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Johnson Controls YORK YK Style G OPTIVIEW Operation And Maintenance Download Page 268

JOHNSON CONTROLS

8

FORM 160.75-N1 

ISSUE DATE: 4/30/2014

SECTION 1 - INTRODUCTION

5.  Do not charge the compressor with oil.
6.  Do not charge the unit with refrigerant.
7.  Do not attempt to start the system.
8.  Do not run hot water (110°F / 43°C max) or steam 

through the evaporator or condenser at any time.

SHIPMENT

The chiller may be ordered and shipped in any of the 

following forms:

Form 1 –

  Factory Assembled Unit, complete with mo-

tor, refrigerant and oil charges.

•  The motor/compressor assembly mounted, 

with all necessary interconnecting piping 

assembled. OptiView™ Control Center is 

mounted on the unit. Complete unit factory 

leak tested, evacuated and charged with R-

134A.
An optional Solid State Starter or Variable 

Speed Drive can be factory mounted and 

wired.

•  Miscellaneous material  –  Four (4) vibration 

isolation pads (or optional spring isolators 

and brackets). K7 units will be shipped with 

8 Vibration Isolation Pads.

Form 2 –

  Factory Assembled Unit, complete with mo-

tor (refrigerant and oil charges shipped sepa-

rately).

•  The motor/compressor assembly mounted, 

with all necessary interconnecting piping 

assembled. OptiView™ Control Center is 

mounted on the unit. Complete unit fac-

tory leak tested, evacuated and charged with 

holding charge of nitrogen.
An optional Solid State Starter or Variable 

Speed Drive can be factory mounted and 

wired.

•  Miscellaneous material  –  Four (4) vibration 

isolation pads (or optional spring isolators). 

K7 units will be shipped with 8 Vibration 

Isolation Pads.

Form 3 –  

Driveline Separate From Shells  –  Shipped as 

two major assemblies. Unit first factory assem-

bled, refrigerant piped, wired and leak tested; 

then dismantled for shipment. 

•  Compressor/motor assembly removed from 

shells and skidded. Evaporator/condenser is 

not skidded.

•  All wiring integral with compressor is left on 

it, and all conduit is left on shell. All open-

ings on compressor, oil separator, and shell 

are closed and charged with dry nitrogen (2 

to 3 PSIG) (115/122 kPa). 

•  Miscellaneous packaging of control center, 

tubing, water temperature controls, wiring, 

oil, isolators, solid state starter (option), etc.; 

refrigerant charge shipped separately.

Units shipped dismantled MUST be re-

assembled by, or under the supervision of, 

a Johnson Controls representative. Refer 

to Installation - Unit (Form 160.75-N3)

Form 7 –  

Split Shells – Shipped as three major assem-

blies. Unit first factory assembled, refriger-

ant piped, wired and leak tested; then dis-

mantled for shipment. 

•  Compressor/motor assembly removed from 

shells and skidded.

•  Evaporator and condenser shells are sepa-

rated at tube sheets and are not skidded. Re-

frigerant lines between shells are flanged and 

capped, requiring no welding.

•  All wiring integral with compressor is left 

on it. All wiring harnesses on shells are re-

moved. All openings on compressor and 

shells are closed and charged with dry nitro-

gen (2 to 3 psig) (115/122 kPa).

•  Miscellaneous packaging of control center, 

tubing, water temperature controls, wiring, 

oil isolators, solid state starter (option), etc.; 

refrigerant charge shipped separately.

Units shipped dismantled MUST be re-

assembled by, or under the supervision of, 

a Johnson Controls representative. Refer 

to Installation - Unit (Form 160.75-N3)

When more than one chiller is involved, the major 

parts of each unit will be marked to prevent mixing 

of assemblies. (Piping and Wiring Drawings to be fur-

nished by Johnson Controls)

Summary of Contents for YORK YK Style G OPTIVIEW

Page 1: ... 134a WITH OPTIVIEWTM CONTROL CENTER FOR ELECTRO MECHANICAL STARTER SOLID STATE STARTER AND VARIABLE SPEED DRIVE CENTRIFUGAL LIQUID CHILLERS OPERATIONS AND MAINTENANCE Supersedes 160 75 O1 508 Form 160 75 O1 211 LD15222 ...

Page 2: ...individual shall also be familiar with and comply with all applicable governmental standards and regula tions pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to specific situations Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken Indicates a potentially hazardous s...

Page 3: ...0 00 O7 Installation Unit 160 75 N1 Optiview Control Center Operation and Maintenance 160 54 O1 Wiring Diagram Field Connections for YK Chiller Style G OptiView Control Center with Remote Low or Medium Voltage EMS or Unit Mounted Low or Medium Voltage SSS 160 75 PW1 Wiring Diagram Field Connections for YK Chiller Style G OptiView Control Center with Remote Medium Voltage SSS 160 75 PW2 Wiring Diag...

Page 4: ... 4 NOMENCLATURE YK KC K4 H9 CY G MOTOR CODE POWER SUPPLY for 60 Hz 5 for 50 Hz COMPRESSOR CODE CONDENSER CODE EVAPORATOR CODE MODEL STYLE Design Level Refer to YK Engineering Guide for Form 160 75 EG1 Shell Motor Compressor combinations ...

Page 5: ...ral 17 Compressor 17 Capacity Control 17 Compressor Lubrication System 17 Oil Pump 17 Oil Heater 21 Motor Driveline 21 Heat Exchangers 21 Refrigerant Flow Control 22 Optional Service Isolation Valves 22 Optional Hot Gas Bypass 22 OptiView Control Center 22 Solid State Starter Optional 22 Variable Speed Drive Optional 22 SECTION 4 OPERATIONAL MAINTENANCE 23 Oil Return System 23 Changing The Dehydra...

Page 6: ...onents Front View 18 FIGURE 10 System Components Rear View 19 FIGURE 11 Schematic Drawing YK Compressor Lubrication System 20 FIGURE 12 Oil Return System 23 FIGURE 13 Charging Oil Reservoir With Oil 24 FIGURE 14 Evacuation Of Chiller 27 FIGURE 15 Saturation Curve 29 FIGURE 16 Diagram Megging Motor Windings 30 FIGURE 17 Motor Starter Temperature And Insulation Resistances 31 MeggingTheMotor 30 Comp...

Page 7: ...uid is then returned to the chiller to complete the chilled liquid circuit SECTION 1 DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION SYSTEM OPERATION DESCRIPTION The YORK Model YK Chiller is commonly applied to large air conditioning systems but may be used on other applications The chiller consists of an open motor mounted to a compressor with integral speed increasing gears condenser evapora...

Page 8: ...components of a chiller are selected to han dle the refrigerant which would be evaporated at full load design conditions However most systems will be called upon to deliver full load capacity for only a rela tively small part of the time the unit is in operation CAPACITY CONTROL The major components of a chiller are selected for full load capacities therefore capacity must be controlled to maintai...

Page 9: ...FILM EVAPORATOR Rev 2 10 11 2010 Dan Sowers dan sowers ext jci com 717 771 7535 YK Mod G Refrigerant Flow Thru Cross Section Diagram Falling Film Evaporator COMPRESSOR EVAPORATOR DISCHARGE PRE ROTATION VANES SUCTION BAFFLE SUB COOLER LIQUID LEVEL CONDENSER LIQUID LEVEL VALVE HOT GAS BYPASS VALVE LIQUID LEVEL SUCTION OPTIONAL ISOLATION VALVE OPTIONAL ISOLATION VALVE OPTIONAL HOT GAS BYPASS LINE LD0...

Page 10: ...OR Rev 2 12 09 2010 Dan Sowers dan sowers ext jci com 717 771 7535 YK Mod G Refrigerant Flow Thru Cross Section Diagram Flooded Evaporator COMPRESSOR EVAPORATOR DISCHARGE PRE ROTATION VANES MESH ELIMINATORS or SUCTION BAFFLE SUB COOLER LIQUID LEVEL CONDENSER SUCTION LIQUID LEVEL VALVE LIQUID LEVEL OPTIONAL ISOLATION VALVE OPTIONAL ISOLATION VALVE HOT GAS BYPASS VALVE OPTIONAL HOT GAS BYPASS LINE L...

Page 11: ...he RUN position If the unit was previously started press the STOP RESET side of the COMPRESSOR switch and then press the START side of the switch to start the chill er When the start switch is energized the Con trol Center is placed in an operating mode and any malfunction will be noted by messages on a graphic display SECTION 2 SYSTEM OPERATING PROCEDURES OIL HEATERS If the oil heater is de energ...

Page 12: ...AND SOLID STATE STARTER Not for all shutdowns Refer to Display Messages in manual Optiview Control Center Operation and Maintenance Form 160 54 O1 Figure 7 CHILLER STARTING SEQUENCE AND SHUTDOWN SEQUENCE VARIABLE SPEED DRIVE Not for all shutdowns Refer to Display Messages in manual Optiview Control Center Operation and Maintenance Form 160 54 O1 LD15610 ...

Page 13: ...p the entering condenser water temperature may be as much as 25 F 14 C colder than the stand by return chilled water temperature Cooling tower fan cycling will normally provide adequate control of the entering condenser water temperature on most instal lations Heat recovery chillers and chillers using optional head pressure control would use a signal provided by the microprocessor to control main ...

Page 14: ...motor current on the SYSTEM Screen 8 Check for any signs of dirty or fouled condenser tubes The temperature difference between water leaving condenser and saturated condensing tem perature should not exceed the difference recorded for a new unit by more than 4 F 2 2 C Weekly 1 Check the refrigerant charge Refer to Checking The Refrigerant Charge During Unit Shutdown on Page 30 Monthly 1 Leak check...

Page 15: ...View panel or rapid stop with the COM PRESSOR STOP RESET switch The compressor will stop automatically The oil pump will contin ue to run for coastdown period The oil pump will then stop automatically 2 Stop the chilled water pump if not wired into the Microcomputer Control Center in which case it will shut off automatically simultaneously with the oil pump The actual water pump contact opera tion...

Page 16: ...FORM 160 75 O1 211 JOHNSON CONTROLS 16 SECTION 2 SYSTEM OPERATING PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 17: ... with forced lubrication as follows 1 Compressor Drive Shaft Low Speed A Shaft seal B Front and rear journal bearings one on each side of driving gear C Low speed thrust bearing forward and re verse 2 Compressor Driven Shaft High Speed A Forward and reverse high speed thrust bearing B Two journal bearings 3 Speed Increasing Gears A Meshing surfaces of drive and pinion gear teeth To provide the req...

Page 18: ... 18 SECTION 3 SYSTEM COMPONENTS DESCRIPTION FRONT VIEW Figure 9 SYSTEM COMPONENTS FRONT VIEW VARIABLE SPEED DRIVE EVAPORATOR COMPRESSOR SUCTION RELIEF VALVES SIGHT GLASS VARIABLE SPEED OIL PUMP CONTROL BOX OPTIVIEW CONTROL CENTER LD15222 ...

Page 19: ...TION 3 SYSTEM COMPONENTS DESCRIPTION JOHNSON CONTROLS 19 FORM 160 75 O1 211 3 LD15223 Figure 10 SYSTEM COMPONENTS REAR VIEW DISCHARGE LINE COMPRESSOR OIL PUMP HOUSING LIQUID LINE REAR VIEW MOTOR CONDENSER ...

Page 20: ...ES OIL COOLER OIL TEMP CONTROL REFRIG THRUST COLLAR BEARING PRV INLET VALVES BEARING PINION GEAR SHAFT IMPELLER H S SHAFT SEAL LOW SPEED THRUST COVER LOW SPEED GEAR LOW SPEED GEAR REAR BEARING DOUBLE BELLOWS SHAFT SEAL HIGH SPEED THRUST COVER THRUST COLLAR MAIN JOURNAL AND THRUST BEARING HIGH PRESSURE TRANSDUCER EMERGENCY OIL RESERVE COMPRESSOR ROTOR SUPPORT SECTION OIL Figure 11 SCHEMATIC DRAWING...

Page 21: ...e and maintain reliable control A specifically designed spray distributor provides uniform distribu tion of refrigerant over the entire length to yield opti mum heat transfer The hybrid falling film evaporator design has suction baffles around the sides and above the falling film section to prevent liquid refrigerant car ryover into the compressor Evaporators codes M thru Z are flooded type with a...

Page 22: ...the refrigerant charge in either the evaporator or condenser to allow service access to the system A refrigerant pump out unit will be required to isolate the refrigerant Isolation of the refrigerant in this system must be performed by a qualified service technician OPTIONAL HOT GAS BYPASS Hot gas bypass is optional and is used to eliminate compressor surge during light load or high head op eratio...

Page 23: ...om the evaporator through the dehy drator to the compressor sump CHANGING THE DEHYDRATOR To change the dehydrator use the following procedure 1 Isolate the dehydrator at the stop valves 2 Remove the dehydrator Refer to Figure 12 on Page 23 3 Assemble the new filter drier 4 Open evaporator stop valve and check dehydrator connections for refrigerant leaks 5 Open all the dehydrator stop valves 4 OIL ...

Page 24: ...il and connect the pump discharge connection to the oil charg ing valve A located on the remote oil reservoir cover plate Refer to Figure 13 on Page 24 Do not tighten the connection at the charging valve until after the air is forced out by pumping a few strokes of the oil pump This fills the lines with oil and prevents air from being pumped into the system 3 Open the oil charging valve and pump o...

Page 25: ...em Remove obstruction Temperature difference between leav ing chilled water and refrigerant in the evaporator greater than normal with normal discharge temperature Evaporator tubes dirty or restricted Clean evaporator tubes Temperature of chilled water too low with with low motor amperes Insufficient load for system capacity Check prerotation vane motor operation and setting of low water temperatu...

Page 26: ... oil supply inlet Check oil inlet for blockage 8 SYMPTOM OIL PRESSURE GRADUALLY DECREASES Noted by Observation of Daily Log Sheets When oil pump VSD frequency in creases to 55 hz to maintain target oil pressure Oil filter is dirty Change oil filter 9 SYMPTOM OIL PRESSURE SYSTEM CEASES TO RETURN AN OIL REFRIGERANT SAMPLE Oil refrigerant return not functioning Filter drier in oil return system dirty...

Page 27: ...can be used to de tect any leaks too small to be found by the soap test To test with R 22 proceed as follows 1 With no pressure in the system charge R 22 gas into the system through the charging valve to a pressure of 2 PSIG 14 kPa 2 Build up the system pressure with dry nitrogen to approximately 75 to 100 PSIG 517 to 690 kPa To be sure that the concentration of refrigerant has reached all part of...

Page 28: ...es and shell are heated evenly 5 Close the system charging valve and the stop valve between the vacuum indicator and the vacuum pump Then disconnect the vacuum pump leaving the vacuum indicator in place 6 Hold the vacuum obtained in Step 3 in the system for 8 hours the slightest rise in pressure indicates a leak or the presence of moisture or both If after 24 hours the wet bulb temperature in the ...

Page 29: ...been pressure tested and found to be tight prior to evacuation then the saturation tempera ture recordings should follow a curve similar to the typ ical saturation curve shown as Figure 15 on Page 29 The temperature of the water in the test tube will drop as the pressure decreases until the boiling point is reached at which point the temperature will level off and remain at this level until all of...

Page 30: ...level in the evaporator sight glass The refrigerant charge should always be checked and trimmed when the system is shut down The refrigerant charge level must be checked after the pressure and temperature have equalized between the condenser and evaporator This would be expected to be 4 hours or more after the compressor and water pumps are stopped The level should visible in the sight glass Charg...

Page 31: ...NTENANCE JOHNSON CONTROLS 31 FORM 160 75 O1 211 LD00476 Figure 17 MOTOR STARTER TEMPERATURE AND INSULATION RESISTANCES Minimum Insulation Resistance vs Temperature per IEEE Std 43 Open Motors TEMPERATURE F MEGOHMS 6 ...

Page 32: ...to erratic performance Condenser In a condenser trouble due to fouled tubes is usually indicated by a steady rise in head pressure over a pe riod of time accompanied by a steady rise in condens ing temperature and noisy operation These symptoms may also be due to foul gas buildup Purging will re move the foul gas revealing the effect of fouling Tube Fouling Fouling of the tubes can be due to depos...

Page 33: ...use carbon tetrachloride for this purpose since its fumes give the same flame discoloration that the refrigerant does 3 With nitrogen or dry air blow out the tubes to clear them of traces of refrigerant laden moisture from the circulation water As soon as the tubes are clear a cork should be driven into each end of the tube Pressurize the dry system with 50 to 100 PSIG 345 to 690 kPa of nitrogen R...

Page 34: ...minum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter espe cially during the initial start up and first several months of operation However if aluminum particles continue to accumulate and the same conditions continue to stop the unit operation after a new filter is installed notify the nearest Johnson Controls office to request the p...

Page 35: ... dete rioration of windings GREASED BEARINGS Motor Operation and Maintenance manuals are sup plied with the chillers providing maintenance sched ules and instructions for the specific motors The fol lowing are lubrication schedules for the most common motors RAM Motor Lubrication Frame 143T thru 256T are furnished with double sealed ball bearings pre lubricated prior to installa tion Grease fittin...

Page 36: ...C greater than the difference recorded on a new unit it is a good indication that the con denser tubes require cleaning Refer to SECTION 6 MAINTENANCE of this manual for condenser tube cleaning instructions 2 The evaporator tubes under normal circumstances will not require cleaning If the temperature dif ference between the refrigerant and the chilled water increases slowly over the operating seas...

Page 37: ... air filters if applicable X 2 Perform oil analysis on compressor lube oil 1 X Perform refrigeration analysis 1 X Perform vibration analysis X Clean tubes X 2 Perform Eddy current testing and inspect tubes 2 5 Years Lubricate motor Refer to motor manufacturer s recommentations For operating and maintenance requirements listed above refer to appropriate service literature or contact your local YORK...

Page 38: ...JOHNSON CONTROLS 38 FORM 160 75 O1 111 NOTES ...

Page 39: ...ultiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range Table 4 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effect ton 3 516 Kilowatts kW Power Horsepower 0 7457 Kilowatts kW Flow Rate Gallons Minute gpm 0 0631 Liters Second l s Length Feet ft 304 8 Meters m Inches in 25 4 Millimeters mm Weight Pounds lbs 0 4538 Kilogr...

Page 40: ...1 1001 www york com P O Box 1592 York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by Johnson Controls 2011 ALL RIGHTS RESERVED Form 160 75 O1 211 Supersedes 160 75 O1 309 ...

Page 41: ...NLY WITH OPTIVIEW CONTROL CENTER FOR ELECTRO MECHANICAL STARTER SOLID STATE STARTER AND VARIABLE SPEED DRIVE OPTIVIEW CONTROL CENTER CENTRIFUGAL LIQUID CHILLERS OPERATION MANUAL Supersedes 160 54 O1 1013 Form 160 54 O1 914 Issue Date September 10 2014 ...

Page 42: ...als This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to specific situations Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken Indicates a potentially haz...

Page 43: ...forming any work on the chiller CHANGE BARS Revisions made to this document are indicated with a line along the left or right hand column in the area the revision was made These revisions are to technical in formation and any other changes in spelling grammar or formatting are not included ASSOCIATED LITERATURE MANUAL DESCRIPTION FORM NUMBER Installation 160 54 N1 OptiView Control Center Service I...

Page 44: ...N CONTROLS 4 NOMENCLATURE YK KC K4 H9 CY G MOTOR CODE POWER SUPPLY for 60Hz 5 for 50Hz COMPRESSOR CODE CONDENSER CODE EVAPORATOR CODE MODEL STYLE Design Level Refer to YK Engineering Guide Form 160 75 EG1 for Shell Motor Compressor combinations ...

Page 45: ...n 65 Variable Geometry Diffuser Screen 69 Variable Geometry Diffuser Setpoints Screen 71 Pre Rotation Vanes Calibration Screen 75 VSD Tuning Screen 77 Oil Sump Screen 79 Electro Mechanical Starter Screen 83 Mod A Solid State Starter Screen 85 Mod B Solid State Starter Screen 87 Medium Voltage Solid State Starter Screen 89 Variable Speed Drive Screen 91 Medium Voltage Variable Speed Drive Screen 93...

Page 46: ...3 DISPLAY MESSAGES 175 Status Messages 175 Run Messages 176 Start Inhibit Messages 177 Warning Messages 177 Routine Shutdown Messages 181 Cycling Shutdown Messages 181 Mod B Solid State Starter Cycling Shutdown Messages 184 Compressor Motor Variable Speed Drive Cycling Shutdown Messages 186 Safety Shutdown Messages 191 Mod B Solid State Starter Safety Shutdown Messages 198 Compressor Motor Variabl...

Page 47: ...urge Protection Screen 65 FIGURE 21 Variable Geometry Diffuser Screen 69 FIGURE 22 Variable Geometry Diffuser Setpoints Screen 71 FIGURE 23 Pre Rotation Vanes Calibration Screen 75 FIGURE 24 VSD Tuning Screen 77 FIGURE 25 Oil Sump Screen 79 FIGURE 26 Electro Mechanical Starter Screen 83 FIGURE 27 Mod A Solid State Starter Screen 85 FIGURE 28 Mod B Solid State Starter Screen 87 FIGURE 29 Medium Vol...

Page 48: ...en 169 FIGURE 61 Common Slots Screen 171 FIGURE 62 Printer 203 FIGURE 63 Breckman Printer 207 FIGURE 64 Communications Block Diagram 207 FIGURE 65 Sample Printout Status 208 FIGURE 66 Sample Printout Setpoints 210 FIGURE 67 Sample Printout Schedule 212 FIGURE 68 Sample Printout Sales Order 212 FIGURE 69 Sample Printout History 214 FIGURE 70 Sample Printout Security Log Report 216 FIGURE 71 Sample ...

Page 49: ...oard that is installed inside of the Control Center SECTION 1 DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION SYSTEM OPERATION DESCRIPTION The YORK Model YK Chiller is commonly applied to large air conditioning systems but may be used on oth er applications The chiller consists of an open motor mounted to a compressor with integral speed increasing gears condenser evaporator and variable flow ...

Page 50: ...upplied to the chiller from an external source usually a cooling tower The condensed refrig erant drains from the condenser into the liquid return line where the variable orifice meters the flow of liq uid refrigerant to the cooler to complete the refrigerant circuit The major components of a chiller are selected to han dle the refrigerant which would be evaporated at full load design conditions H...

Page 51: ...w Thru Cross Section Diagram Falling Film Evaporator LEGEND High Pressure Vapor High Pressure Liquid Refrigerant Low Pressure Liquid Refrigerant Low Pressure Vapor COMPRESSOR EVAPORATOR DISCHARGE PRE ROTATION VANES SUCTION BAFFLE SUB COOLER LIQUID LEVEL CONDENSER LIQUID LEVEL VALVE HOT GAS BYPASS VALVE LIQUID LEVEL SUCTION OPTIONAL ISOLATION VALVE OPTIONAL ISOLATION VALVE OPTIONAL HOT GAS BYPASS L...

Page 52: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 12 SECTION 1 DESCRIPTION OF SYSTEM AND FUNDAMENTALSOF OPERATION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 53: ...led in the DISPLAY MES SAGES portion of this manual There are certain screens displayed values program mable setpoints and manual control shown in this man ual that are for Service Technician use only They are only displayed when logged in at SERVICE access lev el or higher The setpoints and parameters displayed on these screens are explained in detail in OptiView Con trol Center Service Instructi...

Page 54: ...rsion C OPT 01 16 307 or later Style B Solid State Starter Modbus appli cations require software version C OPT 01 18 307 or later The upgrade includes a larger BRAM U38 and an additional RS 485 port on COM2 serial port for Modbus communications When used in larger BRAM configuration requires software ver sion C OPT 01 15 xxx or later This board is backward compatible with YK chillers presently usi...

Page 55: ...symbol In order to reject entry of a setpoint or dis miss an entry form the X key is provided as a universal Cancel symbol Cursor Arrow keys are pro vided to allow movement on screens which contain a large amount of entry data In addi tion these keys can be used to scroll through history and event logs The Start Stop control is operated via a three position rocker switch When toggled all the way t...

Page 56: ...bol In some cases the value may be ren dered invalid by other conditions and the display will use X s to indicate this PROGRAMMABLE Values in this group are available for change by the user In order to program any setpoints on the system the user must first be logged in with the appropriate ac cess level Each of the programmable values requires a specific access level which will be indicated besid...

Page 57: ...s Some keys are used to perform manual control func tions These may involve manual control of items such as the Pre rotation Vanes variable orifice or oil pump speed Other keys in this category are used to initiate terminate processes such as calibrations or reports Free Cursor On screens containing many setpoints a specific SOFT key may not be assigned to each setpoint value A SOFT key will be as...

Page 58: ...Gas Bypass Page 63 Surge Protection Screen Page 65 Variable Geometry Diffuser Page 69 Pre rotation Vanes Calibration Page 75 VSD Tuning Page 77 Oil Sump Page 79 Motor Page 83 Electro Mechanical Starter Version Page 83 Mod A Solid State Starter Page 85 Mod B Solid State Starter Page 87 Medium Voltage Solid State Starter Page 89 VSD Page 91 VSD Details Page 97 ACC Details Page 101 Surge Map Page 109...

Page 59: ...aporator Pressure R22 brine 25 0 100 0 PSIG 172 4 689 6 KPAG Evaporator Pressure R134a 5 5 77 4 PSIG 37 9 533 7 KPAG Evaporator Pressure R134a Heat Pump Duty 0 0 125 0 PSIG 0 0 861 8 KPAG Evaporator Temperature R22 water 13 0 67 0 F 10 5 19 4 C Evaporator Temperature R22 brine 18 0 51 4 F 27 7 10 7 C Evaporator Temperature R134a 44 9 64 7 F 42 7 18 1 C Oil Sump Pressure R22 23 2 271 8 PSIG 160 0 1...

Page 60: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 20 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 61: ... the condenser Condenser Liquid Temperature Return Displays the temperature of the liquid as it enters the condenser Motor Run LED Is ON when the digital output controlling the motor starter contact is on Input Power kW Available only if the chiller system is utilizing a Variable Speed Drive VSD Medium Voltage Variable Speed Drive MV VSD Mod B Solid State Starter or Me dium Voltage Solid State Sta...

Page 62: ...vents unauthorized changes to the chiller if a user was logged in at a higher access level and failed to logout Proper procedure requires that after making necessary setpoint adjustments the user return to the HOME Screen and logout Logout Access Level Required OPERATOR This key is displayed when a user is logged in at any level other than VIEW Pressing it will return the ac cess level to VIEW Pri...

Page 63: ...cluding control of the liquid level functions Compressor A detailed view of all the compressor parameters This includes Pre rotation Vane control Hot Gas Bypass Control Proximity Probe Calibration and PRV Calibra tion Oil Sump A detailed view of all the oil pump and oil sump pa rameters This includes the Variable Speed Oil Pump when installed It also controls the Seal Lubrication functionality Mot...

Page 64: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 24 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 65: ...f the compressor as it travels to the condenser Chilled Liquid Temperature Leaving Displays the temperature of the liquid as it leaves the evaporator Chilled Liquid Temperature Return Displays the temperature of the liquid as it enters the evaporator Chilled Liquid Temperature Setpoint Displays the active temperature setpoint to which the chiller is controlling the evaporator liquid This value SYS...

Page 66: ...re version C OPT 01 21 307 and later Displays the Hot Water Setpoint to which the Leaving Heating Condenser Liquid Temperature is being con trolled Only appears when Heat Recovery is enabled and Hot Water Control is enabled Delta P Software version C OPT 01 21 307 and later Displays the pressure difference between the condens er and evaporator condenser minus evaporator This is also called the Hea...

Page 67: ...ion Temperature Displays the present saturation temperature in the evaporator Return Chilled Liquid Temperature Displays the temperature of the liquid as it enters the evaporator Leaving Chilled Liquid Temperature Displays the temperature of the liquid as it leaves the evaporator Evaporator Refrigerant Temperature Displays the temperature of the refrigerant in the evap orator if the sensor is pres...

Page 68: ...rammed value is 45 F then the remote device can set the Leaving Chilled Liquid Temperature Setpoint over the range of 45 0 to 55 0 F Local Leaving Chilled Liquid Temperature Setpoint Access Level Required OPERATOR This value allows the user to define the Leaving Chilled Liquid Temperature that is to be maintained by the chiller It is programmable over the range of 38 0 F to 70 0 F water or 10 0 F ...

Page 69: ... the Leaving Chilled Liquid Temperature Setpoint It is program mable over a range of 0 F to 70 F above the setpoint to a maximum restart value of 80 F The chiller will automatically restart when this temperature is reached This setpoint can be used to reduce chiller cycling by delaying the chiller restart until the cooling load has increased Brine Low Evaporator Cutout Access Level Required SERVIC...

Page 70: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 30 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 71: ...and Head Pressure Control DISPLAY ONLY Leaving Condenser Liquid Temperature Displays the water temperature as it leaves the con denser Leaving Condenser Liquid Temperature Setpoint Software version C OPT 01 23 307 and later Displays the active setpoint to which the Heat Pump is controlling the Leaving Condenser Liquid Tempera ture Only displayed when Heat Pump is enabled on the SETUP Screen and th...

Page 72: ...plays the difference between the Condenser Re frigerant temperature and the Drop Leg Refrigerant temperature The Condenser Refrigerant temperature will be represented by the Condenser Saturation tem perature If the Drop Leg Sensor is not present this temperature is not displayed High Pressure Switch Open Closed Displays the present position of the high pressure switch This will indicate whether a ...

Page 73: ...SERVICE Moves to the subscreen allowing programming of the refrigerant liquid level control setpoints Heat Recovery Software version C OPT 01 21 307 and later Access Level Required SERVICE Moves to a sub screen allowing programming and viewing of the Heat Recovery setpoints and parame ters Only appears when the Heat Recovery is enabled Head Pressure Control Software version C OPT 01 21 307 and lat...

Page 74: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 34 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 75: ...ically disabled and locked When Heat recovery is enabled the condenser flow animation will show flow when either the Condenser Liquid Flow Switch or the Heating Condenser Liquid Flow Switch says flow is present When Heat Recov ery is disabled the condenser flow animation is based on the standard Condenser Flow Switch This screen also serves as a gateway to controlling the Refrigerant Level Heat Re...

Page 76: ...l for both features at the same time Normally it will be performing Hot Water Control unless certain operat ing conditions cause it to switch over to Head Pressure Control When performing Hot Water Control Hot Water is displayed When performing Head Pressure Control Head Pressure is displayed There are also conditions under which it is not controlling either one in which case Inactive is displayed...

Page 77: ...efault 0 0 Allows the Control Valve to be manually set to a pre determined position between 0 0 and 100 Only appears when Hot Water Control is enabled or Head Pressure Control is enabled Control Valve Output Settings Auto Places the Control Valve in automatic control Only ap pears when Hot Water Control is enabled or Head Pres sure Control is enabled Change Setpoints Use to enter the Hot Water Con...

Page 78: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 38 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION NAVIGATION Home Returns user to HOME Screen Condenser Returns user to CONDENSER Screen ...

Page 79: ...tiView Control Center Service Instructions Form 160 54 M1 for operation instruc tions and explanation of all programmable setpoints and displayed values DISPLAY ONLY Return Condenser Liquid Temperature Displays the temperature of the liquid as it enters the standard condenser tube bundle Leaving Condenser Liquid Temperature Displays the temperature of the liquid as it leaves the standard condenser...

Page 80: ...ontrol Valve Output Settings Set 0 0 to 100 default 0 0 Allows the Control Valve to be manually set to a pre determined position between 0 0 and 100 Control Valve Output Settings Auto Places the Control Valve in automatic control Change Setpoints Use to enter the Head Pressure Control PID variables below Pressing this key places a green box around the first changeable setpoint Use the up down left...

Page 81: ... locked The Condenser Temperature Range Setpoint is set to Extended The Condenser High Pressure Warning Setpoint threshold is set to 193 PSIG The Quick Start feature is only available in Cooling mode and is automatically disabled when Heating mode is selected If chiller is equipped with a VSD it will operate at full speed 50Hz or 60Hz at all times in Heating mode In Cooling mode it operates normal...

Page 82: ...in Leaving Condenser Liquid Temperature Programmable over the range of NOR MAL 50 default 30 10 Normal is the stan dard setting and provides the longest PRV pulse for a given change The 50 30 and 10 selections pro vide decreasing pulse durations for the same amount of change in the Leaving Condenser Liquid Temperature The 10 selection provides the shortest pulse duration Select smaller settings as...

Page 83: ... Level Required OPERATOR This setpoint allows the user to specify the Leav ing Condenser Liquid Temperature at which the Heat Pump will restart after a shutdown on a LEAVING CONDENSER LIQUID TEMPERATURE HIGH TEMPERATURE cycling shutdown in Heating mode This is done by defining an offset below the Leaving Condenser Liquid Temperature Setpoint It is program mable over a range of 0 to 67 F default 0 ...

Page 84: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 44 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 85: ...peration instruc tions and explanation of all programmable setpoints and displayed values DISPLAY ONLY Refrigerant Level Position Displays the present position of the liquid level The refrigerant level is animated in the cutaway view of the condenser When the actual level is 0 to 15 the level is shown about 50 full When the actual level is 16 to 31 the level is shown about 60 full When the actual ...

Page 86: ...e the amount of change in the level within the Level Control Period is compared to the Rate Limit Open if level greater than setpoint Refrigerant Level Control Rate Limit Close This key establishes the response to the rate of change the amount of change in the level within the Level Control Period is compared to the Rate Limit Close if level less than setpoint Refrigerant Level Control Raise Manua...

Page 87: ...ys the present position of the liquid level The refrigerant level is animated in the cutaway view of the condenser When the actual level is 0 to 15 the level is shown about 50 full When the actual level is 16 to 31 the level is shown about 60 full When the actual level is 32 to 47 the level is shown about 70 full When the actual level is 48 to 63 the level is shown about 80 full When the actual le...

Page 88: ...0 seconds default 50 Ramp up Time This ramp limit allows the level to go from the present level to the Refrigerant Level Setpoint over a period of time programmed as the Ramp Up Time Setpoint 3 to 15 minutes default 8 NAVIGATION Home Access Level Required VIEW Returns user to HOME Screen Condenser Access Level Required VIEW Returns user to CONDENSER Screen Setpoints Access Level Required SERVICE M...

Page 89: ...he actual level is 16 to 31 the level is shown about 60 full When the actual level 32 to 47 the level is shown about 70 full When the actual level is 48 to 63 the level is shown about 80 full When the actual level is 64 to 79 the level is shown as about 90 full Actual levels above 79 are shown as 100 full PROGRAMMABLE Refrigerant Level Setpoint Displays the setpoint to which the refrigerant level ...

Page 90: ...s key establishes the response to the rate of change the amount of change in the level within the Level Control Period is compared to the Rate Limit Close if level less than setpoint Refrigerant Level Control Raise Manual This key puts the control into manual mode and sends a RAISE command to the variable orifice Refrigerant Level Control Lower Manual This key puts the control into manual mode and...

Page 91: ... 9 for 60 seconds before the Zone 1 parameters are used If the error is greater than 9 the Zone 2 parameters are immediately implemented Requires a login access level of SERVICE Service Technicians refer to the OptiView Control Center Service Instructions Form 160 54 M1 for operation instruc tions and explanation of all programmable setpoints and displayed values DISPLAY ONLY Refrigerant Level Pos...

Page 92: ...s the time remaining in the Ramp Up time countdown timer while a Refrigerant Level target ramp is in effect PROGRAMMABLE Setpoint Specifies the desired refrigerant level to be maintained in the condenser Valve Preset Time Specifies the duration of pre positioning close pulse during the System Prelube when starting the chiller Ramp Up Time Specifies the duration of the ramp up time applied to the R...

Page 93: ...e pressure differential between the high side oil pressure transducer compressor bearing input and the low side oil pressure transducer oil sump The displayed value includes offset pressure derived from auto zeroing during the System Prelube If either of the transducers used to calculate this differential is out of range the display field will show XX X The offset pressure is the pressure differen...

Page 94: ... Position Variable Speed Drive and Hot Gas Option Only Access Level Required SERVICE This value displays the present position of the Pre rota tion Vanes as a percentage between 0 and 100 Full Load Amps Access Level Required SERVICE Displays the motor current as a percentage of the Full Load Amps FLA value Phase A B C Current Solid State Starter Only Access Level Required SERVICE Displays the 3 pha...

Page 95: ...n allowing calibration of the Pre rotation Vanes VSD Tuning Variable Speed Drive Only Access Level Required SERVICE Moves to the subscreen allowing advanced tuning of the Variable Speed Drive Hot Gas Access Level Required SERVICE Moves to a subscreen that allows programming of the Hot Gas Bypass control setpoints and manual control of the Hot Gas Bypass valve Only displayed if Hot Gas Bypass featu...

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Page 97: ...lay field will show XX X The offset pressure is the pressure differential between the high oil pressure HOP transducer and the low oil pressure LOP transducer outputs during a three 3 second period beginning ten 10 seconds into the System Prelube During this time the transducers will be sensing the same pressure and their outputs should indicate the same pressure However due to accuracy tolerances...

Page 98: ...anes Open LED Access Level Required SERVICE Indicates whether the vanes are in the process of opening Pre rotation Vanes Close LED Access Level Required SERVICE Indicates whether the vanes are in the process of closing Pre rotation Vanes Position Variable Speed Drive and Hot Gas Option Only Access Level Required SERVICE This value displays the present position of the Pre rota tion Vanes as a perce...

Page 99: ...ing calibration of the Pre rotation Vanes VSD Tuning Variable Speed Drive Only Access Level Required SERVICE Moves to the subscreen allowing advanced tuning of the Variable Speed Drive Hot Gas Access Level Required SERVICE Moves to a subscreen that allows programming of the Hot Gas Bypass control setpoints and manual control of the Hot Gas Bypass valve Only displayed if Hot Gas Bypass feature has ...

Page 100: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 60 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 101: ...he conclusion of a cali bration sequence Oil Pressure Displays the pressure differential between the high side oil pressure transducer compressor bearing input and the low side oil pressure transducer oil sump The displayed value includes offset pressure derived from auto zeroing during the System Prelube If either of the transducers used to calculate this differential is out of range the display ...

Page 102: ...ation Press this key to cancel calibration Accept Calibration Press this key to accept calibration Fault Acknowledge This option is only displayed if a fault is present Al lows clearing of High Speed Thrust Bearing related shutdowns NAVIGATION Home Access Level Required VIEW Returns user to HOME Screen Compressor Access Level Required VIEW Returns user to COMPRESSOR Screen ...

Page 103: ...n the valve is shown in its relative position The valve position is animated When the actual position is 0 to 19 the valve is shown fully closed When actual position is 20 to 39 the valve is shown 25 open When the actual position is 40 to 59 the valve is shown 50 open when actual is 60 to 79 the valve is shown as 75 open Positions greater than 79 are shown as full open Pre rotation Vanes Position ...

Page 104: ...hese messages Software versions C OPT 01 18 307 and earlier display OVERRIDE for any of these conditions For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Close Percentage 5 to 15 This is the incrementa...

Page 105: ...riable Speed Drive VSD Adaptive Capacity Control ACC Surge Detection The ACC Surge Detection creates a surge map used to control the speed of the drive If equipped with an ACC Board new production chillers prior to March 2007 the ACC Surge Detection is performed there If not equipped with an ACC Board new production chillers after March 2007 the ACC Surge Detection is performed in the Microboard R...

Page 106: ... Time Remaining Displays the time remaining in the 10 minute Extended Run period During this period the Pre rotation Vanes are driven closed and WARNING SURGE PROTEC TION EXCESS SURGE LIMIT is displayed Refer to operation under Count Limit on Page 67 For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for opera...

Page 107: ...ng the message WARNING EXCESS SURGE DETECTED Refer to Hot Gas Bypass and Variable Speed Drive exceptions See Shut down Enabled Disabled on Page 66 and Ex tended Run Enabled Disabled on Page 66 If the Shutdown Setpoint is Enabled and the Extend ed Run Setpoint is Disabled the chiller will perform a safety shutdown and display Surge Protection Excess Surge Refer to Hot Gas Bypass and Variable Speed ...

Page 108: ...ATE 9 10 2014 JOHNSON CONTROLS 68 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION NAVIGATION Home Access Level Required VIEW Returns user to HOME Screen Compressor Access Level Required VIEW Returns user to COMPRESSOR Screen ...

Page 109: ... the VGD is in the fully closed position Otherwise displayed as OPEN Diffuser Gap Close LED Illuminates when a close signal is being applied to the VGD Diffuser Gap Open LED Illuminates when an open signal is being applied to the VGD Surge Avoidance Surge Detected LED Software version C OPT 01 23 307 and later Illuminates momentarily when a surge is detected by the Surge Protection feature If equi...

Page 110: ...Reacting Probing Surge Reacting Surge Waiting Hot Gas Override Time Remaining While the VGD is in the Stall Waiting State displays the time remaining in the Probe Wait Time interval value programmed as the Probe Wait Time setpoint Diffuser Gap Control Mode Indicates whether the VGD is under manual or auto matic control PROGRAMMABLE VGD Open Manual This key puts the VGD in manual mode and sends an ...

Page 111: ... per formed by Service Technician VGD Closed Limit Switch Software version C OPT 01 23 307 and later Displays the status of the VGD Limit Switch Dis played as CLOSED when the switch is closed This would be when the VGD is in the fully closed position Otherwise displayed as OPEN Diffuser Gap Close LED Illuminates when a close signal is being applied to the VGD Diffuser Gap Open LED Illuminates when...

Page 112: ...pen Pulse 1 to 9 seconds default 2 Specifies the length of the open pulse applied to the VGD during 10 second peri ods while in the Probing state High Limit 0 5 to 1 2VDC default 0 6VDC 0 8VDC with soft ware version C OPT 01 22 307 or earlier Specifies the Stall Detector Board output voltage that represents an acceptable amount of stall noise The minimum difference between the High Limit Setpoint ...

Page 113: ...INTRODUCTION JOHNSON CONTROLS 73 FORM 160 54 O1 ISSUE DATE 9 10 2014 2 NAVIGATION Home Access Level Required SERVICE Returns user to HOME Screen VGD Screen Access Level Required SERVICE Returns user to VARIABLE GEOMETRY DIFFUSER Screen ...

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Page 115: ...ages These are text messages which step the user through the calibration process and indicate its success or failure Pre rotation Vanes Voltage Software version C OPT 01 23 307 and later Displays the Pre rotation Vanes position potentiom eter feedback voltage when the PRV potentiometer is connected directly to the 031 02430 Microboard This applies to those chillers equipped with Variable Geom etry...

Page 116: ...OGRAMMABLE Start Calibration This option is hidden after calibration has started Cancel Calibration This option only becomes available after calibration has started NAVIGATION Home Access Level Required VIEW Returns user to HOME Screen Compressor Access Level Required VIEW Returns user to COMPRESSOR Screen ...

Page 117: ...requency Displays the frequency at which the drive is operating the motor This value is returned from the drive Pre rotation Vanes Position Displays the present Pre rotation Vane position as a value between 0 closed and 100 full open Delta P P Displays the chiller head pressure calculated as condens er pressure evaporator pressure evaporator pressure Temperature Differential LCHLT Setpoint Display...

Page 118: ...tware version the ISN through serial communications can no longer change this setpoint Fixed Puts the drive frequency control in fixed speed mode commanding it to run at maximum frequency 50Hz or 60Hz Raise Puts the drive frequency control into manual mode Each time it is pressed it increases the Command Frequency to the drive by the amount defined by the MANUAL INCREMENT key It will not raise the...

Page 119: ... Page 53 If either of the transducers used to calculate this differential is out of range the display field will show XX X Oil Sump Temperature Displays the temperature of the oil in the sump Oil Saturated Condenser Temperature Differential Software version C OPT 01 21 307 and later Variable Speed Oil Pump Only Displays the difference between the Oil Sump Temper ature and the Saturated Condenser T...

Page 120: ... requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Standby Lube Enabled Disabled Access Level Required SERVICE Allows the user to enable or disable the standby lube operation When enabled this function causes the ...

Page 121: ...ICE This key allows the user to specify a fixed manual speed at which the VSOP will run Raise Access Level Required SERVICE This key puts the VSOP control into manual mode and increments the present speed command by 0 5Hz Lower Access Level Required SERVICE This key puts the VSOP control into manual mode and decrements the present speed command by 0 5Hz Auto Access Level Required SERVICE This key ...

Page 122: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 82 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 123: ... nonzero For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Local Motor Current Limit Access Level Required OPERATOR Allows the user to specify the maximum allowed mo tor current as a percentage of FLA W...

Page 124: ...evel Required VIEW Returns user to HOME Screen Motor Lube Software version C MLM 01 14 xxx and later or C OPT 01 14 306 and later Access Level Required VIEW Moves to the subscreen allowing operator acknowledge ment of the compressor motor lubrication and viewing of the compressor motor lubrication parameters Motor Details Software version C OPT 01 22 307 and later Access Level Required SERVICE Mov...

Page 125: ...ogrammed value Pulldown Demand Time Left Displays the time remaining in the programmed pulldown period if the value is nonzero Scale Model Display information about the Liquid Cooled Solid State Starter Rating and the maximum allowed Full Load Amps Voltage Phase A B C Display the 3 phase input line voltage values being read from the Solid State Starter Current Phase A B C Display the 3 phase motor...

Page 126: ...the maximum amps at which the motor can op erate This value is viewable when logged in under the OPERATOR or VIEW access level Supply Voltage Range Access Level Required SERVICE Allows the user to select a specific voltage range for voltage checking When not disabled this line voltage range is used to determine a low line and high line volt age threshold for initiating a shutdown Current Unbalance...

Page 127: ...Link Gateway interface in ISN Remote mode or a locally programmed value in Local mode Pulldown Demand Time Left Displays the time remaining in the programmed pulldown period Input Power Displays the kilowatts measured by the Solid State Starter KW Hours Displays the cumulative amount of kilowatts used over time Starter Model Displays the Solid State Starter model that is applied to the chiller Sta...

Page 128: ...in at OPERATOR or VIEW access level Voltage Range Access Level Required SERVICE Allows the user to select specific line voltage range for voltage checking When not disabled this line voltage range is used to determine a low line and high line volt age threshold for initiating a shutdown Starting Current Access Level Required SERVICE Defines the maximum allowed motor starting amps The Solid State S...

Page 129: ... Digital Remote mode E Link Gateway interface in ISN Remote mode or a locally programmed value in Local mode Pulldown Time Left Displays the time remaining in the programmed pulldown period Input Power Displays the kilowatts measured by and transmitted from the starter KW Hours Displays the cumulative kilowatt hours The mi croboard calculates this value from the Input Power transmitted from the st...

Page 130: ...Current Limit Setpoint during this time period The Pre rotation Vanes are used to limit the motor current to this value Pulldown Demand Time Access Level Required OPERATOR Allows the user to set the period of time for which the pulldown demand limit will be in effect Full Load Amps Access Level Required SERVICE Defines the maximum amps at which the motor can operate This value is viewable when log...

Page 131: ... in Digital Remote mode E Link Gateway interface in ISN mode or a locally programmed value Pulldown Demand Time Left Displays the time remaining in the programmed pulldown period if the value is nonzero Output Voltage Displays the output voltage measured to the motor Output Frequency Displays the present output frequency to the motor Output Current Phase A B C Displays the phase current measured t...

Page 132: ...down limit time This value will override the Motor Current Limit value during this time period This function is used to provide energy savings following chiller start up Pulldown Demand Time Access Level Required OPERATOR Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chiller starts kWH Reset Access Level Required ADMIN Allows the user to re...

Page 133: ... 10VDC or 2 to 10VDC input in Analog Remote mode PWM signal in Digital Remote mode E Link Gateway interface in ISN mode or a locally programmed value Pulldown Demand Time Left Displays the time remaining in the programmed pulldown period if the value is not zero Output Voltage Displays the output voltage to the motor Value is pro vided by the MV VSD Output Frequency Displays the present output fre...

Page 134: ... defined in the lookup table the model num ber is displayed as INVALID and the chiller will not be allowed to run while this is displayed Table 2 VOLTAGE V MOTOR RATED VOLTAGE V 2300 V 3300 V 4160 V Model in HP 500 107 A 78 A 62 A 600 129 A 93 A 74 A 700 157 A 110 A 87 A 800 172 A 124 A 99 A 900 202 A 141 A 112 A 1000 224 A 156 A 125 A 1250 280 A 195 A 155 A 1500 336 A 235 A 186 A 1750 392 A 274 A...

Page 135: ...and Time Access Level Required OPERATOR Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chiller starts Full Load Amps Access Level Required SERVICE Defines the maximum amps at which the motor can operate this value is viewable when logged in at VIEW or OPERATOR level With software version C OPT 01 20 307 and later the maximum program mable va...

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Page 137: ...le Speed Drive this is the data returned by the VSD Logic Board Current Limit Setpoint Displays the current limit value in use This value could come from a 0 to 20mA 4 to 20mA 0 to 10VDC or 2 to 10VDC input in Analog Remote mode PWM signal in Digital Remote mode E Link Gateway interface in ISN mode or a locally programmed value Pulldown Demand Time Left Displays the time remaining in the programme...

Page 138: ...w Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Local Motor Current Limit Access Level Required OPERATOR Allows the user to specify the maximum allowed mo tor current as a percentage of FLA When the motor current reaches this value the Pre rotation Vanes will not be permitted to open f...

Page 139: ...output from the controls is commanding the motor to RUN Motor Current Full Load Amps Displays the motor current as a percentage of the Full Load Amps FLA value For the Variable Speed Drive this is the data returned by the VSD Logic Board Current Limit Setpoint Displays the current limit value in use This value could come from a 0 to 20mA 4 to 20mA 0 to 10VDC or 2 to 10VDC input in Analog Remote mo...

Page 140: ...operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Local Motor Current Limit Access Level Required OPERATOR Allows the user to specify the maximum allowed mo tor current as a percentage of FLA When the motor current reaches this value the Pre rotation Vanes will not be permitted to open further If the motor current rises above this value the Pre...

Page 141: ...nt Displays the current limit value in use This value could come from a 0 to 20mA 4 to 20mA 0 to 10VDC or 2 to 10VDC input in Analog Remote mode PWM signal in Digital Remote mode E Link Gateway interface in ISN mode or a locally programmed value Pulldown Demand Time Left Displays the time remaining in the programmed pulldown period if the value is nonzero VSD Output Frequency Displays the frequenc...

Page 142: ...n effect after the chiller starts Surge Sensitivity Allows the user to define the surge detection sensitivity of the ACC Surge Detection Surge Margin Adjust When the ACC maps a surge point it will begin to adjust the chiller Command Frequency and vane con trols at a certain Margin from the mapped point This programmable value allows the Service Technician to modify the Margin at which these adjust...

Page 143: ... Control Center Service Instructions Form 160 54 M1 for operation instruc tions and explanation of all programmable setpoints and displayed values DISPLAY ONLY Full Load Amps Displays the motor current as a percentage of chiller Full Load Amps as calculated by the microboard from current values returned from the drive Logic Board Current Limit Setpoint Displays the current limit setpoint value in ...

Page 144: ...ammable setpoints and displayed values PROGRAMMABLE Surge Margin Adjust This value determines how close the frequency reduc tion will be allowed to get to the surge line It is sent to the ACC Board Programmable over the range of 0 0 default to 25 0Hz Service Technicians should refer to Variable Speed Drive Service Instructions Form 160 00 M4 prior to adjusting this setpoint Auto Map Print Enable D...

Page 145: ...earlier production chillers could be in the MODBUS configuration All Medium Voltage Variable Speed Drives MV VSD use MODBUS protocol Requires a login access level of SERVICE Service Technicians refer to the OptiView Control Center Service Instructions Form 160 54 M1 for operation instruc tions and explanation of all programmable setpoints and displayed values DISPLAY ONLY Full Load Amps Displays t...

Page 146: ...oard while the drive is running at less than maximum frequency Surge Avoidance Surge Detected LED Illuminates momentarily when a surge is detected by the Surge Protection feature This feature only detects surges that occur while the drive is running at maxi mum frequency ACC Surge Count Increments when a surge is detected while the drive is running at less than maximum frequency Surge Map Point Co...

Page 147: ...this manual Manual Surge Point Allows the Service Technician to manually log the present running operating conditions into the surge map as a valid surge point When this key is pressed a dialog box appears requesting a special password to proceed Surge Map Print Allows the Service Technician to print the entire surge map to a connected printer as shown in SECTION 4 PRINTING of this manual Surge Ma...

Page 148: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 108 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 149: ...t the will be replaced by an O This screen is applicable to Variable Speed Drives VSD with the Motor Communications Protocol Setpoint set to MODBUS ACC Board is not pres ent and Medium Voltage Variable Speed Drives MV VSD It is not accessible if equipped with a VSD in YORK Motor Communications Protocol Setpoint con figuration ACC Board is present Requires a login access level of SERVICE Service Te...

Page 150: ... Delta P P For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Map View Allows a Service Technician to change the view from table to list Manual Surge Point Allows the Service Technician to manually log t...

Page 151: ...ns Protocol Setpoint set to MODBUS ACC Board is not pres ent and Medium Voltage Variable Speed Drives MV VSD It is not accessible if equipped with a VSD in YORK Motor Communications Protocol Setpoint con figuration ACC Board is present Requires a login access level of SERVICE Service Technicians refer to the OptiView Control Center Service Instructions Form 160 54 M1 for operation instruc tions an...

Page 152: ...O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 112 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION NAVIGATION Home Returns user to HOME Screen VSD Returns user to VSD Screen ACC Details Returns user to ACC DETAILS Screen ...

Page 153: ... to 20mA 4 to 20mA 0 to 10VDC or 2 to 10VDC input in Analog Remote mode PWM signal in Digital Remote mode E Link Gateway interface in ISN mode or a locally programmed value Pulldown Demand Time Left Displays the time remaining in the programmed pulldown period if the value is nonzero Operating Mode Run Stop Indicates whether the Harmonic Filter is operating VSD Model Access Level Required SERVICE ...

Page 154: ...splays the 3 phase RMS Voltages across each line For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Local Motor Current Limit Access Level Required OPERATOR Allows the user to specify the maximum allowed...

Page 155: ... this manual for de tails of these messages To provide a record of when a motor lubrication is per formed the Operator enters his her initials name or user ID using the MOTOR LUBE ACKNOWLEDGE key The date and time of this entry is automatically logged as the Date of Last Lubrication and Time of Last Lubrication This also clears any motor lubrica tion warning or safety that is in effect and resets ...

Page 156: ...he entry must be a minimum of 3 charac ters and a maximum of 8 characters 1 At the keypad log in at OPERATOR access lev el using password 9 6 7 5 If resetting the safety shutdown Motor Lack Of Lubrication place Compressor Switch in Stop Reset O position 2 Press the MOTOR LUBE ACKNOWLEDGE key on the MOTOR LUBRICATION Screen A dialog box appears A red box highlights the first change able location 3 ...

Page 157: ...s used to enable or disable the safe ty shutdown that occurs at 1400 operating hours since last lubrication The safety shutdown can be enabled or disabled per the customer s preference If enabled the safety shutdown will occur at the normal 1400 hours If disabled a warning will be displayed but the safety shutdown will not occur NAVIGATION Home Access Level Required VIEW Returns user to HOME Scree...

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Page 159: ...routine that plots a baseline over a 1 hour period while the chiller is running This screen also serves as a gateway to a subscreen that allows programming of the winding High Tempera ture Warning Safety Shutdown thresholds and bearing High Temperature and High Vibration Warning Safety Shutdowns Also individual winding temperature sen sors can be disabled on this screen DISPLAY ONLY Motor Run LED ...

Page 160: ...ed invalid and displays as XXX X When the Bearing Temperature Protection Setpoint is set to Disable no temperatures are dis played and the heading text and data boxes do not ap pear Vibration Displays the Shaft End and Opposite End vibration val ues The vibration values are not in any particular units of measure They are relative values The larger the number the greater the magnitude of vibration ...

Page 161: ...ing RTD s via the Motor Monitoring Board serial communications TRANSMITTER Enables and displays the 3 Motor Winding Temperatures as reported by the winding transmitters via the Motor Monitoring Board serial communications VSD TRANSMITTER Enables and displays the 3 Motor Winding Temperatures as reported by the winding transmitters via the VSD Logic Board serial communications Bearing Temperature Pr...

Page 162: ... serial communications FLOAT Enables the float sensor digital input and displays the leak status as reported by the float leak sensor via the Motor Monitoring Board se rial communications Manual Baseline Motor Bearing Vibration Access Level Required SERVICE Used to manually enter a vibration baseline value 0 1 to 5 default 2 for the Shaft End and Opposite Shaft End bearings The vibration values ar...

Page 163: ...WINDING SETUP Setpoint key Not shown when Winding Tem perature Protection Setpoint on the MOTOR DETAILS Screen is set to Disabled Winding Hotspot Allowance Displays the Winding Hotspot Allowance temperature Not shown when Winding Temperature Protection Setpoint on the MOTOR DETAILS Screen is set to Disabled Motor Bearings High Vibration Shutdown Displays the High Vibration safety shutdown threshol...

Page 164: ...ta box reflects enabled or disabled status This could be applied to de fective sensors or for service reasons When a sensor is disabled the respective temperature data box does not appear on the MOTOR DETAILS Screen Winding Setup Access Level Required SERVICE Not shown when Winding Temperature Protection Setpoint on MOTOR DETAILS Screen is set to Dis abled Allows a Service Technician to program th...

Page 165: ...tion Baseline X3 Opposite Shaft End High Vibration Shutdown Default Opposite Shaft End Vibration Baseline X3 If no baseline values are entered by either the auto baseline routine or manual entry the message WARN ING MOTOR BEARING VIBRATION BASE LINE NOT SET is displayed and the baseline values are set to X X while this message is displayed When the Motor Vibration Protection Setpoint is set to Dis...

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Page 167: ... is calculated by subtract ing the Leaving Chilled Liquid Temperature Cycling Offset Shutdown from the Leaving Chilled Liquid Temperature Setpoint If this value is below the abso lute minimum allowed shutdown temperature the mini mum value is displayed Leaving Chilled Liquid Temperature Cycling Restart Displays the Leaving Chilled Liquid Temperature at which the chiller will restart after it has s...

Page 168: ...s case the incoming setpoint is not an offset that is ap plied to the locally programmed BASE Setpoint value but rather is the setpoint value itself Leaving Chilled Liquid Temperature Cycling Offset Shutdown Access Level Required OPERATOR This value allows the user to specify the Leaving Chilled Liquid Temperature at which the chiller will shut down on a LEAVING CHILLED LIQUID LOW TEMPERATURE cycl...

Page 169: ...s value will override the Motor Current Limit value during this time period This function is used to provide energy savings following chiller start up Pulldown Demand Time Access Level Required OPERATOR Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chiller starts Print Access Level Required VIEW Generates setpoints print report NAVIGATION H...

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Page 171: ...n also serves as a gateway to more subscreens for defining general system parameters DISPLAY ONLY 031 01730 000 Microboard Chilled Liquid Pump Operation Displays Standard or Enhanced Motor Type Displays Fixed Speed or Variable Speed Refrigerant Selection Displays R 22 or R134a Anti Recycle Displays Disabled or Enabled Power Failure Restart Displays Manual or Automatic Liquid Type Displays Water or...

Page 172: ...be disabled 12 24 Hr Access Level Required OPERATOR Allows the user to specify the format in which the time will be presented to the user This setpoint will affect the display of the time on the chiller panel and on all reports generated 12 hour time format will include the AM and PM modifiers and show the range of time be tween 1 00 and 12 59 while the 24 hour time format will show the range of t...

Page 173: ...oint above Allows the Service Technician to enter the Modbus Address of the VSD Logic Board or Style B LCSSS Logic Trigger Board The Motor Node ID Setpoint must be set to 1 to match the address assigned to the VSD Logic Board or Style B LCSSS Logic Trigger Board This setpoint and entry instructions are described in detail in Sec tions Microboard 031 02430 000 and 031 02430 001 and LTC I O Board of...

Page 174: ...roboard J7 If not equipped with Hot Gas Bypass but equipped with a VGD it is connected to the Microboard J7 Disabled Set to this position when not equipped with a PRV potentiometer If equipped with a VSD MVVSD or the Hot Gas Bypass or Variable Ge ometry Diffuser is enabled this setpoint is auto matically enabled and cannot be set to disabled Motor Monitoring Software version C OPT 01 22 307 and la...

Page 175: ...ca pability while operating Comms Access Level Required VIEW Moves to the subscreen allowing configuration of sys tem communications Printer Access Level Required VIEW Moves to the subscreen allowing configuration and control of printer functions Sales Order Access Level Required VIEW Moves to the subscreen displaying the Sales Order in formation for the chiller system Operations Access Level Requ...

Page 176: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 136 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 177: ...ike a normal start however the vanes will begin to open at the beginning of prelube instead of waiting until Sys tem Run At the completion of prelube the VSD is started and after the VSD achieves its Start Fre quency the speed ramp rate is faster than with normal control In order to use this feature the chiller must be equipped with a Variable Speed Drive in Modbus Protocol Con figuration or a Med...

Page 178: ...n at SER VICE access level However once Disabled it re quires an ADMIN password to enable it again as ex plained above Quick Start mode will be automatically disabled when any of the following occur The Motor Drive Type is changed to something other than VSD or MVVSD or the Motor Communications Protocol is changed to YORK or the Heat Pump Duty if enabled Operational Setpoint is set to Heating mode...

Page 179: ...rammed on either the ACC Screen or the QUICK START Screen It sets the Delta T needed to be met to enable surge mapping and speed reduction initially on startup Quick Ramp Current Threshold Access Level Required SERVICE 20 to 80 FLA default 50 This setpoint sets the motor current threshold where the VSD speed com mand ramp rate changes At or below this threshold the speed command ramp is 4X of stan...

Page 180: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 140 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 181: ...he Start time of Day 2 can be set to 12 00 AM The chiller will not stop but continue to operate until the stop of Day 2 The user has the ability to define a standard set of Start Stop times which are utilized every week The user may then specify exception Start Stop combinations for any day of the week up to 6 weeks in advance At the end of each week the schedule for the next week is created by co...

Page 182: ...quired OPERATOR Allows the user to enable or disable the monitoring function which enforces the scheduled starting and stopping of the chiller Repeat Sunday Schedule Access Level Required OPERATOR Duplicates the schedule defined for Sunday for the re mainder of the standard weekdays Reset All Exception Days Access Level Required OPERATOR Deletes all programming for exception days within the next 6...

Page 183: ...ervice Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE System Language Access Level Required OPERATOR Allows the user to define the language for all Screens The desired language is selected by scrolling through the list of those available English is the Default language and is selected by pressing the key when...

Page 184: ...cify up to four 4 custom password values Each password will then require a corresponding User ID and user level Custom User Access Level 4 Access Level Required SERVICE This allows the user to specify up to four 4 custom UserAccess Levels Each access level will then require a corresponding password and User ID Date Format Software version C OPT 01 23 307 and later Access Level Required OPERATOR Th...

Page 185: ...xplanation of all pro grammable setpoints and displayed values PROGRAMMABLE Chiller ID Access Level Required OPERATOR Define the numeric chiller ID when used within an ISN network of chillers This ID number is also printed at the top of reports obtained with a local printer Printer Setup and COM 2 Setup Access Level Required OPERATOR Pressing either key places a green selection box around the firs...

Page 186: ...all communicate to the printer COM 2 Baud Rate Define the baud rate at which the panel shall communi cate through the modem port COM 2 Data Bit s Define the number of data bits with which the panel shall communicate to the modem port COM 2 Parity Bit s Define the number of parity bits with which the panel shall communicate through the modem port COM 2 Stop Bit s Define the number of stop bits with...

Page 187: ...ccess Level Required OPERATOR Set the time at which scheduled print logs will begin Output Interval Access Level Required OPERATOR Define the interval at which log printing will occur Automatic Printer Logging Enabled Disabled Access Level Required OPERATOR Enable the printer to begin printing status reports be ginning at the programmed start time and recurring at the interval defined above Printe...

Page 188: ...type to print when the PRINT RE PORT key is selected This can vary from status report present system parameters Setpoints report present value of the system setpoints Schedule report present value of the system schedule times or a Sales Order Data report information provided on the SALES OR DER Screen A print report is generated upon comple tion of selection Print All Histories Access Level Requir...

Page 189: ...the micropanel Chiller Serial Number Factory defined serial number for the chiller system YORK Order Number Factory defined order number under which the chiller was sold System Information Factory defined conditions for which the chiller was originally rated and sold Condenser and Evaporator Design Load Information Factory defined description of the condenser and evap orator configuration at time ...

Page 190: ...Location Access Level Required SERVICE Factory defined job name and location the chiller is destined for Print Access Level Required VIEW This generates a listing of the Sales Order data NAVIGATION Home Access Level Required VIEW Returns user to HOME Screen Setup Access Level Required VIEW Returns user to SETUP Screen ...

Page 191: ...54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Control Source Access Level Required OPERATOR Define whether the control of the chiller will be Lo cal Digital Remote Analog Remote Modem Remote or ISN Remote Number of Starts Access Level Required ADMIN Displays the number of the starts the chiller has initi ated This may be reprogram...

Page 192: ...ired SERVICE Enables and disables the Variable Geometry Diffuser feature If equipped with this feature it should be en abled Otherwise it should be disabled Chiller Style Compressor Flash Memory Card version C MLM 01 07 xxx and later Access Level Required SERVICE Used to enter the chiller style compressor combination Once the applicable chiller style compressor combina tion is entered the program ...

Page 193: ... de scription of the last normal shutdown A normal shut down is defined as Local Panel rocker switch Remote Digital Analog or ISN Last Fault While Running This window displays the date and time and the de scription of the last safety or cycling shutdown while the system was running Last Ten Faults This window displays a chronological listing most recent first of the date and time and the descripti...

Page 194: ...ining the value of select chiller parameters at the time of the associated shutdown Trending Access Level Required VIEW Causes a move to a subscreen allowing the user to view trending data on selected chiller parameters Custom View Flash Memory Card version C MLM 01 04 or later Access Level Required VIEW Causes a move to a subscreen allowing the user to view the CUSTOM SETUP Screen Security Log Fl...

Page 195: ...ICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Page Up Access Level Required VIEW Scroll up in the displayed data if applicable Page Down Access Level Required VIEW Scroll down in the displayed data if applicable Print History Access Level R...

Page 196: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 156 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 197: ... of the change access level and User ID used to make the change the old setpoint value and the new setpoint value Requires a login access level of SERVICE Service Technicians refer to the OptiView Control Center Service Instructions Form 160 54 M1 for operation instruc tions and explanation of all programmable setpoints and displayed values DISPLAY ONLY Category Displays the category of the setpoi...

Page 198: ...in the displayed data if applicable NAVIGATION Home Access Level Required SERVICE Returns user to HOME Screen History Access Level Required SERVICE Returns user to HISTORY Screen View Details Access Level Required SERVICE Causes a move to a subscreen containing the details of the setpoint change selected with the LOG ENTRY key ...

Page 199: ...ans refer to the OptiView Control Center Service Instructions Form 160 54 M1 for operation instruc tions and explanation of all programmable setpoints and displayed values DISPLAY ONLY Description Displays the setpoint category that was changed Time Displays the time the setpoint was changed Date Displays the date the setpoint was changed Access Level Displays the login Access Level used to make t...

Page 200: ... 10 2014 JOHNSON CONTROLS 160 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION NAVIGATION Home Access Level Required SERVICE Returns user to HOME Screen Security Log Access Level Required SERVICE Returns user to SECURITY LOG Screen ...

Page 201: ...here for monitoring by operations personnel DISPLAY ONLY None For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Print Access Level Required VIEW This generates a listing of the parameters displayed on t...

Page 202: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 162 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 203: ...age Down Scroll down through list of available parameters Select First use the PAGE UPand PAGE DOWN keys to scroll through the Slot Numbers list and note the number of the parameter s to be displayed Pressing the SELECT key places a green colored selection box around Cus tom Slot 1 If it is desired to change an already entered parameter use the 5 and 6 keys to place the selection box around the Sl...

Page 204: ... 9 10 2014 JOHNSON CONTROLS 164 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION NAVIGATION Home Access Level Required VIEW Returns user to HOME Screen Custom View Access Level Required SERVICE Returns user to CUSTOM VIEW Screen ...

Page 205: ... Points simultane ously or select a single Data Point for display The parameters are sampled at the selected Data Col lection Interval and plotted using 450 data points across the X Axis If the actual value of the sampled param eter is less than the Y Axis label minimum for that parameter the value will be plotted at the minimum value Similarly if the actual value is greater than the Y Axis label ...

Page 206: ...g this key stops the trending The trend data is frozen on the display until another graph is started with the START key The STOP key is only available if trending is running Print Flash Memory Card version C MLM 01 05 xxx and later Access Level Required VIEW Allows the data on the TREND Screen to be printed in tabular format If set to existing a snapshot of the data presently on the screen is sent...

Page 207: ...ccess Level Required OPERATOR Selects Continuous One Screen Or Triggered If com pressor application is other than P applies only to Flash Memory Card version C MLM 01 05 xxx and later type of graph Collection Interval Access Level Required OPERATOR Selects the interval at which the parameters are sam pled There are 450 data points displayed across the X Axis of the graph Each point represents the ...

Page 208: ...ter being monitored To change use the SELECT key as described above and enter the desired value The value must always be set to a value less than the Data Point Max Otherwise a red graph is displayed on the TREND Screen with the words TREND MAX MUST BE TREND MIN If the parameter selected for this data point is a digital type on off this value must be set to zero 0 Zero indicates the OFF state Data...

Page 209: ...he Primary Operator as a comparator If it is evaluated as true then the data collection is started or stopped after any selected trigger delay per the selected Trigger Ac tion A Secondary Trigger can be evaluated with the Prima ry Trigger to start stop data collection The Primary to Secondary Operator is used to define the trigger com binations required to be true to start stop data collec tion Th...

Page 210: ...s Display is in days hours minutes and seconds The delay timer begins when the triggers evaluate as true If the Trigger Action is set to Start data collection will begin after the triggers evaluate as true and the delay timer has elapsed If the Trigger Action is set to Stop data col lection will stop after the triggers evaluate as true and the delay timer has elapsed Primary to Secondary Operator ...

Page 211: ... are the Slot Numbers of the most commonly used parameters For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Page Down Access Level Required OPERATOR Scroll down in the displayed data Page Up Access Lev...

Page 212: ...1285 Pre Rotation Vanes Control Mode 1296 Discharge Temperature 1536 Oil Differential Pressure 1537 Oil Sump Temperature SLOT NUMBER DESCRIPTION 1538 Oil Pump Control Mode 1539 Oil Pump Is Pump On 1540 Oil Pump Manual Time Left 1541 Oil Heater Is Control Enabled 1542 Oil Heater Is Heater On 1543 Oil Return Solenoid Is Solenoid On 1792 Leaving Chilled Liquid Temperature 1793 Leaving Chilled Liquid ...

Page 213: ...rrent Unbalance Check Enabled Mod B Solid State Starters 2570 LcSss Input Power 2571 LcSss Kilowatt Hours 2572 LcSss Phase A Current 2573 LcSss Phase B Current 2574 LcSss Phase C Current SLOT NUMBER DESCRIPTION 2575 LcSss Phase A Voltage 2576 LcSss Phase B Voltage 2577 LcSss Phase C Voltage 2578 LcSss Phase A Temperature 2579 LcSss Phase B Temperature 2580 LcSss Phase C Temperature 2581 LcSss Star...

Page 214: ...nd Distortion 2890 Filter Maximum Total Harmonic Distortion 2891 Filter Maximum Total Demand Distortion 8192 Oil Pump Pressure 8193 Oil Sump Pressure 8194 Oil Seal Lube Is Control Enabled 8195 Oil Seal Lube Time To Next Lube SLOT NUMBER DESCRIPTION 8196 Oil Seal Lube Time Left 8197 VSOP Speed Command 8198 VSOP Control Mode 8199 VSOP Manual Command Frequency 8200 VSOP Is Pulldown In Effect 8201 VSO...

Page 215: ...s the Compressor Switch to the Stop Reset O position System Prelube A chiller start has been initiated and the pre start lu brication is being performed The prelube duration is either 50 seconds or 180 seconds as configured with a Microboard Program Switch The prelube duration must never be changed by anyone other than a quali fied Service Technician The standard prelube duration is 50 seconds Sys...

Page 216: ...uty is enabled and the Heat Pump Duty Operational mode setpoint is set to Cooling mode Heat Pump Leaving Condenser Liquid Control Software version C OPT 01 23 307 and later The Heat Pump is running controlling the Leaving Condenser Liquid Temperature to the Leaving Con denser Liquid Temperature Setpoint In this mode Heat Pump Duty is enabled and the Heat Pump Duty Operational mode setpoint is set ...

Page 217: ...hibit is set VSD Frequency 0Hz Software version C MLM 01 14 xxx and later or C OPT 01 14 306 and later This start inhibit is set whenever the chiller is shut down and a Compressor Motor Variable Speed Drive VSD Output Frequency of greater than 0Hz is detect ed This fault is released and the chiller can be start ed after the frequency is at 0Hz and the Compressor Switch is placed in the Stop Reset ...

Page 218: ...tion Vanes are inhibited from further opening This message automatically clears and the Vanes are permitted to open when the condenser pressure decreases to 5 PSIG below the Setpoint Warning Evaporator Low Pressure Limit The Evaporator Pressure has decreased to the Warn ing threshold This threshold is fixed in Water cooling applications In Brine cooling applications the thresh old is a fixed amoun...

Page 219: ... returns normal operation Warning Loss of Subcooler Liquid Seal Software version C OPT 01 25C 308 and later This Warning is displayed if the chiller has been run ning for 30 minutes or more and the Drop Leg Tem perature is less than the Return Condenser Liquid Temperature continuously for two minutes Setting the Drop Leg Sensor installed to Disabled will prevent this warning from being displayed W...

Page 220: ...uto Lube Setpoint on the MOTOR LUBRICATION Screen enabled Warning Motor Bearing Lube Required Software version C MLM 01 14 xxx and later or C OPT 01 14 306 and later The Operating Hours Since Last Motor Lubrication has exceeded 1200 hours This replaces WARNING MO TOR BEARING LUBE SUGGESTED above This is displayed until manually cleared by the Operator or the Operating Hours Since Last Motor Lubric...

Page 221: ...anes are driven fully closed prior to shutting down the chiller Local Stop A local shutdown command has been received by plac ing the Keypad Start Run Stop Reset switch in the Stop O position Place Compressor Switch In Run Position The Control Center is in either Digital or ISN Remote mode The Operator is requested to place the Compres sor Switch in the RUN position The Control Center will not acc...

Page 222: ...ammed Leaving Condenser Liquid Temperature Cycling Offset Shutdown Setpoint This shutdown is only applicable to Heat Pump Duty en abled and operating in Heating mode Heat Pump Op erational Setpoint set to Heating mode Refer to HEAT PUMP Screen Anytime the Leaving Condenser Liq uid Temperature Setpoint is decreased the shutdown threshold becomes 125 F for the next 10 minutes Af ter 10 minutes have ...

Page 223: ...c onds to initiate the shutdown and produce this message An LED on the respective device illuminates to iden tify the specific fault that has occurred Refer to Solid State Starter Mod A Operation and Maintenance Form 160 46 OM3 1 for details of Solid State Starter initiated shutdowns and OptiView Control Center Service Instructions Form 160 54 M1 for CM 2 initi ated shutdowns The chiller will auto...

Page 224: ...h the same message if the Liquid Cooled Solid State Starter does not receive a response from the Control Center after 10 consecutive attempts to communicate with the Control Center after Initialization has been successfully com pleted The Control Center attempts to establish com munications until successful LCSSS Shutdown Requesting Fault Data The Liquid Cooled State Starter Logic Trigger Board ha...

Page 225: ...aly such as sag or jitter A power line frequency jitter of up to 3Hz second can be tolerated The chiller will automatically restart when lock has resumed LCSSS Low Supply Line Voltage The Liquid Cooled Solid State Starter Logic Trigger Board has detected that the compressor motor AC Power Line Voltage in any phase decreased below the low line voltage threshold continuously for 20 seconds The chill...

Page 226: ... seconds this message is typically displayed for a few seconds and then replaced with one of the below listed fault messages VSD Stop Contacts Open Refer to VSD Shutdown Requesting Fault Data on Page 186 If the Control Center s Microboard does not receive the cause of the fault over the Serial Link within 20 seconds it is assumed it is not forthcoming and that message is replaced with VSD STOP CON...

Page 227: ... is gated on If the voltage across the IGBT is greater than a set threshold the IGBT is gated off and a shutdown pulse is sent to the VSD Logic Board shutting down the entire VSD system Agate driver fault can be initiated when the VSD is not running VSD Phase B Gate Driver See Phase A Gate Driver message above VSD Phase C Gate Driver See Phase A Gate Driver message above VSD Single Phase Input Pow...

Page 228: ...are internal VSD fan failure VSD water pump failure or an entering condenser water temperature that ex ceeds the allowable limit for the job Additional causes for the shutdown are Plugged Strainer The standard 1 5 Y strainer contains a woven mesh element with 20 stainless steel wires per inch This has been found to work adequately on most applications Some users may have very dirty condenser water...

Page 229: ...charge relay is energized If this condition is not met a shutdown is per formed and this message is generated VSD Precharge Low DC Bus Voltage 575V 60Hz applications Software version C OPT 01 15 xxx or later If the DC Link Voltage does not reach at least 60VDC within 4 seconds or at least 600VDC within 20 sec onds after the precharge command has been received this shutdown is performed VSD Low Inv...

Page 230: ...vice Harmonic Filter High Phase B Current See Harmonic Filter High Phase A Current message above Harmonic Filter High Phase C Current See Harmonic Filter High Phase A Current message above Harmonic Filter Phase Locked Loop This shutdown indicates that a circuit called Phase Locked Loop on the Filter Logic Board has lost syn chronization with the incoming power line This is usually indicative of an...

Page 231: ...a redundant run command does not occur on the serial data link from the VSD Logic Board before the timer expires a shutdown is performed and this message is generated Harmonic Filter DC Current Transformer 1 During initialization with no current flowing through the DC Current Transformers DCCT s the DCCT output voltages are measured and compared with a preset limit via the Filter Logic Board If th...

Page 232: ...greater than 25 0 F colder than the Leav ing Chilled Liquid Temperature In order to initiate a shutdown the difference must be outside the acceptable range continuously for 10 minutes For Steam Turbine drive applications this check is bypassed for the first 20 minutes of chiller operation The chiller can be started after the Compressor Switch is placed in the Stop Reset O position Evaporator Trans...

Page 233: ...ore than 300 0 PSIG R134a or R22 This is outside the normal operating range of the transducer This is generally indicates a defective transducer The chiller can be started after the trans ducer is indicating a pressure that is within range and the Compressor Switch is placed in the Stop Reset O position Auxiliary Safety Contacts Closed The Auxiliary safety shutdown contacts connected to I O Board ...

Page 234: ...ce the oil pump is not running during this period and the actual differential oil pres sure is 0 PSID The transducers are sensing the same pressure during this period and their outputs should be similar The chiller can be started after the Compressor Switch is placed in the Stop Reset O position Oil Variable Speed Pump Setpoint Not Achieved This is only applicable to chillers equipped with the Oil...

Page 235: ...checked during the last 20 seconds of System Prelube during System Run and during coastdown Therefore the fault is only detected during those periods Also the 10mil thresh old must be exceeded for 2 continuous seconds instan taneous with previous software This shutdown must be evaluated by a qualified Service Technician prior to starting the chiller Starting the chiller without this evaluation cou...

Page 236: ...tch contacts connected to TB3 81 have opened This occurs when the Bearing position decreases to less than the allowed position This shutdown must be evaluated by a qualified Service Technician prior to starting the chiller Starting the chiller without this evaluation could result in severe compressor damage To prevent the chiller from starting without the proper evaluation restart is inhibited unt...

Page 237: ...an open RTD or any individual winding temperature sensor that has been disabled with the Temperature Disable Setpoint on the MOTOR SETPOINTS Screen Motor High Bearing Temperature Software version C OPT 01 22 307 and later This safety shutdown occurs when either of the enabled motor bearing temperatures exceeds the programmed High Bearing Temperature Shutdown threshold for 3 continuous seconds The ...

Page 238: ...sly for 40 seconds The chiller can be started after the Compressor Switch is placed in the Stop Reset O position LCSSS Phase X Shorted SCR Flash Memory Card version C MLM 01 04 or later A shorted Silicon Controlled Rectifier SCR in phase A B or C designated as X in the message has been detected by the Liquid Cooled Solid State Starter Logic Trigger Board The voltage across each SCR in monitored to...

Page 239: ...Board is pressed and the Compressor Switch is placed in the Stop Reset O position VSD High Phase A Inverter Heatsink Tem perature Style D VSD This shutdown will occur if the heatsink temperature exceeds 158 F on any of the output pole assemblies This shutdown will seldom occur In most cases where the coolant temperature has risen abnormally the VSD will shut down on Ambient Temperature 140 0 F bef...

Page 240: ...cutive times If the VSD fails to make pre charge on three consecutive tries the unit will shut down lockout and display this message The chiller can be started after the Compressor Switch is placed in the Stop Reset O position Harmonic Filter High Heatsink Temperature Style D VSD The Harmonic Filter power assembly has one heat sink transmitter on the 503 HP units and two heatsink transmitter on th...

Page 241: ... to the VSD divided by the chiller Full Load Amps in percent A standard VSD less the optional filter typically has an input cur rent TDD level on the order of 28 30 The chiller can be started after the Compressor Switch is placed in the Stop Reset O position VSD Low Frequency Detected Software version C MLM 01 14 xxx and later or C OPT 01 14 306 and later After a 20 second bypass after entering Sy...

Page 242: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 202 SECTION 3 DISPLAY MESSAGES THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 243: ...Card version C MLM 01 05 xxx and later Prints a snapshot of the existing TREND Screen data or prints new data collected after the TREND PRINT key is pressed The printer can be permanently connected to the Con trol Center or connected as required to produce a report If permanently connected a DATA LOGGING feature can produce a status report automatically beginning at an Operator selected start time...

Page 244: ... Primary differences between printers involve the formatting control codes required by the printer These codes are sent from the Control Center to the printer For example Weigh Tronix printers require a control code to select 40 column width This same code is interpreted by the Okidata printer as an instruction to print wide characters In some instances a printer will ignore a code it cannot inter...

Page 245: ...Level Required OPERATOR Using the PRINTER Screen set the printer type to Weigh Tronix Automatic Data Logging Access Level Required OPERATOR If automatic data logging is desired a status report can be automatically printed at a specified interval begin ning at a specified time using the PRINTER Screen The interval is programmable over the range of 1 min ute to 1440 minutes in 1 minute increments Th...

Page 246: ...as a txt file When the print file has been recorded select Transfer from the toolbar and capture from the drop down menu and select Stop This will stop the transfer and allow access to the capture file The following additional RS232 connections are used to wire up serial devices for desktop and laptop computers RS 232 PIN ASSIGNMENTS DB25 PC SIGNAL SET OLDER DESKTOPS ONLY Pin 1 Protective Ground P...

Page 247: ...se 20 rolls of paper PRINTER CONNECTIONS Connect the printer to the Control Center Microboard as follows Only one printer can be connected at a time Table 6 BRECKNELL CP130 Modify the cable and connect as shown below MICROBOARD PRINTER FUNCTION J2 4 Pin 3 TX Data to the printer J2 2 Pin 5 Busy signal from the printer J2 9 Pin 6 Signal Common LD17609 Figure 63 BRECKMAN PRINTER MICRO OPTIVIEW R TX1 ...

Page 248: ...Sump Oil Pressure LOP 75 8 Psig Pump Oil Pressure HOP 124 6 Psig Oil Pressure 47 8 Psid Oil Sump Temperature 150 0 F Oil Heater Off If Mod D Chiller or higher Oil Return Solenoid Off If Mod D Chiller or higher Figure 65 SAMPLE PRINTOUT STATUS Skip the following section if Hot Gas Bypass is not enabled Hot Gas Valve Position 15 Pre Rotation Vanes Position 75 Surge Total Surge Count 127 Surge Window...

Page 249: ... Phase B Heatsink Temperature If TMIII VSD 99 F Phase C Heatsink Temperature If TMIII VSD 97 F Baseplate Temperature If VyperDrive VSD 106 F FIGURE 64 SAMPLE PRINTOUT STATUS CONT D Skip the following section if Motor Type is not VSD or Filter is not present Harmonic Filter Data Precharge Contactor Off Supply Contactor On Operating Mode Running Phase Rotation ABC Total Supply kVA 148 kVA Total Powe...

Page 250: ...t Evaporator Leaving Chilled Local Setpoint 45 0 F Leaving Chilled ISN Setpoint 45 0 F Leaving Chilled Modem Setpoint 45 0 F Leaving Chilled Analog Setpoint 45 0 F Leaving Chilled Digital Setpoint 45 0 F Remote Range 10 0 F Sensitivity Normal Restart Offset 0 0 F Restart Setpoint 45 0 F Shutdown Offset 4 0 F Shutdown Setpoint 41 0 F Brine Low Evaporator Cutout 54 3 Psig Smart Freeze Off Refrigeran...

Page 251: ...Mod B SSS Liquid Cooled Solid State Starter Local Motor Current Limit 100 Remote ISN Current Limit 100 Remote Analog Current Limit 100 Remote Digital Current Limit 100 Remote Modem Current Limit 100 Pulldown Demand Limit 100 Pulldown Demand Time 0 Min Starter Model 26L Voltage Range 440 480 Full Load Amps 275 A Starting Current 1150 A Open SCR Enabled FIGURE 65 SAMPLE PRINTOUT SETPOINTS CONT D Sho...

Page 252: ...OP OFF 13 APR 1999 START 8 00 AM STOP 10 00 PM Figure 68 SAMPLE PRINTOUT SALES ORDER YORK SALES ORDER CHILLER ID 3 1997 1999 YORK INTERNATIONAL CORPORATION MON 29 MAR 1999 1 28 PM ORDER INFORMATION COMMISSIONING DATE 01 JAN 1999 JOB NAME JOB LOCATION MODEL NUMBER YORK ORDER NUMBER PANEL SERIAL NUMBER CHILLER SERIAL NUMBER DESIGN LOAD CONDENSER PASSES DESIGN WORKING PRESSURE FOULING FACTOR PRESSURE...

Page 253: ... 9 10 2014 4 NAMEPLATE INFORMATION MOTOR CODE POWER VOLTS PHASES FREQUENCY HZ LOOKED ROTOR AMPS FULL LOAD AMPS INRUSH AMPS SYSTEM INFORMATION REFRIGERANT TONS GEAR CODE LIQUID TYPE BRINE PERCENT KILOWATTS INPUT VSD SSS EM FIGURE 67 SAMPLE PRINTOUT SALES ORDER CONT D ...

Page 254: ...id Off If Mod D Chiller or higher Oil Sump Oil Pump Run Output Off Sump Oil Pressure LOP 75 8 Psig Pump Oil Pressure HOP 76 6 Psig Oil Pressure 0 0 Psid Oil Sump Temperature 150 0 F Oil Heater Off If Mod D Chiller or higher Oil Return Solenoid Off If Mod D Chiller or higher Skip the following section if Hot Gas Bypass is not enabled Hot Gas Valve Position 0 Pre Rotation Vanes Position 0 Surge Tota...

Page 255: ...D 93 F Phase B Heatsink Temperature If TMIII VSD 99 F Phase C Heatsink Temperature If TMIII VSD 97 F Baseplate Temperature If VyperDrive VSD 106 F Skip the following section if Motor Type is not VSD or Filter is not present Harmonic Filter Data Precharge Contactor Off Supply Contactor Off Operating Mode Stopped Phase Rotation ABC Total Supply kVA 0 kVA Total Power Factor 0 00 DC Bus Voltage 608 V ...

Page 256: ...ATION Fri 05 Oct 2001 4 48 04 PM Log Entry 1 Evaporator Leaving Chilled Local Setpoint Date 05 Oct 2001 Time 4 23 49 PM Access Level Service User Id 4268 Old Value 46 5 F New Value 48 0 F Log Entry 2 Condenser High Pressure Warning Threshold Date 05 Oct 2001 Time 1 36 12 PM Access Level Service User Id 4268 Old Value 162 5 Psig New Value 225 0 Psig Log Entry 3 Condenser Drop Leg Date 05 Oct 2001 T...

Page 257: ...illed Active Setpoint 45 0 F Leaving Chilled Liquid Temperature 50 0 F Return Chilled Liquid Temperature 59 3 F Leaving Condenser Liquid Temperature 85 0 F Return Condenser Liquid Temperature 94 9 F Evaporator Pressure 7 2 Psig Condenser Pressure 13 8 Psig Full Load Amps 94 D P P 1 20 Prv Pos 89 Freq 58 Hz D P P 1 41 Prv Pos 71 Freq 46 Hz D P P 0 98 Prv Pos 73 Freq 52 Hz D P P 0 71 Prv Pos 86 Freq...

Page 258: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 218 NOTES ...

Page 259: ...Celsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range Table 7 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effect ton 3 516 Kilowatts kW Power Horsepower 0 7457 Kilowatts kW Flow Rate Gallons Minute gpm 0 0631 Liters Second l s Length Feet ft 0 3048 Meters m Inches in 25 4 Millimeters mm Weight Pounds lbs 0 4...

Page 260: ...USA 17405 1592 Subject to change without notice Printed in USA Copyright by Johnson Controls 2014 ALL RIGHTS RESERVED Form 160 54 O1 914 Issue Date September 10 2014 Supersedes 160 54 O1 1013 Tele 800 861 1001 www johnsoncontrols com ...

Page 261: ...OPTIVIEW CONTROL CENTER FOR ELECTRO MECHANICAL STARTER SOLID STATE STARTER AND VARIABLE SPEED DRIVE CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS Supersedes 160 75 N1 311 Form 160 75 N1 414 LD15222 Issue Date April 30 2014 ...

Page 262: ...als This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to specific situations Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken Indicates a potentially haz...

Page 263: ...ision was made These revisions are to technical in formation and any other changes in spelling grammar or formatting are not included ASSOCIATED LITERATURE MANUAL DESCRIPTION FORM NUMBER Solid State Starter Mod B Operation and Maintenance 160 00 O2 Variable Speed Drive Operation 160 00 O1 Installation Unit 160 54 N1 Operation OptiView Control Panel 160 54 O1 Renewal Parts Unit 160 75 RP1 Renewal P...

Page 264: ...E 4 30 2014 NOMENCLATURE YK KC K4 H9 CY G MOTOR CODE POWER SUPPLY for 60 Hz 5 for 50 Hz COMPRESSOR CODE CONDENSER CODE EVAPORATOR CODE MODEL STYLE Design Level Refer to YK Engineering Guide Form 160 75 EG1 for Shell Motor Compressor combinations ...

Page 265: ...act Waterboxes A thru L Evaporators 31 FIGURE 20 Dimensions Evaporator Compact Waterboxes M thru Z Evaporators 32 FIGURE 21 Dimensions Condenser Compact Waterboxes Standard mm 33 FIGURE 22 Dimensions Condenser Compact Waterboxes Standard mm 34 FIGURE 23 Dimensions Condenser Heat Recovery Compact Waterboxes Standard mm 35 FIGURE 24 Dimensions Evaporator Nozzle Arrangements Standard mm 36 FIGURE 25 ...

Page 266: ...JOHNSON CONTROLS 6 FORM 160 75 N1 ISSUE DATE 4 30 2014 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 267: ...or or control center LD15222 CONDENSER CONTROL CENTER COMPRESSOR MOTOR EVAPORATOR Figure 1 MODEL YK CHILLER GENERAL This manual describes the installation of a YORK YK Mod G Centrifugal Chiller This unit can be shipped as a single factory assembled piped wired package requiring a minimum of field labor to make chilled water connections condenser water connections re frigerant atmospheric relief co...

Page 268: ...d refrigerant piped wired and leak tested then dismantled for shipment Compressor motor assembly removed from shells and skidded Evaporator condenser is not skidded All wiring integral with compressor is left on it and all conduit is left on shell All open ings on compressor oil separator and shell are closed and charged with dry nitrogen 2 to 3 PSIG 115 122 kPa Miscellaneous packaging of control ...

Page 269: ...kidded unit INSPECTION DAMAGE SHORTAGE The unit shipment should be checked on arrival to see that all major pieces boxes and crates are received Each unit should be checked on the trailer or rail car when received before unloading for any visible signs of damage Any damage or signs of possible damage must be reported to the transportation company imme diately for their inspection Johnson Controls ...

Page 270: ... of evaporator and condenser tubes see Clearance Adoorway or other sufficiently large opening properly located may be used The chiller should be located in an indoor location where temperatures range from 40 F to 110 F 4 4 C to 43 3 C MOTORS The YK open motor is air cooled Check state local and other codes for ventilation requirements FOUNDATION A level floor mounting pad or foundation must be pro...

Page 271: ...HES MM UNIT WEIGHT 53 531 100 464 Lbs 45 570 58 968 Kgs LD12641 UNIT WEIGHT UP TO 16 365 Lbs 7 423 Kgs LD12638 UNIT WEIGHT 16 366 28 835 Lbs 7 424 13 080 Kgs LD12639 UNIT WEIGHT 28 836 53 530 Lbs 13 081 24 281 Kgs LD12640 Figure 3 NEOPRENE ISOLATORS UNIT WEIGHT 100 465 130 000 Lbs 45 570 58 967 Kgs LD12642 ...

Page 272: ...mm 16 366 28 835 Lbs 7 424 13 08 Kgs See Figures 11 16 See Figures 11 16 6 152mm 8 203mm 28 836 53 530 Lbs 13 081 24 281 Kgs See Figures 11 16 See Figures 11 16 6 152mm 8 203mm 53 531 100 464 Lbs 24 281 45 569 Kgs See Figures 11 16 See Figures 11 16 10 254mm 8 203mm 100 465 130 000 Lbs 45 570 58 967 Kgs See Figures 11 16 See Figures 11 16 10 254mm 8 203mm K7 See Figures 15 16 See Figures 15 16 10 ...

Page 273: ...SPRING ISOLATORS LD12645 LD126544 UNIT WEIGHT 10 000 Lbs UP TO 35 009 Lbs 4 536 Kgs UP TO 15 880 Kgs UNIT WEIGHT 35 010 Lbs UP TO 58 349 Lbs 15 881 Kgs UP TO 26 467 Kgs UNIT WEIGHT 89 341 Lbs UP TO 115 000 Lbs 40 252 Kgs UP TO 52 164 Kgs LD12646 UNIT WEIGHT 115 000 Lbs UP TO 190 000 Lbs 52 163 Kgs UP TO 86 182 Kgs LD12647 ...

Page 274: ...35 009 Lbs 4 536 15 880 Kgs See Figures 11 16 See Figures 11 16 6 152 6 7 8 175 5 1 2 140 35 010 58 349 Lbs 15 881 26 467 Kgs See Figures 11 16 See Figures 11 16 9 229 7 178 6 1 4 159 89 341 115 000 Lbs 40 252 52 164 Kgs See Figures 11 16 See Figures 11 16 13 1 2 343 8 203 5 127 115 000 190 000 Lbs 52 163 86 182 Kgs See Figures 11 16 See Figures 11 16 16 406 17 432 16 1 4 413 LD12643a ...

Page 275: ...L SPRING ISOLATORS When ordered spring type isolator assemblies will be furnished with the unit The 4 assemblies are identical and can be placed at any of the 4 corners of the unit While the unit is still suspended by the rigging the iso lators should be bolted to the unit by inserting the cap screw s through the hole s in the mounting bracket into the tapped hole in the top of the isolator leveli...

Page 276: ...valve is needed in the flow path for the starter heat exchanger to regulate cooling above the equipment room dewpoint for applications using cooling sources other than evaporative air exchange meth ods such as wells bodies of water and chilled water The temperature control valve should be the type to open on in creasingdrivecoolanttemperature fail closed andsetfora temperatureabovedewpoint Itcanbe...

Page 277: ...d to the OptiView control panel These solid state flow sensors have a small internal heat ing element and use the cooling effect of the flowing fluid to sense when an adequate flow rate has been established Waterbox Drain and Vent Valves Drain and vent valves by others should be installed in the connections provided in the evaporator and con denser liquid heads These connections may be piped to dr...

Page 278: ...ight can be adjusted Chillers equipped with P and Q compressors the control panel height is NOT adjustable The OptiV iew Control Center is placed in a position above the evaporator for shipping To move the control center into position for operation proceed as follows 1 While supporting the control center remove the hardware between the support arms and the evap orator 2 Swing the control center in...

Page 279: ... is factory connected to the Solid State Starter or Variable Speed Drive or an optional factory installed discon nect switch See Field Wiring Diagram All wiring to the control panel and the oil pump starter is completed by the factory A control transformer is furnished with the Solid State Starter or Variable Speed Drive INSULATION DO NOT field insulate until the unit has been leak tested under th...

Page 280: ...JOHNSON CONTROLS 20 FORM 160 75 N1 ISSUE DATE 4 30 2014 section 2 installation Figure 10 UNIT INSULATION LD12649 Input Drain and Charging ...

Page 281: ... M4 K1 KT to KX K5 to K7 KP to KS K2 to K4 CS DC ES EV 5CN 5DC 5EN 5EO K1 K2 MQ to MS M2 to M4 MP to MS M2 to M4 NQ to NS N2 to N4 NP to NS N2 to N4 PQ to PS P2 to P4 PQ to PS P2 to P4 QQ to QS Q2 to Q4 QQ to QS Q2 to Q4 K3 NQ to NS N2 to N4 NP to NS N2 to N4 DA DJ 5DA 5DH QQ to QV Q2 to Q4 QQ to QS Q2 to Q4 RQ RS RV R3 R5 R7 RQ to RS R2 to R4 K4 RP RR RT R2 R4 R6 RQ to RS R2 to R4 DA DJ 5DA 5DJ S...

Page 282: ...P to ET CU CY EU EV 5CP 5CU FC to FE F3 to F5 FQ to FT P8 P9 GC to GE G3 to G5 EV to EX E3 to E4 CH CZ EH EV 5CE 5CU 5EE 5EO HC to HE H3 to H5 FV to FX F3 to F4 H9 KC KD K8 K9 K0 KP KQ KR KS K2 K3 K4 CN CA EN EV 5CK 5CW 5EK 5EO IB ID IF IH I2 I4 I6 I8 KP KQ KR KS K2 K3 K4 MB MD MF M5 M7 M8 MP MQ MR MS M2 M3 M4 K1 IB ID IF IH I2 I4 I6 I8 KP KQ KR KS K2 K3 K4 CS DC ES EV 5CN 5DC 5EN 5EO K1 K2 MB MD ...

Page 283: ...12 0 16 0 P8 COMPRESSOR EVAPORATOR CONDENSER SHELL CODES G E H F J J L L A 6 11 6 11 7 6 1 2 7 6 1 2 B 10 6 10 6 10 11 10 11 C 2 0 2 0 2 1 1 4 2 1 1 4 D 1 5 1 2 1 5 1 2 1 8 1 8 E 12 0 16 0 12 0 16 0 P9 COMPRESSOR EVAPORATOR CONDENSER SHELL CODES H F J J L L A 6 11 7 6 1 2 7 6 1 2 B 10 3 10 8 1 2 10 8 1 2 C 2 0 2 1 1 4 2 1 1 4 D 1 5 1 2 1 8 1 8 E 16 0 12 0 16 0 Q6 COMPRESSOR EVAPORATOR CONDENSER SH...

Page 284: ...299 C 495 495 495 D 445 594 445 E 3 658 3 658 4 877 P8 COMPRESSOR EVAPORATOR CONDENSER SHELL CODES E E F F G G H H A 2 108 2 108 2 299 2 299 B 3 200 3 200 3 327 3 327 C 610 610 641 641 D 445 445 508 508 E 3 658 4 877 3 658 4 877 P9 COMPRESSOR EVAPORATOR CONDENSER SHELL CODES H F J J L L A 2 108 2 299 2 299 B 3 124 3 264 3 264 C 610 641 641 D 445 508 508 E 4 877 3 658 4 877 Q3 COMPRESSOR EVAPORATOR...

Page 285: ...ons 4 To determine overall height add 7 8 22 mm for isolators 5 Use of motors with motor hoods may increase overall unit dimensions Figure 13 DIMENSIONS H COMPRESSOR UNITS FT IN H COMPRESSOR UNITS STANDARD ADDITIONAL OPERATING HEIGHT CLEARANCE TO FLOOR Type of Chiller Mounting M Neoprene Pad Isolators 1 3 4 Spring Isolators 1 Deflection 1 Direct Mount 3 4 H9 COMPRESSORS EVAPORATOR CONDENSER SHELL ...

Page 286: ... flanges connections 4 To determine overall height add 22 mm 7 8 inch for isolators 5 Use of motors with motor hoods may increase overall unit dimensions Figure 14 DIMENSIONS H COMPRESSOR UNITS MM H COMPRESSOR UNITS METRIC ADDITIONAL OPERATING HEIGHT CLEARANCE Type of Chiller Mounting M Neoprene Pad Isolators 44 Spring Isolators 25mm Deflection 25 Direct Mount 19 H9 COMPRESSORS EVAPORATOR COND SHE...

Page 287: ... 2 1 1 4 E 14 0 14 0 16 0 14 0 16 0 ADDITIONAL OPERATING HEIGHT CLEARANCE Type of Chiller Mounting M Neoprene Pad Isolators 1 3 4 Spring Isolators 1 Deflection 1 Direct Mount 3 4 K7 COMPRESSOR EVAPORATOR CONDENSER SHELL CODES W W Z Y Z Z A 10 3 12 7 11 3 B 12 2 14 1 5 8 12 10 C 2 8 2 11 1 2 2 11 1 2 D 2 5 1 2 3 4 2 8 E 22 0 18 0 18 0 K3 COMPRESSOR EVAPORATOR CONDENSER SHELL CODES N N Q Q R R A 8 7...

Page 288: ...OR EVAPORATOR CONDENSER SHELL CODES N N Q Q R R A 2 616 2 781 2 972 B 3 251 3 505 3 607 C 724 749 813 D 584 641 699 E 4 877 4 877 4 877 ADDITIONAL OPERATING HEIGHT CLEARANCE Type of Chiller Mounting M Neoprene Pad Isolators 44 Spring Isolators 1 Deflection 25 Direct Mount 19 K4 COMPRESSOR EVAPORATOR CONDENSER SHELL CODES R R S S S V X T X X A 2 972 2 972 3 124 3 302 3 429 B 3 632 3 632 3 759 3 759...

Page 289: ... W X Z F 1 2 1 4 362 1 3 381 1 3 1 2 394 1 3 3 4 400 1 5 1 2 445 1 11 5 8 600 1 11 5 8 600 2 0 5 8 625 2 1 3 4 654 G 0 6 1 2 165 0 7 178 0 7 1 2 191 0 7 3 4 197 0 9 1 2 241 1 3 5 8 397 1 3 5 8 397 1 4 3 4 425 1 5 3 4 451 THREE PASS EVAPORATORS CODES DIMENSIONS A C D E F G H I J K L M N P Q R S W X Z F 1 2 1 4 362 1 3 381 1 3 1 2 394 1 3 3 4 400 1 5 1 2 445 1 11 5 8 600 1 11 5 8 600 2 0 5 8 625 2 1...

Page 290: ... 4 3 4 730 1 10 1 2 572 DOUBLE BUNDLE HEAT RECOVERY CONDENSERS CODES B I O U Y DIMENSIONS TOWER HEATING TOWER HEATING TOWER HEATING TOWER HEATING TOWER HEATING H 1 6 1 2 470 1 5 432 1 7 1 2 495 1 4 3 4 425 1 9 1 2 546 1 6 457 1 10 1 4 565 1 8 508 2 4 3 4 730 1 10 1 2 572 J 0 10 1 2 267 0 9 229 0 11 1 2 292 0 8 3 4 222 1 1 1 2 343 0 10 254 1 2 1 4 362 1 0 305 1 8 3 4 527 1 2 1 2 368 THREE PASS COND...

Page 291: ... 3 381 2 9 838 E F 14 355 10 254 8 203 1 7 483 2 2 660 1 4 406 3 0 914 1 4 406 3 0 914 G H 14 355 10 254 8 203 2 0 610 2 3 1 2 699 1 3 1 2 394 3 3 1 2 1 003 1 3 1 2 394 3 3 1 2 1 003 I J K L 16 406 12 305 10 254 2 1 1 4 641 2 6 762 1 5 432 3 7 1092 1 5 432 3 7 432 LD07598a NOTES 1 Standard water nozzles are furnished as welding stub outs with grooves allowing the option of welding flanges or use o...

Page 292: ...ULAR EVAPORATOR SHELL CODE NOZZLE PIPE SIZE IN MM EVAPORATOR NOZZLE DIMENSIONS FT IN MM NUMBER OF PASSES 1 PASS 2 PASS 3 PASS 1 2 3 C AA5 BB5 DD5 EE BB5 DD5 M N 18 457 14 356 12 304 2 4 1 2 724 3 0 914 1 8 1 2 521 4 3 1 2 1308 1 8 1 2 521 4 3 1 2 1308 P Q 18 457 14 356 12 304 2 5 1 2 749 3 1 1 2 953 1 10 559 4 5 1346 1 10 559 4 5 1346 QV QT 20 508 16 406 12 305 2 5 1 2 749 3 1 1 2 953 1 11 1 2 597...

Page 293: ... 3 PASS 1 2 3 D CC5 BB5 DD5 BB5 DD5 A 10 254 6 152 6 152 1 3 381 2 4 711 1 9 1 2 546 2 10 1 2 876 1 9 1 2 546 2 10 1 2 876 C D 12 305 8 203 6 152 1 3 1 2 394 2 6 762 1 10 3 8 568 3 1 5 8 956 1 10 3 8 568 3 1 5 8 956 E F 14 356 10 254 8 203 1 5 1 2 445 2 8 813 1 11 3 4 603 3 4 1 4 1022 1 11 3 4 603 3 4 1 4 1022 J K L 16 406 10 254 10 254 1 8 508 3 0 914 2 3 686 3 9 1 143 2 3 686 3 9 1 143 M N 20 50...

Page 294: ... ROUND CONDENSER SHELL CODE NOZZLE PIPE SIZE IN MM CONDENSER NOZZLE DIMENSIONS FT IN MM NUMBER OF PASSES 1 PASS 2 PASS 3 PASS 1 2 3 D CC5 BB5 DD5 BB5 DD5 R S 20 508 18 457 14 356 2 3 1 2 699 3 10 1 2 1181 2 9 1 2 851 4 11 1 2 1 511 2 9 1 2 851 4 11 1 2 1 511 T V W 24 610 18 457 16 406 2 5 1 2 749 3 11 1 2 1207 2 9 838 5 2 1 575 2 9 838 5 2 1 575 X Z 24 610 20 508 16 406 2 8 813 4 1 1 4 1251 2 9 1 ...

Page 295: ...8 7 8 530 1 9 1 4 540 3 6 1 2 1 018 0 9 1 16 230 I 14 355 10 254 8 203 1 11 3 8 594 1 10 1 4 565 3 8 1 8 1 121 0 10 1 8 257 O 16 406 12 304 10 254 2 3 3 8 695 2 0 3 8 619 4 1 1 8 1 248 0 11 13 16 300 U 18 457 14 355 10 254 2 4 1 2 724 2 11 3 16 894 5 2 13 16 1 595 1 0 3 8 314 Y 24 609 20 508 16 406 3 4 1 016 3 3 15 16 1 014 6 3 7 8 1 927 1 5 7 8 454 M K D C L Compressor End Front of Unit D C L Mot...

Page 296: ...roper operation of the sub cooler to achieve rated performance 5 Add dimension M as shown on pages per unit dimensions page for the appropriate isolator type EVAPORATOR SHELL CODE EVAPORATOR NOZZLE DIMENSIONS FT IN MM 1 PASS 2 PASS 3 PASS F I F G I F I A 1 7 483 0 8 3 4 222 1 5 432 0 6 1 2 165 0 7 3 4 197 1 5 432 0 7 3 4 197 C D 1 10 3 4 578 0 10 5 8 270 1 8 5 8 524 0 7 178 0 9 1 2 241 1 8 5 8 524...

Page 297: ...FT IN MM 1 PASS 2 PASS 3 PASS H K H J K H K A 1 9 533 0 9 7 8 251 1 4 3 4 425 0 6 152 0 7 3 4 197 1 4 3 4 425 0 7 3 4 197 B6 1 10 1 2 572 0 10 1 2 267 1 8 508 0 10 1 2 267 0 9 1 4 235 1 8 508 0 9 1 4 235 C D 2 0 610 0 11 1 8 283 1 7 1 2 495 0 6 3 8 162 0 9 229 1 7 1 2 495 0 9 229 E F 2 0 1 2 622 0 11 1 2 292 1 10 1 4 565 0 7 178 0 9 7 8 251 1 10 1 4 565 0 9 7 8 251 I6 2 3 686 1 0 3 4 324 1 10 1 2 ...

Page 298: ...11 1 2 597 4 5 1 2 1359 0 11 279 1 9 7 8 556 I J K L 16 406 12 305 10 254 2 1 1 4 641 5 0 3 8 1 534 5 0 3 8 1 534 0 10 1 2 267 2 2 1 2 673 5 0 3 8 1 534 0 10 1 2 267 2 2 1 2 673 M N 18 457 14 356 12 305 2 4 1 2 724 5 8 1 2 1 740 5 8 1 2 1 740 1 2 356 2 2 1 2 673 5 8 1 2 1 740 1 2 356 2 4 3 4 730 P Q 18 457 14 356 12 305 2 5 1 2 749 6 0 1 8 1 832 6 0 1 8 1 832 1 3 381 2 6 1 2 775 6 0 1 8 1 832 1 3 ...

Page 299: ...94 1 8 508 1 3 3 8 391 3 11 1 194 1 8 508 1 3 3 8 391 C D 12 305 8 203 6 152 1 3 1 2 394 4 3 1 295 4 3 1 295 1 8 508 1 6 1 2 470 4 3 1295 1 8 508 1 6 1 2 470 E F 14 356 10 254 8 203 1 5 1 2 445 4 7 1 397 4 7 1 397 1 10 559 1 9 533 4 7 1 397 1 10 559 1 9 533 J K L 16 406 10 254 10 254 1 8 508 5 1 1 549 5 1 1 549 1 9 533 1 9 1 2 546 5 1 1 549 1 9 533 1 9 1 2 546 M N 20 508 14 356 10 254 1 11 584 5 9...

Page 300: ...or End C om pressor End Front of U nit 19 T T D CL D C L M 20 14 S V V D 3 PASS 11 16 M M S S D D U U C L L C Front of U nit 13 M M S D U CL Compressor End Motor End Front of Unit 12 T T 18 M S D U C L Motor End Compressor End Front of Unit 17 T T D CL D C L M V V M M S U CL C om pressor End M otor End Front of U nit 15 T T M S D U CL M otor End C om pressor End Front of U nit 19 T T D CL D C L M ...

Page 301: ... 2 4 3 4 730 2 7 1 8 790 I 14 355 10 254 8 203 1 11 3 8 593 2 4 1 2 723 1 1 330 2 5 1 8 740 2 10 5 8 879 O 16 406 12 305 10 254 2 3 3 8 695 2 7 1 8 790 1 1 3 8 339 2 10 1 4 870 3 4 1 2 1029 U 18 457 14 355 10 254 2 4 1 2 723 3 6 9 16 1081 1 11 3 16 589 3 1 7 8 962 3 7 1 2 1105 Y 24 610 20 508 16 406 3 4 1016 4 2 5 16 1278 1 10 5 16 582 4 4 3 4 1340 4 11 11 16 1516 3 PASS 1 2 3 D S T U V B 10 254 8...

Page 302: ... 16 329 2 925 1 327 K K K1 31 100 14 107 36 200 16 420 3 248 1 473 K O H9 34 483 15 641 44 776 20 310 3 260 1 479 M M H9 34 200 15 513 43 600 19 777 3 665 1 662 M M K1 K2 38 300 17 373 47 100 21 364 3 665 1 662 M U K2 45 178 20 493 58 017 26 316 3 540 1 606 N N K1 K2 28 530 18 549 50 800 23 043 4 225 1 916 N N K3 48 000 21 773 54 100 24 540 4 225 1 916 P P K1 K2 41 500 18 824 51 900 23 542 3 855 1...

Page 303: ...1 K2 45 800 19902 56 545 24571 3 500 1521 Q Q K3 46 500 20206 59 945 26048 3 500 1521 NOTE Refrigerant charge quantity and weights will vary based on tube count configuration and chiller performance Use for reference only Refer to YORKworks Performance Page or chiller nameplate for actual charge requirement Table 4 EVAPORATOR MARINE WATERBOX WEIGHTS LBS KGS TO BE ADDED TO STANDARD UNIT WEIGHTS SHO...

Page 304: ... 702 772 I 2 066 937 1 070 485 2 032 922 3 017 1 396 1 416 642 2 738 1 242 J K L 1 029 467 1 167 529 1 151 522 2 309 1 047 2 448 1 110 2 431 1 103 M N 2 466 1 119 1 330 603 2 324 1 054 4 863 2 206 2 448 1 110 4 582 2 078 O 2 985 1 354 1 443 655 2 987 1 355 4 435 2 012 2 172 985 3 979 1 805 P Q 3 700 1 678 1 858 843 3 752 1 702 6 561 2 976 3 132 1 421 5 991 2 717 R S 3 806 1 726 1 946 883 3 960 1 7...

Page 305: ...elsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range Table 6 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effect ton 3 516 Kilowatts kW Power Horsepower 0 7457 Kilowatts kW Flow Rate Gallons Minute gpm 0 0631 Liters Second l s Length Feet ft 0 3048 Meters m Inches in 25 4 Millimeters mm Weight Pounds lbs 0 45...

Page 306: ...ania USA 17405 1592 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2014 www johnsoncontrols com ALL RIGHTS RESERVED Form 160 75 N1 414 Issue Date April 30 2014 Supersedes 160 75 N1 311 ...

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