York YD Series Operation Manual Download

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JOHNSON CONTROLS

FORM 160.69-O1

ISSUE DATE: 9/30/2012

SECTION 2 – OPTIVIEW CONTROL CENTER

Chiller Current is limited to 1120 amps. If only one

motor is running, the Motor Current Limit (see Motor

Current Limit Setpoint above) for that motor would be

set to 100% and it would be allowed to operate at its

maximum of 800 amps, However, if both motors are

running, each would be limited to 560 amps per motor,

producing a Chiller Current of 1120 amps.

Lead Compressor Pulldown Time

(Software Version C.OPT.11.03.01.004 (and later))

Access Level Required:

OPERATOR

This setpoint is used to limit the chiller to single com-

pressor operation for a specified duration (0-255 min-

utes) when starting the chiller. While this pulldown

time is in effect, “System in Lead Compressor Pull-

down” is displayed on the system details line along

with the time remaining in the period. During this

time, only the lead compressor is permitted to run. The

lag compressor will not be brought on line. After this

time has elapsed, the lag compressor can be brought

on line per normal operation. While this period is in ef-

fect, the lead compressor motor current will be limited

to the value programmed for the

Lead Compressor

Pulldown Demand Limit

Setpoint (30-100% FLA).

The CHILLER PULLDOWN DEMAND LIMIT

Setpoint (that was used during the CHILLER PULL-

DOWN PERIOD in previous software versions, see

above) has been removed in this and later software

versions. Although this setpoint has been removed, the

logic in the CHILLER PULLDOWN PERIOD that is

used to determine if it is necessary to bring on the Lag

compressor (to meet load) still exists. This period is

still in effect from start until the Leaving Chilled Liq-

uid Temperature is within 2ºF of the Leaving Chilled

Liquid Temperature Setpoint. However, the “Chiller

Pulldown In Effect” LED (that indicated when the

Chiller Pulldown Period is in effect) has been elimi-

nated from the MOTOR Screen to avoid confusion

with the Lead Compressor Pulldown Demand Limit

feature.
After the Lead Compressor Pulldown Time Setpoint

has elapsed, the chiller current limit will be limited to

the value programmed for the

Chiller Current Limit

Setpoint. As in previous software versions, this setpoint

is applied to the total chiller current (30% to 100% of

the Chiller Full Load Amps). For example, if the Chill-

er FLA is 1600 Amps, the FLA of each motor is 800

Amps. If this setpoint is set to 70%, the Chiller Cur-

rent would be limited to 1120 Amps. If both compres-

sors are running, each would be limited to 560 amps. If

only one motor is running, the motor would be allowed

to operate all the way up to its full load amps of 800

Amps, because the total chiller current is being limited

to 1120 Amps.

Lead Compressor Pulldown Demand Limit

(Software Version C.OPT.11.03.01.004 (and later))

Access Level Required:

OPERATOR

Allows the user to specify a motor current limit (30%

to 100% FLA) that’s applied to the Lead compres-

sor motor during the time period programmed as the

LEAD COMPRESSOR PULLDOWN TIME Setpoint

(see above). This current limit applies to the full load

amps of the Lead compressor motor only, not the Chill-

er Full Load Amps (total of both compressors). For ex-

ample, if the Chiller Full Load Amps is 2000A, then

each compressor’s FLA is 1000A. If set to 80%, then

the lead compressor motor current would be limited to

800A (80% x 1000) for the duration of this period.

Navigation

Home

Access Level Required:

VIEW

Causes a return to the Home Screen.

Motor Lube Screen

(Software version C.MLM.11.02.xxx (and later) or

C.OPT.11.02.300 (and later)).

Access Level Required:

VIEW

Moves to the sub-screen allowing operator acknowl-

edgement of the compressor motor lubrication and

viewing of the compressor motor lubrication param-

eters.

Summary of Contents for YD Series

Page 1: ...LD08634 R 134A MODEL YD STYLE A B WITH OPTIVIEW CONTROL CENTER OPTIVIEW CONTROL CENTER CENTRIFUGAL LIQUID CHILLERS OPERATION Supersedes 160 69 O1 208 Form 160 69 O1 912 Issue Date September 30 2012 ...

Page 2: ...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 3: ...tice Johnson Controls makes no commitment to update or provide current information automatically to the manual owner Updated manuals if applicable can be obtained by contacting the nearest Johnson Controls Service office Operating service personnel maintain responsibility for the applicability of these documents to the equipment If there is any question regarding the applicability of these documen...

Page 4: ...W CB 5CX DA 5DA DB 5DB DC 5DC DE 5DE DF 5DF DG 5DG DH 5DH DJ 5DJ DK 5DK DL 5DL NOMENCLATURE YD XF XA J2 CA A B or C POWER SUPPLY for 60 Hz 5 for 50 Hz DESIGN LEVEL MODEL CONDENSER CODE XA XB XC XD YA YB YC YD ZA ZB ZC ZD AA AB AC AD EVAPORATOR CODE XF XH YF YG YH ZF ZG XH AF AG AH COMPRESSOR CODE J1 J2 J3 J4 J5 ...

Page 5: ...le Geometry Diffuser VGD 1 Screen 51 Variable Geometry Diffuser VGD 2 Screen 53 Variable Geometry Diffuser VGD Setpoints Screen 55 VGD 1 55 VGD 2 56 VGD 1 57 VGD 2 57 Variable Geometry Diffuser VGD 1 Calibration Screen 58 Variable Geometry Diffuser VGD 2 Calibration Screen 59 Display Only 59 Hot Gas Bypass Screen 60 Surge Protection Screen 62 Surge Protection Screen Single Compressor Operation 64 ...

Page 6: ...nd Screen 107 Trend Setup Screen 109 Advanced Trend Setup Screen 111 Common Slots Screen 113 Slot Numbers 114 Display Messages 115 Start Inhibit Messages 117 SECTION 3 PRINTERS 135 Printing Overview 135 Acceptable Printers 136 Printer Connections 136 Printer Setup 137 Control Center Setup 137 Downloading System Prints to a Laptop 137 TABLE OF CONTENTS CONT D ...

Page 7: ...GURE 23 Capacity Compressor Cycling 69 FIGURE 24 Oil Sump Screen 73 FIGURE 25 Oil Pump 1 Screen 75 FIGURE 26 Oil Pump 2 Screen 77 FIGURE 27 Electro Mechanical Starter Screen 79 FIGURE 28 Motor Lubrication Screen 83 FIGURE 29 Setpoints Screen 86 FIGURE 30 Setup Screen 89 FIGURE 31 Schedule Screen 92 FIGURE 32 User Screen 94 FIGURE 33 Comms Screen 95 FIGURE 34 Printer Screen 96 FIGURE 35 Sales Order...

Page 8: ...JOHNSON CONTROLS 8 FORM 160 69 O1 ISSUE DATE 9 30 2012 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 9: ...ESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION SYSTEM OPERATION DESCRIPTION The following is a high level description of the chill er control It describes the overall operation Control Center components chiller components and program mable setpoints are referenced Refer to Figure 2 on page 15 to view the chiller operation flowchart The YD dual compressor chiller consists of one evapo rator one...

Page 10: ...features are detailed separately below If equipped with the compressor Variable Geometry Diffuser VGD the chiller is started with the VGD in the fully open position Upon receipt of a chiller start signal the Lead com pressor is selected The compressor with the least amount of run time that is ready to run is selected as the Lead compressor unless Locked out The Lead compressor enters the Prelube p...

Page 11: ...ollow Lead motor cur rent Meanwhile the Lead compressor Pre rotation Vanes have been modulated to maintain the Leaving Chilled Liquid Temperature setpoint unless Lag Start with High Head was performed When the Lag mo tor current is within 5 of the Lead motor current the run time of the compressors are evaluated to deter mine which should be the Lead compressor The one with the least amount of run ...

Page 12: ...sitioning of the Refrigerant Level Con trol Valve while bringing on the Lead compressor It displays Lag Start when performing the Refrigerant Level Control Lag Start mode while starting the Lag compressor The Override Time Remaining displays the time remaining in the Valve Preset mode or the time remaining in the Lag Start mode In the first case it is the time remaining in the Valve Preset Timer p...

Page 13: ...uld be allowed to operate all the way up to its full load amps of 800 Amps because the total chiller current is being limited to 1120 Amps Compressor Lockout The COMPRESSOR LOCKOUT Setpoint available on the Capacity Compressor Cycling Screen can be used to lockout either compressor The designated compressor will not be permitted to run This feature is useful when it is desired to perform service o...

Page 14: ...re rotation Vanes are driven closed When the Vanes have fully closed or 210 seconds have elapsed whichever occurs first the Discharge Valve is then driven closed When the Discharge Valve has fully closed or 40 seconds have elapsed whichever occurs first the run signal to the compressor motor starter is de energized and the com pressor enters Coastdown If any Discharge Valve does not close within 4...

Page 15: ... Compressor Discharge Valve Electro Mechanical Starter Chiller Start Sequence Auto zero the 3 Oil Pressure Transducers Pre Lube cycle Lead Compressor Normal Sequence Extended prelube switch applies only to lead compressor Is Lead Compr Disch Valve Open 40 seconds Alarm Fault No Yes Start Lead Compressor normal sequence Enable capacity controls logic Lead compressor PRVs responding to LChWT Chiller...

Page 16: ...point Timer Is Lag Compressor Ready to Start Yes Yes Yes NO No No Pre Lube Lag Oil Pump Don t auto zero oil pressure transducers No No 2n Trend rate of pull down on startup to decide on d compr Antirecycle time met Ready to Start Lag Transition Period Level Control Settings for 2 compressor start Pulse VO valve open only 5 sec every 10 sec to maintain Liq Level 20 Is Diff Press P 1 6 High Head No ...

Page 17: ...ow motor current of Lead System Run Two Compressors 40 Seconds Alarm Fault No Delay 50 seconds To allow motor starting transition time Are Motor Currents Equal within 5 Yes 2 Minutes after valve open End VO valve transition period Level set points returned to normal Yes Normal Safety Checks Except for oil low temp differential Lag Vanes Lead Vanes Yes No Does Surge Exist No No Refer to Anti Surge ...

Page 18: ... Lag Compressor Discharge Valve Lag Compr Disch Valve Closed Stop Lag Compressor Motor Drive Lag Compressor vanes closed Post Lube Run Time Lag Compressor Yes No Yes 1 Compr Running Restart 2nd compr if needed per previous As motor currents fall below 50 with two compressors running a single compressor should be able to handle the load Field adjust current range from 30 to 70 of FLA with default o...

Page 19: ...alves on both compressors Stop both compressor motors Post Lube Run time both compr oil pumps Energize Oil Heater 1 Compressor Running from Page 1 or 4 Chiller normal or cycling stop signal Stop Lead compressor motor Post Lube Run time lead compr oil pump Energize Oil Heater System Standby Alarm Fault Proceed to stop motors PRV Motor Switches Closed or 150 Seconds Close vanes on Lead compressor Ye...

Page 20: ...ault Stop manual or auto restart Stop both compressors simultaneously Chiller Fault Condition Post Lube Run time both compr oil pumps Energize Oil Heater 1 Compressor Running from Page 1 or 4 Chiller Fault Condition Post Lube Run time lead compr oil pump Energize Oil Heater System Standby Close compressor vanes and close discharge valves Stop Lead both compressor Close compressor vanes and close d...

Page 21: ...ing LChWT Lag Compressor following current of Lead No Yes No Yes Close Compressor Pre rotation Vane Motors No Have of Total Surge Counts Exceeded the allowed within time period setting Stop and Lockout the lag compressor Provide screen warning Yes Anti Surge Control Algorithm User Programmable Number of Surge Counts Allowed Default 3 range 2 to 8 Count Window time period Default 60 min range 15 to...

Page 22: ...JOHNSON CONTROLS 22 FORM 160 69 O1 ISSUE DATE 9 30 2012 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 23: ...displayed when logged in at SERVICE ac cess level or higher The Setpoints and parameters displayed on these screens are explained in detail in YORK Service Manual 160 69 M1 These parameters affect chiller operation and should never be modified by anyone other than a qualified Service Technician They are shown in this book for reference only Advanced Diagnostics and troubleshooting informa tion for...

Page 24: ...03 01 004 or later This board is backward compatible with YD chillers presently using the 031 01730 000 or 031 02430 000 mi croboard Earlier vintage chillers could be equipped with a later Microboard due to service replacement Software versions are alpha numeric codes that repre sent the application and revision level per below Each time the software is revised the level increments C MLM 11 xx yzz...

Page 25: ...top control is operated via a three position rocker switch When toggled all the way to the right it is considered in the STOP RESET position When in the middle position this is considered the RUN state When toggled to the left most position it is considered in the START state Each state is described in detail below STOP RESET O When in this position the chiller will not run un der any condition Th...

Page 26: ...When power is applied to the chiller the system begins with an Access Level of VIEW This will allow the user to navigate to most screens and observe the val ues displayed there However the user will not be al lowed to change any values To change any values the user must return to the Home Screen shown by de fault when power is applied to the system and use the LOGIN button or utilize the CHANGE SE...

Page 27: ...ory 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 assigned to enable the cursor arrow keys below the numeric keypad which are used to high light the desired setpoint field At this point the key is pressed to bring up a dialog prompting the us...

Page 28: ...chart and select English per the USER Screen instructions in this book Home Screen System Screen Evaporator Condenser Level Control Compressors Compressor 1 Proximity Probe Calibrate Pre Rotation Vanes Calibration Compressor 2 Proximity Probe Calibrate Pre Rotation Vanes Calibration Hot Gas Bypass Surge Protection Capacity Compressor Cycling Oil Sump Oil Pump 1 Oil Pump 2 Motor EM Starter Version ...

Page 29: ...Temperature 8 0 133 5 F 13 3 56 3 C Return Condenser Liquid Temperature 8 0 133 5 F 13 3 56 3 C Evaporator Refrigerant Temperature Optional 0 0 126 1 F 17 7 52 3 C Discharge Temperature 31 8 226 3 F 0 1 107 9 C Oil Temperature 31 8 226 3 F 0 1 107 9 C Condenser Pressure 0 0 315 0 PSIG 0 0 2172 4 KPAG Condenser Temperature 98 7 160 1 F 72 6 71 7 C Evaporator Pressure 5 5 77 4 PSIG 37 9 533 7 KPAG E...

Page 30: ...e of the liquid as it enters the evaporator Condenser Liquid Temperature Leaving Displays the temperature of the liquid as it leaves the condenser Condenser Liquid Temperature Return Displays the temperature of the liquid as it enters the condenser Motor 1 Motor Run LED On when the digital output controlling compressor 1 motor starter is on Full Load Amps Displays the percentage of compressor moto...

Page 31: ...enerate a hard copy report of the present system status This provides a snapshot of the primary operating conditions at the time the key is pressed The History page provides enhanced report ing capability See HISTORY below Message Clear Access Level Required SERVICE When certain safety or cycling conditions have been detected and the chiller has been shutdown the main status display of the chiller...

Page 32: ...Probe calibration and PRV cali bration Oil Sump A detailed view of all the oil pump and oil sump pa rameters It also controls the Seal Lubrication func tionality Motor A detailed view of the motor controller parameters specific to the controller type presently utilized on the chiller system This allows programming of the Cur rent Limit and the Pulldown Demand Limit values Setpoints This screen pro...

Page 33: ...ge the display will show XX X Full Load Amps Displays the percentage of compressor motor 1 full load amps being utilized by compressor 1 motor Compressor 2 Discharge Temperature Displays the temperature of the refrigerant in its gas eous state at discharge of the compressor 2 as it trav els to the condenser Oil Pressure Displays the pressure differential between the Pump oil pressure transducer ou...

Page 34: ...condenser Condenser Saturation Temperature Displays the saturation temperature in the condenser Oil Sump Temperature Displays the temperature of the oil in the sump Chiller Current Limit Setpoint Displays the Chiller Current Limit Setpoint The Chill er Current Limit Setpoint could be from a 0 20mA 4 20mA 0 10Vdc or 2 10Vdc input in Analog remote mode or PWM input in Digital remote mode or Mi croga...

Page 35: ...ure 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 present Small Temperature Difference Displays the difference between the Leaving Chilled Liquid temperature and ...

Page 36: ...de can define the setpoint through a serial data stream In this case the incoming setpoint is not an offset that is applied to the locally programmed Base setpoint value but rather is the setpoint value itself Leaving Chilled Liquid Temperature Cycling Off set Shutdown Access Level Required OPERATOR This value allows the user to specify the Leaving Chilled Liquid Temperature at which the chiller w...

Page 37: ...er is not in Brine mode It allows the user to enable the Smart Freeze Point Operation which allows the chiller to run clos er to the freeze point without shutting down Service Technicians refer to YORK Service Manual 160 69 M1 Refrigerant Enabled Disabled Access Level Required SERVICE When an Evaporator Refrigerant Sensor has been in stalled it must be enabled via this toggle before the system wil...

Page 38: ...nser Small Temperature Difference Displays the difference between the Condenser Refrig erant temperature and the Leaving Condenser Liquid temperature The Condenser Refrigerant temperature will be represented by the Condenser Saturation tem perature Drop Leg Refrigerant Temperature Displays the temperature of the refrigerant in the drop leg between the condenser and evaporator shells if the sensor ...

Page 39: ...Service Technicians refer to YORK Service Manual 160 69 M1 Programmable High Pressure Warning Threshold Access Level Required SERVICE This value allows the user to define the condenser pres sure at which the chiller will initiate a warning Drop Leg Enabled Disabled Access Level Required SERVICE When a Drop Leg Refrigerant Sensor has been installed it must be enabled via this toggle before the syst...

Page 40: ...ne 1 the error must be less than or equal to 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 SER VICE Service technicians refer to YORK Service manual 160 69 M1 for opera tion instructions and explanation of all programmable setpoints and displayed values Display Only Refrigeran...

Page 41: ...me programmed as the Ramp Up Time setpoint Ramp Up Time Remaining Displays the time remaining in the Ramp Up time countdown timer while a Refrigerant Level target ramp is in effect Programmable Refrigerant Level Control Raise Manual This key puts the level control into manual mode and sends a RAISE command to the variable orifice Refrigerant Level Control Lower Manual This key puts the level contr...

Page 42: ...essor Compressor 1 Oil Pressure Displays the pressure differential between the Pump Oil Pressure transducer for compressor 1 and the common Sump oil pressure transducer If either of these transducers are out of range the display field will show XX X PSID The displayed value includes the offset pressure derived from auto zeroing during the system pre lube period The offset pressure is the pressure ...

Page 43: ...e lube Discharge Temperature Displays the temperature of the refrigerant in its gas eous state at the discharge of the compressor 2 as it travels to the condenser Discharge Superheat Displays compressor 2 discharge superheat calcu lated as discharge temperature condenser saturation temperature Programmable None Navigation Home Access Level Required VIEW Causes an instant return to the Home Screen ...

Page 44: ...sure differential between compressor 1 Pump Oil Pressure Transducer and the Sump Oil Pressure trans ducer outputs during a three 3 second period begin ning ten 10 seconds into the system pre lube period During this time the transducers are sensing the same pressure and their outputs should indicate the same pressure However due to accuracy tolerances in trans ducers differences can exist Therefore...

Page 45: ...ane control into manual mode and applies an open command to the vanes Pre rotation Vanes Close Manual This key puts the vane control into manual mode and applies a close command to the vanes Pre rotation Vanes Hold Manual This key puts the vanes into manual mode and applies a hold command to the vanes Pre rotation Vanes Auto This key returns the vane control to automatic mode Discharge Valve Manua...

Page 46: ... during the system pre lube period The offset pressure is the pressure differential between compressor 2 Pump Oil Pressure Transducer and the Sump Oil Pressure trans ducer outputs during a three 3 second period begin ning ten 10 seconds into the system pre lube period During this time the transducers are sensing the same pressure and their outputs should indicate the same pressure However due to a...

Page 47: ...ot fully sealed Pre rotation Vanes Open Manual This key puts the vane control into manual mode and applies an open command to the vanes Pre rotation Vanes Close Manual This key puts the vane control into manual mode and applies a close command to the vanes Pre rotation Vanes Hold Manual This key puts the vanes into manual mode and applies a hold command to the vanes Pre rotation Vanes Auto This ke...

Page 48: ...Displays the distance between the high speed thrust collar and the proximity probe that is used to measure the position High Speed Thrust Bearing Proximity Reference Position Displays the presently defined offset reference posi tion This value is defined at the conclusion of a cali bration sequence Oil Pressure Displays the pressure differential between the pump oil pressure transducer compressor ...

Page 49: ... calibration has started Service Technicians refer to YORK Service Manual 160 69 M1 for an explanation of this setpoint Accept Calibration This option only becomes available after the calibra tion sequence is complete Service Technicians refer to YORK Service Manual 160 69 M1 for an explanation of this setpoint Fault Acknowledge This option is only displayed if a fault is present Al lows clearing ...

Page 50: ...losing LED Indicates the vanes are closing Calibration in Progress LED Indicates the calibration sequence is in progress Calibration Messages These are text messages which step the user through the calibration process and indicate its success or fail ure Pre Rotation Vanes Voltage Displays the Pre Rotation Vanes position potentiom eter feedback voltage Programmable Start Calibration This option is...

Page 51: ...ge is above the High Limit 1 threshold Display Only Stall Detector Voltage Displays the Stall Detector Board output voltage x xxVdc Stall DC Pressure Voltage Displays the Stall Pressure Transducer output voltage x xx Vdc Pre rotation Vanes Position Displays the position of the Pre rotation vanes over the range of 0 fully closed to 100 fully open Displayed as XXX until calibration procedure is per ...

Page 52: ...remaining in the Probe Wait Time interval value programmed as the Probe Wait Time Setpoint while the VGD is in the Stall Waiting state or Surge Waiting State Diffuser Gap Control Mode Indicates whether the VGD is under manual open close hold or automatic control Programmable VGD Open Manual This key puts the VGD in manual mode and sends an open command to the VGD VGD Close Manual This key puts the...

Page 53: ...isplay Only Stall Detector Voltage Displays the Stall Detector Board output voltage x xx Vdc Stall DC Pressure Voltage Displays the Stall Pressure Transducer output voltage x xx Vdc Pre rotation Vanes Position Displays the position of the Pre rotation vanes over the range of 0 fully closed to 100 fully open Displayed as XXX until calibration procedure is per formed by Service Technician Variable G...

Page 54: ...remaining in the Probe Wait Time interval value programmed as the Probe Wait Time Setpoint while the VGD is in the Stall Waiting state or Surge Waiting State Diffuser Gap Control Mode Indicates whether the VGD is under manual open close hold or automatic control Programmable VGD Open Manual This key puts the VGD in manual mode and sends an open command to the VGD VGD Close Manual This key puts the...

Page 55: ... of 0 fully closed to 100 fully open Displayed as XXX until calibration procedure is per formed by Service Technician Variable Geometry Diffuser Position Displays the position of the VGD over the range of 0 fully closed to 100 fully open Displayed as XXX until calibration procedure is performed by Service Technician Diffuser Gap Close LED Illuminates when a close signal is being applied to the VGD...

Page 56: ...ulsed open according to the OPEN PULSE Setpoint as long as both compressor s PRV s are above this value While this is in effect PRV Position Override is displayed as Control Status PRV Offset 0 5 default 3 This setpoint applies to both VGD controls If the VGD control is in the Stall Waiting state and the Pre rotation vanes position changes by more than this value the Probing state will be entered ...

Page 57: ...he High Limit setpoint the High Limit setpoint is adjusted so that it is 0 1vdc above the newly entered Low Limit value VGD 2 High Limit 0 5 1 2Vdc default 0 8 Specifies the Stall Detec tor Board output voltage that represents an acceptable amount of stall noise The minimum difference between the High Limit setpoint and the Low Limit setpoint is 0 1 vdc If a Low Limit setpoint is entered which is ...

Page 58: ...Volt age Displays the VGD position potentiometer feedback voltage VARIABLE GEOMETRY DIFFUSER VGD 1 CALIBRATION SCREEN Calibration In Progress LED Illuminates when a calibration sequence is in progress Calibration Messages These are text messages which step the user through the calibration process and indicate its success or fail ure Programmable Start Calibration Initiates the calibration start Se...

Page 59: ...or Volt age Displays the VGD position potentiometer feedback voltage VARIABLE GEOMETRY DIFFUSER VGD 2 CALIBRATION SCREEN Calibration In Progress LED Illuminates when a calibration sequence is in progress Calibration Messages These are text messages which step the user through the calibration process and indicate its success or fail ure Programmable Start Calibration Initiates the calibration start...

Page 60: ...e is shown 25 open When actual position is 40 to 59 the valve is shown 50 open When actual position is 60 to 79 the valve is shown as 75 open Positions great er than 79 shown as full open Lead Pre Rotation Vanes Position Displays the position of the Lead Compressor Pre Rotation Vanes over the range of 0 closed to 100 fully open Displayed at XXX until calibration pro cedure is performed by service ...

Page 61: ...rvice Manual 160 69 M1 Surge Sensitivity Service technicians refer to YORK Service Manual 160 69 M1 Minimum Load Service technicians refer to YORK Service Manual 160 69 M1 Maximum Open Service Technicians refer to YORK Service Manual 160 69 M1 Hot Gas Bypass Control Open Manual This key puts the Hot Gas Bypass Control in manual mode and increases the valve position by 5 Hot Gas Bypass Control Clos...

Page 62: ... thus providing a rolling count of the total single compressor surge events that have occurred within the last number of minutes displayed as the SURGE WINDOW TIME This value is reset when one or both compressors have shutdown Surge Window Count Displays the number of single compressor surge events that have occurred in the last 1 to 5 minutes as pro grammed with the COUNT WINDOW setpoint If the s...

Page 63: ...ts detected over the lifetime of the chiller Surge Detected LED Illuminates for 5 seconds each time a dual compressor surge is detected Lead Compressor Identifies the compressor that has been assigned as the lead compressor Lead Full Load Amps Displays the motor current of the lead compressor as a percentage of the full load amps of that compressor motor Lead Pre rotation Vanes Position Displays t...

Page 64: ...ammed as the COUNT WINDOW setpoint When it reaches the COUNT WINDOW min utes the number of surge events in the oldest minute is discarded and the number of surge events in the most recent minute is added thus providing a rolling count of the total surge events that have occurred in the last COUNT WINDOW minutes This value is reset when the chiller shuts down Surge Window Count Displays the number ...

Page 65: ...ibit are au tomatically cleared provided the SURGE WINDOW COUNT is less than or equal to the COUNT LIMIT If the SHUTDOWN setpoint is Enabled and the SURGE WINDOW COUNT exceeds the COUNT LIMIT at the completion of this period a safety shutdown is performed and Surge Protection Excess Surge is displayed If the Hot Gas Bypass control is Enabled the Hot gas Bypass Valve position must be 100 before the...

Page 66: ... Protection Excess Surge is displayed See Hot Gas Bypass exceptions above Surge Sensitivity Access Level Required SERVICE Allows the user to define the surge detection sensitiv ity Selectable over the range of 0 3 to 1 3 default 0 3 The smaller the number the greater the sensitivity Clear Surge Count Access Level Required ADMIN Allows user to set the Single Compressor Total Surge Count to zero Nav...

Page 67: ...essor surge events that have oc curred within the last number of minutes displayed as the SURGE WINDOW TIME This value is reset when one or both compressors have shutdown Surge Window Count Displays the number of dual compressor surge events that have occurred in the last 15 to 120 minutes as programmed with the COUNT WINDOW setpoint If the lag compressor has been running for less than the COUNT W...

Page 68: ...e compressor that has been assigned as the lead compressor Lead Full Load Amps Displays the motor current of the lead compressor as a percentage of the full load amps of that compressor motor Lead Pre rotation Vanes Position Displays the position of the lead compressor pre rota tion vanes position Lead Variable Geometry Diffuser Position Displays the position of the lead compressor Variable Geomet...

Page 69: ...id Temperature as X X ºF Minute Value displayed represents a five point rolling average obtained as fol lows After the first 3 minutes of chiller run time the Leaving Chilled Liquid Temperature is sampled once every minute The previous reading is subtracted from the present reading and the last 5 results are averaged to obtain a five point rolling average Displayed as zero when chiller is not runn...

Page 70: ...e Minimum Rate Setpoint whereupon Waiting Minimum Rate Time is displayed the Chiller Pulldown Period is no longer in effect whereupon Checking Maximum Delta T is displayed or the Chiller Pulldown Limit Setpoint is set to 50 or less When Waiting Minimum Rate Time is displayed it will be displayed until the Chiller Pull down Period has ended whereupon Checking Maxi mum Delta T is displayed the Delta...

Page 71: ...e Waiting Minimum Load Time Programmable Minimum Rate and Minimum Rate Time Access Level Required SERVICE Allows the user to define the minimum rate of change of the Leaving Chilled Liquid Temperature that must be met by the lead compressor during the Chiller Pull down Period this period is in effect until the Leaving Chilled Liquid Temperature is within 2ºF of setpoint If this requirement is not ...

Page 72: ...ady Upon completion of coastdown the selected compressor will remain locked out until the lockout is released With previous software versions a compres sor can be locked out only while it is shutdown Compressor Mode Software version C OPT 11 03 01 004 and later Access Level Required OPERATOR Allows the user to select either NORMAL or SINGLE COMPRESSOR operating mode In Normal Mode the second compr...

Page 73: ...tput LED Illuminates when compressor 1 Variable Speed Oil Pump being commanded to run Pump Oil Pressure HOP Displays the high side oil pressure measured at the compressor 1 bearing input Oil Pressure Displays the pressure differential between the Pump oil pressure HOP transducer for compressor 1 and the common Sump oil pressure LOP transducer If this compressor is the lead compressor includes offs...

Page 74: ... Frequency Displays the speed command applied to compressor 2 Variable Speed Oil Pump Setpoint or Target Oil Pressure Displays the oil pressure that compressor 2 Variable Speed Oil Pump is controlling to During the pre lube and for the first 15 seconds of System Run this is the Target Setpoint and is fixed at 45 0 PSID For the re mainder of compressor 2 run it is the programmed Setpoint Oil Pressu...

Page 75: ...or Screen If either transducer used to calculate this differential is out of range the display field will show XX X Pump Oil Pressure HOP Displays the high side oil pressure measured at the compressor 1 bearing input Oil Pump Drive Command Frequency Displays the speed command that is being applied to compressor 1 Variable Speed Drive Oil Pump Setpoint or Target Oil Pressure Displays the oil pressu...

Page 76: ...ump will control to during automatic speed control opera tion Range is 20 0 to 45 0 PSID Service Technicians refer to Service Manual 160 69 M1 Control Period Access Level Required SERVICE Allows the user to define the output interval of the in crement or decrement speed commands to compressor 1 Variable Speed Oil Pump By default the interval is 900ms Range is 300ms to 2 7 seconds and is program ma...

Page 77: ...or Screen If either transducer used to calculate this differential is out of range the display field will show XX X Pump Oil Pressure HOP Displays the high side oil pressure measured at the compressor 2 bearing input Oil Pump Drive Command Frequency Displays the speed command that is being applied to compressor 2 Variable Speed Drive Oil Pump Setpoint or Target Oil Pressure Displays the oil pressu...

Page 78: ...ump will control to during automatic speed control opera tion Range is 20 0 to 45 0 PSID Service Technicians refer to Service Manual 160 69 M1 Control Period Access Level Required SERVICE Allows the user to define the output interval of the in crement or decrement speed commands to compressor 2 Variable Speed Oil Pump By default the interval is 900ms Range is 300ms to 2 7 seconds and is program ma...

Page 79: ...or FLA ratings with each motor having an equal FLA rating For example if the Chiller FLA is 1600 amps the FLA of each mo tor is 800 amps The Chiller Current Limit Setpoint is expressed as a percentage 30 to 100 of Chiller FLA In this example the chiller FLA is 1600 amps If the Chiller Current Limit Setpoint is set at 70 the Chiller Current is limited to 1120 amps If only one motor is running the M...

Page 80: ... it is the active Chiller Current Limit value Software version C OPT 11 03 01 004 and later It is the active Chiller Current Limit value If only compressor motor 1 is running Software version C OPT 11 02B xxx and earlier If the Chiller Pulldown Demand Limit is in effect it is twice the Chiller Pulldown Demand Limit up to 100 If the Chiller Pulldown Demand Limit is not in effect it is twice the Chi...

Page 81: ...ed to 1120 amps If only one motor is running the Motor Current Limit see Motor Current Limit Setpoint above for that mo tor would be set to 100 and it would be allowed to operate at its maximum of 800 amps However if both motors are running each would be limited to 560 amps per motor producing a Chiller Current of 1120 amps If equipped with software version C OPT 11 02B xxx and earlier this setpoi...

Page 82: ...oint However the Chiller Pulldown In Effect LED that indicated when the Chiller Pulldown Period is in effect has been elimi nated from the MOTOR Screen to avoid confusion with the Lead Compressor Pulldown Demand Limit feature After the Lead Compressor Pulldown Time Setpoint has elapsed the chiller current limit will be limited to the value programmed for the Chiller Current Limit Setpoint As in pr...

Page 83: ...ormed the Operator enters his her initials name or user ID using the Motor Lube Acknowledge key This entry implies both motors were lubricated The date and time of this entry is automatically logged as the Date of Last Lubrication and Time of Last Lubrica tion This also clears any motor lubrication warning or safety that is in effect and resets the Operating Hours Since Last Lubrication to zero MO...

Page 84: ... dia log box appears A red box highlights the first changeable location 3 Use the keys to scroll sequentially through the alphabet to enter letters or numbers Each time the is pressed the next higher sequential al phabet letter or number is displayed Each time the is pressed the next lower alphabet letter or number is displayed When the desired letter or number is displayed use the key to forward ...

Page 85: ...ccurs 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 Service Techni cians refer to procedure in Service Manual 160 69 M1 Navigation Home Access Level Required VIEW Causes an ins...

Page 86: ...alue is displayed Leaving Chilled Liquid Temperature Cycling Re start Displays the Leaving Chilled Liquid Temperature at which the chiller will restart after it has shut down due to over cooling temperature This value is calculated by adding the Leaving Chilled Liquid Temperature Cycling Offset Restart to the Leaving Chilled Liquid Temperature Setpoint Chiller Current Limit Setpoint Displays the c...

Page 87: ...e chiller will shut down on a LEAVING CHILLED LIQUID LOW TEMPERATURE cycling shutdown This is done by defining an offset below the Leaving Chilled Liquid Temperature setpoint It is programmable over a range of 1 F to 64 F below the setpoint to a minimum cut out of 36 F water 34 F water with Smart Freeze enabled or 6 F brine It establishes the minimum allowed temperature for the Leaving Chilled Liq...

Page 88: ...nstant the chiller enters System Run until the Leaving Chilled liquid temperature is within 2º F of the Leaving Chilled Liquid Temperature Setpoint Refer to the Electro me chanical Starter Screen for a detailed explanation of the Chiller Pulldown Demand Current Setpoint Print Access Level Required VIEW Generates Setpoints print report Navigation Home Access Level Required VIEW Causes an instant re...

Page 89: ...lection Displays R134a Anti Recycle Displays Disabled or Enabled Power Failure Restart Displays Manual or Automatic Liquid Type Displays Water or Brine Coastdown Displays Standard 150 seconds or Enhanced 15 minutes Steam Turbine applications Pre Run Displays Standard 50 seconds or Extended 180 seconds 031 02430 000 031 02430 001 Microboard Refrigerant Selection Displays R22 or R134a Liquid Type Di...

Page 90: ...es a green selection box around the first change able setpoint The access level determines which set points can be changed Use the and keys to place the selection box around the desired setpoint With the setpoint selected press the ENTER key A dialog box appears with the range of settings Chilled Liquid Pump Operation Access Level Required SERVICE Allows a Service Technician to select chilled liqu...

Page 91: ...erating Refer to YORK Service Manual 160 69 M1 Comms Access Level Required VIEW Moves to the sub screen allowing configuration of system communications Printer Access Level Required VIEW Moves to the sub screen allowing configuration and control of printer functions Sales Order Access Level Required VIEW Moves to the sub screen displaying the Sales Order in formation for the chiller system Operati...

Page 92: ...y If the user desires the chiller to operate continuously through several days the Stop time of Day 1 can be set to 11 59 PM and the 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 com...

Page 93: ...R 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 weeks Select ...

Page 94: ...after the user navigates from the USER Screen to another Screen English Metric Units Access Level Required OPERATOR Define the unit system English or Metric used by the chiller display Custom User ID 4 Access Level Required SERVICE This allows the user to specify up to four 4 Custom User ID values Each user ID will then require a cor responding Password and User Level A User ID can be defined for ...

Page 95: ...TER key A dialog box is displayed permitting data entry Printer Baud Rate Define the baud rate at which the panel shall commu nicate to the printer Printer Data Bit s Define the number of data bits with which the panel shall communicate to the printer Printer Parity Bit s Define the number of parity bits with which the panel shall communicate to the printer Printer Stop Bit s Define the number of ...

Page 96: ...printing status reports be ginning at the programmed start time and recurring at the interval defined above Printer Type Access Level Required SERVICE Define the printer type connected to the chiller system Print Report Access Level Required OPERATOR Select the report type to print when the Print Report key is selected This can vary from Status report pres ent system parameters Setpoints report pr...

Page 97: ...tory defined order number under which the chiller was sold System Information Factory defined conditions for which the chiller was originally rated and sold The Kilowatts Input is the total for the chiller Condenser and Evaporator Design Load Information Factory defined description of the condenser and evap orator configuration at time of shipment Nameplate Information Factory defined information ...

Page 98: ...een reset due to a Microboard replacement but should not be done so arbitrarily Operating Hours Access Level Required ADMIN Displays the total accumulated run time of the chiller This may be reprogrammed to a desired value gener ally when this value has been reset due to a Microboard replacement but should not be done so arbitrarily Hot Gas Control Enabled Disabled Access level required SERVICE En...

Page 99: ...ndenser water flow sensors The chiller will accept either site installed paddle type Digital flow sensors or factory mounted Analog flow sensors to sense the evaporator and condenser wa ter flow The paddle type flow sensors are identified as Digital because they are equipped with normally open contacts that when closed apply 115Vac to I O Board digital inputs on terminal TB4 12 evaporator and TB4 ...

Page 100: ...n This window displays the date and time and the 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 rec...

Page 101: ...alue of select chiller parameters at the time of the associated shutdown Trending Access Level Required VIEW Causes a move to a sub screen allowing the user to view trending data on selected chiller parameters Custom View Access Level required VIEW Causes a move to a sub screen allowing the user to view the Custom Setup Screen Security Log Access Level Required SERVICE Causes a move to a sub scree...

Page 102: ...y Only History Printout This is the on screen printout of the system parameters 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 Required VIEW This generates a report listing the status of the chiller parameters at the time of the selected shu...

Page 103: ...el of SER VICE Display Only Category Displays the category of the setpoint motor evapora tor condenser etc Setpoint Displays the setpoint that was changed New Value Displays the value that was entered at the time of the setpoint change Programmable Log Entry Allows the user to select a particular setpoint change for detail viewing Print Generates a detailed report of all setpoint changes list ed i...

Page 104: ...s 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 the setpoint change User ID Displays the login User ID used to make the setpoint change Old Value Displays the previous setpoint value New Value Displays the value entered at the time of the setpoint chang...

Page 105: ...t completion of the service call the display can be cleared or the parameters can be left there for monitoring by operations personnel Display Only None Programmable Print Access Level Required VIEW This generates a listing of the parameters displayed on this screen Navigation Home Access Level Required VIEW Causes an instant return to the Home Screen History Access Level Required VIEW Causes an i...

Page 106: ...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 slot number to be changed With the selection box around the slot number to be changed or entered press the ENTER key A dialog box is dis played permitting d...

Page 107: ...arameter the value will be plotted at the min imum value Similarly if the actual value is greater than the Y Axis label maximum for that parameter the value will be plotted at the maximum value There are three types of charts that can be created ONE SCREEN CONTINUOUS or TRIGGERED not ap plicable to Flash Memory Card version C MLM 01 04 xxx and earlier When plotting reaches the end of the X axis if...

Page 108: ...t 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 to the printer If set to NEW all data collected after pressing this key will be sent to the printer as it is collected If set to DIS ABLED no data is sent to the printer Refer to PRINT ERS section of this book for printout exampl...

Page 109: ...he DATA COLLECTION INTERVAL or the interval at which the parameter is sampled This interval is pro grammable over the range of 1 second to 3600 seconds 1 hour in one second increments The selected inter val not only determines the sample interval but also the full screen time display The full screen time dis play is a result of the selected interval in seconds mul tiplied by the 450 data points Fo...

Page 110: ...een 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 Point Max 1 6 Access Level Required OPERATOR Only displayed if the associated slot number is not zero This is the maximum value displayed for the Y Axis Selecting a parameter for a Data Point sets this to the defaul...

Page 111: ... started or stopped af ter any selected Trigger delay per the selected Trigger Action A Secondary Trigger can be evaluated with the Pri mary Trigger to start stop data collection The Primary to Secondary Operator is used to define the Trigger combinations required to be true to start stop data col lection The Secondary Trigger is setup and evaluated the same as the Primary Trigger Entry fields are...

Page 112: ...t 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 Access Level Required OPERATOR Selects whether the Primary Trigger Secondary Trig ger or both have to be true in order to start or stop data ...

Page 113: ...er the pa rameters Slot Numbers into Data Points 1 through 6 Requires a login access level of OPERA TOR or higher Display Only Slot Numbers These are the slot numbers of the most commonly used parameters Programmable Page Down Access Level Required OPERATOR Scroll down in the displayed data Page Up Access Level Required OPERATOR Scroll up in the displayed data Print Access Level Required OPERATOR ...

Page 114: ... COMPRESSOR 2 18441 Discharge Temperature 18442 Discharge Superheat 18433 Discharge High Pressure Switch 18465 Discharge Valve 18464 Discharge Valve Close Command 18463 Discharge Valve Open Command 18443 Vane Motor Switch 18444 Pre Rotation Vanes Position 18445 Pre Rotation Vanes Opening 18446 Pre Rotation Vanes Closing 18437 High Speed Thrust Bearing Proximity Dif ferential SLOT NO DESCRIPTION SU...

Page 115: ...s configured with a Microboard Program Switch The Pre lube duration must never be changed by anyone other than a qualified Service Technician The stan dard Prelube duration is 50 seconds SYSTEM RUN The chiller is running under the condition described in the Details Line of the Status Bar SYSTEM COASTDOWN The chiller has shut down and the Post run lubrication is being performed The Coastdown durati...

Page 116: ...nt 0 255 minutes is in effect The time remaining in the period is also displayed For the duration of this period only the Lead compressor will be permitted to run The Lag compressor will not be brought on line during this period A current limit may be applied to the Lead motor during this period using the LEAD COMPRESSOR PULLDOWN DE MAND LIMIT setpoint 30 100 Refer to complete explanation in SECTI...

Page 117: ...bited from start ing because compressor 2 Discharge Valve is not closed This start inhibit is released when the valve has fully closed MOTOR 1 ANTI RECYCLE The chiller both compressors is inhibited from start ing because compressor 1 motor is in the 30 minute anti recycle period and compressor 2 is unable to run This start inhibit is released when the 30 minute timer expires MOTOR 2 ANTI RECYCLE T...

Page 118: ... the WARNING RESET Keypad key is pressed in OPERATOR or higher access level Condition not checked in Brine mode WARNING CONDENSER OR VGD 1 SEN SOR FAILURE Software version C MLM 11 02 xxx and later or C OPT 11 02 300 and later The difference between Compressor 1 Stall Pressure Transducer output and the Condenser Pressure Trans ducer output has exceeded 0 28 Vdc for 3 continu ous minutes while comp...

Page 119: ...ible damage from an extreme stall condition This message can be cleared after the Stall Detector Voltage returns to less than two times the HIGH LIM IT Setpoint and the WARNING RESET key is pressed in SERVICE access level The Extreme Stall condition is not checked under the following conditions While the VGD is in Manual control mode While the VGD is fully closed position is 0 VGD Limit Switch clo...

Page 120: ... sump is the Mini mum Oil Level as shown below It will automatically clear when the level is Minimum Oil Level Condition Minimum Oil Level No compressors running 50 1 compressor running 40 2 compressors running 30 WARNING OIL PUMP 1 SEAL LUBRICA TION IN PROGRESS The 2 minute seal lubrication cycle that occurs once every 24 hours while the compressor 1 is not run ning is in progress for compressor ...

Page 121: ...r The Operating Hours Since Last Motor Lubrication has exceeded 1000 hours the greater of either Motor 1 Operating Hours or Motor 2 Operating Hours is used for this calculation This warning will be dis played until manually cleared by the Operator or the Operating Hours Since Last Motor Lubrication exceed 1200 hours whereupon it is replaced by the message Warning Motor Bearing Lube Required below ...

Page 122: ...emote mode via I O Board TB4 7 8 or in ISN Integrated Systems Network Remote mode via the MicroGateway serial communications If the chiller is running when this occurs the Pre rotation Vanes are driven fully closed prior to shutting down the chiller LOCAL STOP Alocal shutdown command has been received by plac ing the Keypad Start Run Stop Reset Switch in the stop O position PLACE COMPRESSOR SWITCH...

Page 123: ... Capacity Compressor Cycling Screen this fault does not cause compressor 1 to shutdown or prevent it from starting When this fault occurs on a locked out compressor it is displayed as a warning This allows the user to know that a fault exists on the locked out compressor The condition must be corrected prior to the lockout being removed from the compressor If it is not the warning condition will r...

Page 124: ...acts con nected to the I O Board TB3 70 The drive initiates a shutdown anytime its internal protection circuits will not permit the Drive to run The contacts remain open until its internal protection circuits are satisfied and any applicable manual resets are performed Refer to YORK Variable Speed Oil Pump Drive Service Man ual 160 52 M2 With software version C OPT 11 03 01 004 or later if compres...

Page 125: ...s been in the position continuously for at least 3 seconds This prevents the possibility of initiating a fault due to switch bounce EXPANSION I O SERIAL COMMUNICA TIONS The chiller both compressors has shutdown because the serial communications from the I O Boards to the Microboard has been lost for 20 continuous seconds The chiller can restart when the serial communications have been restored OIL...

Page 126: ...the freeze threshold is 32 8 F If RT7 is not enabled the evaporator refrigerant temperature used is the Evaporator Saturation Temperature derived from the Evaporator Pressure Transducer and the freeze threshold is 34 0 F The total count is incremented once for every sec ond the evaporator refrigerant temperature is below the freeze threshold but is never decremented below zero The number of second...

Page 127: ...ompressor it is displayed as a warning This allows the user to know that a fault exists on the locked out compressor The condition must be corrected prior to the lockout being removed from the compressor If it is not the warning condition will revert back to a shut down as soon as the lockout is removed and will cause the chiller to trip DISCHARGE 2 HIGH TEMPERATURE The chiller both compressors ha...

Page 128: ...lid until it has been in the position continuously for at least 3 seconds This prevents the possibility of initiat ing a fault due to switch bounce AUXILIARY SAFETY CONTACTS CLOSED The chiller both compressors has shutdown because locally installed external safety shutdown contacts connected to I O Board TB4 31 have closed initiating a safety shutdown The chiller can be started after the contacts ...

Page 129: ...m pressor 1 Pump transducer and the Sump transducer decreased to 15 0 PSID while compressor 1 was running or went below 25 0 PSID during the last 5 seconds of compressor 1 Prelube This fault is only checked if both the compressor 1 Pump transducer and the Sump transducer are in range The chiller can be started after the COMPRESSOR switch is placed in the Stop reset O position OIL PUMP 2 LOW DIFFER...

Page 130: ... OR 2 After the first 30 seconds of compressor 2 run the differential oil pressure was the Setpoint Target oil pressure with the oil pump drive speed command at 60 Hz for 5 continuous seconds The chiller can be started after the COMPRESSOR switch is placed in the Stop reset O position SURGE PROTECTION EXCESS SURGE Applies only to single compressor operation and if the Surge Protection SHUTDOWN set...

Page 131: ...tantaneous or decreased 25 mils for 2 continuous seconds from the Refer ence Position The minimum allowed clearance is 23 mils Therefore if the Reference Position is 47 mils the shutdown will occur when the actual position is 22 mils The chiller cannot be started until the spe cial reset procedure is performed as referenced in the CAUTION below With software version C OPT 11 03 01 004 or later if ...

Page 132: ...rsion C MLM 11 02 xxx and later or C OPT 11 02 300 and later the opera tion is as follows the clearance is only checked dur ing 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 threshold must be exceeded for 2 continuous seconds instantaneous with previous software This shutdown must be evaluated b...

Page 133: ...rication It also resets the Operating Hours Since Last Lubrication to zero The date this warning occurs is stored as the Date of Last Motor Lubrication Warning or Fault With software version C OPT 11 03 01 004 and later if the SHUT DOWN setpoint on the Motor Lubrication Screen is disabled this message will be displayed as a warning but the safety shutdown will not be performed COMPRESSOR 1 PRV NOT...

Page 134: ...JOHNSON CONTROLS 134 FORM 160 69 O1 ISSUE DATE 9 30 2012 SECTION 2 OPTIVIEW CONTROL CENTER THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 135: ...f printer is con nected at time of shutdown Trend Flash Memory 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 re...

Page 136: ... 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 137: ...l Center must be entered Se lection determines the control codes that are sent to the Printer These codes determine such things as lines per inch character width and general formatting 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...

Page 138: ...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 139: ... 3 PRINTERS FORM 160 69 O1 ISSUE DATE 9 30 2012 3 MICRO OPTIVIEW R TX1 G RX1 PC HYPERTERMINAL E LINK COM 1 RS 232 TX DB9 2 5 4 Port 2B RX TX COM GND DSR GTX GRX COM 4B J2 9 4 2 J2 7 6 Figure 48 COMMUNICATIONS BLOCK DIAGRAM LD14492 ...

Page 140: ...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 49 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 141: ... 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 49 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 142: ...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 143: ...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 50 SAMPLE PRINTOUT SETPOINTS CONT D Sho...

Page 144: ...OP OFF 13 APR 1999 START 8 00 AM STOP 10 00 PM Figure 52 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 145: ... 9 30 2012 3 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 52 SAMPLE PRINTOUT SALES ORDER CONT D ...

Page 146: ...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 147: ...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 148: ...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 149: ...Celsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range Table 2 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 150: ...ia USA 17405 1592 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2012 www johnsoncontrols com ALL RIGHTS RESERVED Form 160 69 O1 912 Issue Date September 30 2012 Supersedes 160 69 O1 208 ...

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