York OPTIVIEW YK Service Instructions Manual Download Page 258

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258

FORM 160.54-M1

ISSUE DATE: 10/25/2019

SECTION 32 - MOTOR MONITORING

JCI COMPANY CONFIDENTIAL

JOHNSON CONTROLS

MOTOR MONITORING BOARD BASIC BLOCK DIAGRAM

FIGURE 99 -

MOTOR MONITORING BOARD BASIC BLOCK DIAGRAM

+12VDC

RET

+24VDC

-12VDC

TB4

TP3

TP1

TP4

TP5

TP2

TP8

+5VDC

GND

+15VDC

-12VDC

RS-485

XCVR

MODBUS ADDRESS SELECT

PROGRAMMING

PORT

RX CR12

TX CR13

ATUS

CR8

SW1

5VDC REG

15VDC REG

POWER CR6

CR18-19

CR16-17

SELECT

MUX

SELECT

MUX

SELECT

DIGIT

INPUTS

CONFIGURABLE ANALOG

INPUTS

TD ANALOG

INPUTS

VIBRA

TION ANALOG

INPUTS

OPT0 COUPLER

(SEE FIGURE 104)

PULL-UP/DOWN COUPLER (SEE FIGURE 105)

LOAD RESIST

ORS

(SEE FIGURE 101)

GAIN 1:1, 1

1:1, 21:1

(SEE FIGURE 102)

TB8

TB7

TB1/TB2

TB5/TB6

TB3

+24VDC/AC

+5VDC

THERMIST

TRANSDUCER 0-5VDC 0-10VDC 4-20MA

RTD

ACCELEROMETERS

MUX

(SEE FIGURE 103)

RS-485

COMMS

LD15001

Summary of Contents for OPTIVIEW YK

Page 1: ...YLE G CENTRIFUGAL LIQUID CHILLERS WITH OPTIVIEW CONTROL CENTER SERVICE INSTRUCTIONS Supersedes 160 54 M1 319 Form 160 54 M1 1019 Issue Date October 25 2019 This is a company confidential document and...

Page 2: ...duct labels this document and any referenced materials This in dividual shall also be familiar with and comply with all applicable industry and governmental standards and regulations pertaining to the...

Page 3: ...mote Low or Medium Voltage EMS 160 75 PW5 Wiring Diagram YK Chiller Style G OptiView Control Center with Unit Mounted Low or Medium Voltage SSS Unit Mounted Low Voltage with Modbus or Remote Medium Vo...

Page 4: ...118 110 111 112 Mod B Solid State Starter or Variable Speed Drive w Modbus Communications no VGD NEMA 1 Mod B Solid State Starter or Variable Speed Drive w Modbus Communications and VGD no J7 compress...

Page 5: ...73 Chiller Operating Program 74 Program Jumpers 77 Program Switches 78 Configuration and Setup 84 Downloading a Program from a Program Card 88 SECTION 6 I O BOARD 97 I O Board 97 Digital Inputs 97 Dig...

Page 6: ...led Liquid Temperature 205 Leaving Condenser Liquid Temperature Heat Pump Mode 207 SECTION 23 HOT GAS BYPASS 211 Setpoints 211 Operation 212 Hot Gas Operation with Variable Geometry Diffuser VGD 213 M...

Page 7: ...t Modes 247 Setpoints 247 Operation 249 SECTION 31 HEAT PUMP DUTY 253 Inputs Outputs 253 Setpoints 253 Control 254 Hot Gas Bypass Control 255 Heat Recovery and Head Pressure Control 255 Quick Start 25...

Page 8: ...r 293 High Condenser Pressure Fault While Shutdown Reset Procedure 295 Motor Lubrication Notification 295 Quick Start 298 Heat Pump Duty 299 Motor Monitoring Software Version C Opt 01 22 307 and Later...

Page 9: ...ve October 2006 350 SI0164 Software Enhancements Effective April 2007 351 SI0186 Software Enhancements Effective October 2006 354 SI0201 Software Enhancements Ver 19 Effective October 2008 356 SI0210...

Page 10: ...Configurable Analog and Remote Setpoint Inputs 70 FIGURE 23 Configurable Analog and Remote Setpoint Inputs Heat Pump Duty 71 FIGURE 24 Low Voltage Digital Inputs 72 FIGURE 25 Microboard 031 03630 001...

Page 11: ...2 FIGURE 70 High Speed Thrust Bearing Limit Switch Interface 163 FIGURE 71 High Speed Thrust Bearing Limit Switch 164 FIGURE 72 Refrigerant Liquid Level Sensor 168 FIGURE 73 Refrigerant Liquid Level C...

Page 12: ...itoring Board Diagnostic Screen 309 FIGURE 110 I O Board Diagnostic Screen 311 FIGURE 111 Keypad Test Screen 313 FIGURE 112 Display Test Main Screen 314 FIGURE 113 Bit Patterns Test Screen 316 FIGURE...

Page 13: ...ure Heat Pump Applications 191 TABLE 18 Return and Leaving Condensing Water 192 TABLE 19 Oil and Discharge Temperature 195 TABLE 20 Drop Leg Refrigerant Sensor 200 TABLE 21 Evaporator Refrigerant Sens...

Page 14: ...JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS 14 FORM 160 54 M1 ISSUE DATE 03 11 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 15: ...l supporting doc uments are required to service the system OptiView Control Panel Operation Form 160 54 O1 ex plains the operation of the OptiView Control Center keypad how to enter setpoints and expl...

Page 16: ...JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS 16 FORM 160 54 M1 ISSUE DATE 03 11 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 17: ...is sensing Typical output voltage range of both is 0 5 to 4 5 VDC These are Analog Inputs to the OptiView Control Center Digital inputs are ON OFF inputs to the OptiView Control Center in the form of...

Page 18: ...oboards Since the newer versions microboard are backward compatible to earlier vintage OptiView Control Cen ters earlier chillers could be equipped with a later ver sion microboard due to service repl...

Page 19: ...lied with factory mounted flow sensors on the evaporator and condenser These are electronic thermal type sen sors The operating principle of the sensor is thermal con ductivity It uses the cooling eff...

Page 20: ...rotocol re quires software version C OPT 01 18 307 or later The medium voltage solid state starter Figure 4 on page 25 serially communicates with the microboard using RS 485 Modbus Protocol Earlier vi...

Page 21: ...chiller is provided with a compressor motor VSD or the optional hot gas bypass the PRV potentiometer for those features is used Otherwise a PRV potenti ometer is provided interfaced to the microboard...

Page 22: ...T GAS VALVE HEAT RECOVERY VALVE HEAD PRESSURE VALVE HEATING CONDENSER FLOW SWITCH HEATING CONDENSER TEMPERATURES VARIABLE ORIFICE CONTROL VARIABLE GEOMETRY DIFFUSER CONTROL PRE ROTATION VANE CONTROL S...

Page 23: ...ORIFICE CONTROL PRE ROTATION VANE CONTROL STATUS ALARM CHILLER SOLENOID VALVES OIL PUMP STARTER OIL HEATER ON OFF CHILLED AND CONDENSER WATER PUMP STARTERS COMPRESSOR MOTOR START MOTOR CONTROLLER SHUT...

Page 24: ...RATURES AND PRESSURES CONDENSER REFRIGERANT LEVEL HIGH SPEED THRUST BEARING POSITION NOT APPLICABLE TO P COMPRESSORS AND STYLE F AND LATER CHILLERS WITH G OR H5 8 COMPRESSORS REMOTE LEAVING CHILLED WA...

Page 25: ...TEMPERATURES AND PRESSURES CONDENSER REFRIGERANT LEVEL HIGH SPEED THRUST BEARING POSITION NOT APPLICABLE TO P COMPRESSORS AND STYLE F AND LATER CHILLERS WITH G OR H5 8 COMPRESSORS REMOTE LEAVING CHILL...

Page 26: ...AND PRESSURES CONDENSER REFRIGERANT LEVEL HIGH SPEED THRUST BEARING POSITION NOT APPLICABLE TO P COMPRESSORS AND STYLE F AND LATER CHILLERS WITH G AND H5 8 COMPRESSORS REMOTE LEAVING CHILLED WATER TEM...

Page 27: ...RESSORS AND STYLE F AND LATER CHILLERS WITH G AND H5 8 COMPRESSORS REMOTE LEAVING CHILLED WATER TEMP AND CURRENT LIMIT SETPOINTS 0 20mA 4 20 mA 0 10 VDC 2 10VDC VANE MOTOR SWITCH REMOTE CYCLING HIGH P...

Page 28: ...ND H5 8 COMPRESSORS REMOTE LEAVING CHILLED WATER TEMP AND CURRENT LIMIT SETPOINTS 0 20mA 4 20 mA 0 10 VDC 2 10VDC VANE MOTOR SWITCH REMOTE CYCLING HIGH PRESSURE SAFETY LOCAL START STOP SWITCH CHILLED...

Page 29: ...EN LIQUID LINE VENT LINE AND OIL RETURN SOLENOIDS VANES CLOSING TIME DEPENDENT ON INITIAL VANE POSITION OIL PRESSURE CHECK OIL PUMP ON 150 SEC 2 5 MIN SYSTEM RUN SYSTEM PRELUBE VANES CLOSING BEFORE SH...

Page 30: ...N OIL PRESSURE CHECK OIL PUMP ON 150 SEC 2 5 MIN SYSTEM COASTDOWN SYSTEM SHUTDOWN TIME IN SECONDS MINUTES DISPLAY MESSAGE 600 10 RESTART ONLY AFTER FIFTH SUCCESSIVE RESTART RESTART IF FIVE SUCCESSIVE...

Page 31: ...to place The memory card is a replaceable component Refer to YORK Renewal Parts OptiView Control Center Form 160 54 RP1 The version of the memory card is an alpha numeric code that represents the appl...

Page 32: ...he microprocessor responds by de energizing the run digital output through the FPGA shutting down the chiller and retrieving the POWER FAILURE mes sage from the Program and sending it to the Display C...

Page 33: ...was initially pro grammed at the YORK factory If both values are the same it is considered pass If the calculated value is different than the stored value it is con sidered fail 5 BRAM quick test Tes...

Page 34: ...ace The microboard retrieves certain operating parame ters via J10 from the compressor motor starter con trol board CM 2 Current Board for Electromechani cal starter or Style A Solid State Starter Log...

Page 35: ...A115 VAC input to the I O Board is converted to a logic low less than 1 VDC A 0 VAC input to the I O Board is converted to a logic high more than 4 VDC See SECTION 6 I O BOARD of this manual for detai...

Page 36: ...d resistor to the 5 VDC This applies more than 4 VDC to the microboard input evaporator J7 14 condenser J7 16 When a flow rate less than the setpoint is sensed the solid state relay output is turned O...

Page 37: ...rent sup ply and control voltages for their displays and back lights Program Jumpers JP2 through JP5 and JP7 and JP8 must be configured to provide the required sup ply and control voltages to the disp...

Page 38: ...t via the RS 232 E Link Gateway interface at J2 or directly to the microboard at J22 See Figure 15 on page 47 The inputs at J22 are configured with Program Jumpers JP23 and JP24 to accept these inputs...

Page 39: ...39 SECTION 3 MICROBOARD 031 01730 000 FORM 160 54 M1 ISSUE DATE 10 25 2019 JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL 3 Figure 10 MICROBOARD 031 01730 000 LD07776...

Page 40: ...CARD RETAINER CLIP PRESS DOWN TO RELEASE CARD ELASTOMERIC CONNECTOR LD06855 LD04049 WRITE PROTECT SWITCH OPTIONAL MUST BE IN ENABLED POSITION CINS CINS GND VCC 3V 5V KEY ALIGNMENT NOTCH PAD 60 PAD 30...

Page 41: ...OHNSON CONTROLS JCI COMPANY CONFIDENTIAL 3 VOLTAGE REG VOLTAGE REG 12VDC 5VDC GND 12 VDC Y Y Y Y TP2 TP1 TP4 TP3 12VDC 5VDC ANALOG 5VDC DIGITAL 3 3VDC FROM POWER SUPPLY F2 F1 5A 5A REV E and later boa...

Page 42: ...0D367 368 NEC NL6448AC33 24 and LG Semicon LP104V2 W displays JP5 Display backlight power Determines the power supply voltage applied to the Display Backlight Inverter Board Pins 1 2 12 VDC SHARP LQ10...

Page 43: ...nowledge assignment Assigns selected PC 104 DMA acknowledge to PDACK0 on the microprocessor DMA ac knowledge selections are silk screened on the microboard adjacent to the program jumper Not used on Y...

Page 44: ...e following solenoid valves TB1 34 Liquid Line TB1 61 Oil Return and Vent Line connected in parallel TB1 62 High Speed Thrust 3 Prerun Determines the duration of the system pre lube period ON Extended...

Page 45: ...11 Not Used 12 Watchdog Protection Used in conjunction with Program Jumper JP1 see Program Jumpers on page 42 to enable disable the program watchdog protection With JP1 IN this switch setting has no...

Page 46: ...See Figure 115 on page 319 for details TX RX TX RX TX RX TX RX TX RX MICRO UART COM 1 COM 4B NOTE 1 COM 4A NOTE 1 COM 2 COM 3 COM 5 OPTO COUPLE RS 485 RS 232 RS 485 RS 232 OPTIONAL I O HOT GAS BYPASS...

Page 47: ...e on pins 2 3 on style F and later chillers equipped with factory mounted thermal type flow sensors FACTORY MOUNTED EVAPORATOR THERMAL TYPE FLOW SENSOR style F and later chillers note 2 REMOTE CURRENT...

Page 48: ...JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS 48 FORM 160 54 M1 ISSUE DATE 03 11 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 49: ...ty Control ACC func tionality is contained in the microboard and the ACC Board is not used New production Style B LCSSS after mid 2008 The board is supplied with 12 VDC J1 3 12 VDC J1 4 5 VDC J1 1 and...

Page 50: ...ownloading the latest version from a Program card using the proce dure in the Service Replacement section of this manual Program Card The on board program can be upgraded by download ing the latest pr...

Page 51: ...temperature range is 20 to 65 C 4 to 149 F Alabel adhered to the Program card contains the version and YORK part number The version is an alphanumeric code that identifies the chiller model applicabi...

Page 52: ...imer that times out if not given a reset pulse within its time out period 1 to 2 25 sec onds To prevent a time out the microprocessor sends a reset pulse to the Watchdog circuit every time the complet...

Page 53: ...applying a 3 bit binary address to the multiplexer A 0 to 5 VDC analog value is returned from each channel The function of each is in the table below The microprocessor determines which board and ther...

Page 54: ...new production VSD communicate with Microboard 031 02430 001 using the same interface protocol After March 2007 new production Variable Speed Drives communicate with Microboard 031 02430 001 via COM2...

Page 55: ...temperatures and status from the microboard It holds it for retrieval by third party de vices See SECTION 19 COMMUNICATIONS of this manual Digital inputs The I O Board converts the 115 VAC inputs to...

Page 56: ...low rate less than the setpoint is sensed the solid state relay output is turned OFF resulting in no conduction through the load resis tor This applies less than 1 VDC to the microboard in put To dete...

Page 57: ...ay Interface Board to determine the manufacturer of the display Each display manufacturer requires a slightly different control The program in the BIOS EPROM configures the microboard for correct oper...

Page 58: ...SETPOINTS AND RESET PROCEDURES of this manual Chilled Liquid Pump Operation Determines Chilled Liquid Pump control contacts I O Board TB2 44 45 operation when chiller shuts down on cycling shutdowns...

Page 59: ...Drive Oil Pump have a Program controlled Oil Heater and a different complement of solenoid valves than chillers equipped with a Fixed Speed Oil Pump A de scription of the two Oil Pumps is as follows...

Page 60: ...tate Starter Applications Enter 1 for the Motor Node ID setpoint Then set the Mod busAddress of the Logic Trigger Board 031 02505 to 1 by setting Switch SW1 Position 1 to ON with all other positions O...

Page 61: ...ice Replacement If the microboard is replaced within the warranty pe riod the defective board must be returned to YORK per the warranty return procedure Use the return in structions and return address...

Page 62: ...1 031 01730 000 031 02028 000 031 01796 002 NOTE Refer to the following BRAM transfer exception When transferring a 32KB BRAM from 031 02430 000 Board to 031 02430 001 board applications other than MV...

Page 63: ...s 2 and 3 left hand pins 4 Insert Program card into Microboard connector U33 5 Restore power to OptiView Control Center A white screen appears displaying Flash Check sum Test and the microboard 7 segm...

Page 64: ...d LG Semicon LP104V2 W 031 02046 000 displays JP4 Display Backlight enable signal logic levels De termines the logic levels of the Backlight Enable signal Pins 1 2 12 VDC 0 VDC not used Pins 2 3 5 VDC...

Page 65: ...1 2 Not Used Pins 2 3 Factory mounted condenser Thermal type flow sensor new production chillers be fore June 2009 JP23 Remote Current Limit setpoint J22 type Con figures Analog Input for 0 to 10 VDC...

Page 66: ...D 031 02430 000 AND 031 02430 001 JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS Figure 17 MICROBOARD 031 02430 000 AND 031 02430 001 LD09254a Jumpers Test Points L E D Switches PROGRAM SWITCHES PROGRAM DO...

Page 67: ...IN WRITE PROTECT POSITION SWITCH IN WRITE POSITION 031 02474 001 LD09255A 3 3 VDC VOLTAGE REG 2 5 VDC VOLTAGE REG 5 VDC GND TP1 5 VDC VCC 3 3 VDC F1 J1 1 J1 2 5A TP3 TP2 2 5 VDC TP5 5 VDC VOLTAGE REG...

Page 68: ...S CONTROL TO BACKLIGHT INVERTER BOARD JP8 JP7 5 0 VDC 10 K LD04054 NOTES 1 J6 6 not connected N C to Backlight Inverter Board when display is manufactured by Sharp or NEC 2 The position of Program Jum...

Page 69: ...s 2 and 3 for RS 232 operation The COM 2 RS 485 port is not present on 031 02430 000 Microboard LD15644 MICRO UART COM 1 COM 4B NOTE 1 COM 4A NOTE 1 RS 232 RS 485 COM 2 NOTE 3 RS 485 RS 232 PRINTER NO...

Page 70: ...ed to Microboard J14 See Figure 24 on page 72 3 Factory mounted evaporator Thermal type flow sensor new production chillers before June 2009 or Leaving Chilled Liquid Temperature Thermistor chillers e...

Page 71: ...D15436 NOTE 1 Program Jumper JP21 must be positioned on pins 2 3 REMOTE CURRENT LIMIT SETPOINT REMOTE LEAVING CHILLED LIQUID TEMP SETPOINT REMOTE SETPOINT GND CONNECTIONS 0 10 VDC 2 10 VDC 0 20 mA 4 2...

Page 72: ...as shown above Program Jumpers JP10 through JP12 must be positioned on pins 2 3 and software version C OPT 01 21 307 and later is required On new production chillers before June 2009 the Thermal type...

Page 73: ...separate bat tery backed up Real Time Clock to maintain the time during power outages The RTC Battery is a CR2032 button cell Lithium battery which can last over 10 years and is readily available at...

Page 74: ...components to ensure that those components are operational The sequence of events in the boot up process are list ed in the Table 8 on page 74 The progress and pass fail status of each step is displa...

Page 75: ...o enter the connector Operating temperature range for Commercial grade SD cards is 25 C to 85 C 13 F to 185 F A label on the Program card contains the version and JCI part number The version is an alp...

Page 76: ...g circuit times out and sends a reset to the microprocessor initiating a re boot If running the chiller shuts down The display momentarily blanks and the white screen is displayed while the boot up pr...

Page 77: ...used JP7 JP8 Display brightness control technique Determines whether the display brightness is controlled by a variable resistance or a variable voltage IN Variable voltage 0 to 5 0 VDC SHARP LQ10D367...

Page 78: ...Ohm terminating resistor across the COM5B RS 485 port IN Not used OUT Normal position no bias applied JP29 Applies a pull down voltage to the COM5B terminal IN Not used OUT Normal position PROGRAM SW...

Page 79: ...3 bit binary address to the multiplexer A 0 to 5 VDC analog value is returned from each chan nel The function of each is in Table 9 on page 79 The microprocessor determines which board and therefore...

Page 80: ...50Hz is selected on the SETUP Screen as the Motor Drive Type additional setpoints must be entered on this Screen The appropriate serial port COM2 Modbus or COM5 YORK must be enabled using the Motor Co...

Page 81: ...The microboard turns on the Triac by applying a logic low less than 1 VDC to the Triac driver on the I O Board It turns it OFF by applying a logic high greater than 4 VDC See SECTION 6 I O BOARD of t...

Page 82: ...evice A green RX LED illuminates as data is received from another device The RS 232 voltages are industry standard 5 to 25 VDC and 5 VDC to 25 VDC logic levels The RS 485 voltages are indus try standa...

Page 83: ...ment The microboard controls the backlight brightness via the Lamp Dimmer circuit output at J6 7 In order to extend the life of flourescent Backlight lamps the brightness is driven to 50 after 10 minu...

Page 84: ...D applications can be started at the completion of System Coastdown up to 5 times On the 5th shutdown a 10 minute timer is started and restart is inhibited until the timer has elapsed 2 Disabled Disab...

Page 85: ...s is as follows 1 YORK Enables COM 5 J15 serial port On Variable Speed Drive applications used when the microboard is interfaced to the VSD via the ACC Board On Style B Liquid Cooled Solid State Start...

Page 86: ...connected to the ACC Board In Modbus Protocol configuration it is con nected to the microboard J7 If not equipped with a VSD but equipped with Hot gas bypass the connection point is deter mined by whi...

Page 87: ...will need to be cut from the 02430 P20 plug Strip the 3 wires 1 8 and insert them in the new 03630 J20 plug Note that pin 1 on the 03630 board is oppo site of where it was on the 02430 board It is now...

Page 88: ...OptiView Control Center A white screen appears displaying Flash Check sum Test and the microboard 7 segment LEDs U25 and U26 displays Ch While this is dis played the microboard is performing a checksu...

Page 89: ...displayed in the Status Code box Otherwise a message in the status box indicates the step that failed 8 Remove power from OptiView Control Center 9 Remove Program card from Microboard connec tor J26...

Page 90: ...1 22 12 1 J9 10 20 1 11 CR61 J15 1 6 1 GND GTX GRX DTR TX1 RX1 DSR GND 8 J2 Printer BAS BLK RED To E Link Board DRX DTX SW1 ON 1 CR60 J33 1 4 RX4 TX4 RX1 TX1 RX5A TX5A TP1 GND To Keypad On Door To Dis...

Page 91: ...power supply voltages with a Digital Volt Meter in reference to Ground at TP1 or TP11 VOLTAGE TEST POINT VOLTAGE RANGE FUSE LED 5 VDC TP3 4 92 to 5 28 VDC F1 5A CR56 12 VDC TP4 11 58 to 12 5 VDC F2 5...

Page 92: ...TO BACKLIGHT INVERTER BOARD JP8 JP7 5 0 VDC 10 K LD04054 NOTES 1 J6 6 not connected N C to Backlight Inverter Board when display is manufactured by Sharp or NEC 2 The position of Program Jumpers JP7...

Page 93: ...SR GTX GRX TX1 RX1 CR42 CR41 R G CR36 CR39 R G TX4 RX4 TX2 RX2 CR37 CR40 R G COM 3 COM 5 OPTO COUPLE RS 485 3 2 1 4 5 1 2 3 4 5 6 J12 J15 TX RX COMMON NOTE 2 NOTE 2 5VDC GND SHIELD TX3 RX3 TX5 RX5 CR3...

Page 94: ...sensors are connected to Microboard J14 See Figure 32 on page 96 3 Factory mounted evaporator Thermal type flow sensor new production chillers before June 2009 or Leaving Chilled Liquid Temperature T...

Page 95: ...Evaporator flow sensor for chillers produced before June 2009 and Leaving Chilled Liquid Temperature sensor for Heat Pump Duty chillers REMOTE CURRENT LIMIT SETPOINT REMOTE LEAVING CHILLED LIQUID TEMP...

Page 96: ...Program Jumpers JP10 through JP12 must be positioned on pins 2 3 and software version C OPT 01 21 307 and later is required On new production chillers before June 2009 the Thermal type flow sensors a...

Page 97: ...ion of the I O Board contains 12 VDC coil relays that are driven by the microboard s logic level outputs The contacts of these 12 VDC relays operate the external 115 VAC coil de vices On the I O Board...

Page 98: ...ed previously in this section Triacs control the current through the open and close windings The Refrigerant Level Variable Orifice Actuator on new production chillers is manufactured by Belimo This a...

Page 99: ...eypad COMPRESSOR switch is placed in the Stop Reset O position On cycling shutdowns the contacts will close when the cycling condition clears On safety shutdowns the contacts will close only after the...

Page 100: ...from standard logic it remains closed During startup the operation is not changed from standard logic it remains closed for 1 minute af ter System run K13 Compressor Motor Starter start TB1 6 16 Cont...

Page 101: ...101 SECTION 6 I O BOARD FORM 160 54 M1 ISSUE DATE 10 25 2019 JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL 6 LD04055 Figure 33 I O BOARD...

Page 102: ...and H5 8 compressors FACTORY CONNECTIONS TB3 32 J2 1 TB3 30 TB3 28 TB3 71 TB3 70 TB3 18 TB3 80 TB3 81 J1 J1 J1 J1 J1 10 11 12 13 14 FIELD CONNECTIONS 115VAC 115VAC 115VAC TB4 7 TB4 1 TB4 8 TB4 1 TB4...

Page 103: ...NFIDENTIAL 6 Figure 35 I O BOARD TYPICAL OPTOCOUPLER CIRCUIT OPTO COUPLER TYPICAL 20 CKTS 5VDC J19 21 JI Y JI 22 23 NEUTRAL TB3 2 TB4 X TB3 X LD04057 Figure 36 I O BOARD TYPICAL FIELD CONNECTIONS 115V...

Page 104: ...MLM 01 04 xxx and later NOT USED NOT USED NOT USED NOT USED OIL HEATER ON OFF P compressors and all style F and later chillers equipped with Flash Memory Card version C MLM 01 07 xxx or later version...

Page 105: ...ESSOR MOTOR STARTER 115VAC NEUTRAL Q2 Q1 K13 K18 K14 TB1 6 TB1 16 16 1 53 CM TM NOTE 2 TO I O BOARD J2 1 TO I O BOARD TB3 32 START RUN STOP 1 HP Not applicable to P compressors or style F and later ch...

Page 106: ...RIGERANT LEVEL CONTROL CLOSE 3 2 VARIABLE GEOMETRY DIFFUSER ACTUATOR BARBER COLEMAN FIELD 115VAC OPEN CLOSE X L1 L2 3 2 TB1 158 TB1 160 TB1 159 1 2 2 1 G G TRIAC DRIVER TRIAC DRIVER J1 31 J1 30 VARIAB...

Page 107: ...d in each window of the pixel is a transistor the conduction of which determines the amount of light that will pass through the window The conduction of each transistor is controlled by a signal from...

Page 108: ...tion of this process is included in the preceding Microboard section and the Display Interface Board section that follows The DC power source to operate the Display is provided by the microboard J5 So...

Page 109: ...ges may damage the display 4 A laminated film is adhered to the display front glass surface to prevent it from being scratched Peel off very slowly to prevent static damage Always remove control power...

Page 110: ...nstallation New lamps may be installed as follows 1 Slide new lamp into Display from left to right un til lamp housing is fully inserted 2 Secure lamp with lamp retaining screw 3 Connect lamp AC power...

Page 111: ...pers per label 2 025 33752 000 before October 2002 025 40317 000 after October 2002 LIQUID CRYSTAL DISPLAY SHARP LQ10D368 MOUNTING PLATE DISPLAY INTERFACE BOARD 031 01765 002 DISPLAY CABLE 031 01769 0...

Page 112: ...0 003 BACKLIGHT INVERTER BOARD 031 01789 000 LABEL BACKLIGHT BULB 025 34564 000 4564 1 4 Figure 41 LIQUID CRYSTAL DISPLAY ASSEMBLY LG SEMICON LP104V2 W 031 02046 000 LD05525 NOTE 1 Configure Microboar...

Page 113: ...LAY PERIOD DISPLAY PERIOD DISPLAY PERIOD HSYNC ENABLE CLK 25 18 MHz RGB 39 72 NS Figure 43 LIQUID CRYSTAL DISPLAY TYPICAL CONTROL SIGNAL TIMING LD04066 NOTES 1 BP Back Porch 4 48 CLKS 2 FP Front Porch...

Page 114: ...4 M1 ISSUE DATE 10 25 2019 SECTION 7 LIQUID CRYSTAL DISPLAY JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS Figure 45 DISPLAY SHARP LQ104V1DG61 031 02886 000 AND LG LP104V2 W 031 02046 000 LD14075 SCREW FOR...

Page 115: ...open the voltage level is the VCC logic level which is either 3 3 VDC or 5 0 VDC depending on the display refer to Microboard Program Jumper JP2 The following are the different Display Interface Board...

Page 116: ...031 03441 000 J1 30 VCC J1 31 GND Display Interface Boards are available individually for service replacement The part number of the Display Interface Board for the installed display is listed on a l...

Page 117: ...CC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 GND GND CLK HSYNC VSYNC R0 R1 R2 R3 R4 R5 G0 G1 G2 G3 G4...

Page 118: ...9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 GND J1 J2 GND GND GND GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38...

Page 119: ...e signal This signal turns the lamp ON and OFF Some manufactur ers require this signal to be 12 VDC others require 5 VDC Program Jumper JP4 must be positioned to provide the required voltage Further s...

Page 120: ...DISPLAY BACKLIGHT INVERTER BOARD SHARP LQ10D367 368 031 01774 000 AND LG SEMICON LP104V2 W 031 02046 000 LD09568a J6 10 9 8 7 6 5 4 3 2 1 N C N C N C N C N C N C MICRO BOARD INVERTER BOARD 1 2 3 4 5 N...

Page 121: ...LIGHT ENABLE NOTE 1 GND GND 12 VDC NOTE 3 12 VDC NOTE 3 DISPLAY BACKLIGHT INVERTER BOARD PART NUMBER 031 02889 000 FOR SHARP LQ104V1DG6 031 02886 000 DISPLAYS RETURN 500 1400 VAC Figure 49 DISPLAY BAC...

Page 122: ...JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS 122 FORM 160 54 M1 ISSUE DATE 03 11 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 123: ...e remaining rows and reads the columns A logic low in any column in dicates a key in that column and row is pressed For example if at the time row 4 is being driven low if column 3 is low then the mic...

Page 124: ...124 FORM 160 54 M1 ISSUE DATE 10 25 2019 SECTION 10 KEYPAD JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS Figure 50 KEYPAD INTERFACE CONNECTOR LD04074...

Page 125: ...125 SECTION 10 KEYPAD FORM 160 54 M1 ISSUE DATE 10 25 2019 JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL 10 Figure 51 KEYPAD LD04075 LD04076...

Page 126: ...JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS 126 FORM 160 54 M1 ISSUE DATE 03 11 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 127: ...circuits and is labeled as the 5 VDC Analog supply It is also routed to all Pressure Trans ducers Temperature Thermistors Proximity probe and Motor Controller Board CM 2 Mod A Solid State Starter Logi...

Page 128: ...Mod A Solid State Starter Logic Trigger Board Mod B Solid State Starter Adaptive Capacity Control VSD 5 Refer to FIGURE 66 67 68 and 69 starting on page 160 for Proximity probe Power Connections Not...

Page 129: ...tor current signal input at J1 1 and J1 2 is ap plied to potentiometer R8 This is factory adjusted field adjusted on service replacements to illuminate the 105 CURR indicator CR6 when the compressor m...

Page 130: ...essor motor Cur rent Limit at 100 FLA and 104 FLA When motor current rises to 100 FLA the microboard prevents any further current rise by inhibiting further Pre ro tation Vanes PRV opening until it de...

Page 131: ...ORM 160 54 M1 ISSUE DATE 10 25 2019 JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL 12 Figure 54 CM 2 CURRENT MODULE ELECTROMECHANICAL STARTER APPLICATION LD04079 Figure 55 CM 2 CURRENT MODULE ELECTROMECHAN...

Page 132: ...ower supply B Requires passing motor lead through CT twice before connect ing to power supply C Requires passing motor lead through CT three times before connecting to power supply D Calculates resist...

Page 133: ...bed below for the Style B LCSSS Microboard 031 02430 001 equipped with the 128K BRAM and software C OPT 01 15 xxx or later is re quired for this application Microboard Program Jump ers JP14 and JP17 m...

Page 134: ...er Board is replaced with 031 02505 in new production chillers YORK protocol is used until mid 2008 See Figure 58 on page 137 On new production chillers after mid 2008 Microboard 031 02430 001 COM 2 J...

Page 135: ...el designation Thefollowingaretheprogrammablesetpointsassociated with the LCSSS They are programmed on the MOTOR Screen See programming instructions in SECTION 33 SYSTEM CALIBRATION SERVICE SETPOINTS...

Page 136: ...or Pulldown Demand Limit setpoint 30 to 100 FLA that is in effect The microboard calculates the Full Load Amps FLA by divid ing the highest phase of the 3 phase motor current received from the Logic T...

Page 137: ...GND RX TX 5 4 3 2 1 TB2 TB1 24 16 53 START STOP STARTER MOTOR CONTROLLER INITIATED SHUTDOWN 115VAC 16 53 TB6 TB6 25 24 2 36 37 25 16 1 TB5 TB1 J2 LD04648B NOTES CONDOR Power Supply 13 POWER ONE Power...

Page 138: ...CATIONS MODBUS PROTOCOL CONTROL CENTER SOLID STATE STARTER GND 24 VDC J13 6 J30 P30 6 12 J1 J19 J2 2 36 37 10 J20 2 8 9 MOTOR CONTROLLER SHUTDOWNS STOP COM2 START GND 12 VDC 5 4 3 2 1 1 2 3 4 TB2 J14...

Page 139: ...L LED illuminates and remains illuminated until manu ally reset with the S1 RESET switch The chiller will automatically restart when the contacts close The Starter Trigger Board monitors the Starter s...

Page 140: ...VAC maximum FLA 551 full scale 1574A 1 77 to 2 39 VDC 26L 300 VAC maximum FLA 916 full scale 2938A 2 40 to 3 08 VDC 26L 600 VAC maximum FLA 916 full scale 2938A 3 09 to 3 87 VDC 33L 300 VAC maximum F...

Page 141: ...NTERFACE LD04649 CONTROL CENTER SOLID STATE STARTER POWER SUPPLY MICRO BOARD I O BOARD L C S S S LOGIC PCB 031 00936 2 36 37 2 36 37 J1 J19 J1 2 MOTOR CONTROLLER SHUTDOWN J1 36 STOP J1 37 START 25 16...

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Page 143: ...COM2 Modbus or COM5 YORK must be enabled using the Motor Communications Protocol setpoint The selections are Modbus or York Microboard 031 02430 001 must be equipped with 128KB BRAM 031 02565 000 to...

Page 144: ...VSD Logic Board s response and the Harmonic Filter s response to the microboard There are three different commands issued from the mi croboard Test and Initialize Fault Data Request Status Data Reques...

Page 145: ...1 for complete listing of messages and begins send ing normal Status Data Request commands If the fault data is not returned to the microboard within 2 seconds it sends the command every 2 seconds unt...

Page 146: ...or current is less than 80 FLA 0 2 Hz every 1 FLA 80 second if Leaving Chilled Liquid Temperature is greater than 0 2 F below the setpoint and the motor current is greater than 80 but less than 98 FLA...

Page 147: ...ement resulting in leaving chilled liquid temperature control instability This instability can be reduced by adjusting the Sen sitivity setpoint on the OptiView EVAPORATOR Screen The 50 selection redu...

Page 148: ...s illuminated as a visual indication that one or both of these conditions are in effect Otherwise the speed is increased 0 8Hz and the surge event is plotted on the Surge Map The Surge Margin Adjust s...

Page 149: ...on page 152 It coordinates the serial data communications between the OptiView Control Center Microboard and the VSD Logic Board and Harmonic Filter Logic Board This serial data is in 0 to 5 VDC form...

Page 150: ...s shown for reference only It momentarily illuminates when the Surge Protection feature See SECTION 25 SURGE PROTECTION detects a surge These are only those surges that occur while the drive is runnin...

Page 151: ...to de crease the frequency below the mapped point In previous software versions the initial ramp is com plete when either of the following conditions occur Delta T is less than ACC Mapping Enable VSD...

Page 152: ...IAL JOHNSON CONTROLS MICROBOARD RECEIVE LED VSD TRANSMIT LED VSD RECEIVE LED MANUAL SURGE POINT SWITCH MICRO TPC POWER FAIL MICRO BOARD TRANSMIT LED SURGE LED VALID SURGE POINT LED TPB GND TPA 5 VDC B...

Page 153: ...gure 63 SERIAL COMMUNICATIONS INTERFACE YORK PROTOCOL LD12567 10 8 J8 COND PRESSURE EVAP PRESSURE TX GND RX J18 1 2 3 J11 1 2 3 VSD LOGIC BOARD 031 01433 031 02077 031 02506 ADAPTIVE CAPACITY CONTROL...

Page 154: ...COMPANY CONFIDENTIAL JOHNSON CONTROLS Figure 64 SERIAL COMMUNICATIONS INTERFACE MODBUS PROTOCOL LD12569 VSD LOGIC BOARD 031 02506 MICROBAORD 031 03630 001 031 02430 001 GND 12 VDC J11 1 2 3 J16 2 3 4...

Page 155: ...2 3 BRAM EPROM RAM MICRO J8 3 1 RED GREEN SERIAL DATA CR5 CR4 VS XMT VS RCV VSD LOGIC BOARD J10 J3 3 1 RED GREEN SERIAL DATA CR6 CR7 YM RCV YM XMT 2 3 HARMONIC FILTER LOGIC BOARD J6 2 1 POWER SUPPLY...

Page 156: ...156 FORM 160 54 M1 ISSUE DATE 10 25 2019 JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 157: ...logged on a label adhered to the inside of the OptiView Control Center door This value remains the Reference Position until the compressor is rebuilt whereupon the calibration proce dure must be repea...

Page 158: ...Table 12 on page 159 For service replacement refer to part number listed in Renewal Parts OptiView Control Center Form 160 54 RP1 or the unit renewal parts manual For Microboard 031 01730 000 Microboa...

Page 159: ...e probe See Figure 67 on page 160 025 35900 001 24 VDC 5 VDC Production from March 2003 until March 2006 Senses proximity only Does not sense High Speed Drain Temperature Supersedes probe 025 35900 00...

Page 160: ...gic Board or Adaptive Capacity Control Board as determined by the Starter Application Figure 66 PROXIMITY PROBE INTERFACE PROBE PART NUMBER 025 30961 000 LD04090 LD05532C NOTES 1 24 VDC Reference for...

Page 161: ...5 40496 002 and Probe to Electronics Module interconnecting cable 025 40496 003 5 When replacing previous probe versions with this probe use the existing cable and retrofit kit 364 51806 000 consistin...

Page 162: ...ON 15 PROXIMITY PROBE JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS Figure 69 PROXIMITY PROBE LD06510 LD05529a 24VDC PROBE 2 0 YORK PART NUMBER 025 30961 000 24VDC PROBE 2 0 YORK PART NUMBER 025 35900 000...

Page 163: ...e switch to the pressure inside the com pressor A set of normally closed contacts inside the switch open when the switch is exposed to a pressure of greater than 15 to 25 psig One side of these contac...

Page 164: ...25 2019 SECTION 16 HIGH SPEED THRUST BEARING LIMIT SWITCH JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS Figure 71 HIGH SPEED THRUST BEARING LIMIT SWITCH GRD PIN GRN YEL PINS 1 AND 2 BLK GRN YEL PRESSURE...

Page 165: ...ET PROCEDURES of this manual There are different versions of the Level Sensors as shown in Figure 71 on page 164 The operation of the sensors is the same However the differences affect the way the sen...

Page 166: ...d to the actuator to maintain the level to the Level setpoint The duration of the sig nal determines the magnitude of change to the Orifice position The duration of the signal and whether it is an ope...

Page 167: ...rther yields smaller influence To establish 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...

Page 168: ...168 FORM 160 54 M1 ISSUE DATE 10 25 2019 SECTION 17 REFRIGERANT LEVEL CONTROL JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS Figure 72 REFRIGERANT LIQUID LEVEL SENSOR LD09256 F UP E DN MAX MIN OR 1 2 3...

Page 169: ...61 162 REFER TO FIGURE 29 CLOSE OPEN I O BOARD J1 28 29 TB1 163 161 162 REFER TO FIGURE 29 CLOSE OPEN LEVEL OUTPUT GND 12VDC 3 2 1 LIQUID LEVEL SENSOR ORIFICE VALVE ACTUATOR BARBER COLEMAN ACTUATOR 11...

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Page 171: ...or the remainder of System run and the Coastdown period it operates it over the same frequen cy range to maintain the pressure to the programmed oil pressure setpoint When the chiller is started 13 se...

Page 172: ...eed command is changed as required to invoke VSD fre quency changes to increase or decrease the oil pres sure If the error between the Oil Pressure setpoint and the actual oil pressure is less than pl...

Page 173: ...rs and all Style F and later chillers When the oil pump is not operating the heater is turned ON and OFF to maintain a target value of 50 F above the Condenser Saturation Temperature If the calculat e...

Page 174: ...SPEED COMMAND START STOP 12VDC MICRO BOARD J19 J20 35 PWM V EN OIL PUMP VSD I O BOARD TB1 J1 35 6 6 34 TB3 70 OIL HEATER ON OFF OIL PUMP IM OIL HEATER 1HTR 2 STATUS VSD 70 STATUS 0 7 SEC 12VDC 0VDC 12...

Page 175: ...t is connected to the E Link Gateway is going to provide remote Start Stop signals Remote Leaving Chilled Liquid Temperature and or Remote Current Limit Setpoint Resets the Con trol Source must be set...

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Page 177: ...ducers are compared in a process called auto zeroing The differential between the sump and pump oil pressure transducer outputs during a 3 second pe riod beginning 10 seconds after the start of the Sy...

Page 178: ...INAL OUTPUT MILLIVOLTS PRESSURE PSIG NOMINAL OUTPUT VOLTAGE OIL PRESSURE LOW SIDE R22 WATER AND BRINE APPLICATIONS YORK PART NO 025 28678 004 V VOLTS DC P PRESSURE PSIG V P 4 375 58 75 P 58 75 x V 4 3...

Page 179: ...Condenser Hi and Lo Oil X X 025 28678 112 Evaporator X X 025 28678 104 Evaporator X X 025 28678 115 Evaporator Heat Pump Duty X X 025 39464 000 025 40088 000 Stall Detection X X NOTE Transducers 025...

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Page 181: ...s resistor on the mi croboard thus forming a voltage divider network The temperature applied to the thermistor determines the resistance value The resistance value determines the amount of current tha...

Page 182: ...79 5 67 1 8182 21 88 5 62 1 8213 21 97 5 57 1 8243 22 06 5 52 1 8274 22 15 5 47 1 8304 22 24 5 42 1 8335 22 33 5 37 1 8365 22 42 5 32 1 8396 22 51 5 27 1 8426 22 60 5 22 1 8457 22 69 5 17 1 8487 22 7...

Page 183: ...1476 31 41 0 33 2 1506 31 49 0 28 2 1536 31 58 0 23 2 1567 31 67 0 18 2 1597 31 76 0 13 2 1628 31 84 0 09 2 1658 31 93 0 04 2 1689 32 02 0 01 2 1719 32 10 0 06 2 1750 32 19 0 11 2 1780 32 28 0 16 2 1...

Page 184: ...16 5 09 2 4891 41 24 5 13 2 4921 41 33 5 18 2 4952 41 42 5 23 2 4982 41 51 5 28 2 5012 41 60 5 33 2 5043 41 69 5 38 2 5073 41 78 5 43 2 5104 41 87 5 48 2 5134 41 96 5 53 2 5165 42 05 5 58 2 5195 42 1...

Page 185: ...8 16 55 3 1568 61 88 16 60 3 1599 61 98 16 66 3 1629 62 08 16 71 3 1660 62 18 16 77 3 1690 62 28 16 82 3 1721 62 39 16 88 3 1751 62 49 16 94 3 1782 62 59 17 00 3 1812 62 69 17 05 3 1843 62 80 17 11 3...

Page 186: ...24 29 3 5410 75 84 24 36 3 5441 75 96 24 42 3 5471 76 08 24 49 3 5501 76 20 24 56 3 5532 76 32 24 62 3 5562 76 44 24 69 3 5593 76 57 24 76 3 5623 76 69 24 83 3 5654 76 81 24 90 3 5684 76 93 24 96 3 57...

Page 187: ...33 01 0 56 2 0264 35 30 1 83 2 1045 TEMP F TEMP C VIN 37 58 3 10 2 1826 39 87 4 37 2 2607 42 15 5 64 2 3389 44 45 6 92 2 4170 46 76 8 20 2 4951 49 09 9 49 2 5732 51 44 10 80 2 6514 53 82 12 12 2 7295...

Page 188: ...25 44 3 64 1 9434 25 58 3 57 1 9482 25 72 3 49 1 9531 25 86 3 41 1 9580 26 00 3 33 1 9629 26 14 3 26 1 9678 26 28 3 18 1 9727 26 42 3 10 1 9775 26 56 3 02 1 9824 26 71 2 94 1 9873 26 85 2 86 1 9922 2...

Page 189: ...9 15 9 53 2 7588 49 30 9 61 2 7637 49 44 9 69 2 7686 49 59 9 77 2 7734 49 74 9 86 2 7783 49 89 9 94 2 7832 50 04 10 02 2 7881 50 19 10 11 2 7930 50 34 10 19 2 7979 50 48 10 27 2 8027 50 63 10 35 2 807...

Page 190: ...33 70 63 21 46 3 4082 70 81 21 56 3 4131 70 99 21 66 3 4180 71 17 21 76 3 4229 71 36 21 87 3 4277 71 54 21 97 3 4326 71 72 22 07 3 4375 71 91 22 17 3 4424 72 09 22 27 3 4473 72 28 22 38 3 4521 72 46 2...

Page 191: ...7 1 57 2 0728 31 41 0 33 2 1509 33 66 0 92 2 229 TEMP F TEMP C VIN 35 9 2 17 2 3071 38 15 3 42 2 3853 40 41 4 67 2 4634 42 69 5 94 2 5415 44 99 7 22 2 6196 47 31 8 51 2 6978 49 67 9 82 2 7759 52 06 11...

Page 192: ...3 10 68 2 2021 51 38 10 77 2 2070 51 53 10 85 2 2119 51 68 10 93 2 1268 51 83 11 02 2 2217 51 97 11 10 2 2266 52 12 11 18 2 2314 52 27 11 26 2 2363 52 42 11 35 2 2412 52 57 11 43 2 2461 52 72 11 51 2...

Page 193: ...2 24 74 2 9980 76 69 24 83 3 0029 76 85 24 92 3 0078 77 02 25 01 3 0127 77 19 25 11 3 0176 77 36 25 20 3 0225 77 53 25 30 3 0273 77 70 25 39 3 0322 77 86 25 48 3 0371 78 03 25 57 3 0420 78 20 25 67 3...

Page 194: ...3 6328 101 23 38 46 3 6377 101 45 38 59 3 6426 101 67 38 71 3 6475 101 89 38 83 3 6523 102 11 38 95 3 6572 102 33 39 08 3 6621 102 55 39 20 3 6670 102 78 39 33 3 6719 103 00 39 45 3 6768 103 22 39 57...

Page 195: ...20 0 6201 65 09 18 38 0 6250 65 42 18 57 0 6299 65 75 18 75 0 6348 66 08 18 93 0 6396 66 40 19 11 0 6445 66 72 19 29 0 6494 67 04 19 47 0 6543 67 36 19 65 0 6592 67 68 19 82 0 6641 68 00 20 00 0 6689...

Page 196: ...5 80 41 00 1 4307 105 99 41 11 1 4355 106 19 41 22 1 4404 106 39 41 33 1 4453 106 59 41 44 1 4502 106 79 41 55 1 4551 106 99 41 66 1 4600 107 19 41 78 1 4648 107 39 41 89 1 4697 107 59 42 00 1 4746 10...

Page 197: ...66 136 55 58 09 2 2314 136 73 58 19 2 2363 136 92 58 29 2 2412 137 10 58 39 2 2461 137 28 58 49 2 2510 137 46 58 59 2 2559 137 65 58 70 2 2607 137 83 58 80 2 2656 138 01 58 90 2 2705 138 19 59 00 2 27...

Page 198: ...5 75 81 3 0469 168 66 75 93 3 0518 168 87 76 04 3 0566 169 07 76 16 3 0615 169 28 76 27 3 0664 169 49 76 39 3 0713 169 70 76 51 3 0762 169 91 76 62 3 0811 170 12 76 74 3 0859 170 33 76 86 3 0908 170 5...

Page 199: ...1 93 96 3 7158 201 39 94 11 3 7207 201 68 94 27 3 7256 201 97 94 44 3 7305 202 25 94 59 3 7354 202 54 94 75 3 7402 202 82 94 91 3 7451 203 11 95 07 3 7500 203 40 95 23 3 7549 203 69 95 39 3 7598 203 9...

Page 200: ...29 78 3 254 88 56 31 42 3 332 91 59 33 11 3 410 94 75 34 86 3 488 98 06 36 70 3 566 101 50 38 61 3 644 105 10 40 61 3 722 108 90 42 73 3 801 112 92 44 96 3 879 117 17 47 32 3 957 121 76 49 87 4 035 T...

Page 201: ...EMPERATURE SENSOR TEMP F TEMP C VIN 32 63 0 35 1 713 37 47 3 03 1 870 42 23 5 68 2 026 46 96 9 97 2 182 51 68 10 93 2 338 56 44 13 57 2 495 61 28 16 26 2 651 66 23 19 01 2 807 71 36 21 86 2 963 76 70...

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Page 203: ...the locally programmed Local BASE value ISN BAS Remote Mode ISN Remote Mode uses RS 232 serial port via E Link Gateway The Analog Inputs are connected to the microboard J22 as shown in Figure 30 on p...

Page 204: ...roboard J22 1 signal and J22 5 GND The setpoint varies linearly from 100 to 30 FLA as the input varies from 2 to 10 VDC This input will only be accepted when Analog Remote Mode is selected the Remote...

Page 205: ...F water applications with Smart Freeze protection enabled 10 F to 70 F brine applications The Remote Input Signal changes the setpoint by cre ating an offset above the locally programmed Leaving Chil...

Page 206: ...t to Microboard J22 3 signal and J22 5 GND A 0 VDC signal produces a 0 F offset A 10 VDC signal produces the maximum offset above the Local setpoint value as al lowed by the Remote Reset Temperature R...

Page 207: ...uces the maximum allowed offset above the Local Setpoint value as allowed by the Remote Reset Temperature Range setpoint The relay contacts should close for 1 to 11 seconds at least once every 30 minu...

Page 208: ...t must be set to 0 to 10 VDC or 2 to 10 VDC as detailed below regardless of the whether the signal is a voltage or current signal type The Remote Reset Temperature Range in the fol lowing descriptions...

Page 209: ...B4 1 115 VAC A 1 second closure produces a 0 F offset An 11 second closure produces the maximum allowed offset above the Local Setpoint as allowed by the Re mote Reset Temperature Range setpoint Selec...

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Page 211: ...Operations The load conditions are represent ed by the value Temperature Differential Leaving Chilled Liquid Temperature minus setpoint on the hot gas screen The surge events it reacts to are de tect...

Page 212: ...f Heat Pump Duty is enabled the Hot gas operates as it does in a standard YK chiller without Heat Pump ability However in Heating Mode Hot gas operation is the same as Cooling Mode except for the oper...

Page 213: ...ot gas bypass Screen in SERVICE access level Manual control has priority over Minimum Load Override Variable Speed Drive Override and Auto matic Control When the OPEN or CLOSE key is pressed the valve...

Page 214: ...any compatibility issues PRE ROTATION VANES POTENTIOMETER A 2 5K ohm potentiometer mounted on the Pre rota tion Vanes control arm provides a 0 to 5 VDC voltage that represents a PRV position of 0 ful...

Page 215: ...PRESSURE 18 21 12 11 12 11 2 3 J8 RS 485 COM 3 J12 ACTUATOR POSITIONING VANE POSITION J9 P1 P10 2 5 3 2 1 OPEN VANE POSITION 0 100 2 5 K OPTIONAL HOT GAS BYPASS ACTUATOR 0 10 VDC 3 24 VAC GND 2 1 GND...

Page 216: ...SDUCER HOT GAS BYPASS CONTROL VALVE 0 10VDC RS 485 COM 3 J7 VANE POSITION EVAP PRESSURE COND PRESSURE J12 2 3 22 10 11 J8 18 21 J9 4 12 3 11 TB1 VALVE POSITIONING SERIAL COMMS 2 3 AO1 GND OPEN NOTES 1...

Page 217: ...Temperature cycling shutdown threshold becomes a minimum of 34 0 F Unless Smart Freeze protection is activated the fixed Low Evaporator Pressure Safety thresholds R22 54 3 psig 29 6 F R 134a 25 0 psig...

Page 218: ...Low Leaving Chilled Liquid Tem perature cycling shutdown threshold is 1 to 34 0 F below the Leaving Chilled Liquid Temperature setpoint as programmed or a minimum of 36 0 F 2 The Low Evaporator Pressu...

Page 219: ...Modbus Protocol configu ration The SURGE PROTECTION Screen accessible from the COMPRESSOR Screen displays all parameters relevant to this feature All setpoints for this feature are maintained on this...

Page 220: ...wn or Extended Run features have been enabled as explained below the chiller will continue to run under the same conditions displaying WARNING EXCESS SURGE DETECTED This message will be displayed unti...

Page 221: ...rsion C MLM 01 09 xxx and later or C OPT 09 301 and later The Extended Run Mode Shutdown Mode and EXCESS SURGE WARNING message will not be implemented unless the VSD out put frequency is at maximum Eq...

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Page 223: ...s the voltage pulsations into an analog voltage that represents the magnitude of the stall noise This analog voltage is displayed on the VARIABLE GE OMETRY DIFFUSER Screen as STALL DETECTOR VOLTAGE an...

Page 224: ...IME Stall Reacting If a stall is detected from the Probing Stall Waiting or Surge Waiting software version C OPT 01 23 307 and later states the state is changed to Stall Reacting In this state the dif...

Page 225: ...r the Open Pulse setpoint While this is in effect Control Status displays PRV POSITION OVERRIDE STALL SENSOR VALIDATION Software version C MLM 01 14 xxx and later or C OPT 01 14 306 and later This fea...

Page 226: ...VGD control remains in the Stall Waiting or Surge Waiting states before enter ing the Probing state Open Pulse 1 9 seconds default 2 Specifies the length of the open pulse applied to the VGD during 10...

Page 227: ...ith Stall Transducer 025 39464 000 Later chillers are shipped with Stall Transducer 025 40088 000 These transducers require different wiring connections at the transducer Check the part number of the...

Page 228: ...ince the PRV Position VGD Inhibit Setpoint was the original vehicle to avoid VGD reaction to high gas flow low head condi tions this setpoint should be set to 95 or 100 to avoid interference when Enha...

Page 229: ...Hold VGD for Probe Wait Time Look for 2nd Surge and if occurs set HG Control True HOT GAS OVERRIDE Hold VGD Wait timer done Detect Stall Hot Gas Valve Open Hot Gas Valve Open Hot Gas Valve Open Hot G...

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Page 231: ...R4 LED illuminates When the I O Board responds the I O Board s TX CR5 LED illuminates When the response is received at the microboard the microboard s RX3 CR16 il luminates SECTION 27 LARGE TONNAGE CH...

Page 232: ...S ANALOG INPUTS DIGITAL OUTPUTS PULL UP DOWN SELECTS see FIG 85 RELAYS see FIG 86 TRIACS see FIG 87 12VDC see FIG 88 LOAD RESISTORS see FIG 89 MUX MUX VOLTAGE DIVIDER 5VDC REG 24VDC 24V RET 12V RET 12...

Page 233: ...s a detail of an output and is rep resentative of all these outputs Each relay has one set of normally open contacts that are closed and opened under Program control The relay contact rating is 250 VA...

Page 234: ...5 VDC 0 to 10 VDC 4 to 20mA Transducer or Thermistor input The on board software configures each input per the requirements of the input type The configuration con sists of selecting the appropriate i...

Page 235: ...ard only 14 AI13 15 Ret AI14 J11 16 5 VDC 001 board only 17 AI14 18 Ret AI15 J11 19 5 VDC 001 board only 20 AI15 21 Ret AI16 J11 22 5 VDC 001 board only 23 AI16 24 Ret ANALOG OUTPUTS There are five an...

Page 236: ...creen available as follows Service Access level The voltage value of each analog input at the board in put terminals pins as interpreted by the I O Board and transmitted to the microboard is displayed...

Page 237: ...t recovery circuit control is only active when the flow sensor indicates flow If the chiller is equipped for Heat Recovery the feature must be ENABLED on the SETUP Screen Otherwise it must be DISABLED...

Page 238: ...ATING CONDENSER WATER THERMISTOR REMOTE HOT WATER SETPOINT 0 10VDC or 4 20mA HEATING CONDENSER WATER FLOW SWITCH 120VAC NOTE 2 NOTE 2 NOTES 1 If Head Pressure Control is ENABLED and Hot Water Control...

Page 239: ...4 to 20mA input signal type for the Re mote Hot Water setpoint input When Hot Water Control is active the Control Valve Output is modulated by a direct acting PID control The inputs to the PID control...

Page 240: ...enabled there is not a Control Valve for each feature Rather there is one common valve that is either performing Hot Water Con trol for Heat Recovery or it is performing Head Pres sure Control It wil...

Page 241: ...figure the LTC I O Board input TB9 3 4 to accept either a 0 to 10 VDC or 4 to 20mA input for the Remote setpoint input This setpoint must be set to the same value for the actual input applied Otherwis...

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Page 243: ...rogrammed Head Pres sure Condenser Pressure minus Evaporator Pressure setpoint The output is direct acting as the Head Pres sure increases above the setpoint the valve is driven more open to provide l...

Page 244: ...everse acting default Direct Set to Direct for this application SET Is used to manually set the Head Pres sure Control Valve to any position between 0 0 and 100 AUTO Returns the Head Pressure Control...

Page 245: ...is displayed and the valve is set to 0 position Which feature is controlling the vale at any given instant and when it is inactive is determined by operating conditions as shown in flow chart in SECTI...

Page 246: ...JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS 246 FORM 160 54 M1 ISSUE DATE 03 11 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 247: ...ept for the trig ger board with 115 VAC from a UPS will reduce the time to restart after a power failure due to elimination of the OptiView reboot time This provides the fastest possible ability to st...

Page 248: ...down If the Quick Pulldown Setpoint Offset is not reached in the Pulldown Override Time PRV and ACC speed control will revert back to normal automatic control VSD Start Frequency 60Hz units with quick...

Page 249: ...emote is present No faults inhibits present Chilled liquid flow switch is closed Since there is no Pre lube the Auto zeroing that nor mally occurs between the Oil Pressure Transducers during Pre lube...

Page 250: ...setpoint has elapsed whichever occurs first or the motor current is greater than 100 FLA the Quick Pulldown terminates and all VSD speed control returns to normal control Summary The following table c...

Page 251: ...is kept on for 30 seconds after coastdown is completed If a quick restart is not initi ated within 30 seconds of the end of coastdown the pump is returned to normal control Condenser Level Control Wh...

Page 252: ...ailable to it from TB5 23 when the chiller run signal is enabled Since the Oil Heater logic with Quick Start as described above requires the heater to be turned on while the Oil Pump is running which...

Page 253: ...en enabled Heat Pump Duty becomes dis abled and disappears from the SETUP Screen When enabled the HEAT PUMP Screen is accessible from the CONDENSER Screen Operational Mode Sets the Heat Pump operation...

Page 254: ...en this temperature is reached This setpoint can be used to reduce chiller cycling by delaying the Heat Pump restart until the heating load has increased Requires OPERATOR or higher access level Heati...

Page 255: ...xceeds the Minimum Load setpoint 1 to 4 F above the Leaving Condens er Liquid Temperature Setpoint the Hot gas valve is opened to the position allowed per the Maximum Open setpoint 25 to 100 For examp...

Page 256: ...MA input J22 4 3 Input resets Leaving Chilled Setpoint when heat pump operational mode setpoint is set to Cooling Input resets Leaving Condenser Setpoint when heat pump operational mode setpoint are...

Page 257: ...R DETAILS Screen allow any combination of these items to be enabled or disabled based on the actual equipment applied The motor could be equipped with different types of sensors for this monitoring Ei...

Page 258: ...T PROGRAMMING PORT RX CR12 TX CR13 STATUS CR8 1 8 4 2 SW1 J1 P R O C E S S O R 5VDC REG 15VDC REG POWER CR6 CR18 19 CR16 17 SELECT MUX SELECT MUX SELECT DIGITAL INPUTS CONFIGURABLE ANALOG INPUTS RTD A...

Page 259: ...ing 000 or 001 The different boards are identified by the 3 digit suffix 000 or 001 The 001 board is fully populated and can be used in any application On the 000 board the RTD analog input and vibrat...

Page 260: ...emperatures are sent via existing VSD to Microboard Serial Communications 3 The 001 board is required 4 Either the 000 or 001 board can be used 5 Bearing temperatures can either be provided via direct...

Page 261: ...tch is open low when closed In the Pull down configuration the input is low when the input switch is open high when closed Both of these inputs have an LED DI1 and DI2 that il luminates when the input...

Page 262: ...d when the motor is not equipped with winding temperature sensors or if is desired to disable the feature for service rea sons This is the default setting The Motor Moni toring Board is commanded to n...

Page 263: ...NDING TEMPERATURE SHUTDOWN safety threshold is programmable over the range of 266 320 F default 311 The WINDING HOTSPOT ALLOW ANCE safety shutdown threshold is programmable over the range of 0 18 F de...

Page 264: ...s via the Motor Monitoring Board serial commu nications The microboard commands the Motor Monitoring Board to read the sensor inputs at the following points TB5 7 8 9 Motor Bearing Opposite Shaft End...

Page 265: ...be set to the sensor type that is used Once set the mi croboard via serial communications commands the Motor Monitoring Board to read the appropriate sen sor inputs and it also sends configuration co...

Page 266: ...Shaft End and Opposite Shaft End vibration values are compared to warning and safety shutdown thresholds The actual thresholds used will be either the values derived from the Vibra tion Baseline setpo...

Page 267: ...e baseline derived Shutdown and Warning thresh olds override the thresholds entered with the Vibration Setup setpoint Thresholds entered with the Vibration Setup setpoint after baseline derived Shutdo...

Page 268: ...mands the Motor Monitoring Board to read the sensor input at TB8 4 5 6 The optical sensor contains a switch that is connected between TB7 5 input and TB7 6 GND With no leak being detected the switch c...

Page 269: ...57 53 967 129 14 13963 56 178 133 12 12902 58 332 137 00 11954 60 438 140 79 11101 62 503 144 51 10329 64 534 148 16 9629 66 538 151 77 8989 68 518 155 33 8403 70 482 158 87 7864 72 433 162 38 7367 74...

Page 270: ...JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS 270 FORM 160 54 M1 ISSUE DATE 03 11 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 271: ...y 4 If the dialog box begins with the word Enter use the numeric keys to enter the desired value Lead ing zeroes are not necessary Press the key to place a decimal point at the appropriate place Press...

Page 272: ...ve this voltage Adjust both resistors equally such that the combined resistance equals the cal culated value 6 Manually operate the Pre rotation Vanes by pressing the OPEN CLOSE and HOLD Keypad keys a...

Page 273: ...to desired value 3 Press ENTER key Open SCR Enable Disable This allows the Open SCR safety check performed by the Logic Trigger Board to be disabled This must NEV ER be disabled unless advised by the...

Page 274: ...calibration if necessary If the Logic Board is field replaced field calibration is neces sary Logic Board Program Jumper JP5 300V 600V must be placed in the appropriate position per the com pressor mo...

Page 275: ...ad a Select COMPRESSOR Screen b Run chiller and monitor Compressor Motor current on the COMPRESSOR Screen c Manually operate the Pre rotation Vanes by pressing the OPEN CLOSE and HOLD keys as required...

Page 276: ...IVE CAPACITY CONTROL BOARD for the different pos sible configurations before proceeding 1 At the keypad log in at SERVICE access level unless otherwise noted using password 1 3 8 0 2 Enter the followi...

Page 277: ...ps VSD This is the Full Load Amps FLA of the chiller as listed on the SALES ORDER Screen The microboard uses the programmed value to perform Current Lim it functions and display compressor motor curre...

Page 278: ...C Mapping Enable software version C OPT 01 21 307 and later Modbus Pro tocol configuration only Sets the Delta T Leaving Chilled Liquid Temperature setpoint needed to be met to enable surge mapping an...

Page 279: ...y a qualified Service technician before restarting the chiller Depending upon the ac tual shutdown message the evaluation could require a bearing inspection To prevent the chiller from restart ing wit...

Page 280: ...reater than 50 0 F and less than or equal to 179 F 1 Place the keypad Rocker Switch in the Stop Reset O position 2 At the keypad login at SERVICE access level us ing access code 1 3 8 0 3 After Coastd...

Page 281: ...s Flash memory card version C MLM 01 06 xxx and later and P compres sors with C MLM 04 02 xxx The Default value varies depending upon the Flash memory card version and com pressor application versions...

Page 282: ...in model chillers the oil pump is driven by a small Variable Speed Drive A complete description of the Drive operation and the setpoints that affect this con trol are provided in SECTION 18 OIL PUMP V...

Page 283: ...Pre rotation Vanes are inhibited from further opening is program mable over the range of 44 9 to 162 5 psig R 134a or 84 0 to 246 3 psig R22 The Default value for R 134a is 162 5 psig The Default for...

Page 284: ...control operation PRV open and close pulses are standard durations for any given error Longest allowed pulse is 18 seconds in duration This selection will provide proper operation in most application...

Page 285: ...ature is displayed on the EVAPORATOR Screen and is also used in the SMART FREEZE PROTECTION LOW EVAPORA TOR PRESSURE safety shutdown threshold calculation as explained in SECTION 24 SMART FREEZE PRO T...

Page 286: ...s Service Office 2 Select OPERATIONS screen 3 Press NUMBER of STARTS or OPERATING HOURS key as appropriate 4 Using numeric keypad keys enter desired number 5 Press ENTER key SERVICE PHONE NUMBERS Appl...

Page 287: ...r Com missioning Date is entered at the YORK factory at the time of chiller manufacture The Service techni cian must enter the Chiller Commissioning Date and modify the Job Name or Job Location if nec...

Page 288: ...and minus sign can be selected after scrolling through the entire alphabet During the entry process the key can be used to backspace and the key can be used to forward space 8 Press ENTER key 9 Use an...

Page 289: ...TAILS key This moves to the SECURITY LOG DETAILS Screen The SECURITY LOG DETAILS Screen displays the following setpoint change details The setpoint is se lected from the list on the SECURITY LOG Scree...

Page 290: ...ct CHILLER STYLE COM PRESSOR combination must be entered Once the ap plicable Chiller Compressor combination is entered the program automatically bundles the functionality and chiller control per the...

Page 291: ...FAULT FLOW SWITCH OIL VARIABLE SPEED PUMP PRESSURE SETPOINT NOT ACHIEVED THRESHOLD Style CDE GHJ Compr Probe TB1 34 3 5 sec Digital Paddle Type 35 psid Style E P Compr Limit Switch TB1 64 10 0 sec Dig...

Page 292: ...n the Ther mal type flow sensors are connected to the microboard J7 See Figure 22 on page 70 Select DIGITAL when the Paddle type sensors are connected to the I O Board TB4 See Figure 34 on page 102 Wi...

Page 293: ...OPT 01 21 307 and later Head Pressure Control enable disable software version C OPT 01 21 307 and later Heat Pump Duty enable disable software ver sion C OPT 01 23 307 and later only appears when log...

Page 294: ...0 95 with software version C OPT 01 22 and earlier Software version C MLM 01 14 xxx and later or C OPT 01 14 306 and later Use the following procedure 1 At the keypad log in at SERVICE access level us...

Page 295: ...afety that is in effect and resets the Operating Hours Since Last Lubrication to zero will illuminate and an open signal is applied to the PRV After a 60 second delay the program begins evaluating the...

Page 296: ...iod decimal point During the entry process if it is desired to exit the dialog box and retain the previous entry press the CAN CEL X key 5 When all of the desired characters have been en tered press t...

Page 297: ...is done by entering his her initials name or User ID as a 3 to 8 character string The entry is displayed as the operator initials at Last Lubrication The date and time of this entry is automatically l...

Page 298: ...login at SERVICE access level us ing access level 1 3 8 0 2 From the MOTOR Screen select the MOTOR LUBE Screen 3 Press the AUTO LUBE key 4 Use the and keys to select Enable or Disable as desired per a...

Page 299: ...tpoints Refer to the HEAT PUMP Screen section in Operation Manual 160 54 O1 and enter the following setpoints Heating Sensitivity Operational Mode Leaving Condenser LiquidTemperature Setpoint Leaving...

Page 300: ...when the motor is equipped with bearing vibration sensors Set to Disabled when the motor is not equipped with bear ing vibration sensors or when it is desired to disable the feature for service reason...

Page 301: ...wn thresholds along with the vibration input gain Also individual winding temperature sen sors can be disabled on this screen Temperature Disable This setpoint allows the individual winding tempera tu...

Page 302: ...eline setpoints on MO TOR DETAILS screen The values used depend on the sequence in which they are entered Whichever values are entered last are the ones that are used The active threshold values are d...

Page 303: ...protection setpoint on the MOTOR DETAILS Screen is set to disabled To enter desired values 1 Press BEARING SETUP key A green box ap pears around the High Bearing Temperature Shut down setpoint 2 Pres...

Page 304: ...JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS 304 FORM 160 54 M1 ISSUE DATE 03 11 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 305: ...ual There are two versions of the Diagnostics screens available as follows 1 Shown in Figure 98 on page 257 through Figure 108 on page 308 These screens are used during the diagnostics and troubleshoo...

Page 306: ...nit Setpoints Many of the control parameters are automatically con figured by pressing this button after the Sales Order screen is entered Failure to press this button can result in unstable control N...

Page 307: ...lotted See Table 33 Data Logging on page 378 for a list of the chiller parameters that are data logged Eject SD Card Pressing this button before remov ing the SD card prevents it from being corrupted...

Page 308: ...the diagnostics have sub screens that are accessed from the selected diagnostic screen The sub screens are shown indented below MAIN SCREEN Monitor Monitoring Board software version C OPT 01 22 307 a...

Page 309: ...B1 8 Motor Winding Phase C Temperature 50K Ohm thermistor TB2 11 Not used TB2 8 Not used TB2 5 Not used TB2 2 Not used TB1 11 Not used VIBRATION INPUTS Gain Displays the value programmed for the Vibra...

Page 310: ...Leak Detector low voltage optical TB7 2 Not used TB8 5 6 Motor Cooling Coil Leak Detector float switch TB8 2 3 Not used MODBUS COMMUNICATION COUNTERS The following error counts are displayed Pressing...

Page 311: ...s displayed a xx xxmA The voltage value and the current value are directly scaled over their respective ranges of 0 to 10 VDC and 0 to 20mA For example when the voltage output ter minal 2 is at 0 VDC...

Page 312: ...herwise it is ex tinguished To test an output each output can be manually set to ON or OFF The motor controller circuit must be opened before manual control is allowed Removing J2 from the I O Board o...

Page 313: ...a Disconnect the Ribbon Cable from the keypad b Identify row column coordinate of the key to be tested See Figure 51 on page 125 c In the keypad connector locate the pins of the row column coordinate...

Page 314: ...ned by a red border are displayed If the vertical bars are not stable or straight or the red border is not com pletely visible then either the microboard Pro gram Jumpers are not configured correctly...

Page 315: ...iption of the All Red test above All White This test verifies the display s ability to turn on all pixels to display a completely white screen Any pixel that does not turn on will appear as a black do...

Page 316: ...fective component perform tests in the fol lowing order 1 Display Ribbon Cable Using an Ohmmeter perform a continuity test on all conductors in the ribbon cable An open circuit would indicate the ribb...

Page 317: ...20 through J5 25 should be greater than 3 0 VDC If not the microboard is defective e With the All Black test selected the volt age at Microboard J5 6 through J5 11 J5 13 through J5 18 and J5 20 throug...

Page 318: ...n must install a wire loop back connection as described below See SECTION 3 MICROBOARD 031 01730 000 and Figure 14 on page 46 of this manual for description of the Serial data Ports PROCEDURE 1 Using...

Page 319: ...ls COM 1 tests are terminated COM 2 Three tests are performed Test data is sent from TX J13 5 to RX J13 3 at 19200 Baud DTR J13 7 is set to a Logic High and read at DSR J13 2 and DCD J13 1 RTS J13 4 i...

Page 320: ...energize the relays The state of any output can be manually set to either the Enabled Logic Low or Disabled Logic High state PROCEDURE Digital inputs 1 The Digital inputs are listed on this screen acc...

Page 321: ...ing the de vice it is connected to If relay does not de ener gize or triac does not turn off perform appropriate troubleshooting procedure below 7 When all desired tests have been performed press DIAG...

Page 322: ...a If a relay is selected as the output the con tacts of the relay should be closed If they are not closed replace the I O Board b If a Triac is selected as the output the Triac should be turned on If...

Page 323: ...mperature Analog Input Proximity probe DC Volt age reference or a 0 to 10 VDC Remote Setpoint input at channels 27 and 28 The following is a list of the Analog Inputs displayed See the appropriate Sec...

Page 324: ...s malfunctioning All inputs except chan nel 0 15 through 22 27 and 28 are sensors that connect directly to the microboard via shielded cable Channel 0 is a reference voltage for the Analog circuits on...

Page 325: ...ify sensor accuracy using appropriate test de vice Replace the sensor if necessary Channels 15 22 1 Disconnect both ends of the ribbon cable connected to Microboard J10 Using an Ohmmeter perform a con...

Page 326: ...JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS JOHNSON CONTROLS 326 FORM 160 54 M1 ISSUE DATE 03 11 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 327: ...ess level To ensure access to all set points login at SERVICE access level before begin ning The setpoints are grouped under the display screen in which they appear The indented screens are subscreens...

Page 328: ...sion C MLM 01 07 xxx and later or C OPT 01 14 xxx and later ____ Ramp up Time Software ver sion C MLM 01 07 xxx and later or C OPT 01 14 xxx and later ____ Rate Limit Software version C MLM 01 14 xxx...

Page 329: ...esired pulldown demand limit and time setpoint 160 54 O1 Solid State Starter Applications 160 54 M1 Mod B Solid State Starter Verify the following setpoints were programmed ____ Full Load Amps ____ St...

Page 330: ...22 307 and later ____ Temperature Disable ____ Winding Setup ____ Vibration Setup ____ Vibration Gain ____ Bearing Setup 14 SETPOINTS Screen 160 54 O1 With the exception of the Remote Analog Input Ra...

Page 331: ...d later ____ Heat Pump Duty Enable Disable Software version C OPT 01 23 307 and later QUICK START Screen Software version C OPT 01 21 307 and later ____ Quick Start Mode Enable Disable ____ Quick Star...

Page 332: ...ptional Enable Disable ____ VariableGeometryDiffuser Enable Disable Chillers equipped with Variable Geometry Diffuser Software version C MLM 01 10 xxx and later or C OPT 01 10 302 and Later ____ Edit...

Page 333: ...p after the completion of one screen of data If stop is selected data collection will begin when manually initiated and will stop when all triggers have been sat isfied and any selected trigger delay...

Page 334: ...three inverter assemblies are mounted on a single baseplate instead of three individual heat sink assemblies like other models Therefore the VSD DETAILS screen and the HARMONIC FIL TER DETAILS screen...

Page 335: ...is terminated and it will im mediately enter a normal coastdown period Leaving Chilled Liquid Low Temperature Remote Stop Multi unit Cycling Contacts Open SI0019 SOFTWARE ENHANCEMENTS EFFECTIVE MARCH...

Page 336: ...re is now only executed imme diately after chiller start Subsequent ramp func tions during chiller run have been eliminated Rate Limit Open Setpoint Now programmable over the range of 5 to 50 Previous...

Page 337: ...will be supplied in place of 031 02073 002 The various YK chiller modification level style compressor combinations are equipped differently and have different control requirements Variables include t...

Page 338: ...d by the thermistors are compared Flowing liquid carries heat away from the heated sensor tip lowering its temperature The lower temperature differential between the two therm istors indicates the liq...

Page 339: ...evel control is disabled the refrigerant level lower output is energized Upon entering chiller pre lube the refrigerant level raise output is energized for the length of the programmable valve preset...

Page 340: ...be entered The se lections are ANALOG thermal type or DIGITAL paddle type If Analog is selected the program reads the thermal type flow sensor inputs at Microboard An alog Inputs J7 14 evaporator and...

Page 341: ...TER BASEPLATE TEMPERATURE Same as Phase A above HARMONIC FILTER HIGH BASEPLATE TEMPERATURE The chiller has shutdown because the baseplate tem perature has increased to greater than 194 F E LINK GATEWA...

Page 342: ...oint key is now labeled CHILLER STYLE COMPRESSOR English only The functionality of this setpoint has changed slightly as follows The previous choice of Style F chiller G H comp is now Style F chiller...

Page 343: ...um before the above surge features are performed SI0080 SOFTWARE ENHANCEMENTS EFFECTIVE JANUARY 2004 For all applications the count Window setpoint default is now three minutes was five minutes The co...

Page 344: ...revert to using the previous calibration values If they were not previously calibrated successfully they will remain uncalibrated VSD ADAPTIVE CAPACITY CONTROL STABILITY LIMIT SETPOINT This compresso...

Page 345: ...is anticipatory fault is only performed while the chiller is stopped If a CONDENSER HIGH PRES SURE fault is detected while the chiller is in pre lube system run or coastdown the fault is handled in th...

Page 346: ...hether the pump is running or not Invalid System Details Messages In previous flash memory card versions certain oper ating conditions that could cause messages on the sys tem details line of the disp...

Page 347: ...0 minutes the VGD is driven to the full open po sition and WARNING CONDITIONS OVERRIDE VGD is displayed until the stall detector voltage re turns to less than two times the high limit setpoint and the...

Page 348: ...greater than 15 FLA motor cur rent is detected while the chiller is shutdown Previ ously it was not put into effect until the invalid motor current was present for at least 10 seconds VSD FREQUENCY 0H...

Page 349: ...lf DC link voltage does not remain within plus or minus 106 VDC of the DC link voltage divided by 2 during the pre charge interval this shutdown is performed VSD LOW DC BUS VOLTAGE If the DC Link Volt...

Page 350: ...ion YK chillers It is backward compatible to all previous YK chillers equipped with microboard P N 031 02430 000 or 031 02430 0001 The enhancements are outlined below The version and part number for b...

Page 351: ...Leaving Chilled Liquid Flow Switch Open The chilled water flow switch has remained open for five continuous seconds two continuous seconds with soft ware version C OPT 01 15A xxx and earlier while the...

Page 352: ...d With this setting no lubrication warnings or shutdown will occur If the auto lube setpoint is disabled as it should be when not equipped with the automatic motor lubri cation hardware the motor lubr...

Page 353: ...ting the Motor Node ID setpoint to 1 If these two values are not set to the same number the VSD logic board will not communicate with the microboard NEW SETPOINTS The following new setpoints are progr...

Page 354: ...n the refrigerant selection Microboard SW1 1 is set to R 22 and the oil pump package SETUP Screen is set to VARIABLE SPEED the OIL VARIABLE SPEED PUMP SETPOINT NOT ACHIEVED safety shutdown is not perf...

Page 355: ...JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL 36 REMOTE RESET TEMPERATURE RANGE SETPOINT In previous software versions this setpoint could be set to 10 F or 20 F In this version it can be set to 10 F 20...

Page 356: ...n is performed by the microboard The Motor Communications Protocol setpoint must be set to Modbus in this configuration This configuration is referred to below as Modbus Protocol configuration All MV...

Page 357: ...r the VPT LED CR8 on the ACC board ACC Surge Detected Illuminates momentarily when a surge is detected by the ACC function in the microboard while the drive is running at less than maximum frequency S...

Page 358: ...printer Therefore this view cannot be selected while a print is in process The PAGE UP and PAGE DOWN keys are used to scroll to the previous or next listing Hot gas bypass Screen The hot gas bypass co...

Page 359: ...urge protection feature Surge Avoidance Surge Detection Programmable over the range of 0 3 default to 1 3 Smaller values increase the sensitivity If equipped with a liquid cooled solid state or electr...

Page 360: ...s shown in OptiView Control Panel Operation Form 160 54 O1 FIGURE 44 to allow selection of standard default or extended which is set at the factory and requires an ADMIN password to change it It is on...

Page 361: ...Voltage x10 40034 Rated Output KW x10 40058 Rated Output Frequency History Data x10 40059 Rated Output KW History Data x10 MV VSD Model The MV VSD model is displayed on the MV VSD DRIVE screen in the...

Page 362: ...eives a 100 speed command from the OptiView Control Center If the value received is not 50 Hz or 60 Hz INVALID is displayed If this is the case then the motor voltage rating above determines the maxim...

Page 363: ...quipped with any of the above options this setpoint is automatically set to enabled and cannot be changed If not equipped with any of the above options nor with a PRV potentiometer this should be set...

Page 364: ...t to another two surges and the initial ramp shall be continued This logic shall be in effect during the entire initial ramp and take action as many times as necessary FREQUENCY COMMAND INCREASE MOTOR...

Page 365: ...for the Y Axis Heat Recovery This software supports the new heat recovery option This option uses two tube bundles in the condenser The lower bundle is the standard condenser bundle and is piped to t...

Page 366: ...al Form 160 54 M1 Quick Start Mode The quick start feature is useful in data center and pro cess control applications where it is desirable to re es tablish cooling as fast as possible after a shutdow...

Page 367: ...will appear on the SETPOINTS screen Pressing this key will navigate to the QUICK START screen where the quick start mode setpoint is used to enable disable this feature as explained in the setpoints...

Page 368: ...otor could be equipped with different types of sensors for this monitoring Either RTDs or thermistors could be applied for winding and bearing temperature monitoring Motor cooling coil leak detection...

Page 369: ...lluminates when running at less than full speed Setpoints The following enhancements have been made The VGD high limit setpoint default changed from 0 8V to 0 6V The VGD low limit setpoint default cha...

Page 370: ...layed on the surge map screen SI0252 SOFTWARE ENHANCEMENTS VER 23 EFFECTIVE MAY 2011 CONT D HISTORY SCREEN The following enhancements were made The VGD pressure voltage is now displayed as discharge p...

Page 371: ...ap anese Korean or Chinese the SELECTION arrow is replaced with a green box around the selected output DATE FORMAT The calendar date can be displayed in three different formats Change the format using...

Page 372: ...on has been added to the Diagnostics Screen to enable disable the bootup flash checksum test When set to enabled the SI0265 SOFTWARE ENHANCEMENTS VER 24 EFFECTIVE MAY 2012 flash checksum test is run e...

Page 373: ...did not work properly in V17 through V23 after any immediate shutdown Cy cling Fault This start inhibit feature has been corrected to function properly Heat Pump Duty The Heat Pump Duty enable on the...

Page 374: ...ow correctly displays the Return Con denser Liquid Temperature Incorrect Display of MVSSS KW The largest size MVSSS starters now correctly displays the amount of displayed KW Incorrect MVSSS Starter M...

Page 375: ...control did not allow the VSD speed to be increased to control capacity until the PRV position was greater than or equal to 98 PRV position Once above 98 PRV VSD speed increases were allowed until the...

Page 376: ...s disabled the outputs will be placed into the open position and the inputs ignored Isolation Valve I O BOARD REFERENCE HEADER TERMINAL ITEM I O Board K6 J19 44 152 153 Isolation Valves Open Output I...

Page 377: ...ndenser heading Data Logging Figure 118 DIAGNOSTIC SCREEN LD17022 Data Logging Control When Data Logging is enabled data values are seri ally transmitted to the RS 232 port at an interval de fined by...

Page 378: ...de HGBP Mode 20 Condenser Refrigerant Liquid Level Liquid Level 21 Active Refrigerant Level Setpoint Act Level Setp 22 Level Control State Level Control State 23 Evaporator Small Temperature Differenc...

Page 379: ...olt 61 VSD Phase A Current VSD Phase A Cur 62 VSD Phase B Current VSD Phase B Cur 63 VSD Phase C Current VSD Phase C Cur 64 VSD Trigger SCR On VSD SCR On 65 VSD Converter Heatsink Temperature VSD Conv...

Page 380: ...Voltage LCSSS Phase A Volt 56 LCSSS Phase B Voltage LCSSS Phase B Volt 57 LCSSS Phase C Voltage LCSSS Phase C Volt 58 LCSSS Phase A Temperature LCSSS Phase A Temp 59 LCSSS Phase B Temperature LCSSS P...

Page 381: ...ave a minimum limit of 0 and a maxi mum limit of 100 with an initial default position of 0 MINIMUM MAXIMUM DEFAULT P 0 5 2 I 0 5 2 D 0 5 0 The PID reaction can be tuned using the Change Setpoints butt...

Page 382: ...he Sales Order Screen the field descriptor has been changed for Tubes to Tubes Code 4 The LCSSS communications has been changed for Modbus ASCII to Modbus RTU PROGRAM SETTING SCREEN MODE LOW LIMIT HIG...

Page 383: ...re 9 The Cursor Keys action has been changed to re peat every 150mS as long as the key is held in This will make navigating Raptyr waveforms easier 10 The COM2 port on the OptiView Control Panel used...

Page 384: ...r greater than the Subcooler Effectiveness High value continuously for two minutes after running for at least 30 minutes the warning WARNING LOSS OF SUBCOOLER LIQUID SEAL will be displayed The warning...

Page 385: ...l language selections except English the VSD communication protocol selection box was not dis played until the 02430 microboard established commu nications with the VSD This prevented the user from se...

Page 386: ...completed lube acknowledgement will clear the message Warning LackofMotorOilChangeisdisplayedat 6000operatinghourssincethelastmotorlubrication A completed lube acknowledgement will clear the message...

Page 387: ...Lubrication In Progress UNIT WARNING CODES 19 Warning Auto Lube Req d On Next Shutdown 20 Warning Auto Lube Grease Level Low 21 Warning Auto Lube Failed 22 Warning Motor Oil Change Suggested 23 Warnin...

Page 388: ...388 FORM 160 54 M1 ISSUE DATE 10 25 2019 JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS NOTES...

Page 389: ...renheit to Celsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range Table 34 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Ref...

Page 390: ...49 1 800 524 1330 Subject to change without notice Printed in USA Copyright by Johnson Controls 2019 www johnsoncontrols com ALL RIGHTS RESERVED Form 160 54 M1 1019 Issue Date October 25 2019 Supersed...

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