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York YK Series, Operation Manuals

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SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALSOF OPERATION 

JOHNSON CONTROLS

11

FORM 160.54-O1 

ISSUE DATE: 9/10/2014

1

LD00924A

FIGURE 3 - 

REFRIGERANT FLOW-THRU CHILLER

Rev. 2 (10-11-2010)

Dan Sowers

[email protected]

(717) 771-7535

YK Mod G

Refrigerant Flow-Thru Cross-Section Diagram

(Falling-Film Evaporator)

LEGEND

High Pressure Vapor

High Pressure Liquid Refrigerant

Low Pressure Liquid Refrigerant

Low Pressure Vapor

COMPRESSOR

EVAPORATOR

DISCHARGE

PRE-ROTATION

VANES

SUCTION

BAFFLE

SUB-COOLER

LIQUID LEVEL

CONDENSER

LIQUID LEVEL

VALVE

HOT GAS

BYPASS VALVE

LIQUID LEVEL

SUCTION

OPTIONAL

ISOLATION

VALVE

OPTIONAL

ISOLATION

VALVE

OPTIONAL HOT GAS

BYPASS LINE

Refrigerant Flow-Thru Chiller  

(Falling Film Evaporator)

Summary of Contents for YK Series

Page 1: ...LY WITH OPTIVIEW CONTROL CENTER FOR ELECTRO MECHANICAL STARTER SOLID STATE STARTER AND VARIABLE SPEED DRIVE OPTIVIEW CONTROL CENTER CENTRIFUGAL LIQUID CHILLERS OPERATION MANUAL Supersedes 160 54 O1 10...

Page 2: ...ls 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...

Page 3: ...orming any work on the chiller CHANGE BARS Revisions made to this document are indicated with a line along the left or right hand column in the area the revision was made These revisions are to techni...

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

Page 5: ...65 Variable Geometry Diffuser Screen 69 Variable Geometry Diffuser Setpoints Screen 71 Pre Rotation Vanes Calibration Screen 75 VSD Tuning Screen 77 Oil Sump Screen 79 Electro Mechanical Starter Scre...

Page 6: ...DISPLAY MESSAGES 175 Status Messages 175 Run Messages 176 Start Inhibit Messages 177 Warning Messages 177 Routine Shutdown Messages 181 Cycling Shutdown Messages 181 Mod B Solid State Starter Cycling...

Page 7: ...rge Protection Screen 65 FIGURE 21 Variable Geometry Diffuser Screen 69 FIGURE 22 Variable Geometry Diffuser Setpoints Screen 71 FIGURE 23 Pre Rotation Vanes Calibration Screen 75 FIGURE 24 VSD Tuning...

Page 8: ...n 169 FIGURE 61 Common Slots Screen 171 FIGURE 62 Printer 203 FIGURE 63 Breckman Printer 207 FIGURE 64 Communications Block Diagram 207 FIGURE 65 Sample Printout Status 208 FIGURE 66 Sample Printout S...

Page 9: ...ard that is installed inside of the Control Center SECTION 1 DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION SYSTEM OPERATION DESCRIPTION The YORK Model YK Chiller is commonly applied to large air...

Page 10: ...pplied to the chiller from an external source usually a cooling tower The condensed refrig erant drains from the condenser into the liquid return line where the variable orifice meters the flow of liq...

Page 11: ...Thru Cross Section Diagram Falling Film Evaporator LEGEND High Pressure Vapor High Pressure Liquid Refrigerant Low Pressure Liquid Refrigerant Low Pressure Vapor COMPRESSOR EVAPORATOR DISCHARGE PRE R...

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

Page 13: ...ed in the DISPLAY MES SAGES portion of this manual There are certain screens displayed values program mable setpoints and manual control shown in this man ual that are for Service Technician use only...

Page 14: ...sion C OPT 01 16 307 or later Style B Solid State Starter Modbus appli cations require software version C OPT 01 18 307 or later The upgrade includes a larger BRAM U38 and an additional RS 485 port on...

Page 15: ...ymbol In order to reject entry of a setpoint or dis miss an entry form the X key is provided as a universal Cancel symbol Cursor Arrow keys are pro vided to allow movement on screens which contain a l...

Page 16: ...ol In some cases the value may be ren dered invalid by other conditions and the display will use X s to indicate this PROGRAMMABLE Values in this group are available for change by the user In order to...

Page 17: ...Some keys are used to perform manual control func tions These may involve manual control of items such as the Pre rotation Vanes variable orifice or oil pump speed Other keys in this category are use...

Page 18: ...as Bypass Page 63 Surge Protection Screen Page 65 Variable Geometry Diffuser Page 69 Pre rotation Vanes Calibration Page 75 VSD Tuning Page 77 Oil Sump Page 79 Motor Page 83 Electro Mechanical Starter...

Page 19: ...porator Pressure R22 brine 25 0 100 0 PSIG 172 4 689 6 KPAG Evaporator Pressure R134a 5 5 77 4 PSIG 37 9 533 7 KPAG Evaporator Pressure R134a Heat Pump Duty 0 0 125 0 PSIG 0 0 861 8 KPAG Evaporator Te...

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

Page 21: ...the condenser Condenser Liquid Temperature Return Displays the temperature of the liquid as it enters the condenser Motor Run LED Is ON when the digital output controlling the motor starter contact is...

Page 22: ...ents unauthorized changes to the chiller if a user was logged in at a higher access level and failed to logout Proper procedure requires that after making necessary setpoint adjustments the user retur...

Page 23: ...luding control of the liquid level functions Compressor A detailed view of all the compressor parameters This includes Pre rotation Vane control Hot Gas Bypass Control Proximity Probe Calibration and...

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

Page 25: ...the compressor as it travels to the condenser Chilled Liquid Temperature Leaving Displays the temperature of the liquid as it leaves the evaporator Chilled Liquid Temperature Return Displays the temp...

Page 26: ...e version C OPT 01 21 307 and later Displays the Hot Water Setpoint to which the Leaving Heating Condenser Liquid Temperature is being con trolled Only appears when Heat Recovery is enabled and Hot Wa...

Page 27: ...on Temperature Displays the present saturation temperature in the evaporator Return Chilled Liquid Temperature Displays the temperature of the liquid as it enters the evaporator Leaving Chilled Liquid...

Page 28: ...ammed value is 45 F then the remote device can set the Leaving Chilled Liquid Temperature Setpoint over the range of 45 0 to 55 0 F Local Leaving Chilled Liquid Temperature Setpoint Access Level Requi...

Page 29: ...the Leaving Chilled Liquid Temperature Setpoint It is program mable over a range of 0 F to 70 F above the setpoint to a maximum restart value of 80 F The chiller will automatically restart when this t...

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

Page 31: ...nd Head Pressure Control DISPLAY ONLY Leaving Condenser Liquid Temperature Displays the water temperature as it leaves the con denser Leaving Condenser Liquid Temperature Setpoint Software version C O...

Page 32: ...lays the difference between the Condenser Re frigerant temperature and the Drop Leg Refrigerant temperature The Condenser Refrigerant temperature will be represented by the Condenser Saturation tem pe...

Page 33: ...ERVICE Moves to the subscreen allowing programming of the refrigerant liquid level control setpoints Heat Recovery Software version C OPT 01 21 307 and later Access Level Required SERVICE Moves to a s...

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

Page 35: ...cally disabled and locked When Heat recovery is enabled the condenser flow animation will show flow when either the Condenser Liquid Flow Switch or the Heating Condenser Liquid Flow Switch says flow i...

Page 36: ...for both features at the same time Normally it will be performing Hot Water Control unless certain operat ing conditions cause it to switch over to Head Pressure Control When performing Hot Water Con...

Page 37: ...fault 0 0 Allows the Control Valve to be manually set to a pre determined position between 0 0 and 100 Only appears when Hot Water Control is enabled or Head Pressure Control is enabled Control Valve...

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

Page 39: ...iView Control Center Service Instructions Form 160 54 M1 for operation instruc tions and explanation of all programmable setpoints and displayed values DISPLAY ONLY Return Condenser Liquid Temperature...

Page 40: ...ntrol Valve Output Settings Set 0 0 to 100 default 0 0 Allows the Control Valve to be manually set to a pre determined position between 0 0 and 100 Control Valve Output Settings Auto Places the Contro...

Page 41: ...locked The Condenser Temperature Range Setpoint is set to Extended The Condenser High Pressure Warning Setpoint threshold is set to 193 PSIG The Quick Start feature is only available in Cooling mode a...

Page 42: ...n Leaving Condenser Liquid Temperature Programmable over the range of NOR MAL 50 default 30 10 Normal is the stan dard setting and provides the longest PRV pulse for a given change The 50 30 and 10 se...

Page 43: ...Level Required OPERATOR This setpoint allows the user to specify the Leav ing Condenser Liquid Temperature at which the Heat Pump will restart after a shutdown on a LEAVING CONDENSER LIQUID TEMPERATUR...

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

Page 45: ...eration instruc tions and explanation of all programmable setpoints and displayed values DISPLAY ONLY Refrigerant Level Position Displays the present position of the liquid level The refrigerant level...

Page 46: ...the amount of change in the level within the Level Control Period is compared to the Rate Limit Open if level greater than setpoint Refrigerant Level Control Rate Limit Close This key establishes the...

Page 47: ...s the present position of the liquid level The refrigerant level is animated in the cutaway view of the condenser When the actual level is 0 to 15 the level is shown about 50 full When the actual leve...

Page 48: ...seconds default 50 Ramp up Time This ramp limit allows the level to go from the present level to the Refrigerant Level Setpoint over a period of time programmed as the Ramp Up Time Setpoint 3 to 15 m...

Page 49: ...e actual level is 16 to 31 the level is shown about 60 full When the actual level 32 to 47 the level is shown about 70 full When the actual level is 48 to 63 the level is shown about 80 full When the...

Page 50: ...key establishes the response to the rate of change the amount of change in the level within the Level Control Period is compared to the Rate Limit Close if level less than setpoint Refrigerant Level...

Page 51: ...9 for 60 seconds before the Zone 1 parameters are used If the error is greater than 9 the Zone 2 parameters are immediately implemented Requires a login access level of SERVICE Service Technicians ref...

Page 52: ...the time remaining in the Ramp Up time countdown timer while a Refrigerant Level target ramp is in effect PROGRAMMABLE Setpoint Specifies the desired refrigerant level to be maintained in the condens...

Page 53: ...pressure differential between the high side oil pressure transducer compressor bearing input and the low side oil pressure transducer oil sump The displayed value includes offset pressure derived fro...

Page 54: ...Position Variable Speed Drive and Hot Gas Option Only Access Level Required SERVICE This value displays the present position of the Pre rota tion Vanes as a percentage between 0 and 100 Full Load Amps...

Page 55: ...allowing calibration of the Pre rotation Vanes VSD Tuning Variable Speed Drive Only Access Level Required SERVICE Moves to the subscreen allowing advanced tuning of the Variable Speed Drive Hot Gas A...

Page 56: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 56 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK...

Page 57: ...ay field will show XX X The offset pressure is the pressure differential between the high oil pressure HOP transducer and the low oil pressure LOP transducer outputs during a three 3 second period beg...

Page 58: ...nes Open LED Access Level Required SERVICE Indicates whether the vanes are in the process of opening Pre rotation Vanes Close LED Access Level Required SERVICE Indicates whether the vanes are in the p...

Page 59: ...ng calibration of the Pre rotation Vanes VSD Tuning Variable Speed Drive Only Access Level Required SERVICE Moves to the subscreen allowing advanced tuning of the Variable Speed Drive Hot Gas Access L...

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

Page 61: ...e conclusion of a cali bration sequence Oil Pressure Displays the pressure differential between the high side oil pressure transducer compressor bearing input and the low side oil pressure transducer...

Page 62: ...tion Press this key to cancel calibration Accept Calibration Press this key to accept calibration Fault Acknowledge This option is only displayed if a fault is present Al lows clearing of High Speed T...

Page 63: ...the valve is shown in its relative position The valve position is animated When the actual position is 0 to 19 the valve is shown fully closed When actual position is 20 to 39 the valve is shown 25 o...

Page 64: ...ese messages Software versions C OPT 01 18 307 and earlier display OVERRIDE for any of these conditions For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control...

Page 65: ...iable Speed Drive VSD Adaptive Capacity Control ACC Surge Detection The ACC Surge Detection creates a surge map used to control the speed of the drive If equipped with an ACC Board new production chil...

Page 66: ...Time Remaining Displays the time remaining in the 10 minute Extended Run period During this period the Pre rotation Vanes are driven closed and WARNING SURGE PROTEC TION EXCESS SURGE LIMIT is displaye...

Page 67: ...g the message WARNING EXCESS SURGE DETECTED Refer to Hot Gas Bypass and Variable Speed Drive exceptions See Shut down Enabled Disabled on Page 66 and Ex tended Run Enabled Disabled on Page 66 If the S...

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

Page 69: ...the VGD is in the fully closed position Otherwise displayed as OPEN Diffuser Gap Close LED Illuminates when a close signal is being applied to the VGD Diffuser Gap Open LED Illuminates when an open si...

Page 70: ...eacting Probing Surge Reacting Surge Waiting Hot Gas Override Time Remaining While the VGD is in the Stall Waiting State displays the time remaining in the Probe Wait Time interval value programmed as...

Page 71: ...per formed by Service Technician VGD Closed Limit Switch Software version C OPT 01 23 307 and later Displays the status of the VGD Limit Switch Dis played as CLOSED when the switch is closed This woul...

Page 72: ...en Pulse 1 to 9 seconds default 2 Specifies the length of the open pulse applied to the VGD during 10 second peri ods while in the Probing state High Limit 0 5 to 1 2VDC default 0 6VDC 0 8VDC with sof...

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

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

Page 75: ...ges These are text messages which step the user through the calibration process and indicate its success or failure Pre rotation Vanes Voltage Software version C OPT 01 23 307 and later Displays the P...

Page 76: ...GRAMMABLE Start Calibration This option is hidden after calibration has started Cancel Calibration This option only becomes available after calibration has started NAVIGATION Home Access Level Require...

Page 77: ...equency Displays the frequency at which the drive is operating the motor This value is returned from the drive Pre rotation Vanes Position Displays the present Pre rotation Vane position as a value be...

Page 78: ...ware version the ISN through serial communications can no longer change this setpoint Fixed Puts the drive frequency control in fixed speed mode commanding it to run at maximum frequency 50Hz or 60Hz...

Page 79: ...Page 53 If either of the transducers used to calculate this differential is out of range the display field will show XX X Oil Sump Temperature Displays the temperature of the oil in the sump Oil Satur...

Page 80: ...requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoin...

Page 81: ...CE This key allows the user to specify a fixed manual speed at which the VSOP will run Raise Access Level Required SERVICE This key puts the VSOP control into manual mode and increments the present sp...

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

Page 83: ...nonzero For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pr...

Page 84: ...vel Required VIEW Returns user to HOME Screen Motor Lube Software version C MLM 01 14 xxx and later or C OPT 01 14 306 and later Access Level Required VIEW Moves to the subscreen allowing operator ack...

Page 85: ...grammed value Pulldown Demand Time Left Displays the time remaining in the programmed pulldown period if the value is nonzero Scale Model Display information about the Liquid Cooled Solid State Starte...

Page 86: ...he maximum amps at which the motor can op erate This value is viewable when logged in under the OPERATOR or VIEW access level Supply Voltage Range Access Level Required SERVICE Allows the user to sele...

Page 87: ...ink Gateway interface in ISN Remote mode or a locally programmed value in Local mode Pulldown Demand Time Left Displays the time remaining in the programmed pulldown period Input Power Displays the ki...

Page 88: ...n at OPERATOR or VIEW access level Voltage Range Access Level Required SERVICE Allows the user to select specific line voltage range for voltage checking When not disabled this line voltage range is u...

Page 89: ...Digital Remote mode E Link Gateway interface in ISN Remote mode or a locally programmed value in Local mode Pulldown Time Left Displays the time remaining in the programmed pulldown period Input Power...

Page 90: ...urrent Limit Setpoint during this time period The Pre rotation Vanes are used to limit the motor current to this value Pulldown Demand Time Access Level Required OPERATOR Allows the user to set the pe...

Page 91: ...in Digital Remote mode E Link Gateway interface in ISN mode or a locally programmed value Pulldown Demand Time Left Displays the time remaining in the programmed pulldown period if the value is nonzer...

Page 92: ...own limit time This value will override the Motor Current Limit value during this time period This function is used to provide energy savings following chiller start up Pulldown Demand Time Access Lev...

Page 93: ...10VDC or 2 to 10VDC input in Analog Remote mode PWM signal in Digital Remote mode E Link Gateway interface in ISN mode or a locally programmed value Pulldown Demand Time Left Displays the time remaini...

Page 94: ...defined in the lookup table the model num ber is displayed as INVALID and the chiller will not be allowed to run while this is displayed Table 2 VOLTAGE V MOTOR RATED VOLTAGE V 2300 V 3300 V 4160 V Mo...

Page 95: ...nd Time Access Level Required OPERATOR Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chiller starts Full Load Amps Access Level Required SERVI...

Page 96: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 96 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK...

Page 97: ...e Speed Drive this is the data returned by the VSD Logic Board Current Limit Setpoint Displays the current limit value in use This value could come from a 0 to 20mA 4 to 20mA 0 to 10VDC or 2 to 10VDC...

Page 98: ...Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Local Motor Current Limit Access Level...

Page 99: ...utput from the controls is commanding the motor to RUN Motor Current Full Load Amps Displays the motor current as a percentage of the Full Load Amps FLA value For the Variable Speed Drive this is the...

Page 100: ...peration instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Local Motor Current Limit Access Level Required OPERATOR Allows the user to specify the maximum a...

Page 101: ...t Displays the current limit value in use This value could come from a 0 to 20mA 4 to 20mA 0 to 10VDC or 2 to 10VDC input in Analog Remote mode PWM signal in Digital Remote mode E Link Gateway interfa...

Page 102: ...effect after the chiller starts Surge Sensitivity Allows the user to define the surge detection sensitivity of the ACC Surge Detection Surge Margin Adjust When the ACC maps a surge point it will begi...

Page 103: ...Control Center Service Instructions Form 160 54 M1 for operation instruc tions and explanation of all programmable setpoints and displayed values DISPLAY ONLY Full Load Amps Displays the motor current...

Page 104: ...mmable setpoints and displayed values PROGRAMMABLE Surge Margin Adjust This value determines how close the frequency reduc tion will be allowed to get to the surge line It is sent to the ACC Board Pro...

Page 105: ...arlier production chillers could be in the MODBUS configuration All Medium Voltage Variable Speed Drives MV VSD use MODBUS protocol Requires a login access level of SERVICE Service Technicians refer t...

Page 106: ...ard while the drive is running at less than maximum frequency Surge Avoidance Surge Detected LED Illuminates momentarily when a surge is detected by the Surge Protection feature This feature only dete...

Page 107: ...his manual Manual Surge Point Allows the Service Technician to manually log the present running operating conditions into the surge map as a valid surge point When this key is pressed a dialog box app...

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

Page 109: ...the will be replaced by an O This screen is applicable to Variable Speed Drives VSD with the Motor Communications Protocol Setpoint set to MODBUS ACC Board is not pres ent and Medium Voltage Variable...

Page 110: ...Delta P P For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all...

Page 111: ...s Protocol Setpoint set to MODBUS ACC Board is not pres ent and Medium Voltage Variable Speed Drives MV VSD It is not accessible if equipped with a VSD in YORK Motor Communications Protocol Setpoint c...

Page 112: ...1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 112 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION NAVIGATION Home Returns user to HOME Screen VSD Returns user to VSD Screen ACC Details Returns user to ACC DE...

Page 113: ...to 20mA 4 to 20mA 0 to 10VDC or 2 to 10VDC input in Analog Remote mode PWM signal in Digital Remote mode E Link Gateway interface in ISN mode or a locally programmed value Pulldown Demand Time Left Di...

Page 114: ...plays the 3 phase RMS Voltages across each line For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operatio...

Page 115: ...this manual for de tails of these messages To provide a record of when a motor lubrication is per formed the Operator enters his her initials name or user ID using the MOTOR LUBE ACKNOWLEDGE key The d...

Page 116: ...e entry must be a minimum of 3 charac ters and a maximum of 8 characters 1 At the keypad log in at OPERATOR access lev el using password 9 6 7 5 If resetting the safety shutdown Motor Lack Of Lubricat...

Page 117: ...used to enable or disable the safe ty shutdown that occurs at 1400 operating hours since last lubrication The safety shutdown can be enabled or disabled per the customer s preference If enabled the s...

Page 118: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 118 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK...

Page 119: ...outine that plots a baseline over a 1 hour period while the chiller is running This screen also serves as a gateway to a subscreen that allows programming of the winding High Tempera ture Warning Safe...

Page 120: ...d invalid and displays as XXX X When the Bearing Temperature Protection Setpoint is set to Disable no temperatures are dis played and the heading text and data boxes do not ap pear Vibration Displays...

Page 121: ...ng RTD s via the Motor Monitoring Board serial communications TRANSMITTER Enables and displays the 3 Motor Winding Temperatures as reported by the winding transmitters via the Motor Monitoring Board s...

Page 122: ...serial communications FLOAT Enables the float sensor digital input and displays the leak status as reported by the float leak sensor via the Motor Monitoring Board se rial communications Manual Baseli...

Page 123: ...INDING SETUP Setpoint key Not shown when Winding Tem perature Protection Setpoint on the MOTOR DETAILS Screen is set to Disabled Winding Hotspot Allowance Displays the Winding Hotspot Allowance temper...

Page 124: ...a box reflects enabled or disabled status This could be applied to de fective sensors or for service reasons When a sensor is disabled the respective temperature data box does not appear on the MOTOR...

Page 125: ...ion Baseline X3 Opposite Shaft End High Vibration Shutdown Default Opposite Shaft End Vibration Baseline X3 If no baseline values are entered by either the auto baseline routine or manual entry the me...

Page 126: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 126 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK...

Page 127: ...is calculated by subtract ing the Leaving Chilled Liquid Temperature Cycling Offset Shutdown from the Leaving Chilled Liquid Temperature Setpoint If this value is below the abso lute minimum allowed s...

Page 128: ...case the incoming setpoint is not an offset that is ap plied to the locally programmed BASE Setpoint value but rather is the setpoint value itself Leaving Chilled Liquid Temperature Cycling Offset Sh...

Page 129: ...value will override the Motor Current Limit value during this time period This function is used to provide energy savings following chiller start up Pulldown Demand Time Access Level Required OPERATO...

Page 130: ...FORM 160 54 O1 ISSUE DATE 9 10 2014 JOHNSON CONTROLS 130 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK...

Page 131: ...also serves as a gateway to more subscreens for defining general system parameters DISPLAY ONLY 031 01730 000 Microboard Chilled Liquid Pump Operation Displays Standard or Enhanced Motor Type Display...

Page 132: ...e disabled 12 24 Hr Access Level Required OPERATOR Allows the user to specify the format in which the time will be presented to the user This setpoint will affect the display of the time on the chille...

Page 133: ...int above Allows the Service Technician to enter the Modbus Address of the VSD Logic Board or Style B LCSSS Logic Trigger Board The Motor Node ID Setpoint must be set to 1 to match the address assigne...

Page 134: ...oboard J7 If not equipped with Hot Gas Bypass but equipped with a VGD it is connected to the Microboard J7 Disabled Set to this position when not equipped with a PRV potentiometer If equipped with a V...

Page 135: ...a pability while operating Comms Access Level Required VIEW Moves to the subscreen allowing configuration of sys tem communications Printer Access Level Required VIEW Moves to the subscreen allowing c...

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

Page 137: ...ke a normal start however the vanes will begin to open at the beginning of prelube instead of waiting until Sys tem Run At the completion of prelube the VSD is started and after the VSD achieves its S...

Page 138: ...at SER VICE access level However once Disabled it re quires an ADMIN password to enable it again as ex plained above Quick Start mode will be automatically disabled when any of the following occur Th...

Page 139: ...ammed on either the ACC Screen or the QUICK START Screen It sets the Delta T needed to be met to enable surge mapping and speed reduction initially on startup Quick Ramp Current Threshold Access Level...

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

Page 141: ...e 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 u...

Page 142: ...uired OPERATOR Allows the user to enable or disable the monitoring function which enforces the scheduled starting and stopping of the chiller Repeat Sunday Schedule Access Level Required OPERATOR Dupl...

Page 143: ...rvice Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE System Language Access Level Required OPERATOR Allows the...

Page 144: ...ify up to four 4 custom password values Each password will then require a corresponding User ID and user level Custom User Access Level 4 Access Level Required SERVICE This allows the user to specify...

Page 145: ...planation of all pro grammable setpoints and displayed values PROGRAMMABLE Chiller ID Access Level Required OPERATOR Define the numeric chiller ID when used within an ISN network of chillers This ID n...

Page 146: ...ll communicate to the printer COM 2 Baud Rate Define the baud rate at which the panel shall communi cate through the modem port COM 2 Data Bit s Define the number of data bits with which the panel sha...

Page 147: ...cess Level Required OPERATOR Set the time at which scheduled print logs will begin Output Interval Access Level Required OPERATOR Define the interval at which log printing will occur Automatic Printer...

Page 148: ...ype to print when the PRINT RE PORT key is selected This can vary from status report present system parameters Setpoints report present value of the system setpoints Schedule report present value of t...

Page 149: ...he micropanel Chiller Serial Number Factory defined serial number for the chiller system YORK Order Number Factory defined order number under which the chiller was sold System Information Factory defi...

Page 150: ...ocation Access Level Required SERVICE Factory defined job name and location the chiller is destined for Print Access Level Required VIEW This generates a listing of the Sales Order data NAVIGATION Hom...

Page 151: ...4 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMMABLE Control Source Access Level Required OPERATOR Define whether the control of the chiller...

Page 152: ...red SERVICE Enables and disables the Variable Geometry Diffuser feature If equipped with this feature it should be en abled Otherwise it should be disabled Chiller Style Compressor Flash Memory Card v...

Page 153: ...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...

Page 154: ...ning the value of select chiller parameters at the time of the associated shutdown Trending Access Level Required VIEW Causes a move to a subscreen allowing the user to view trending data on selected...

Page 155: ...CE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 for operation instructions and explanation of all pro grammable setpoints and displayed values PROGRAMM...

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

Page 157: ...of the change access level and User ID used to make the change the old setpoint value and the new setpoint value Requires a login access level of SERVICE Service Technicians refer to the OptiView Cont...

Page 158: ...n the displayed data if applicable NAVIGATION Home Access Level Required SERVICE Returns user to HOME Screen History Access Level Required SERVICE Returns user to HISTORY Screen View Details Access Le...

Page 159: ...ns refer to the OptiView Control Center Service Instructions Form 160 54 M1 for operation instruc tions and explanation of all programmable setpoints and displayed values DISPLAY ONLY Description Disp...

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

Page 161: ...ere for monitoring by operations personnel DISPLAY ONLY None For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1...

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

Page 163: ...ge Down Scroll down through list of available parameters Select First use the PAGE UPand PAGE DOWN keys to scroll through the Slot Numbers list and note the number of the parameter s to be displayed P...

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

Page 165: ...Points simultane ously or select a single Data Point for display The parameters are sampled at the selected Data Col lection Interval and plotted using 450 data points across the X Axis If the actual...

Page 166: ...this key stops the trending The trend data is frozen on the display until another graph is started with the START key The STOP key is only available if trending is running Print Flash Memory Card ver...

Page 167: ...cess Level Required OPERATOR Selects Continuous One Screen Or Triggered If com pressor application is other than P applies only to Flash Memory Card version C MLM 01 05 xxx and later type of graph Col...

Page 168: ...er being monitored To change use the SELECT key as described above and enter the desired value The value must always be set to a value less than the Data Point Max Otherwise a red graph is displayed o...

Page 169: ...e Primary Operator as a comparator If it is evaluated as true then the data collection is started or stopped after any selected trigger delay per the selected Trigger Ac tion A Secondary Trigger can b...

Page 170: ...Display is in days hours minutes and seconds The delay timer begins when the triggers evaluate as true If the Trigger Action is set to Start data collection will begin after the triggers evaluate as...

Page 171: ...are the Slot Numbers of the most commonly used parameters For fields requiring access level of SER VICE Service Technicians refer to the OptiView Control Center Service Instruc tions Form 160 54 M1 fo...

Page 172: ...285 Pre Rotation Vanes Control Mode 1296 Discharge Temperature 1536 Oil Differential Pressure 1537 Oil Sump Temperature SLOT NUMBER DESCRIPTION 1538 Oil Pump Control Mode 1539 Oil Pump Is Pump On 1540...

Page 173: ...rent Unbalance Check Enabled Mod B Solid State Starters 2570 LcSss Input Power 2571 LcSss Kilowatt Hours 2572 LcSss Phase A Current 2573 LcSss Phase B Current 2574 LcSss Phase C Current SLOT NUMBER DE...

Page 174: ...d Distortion 2890 Filter Maximum Total Harmonic Distortion 2891 Filter Maximum Total Demand Distortion 8192 Oil Pump Pressure 8193 Oil Sump Pressure 8194 Oil Seal Lube Is Control Enabled 8195 Oil Seal...

Page 175: ...the Compressor Switch to the Stop Reset O position System Prelube A chiller start has been initiated and the pre start lu brication is being performed The prelube duration is either 50 seconds or 180...

Page 176: ...ty is enabled and the Heat Pump Duty Operational mode setpoint is set to Cooling mode Heat Pump Leaving Condenser Liquid Control Software version C OPT 01 23 307 and later The Heat Pump is running con...

Page 177: ...ibit is set VSD Frequency 0Hz Software version C MLM 01 14 xxx and later or C OPT 01 14 306 and later This start inhibit is set whenever the chiller is shut down and a Compressor Motor Variable Speed...

Page 178: ...ion Vanes are inhibited from further opening This message automatically clears and the Vanes are permitted to open when the condenser pressure decreases to 5 PSIG below the Setpoint Warning Evaporator...

Page 179: ...returns normal operation Warning Loss of Subcooler Liquid Seal Software version C OPT 01 25C 308 and later This Warning is displayed if the chiller has been run ning for 30 minutes or more and the Dro...

Page 180: ...to Lube Setpoint on the MOTOR LUBRICATION Screen enabled Warning Motor Bearing Lube Required Software version C MLM 01 14 xxx and later or C OPT 01 14 306 and later The Operating Hours Since Last Moto...

Page 181: ...nes are driven fully closed prior to shutting down the chiller Local Stop A local shutdown command has been received by plac ing the Keypad Start Run Stop Reset switch in the Stop O position Place Com...

Page 182: ...mmed Leaving Condenser Liquid Temperature Cycling Offset Shutdown Setpoint This shutdown is only applicable to Heat Pump Duty en abled and operating in Heating mode Heat Pump Op erational Setpoint set...

Page 183: ...onds to initiate the shutdown and produce this message An LED on the respective device illuminates to iden tify the specific fault that has occurred Refer to Solid State Starter Mod A Operation and M...

Page 184: ...the same message if the Liquid Cooled Solid State Starter does not receive a response from the Control Center after 10 consecutive attempts to communicate with the Control Center after Initialization...

Page 185: ...ly such as sag or jitter A power line frequency jitter of up to 3Hz second can be tolerated The chiller will automatically restart when lock has resumed LCSSS Low Supply Line Voltage The Liquid Cooled...

Page 186: ...seconds this message is typically displayed for a few seconds and then replaced with one of the below listed fault messages VSD Stop Contacts Open Refer to VSD Shutdown Requesting Fault Data on Page 1...

Page 187: ...is gated on If the voltage across the IGBT is greater than a set threshold the IGBT is gated off and a shutdown pulse is sent to the VSD Logic Board shutting down the entire VSD system Agate driver fa...

Page 188: ...re internal VSD fan failure VSD water pump failure or an entering condenser water temperature that ex ceeds the allowable limit for the job Additional causes for the shutdown are Plugged Strainer The...

Page 189: ...harge relay is energized If this condition is not met a shutdown is per formed and this message is generated VSD Precharge Low DC Bus Voltage 575V 60Hz applications Software version C OPT 01 15 xxx or...

Page 190: ...ice Harmonic Filter High Phase B Current See Harmonic Filter High Phase A Current message above Harmonic Filter High Phase C Current See Harmonic Filter High Phase A Current message above Harmonic Fil...

Page 191: ...redundant run command does not occur on the serial data link from the VSD Logic Board before the timer expires a shutdown is performed and this message is generated Harmonic Filter DC Current Transfo...

Page 192: ...reater than 25 0 F colder than the Leav ing Chilled Liquid Temperature In order to initiate a shutdown the difference must be outside the acceptable range continuously for 10 minutes For Steam Turbine...

Page 193: ...re than 300 0 PSIG R134a or R22 This is outside the normal operating range of the transducer This is generally indicates a defective transducer The chiller can be started after the trans ducer is indi...

Page 194: ...e the oil pump is not running during this period and the actual differential oil pres sure is 0 PSID The transducers are sensing the same pressure during this period and their outputs should be simila...

Page 195: ...hecked during the last 20 seconds of System Prelube during System Run and during coastdown Therefore the fault is only detected during those periods Also the 10mil thresh old must be exceeded for 2 co...

Page 196: ...ch contacts connected to TB3 81 have opened This occurs when the Bearing position decreases to less than the allowed position This shutdown must be evaluated by a qualified Service Technician prior to...

Page 197: ...n open RTD or any individual winding temperature sensor that has been disabled with the Temperature Disable Setpoint on the MOTOR SETPOINTS Screen Motor High Bearing Temperature Software version C OPT...

Page 198: ...ly for 40 seconds The chiller can be started after the Compressor Switch is placed in the Stop Reset O position LCSSS Phase X Shorted SCR Flash Memory Card version C MLM 01 04 or later A shorted Silic...

Page 199: ...oard is pressed and the Compressor Switch is placed in the Stop Reset O position VSD High Phase A Inverter Heatsink Tem perature Style D VSD This shutdown will occur if the heatsink temperature exceed...

Page 200: ...utive times If the VSD fails to make pre charge on three consecutive tries the unit will shut down lockout and display this message The chiller can be started after the Compressor Switch is placed in...

Page 201: ...to the VSD divided by the chiller Full Load Amps in percent A standard VSD less the optional filter typically has an input cur rent TDD level on the order of 28 30 The chiller can be started after the...

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

Page 203: ...ard 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...

Page 204: ...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...

Page 205: ...evel Required OPERATOR Using the PRINTER Screen set the printer type to Weigh Tronix Automatic Data Logging Access Level Required OPERATOR If automatic data logging is desired a status report can be a...

Page 206: ...s 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...

Page 207: ...e 20 rolls of paper PRINTER CONNECTIONS Connect the printer to the Control Center Microboard as follows Only one printer can be connected at a time Table 6 BRECKNELL CP130 Modify the cable and connect...

Page 208: ...ump 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 o...

Page 209: ...Phase B Heatsink Temperature If TMIII VSD 99 F Phase C Heatsink Temperature If TMIII VSD 97 F Baseplate Temperature If VyperDrive VSD 106 F FIGURE 64 SAMPLE PRINTOUT STATUS CONT D Skip the following s...

Page 210: ...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...

Page 211: ...od 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 Pu...

Page 212: ...P OFF 13 APR 1999 START 8 00 AM STOP 10 00 PM Figure 68 SAMPLE PRINTOUT SALES ORDER YORK SALES ORDER CHILLER ID 3 1997 1999 YORK INTERNATIONAL CORPORATION MON 29 MAR 1999 1 28 PM ORDER INFORMATION COM...

Page 213: ...9 10 2014 4 NAMEPLATE INFORMATION MOTOR CODE POWER VOLTS PHASES FREQUENCY HZ LOOKED ROTOR AMPS FULL LOAD AMPS INRUSH AMPS SYSTEM INFORMATION REFRIGERANT TONS GEAR CODE LIQUID TYPE BRINE PERCENT KILOWA...

Page 214: ...d 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 M...

Page 215: ...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...

Page 216: ...TION 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 C...

Page 217: ...lled Active Setpoint 45 0 F Leaving Chilled Liquid Temperature 50 0 F Return Chilled Liquid Temperature 59 3 F Leaving Condenser Liquid Temperature 85 0 F Return Condenser Liquid Temperature 94 9 F Ev...

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

Page 219: ...elsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range Table 7 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effe...

Page 220: ...SA 17405 1592 Subject to change without notice Printed in USA Copyright by Johnson Controls 2014 ALL RIGHTS RESERVED Form 160 54 O1 914 Issue Date September 10 2014 Supersedes 160 54 O1 1013 Tele 800...

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