 SERIAL SLAVE COMMUNICATION PORTS PORT TO PROTOCAL GATEWAY FIGURE 86 - SERIAL PORT LOCATIONS JOHNSON CONTROLS...
Page 145: Serial Communications Setup
A delay of 15 seconds or more of inac- • 9600 tive communications (time between valid responses) will cause this message • 19200 to display. • 38400 • 57600 • 115200 HOME >> SETUP >> SERIAL COMMUNICATIONS LD15259 FIGURE 87 - COMMUNICATIONS SETUP JOHNSON CONTROLS...
Page 146: Table 12 - Serial Communication Setup
________ (0 - 255) Com 1 Com 3 1200 2400 4800 9600 Baud Rate 19200 38400 57600 115200 Data Bits Stop Bits None Parity Even None Modbus ASCII Protocol Modbus RTU AB DF1 Full Duplex AB DF1 Half Duplex JOHNSON CONTROLS...
Page 147: Table 13 - Communications Board
TABLE 13 - COMMUNICATIONS BOARD SIGNAL DESCRIPTION Data Carry Detect Serial In or Receive Data SOUT Serial Out or Transmit Data Data Terminal Ready Ground Data Set Ready Request To Send Clear To Send VCC_ Power Source LD15236 JOHNSON CONTROLS...
Page 148: Figure 88 - Communications Data Logging Screens
Quantum™ LX is receiving and transmitting, one port at a time. HOME >> SETUP >> DIAGNOSTICS >> COMMUNICATION LOGS LD15282 FIGURE 88 - COMMUNICATIONS DATA LOGGING SCREENS JOHNSON CONTROLS...
Page 149: Figure 89 - Modbus Tcp Communications Log
07 · D0 00 · 02 # of registers to read Address of first register (2001) Read holding register Panel ID # of bytes in command Always 0 for Modbus TCP Transaction Identifier FIGURE 90 - HOW THE DATA PACKETS ARE CREATED JOHNSON CONTROLS...
Page 150: Figure 91 - Data Station Pinout
• Ethernet Industrial Protocol with Allen-Bradley data table structures See the CYK protocol list document in the chiller IOM. Additional protocols and media are supported by the RedLion Data Station Plus. LD15297 FIGURE 91 - DATA STATION PINOUT JOHNSON CONTROLS...
Page 151: Figure 92 - Virtual Hmi
Example Hookups Connecting the Quantum LX Industrial Control Cen- ter to an existing network can be done in many ways. Here are a few examples. LD16258 FIGURE 92 - VIRTUAL HMI LD16259 FIGURE 93 - BACNET IP OVER ETHERNET JOHNSON CONTROLS...
Page 152: Figure 94 - Bacnet Mstp Over Rs-485
FIGURE 94 - BACNET MSTP OVER RS-485 Use an RJ-45 connector. Pinout references the JACK. DaisyChain A RS485 A cut-off Ethernet patchcord connector makes a suit- able cable. COMM TxEN DaisyChain B LD16261 FIGURE 95 - RJ-45 CONNECTOR JOHNSON CONTROLS...
Page 153: Figure 96 - Modbus Rtu Or Ab Df1 Over Rs-485
FORM 160.82-OM1 SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING ISSUE DATE: 8/30/2013 LD16262 FIGURE 96 - MODBUS RTU OR AB DF1 OVER RS-485 LD16263 FIGURE 97 - CREATE YOUR OWN JOHNSON CONTROLS...
Page 154 • Right click on any of the data blocks, and select VIEW to see the data. • Confirm that the data on the chiller matches the points in the data block per the protocol listing provided in this document. JOHNSON CONTROLS...
Page 155: Table 14 - Quantum Lx For Cyk Protocol List
Emergency Stop 10020 N10:19 BI0020 R1 Relay 10021 N10:20 BI0021 10022 N10:21 BI0022 10023 N10:22 BI0023 Blank 10024 N10:23 BI0024 10025 N10:24 BI0025 10026 N10:25 BI0026 LS Liquid Line Solenoid Valve 10027 N10:26 BI0027 HS Liquid Line Solenoid Valve JOHNSON CONTROLS...
Page 156 AI0011 HS Oil Reservoir Level Only on ice thermal storage 42012 N20:11 AI0012 Subcooler Refrig. Liquid Level 42013 N20:12 AI0013 Economizer Refrig. Liquid Level 42014 N20:13 AI0014 LS Comp HS Thrust Bearing Probe Gap Only on certain compressors JOHNSON CONTROLS...
Page 157 AI0049 User defined analog input #18 42050 N20:49 AI0050 User defined analog input #19 42051 N20:50 AI0051 User defined analog input #20 42052 N20:51 AI0052 42053 N20:52 AI0053 42054 N20:53 AI0054 Blank 42055 N20:54 AI0055 42056 N20:55 AI0056 JOHNSON CONTROLS...
Page 158 Analog output #10 42088 N20:87 AI0088 Analog output #11 42089 N20:88 AI0089 Analog output #12 42090 N20:89 AI0090 Analog output #13 42091 N20:90 AI0091 Analog output #14 42092 N20:91 AI0092 Analog output #15 42093 N20:92 AI0093 Analog output #16 JOHNSON CONTROLS...
Page 159 N30:35 AI0135 Auto Economizer Outlet Valve 43037 N30:36 AI0136 Manual Economizer Outlet Valve 43038 N30:37 AI0137 Chilled Water Out Temp PID Output 43039 N30:38 AI0138 Heat Pump Control PID Output 43040 N30:39 AI0139 HS Motor Load PID Output JOHNSON CONTROLS...
Page 160 Refer to alarm Table for to offset in alarm table) 43076 N30:75 AI0175 offset 43077 N30:76 AI0176 43078 N30:77 AI0177 43079 N30:78 AI0178 43080 N30:79 AI0179 43081 N30:80 AI0180 not used 43082 N30:81 AI0181 43083 N30:82 AI0182 Process Stopped Flag JOHNSON CONTROLS...
Page 161 N30:118 AI0218 43120 N30:119 AI0219 Range Converter Result 43121 N30:120 AI0220 HSR3 43122 N30:121 AI0221 LS Motor Load Percent 43123 N30:122 AI0222 HS Motor Load Percent LCSSS / MVSSS Starter 43124 N30:123 AI0223 LS Motor Kilowatts Comms Only JOHNSON CONTROLS...
Page 162 AI0312 HS Pre-Rotation Vanes Mode 0=Auto, 1=Manual 44014 N40:13 AI0313 HS VS Oil Pump Drive Mode 0=Auto, 1=Manual 44015 N40:14 AI0314 LS VS Oil Pump Drive Mode 0=Auto, 1=Manual 44016 N40:15 AI0315 Hot Gas Valve Mode 0=Auto, 1=Manual JOHNSON CONTROLS...
Page 163 N50:4 AI0504 Warning: High Discharge Temperature 45006 N50:5 AI0505 Warning: High Discharge Pressure 45007 N50:6 AI0506 Warning: High Stage Proximity Forward 45008 N50:7 AI0507 Warning: High Stage Proximity Reverse 45009 N50:8 AI0508 Warning: High Stage High Oil Pressure JOHNSON CONTROLS...
Page 164 Warning: High Sideload Differential 45041 N50:40 AI0540 Warning: Hs Oil Drain Not Open 45042 N50:41 AI0541 Warning: Hs Oil Drain Not Closed 45043 N50:42 AI0542 Warning: Hs Thrust Probe Cal Active 45044 N50:43 AI0543 Warning: Ls Thrust Probe Cal Active JOHNSON CONTROLS...
Page 165 45082 N50:81 AI0581 Auxiliary Input 10 Shutdown 45083 N50:82 AI0582 Auxiliary Input 10 Warning 45084 N50:83 AI0583 High Auxiliary Analog 1 Shutdown 45085 N50:84 AI0584 High Auxiliary Analog 1 Warning 45086 N50:85 AI0585 Low Auxiliary Analog 1 Shutdown JOHNSON CONTROLS...
Page 166 AI0618 Low Auxiliary Analog 9 Warning 45120 N50:119 AI0619 High Auxiliary Analog 10 Shutdown 45121 N50:120 AI0620 High Auxiliary Analog 10 Warning 45122 N50:121 AI0621 Low Auxiliary Analog 10 Shutdown 45123 N50:122 AI0622 Low Auxiliary Analog 10 Warning JOHNSON CONTROLS...
Page 167 AI0660 High Auxiliary Analog 13 Warning 45162 N50:161 AI0661 Low Auxiliary Analog 13 Shutdown 45163 N50:162 AI0662 Low Auxiliary Analog 13 Warning 45164 N50:163 AI0663 High Auxiliary Analog 14 Shutdown 45165 N50:164 AI0664 High Auxiliary Analog 14 Warning JOHNSON CONTROLS...
Page 168 Trip: +5 Volt Supply Has Failed 45203 N50:202 AI0702 Trip: Bypass Didn’t Close 45204 N50:203 AI0703 Trip: Bypass Didn't Open 45205 N50:204 AI0704 Trip: Low Chilled Flow Switch 45206 N50:205 AI0705 Trip: Low Condenser Flow Switch 45207 N50:206 AI0706 Blank JOHNSON CONTROLS...
Page 169 Trip: Excess Motor Starts In 24 Hour Period 45246 N50:245 AI0745 Trip: R1 Safety Relay Not Set 45247 N50:246 AI0746 Trip: Rack 0 Communication Failure 45248 N50:247 AI0747 Trip: Rack 1 Communication Failure Trip: A Thrust Proximitor Is Tripped (Call Factory 45249 N50:248 AI0748 Service) JOHNSON CONTROLS...
Page 170 N51:28 AI0778 45280 N51:29 AI0779 45281 N51:30 AI0780 45282 N51:31 AI0781 45283 N51:32 AI0782 45284 N51:33 AI0783 45285 N51:34 AI0784 45286 N51:35 AI0785 45287 N51:36 AI0786 45288 N51:37 AI0787 45289 N51:38 AI0788 45290 N51:39 AI0789 45291 N51:40 AI0790 JOHNSON CONTROLS...
Page 171 N51:71 AI0821 45323 N51:72 AI0822 45324 N51:73 AI0823 45325 N51:74 AI0824 45326 N51:75 AI0825 45327 N51:76 AI0826 45328 N51:77 AI0827 45329 N51:78 AI0828 45330 N51:79 AI0829 45331 N51:80 AI0830 45332 N51:81 AI0831 45333 N51:82 AI0832 45334 N51:83 AI0833 JOHNSON CONTROLS...
Page 172 45372 N51:121 AI0871 HS SSS: Phase Locked Loop Alarm 45373 N51:122 AI0872 HS SSS: Power Fault 45374 N51:123 AI0873 HS SSS: Run Signal Alarm 45375 N51:124 AI0874 HS SSS: Current Imbalance 45376 N51:125 AI0875 HS SSS: Current Overload JOHNSON CONTROLS...
Page 173 AI0914 Low Auxiliary Analog Input #2 Sensor Warning 45416 N51:165 AI0915 High Auxiliary Analog Input #2 Sensor Warning 45417 N51:166 AI0916 Low Auxiliary Analog Input #3 Sensor Warning 45418 N51:167 AI0917 High Auxiliary Analog Input #3 Sensor Warning JOHNSON CONTROLS...
Page 174: System Parameters
47173 N101:72 AI1000 Single To 2-Stage Setpoint (differential pressure) Compare to system head 47174 N101:73 AI1001 2-Stage To Single Setpoint (differential pressure) Compare to system head Immediate 2-Stage Threshold (differential tem- Compare to 47175 N101:74 AI1002 perature) (ECdWT-EChWT) JOHNSON CONTROLS...
Page 175: Table 15 - List Alarm Codes
High Auxiliary Analog 1 Warning Low Auxiliary Analog 1 Shutdown Warning: Hs Oil Drain Not Closed Warning: Hs Thrust Probe Cal Active Low Auxiliary Analog 1 Warning Warning: Ls Thrust Probe Cal Active High Auxiliary Analog 2 Shutdown JOHNSON CONTROLS...
Page 176 High Auxiliary Analog 15 Warning 1260 1690 Low Auxiliary Analog 15 Shutdown Blank 1270 1700 Low Auxiliary Analog 15 Warning 1280 1710 High Auxiliary Analog 16 Shutdown 1290 1720 High Auxiliary Analog 16 Warning 1300 1730 Low Auxiliary Analog 16 Shutdown JOHNSON CONTROLS...
Page 177 Trip: High Stage Proximitor Reverse 2550 Trip: HS Oil Pressure Sensors Will Not Zero 2140 Trip: High Stage High Oil Pressure 2560 Trip: Excessive Surge 2150 Trip: High Stage High Oil Temperature 2160 Trip: High Stage Low Oil Pressure JOHNSON CONTROLS...
Page 178 3360 LS SSS: Spare 1 2950 3370 LS SSS: Invalid Starter Model 2960 3380 LS SSS: Phase Loss 2970 3390 LS SSS: Phase Locked Loop Alarm 2980 3400 LS SSS: Power Fault 3410 LS SSS: Run Signal Alarm JOHNSON CONTROLS...
Page 179 High Auxiliary Analog Input #7 Sensor Warning 3830 HS SSS: Phase A Inhibit High Temp 4260 Low Auxiliary Analog Input #8 Sensor Warning 3840 HS SSS: Phase B Inhibit High Temp 4270 High Auxiliary Analog Input #8 Sensor Warning JOHNSON CONTROLS...
Page 180 High Auxiliary Analog Input #18 Sensor Warning 4480 Low Auxiliary Analog Input #19 Sensor Warning 4490 High Auxiliary Analog Input #19 Sensor Warning 4500 Low Auxiliary Analog Input #20 Sensor Warning 4510 High Auxiliary Analog Input #20 Sensor Warning JOHNSON CONTROLS...
Page 181: Section 6 - Troubleshooting
A conduit ground will not work. ground in one panel, typically the “Lead” Do not drive a ground stake at the chiller since machine. extraneous currents will be attracted to the chiller. JOHNSON CONTROLS...
Page 182 23. If the chiller is unexplainably shutting down, check if the machine shares control transformer power with something else. Make sure each chill- er has its own isolation transformer in the motor control center off the three-phase bus with the sec- ondary properly grounded. JOHNSON CONTROLS...
Page 183: Table 16 - 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 184 P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA www.johnsoncontrols.com Copyright © by Johnson Controls 2011 ALL RIGHTS RESERVED Form 160.82-OM1 (813) Issue Date: August 30, 2013 Supersedes: 160.82-OM1 (611)

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