York YK-EP B Operation & Maintenance Manual Download

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YK-EP STYLE B

R-134a COOLING ONLY

WITH OPTIVIEW™ CONTROL CENTER

SOLID STATE STARTER AND VARIABLE SPEED DRIVE

YK-EP

CENTRIFUGAL CHILLER

OPERATION & MAINTENANCE

Supersedes: 160.87-OM1 (417)

Form 160.87-OM1 (818)

Issue Date:

August 24, 2018

R-134a

Summary of Contents for YK-EP B

Page 1: ...34a COOLING ONLY WITH OPTIVIEW CONTROL CENTER SOLID STATE STARTER AND VARIABLE SPEED DRIVE YK EP CENTRIFUGAL CHILLER OPERATION MAINTENANCE Supersedes 160 87 OM1 417 Form 160 87 OM1 818 Issue Date Augu...

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

Page 3: ...IATED LITERATURE DESCRIPTION FORM NUMBER YK EP Installation Checklist and Request for Startup Engineer 160 87 CL1 YK EP Startup Checklist 160 87 CL2 YK EP Maintenance Log Sheet 160 87 MR1 YK EP Instal...

Page 4: ...0 Hz 5 50 Hz M Incoming line frequency in 50 Hz and motor frequency in 60 Hz ECONOMIZER POWER SUPPLY 60 Hz 5 50 Hz PRIMARY MOTOR CODE 60 HZ 50 HZ DD 5DD DE 5DE DF 5DF 5DG DH 5DH DJ 5DJ DK 5DK DL 5DL E...

Page 5: ...e Geometry Diffuser Screen 56 Variable Geometry Diffuser Setpoints Screen 58 Economizer Compressor Variable Geometry Diffuser Screen 60 Economizer VGD Setpoints Screen 62 Pre Rotation Vanes Calibratio...

Page 6: ...end Setup Screen 151 Advanced Trend Setup Screen 153 Common Slots Screen 155 SECTION 3 DISPLAY MESSAGES 161 Status Messages 161 Safety Shutdown Messages 175 Mod B Solid State Starter Safety Shutdown M...

Page 7: ...ion Vanes Calibration Screen 64 FIGURE 25 VSD Tuning Screen 65 FIGURE 26 Oil Sump Screen 67 FIGURE 27 Economizer Oil Pump Screen 69 FIGURE 28 Economizer Capacity Control Screen 71 FIGURE 29 Economizer...

Page 8: ...Diagram 189 FIGURE 71 Sample Printout Status 190 FIGURE 72 Sample Printout Setpoints 192 FIGURE 73 Sample Printout Schedule 194 FIGURE 74 Sample Printout Sales Order 194 FIGURE 75 Sample Printout Hist...

Page 9: ...ve Position 51 TABLE 4 Condenser Refrigerant Level 77 TABLE 5 Voltage V 92 TABLE 6 Condenser Temperature Range 121 TABLE 7 YK EP Trend Slot Numbers 156 TABLE 8 OKIDATA OKIPOS 441 186 TABLE 9 Brecknell...

Page 10: ...FORM 160 87 OM1 ISSUE DATE 8 24 2018 JOHNSON CONTROLS 10 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 11: ...DAMENTALS OF OPERATION SYSTEM OPERATION DESCRIPTION The YORK Model YK EP Chiller is commonly applied to large air conditioning systems but may be used on oth er applications The chiller consists of an...

Page 12: ...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 13: ...e Pressure Liquid Refrigerant Figure 3 REFRIGERANT FLOW THRU CROSS SECTION DIAGRAM Primary Compressor Primary Suction Hot Gas Bypass Control Valve Optional Economizer Suction Hot Gas Bypass Line Optio...

Page 14: ...FORM 160 87 OM1 ISSUE DATE 8 24 2018 JOHNSON CONTROLS 14 SECTION 1 DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION THIS PAGE INTENTIONALLY LEFT BLANK...

Page 15: ...is detailed in the DISPLAY MES SAGES portion of this manual There are certain screens displayed values program mable setpoints and manual control shown in this manual that are for Service Technician...

Page 16: ...ion is revised the respective revision level increments D Industrial chiller Exx Used on Microboard 031 02430 001 01 YKEP chiller xx controls revision level 00 01 etc y language package 0 equals Engli...

Page 17: ...ey is provided as a universal Enter key or Accept symbol In order to reject entry of a setpoint or dismiss an entry form the X key is provided as a uni versal Cancel symbol Cursor Arrow keys are pro v...

Page 18: ...9 6 7 5 using the numeric keypad OPERA TOR access reverts to the VIEW level after 10 continu ous minutes without a keypress If a custom User ID and password have been defined refer to User Screen on P...

Page 19: ...ser to enter a new setpoint value The X key cancels cursor mode Refer to the Schedule Screen on Page 126 for an example NAVIGATION In order to maximize the amount of values which the panel can display...

Page 20: ...tion Page 49 Hot Gas Bypass Page 51 Surge Protection Screen Page 53 Variable Geometry Diffuser Page 56 Pre Rotation Vanes Calibration Page 64 VSD Tuning Page 65 Oil Sump Page 67 Motor Page 81 Electro...

Page 21: ...6 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...

Page 22: ...s the condenser Condenser Liquid Temperature Entering Displays the temperature of the liquid as it enters the condenser Primary Motor Full Load Amps This displays the percentage of Full Load Amps uti...

Page 23: ...ll return the ac cess level to VIEW Print Access Level Required VIEW Use this key to generate a hard copy report of the present system status This provides a snapshot of the primary operating conditio...

Page 24: ...mp and oil sump pa rameters This includes the Variable Speed Oil Pump when installed It also controls the Seal Lubrication functionality Motor A detailed view of the motor controller parameters specif...

Page 25: ...Entering Displays the temperature of the liquid as it enters the evaporator Chilled Liquid Temperature Setpoint Displays the active temperature setpoint to which the chiller is controlling the evapor...

Page 26: ...ssure differential between the high side oil pressure transducer output of oil filter and the low side oil pressure transducer compressor housing The displayed value includes offset pressure derived f...

Page 27: ...centage of Full Load Amps Primary PRV Position Displays how open the PRV vanes are in percentage from 100 fully open to 0 fully closed Primary Motor Run LED Illuminates when the Primary Compressor is...

Page 28: ...oil in the sump Leaving Condenser Liquid Temperature Displays the temperature of the liquid as it leaves the condenser tube bundle Entering Condenser Liquid Temperature Displays the temperature of the...

Page 29: ...mperature 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 Temp...

Page 30: ...define the Leaving Chilled Liquid Temperature that is to be maintained by the chiller It is programmable over the range of 38 0 F to 70 0 F water or 10 0 F to 70 0 F brine If Smart Freeze refer to Pag...

Page 31: ...Temperature Setpoint It is program mable over a range of 0 F to 70 F above the setpoint to a maximum restart value of 80 F The chiller will automatically restart when this temperature is reached This...

Page 32: ...aving Condenser Liquid temperature The Condenser Refrigerant temperature will be represented by the Condenser Saturation tem perature Condenser Pressure Displays the refrigerant pressure in the conden...

Page 33: ...t level is being controlled Level Control Valve Command Displays the level control valve signal 0 to 100 PROGRAMMABLE High Pressure Warning Threshold Access Level Required SERVICE This value allows th...

Page 34: ...explained in the OptiView Control Center Service Manual Requires a login access level of SERVICE DISPLAY ONLY Entering Condenser Liquid Temperature Displays the temperature of the liquid as it enters...

Page 35: ...Valve is at minimum for a 0 command and at maximum for a 100 command When set to reverse the voltage or current signal to the Control Valve is at maximum for a 0 command and at minimum for a 100 comma...

Page 36: ...view of the condenser The actual level of the refrigerant in the tank does not match the percentage displayed in the Level Control Valve Command box The actual levels versus the displayed percentages...

Page 37: ...o 10 default 1 0 Open Pressing this button will set the Condenser Level Con trol Valve Mode to Manual if it had been in Auto It will increase the current Condenser Level Control Valve Command by an am...

Page 38: ...and displayed values DISPLAY ONLY Oil Pressure Displays the pressure differential between the high side oil pressure transducer compressor bearing input and the low side oil pressure transducer oil su...

Page 39: ...ntrol Pre Rotation Vanes Open LED Access Level Required SERVICE Indicates whether the vanes are in the process of open ing Pre Rotation Vanes Close LED Access Level Required SERVICE Indicates whether...

Page 40: ...anes VSD Tuning Variable Speed Drive Only Access Level Required SERVICE Moves to the subscreen allowing advanced tuning of the Variable Speed Drive Hot Gas Access Level Required SERVICE Moves to a sub...

Page 41: ...ntial is out of range the display 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 dur...

Page 42: ...uminates when the Primary Compressor is currently running Compressor Status Access Level Required SERVICE This value displays the economizer compressor status The values are as follows Stopped Prelube...

Page 43: ...to a subscreen that allows programming of the Hot Gas Bypass control setpoints and manual control of the Hot Gas Bypass valve Only displayed if Hot Gas Bypass feature has been enabled on the OPERA TIO...

Page 44: ...bled Coastdown Time Displays the amount of time the economizer compres sor spent in coastdown Motor Auto Lube Type Set to P203 QLS401 Sleeve or None as appropriate Motor Heater Set to Enable if a moto...

Page 45: ...he Pre Rotation Vanes Requires a login access level of SERVICE DISPLAY ONLY Pre Rotation Vanes Opening LED Indicates the vanes are opening Pre Rotation Vanes Closing LED Indicates the vanes are closin...

Page 46: ...tation Vanes actuator mode as Manual or Automatic Open Pressing this button will open the Pre Rotation Vanes Close Pressing this button will close the Pre Rotation Vanes Hold Pressing this button will...

Page 47: ...be viewed at Operator Level DISPLAY ONLY High Pressure Switch Displays whether the high pressure switch is open or closed Discharge Superheat Displays the discharge superheat of the economizer in deg...

Page 48: ...t Access Level Required SERVICE This oversized button will also contain a text box dis playing the Economizer Level Control Valve Manual Increment for manual control Open Access Level Required SERVICE...

Page 49: ...cali bration sequence Oil Pressure Displays the pressure differential between the high side oil pressure transducer compressor bearing input and the low side oil pressure transducer oil sump The disp...

Page 50: ...ation Press this key to cancel calibration Accept Calibration Press this key to accept calibration Fault Acknowledge This option is only displayed if a fault is present Al lows clearing of High Speed...

Page 51: ...present position of the Hot Gas Valve as a value between 0 closed to 100 full open By animation the valve is shown in its relative position The actual position of the valve does not match the percent...

Page 52: ...ssages PROGRAMMABLE Close Percentage Access Level Required SERVICE 5 to 15 Default 15 This is the incremental amount that the Hot Gas Valve will be closed at 10 minute intervals after the HOLD period...

Page 53: ...e Hot Gas Bypass feature Refer to Hot Gas Bypass Screen on Page 51 The detection and counting of surges in this feature is completely independent of the surge detection counting performed by the Varia...

Page 54: ...ith ei ther shutdown If this setpoint is Disabled refer to operation under Count Limit on Page 55 If equipped with a compressor Variable Speed Drive VSD the VSD output frequency must be at maximum bef...

Page 55: ...d if the Surge Window Count is less than or equal to the Count Limit this message and load inhibit are automatically cleared Alternat ing with this message is WARNING EXCESS SURGE DETECTED that contin...

Page 56: ...h Displays the status of the VGD Limit Switch Dis played as CLOSED when the switch is closed This would be when the VGD is in the fully closed position Otherwise it is displayed as OPEN Diffuser Gap C...

Page 57: ...he VGD is in the Stall Waiting State displays the time remaining in the Probe Wait Time interval value programmed as the Probe Wait Time setpoint Diffuser Gap Control Mode Indicates whether the VGD is...

Page 58: ...ully open Displayed as XXX until calibration procedure is per formed by Service Technician VGD Closed Limit Switch Displays the status of the VGD Limit Switch Dis played as CLOSED when the switch is c...

Page 59: ...he Probing state Open Pulse 1 to 5 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 6...

Page 60: ...ed below the setpoint will cause the VGD to open allowing more gas through the compressor Mach Number Displays the speed of the refrigerant gas leaving the compressor in percentage of Mach the speed o...

Page 61: ...e PROGRAMMABLE VGD Actuator Access Level Required SERVICE Displays the current state of the VGD Actuator It will show either Auto or Manual Open with LED Access Level Required SERVICE Pressing this bu...

Page 62: ...setpoint will cause the VGD to open allowing more gas through the compressor Mach Number Displays the speed of the refrigerant gas leaving the compressor in percentage of Mach the speed of sound VGD C...

Page 63: ...State the PRV po sition is PRV wait Start position During the Wait state if PRV position is greater than the PRV wait Start 3 the VGD control will enter the Probing state Stall Wait Time Access Level...

Page 64: ...ndicates 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 failure Pre Rotation Vanes...

Page 65: ...position of the Pre Rotation Vanes in per cent over the range of 0 full close to 100 full open Delta P P Displays the chiller head pressure calculated as con denser pressure evaporator pressure evapo...

Page 66: ...it increases the Command Frequency to the drive by the amount defined by the MANUAL INCREMENT key It will not raise the val ue above the maximum allowed 50 or 60 Hz Lower Access Level Required SERVICE...

Page 67: ...he transduc ers used to calculate this differential is out of range the display field will show XX X Oil Sump Temperature Displays the temperature of the oil in the sump Oil Saturated Condenser Temper...

Page 68: ...ur intervals from when the oil pump was last run for at least 2 minutes Economizer Oil Pump Access Level Required SERVICE Allows the user to navigate to the Economizer Oil Pump Screen Pressure Setpoin...

Page 69: ...to zeroing during the System Prelube Refer to explanation of auto zeroing under the Primary Com pressor Screen on Page 38 If either of the transduc ers used to calculate this differential is out of ra...

Page 70: ...unning for a maximum of ten 10 minutes If a longer running time is desired this key must be pressed again Manual Oil Pump control is disabled and the button hidden during System Prelube System Run Pro...

Page 71: ...lays the temperature that is the result of subtract ing the Economizer Saturation Temperature minus the Economizer Saturation Temperature Setpoint Motor Current FLA Displays the percent of full load a...

Page 72: ...ton with activate the economizer Pre Rotation Vane override and set it to Manual if it was previously in Auto It will increase the Pre Rotation Vane override position by an amount equal to the Man ual...

Page 73: ...Flow Range 5 to 150 PSID Default 30 PSID This displays the low head setpoints at which the econ omizer will activate These points can be changed ac cording to when the operator wishes the economizer t...

Page 74: ...ontrol Max Loading Delta Range 0 1 to 100 0 Default 1 0 Displays the maximum temperature difference used to initiate changes in the economizer mode Econ Temperature Control Max Unloading Delta Range 0...

Page 75: ...er will be the highest at this point Speed of Sound Isentropic Head Omega Surge Mach Mach Number Anti Surge Minimum Econ Temperature Active Anti Surge Minimum Econ Temperature Min Temperature Rate Max...

Page 76: ...GATION Home Access Level Required VIEW Returns the user to the HOME Screen Capacity Control Access Level Required SERVICE Allows the user to navigate to the Economizer Capac ity Control Screen Setpoin...

Page 77: ...position of the liquid level The refrigerant level is animated in the cutaway view of the condenser The actual level of the refrigerant in the tank does not match the percentage displayed in the Level...

Page 78: ...able 0 1 to 15 default 0 5 Ti Access Level Required ADMIN Sets the Integral value of the PID control loop Ad justable 0 1 to 500 default 200 Td Access Level Required ADMIN Sets the Derivative value of...

Page 79: ...ill be allowed to operate Input Power Displays the kilowatts measured by the Solid State Starter KW Hours Displays the cumulative amount of kilowatts used over time Starter Model Displays the Solid St...

Page 80: ...disable the Solid State Starter Open SCR safety detection This must never be disabled unless under advisement of the Johnson Con trols Factory Shorted SCR Enabled Disabled Access Level Required SERVI...

Page 81: ...pulldown period if the value is nonzero PROGRAMMABLE Local Motor Current Limit Access Level Required OPERATOR Allows the user to specify the maximum allowed mo tor current as a percentage of FLA When...

Page 82: ...CENTER INTRODUCTION NAVIGATION Home Access Level Required VIEW Returns user to HOME Screen Motor Lube Access Level Required VIEW Moves to the subscreen allowing operator acknowledge ment of the compr...

Page 83: ...or 2 to 10VDC input in Analog Remote mode PWM signal in Digital Remote mode E Link Gateway interface in ISN mode or a locally programmed value Pulldown Demand Time Left Displays the time remaining in...

Page 84: ...m amps at which the motor can op erate This value is viewable when logged in under the OPERATOR or VIEW access level Supply Voltage Range Access Level Required SERVICE Allows the user to select a spec...

Page 85: ...to 20mA 4 to 20mA 0 to 10VDC or 2 to 10VDC input in Analog Remote mode PWM signal in Digital Remote mode SC EQ communication card in ISN BAS Remote mode or a locally programmed value in Local mode Pul...

Page 86: ...enable or disable the Solid State Starter Open SCR safety detection This must never be disabled unless under advisement of the YORK Factory Shorted SCR Enabled Disabled Access Level Required SERVICE A...

Page 87: ...alog Remote mode PWM signal in Digital Remote mode E Link or SC EQ commu nications interface in ISN Remote mode or a locally programmed value in Local mode Input Power Displays the kilowatts measured...

Page 88: ...Demand Time Access Level Required OPERATOR Allows the user to set the period of time for which the pulldown demand limit will be in effect Full Load Amps Access Level Required SERVICE Defines the max...

Page 89: ...2 to 10VDC input in Analog Remote mode PWM signal in Digital Remote mode E Link or SC EQ com munications interface in ISN mode or a locally pro grammed value Pulldown Demand Time Left Displays the ti...

Page 90: ...uired OPERATOR Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chiller starts kWH Reset Access Level Required ADMIN Allows the user to reset the...

Page 91: ...s FLA Current Limit Setpoint Displays the current limit value in use This value could come from a 0 to 20mA 4 to 20mA 0 to 10VDC or 2 to 10VDC input in Analog Remote mode PWM signal in Digital Remote...

Page 92: ...following table If this results in a model that is not defined in the lookup table the model number is displayed as INVALID and the chiller will not be allowed to run while this is displayed Table 5 V...

Page 93: ...d 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 SERVIC...

Page 94: ...rrent Limit Setpoint Displays the current limit value in use This value could come from a 0 to 20mA 4 to 20mA 0 to 10VDC or 2 to 10VDC input in Analog Remote mode PWM signal in Digital Remote mode E L...

Page 95: ...s value as reported by the VSD PROGRAMMABLE Local Motor Current Limit Access Level Required OPERATOR Allows the user to specify the maximum allowed mo tor current as a percentage of FLA When the mo to...

Page 96: ...r current as a percentage of the Full Load Amps FLA value For the Variable Speed Drive this is the data returned by the VSD Logic Board Current Limit Setpoint Displays the current limit value in use T...

Page 97: ...rent Limit Access Level Required OPERATOR Allows the user to specify the maximum allowed mo tor current as a percentage of FLA When the mo tor current reaches this value the Pre Rotation Vanes will no...

Page 98: ...ICE DISPLAY ONLY Full Load Amps Displays the motor current as a percentage of chiller Full Load Amps as calculated by the microboard from current values returned from the drive Logic Board Current Lim...

Page 99: ...ge is detected while the drive is running at less than maximum frequency Surge Map Point Count Displays the total number of data points contained in the surge map PROGRAMMABLE VSD Start Frequency Sets...

Page 100: ...ECTION 4 PRINTING of this manual Surge Map Clear Allows the Service Technician to clear the surge map When this key is pressed a dialog box appears request ing a special password to proceed NAVIGATION...

Page 101: ...ed it will remain at the last position The Present Operating conditions are indicated with an as shown above and are detailed at the bottom of the screen under present If the present condition is the...

Page 102: ...ta P P Selected Displays the Delta P P of the selected surge point Present Displays the present Delta P P PROGRAMMABLE Map View Allows a Service Technician to change the view from table to list Manual...

Page 103: ...it is set to List The PAGE UP and PAGE DOWN keypad keys are used to scroll to the previous or next list of parameters This screen is applicable to Variable Speed Drives VSD with the Motor Communicati...

Page 104: ...M1 ISSUE DATE 8 24 2018 JOHNSON CONTROLS 104 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 D...

Page 105: ...s 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 or SC EQ com munications interface in ISN mode or a locally...

Page 106: ...ortion L1 L2 L3 Displays the 3 phase Current Total Demand Distortion TDD measurements RMS Supply Current L1 L2 L3 Displays the 3 phase RMS Voltages across each line PROGRAMMABLE Local Motor Current Li...

Page 107: ...This also clears any motor lubrica tion warning or safety that is in effect and resets the operating hours since last lubrication to zero This lubrication notification and shutdown feature can be ena...

Page 108: ...Use the key to backspace if necessary To write over an existing entry or to place a blank space scroll to the beginning of the alphabet The selection prior to the letter A is a blank space Use the ke...

Page 109: ...d manually or by running an auto baseline routine that plots a baseline over a 1 hour period while the chiller is running This screen also serves as a gateway to a subscreen that allows programming of...

Page 110: ...ed invalid and displays as XXX X When the Bearing Temperature Protection Setpoint is set to Disable no temperatures are dis played and the heading text and data boxes do not ap pear Vibration Displays...

Page 111: ...nsmitters via the VSD Logic Board serial communications Bearing Temperature Protection Access Level Required SERVICE Enables the type of temperature sensing device being used to sense motor bearing te...

Page 112: ...Motor Bearing Vibration Access Level Required SERVICE Used to manually enter a vibration baseline value 0 1 to 5 default 2 for the Shaft End and Opposite Shaft End bearings The vibration values are no...

Page 113: ...DETAILS Screen is set to Disabled Winding Hotspot Allowance Displays the Winding Hotspot Allowance temperature Not shown when Winding Temperature Protection Setpoint on the MOTOR DETAILS Screen is set...

Page 114: ...SERVICE Not shown when Winding Temperature Protection Setpoint on MOTOR DETAILS Screen is set to Dis abled Allows a Service Technician to program the High Winding Temperature 266 to 320 F default 311...

Page 115: ...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 116: ...the building This value 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 abs...

Page 117: ...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 70 F below th...

Page 118: ...mand Time Access Level Required OPERATOR Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chiller starts Print Access Level Required VIEW Generat...

Page 119: ...Level Required OPERATOR Allows the user to enable or disable the Real Time Clock in order to conserve battery life The clock will be disabled during manufacturing and must be enabled at system commiss...

Page 120: ...all YK EP chillers whether equipped with the potentiom eter or not The PRV position will be shown on respec tive screens when Enabled Enabled Automatically set to this setting if Hot Gas Bypass or Va...

Page 121: ...by the Chiller Style Compressor Setpoint Style F J7 and G K6 K7 the range is 240 default to 900 seconds All others the range is 150 default to 900 seconds Motor Heater Access Level Required SERVICE S...

Page 122: ...ces Comms Access Level Required VIEW Moves to the subscreen allowing configuration of sys tem communications Printer Access Level Required VIEW Moves to the subscreen allowing configuration and contro...

Page 123: ...n pulse and after the VSD achieves its start frequency the speed ramp rate is faster than with normal control Quick Normal Start If the conditions for a Quick Restart are not met the next time the chi...

Page 124: ...assword to enable it again as ex plained above Quick Start mode will be automatically disabled when any of the following occur The Motor Drive Type is changed to something other than VSD or MVVSD or t...

Page 125: ...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 0 5 F to 4 0 F de fault 1 0 F Quick Ramp Current Threshold Access...

Page 126: ...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 continu...

Page 127: ...quired OPERATOR Allows the user to enable or disable the monitoring function which enforces the scheduled starting and stopping of the chiller Repeat Sunday Schedule Access Level Required OPERATOR Dup...

Page 128: ...SPLAY ONLY None PROGRAMMABLE Data Display Mode Access Level Required OPERATOR Define the unit system English or Metric used by the chiller display System Language Access Level Required OPERATOR Allows...

Page 129: ...intenance personnel User Password 1 4 Access Level Required SERVICE This allows the user to specify up to four 4 custom password values Each password will then require a corresponding User ID and user...

Page 130: ...selection box around the first changeable parameter Use the and keys to place the selection box around the desired param eter to be changed With the selection box around the desired parameter press th...

Page 131: ...com municate to the modem port COM 2 Parity Bit s Displays the number of parity bits the panel uses to communicate through the modem port COM 2 Stop Bit s Displays the number of stop bits the panel us...

Page 132: ...ich log printing will occur 1 minute to 1440 minutes Default 60 minutes Automatic Printer Logging Enabled Disabled Access Level Required OPERATOR Enable the printer to begin printing status reports be...

Page 133: ...type to print when the PRINT RE PORT key is selected This can vary from status report present system parameters Setpoints report present value of the system setpoints Schedule report present value of...

Page 134: ...y defined serial number for the micropanel Chiller Serial Number Factory defined serial number for the chiller system YORK Order Number Factory defined order number under which the chiller was sold Sy...

Page 135: ...Sales Order data NAVIGATION Home Access Level Required VIEW Returns user to HOME Screen Setup Access Level Required VIEW Returns user to SETUP Screen Economizer Order Access Level Required VIEW to Vie...

Page 136: ...by a Service Technician when replacing a mi croboard Change Access Level Required ADMIN to Change Pressing this button displays a Green rectangle around the Motor Code parameter The service technicia...

Page 137: ...quired OPERATOR Defines whether the control of the chiller will be Lo cal Digital Remote Analog Remote Modem Remote or ISN BAS Remote Number of Starts Access Level Required ADMIN Displays the number o...

Page 138: ...le flow switch type Paddle type TB4 or Thermal Type J14 Flow sensors Chiller Style Compressor Access Level Required SERVICE Automatically set to Style G K6 7 Compressor Edit Phone Numbers Access Level...

Page 139: ...dow displays the date and time and the de scription of the last normal shutdown A normal shut down is defined as Local Soft Stop Switch Remote Digital Analog or ISN BAS Last Fault While Running This w...

Page 140: ...setting Trending Access Level Required VIEW Causes a move to a subscreen allowing the user to view trending data on selected chiller parameters Custom View Access Level Required OPERATOR Causes a move...

Page 141: ...Y 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...

Page 142: ...l and User ID used to make the change the old setpoint value and the new setpoint value Requires a login access level of SERVICE DISPLAY ONLY Category Displays the category of the setpoint motor evapo...

Page 143: ...2018 2 NAVIGATION Home Access Level Required SERVICE Returns user to HOME Screen History Access Level Required SERVICE Returns user to HISTORY Screen View Details Access Level Required SERVICE Causes...

Page 144: ...s a login access level of SERVICE DISPLAY ONLY Description Displays the setpoint category that was changed Time Displays the time the setpoint was changed Date Displays the date the setpoint was chang...

Page 145: ...TER INTRODUCTION JOHNSON CONTROLS 145 FORM 160 87 OM1 ISSUE DATE 8 24 2018 2 NAVIGATION Home Access Level Required SERVICE Returns user to HOME Screen Security Log Access Level Required SERVICE Return...

Page 146: ...service call the display can be cleared or the parameters can be left there for monitoring by operations personnel DISPLAY ONLY None Requires a login access level of SERVICE PROGRAMMABLE Print Access...

Page 147: ...ough the Slot Numbers list and note the number of the parameter s to be displayed Pressing the SELECT key places a green colored selection box around Cus tom Slot 1 If it is desired to change an alrea...

Page 148: ...8 24 2018 JOHNSON CONTROLS 148 SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION NAVIGATION Home Access Level Required VIEW Returns user to HOME Screen Custom View Access Level Required SERVICE Returns...

Page 149: ...e Y Axis label minimum for that parameter the value will be plotted at the minimum value Similarly if the actual value is greater than the Y Axis label maximum for that parameter the value will be plo...

Page 150: ...running Print 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 I...

Page 151: ...elects the interval at which the parameters are sam pled There are 450 data points displayed across the X Axis of the graph Each point represents the instan taneous value of the parameter The user sel...

Page 152: ...resolution for the param eter 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...

Page 153: ...omparator If it is evaluated as true then the data collection is started or stopped after any selected trigger delay per the selected Trigger Ac tion A Secondary Trigger can be evaluated with the Prim...

Page 154: ...r Action is set to Start data collection will begin after the triggers evaluate as true and the delay timer has elapsed If the Trigger Action is set to Stop data col lection will stop after the trigge...

Page 155: ...TREND SETUP Screen and enter the parameters Slot Numbers into Data Points 1 through 6 DISPLAY ONLY Slot Numbers These are the Slot Numbers of the most commonly used parameters PROGRAMMABLE Page Down A...

Page 156: ...X X X X X 1809 Evaporator Saturation Temperature X X X X X X 1810 Evaporator Small Temp Difference X X X X X X 1812 Evaporator Refrigerant Temperature X X X X X X 1813 Delta P P X X X X X X CONDENSER...

Page 157: ...X X X X X 8319 Surge Avoidance Surge Detected X X X X X X VARIABLE SPEED OIL PUMP 8197 Oil Pump Drive Command Frequency X X X X X X CONDENSER REFRIGERANT LEVEL CONTROL 29199 Condenser Level Control St...

Page 158: ...a n a n a n a X n a 2818 Input Power n a n a n a X X n a 2819 kW Hours n a n a n a X X n a 2820 DC Bus Voltage n a n a n a X X n a 2821 DC Inverter Link Current n a n a n a X X n a 2822 Output Frequen...

Page 159: ...ch X X X X X X ECONOMIZER VARIABLE SPEED OIL PUMP 30977 Econ Active Oil Pressure Setpoint X X X X X X 30988 Econ Oil Pump VSD Freq Com mand Hz X X X X X X 30994 Econ Oil Pump Run Stop State X X X X X...

Page 160: ...c Head X X X X X X 30475 Econ Omega X X X X X X 30476 Econ Surge Mach X X X X X X 30478 Econ Anti Surge Minimum Tempera ture X X X X X X 30722 Econ PRV Command Pos X X X X X X 31493 Econ Active Load L...

Page 161: ...Status Bar The chiller can be started after the safety condition clears and the Opera tor presses the WARNING RESET button System Prelube A chiller start has been initiated and the pre start lu brica...

Page 162: ...nts a further current rise If the current continues to rise to the Start Close threshold the Vanes begin closing until the current falls to the Stop Close threshold Automatic Vane operation is re sume...

Page 163: ...tion clears and the WARNING RESET Keypad key is pressed in Operator or higher access mode Condition not checked in Brine mode Warning Standby Lube Low Oil Pressure Aminimum of 15 PSID of oil pressure...

Page 164: ...Chiller is running Filter is enabled Filter present status is true Run Time greater than 20 seconds Filter operating mode is stopped This warning is released when the chiller is stopped but will be d...

Page 165: ...ETAILS Screen Also it will not act on any RTD input registering as an open RTD or any individual winding temperature sensor that has been disabled with the Temperature Disable Setpoint on the MOTOR SE...

Page 166: ...running when this occurs the Pre Rotation Vanes are driven fully closed prior to shutting down the chiller Local Stop A local shutdown command has been received by pressing the Soft Stop Key on the H...

Page 167: ...ch closes While this cycling shutdown is active the condenser pump contacts TB2 150 151 remain closed until the chiller is given a stop command or has another fault Motor Controller Contacts Open The...

Page 168: ...l The thresholds are as fol lows SUPPLY VOLTAGE RANGE VOLTS SHUTDOWN VOLTS RESTART VOLTS 380 415 414 400 436 435 415 454 453 440 480 524 523 550 600 655 654 Supply Voltage Range disabled None N A Prox...

Page 169: ...the motor current is greater than 25 of the Job FLA The chiller will automatically restart upon completion of System Coastdown LCSSS Low Phase X Temperature Sensor The Liquid Cooled Solid State Start...

Page 170: ...er Board has detected the line to line RMS voltage in any phase has decreased to less than or equal to 30 of the lowest value of the programed voltage range If the pro grammed voltage range is Disable...

Page 171: ...his shutdown is generated by the VSD if the motor current in phase A exceeds a given limit The mo tor current is sensed by the current transformers on the VSD output pole assemblies and the signals ar...

Page 172: ...be approximately of the total DC Link Voltage Most actual Bus Voltage Imbalance con ditions are caused by a shorted capacitor or a leaky or shorted IGBT transistor in an output phase bank assem bly Th...

Page 173: ...19 HP 50 Hz The chiller has shutdown because the baseplate tem perature has decreased to less than 37 F VSD Low Phase B Inverter Baseplate Temperature VSD part number 371 03789 xxx 503 HP 60 Hz 419 HP...

Page 174: ...lter tripped due to a sag or surge in the voltage feeding the VSD If this message reoc curs preventing the chiller from starting the VSD will require service Harmonic Filter High Phase B Current See H...

Page 175: ...th no current flowing through the DC Current Transformers DCCT s the DCCT output voltages are measured and compared with a preset limit via the Filter Logic Board If the measured values exceed the pre...

Page 176: ...l Evaporator Refrigerant Temperature Sensor If the difference between these temperatures is greater than 3 0 F continuously for 1 minute this shutdown is performed This check is only performed under t...

Page 177: ...T button Oil Low Differential Pressure The differential oil pressure decreased to less than 15 0 PSID while the chiller was running or failed to achieve 25 0 PSID by the last 5 seconds of the System P...

Page 178: ...uto restart or manual re start after power failure by a qualified Service Techni cian following instructions in OptiView Control Center Service Instructions Form 160 54 M1 Motor Or Starter Current Imb...

Page 179: ...d after the Operator presses the WARNING RESET button Surge Protection Excess Surge Applies only if Surge Protection Shutdown feature is Enabled The Surge Window Count surge events exceeded the Count...

Page 180: ...d If an optical sensor is be ing used the input to the Motor Monitoring Board goes high to indicate a leak if a float switch is used the input goes low to indicate a leak This safety shutdown will not...

Page 181: ...rted after manual resets are performed as detailed below Service and troubleshooting information is con tained in Variable Speed Drive Service Instructions Form 160 00 M1 VSD Shutdown Requesting Fault...

Page 182: ...Board and the Operator presses the WARNING RESET button VSD High Phase C Inverter Baseplate Temperature VSD part number 371 03789 xxx 503HP 60 Hz 419HP 50 Hz The chiller has shutdown because the basep...

Page 183: ...n will occur if the TDD ex ceeds 25 continuously for 45 seconds TDD is an acronym for Total Demand Distortion a term defined by the IEEE Std 519 2014 standard as the total root sum square harmonic cur...

Page 184: ...THIS PAGE INTENTIONALLY LEFT BLANK...

Page 185: ...surge points were mapped Compressor Motor Variable Speed Drive applications Access Level Required SER VICE level Printer ACC Trend Prints a snapshot of the existing TREND Screen data or prints new dat...

Page 186: ...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 187: ...Level Required OPERATOR Using the PRINTER Screen set the printer type to Weigh Tronix Automatic Data Logging Access Level Required OPERATOR If automatic data logging is desired a status report can be...

Page 188: ...inted information and the informa tion will be recorded 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 wi...

Page 189: ...paper P N AWT 05 505594 power supply P N AWT 05 505671 case 20 rolls of paper PRINTER CONNECTIONS Connect the printer to the Control Center Microboard as follows Only one printer can be connected at a...

Page 190: ...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...

Page 191: ...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 71 SAMPLE PRINTOUT STATUS CONT D Skip the following s...

Page 192: ...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 193: ...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 P...

Page 194: ...P OFF 13 APR 1999 START 8 00 AM STOP 10 00 PM Figure 74 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 195: ...8 24 2018 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 KILOW...

Page 196: ...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 Chi...

Page 197: ...ase 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...

Page 198: ...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 199: ...illed Active Setpoint 45 0 F Leaving Chilled Liquid Temperature 50 0 F Return Chilled Liquid Temperature 59 3 F Leaving Condenser Liquid Temperature 85 0 F Return Condenser Liquid Temperature 94 9 F E...

Page 200: ...THIS PAGE INTENTIONALLY LEFT BLANK...

Page 201: ...Position SW1 4 on the 03630 is now used in place of JP6 on the 02430 to initiate a program update On the 02430 a BRAM chip stored the configurable setpoints sales data and Real Time Clock The BRAM ch...

Page 202: ...pass fail status is displayed on the white screen CHILLER OPERATING PROGRAM The Chiller Operating Program is a set of instructions to control the chiller It contains the Safety and Cycling shutdown t...

Page 203: ...re a battery Real Time Clock The RTC Real Time Clock uses a common CR2032 button cell lithium battery to maintain the time and date during power outages The battery life is over 10 years This type of...

Page 204: ...shutdown In the HARDWARE watchdog initiated shutdown a program problem on board noise or hardware problem could prevent the watchdog time out If this occurs a re boot is initiated and when the graphic...

Page 205: ...JP8 Display brightness control technique Determines whether the display brightness is controlled by a variable resistance or a vari able voltage IN Variable voltage 0 to 5 0VDC SHARP LQ10D367 LQ10D36...

Page 206: ...termnal Pins 1 2 Not used Pins 2 3 Normal position no bias applied JP27 Applies a pull down voltage to the COM5B terminal IN Not used OUT Normal position no bias applied JP28 Applies a 120 Ohm termina...

Page 207: ...urned from each chan nel The function of each is in the Table 12 on Page 207 The microprocessor determines which board and therefore which starter is present by the value returned from channel 0 Since...

Page 208: ...the setting of the VSD Logic Board Modbus Ad dress Switch SW3 They must be both set to 1 There are two different types of Modbus protocol used Modbus ASCII for Mod D Vyper and Modbus RTU for Raptyr Wh...

Page 209: ...luded are tables to convert the expected output voltage for any temperature applied to the thermistor Flow Switch The chillers are supplied with factory mounted Flow Sensors on the evaporator and cond...

Page 210: ...s Each pixel con sists of 3 windows red green and blue through which a variable amount of light from the Display Backlight is permitted to pass to the front of the display The drive signals determine...

Page 211: ...Setpoints Remote Leaving Chilled Liquid Temperature and Cur rent Limit setpoints can be input via the RS 232 SC EQ communications interface at J2 or directly to the microboard at J22 using a hardwired...

Page 212: ...solenoid valves than chillers equipped with a Fixed Speed Oil Pump A de scription of the two Oil Pumps is as follows 1 Variable Speed con gures the program to oper ate the Variable Speed Drive Oil Pum...

Page 213: ...essure warning and safety thresholds This setpoint allows the software to be used in either standard or high tempera ture applications This setpoint is set at the factory at time of manufacture and re...

Page 214: ...ard 7 Set the Jumpers JP2 through JP12 and JP21 through JP25 and SW1 switch on the 03630 to the same positions as those on the 02430 board A description of these jumpers are found later in this docume...

Page 215: ...plicable to your chiller model For example if your chiller is a YK EPchiller the Program card used MUST be for a YK EP chiller If a YS chiller program is down loaded into a YK EP chiller for example t...

Page 216: ...e The red LED next to this bar illuminates while this procedure is in progress The microboard 7 segment LED Displays U25 and U26 display the steps of the programming process while they are in effect D...

Page 217: ...18 5 Figure 81 MICROBOARD 031 03630 007 TO DISPLAY ON DOOR E LINK POWER FROM POWER SUPPLY J3 POWER OUT TO DISPLAY ON DOOR TO KEYPAD ON DOOR TB4 VGD SD CARD SLOT TB2 J12 COM3 J13 MC1 J24 J25 J2 BAS PRI...

Page 218: ...ltages with a Digital Volt Meter in reference to Ground at TP1 or TP11 VOLTAGE TEST POINT VOLTAGE RANGE FUSE LED 5VDC TP3 4 92 to 5 28VDC F1 5A CR56 12VDC TP4 11 58 to 12 5VDC F2 5A CR57 12VDC TP33 11...

Page 219: ...ER BOARD JP8 JP7 5 0 VDC 10 K NOTES 1 J6 6 not connected N C to Backlight Inverter Board when display is manufactured by Sharp or NEC 2 The position of Program Jumpers JP7 and JP8 determine the output...

Page 220: ...J15 TX RX COMMON 24VDC 12VDC 12VDC GND TX3 RX3 TX5 RX5 CR15 CR38 R G CR35 R G CR43 CR44 R G YORK PROTOCOL STYLE B LCSSS VSD ADAPTIVE CAPACITY CONTROL BOARD OR HOT GAS BYPASS HEAT RECOVERY HEAD PRESSU...

Page 221: ...CONDENSER THERMAL TYPE FLOW SENSOR style F and later chillers note 2 24 VAC 2 4 1 3 NOTE 1 Program Jumpers JP23 JP24 must be positioned on pins 1 2 or 2 3 according to input signal type Voltage OUT Cu...

Page 222: ...TIONS 0 10 VDC 2 10 VDC 0 20 mA 4 20 mA 5 4 3 1 2 16 4 14 2 13 15 MUX 47K JP21 JP22 JP23 JP24 200 7 5 K 1 2 3 1 2 3 1 2 3 1 2 3 71 5 K 5V 3 17 5V J7 J22 0 10 VDC 2 10 VDC 0 20 mA 4 20 mA LEAVING CHILL...

Page 223: ...actory Mounted Heating Condenser Thermal Type Flow Sensor note 1 3 1 Not Used NOTE 1 On new production chillers after June 2009 the Thermal type ow sensors are connected to Microboard J14 as shown abo...

Page 224: ...FORM 160 87 OM1 ISSUE DATE 8 24 2018 JOHNSON CONTROLS 224 NOTES...

Page 225: ...elsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range Table 13 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Eff...

Page 226: ...Pennsylvania USA 17349 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2018 www johnsoncontrols com ALL RIGHTS RESERVED Form 160 87 OM1 818 Issue Date August...

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