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Johnson Controls YORK YK MaxE Operation Manual
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Johnson Controls YORK YK MaxE Operation Manual

Johnson Controls YORK YK MaxE Operation Manual

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optiVieW
CoNtroL CeNter
tM
M
e
CeNtrifUgaL LiqUid ChiLLers
tM
ax
operatioN MaNUaL
Supersedes: 160.54-O1
Form 160.54-O1
ModeL YK (throUgh stYLe g)
r-134a CooLiNg oNLY
With optiVieW
CoNtroL CeNter
tM
for eLeCtro-MeChaNiCaL starter,
soLid state starter
& VariaBLe speed driVe
29420A

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Summary of Contents for Johnson Controls YORK YK MaxE

  • Page 1 optiVieW CoNtroL CeNter CeNtrifUgaL LiqUid ChiLLers operatioN MaNUaL Supersedes: 160.54-O1 Form 160.54-O1 ModeL YK (throUgh stYLe g) r-134a CooLiNg oNLY With optiVieW CoNtroL CeNter for eLeCtro-MeChaNiCaL starter, soLid state starter & VariaBLe speed driVe 29420A...
  • Page 2 Not be installed inside the micro panel. No external wiring is allowed to be run through the micro panel. All wiring must be in accordance with YORK’s published specifications and must be performed oNly by qualified YORK/Johnson Controls personnel. Johnson Controls will not be responsible for damages/problems resulting from improper connections to the controls or application of improper control signals.
  • Page 3 DIAGRAM – UNIT STYLE G wITH SSS, LV VSD wITH MODbUS & MV VSD 160.75-Pw6 NoMeNCLatUre – STYLE (Design Level) MOTOR CODE POwER SUPPLY – for 60 Hz 5 for 50 Hz COMPRESSOR CODE CONDENSER CODE EVAPORATOR CODE MODEL JOHNSON CONTROLS...
  • Page 4 OptiView Control Center ..............11 seCtioN Printers ..................167 ChaNgeaBiLitY of this doCUMeNt In complying with Johnson Controls policy for continu- It is the responsibility of operating/service personnel ous product improvement, the information contained as to the applicability of these documents to the equip- in this document is subject to change without notice.
  • Page 5 CONTROL EXISTING MAP POINTS) ....179 371-03789-xxx (503 HP 60 Hz; 419 HP 50 Hz) .. 78 fig. 21 – VARIAbLE SPEED DRIVE DETAILS SCREEN (VSD with Part Number 371-02767-XXX (60 Hz) or 371-03700-XXX (50 Hz)) ....80 JOHNSON CONTROLS...
  • Page 6 FORM 160.54-O1 this page iNteNtioNaLLY Left BLaNK JOHNSON CONTROLS...
  • Page 7 YORK Solid State Starter air. The warmed liquid is then returned to the chiller to (optional), or Variable Speed Drive (optional). complete the chilled liquid circuit. JOHNSON CONTROLS...
  • Page 8 The major components of a chiller are selected to handle the refrigerant, which would be evaporated at full load design conditions. However, most systems will be called upon to deliver full load capacity for only a relatively small part of the time the unit is in operation. JOHNSON CONTROLS...
  • Page 9 FORM 160.54-O1 COMPRESSOR PREROTATION VANES (See Detail A) DISCHARGE SUCTION DISCHARGE bAFFLE EVAPORATOR CONDENSER ELIMINATOR SUb-COOLER FLOw CONTROL ORIFICE LD00924 OIL COOLER fig. 2 – REFRIGERANT FLOw-THRU CHILLER JOHNSON CONTROLS...
  • Page 10 Control Center FORM 160.54-O1 this page iNteNtioNaLLY Left BLaNK JOHNSON CONTROLS...
  • Page 11 There are certain screens, displayed values, program- 6. Safety Shutdown Contacts mable Setpoints and manual control shown in this book that are for Service Technician use only. They are only 7. Cycling Shutdown Contacts displayed when logged in at SERVICE access level JOHNSON CONTROLS...
  • Page 12 RS-485 port on COM2 serial port for Modbus communications. When used in larger BRAM configuration, requires software version C.OPT.01.15.xxx (or later). This board is backward compatible with YK chillers presently using the 031-01730-000 or 031-02430-000 microboard. JOHNSON CONTROLS...
  • Page 13 The Start/Stop control is operated via a three-position this state to receive a valid remote start signal when rocker switch. When toggled all the way to the right, it is operating under a remote control source. considered in the STOP/RESET position. When in the JOHNSON CONTROLS...
  • Page 14 When power is applied to the chiller, the system begins with an limits of the programmable range, and the default Access Level of VIEW. This will allow the user to navi- value. JOHNSON CONTROLS...
  • Page 15 The system Trend Setup (page 128) will immediately refresh the display with the graphics Advanced Trend Setup (page 130) for that screen. Following is a layout of all the screens Common Slots (page 132) and how they are connected. JOHNSON CONTROLS...
  • Page 16 *Saturation temperatures are calculated values. They will display XXX if the pressure used for the calculation is out of range. **Not applicable to chillers equipped with Flash Memory Card version C.MLM.01.03 and later. ***7.5 PSIG Flash Memory Card Version C.MLM.01.04 and later. JOHNSON CONTROLS...
  • Page 17 FORM 160.54-O1 this page iNteNtioNaLLY Left BLaNK JOHNSON CONTROLS...
  • Page 18 Displays the temperature of the liquid as it enters the heating condenser tube bundle. Only appears when the Motor Run (LED) Heat Recovery is enabled. Is On when the digital output controlling the Motor Starter contact is on. JOHNSON CONTROLS...
  • Page 19 History page provides enhanced reporting capability. (See HISTORY below.) This option will not be present if the chiller is presently configured to log any incoming Adaptive Capacity Control map points. (See the Adap- tive Capacity Control Details screen.) JOHNSON CONTROLS...
  • Page 20 10 shutdown conditions. Oil Sump A detailed view of all the oil pump and oil sump pa- rameters. This includes the Variable Speed Oil Pump when installed. It also controls the Seal Lubrication functionality. JOHNSON CONTROLS...
  • Page 21 0-20mA, 4-20mA, 0-10VDC or heating condenser tube bundle. Only appears when the 2-10VDC input in Analog Remote mode, PWM signal Heat Recovery is enabled. in Digital Remote mode, MicroGateway interface in ISN mode, or a locally programmed value. JOHNSON CONTROLS...
  • Page 22 Displays the refrigerant pressure in the condenser. Condenser Saturation Temperature NaVigatioN Displays the saturation temperature in the condenser. Home Access Level Required: VIEW Oil Sump Temperature Displays the temperature of the oil in the sump. Causes an instant return to the Home Screen. JOHNSON CONTROLS...
  • Page 23 Leaving Chilled Liquid Temperature liquid temperature from going below the minimum Displays the temperature of the liquid as it leaves the allowed value: 36ºF (water), 34ºF (water with smart evaporator. JOHNSON CONTROLS...
  • Page 24 Base Leaving Chilled Liquid Temperature setpoint. This offset may be defined as 10 to 20ºF above the Base setpoint (see the Remote Leaving Chilled JOHNSON CONTROLS...
  • Page 25 Causes an instant return to the Home Screen. to YORK Service Manual 160.54-M1. Sensitivity Access Level Required: SERVICE This value allows the user to adjust the sensitivity of the Leaving Chilled Liquid Temperature control. Service Technicians refer to YORK Service Manual 160.54- JOHNSON CONTROLS...
  • Page 26 Displays the water temperature as it enters the con- condenser tube bundle. Illuminates when liquid flow denser. is present. Otherwise, it is extinguished. Only appears when the Heat Recovery is enabled. Condenser Saturation Temperature Displays the saturation temperature in the condenser. JOHNSON CONTROLS...
  • Page 27 Service Technicians refer to YORK Service Manual Moves to a sub screen allowing programming and 160.54-M1. viewing of the Head Pressure Control setpoints and parameters. Only appears when Head Pressure Control is enabled and Heat Recovery is disabled. JOHNSON CONTROLS...
  • Page 28 Displays the temperature of the liquid as it leaves the serves as a gateway to controlling the Refrigerant Level, standard condenser tube bundle. Heat Recovery and Head Pressure Control. A complete explanation of the Heat Recovery feature is contained in Service Manual 160.54-M1. JOHNSON CONTROLS...
  • Page 29 Hot Water Setpoint). However, it will switch over to Head Pressure Control when certain operating condi- tions are met as shown in the flow chart in Heat Recovery Section 24 in Service Manual 160.54-M1. Only appears when Head Pressure Control is enabled. JOHNSON CONTROLS...
  • Page 30 Control – d Sets the Derivative Gain of the Head Pressure Control (0.00 to 5.00; default 0.00). Use the Change Setpoints key as described above to select/enter this setpoint. Only appears when Head Pressure Control is enabled. JOHNSON CONTROLS...
  • Page 31 FORM 160.54-O1 NaVigatioN home Causes an instant return to the Home Screen Condenser Returns to the Condenser Screen JOHNSON CONTROLS...
  • Page 32 100% output will be at minimum. Control Valve Control Mode dispLaY oNLY Displays whether the Control valve is in automatic or manual control. return Condenser Liquid temperature Displays the temperature of the liquid as it enters the standard condenser tube bundle. JOHNSON CONTROLS...
  • Page 33 5.00; default 2.00). Use the Change Setpoints key as described above to select/enter this setpoint. head pressure Control – d Sets the Derivative Gain of the Head Pressure Control (0.00 to 5.00; default 0.00). Use the Change Setpoints key as described above to select/enter this setpoint. JOHNSON CONTROLS...
  • Page 34 31%, the level is shown about 60% full. When the [Refrigerant Level Control] Period actual level is 32% to 47%, the level is shown about 70% Service Technicians refer to YORK Service Manual full. When the actual level is 48% to 63%, the level is 160.54-M1. JOHNSON CONTROLS...
  • Page 35 Causes an instant return to the Home Screen. 160.54-M1. Condenser [Refrigerant Level Control] Raise (Manual) Access Level Required: VIEW This key puts the level control into manual mode and Return to the Condenser Screen. sends a RAISE command to the variable orifice. JOHNSON CONTROLS...
  • Page 36 50% full. When the actual level is 16% Service Technicians refer to YORK Service Manual to 31%, the level is shown about 60% full. When the 160.54-M1. actual level is 32% to 47%, the level is shown about 70% JOHNSON CONTROLS...
  • Page 37 Access Level Required: VIEW Causes an instant return to the Home Screen. Condenser Access Level Required: VIEW Return to the Condenser Screen. Setpoints Access Level Required: Service Moves to a sub-screen allowing programming of the Refrigerant Level Control Setpoints. JOHNSON CONTROLS...
  • Page 38 31%, the level is shown about 60% full. When the 160.54-M1. actual level 32% to 47%, the level is shown about 70% full. When the actual level is 48% to 63%, the level is shown about 80% full. When the actual level is 64% to JOHNSON CONTROLS...
  • Page 39 [Refrigerant Level Control] Hold (Manual) This key puts the control into manual mode and sends a hold command to the variable orifice [Refrigerant Level Control] Auto Returns the Level Control to automatic mode. JOHNSON CONTROLS...
  • Page 40 9%, the Zone 2 parameters are is shown about 80% full. When the actual level is 64% immediately implemented. to 79%, the level is shown as about 90% full. Actual levels above 79% shown as 100% full. JOHNSON CONTROLS...
  • Page 41 Specifies the desired refrigerant level to be maintained Condenser Access Level Required: VIEW in the condenser. Returns to the Condenser Screen Valve Preset Time Specifies the duration of pre-positioning (close) pulse during the System Pre-lube when starting the chiller. JOHNSON CONTROLS...
  • Page 42 (10) seconds into the system prelube. Oil Return Solenoid (LED) During this time, the transducers will be sensing the same Illuminates when the solenoid is energized. pressure and their outputs should indicate the same pres- JOHNSON CONTROLS...
  • Page 43 [Pre-Rotation Vanes] Hold (Manual) programming of the Surge Protection feature. Service Access Level Required: SERVICE Technicians refer to Service Manual 160.54-M1. This key puts the vane control into manual mode and sends a HOLD command to the vanes. JOHNSON CONTROLS...
  • Page 44 Indicates whether the solenoid is presently energized. to compensate for differences between transducers and assure differential pressure sensing accuracy, the offset Vane Motor Switch (LED) pressure is subtracted algebraically from the differential Indicates whether the vanes are completely closed. JOHNSON CONTROLS...
  • Page 45 Variable Geometry Diffuser (VGD) feature. Service technicians refer to Service [Pre-Rotation Vanes] Hold (Manual) manual 160.54-M1. Access Level Required: SERVICE This key puts the vane control into manual mode and sends a HOLD command to the vanes. JOHNSON CONTROLS...
  • Page 46 Displays the presently defined offset reference position. This option is hidden after calibration has started. This value is defined at the conclusion of a calibration Service Technicians refer to YORK Service Manual sequence. 160.54-M1 for an explanation of this setpoint. JOHNSON CONTROLS...
  • Page 47 Fault Acknowledge This option is only displayed if a fault is present. Al- lows clearing of High Speed Thrust Bearing related shutdowns. Service Technicians refer to YORK Service Manual 160.54-M1 for a more detailed explanation. JOHNSON CONTROLS...
  • Page 48 VSD these are only the surges detected while the drive shown 50% open. when actual is 60% to 79%, the valve is running at maximum frequency. is shown as 75% open. Positions greater than 79% are shown as full open. JOHNSON CONTROLS...
  • Page 49 (30 to 120 minutes) This is the period of time after no more surges are de- Causes an instant return to the Compressor Screen tected that the Hot Gas valve closing will begin. Service Technicians refer to Service manual 160.54-M1. JOHNSON CONTROLS...
  • Page 50 (new production chillers prior to March 2007), the ACC surge detection is performed there. If not equipped with an ACC Board, (new production chillers after March 2007), the ACC surge detection is performed in the JOHNSON CONTROLS...
  • Page 51 Displays the time remaining in the 10-minute “EX- TENDED RUN” period. During this period, the Pre- rotation vanes are driven closed and “WARNING – SURGE PROTECTION – EXCESS SURGE LIMIT” is displayed. Refer to operation under “Count Limit” below. JOHNSON CONTROLS...
  • Page 52 SURGE WINDOW COUNT exceeds the COUNT LIMIT, an Excess Surge situation has occurred. Clear Surge Count When an Excess Surge situation is detected, the action Access Level Required: ADMIN depends upon the following: Allows user to set the Total Surge Count to zero. JOHNSON CONTROLS...
  • Page 53 FORM 160.54-O1 NaVigatioN Home Access Level Required: VIEW Causes an instant return to the Home Screen Compressor Access Level Required: VIEW Causes an instant return to the Compressor Screen. JOHNSON CONTROLS...
  • Page 54 Displays the current state of the VGD control. The states as “Closed” when the switch is closed. This would be are: Stall Waiting, Stall Reacting, Probing, Surge React- when the VGD is in the fully closed position. Otherwise, ing, Surge Waiting, Hot Gas Override. displayed as “Open” JOHNSON CONTROLS...
  • Page 55 [VGD] Close (Manual) This key puts the VGD in manual mode and sends a close command to the VGD. [VGD] Hold (Manual) This key puts the VGD in manual mode and sends a hold command to the VGD. JOHNSON CONTROLS...
  • Page 56 XXX until calibration procedure is performed output voltage goes above the High Limit setpoint. The by Service Technician. count can be reset with an ADMIN access level using the VGD Cycle Count key on the VGD Setpoints Screen. JOHNSON CONTROLS...
  • Page 57 Low Limit setpoint is 0.1 vdc. If a Low Limit setpoint is entered which is less than 0.1vdc below the High Limit setpoint, the High Limit setpoint is adjusted so that it is 0.1VDC above the newly entered Low Limit value. JOHNSON CONTROLS...
  • Page 58 Calibration in Progress (LED) Indicates the calibration sequence is in progress. Compressor Access Level Required: VIEW Calibration Messages Return to the Compressor Screen. These are text messages which step the user through the calibration process and indicate its success or failure. JOHNSON CONTROLS...
  • Page 59 FORM 160.54-O1 this page iNteNtioNaLLY Left BLaNK JOHNSON CONTROLS...
  • Page 60 This value is returned from the drive. Protocol Setpoint set to YORK; ACC Board present), it is only displayed in manual speed control mode and it is the speed command being sent to the ACC Board in Manual Speed Control mode. JOHNSON CONTROLS...
  • Page 61 Puts the drive frequency control into manual mode. Each time it is pressed it increases the Command Frequency to the drive by the amount defined by the Manual Incre- ment key. It will not raise the value above the maximum allowed (50Hz or 60Hz). JOHNSON CONTROLS...
  • Page 62 Saturated Condenser Temperature. This seal lubrication when this function is enabled. Service parameter is useful when analyzing oil heater operation Technicians refer to YORK Service Manual 160.54- since it is used in the control of the oil heater. JOHNSON CONTROLS...
  • Page 63 Access Level Required: SERVICE By default, the automatic VSOP control algorithm oper- ates every 300ms. This key allows the user to specify the control period in multiples of 300ms. Service Techni- cians refer to YORK Service Manual 160.54-M1. JOHNSON CONTROLS...
  • Page 64 (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, proximity probe calibration, seal lubrication, and system coastdown. JOHNSON CONTROLS...
  • Page 65 FORM 160.54-O1 this page iNteNtioNaLLY Left BLaNK JOHNSON CONTROLS...
  • Page 66 Pulldown Demand Time Left Allows the user to set a period of time for which the Displays the time remaining in the programmed pulldown demand limit will be in effect after the chiller pulldown period if the value is nonzero. starts. JOHNSON CONTROLS...
  • Page 67 Causes an instant return to the Home Screen. Motor Lube (Software version C.MLM.01.14.xxx (and later) or C.OPT.01.14.306 (and later)) Access Level required: VIEW Moves to the subscreen allowing operator acknowledge- ment of the compressor motor Lubrication and viewing of the compressor motor lubrication parameters. JOHNSON CONTROLS...
  • Page 68 Display information about the Liquid Cooled-Solid State Access Level Required: OPERATOR Starter Rating and the maximum allowed Full Load Allows the user to set a period of time for which the Amps. pulldown demand limit will be in effect after the chiller starts. JOHNSON CONTROLS...
  • Page 69 YORK Service Manual 160.54-M1. Current Unbalance Check (Enabled / Disabled) Access Level Required: SERVICE Allows the user to control whether the logic checks for current unbalance and initiates a shutdown as a result. Service Technicians refer to YORK Service Manual 160.54-M1. JOHNSON CONTROLS...
  • Page 70 Pre-rotation Vanes will not be Displays the Kilowatts measured by the Solid State permitted to open further. If the motor rises above this Starter. value, the Pre-rotation Vanes will close to reduce the current to this value. JOHNSON CONTROLS...
  • Page 71 Defines the maximum allowed motor starting amps. The ment of the compressor motor Lubrication and viewing Solid State Starter will limit the motor starting current of the compressor motor lubrication parameters. to this value. Service technicians refer to YORK Service manual 160.54-M1. JOHNSON CONTROLS...
  • Page 72 Analog Remote mode, PWM signal in Digital Remote transmitted from the starter. mode, Microgateway interface in ISN Remote mode or a locally programmed value in Local mode. Starter Model Displays the starter model number as transmitted from the starter. JOHNSON CONTROLS...
  • Page 73 The starter will limit the starting current to this value. Service Technicians refer to YORK Service Manual 160.54-M1. KWH Reset Access Level Required: SERVICE Allows the user to reset the cumulative Kilowatt Hours. Service Technicians refer to YORK Service Manual 160.54-M1. JOHNSON CONTROLS...
  • Page 74 Displays the supply kva measured by the filter. pulldown period if the value is nonzero. Total Power Factor Output Voltage Displays the relationship between the Input Power and Displays the output voltage measured to the motor. the Supply kVA. JOHNSON CONTROLS...
  • Page 75 (0). Service Technicians refer to YORK Service Manual 160.54-M1. Filter Inhibit (Harmonic Filter installed only) Access Level Required: SERVICE Disable the filter logic from activating, although the system will still communicate with the device. Only available when chiller is stopped. JOHNSON CONTROLS...
  • Page 76 0-20ma, 4-20ma, 0-10VDC or 2-10Vdc Pre-rotation Vanes Position input in Analog remote Mode, PWM signal in Digital Displays the pre-rotation vane position as a value be- Remote mode, Microgateway interface in ISN mode or tween 0 and 100%. a locally programmed value. JOHNSON CONTROLS...
  • Page 77 438 A 312 A 248 A demand limit will be in effect after the chiller starts. 2250 494 A 345 A 274 A 2500 561 A 391 A 310 A Max. Job/Rated 100% FLA (A) (Programmed Drive Current) JOHNSON CONTROLS...
  • Page 78 KWH Reset ment of the compressor motor lubrication and viewing Access Level Required: SERVICE of the compressor motor lubrication parameters. Allows the user to reset the cumulative Kilowatt Hours to zero. Service Technicians refer to YORK Service manual 160.54-M1. JOHNSON CONTROLS...
  • Page 79 FORM 160.54-O1 this page iNteNtioNaLLY Left BLaNK JOHNSON CONTROLS...
  • Page 80 VSD. input in Analog Remote mode, PWM signal in Digital Remote mode, MicroGateway interface in ISN mode, Converter Heatsink Temperature or a locally programmed value. Displays the heatsink temperature of the converter as reported by the VSD. JOHNSON CONTROLS...
  • Page 81 This function is used to provide energy savings following chiller start-up. Pulldown Demand Time Access Level Required: OPERATOR Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chiller starts. JOHNSON CONTROLS...
  • Page 82 VSD. Pulldown Demand Time Left Baseplate Temperature Displays the time remaining in the programmed Displays the Baseplate temperature of the 3-phase volt- pulldown period if the value is nonzero. age regulators as reported by the VSD. JOHNSON CONTROLS...
  • Page 83 This function is used to provide energy savings following chiller start-up. Pulldown Demand Time Access Level Required: OPERATOR Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chiller starts. JOHNSON CONTROLS...
  • Page 84 Displays the current limit value in use. This value could come from a 0-20mA, 4-20mA, 0-10VDC or 2-10VDC input in Analog Remote mode, PWM signal in Digital Remote mode, MicroGateway interface in ISN mode, or a locally programmed value. JOHNSON CONTROLS...
  • Page 85 Access Level Required: VIEW trols at a certain “margin” from the mapped point. This Returns to the VSD Screen. programmable value allows the service technician to modify the “margin” at which these adjustments will begin to take place. JOHNSON CONTROLS...
  • Page 86 This value is provided by the drive Logic nation of all programmable setpoints Board. and displayed values. Pre-rotation Vanes Position Displays the present pre-rotation vane position as a value between 0% (closed) and 100% (full open). This value is provided by the ACC Board. JOHNSON CONTROLS...
  • Page 87 (in the ACC Board) as a valid surge point. When this key is pressed, a dialog box appears requesting a special password to proceed. Service Technicians refer to procedure and password in YORK Optiview Service Manual 160.54-M1 section 23. JOHNSON CONTROLS...
  • Page 88 Service Manual 160.54-M1 for Board. setpoint entry instructions and expla- nation of all programmable setpoints Pre-rotation Vanes Position and displayed values. Displays the present pre-rotation vane position as a value between 0% (closed) and 100% (full open). JOHNSON CONTROLS...
  • Page 89 Surge Map Point Count Service Technicians refer to procedure and password Displays the total number of data points contained in in YORK OptiView Service Manual 160.54-M1 sec- the surge map. tion 23. JOHNSON CONTROLS...
  • Page 90 Service Technicians Returns to the VSD Screen refer to procedure and password in YORK OptiView Service Manual 160.54-M1 section 23. Surge Map Access Level Required: SERVICE Causes a jump to the sub-screen that displays the surge map. JOHNSON CONTROLS...
  • Page 91 FORM 160.54-O1 this page iNteNtioNaLLY Left BLaNK JOHNSON CONTROLS...
  • Page 92 ACC function in the Microboard, while the drive is (with the Motor Communications Protocol setpoint set running at less than maximum frequency. to MODBUS; ACC Board is not present) and Medium Voltage Variable Speed Drives (MV VSD). It is not JOHNSON CONTROLS...
  • Page 93 Then the REMOVE SURGE POINT key is pressed to remove it. Service Technicians refer to procedure and password in YORK OptiView Service Manual 160.54-M1 section 23. JOHNSON CONTROLS...
  • Page 94 VSD in YORK Motor This key scrolls the contents of the view window to the Communications Protocol Setpoint configuration (ACC next list of parameters. If the window cannot be scrolled Board is present). down, this key is not displayed. JOHNSON CONTROLS...
  • Page 95 FORM 160.54-O1 NaVigatioN Home Causes an instant return to the Home Screen Returns to the VSD Screen ACC Details Causes a return to the ACC Details Screen JOHNSON CONTROLS...
  • Page 96 Remote mode, MicroGateway interface in ISN mode, Displays the total supply Kilovolt-Amps measured by or a locally programmed value. the Harmonic Filter. Pulldown Demand Time Left Displays the time remaining in the programmed pulldown period if the value is nonzero. JOHNSON CONTROLS...
  • Page 97 NaVigatioN RMS Supply Current (L1, L2, L3) Displays the 3-phase RMS Voltages across each line. Home Access Level Required: VIEW Causes an instant return to the Home Screen. Access Level Required: VIEW Returns to the VSD Screen. JOHNSON CONTROLS...
  • Page 98 Filter (A, B, C or C, B, A) Total Supply kVA Pulldown Demand Time Left Displays the total supply Kilovolt-Amps measured by Displays the time remaining in the programmed pulldown period if the value is nonzero. the Harmonic Filter. JOHNSON CONTROLS...
  • Page 99 This function is used to provide energy savings following chiller start-up. Pulldown Demand Time Access Level Required: OPERATOR Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chiller starts. JOHNSON CONTROLS...
  • Page 100 This also clears any motor lubrication warning or tered as a 3 to 8 character string using the Motor Lube safety that is in effect and resets the Operating Hours Acknowledge key. Since Last Lubrication to zero. JOHNSON CONTROLS...
  • Page 101 Causes an instant return to the Motor Screen alphabet. The selection prior to the letter A is a blank space. Use the ● key to enter a period/decimal point. JOHNSON CONTROLS...
  • Page 102 This value is calculated by subtracting the Leaving Chilled Liquid Temperature Cycling Offset – Shutdown from the Leaving Chilled Liquid Tem- perature – Setpoint. If this value is below the absolute minimum allowed shutdown temperature the minimum value is displayed. JOHNSON CONTROLS...
  • Page 103 Chilled Liquid temperature Setpoint and Current Limit Setpoint in ANALOG remote mode. If the remote signal is 0-10VDC or 0-20mA, this setpoint must be programmed for 0-10VDC. If the remote signal is 2-10VDC or 4-20mA, this setpoint must be programmed for 2-10VDC. JOHNSON CONTROLS...
  • Page 104 Quick Start setpoints and Access Level Required: OPERATOR parameters. Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chiller starts. Print Access Level Required: VIEW Generates Setpoints print report. JOHNSON CONTROLS...
  • Page 105 FORM 160.54-O1 this page iNteNtioNaLLY Left BLaNK JOHNSON CONTROLS...
  • Page 106 Displays 60 Hz or 50 Hz Motor Type: 031-02430-000 & 031-02430-001 Microboard Displays Fixed Speed or Variable Speed Refrigerant Selection: Refrigerant Selection Displays R-22 or R134a Displays R22 or R134a Anti-Recycle: Liquid Type Displays Disabled or Enabled Displays Water or Brine JOHNSON CONTROLS...
  • Page 107 0:00 and 23:59. C.OPT.01.16.XXX (and later), the duration is program- mable using the Coastdown Time setpoint below. With earlier software versions, the duration is fixed at 150 seconds. Service Technicians refer to YORK Service manual 160.54-M1. JOHNSON CONTROLS...
  • Page 108 Style B LCSSS Logic/Trigger Board. This setpoint and entry instructions are described in detail in Section 3A and 23 of Service Manual 160.54-M1. The chiller must be stopped with the Start-Run-Stop/Reset switch in the Stop/Reset position to change this setpoint. JOHNSON CONTROLS...
  • Page 109 Moves to the sub-screen allowing configuration of user Head Pressure Control preferences. (Software version C.OPT.01.21.307 and later) Access Level Required: SERVICE Allows the Service Technician to enable or disable the Head Pressure Control feature. Refer to Service Manual 160.54-M1. JOHNSON CONTROLS...
  • Page 110 Quick Pulldown after the VSD achieves its Start Frequency, the speed Setpoint Offset has been reached or the Pulldown Over- ramp rate is faster than with normal control. ride Time has elapsed, whichever occurs first. JOHNSON CONTROLS...
  • Page 111 Depending upon how close the Low Chilled Liquid Temperature shutdown threshold is to the LCHLT setpoint, this could result in a Low Chilled Liquid Temperature cycling shutdown. JOHNSON CONTROLS...
  • Page 112 Control Center FORM 160.54-O1 NaVigatioN Home Access Level Required: SERVICE Causes an instant return to the Home Screen Setpoints Access Level Required: SERVICE Returns to the Setpoints Screen JOHNSON CONTROLS...
  • Page 113 FORM 160.54-O1 this page iNteNtioNaLLY Left BLaNK JOHNSON CONTROLS...
  • Page 114 Stop times which are utilized every week. The user may in combination with the Standard week definition, as then specify exception Start / Stop combinations for any described above. day of the week up to 6 weeks in advance. At the end JOHNSON CONTROLS...
  • Page 115 Places a selection box around a start time for a given day. Use ◄ , ► , ▲ or ▼ cursor arrows to place the box around the desired start or stop time for a given day. Print Access Level Required: VIEW Generates a Schedule print report. JOHNSON CONTROLS...
  • Page 116 This allows the user to specify up to four (4) Custom User ID values. Each user ID will then require a corresponding Password and User Level. A User ID can be defined for various maintenance personnel. Service Technicians refer to YORK Service Manual 160.54-M1. JOHNSON CONTROLS...
  • Page 117 Access Level Required: SERVICE This allows the user to specify up to four (4) Custom User Access Levels. Each Access Level will then require a cor- responding Password and User ID. Service Technicians refer to YORK Service Manual 160.54-M1. JOHNSON CONTROLS...
  • Page 118 With the selection box around the desired parameter, press the ENTER ‘’ key. A dialog box is displayed permitting data entry. In VSD or LCSSS Mod- bus Protocol configuration, COM2 button is not shown because COM2 serial port is used for this interface. JOHNSON CONTROLS...
  • Page 119 FORM 160.54-O1 NaVigatioN Home Access Level Required: VIEW Causes an instant return to the Home Screen. Setup Access Level Required: VIEW Return to the Setup Screen. JOHNSON CONTROLS...
  • Page 120 Automatic Printer Logging (Enabled / Disabled) Access Level Required: OPERATOR Enable the printer to begin printing status reports be- ginning at the programmed start time and recurring at the interval defined above. JOHNSON CONTROLS...
  • Page 121 Sales Order screen). A print report Return to the Setup Screen. is generated upon completion of selection. Print All Histories Access Level Required: OPERATOR Generate a report of the system data at the time of all stored shutdowns. JOHNSON CONTROLS...
  • Page 122 NaVigatioN System Information Factory defined conditions for which the chiller was Home originally rated and sold. Access Level Required: VIEW Causes an instant return to the Home Screen. Setup Access Level Required: VIEW Return to the Setup Screen. JOHNSON CONTROLS...
  • Page 123 FORM 160.54-O1 this page iNteNtioNaLLY Left BLaNK JOHNSON CONTROLS...
  • Page 124 This may be reprogrammed to a desired value, (generally is selected with the Chiller Style/Compressor Setpoint when this value has been reset due to a Microboard re- below. The Service Technicians refer to YORK Service placement), but should not be done so arbitrarily. Manual 160.54-M1. JOHNSON CONTROLS...
  • Page 125 Although the label and number can be changed appro- priately, the default for this entry is “Johnson Controls North American Toll Free Number 1-800-861-1001”. The Local service phone number is displayed as the second number.
  • Page 126 This window displays the date and time and the de- Causes a move to a sub-screen containing the value of scription of the last safety or cycling shutdown while select chiller parameters at the time of the associated the system was running. shutdown. JOHNSON CONTROLS...
  • Page 127 Causes a move to a sub-screen allowing the user to view Custom View a record of the last 75 setpoint changes. (Flash memory Card version C.MLM.01.04 or later) Access Level required: VIEW Causes a move to a sub-screen allowing the user to view the Custom Setup Screen. JOHNSON CONTROLS...
  • Page 128 Access Level Required: VIEW Causes an instant return to the Home Screen. prograMMaBLe Page Up History Access Level Required: VIEW Access Level Required: VIEW Scroll up in the displayed data (if applicable). Causes a return to the History Screen. JOHNSON CONTROLS...
  • Page 129 Displays the category of the setpoint (motor, evaporator, View Details condenser, etc.) Access Level required: SERVICE Setpoint Causes a move to a sub-screen containing the details of Displays the setpoint that was changed. the setpoint change selected with the Log Entry key. JOHNSON CONTROLS...
  • Page 130 Displays the time the setpoint was changed. Security Log Access Level Required: SERVICE Date Causes an instant return to the Security Log Screen. Displays the date the setpoint was changed. Access Level Displays the Login Access Level used to make the setpoint change. JOHNSON CONTROLS...
  • Page 131 Access Level Required: OPERATOR None Causes a jump to the sub-screen that allows selection of the parameters to be displayed. prograMMaBLe Print Access Level Required: VIEW This generates a listing of the parameters displayed on this screen. JOHNSON CONTROLS...
  • Page 132 Access Level Required: VIEW Scroll up through list of available parameters. Causes a return to the Home Screen. Page Down Custom View Scroll down through list of available parameters. Access Level Required: SERVICE Causes a return to the Custom View Screen. JOHNSON CONTROLS...
  • Page 133 FORM 160.54-O1 this page iNteNtioNaLLY Left BLaNK JOHNSON CONTROLS...
  • Page 134 Interval and plotted using 450 data points across on the trending screen. The START key must be pressed the X-Axis. If the actual value of the sampled parameter to initiate a new trend screen. JOHNSON CONTROLS...
  • Page 135 If set to EXISTING, a snapshot of the Only displayed if the trending is stopped. Causes a jump data presently on the screen is sent to the printer. If set to a sub-screen for configuring the trending display. JOHNSON CONTROLS...
  • Page 136 3. Decide if the resultant sample interval and full screen Selects the interval at which the parameters are sampled. display meet the requirements. If not, select a dif- There are 450 data points displayed across the X-Axis ferent sample interval. JOHNSON CONTROLS...
  • Page 137 TRIGGERED has been selected as Chart Only displayed if the associated slot number is not zero. Type. This is the maximum value displayed for the Y-Axis. Se- lecting a parameter for a Data Point sets this to the default JOHNSON CONTROLS...
  • Page 138 Selects the first parameter to be evaluated. Selection is The Secondary Trigger is setup and evaluated the same made from the Slot Numbers listing on the Trend Com- as the Primary Trigger. mon Slots Screen or the Master Slot Numbers List in JOHNSON CONTROLS...
  • Page 139 Selects whether the Primary Trigger, Secondary Trig- Trend Setup ger or both have to be true in order to start or stop data Causes an instant return to the Trend Setup Screen. collection. Selections are AND, OR, XOR and None. If JOHNSON CONTROLS...
  • Page 140 Generates a list of the slot numbers of the available parameters. NaVigatioN Home dispLaY oNLY Causes an instant return to the Home Screen. Slot numbers Trend Setup These are the slot numbers of the most commonly used Causes a return to the Trend Setup Screen. parameters. JOHNSON CONTROLS...
  • Page 141 Liquid Line Solenoid: Is Solenoid On 1283 Pre-Rotation Vanes: Are Vanes Closing 1284 Pre-Rotation Vanes: Are Vanes Holding 1818 Leaving Chilled Liquid: Remote Digital Temperature 1285 Pre-Rotation Vanes: Control Mode Setpoint 1296 Discharge: Temperature 1536 Oil: Differential Pressure 1537 Oil: Sump Temperature JOHNSON CONTROLS...
  • Page 142 ACC: Delta P/P 2846 ACC: Stability Limit (Mod “b” Solid State Starters) 2847 ACC: Surge Margin 2570 LcSss: Input Power 2848 ACC: Manual Surge Command 2571 LcSss: kilowatt Hours 2572 LcSss: Phase A Current 2573 LcSss: Phase b Current JOHNSON CONTROLS...
  • Page 143 8225 HSTb: Proximity Differential 2889 Filter: L3 Total Demand Distortion 8226 HSTb: Proximity Reference Position 2890 Filter: Maximum Total Harmonic Distortion 8280 Stall Detector board output voltage 8281 VGD open 8282 VGD close 8317 Stall DC Pressure Voltage JOHNSON CONTROLS...
  • Page 144 The Prelube duration is either 50 sec- 6. Operator Initiated at Keypad (Flash Memory Card onds or 180 seconds, as configured with a Microboard Pro- version C.MLM.01.06.xxx and later) gram Switch. The Pre-lube duration must never be changed JOHNSON CONTROLS...
  • Page 145 C.MLM.01.10D.xxx (and earlier) or On rise, inhibit open C.OPT.01.10D.xxx (and earlier), the motor current must On fall, allow open exceed 15% FLA for 10 continuous seconds before the On rise, start close start inhibit is set. On fall, stop close JOHNSON CONTROLS...
  • Page 146 Brine mode. amount above the programmable safety shutdown threshold. The Safety threshold in Brine applications is determined by the Brine solution and is determined by the YORK Factory. While this condition is in effect, the Pre-rotation Vanes are JOHNSON CONTROLS...
  • Page 147 Analog I/O Board has been interrupted for at cleared. It will be displayed until the transducer outputs least 20 seconds. are within the acceptable range of each other and the WARNING RESET key in SERVICE access level. JOHNSON CONTROLS...
  • Page 148 RUN position. The Control Center will not accept a date this warning occurs is stored as the “Date of Last Remote start/stop command unless the switch is in the Motor Lubrication Warning or Fault”. With software RUN position. version C.OPT.01.16.xxx (and later), this warning mes- JOHNSON CONTROLS...
  • Page 149 However, LED’s on the respective device illuminate to identify the specific fault that has occurred. Refer to YORK if the power failure duration was less than the duration of JOHNSON CONTROLS...
  • Page 150 The programmed Daily Schedule Setpoint has shutdown the chiller. If this occurs while the chiller is running, the Pre-rotation Vanes are driven fully closed prior to shutting down the chiller. The chiller will automatically restart at the next scheduled start time. JOHNSON CONTROLS...
  • Page 151 Board and connected between TB6-16 and TB6-53 in performed and this message is displayed. This is gener- the Control Center). The Microboard, in the Control ally indicative of defective wiring. Center then sends a request for the cause of the fault to JOHNSON CONTROLS...
  • Page 152 Board has detected that the compressor motor AC power line voltage, in any phase, exceeded the high line voltage threshold continuously for 20 seconds. The chiller will automatically restart when the voltage in all phases returns to the restart level. The thresholds are as follows: JOHNSON CONTROLS...
  • Page 153 VSD trip on an overcurrent fault. cabinet with all fuses in place. A power interruption to the VSD Logic board will also generate this message. JOHNSON CONTROLS...
  • Page 154 If the Half DC Link voltage does not remain within ± it indicates that the low voltage power supplies for the 106VDC of the DC Link Voltage divided by 2 during the logic boards have dropped below their allowable oper- pre-charge interval, this shutdown is performed. JOHNSON CONTROLS...
  • Page 155 500VDC within 15 seconds after the Pre-charge re- open thermistor or broken wiring to the thermistor. The lay is energized. If this condition is not met, a shutdown normal thermistor resistance is 10K ohms at 77°F. is performed and this message is generated. JOHNSON CONTROLS...
  • Page 156 C.MLM.01.06.xxx and later, the communications must indicative of an open fuse in one of the filter’s incoming be interrupted for 10 continuous communications cycles power line. Filter power fuses 11FU, 12FU and 13FU (20 seconds) before the shutdown will occur. should be checked. JOHNSON CONTROLS...
  • Page 157 This center tive and this shutdown is generated. point should be approximately ½ of the total DC link voltage. “HARMOnIC FILTER – DC CURREnT TRAnSFORMER 2” See “Harmonic Filter – DC Current Transformer 1” message above. JOHNSON CONTROLS...
  • Page 158 3.0°F of one another and the COMPRESSOR Enabled by a Service technician (following instructions switch is placed in the Stop-reset (O) position. in Service Manual 160.54-M1) and the Leaving Chilled Liquid temperature Setpoint is less than 38.0°F. JOHNSON CONTROLS...
  • Page 159 The differential oil Pressure increased to greater than 90.0 reset is then 170/170 PSIG . PSID (120.0 PSID with software versions C.MLM.01.08. xxx (and later) or C.OPT.01.08A.xxx (and later)) while the oil pump was running. The differential oil pressure is JOHNSON CONTROLS...
  • Page 160 Optiview Control Center Microboard where the C.OPT.01.18.307 (or later), this safety shutdown is not unbalance calculation is performed. This safety shut- performed when the Refrigerant Selection (microboard down is not performed on Electro-mechanical starter SW1-1) is set to “R22”. applications. JOHNSON CONTROLS...
  • Page 161 50.0°F during “System Run” or the last 10 seconds If equipped with software version C.MLM.01.10.xxx of “System Prelube”. (and later) or C.OPT.01.10.302 (and later), the operation is as follows: the clearance is only checked during the last 20 seconds of “System Prelube”, during “System JOHNSON CONTROLS...
  • Page 162 (Flash Memory Card version C.MLM.01.05.xxx and later) are initiated every 2 seconds, this message is typically (Applies only if Surge Protection SHUTDOWN feature displayed for a few seconds and then replaced with one is Enabled) of the following fault messages. JOHNSON CONTROLS...
  • Page 163 COMPRESSOR switch is placed displayed for a few seconds and then replaced with one in the Stop-Reset (O) position. This check is disabled of the following fault messages. when the chiller is shut down. In certain applications, JOHNSON CONTROLS...
  • Page 164 VSD Logic Board and the COMPRESSOR switch is placed in the stop-reset position (O). (Applicable to VSD with Part Number 371-02767-XXX (60 Hz) and 371-03700-XXX (50 Hz)) (If compressor other than “P”, requires Flash Memory Card version C.MLM.01.05A.xxx and later) JOHNSON CONTROLS...
  • Page 165 194ºF. The chiller can be started after the fault condition clears, the OVERTEMP RESET button on the Filter Logic Board is pressed and the COMPRESSOR switch is placed in the stop-reset position (O). JOHNSON CONTROLS...
  • Page 166 FORM 160.54-O1 JOHNSON CONTROLS...
  • Page 167 FORM 160.54-O1 seCtioN 3 priNters 23887A OkIDATA MICROLINE 184 23889A wEIGH-TRONIX 00085VIP SEIkO DPU-414 fig. 44 – PRINTERS JOHNSON CONTROLS...
  • Page 168 Tampa, Florida 33626 • FIG. 49 - History Phone: 800-800-5441 • FIG. 50 - Security Log (Flash Memory Card ver- Fax: 813-891-4056 sion C.MLM.01.06.xxx and later and www.jacoelectronics.com “P” compressors C.MLM.04.02.xxx and later) Purchase Contact: Katy Buelow kbuelow@jacoelect.com JOHNSON CONTROLS...
  • Page 169 2-7 - on DTR space after power on 2-8 - Not Used • SEIKO Microboard printer function J2-4 pin 3 Tx (data to printer) J2-2 pin 8 DSR (busy signal from printer) J2-9 pin 5 Cabinet shield JOHNSON CONTROLS...
  • Page 170 1-4 = off Auto LF - off • Stop Bits - 1 1-5 = on Setting Command - Enable 1-6 = off Printing density - 100% 1-7 = on Printing density - 100% 1-8 = on Printing, density - 100% JOHNSON CONTROLS...
  • Page 171 PRINTER Screen. • Automatic Printer Logging - Enables and disables automatic data logging • Log Start Time - Enter the time the first print is desired. • Output Interval - Enter the desired interval between prints. JOHNSON CONTROLS...
  • Page 172 [If Mod D Chiller or higher] % Full Load Amps = 95 % Oil Return Solenoid = Off kW Hours = 20723 kWH [If Mod D Chiller or higher] Input Power = 8225 kW fig. 45 – SAMPLE PRINTOUT (STATUS) JOHNSON CONTROLS...
  • Page 173 L3 Supply Current Total Demand Distortion = Phase B Heatsink Temperature [If TMIII VSD] = 99 ~F 2.8 % Phase C Heatsink Temperature [If TMIII VSD] = 97 ~F Baseplate Temperature [If VyperDrive VSD] = 106 ~F fig. 45 – (CONT’D) SAMPLE PRINTOUT (STATUS) JOHNSON CONTROLS...
  • Page 174 Count Window = 5 Min Leaving Chilled ISN Setpoint = 45.0 ~F Leaving Chilled Modem Setpoint = 45.0 ~F Leaving Chilled Analog Setpoint = 45.0 ~F Leaving Chilled Digital Setpoint = 45.0 ~F fig. 46– SAMPLE PRINTOUT (SETPOINTS) JOHNSON CONTROLS...
  • Page 175 Pulldown Demand Time = 0 Min Starter Model = 26L Voltage Range = 440 - 480 Full Load Amps = 275 A Starting Current = 1150 A Open SCR = Enabled fig. 46 – (CONT’D) SAMPLE PRINTOUT (SETPOINTS) JOHNSON CONTROLS...
  • Page 176 8:00 AM STOP 5:00 PM START 8:00 AM STOP 5:00 PM START STOP ExCEPTION DAYS --------------------------------------------------------------------------------- 02 APR 1999 START = OFF STOP 13 APR 1999 START = 8:00 AM STOP 10:00 PM fig. 47 – SAMPLE PRINTOUT (SCHEDULE) JOHNSON CONTROLS...
  • Page 177 NOzzLE ARRANGEMENT OUT LEAVING TEMPERATURE RETURN TEMPERATURE TUBES DESIGN LOAD - EVAPORATOR --------------------------------------------------------------------------------- PASSES DESIGN WORKING PRESSURE FOULING FACTOR PRESSURE DROP NOzzLE ARRANGEMENT IN NOzzLE ARRANGEMENT OUT LEAVING TEMPERATURE RETURN TEMPERATURE TUBES fig. 48 – SAMPLE PRINTOUT (SALES ORDER) JOHNSON CONTROLS...
  • Page 178 Oil Heater = Off % Full Load Amps = 0 % [If Mod D Chiller or higher] kW Hours = 20723 Oil Return Solenoid = Off [If Mod D Chiller or higher] fig. 49 – SAMPLE PRINTOUT (HISTORY) JOHNSON CONTROLS...
  • Page 179 Converter Heatsink Temperature = 102 ~F L1 Supply Current Total Demand Distortion = 0.0 % L2 Supply Current Total Demand Distortion = 0.0 % L3 Supply Current Total Demand Distortion = 0.0 % fig. 49 – (CONT’D) SAMPLE PRINTOUT (HISTORY) JOHNSON CONTROLS...
  • Page 180 Evaporator Saturation Temperature = 41.0 ~F Condenser Saturation Temperature = 78.5 ~F Evaporator Pressure = 70.0 Psig Condenser Pressure = 140.0 Psig Oil Pressure = 45.0 Psid % Full Load Amps = 50 % fig. 52 – SAMPLE PRINTOUT (CUSTOM SCREEN REPORT) JOHNSON CONTROLS...
  • Page 181 = 7.2 Psig Condenser Pressure = 13.8 Psig % Full Load Amps = 94 % fig. 54 – SAMPLE PRINTOUT (ADAPTIVE CAPAC- fig. 53– SAMPLE PRINTOUT (ADAPTIVE CAPAC- ITY CONTROL EXISTING MAP POINTS REPORT) ITY CONTROL NEw MAP POINT REPORT) JOHNSON CONTROLS...
  • Page 182 si MetriC CoNVersioN The following factors can be used to convert from English to the most common Sl Metric values. MULtipLY this to oBtaiN this MeasUreMeNt ENGLISH VaLUe METRIC VaLUe CapaCitY TONS REFRIGERANT EFFECT (ton) 3.516 kILOwATTS (kw) kILOwATTS (kw) NO CHANGE kILOwATTS (kw) poWer...
  • Page 183 FORM 160.54-O1 JOHNSON CONTROLS...
  • Page 184 P.O. box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2009 www.york.com ALL RIGHTS RESERVED Form 160.54-O1 (1209) Supersedes: 160.54-O1...