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YORK OPTIVIEW YK Series
Johnson Controls YORK OPTIVIEW YK Series Manuals
Manuals and User Guides for Johnson Controls YORK OPTIVIEW YK Series. We have
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Johnson Controls YORK OPTIVIEW YK Series manual available for free PDF download: Service Instructions Manual
Johnson Controls YORK OPTIVIEW YK Series Service Instructions Manual (346 pages)
CENTRIFUGAL LIQUID CHILLERS WITH OPTIVIEW CONTROL CENTER
Brand:
Johnson Controls
| Category:
Chiller
| Size: 4 MB
Table of Contents
TABLE 1 - Control Panel Applications
4
Table of Contents
5
Section 1 - Introduction
13
Section 2 - System Architecture
15
FIGURE 1 - Optiview™ Control Center - Electro-Mechanical Starter Applications
20
FIGURE 2 - Optiview™ Control Center - MOD a Solid State Starter Applications
21
FIGURE 3 - Optiview™ Control Center - MOD B Solid State Starter Applications
22
FIGURE 4 - Optiview™ Control Center - Medium Voltage Solid State Starter Applications
23
FIGURE 5 - Optiview™ Control Center - Compressor Motor Variable Speed Drive (YORK Serial Communications Protocol)
24
(Modbus Serial Communications Protocol)
25
FIGURE 6 - Optiview™ Control Center - Compressor Motor Variable Speed Drive
25
FIGURE 7 - Optiview™ Control Center - Compressor Motor Medium Voltage Variable Speed Drive
26
FIGURE 8 - Operation Sequence Timing Diagram (Electro-Mechanical and Solid State Starter Applications)
27
FIGURE 9 - Operation Sequence Timing Diagram (Compressor Motor Variable Speed Drive Applications)
28
Section 3 - Microboard 031-01730-000
29
Boot-Up Step and Description
31
TABLE 2 - Boot-Up LED Indicators
31
TABLE 3 - Addresses and Associated Data
32
Power Supply
36
Service Replacement
36
FIGURE 11 - Flash Memory Card
38
FIGURE 12 - Microboard (031-01730-000) Power Supply Test Points
39
Program Jumpers
40
Program Switches
42
FIGURE 13 - Microboard Lamp Dimmer Circuit
43
FIGURE 14 - Microboard Serial Data Communications Ports
44
FIGURE 15 - Configurable Analog and Remote Setpoint Inputs
45
Section 4 - Microboard 031-02430-000 and 031-02430-001
47
TABLE 4 - Diagnostic Display Codes
48
TABLE 5 - Multiplexer Channels
51
Configuration/Setup
56
FIGURE 16 - BRAM Socket
60
TABLE 6 - Summary of Differences
60
TABLE 7 - Microboard
60
Downloading a Program from Aprogram Card
61
Program Jumpers
62
Program Switches
63
FIGURE 17 - Microboard 031-02430-000 and 031-02430-001
64
FIGURE 18 - Program Card 031-02474-001
65
FIGURE 19 - Microboard (031-02430-000 and 031-02430-001) DC Power Supply Test Points
65
FIGURE 20 - Microboard Lamp Dimmer Circuit
66
FIGURE 21 - Microboard Serial Data Communications Ports
67
FIGURE 22 - Configurable Analog and Remote Setpoint Inputs
68
FIGURE 23 - Configurable Analog and Remote Setpoint Inputs (Heat Pump Duty)
69
FIGURE 24 - Low Voltage Digital Inputs
70
Section 5 - I/O Board
71
I/O Board
71
Digital Inputs
71
Digital Outputs
71
Triacs
72
Relay Timing
72
FIGURE 25 - I/O Board
75
FIGURE 26 - I/O Board Digital Inputs
76
FIGURE 27 - I/O Board Typical Opto-Coupler Circuit
77
FIGURE 28 - I/O Board Typical Field Connections
77
FIGURE 29 - J1 I/O Board Digital Outputs
78
Section 6 - Liquid Crystal Display
81
Backlight Lamp Replacement
83
FIGURE 30 - Display Mounting
84
FIGURE 31 - Liquid Crystal Display Assembly - Sharp LQ10D367/368 (031-01774-000) Display
85
FIGURE 32 - Liquid Crystal Display Assembly - Sharp LQ104V1DG61 (031-02886-000) Display
85
FIGURE 33 - Liquid Crystal Display Assembly - LG Semicon LP104V2-W (031-02046-000)
86
FIGURE 34 - Liquid Crystal Display Typical Control Signal Timing
86
FIGURE 35 - Display (Sharp LQ10D367/368) Lamp Replacement
87
FIGURE 36 - Display (Sharp LQ104V1DG61 (031-02886-000) and LG LP104V2-W (031-02046-000))
87
Section 7 - Display Interface Board
89
FIGURE 37 - Display Interface Board 031-01765-001 and 031-01765-002
91
FIGURE 38 - Display Interface Board 031-02887-000
92
Section 8 - Display Backlight Inverter Board
93
FIGURE 39 - Display Backlight Inverter Board (Sharp LQ10D367/368 (031-01774-000) and
94
LG Semicon LP104V2-W (031-02046-000))
94
FIGURE 40 - Display Backlight Inverter Board - Sharp LQ104V1DG61 Display 031-02886-000
95
Section 9 - Keypad
97
FIGURE 41 - Keypad
98
FIGURE 42 - Keypad
99
FIGURE 43 - Power Supply
101
Section 10 - Power Supply
101
FIGURE 44 - Power Supply - DC Power Distribution (Refer to Optiview™ Control Center Wiring Diagram for Wire Connections)
102
Section 11 - Current Module (CM-2)
103
TABLE 8 - MUX Address
104
FIGURE 45 - CM-2 Current Module (Electro-Mechanical Starter Application)
105
FIGURE 46 - CM-2 Current Module (Electro-Mechanical Starter Applications)
105
FIGURE 47 - CM-2 Current Module - Interface, Current Transformers and Variable Resistors
106
Section 12 - Solid State Starters
107
Solid State Starters
107
Medium Voltage Solid State Starter
107
FIGURE 48 - Style B Liquid Cooled Solid State Starter (LCSSS) - Interface (YORK Protocol)
111
FIGURE 49 - Style B Liquid Cooled Solid State Starter (LCSSS) - Interface (YORK Protocol)
111
FIGURE 50 - Style B Liquid Cooled Solid State Starter (LCSSS) - Interface (Modbus Protocol)
112
FIGURE 51 - Solid State Starter Logic Board
112
TABLE 9 - Microboard Multiplex Channels
114
FIGURE 52 - Mod a Liquid Cooled Solid State Starter (LCSSS) - Interface
115
Section 13 - Adaptive Capacity Control Board
117
YORK Protocol Configuration
117
Modbus Protocol Configuration
124
FIGURE 53 - Compressor Motor Variable Speed Drive (VSD) Adaptive Capacity Control (ACC) Board
126
FIGURE 54 - Serial Communications Interface - YORK Protocol
127
FIGURE 55 - Serial Communications Interface - YORK Protocol
127
FIGURE 56 - Serial Communications Interface - Modbus Protocol
128
FIGURE 57 - Adaptive Capacity Control (ACC) Board
129
Section 14 - Proximity Probe
131
TABLE 10 - Proximity Probes
133
FIGURE 58 - Proximity Probe Interface - Probe Part Number 025-30961-000
134
FIGURE 59 - Proximity Probe Interface - Probe Part Number 025-35900-000 and 025-35900-001
134
FIGURE 60 - Proximity Probe Interface - Probe Part Number 025-40496-000
135
FIGURE 62 - High Speed Thrust Bearing Limit Switch - Interface
137
Section 15 - High Speed Thrust Bearing Limit Switch
137
FIGURE 63 - High Speed Thrust Bearing Limit Switch
138
Section 16 - Refrigerant Level Control
139
Automatic Operation
139
Manual Operation
141
Actuators
141
FIGURE 64 - Refrigerant Liquid Level Sensor
142
FIGURE 65 - Refrigerant Liquid Level Control - Interface
143
Section 17 - Oil Pump Variable Speed Drive
145
Automatic Operation
145
Manual Operation
146
Oil Heater Operation
147
FIGURE 66 - Oil Pump Variable Speed Drive (VSD)
147
FIGURE 67 - Oil Pump VSD / Oil Heater Control - Interface
148
FIGURE 68 - Oil Pump VSD Speed Control Signal
148
Section 18 - Communications
149
FIGURE 69 - E-Link Gateway Interface Block Diagram
149
Section 19 - Pressure Transducers
151
FIGURE 70 - Pressure Transducers
152
TABLE 11 - Pressure Transducer Applications
153
Section 20 - Temperature Thermistors
155
TABLE 12 - Leaving Chilled Liquid Temperature
156
TABLE 14 - Return Chilled Liquid Temperature
162
TABLE 16 - Return and Leaving Condensing Water
166
TABLE 17 - Oil and Discharge Temperature
169
TABLE 18 - Drop Leg Refrigerant Sensor
174
TABLE 19 - Evaporator Refrigerant Sensor
174
TABLE 20 - Leaving and Return Heating Condenser Water Temperature Sensor
175
Section 21 - Remote Setpoints
177
Remote Operating Modes
177
Current Limit
177
Leaving Chilled Liquid Temperature
179
Leaving Condenser Liquid Temperature (Heat Pump Mode)
181
Section 22 - Hot Gas Bypass
185
Setpoints
185
Operation
186
Hot Gas Operation with Variable Geometry Diffuser (VGD)
187
Manual Control
187
I/O Board
187
Pre-Rotation Vanes Potentiometer
188
FIGURE 71 - Interface, Hot Gas Bypass (Analog I/O Board 371-02514-000)
189
FIGURE 72 - Interface, Hot Gas Bypass (I/O Board 031-02895-000)
190
Section 23 - Smart Freeze Protection
191
Section 24 - Surge Protection
193
Surge Detection
193
Excess Surge Detection
194
Surge Protection
194
Hot Gas Bypass/Compressor Motor Variable Speed Drive (VSD) Applications
195
Section 25 - Variable Geometry Diffuser
197
Stall Detection
197
Surge Detection
197
Automatic Operation
197
Stall Sensor Validation
199
Extreme Stall Monitor
199
Manual Operation
200
Setpoints
200
Pre-Rotation Vanes Position
201
I/O Board
201
Stall Transducer
201
Stall Detector Board
201
FIGURE 73 - Variable Geometry Diffuser Block Diagram
202
FIGURE 74 - Variable Geometry Diffuser State Diagram
203
Section 26 - Large Tonnage Chiller (Ltc) I/O Board
205
Digital Inputs
205
FIGURE 75 - LTC I/O Board Basic Block Diagram
206
FIGURE 76 - 120VAC Digital Input
206
Digital Outputs
207
FIGURE 77 - +5VDC Digital Input
207
FIGURE 78 - Relay Outputs
207
FIGURE 79 - Triac Outputs
207
Analog Inputs
208
FIGURE 80 - Open Collector
208
FIGURE 81 - Analog Inputs
208
Analog Outputs
209
FIGURE 82 - Analog Outputs
209
Auto Detection
210
Diagnostic Screen
210
FIGURE 83 - I/O Board (031-02895-XXX)
210
Section 27 - Heat Recovery
211
Inputs/Outputs
211
Control
211
FIGURE 84 - Heat Recovery Block Diagram
212
FIGURE 85 - PID Controller Diagram
213
FIGURE 86 - Heat Recovery Flow Diagram
214
Remote Hot Water Setpoint
215
Condenser Flow Switch Open Fault
215
TABLE 21 - Control Source Setpoints
215
Section 28 - Head Pressure Control
217
Inputs/Outputs
217
FIGURE 87 - Head Pressure Control Block Diagram
217
Control
218
FIGURE 88 - Head Pressure Control Flow Diagram
218
Operation When Equipped with both Heat Recovery and Head Pressure Control
219
Section 29 - Quick Start
221
Quick Start Modes
221
Setpoints
221
Operation
223
TABLE 22 - Compare a Normal Start, Quick Normal Start and a Quick Restart
224
Section 30 - Heat Pump Duty
227
Inputs/Outputs
227
Setpoints
227
Control
228
Hot Gas Bypass Control
229
Heat Recovery and Head Pressure Control
229
Quick Start
229
Variable Speed Drive
229
Condenser Temperature Range
229
Condenser High Pressure Warning
229
GPIC Objects
229
FIGURE 89 - Heat Pump Duty Block Diagram
230
FIGURE 90 - Motor Monitoring Board (031-02893-000/001)
231
Section 31 - Motor Monitoring
231
FIGURE 91 - Motor Monitoring Board Basic Block Diagram
232
Motor Monitoring Board
233
FIGURE 92 - Motor Monitoring Block Diagram
234
FIGURE 93 - Winding Temperature - Thermistors
236
Winding Temperatures
236
Bearing Temperatures
238
FIGURE 94 - Winding and Bearing Temperature - RTD
238
FIGURE 95 - Bearing Vibration Sensor
239
Vibration
239
Cooling Coil Leak Detection
241
FIGURE 96 - Motor Cooling Coil Leak Detector - Float Sensor
241
FIGURE 97 - Motor Cooling Coil Leak Detector - Optical Sensor
242
TABLE 23 - RTD Resistance/Temperature Chart
243
TABLE 24 - Thermistor Resistance/Temperature Chart
243
Section 32 - System Calibration, Service Setpoints and Reset Procedures
245
Electro-Mechanical Starter Applications
245
Solid State Starter Applications
246
Compressor Motor Variable Speed Drive Applications
250
Proximity Probe
253
High Speed Thrust Bearing Limit Switch
254
Refrigerant Level Control
254
Oil Pump Variable Speed Drive
256
Oil Return Min
257
Standby Lubrication
257
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
Chiller Starts and Operating Hours Reset
260
Service Phone Numbers
260
Surge Protection
261
Sales Order Data
261
Custom User ID and Passwords
262
Record Setpoint Changes
263
Chiller Style/Compressor
263
TABLE 25 - Flash Memory Card Version C.MLM.01.07.XXX and C.MLM.01.07A.XXX
264
TABLE 26 - Flash Memory Card Version C.MLM.01.08.XXX
265
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
Flow Switch
266
TABLE 29 - Software Version C.OPT.01.16.XXX (and Later)
266
Microboard 031-02430-000/-001 Setup/Configuration
267
Variable Geometry Diffuser
267
High Condenser Pressure Fault While Shutdown - Reset Procedure
269
Motor Lubrication Notification
269
Quick Start
271
Heat Pump Duty
271
Motor Monitoring Software (Version C.opt.01.22.307 and Later)
272
Motor Details Screen
272
Motor Setpoints Screen
273
Section 33 - Diagnostics and Troubleshooting
277
Diagnostics Screen
278
FIGURE 98 - Diagnostics Screen
278
Main Diagnostics Screen
279
FIGURE 99 - Main Diagnostics
279
Motor Monitoring Board Diagnostic Screen
280
FIGURE 100 - Motor Monitoring Board Diagnostic Screen
280
I/O Board (031-02895-000) Diagnostic Screen
282
FIGURE 101 - I/O Board Diagnostic Screen
282
Keypad Test
284
FIGURE 102 - Keypad Test Screen
284
Display Test Main Screen
285
FIGURE 103 - Display Test Main Screen
285
Bit Patterns Test Screen
287
FIGURE 104 - Bit Patterns Test Screen
287
Serial Inputs / Outputs Test Screen
289
FIGURE 105 - Serial Inputs / Outputs Test Screen
289
FIGURE 106 - Microboard - COM 5 Serial Data Port
290
Digital Inputs / Outputs Test Screen
291
FIGURE 107 - Digital Inputs / Outputs Test Screen
291
Analog Inputs Test Screen
294
FIGURE 108 - Analog Inputs Test Screen
294
Section 34 - System Commissioning Checklist
297
Section 35 - Software Enhancements
303
SI0006 - Software Enhancements Effective May 2001
303
SI0019 - Software Enhancements Effective March 2002
305
SI0034 - Software Enhancements Effective August 2002
307
SI0058 - Software Enhancements Effective February 2003
310
SI0062 - Software Enhancements Effective March 2003
312
SI0080 - Software Enhancements Effective January 2004
313
SI0089 - Software Enhancements Effective May 2004
315
Software Enhancements Effective March 2005
317
SI0148 - Software Enhancements Effective June 2006
319
SI0158 - Software Enhancements Effective October 2006
320
SI0164 - Software Enhancements Effective April 2007
321
SI0186 - Software Enhancements Effective October 2006
324
SI0201 - Software Enhancements (Ver 19) Effective October 2008
326
SI0210 - Software Enhancements (Ver 20) Effective June 2009
331
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
TABLE 30 - Loop Back Connections
341
SI0265 - Software Enhancements (Ver 24) Effective May 2012
342
TABLE 31 - si Metric Conversion
345
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