160.54-m1 - Optiview Control Center - Service Instructions

March 25, 2018 | Author: Paulo Alves de Santana | Category: Relay, Switch, Power Supply, Input/Output, Sensor
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MAXE TM CENTRIFUGAL LIQUID CHILLERSSERVICE INSTRUCTIONS Supersedes: 160.54-M1 (307) Form 160.54-M1 (607) OPTIVIEW™ CONTROL CENTER 371-02264-101 (Electro-Mechanical Starter - NEMA 1) 371-02486-101 (Electro-Mechanical Starter - CE) 371-02448-101 (Electro-Mechanical Starter - NEMA 4/12) 371-02264-102 (Solid State Starter - NEMA 1) 371-02486-102 (Solid State Starter - CE) 371-02448-102 (Solid State Starter - NEMA 4/12) 371-02264-103 (Variable Speed Drive - NEMA 1) 371-02486-103 (Variable Speed Drive - CE) 371-02448-103 (Variable Speed Drive - NEMA 4/12) 371-02778-101 (Electro-Mechanical Starter - NEMA 1) (P Compressors until 8/02) Chillers) 371-04119-103 (Variable Speed Drive – NEMA 4/12) (Style F Chillers) 371-04119-110 (Mod B Solid State Starter or Variable Speed Drive w/Modbus Communuications - no VGD - NEMA 4-12) -111 (Mod B Solid State Starter or Variable Speed Drive w/Modbus communications & VGD, no J7 compressor – NEMA 4-12) -112 (Mod B Solid State Starter or Variable Speed Drive w/Modbus communications & VGD, J7 compressor – NEMA 4-12) 371-04120-101 (Electro-mechanical Starter – CE) (Style F 371-04120-102 (Mod “B” Solid State Starter – CE) (Style F Chillers) 371-02780-101 (Electro-Mechanical Starter - CE) (P Compressors until 8/02) 371-04120-103 (Variable Speed Drive – CE) (Style F Chillers) 371-04120-110 (Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications - no VGD - CE) -111 (Mod B Solid State Starter or Variable Speed Drive w/Modbus communications & VGD, no J7 compressor – CE) 112 (Mod B Solid State Starter or Variable Speed Drive w/Modbus communications & VGD, J7 compressor – NEMA 1) 371-02779-101 (Electro-Mechanical Starter - NEMA 4/12) (P Compressors until 8/02) 371-02778-102 (MOD “B” Solid State Starter - NEMA 1) (P Compressors until 8/02) 371-02780-102 (MOD “B” Solid State Starter - CE) (P Compressors until 8/02) 371-02779-102 (MOD “B” Solid State Starter - NEMA 4/12) (P Compressors until 8/02) 371-02778-103 (Variable Speed Drive - NEMA 1-4) (P Compressors until 8/02) 371-02780-103 (Variable Speed Drive - CE) (P Compressors until 8/02) MODEL YK (THROUGH STYLE G) 371-02779-103 (Variable Speed Drive - NEMA 4/12) (P Compressors until 8/02) 371-04118-101 (Electro-Mechanical Starter – NEMA 1) (Style F Chillers) 371-04118-102 (Style B Solid State Starter – NEMA 1) (Style F Chillers) 371-04118-103 (Variable Speed Drive – NEMA 1) (Style F Chillers) 371-04118-110 (Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications - no VGD - NEMA 1) -111 (Mod B Solid State Starter or Variable Speed Drive w/Modbus communications & VGD, no J7 compressor – NEMA 1) -112 (Mod B Solid State Starter or Variable Speed Drive w/Modbus communications & VGD, J7 compressor – NEMA 1) 371-04119-101 (Electro-Mechanical Starter – NEMA 4/12) (Style F Chillers) 371-04119-102 (Mod “B” Solid State Starter - NEMA 4/12) (Style F Chillers) m Metric Conversions 00614VIP FORM 160.54-M1 (607) IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. During installation, operation, maintenance or service, individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, oils, materials under pressure, rotating components, and both high and low voltage. Each of these items has the potential, if misused or handled improperly, to cause bodily injury or death. It is the obligation and responsibility of operating/service personnel to identify and recognize these inherent hazards, protect themselves, and proceed safely in completing their tasks. Failure to comply with any of these requirements could result in serious damage to the equipment and the property in which it is situated, as well as severe personal injury or death to themselves and people at the site. This document is intended for use by owner-authorized operating/service personnel. It is expected that this individual possesses independent training that will enable them to perform their assigned tasks properly and safely. It is essential that, prior to performing any task on this equipment, this individual shall have read and understood this document and any referenced materials. This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question. SAFETY SYMBOLS The following symbols are used in this document to alert the reader to areas of potential hazard: DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. CAUTION identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution. Usually an instruction will be given, together with a brief explanation. NOTE is used to highlight additional information which may be helpful to you. WARNING indicates a potentially haz ard ous sit u a tion which, if not avoided, could result in death or serious injury. External wiring, unless specified as an optional connection in the manufacturer’s product line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches, transducers and controls may 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 personnel. YORK will not be responsible for damages/problems resulting from improper connections to the controls or application of improper control signals. Failure to follow this will void the manufacturer’s warranty and cause serious damage to property or injury to persons. 2 JOHNSON CONTROLS CHANGEABILITY OF THIS DOCUMENT FORM 160.54-M1 (607) It is the responsibility of operating/service personnel In complying with YORK’s policy for continuous as to the applicability of these documents to the equipproduct improvement, the information contained in ment in question. If there is any question in the mind this document is subject to change without notice. of operating/service personnel as to the applicability of While YORK makes no commitment to update or prothese documents, then, prior to working on the equipvide current information automatically to the manual ment, they should verify with the owner whether the owner, that information, if applicable, can be obtained equipment has been modified and if current literature by contacting the nearest YORK Applied Systems is available. Service office. REFERENCE INSTRUCTIONS DESCRIPTION SOLID STATE STARTER (MOD “A”) – OPERATION & MAINTENANCE SOLID STATE STARTER (MOD “B”) – OPERATION & MAINTENANCE MEDIUM VOLTAGE SOLD STATE STARTER – SERVICE VARIABLE SPEED DRIVE – OPERATION VARIABLE SPEED DRIVE – SERVICE INSTRUCTIONS MEDIUM VOLTAGE VARIABLE SPEED DRIVE – SERVICE VARIABLE SPEED OIL PUMP DRIVE INSTALLATION OPERATION WIRING DIAGRAM – UNIT (STYLE E) WITH ELECTRO-MECHANICAL STARTER WIRING DIAGRAM – UNIT (STYLE E) WITH MOD “A” SOLID STATE STARTER WIRING DIAGRAM – UNIT (STYLE E) WITH MOD “B” SOLID STATE STARTER WIRING DIAGRAM – UNIT (STYLE E) WITH VARIABLE SPEED DRIVE WIRING DIAGRAM – UNIT (STYLE E) (P COMPRESSORS) WITH ELECTRO-MECHANICAL STARTER WIRING DIAGRAM – UNIT (STYLE E) (P COMPRESSORS) WITH MOD “B” SOLID STATE STARTER WIRING DIAGRAM – UNIT (STYLE E) (P COMPRESSORS) VARIABLE SPEED DRIVE RENEWAL PARTS – UNIT RENEWAL PARTS – OPTIVIEW CONTROL CENTER WIRING DIAGRAM – UNIT (STYLE F) (ALL COMPRESSORS) WITH ELECTRO-MECHANICAL STARTER WIRING DIAGRAM – UNIT (STYLE F) (ALL COMPRESSORS) WITH MOD “A” SOLID STATE STARTER WIRING DIAGRAM – UNIT (STYLE F) (ALL COMPRESSORS) WITH VARIABLE SPEED DRIVE WIRING DIAGRAM – UNIT (STYLE F) (ALL COMPRESSORS WITH MEDIUM VOLTAGE VARIABLE SPEED DRIVE OR MEDIUM VOLTAGE SOLID STATE STARTER FORM NO. 160.46-OM3.1 160.00-O2 160.00-M5 160.00-O1 160.00-M1 160.00-M6 160.52-M2 160.54-N1 160.54-O1 160.54-PW1 160.54-PW2 160.54-PW2.1 160.54-PW3 160.54-PW8 160.54-PW9 160.54-PW10 160.49-RP4 160.54-RP1 160.73-PW1 160.73-PW2 160.73-PW3 160.73-PW5 NOMENCLATURE YK CB CB G4 – CM F STYLE (DESIGN LEVEL) POWER SUPPLY – for 60 Hz 5 for 50 Hz COMPRESSOR CODE* CONDENSER CODE* COOLER CODE* MODEL* JOHNSON CONTROLS * Refer to YK Engineering Guide for Shell/Motor/Compressor combinations 3 FORM 160.54-M1 (607) TABLE OF CONTENTS SECTION 1 - INTRODUCTION .................................. 8 SECTION 2 - SYSTEM ARCHITECTURE ............... 10 SECTION 3 - MICROBOARD 031-01730-000 ......... 23 BOOT-UP STEP AND DESCRIPTION .............................. 25 LED INDICATORS .......................................................... 25 PROGRAM JUMPERS/PROGRAM SWITCHES ........... 25 KEYPAD INTERFACE .................................................... 25 CM-2 BOARD OR STYLE A SOLID STATE STARTER INTERFACE.................................................................... 26 STYLE B SOLID STATE STARTER OR VARIABLE SPEED DRIVE INTERFACE .......................................... 26 PRINTER INTERFACE ................................................... 26 MICROGATEWAY INTERFACE ..................................... 26 DIGITAL INPUTS ............................................................ 27 DIGITAL OUTPUTS ........................................................ 27 ANALOG INPUTS........................................................... 27 SERIAL DATA PORTS .................................................... 28 DISPLAY INTERFACE .................................................... 28 REMOTE SETPOINTS ................................................... 29 POWER SUPPLY ........................................................... 29 SERVICE REPLACEMENT ............................................ 29 SECTION 5 - LIQUID CRYSTAL DISPLAY ............. 71 BACKLIGHT LAMP REPLACEMENT ............................. 73 SECTION 6 - DISPLAY INTERFACE BOARD......... 80 SECTION 7 - DISPLAY BACKLIGHT INVERTER BOARD .............................................. 82 SECTION 8 - KEYPAD............................................. 85 SECTION 9 - POWER SUPPLY ............................... 88 SECTION 10 - CURRENT MODULE (CM-2) ........... 90 SECTION 11 - SOLID STATE STARTERS .............. 94 SOLID STATE STARTERS ............................................. 94 SECTION 12 - ADAPTIVE CAPACITY CONTROL BOARD........................ 102 SECTION 13 - PROXIMITY PROBE ...................... 114 SECTION 13A - HIGH SPEED THRUST BEARING LIMIT SWITCH ............................ 120 SECTION 14 - REFRIGERANT LEVEL CONTROL ...................................... 122 AUTOMATIC OPERATION ........................................... 122 MANUAL OPERATION ................................................. 124 ACTUATORS ................................................................ 124 SECTION 3A - MICROBOARD 031-02430-000 and 031-02430-001 ......................... 40 TEST POINTS ................................................................ 40 DIAGNOSTIC DISPLAY CODES .................................... 41 CHILLER OPERATING PROGRAM ............................... 41 PROGRAM CARD .......................................................... 41 PROGRAM DOWNLOAD CONNECTOR U33 ............... 42 PARALLEL PORT CONNECTOR ................................... 42 WATCHDOG CIRCUIT ................................................... 43 PROGRAM JUMPERS/PROGRAM SWITCHES ........... 43 KEYPAD INTERFACE .................................................... 43 CM-2 BOARD OR STYLE A SOLID STATE STARTER INTERFACE.................................................................... 44 MULTIPLEXER CHANNELS .......................................... 44 STYLE B SOLID STATE STARTER OR VARIABLE SPEED DRIVE INTERFACE .......................................... 44 PRINTER INTERFACE ................................................... 45 MICROGATEWAY INTERFACE ..................................... 45 DIGITAL INPUTS ............................................................ 45 DIGITAL OUTPUTS ........................................................ 45 ANALOG INPUTS........................................................... 46 SERIAL DATA PORTS .................................................... 46 DISPLAY INTERFACE .................................................... 47 REMOTE SETPOINTS ................................................... 48 CONFIGURATION/SETUP ............................................. 48 MICROBOARD SERVICE REPLACEMENT .................. 50 PROGRAM CARD SERVICE REPLACEMENT ............. 51 DOWNLOADING A PROGRAM FROM A PROGRAM CARD .......................................................... 51 SECTION 15 - OIL PUMP VARIABLE SPEED DRIVE............................................. 126 AUTOMATIC OPERATION ........................................... 126 MANUAL OPERATION ................................................. 127 OIL HEATER OPERATION ........................................... 128 SECTION 16 - MICROGATEWAY .......................... 130 SECTION 17 - PRESSURE TRANSDUCERS ....... 131 PRESSURE TRANSDUCER APPLICATIONS CHART ..................................................................................... 133 SECTION 18 - TEMPERATURE THERMISTORS . 134 SECTION 19 - REMOTE SETPOINTS................... 152 CURRENT LIMIT .......................................................... 152 LEAVING CHILLED LIQUID TEMPERATURE ............. 154 SECTION 20 - HOT GAS BYPASS ....................... 157 SETPOINTS ................................................................. 157 OPERATION ................................................................. 158 HOT GAS OPERATION WITH VARIABLE GEOMETRY DIFFUSER (VGD)......................................................... 158 MANUAL CONTROL .................................................... 159 ANALOG I/O BOARD ................................................... 159 SECTION 4 - I/O BOARD ........................................ 61 RELAY TIMING ............................................................... 62 SECTION 21 - SMART FREEZE PROTECTION ... 161 4 JOHNSON CONTROLS ........................................ 164 HOT GAS BYPASS/COMPRESSOR MOTOR VARIABLE SPEED DRIVE (VSD) APPLICATIONS ................. 181 STANDBY LUBRICATION ..... 163 EXCESS SURGE DETECTION ........................OPTISAVE FEATURES ........... 165 SURGE DETECTION ............ 183 SMART FREEZE PROTECTION .............................. 173 COMPRESSOR MOTOR VARIABLE SPEED DRIVE APPLICATIONS ..............................SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2003 ........................................................ 164 VARIABLE GEOMETRY DIFFUSER ......................................................... 165 MANUAL OPERATION ............................................... 172 MOD “A” LIQUID COOLED SOLID STATE STARTER ............... 167 PRE-ROTATION VANES POSITION ......................................................................... 177 HIGH SPEED THRUST BEARING LIMIT SWITCH..............................SOFTWARE ENHANCEMENTS EFFECTIVE AUGUST 2002... 202 DIGITAL INPUTS / OUTPUTS TESTS ....................DIAGNOSTICS & TROUBLESHOOTING ............... 171 CALIBRATION VERIFICATION: .... 165 STALL DETECTION (REF FIG 64A) ..... 225 SI0080 ...........SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2002 ...... 238 JOHNSON CONTROLS 5 ..................... 233 SI0158 ...................................................... 179 OIL PUMP VARIABLE SPEED DRIVE ............... 231 SI0148 ..SOFTWARE ENHANCEMENTS EFFECTIVE JANUARY 2004 ..................... 179 REFRIGERANT LEVEL CONTROL ...... 194 SECTION 24 ..............................SOFTWARE ENHANCEMENTS EFFECTIVE FEBRUARY 2003 ...................................................................................................................................................... 234 SI0164 .............................................................................................. 184 EVAPORATOR REFRIGERANT TEMPERATURE .............................. 185 SERVICE PHONE NUMBERS ......................................................... 191 MICROBOARD 031-02430-000 SETUP/ CONFIGURATION ...... 171 ELECTRO-MECHANICAL STARTER APPLICATIONS ........................... 215 SECTION 23 .... 168 SECTION 25 ..................... 187 RECORD SETPOINT CHANGES ........................................... 183 DROP LEG REFRIGERANT TEMPERATURE............................................. 194 MOTOR LUBRICATION NOTIFICATION ..........SURGE PROTECTION ............................................. 175 PROXIMITY PROBE ...................................................................SOFTWARE ENHANCEMENTS EFFECTIVE APRIL 2007 ...SYSTEM CALIBRATION..................................... 168 I/O BOARD ..................SOFTWARE ENHANCEMENTS EFFECTIVE JUNE 2006 ............................................................. 182 LEAVING CHILLED LIQUID TEMPERATURE CONTROL SENSITIVITY .... 229 SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2005 ............................. 182 BRINE LOW EVAPORATOR PRESSURE CUTOUT ..... 185 SALES ORDER DATA ...................... 163 SURGE PROTECTION ................................................ 211 SECTION 26 ................................................................... 186 CUSTOM USER ID AND PASSWORDS ...................... 223 SI0062 ................................. 163 SURGE DETECTION ......................SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2001 .................... 200 SERIAL INPUTS / OUTPUTS TESTS ..................................................... 199 BIT PATTERNS TEST ...................................... 217 SI0034 (203) ........................... 191 SI0019 ....................................... 198 DISPLAY TEST .................................................................................. 192 HIGH CONDENSOR PRESSURE FAULT WHILE SHUTDOWN-RESET PROCEDURE .......... 185 SURGE PROTECTION ............ 215 SI0006 . 184 CHILLER STARTS AND OPERATING HOURS RESET ................................................................................................................ 196 MAIN DIAGNOSTICS SCREEN ... SERVICE SETPOINTS AND RESET PROCEDURES ............................. 172 MOD “B” LIQUID COOLED SOLID STATE STARTER .......... 188 FLOW SWITCH .......................................... 165 AUTOMATIC OPERATION .......................................... 227 SI0089 . 235 SECTION 27 .....54-M1 (607) TABLE OF CONTENTS (CONT'D) SECTION 22 .............................. 182 HIGH CONDENSER PRESSURE WARNING THRESHOLD..........................SERVICE INFORMATION LETTERS / BULLETINS ................... 184 HOT GAS BYPASS CONTROL .. 208 SECTION 22A ..........................SYSTEM COMMISSIONING CHECKLIST .... 197 KEYPAD TEST ................FORM 160......................................... 220 SI0058 ............................................................... 204 ANALOG INPUTS TEST ..................... 167 SETPOINTS .................SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2004 ..................VARIABLE GEOMETRY DIFFUSER......................................................... 171 SOLID STATE STARTER APPLICATIONS ..................................... 187 CHILLER STYLE/COMPRESSOR ...............................SOFTWARE ENHANCEMENTS EFFECTIVE OCTOBER 2006......................... .......................... 78 FIG...COMPRESSOR MOTOR VARIABLE SPEED DRIVE (MODBUS SERIAL COMMUNICATIONS PROTOCOL) ............. 36 – CM-2 CURRENT MODULE (ELECTROMECHANICAL STARTER APPLICATION) .............................................. 56 FIG............ 37 FIG................... 18 – DISPLAY.................... 4 – OPTIVIEW CONTROL CENTER ........... 10A – MICROBOARD LAMP DIMMER CIRCUIT ....110 FIG...... 16 – I/O BOARD TYPICAL FIELD CONNECTIONS ........ 8 – FLASH MEMORY CARD . 25 – DISPLAY (SHARP LQ10D421) LAMP REPLACEMENT......... 7A – MICROBOARD 031-02430-000 ........ 18 FIG...........COMPRESSOR MOTOR VARIABLE SPEED DRIVE .............................. 43A – SERIAL COMMUNICATIONS INTERFACE .............. 19 FIG........................... 93 FIG.. 29 – DISPLAY BACKLIGHT INVERTER BOARD (SHARP LQ10D367/368 (031-01774-000) & LG SEMICON LP104V2-W (031-02046-000)) .......... 43B – SERIAL COMMUNICATIONS INTERFACE ... 81 FIG........ 14 – I/O BOARD DIGITAL INPUTS ... 41 – MOD “A” LIQUID COOLED SOLID STATE STARTER (LCSSS) .. 101 FIG..... 57 FIG............ 67 FIG................... 7 – MICROBOARD 031-01730-000 .......................................... 9A – MICROBOARD (031-02430-000) DC POWER SUPPLY TEST POINTS ... 5 – OPERATION SEQUENCE TIMING DIAGRAM (ELECTRO-MECHANICAL & SOLID STATE STARTER APPLICATIONS) ... 35 – POWER SUPPLY – DC POWER DISTRIBUTION ....................... 31 – DISPLAY BACKLIGHT INVERTER BOARD (NEC NL6448AC33-24) ........................................ 78 FIG........... 34 – POWER SUPPLY ................. 109 FIG.. 74 FIG........................ 30 FIG........INTERFACE .... 12 – CONFIGURABLE ANALOG & REMOTE SETPOINT INPUTS . 4A – OPTIVIEW CONTROL CENTER ...................... 20 FIG. 42 – COMPRESSOR MOTOR VARIABLE SPEED DRIVE (VSD) ADAPTIVE CAPACITY CONTROL (ACC) BOARD ............ 32 – KEYPAD ..... 44 – ADAPTIVE CAPACITY CONTROL (ACC) BOARD ..YORK PROTOCOL ............ 2 – OPTIVIEW CONTROL CENTER ......... 10 – MICROBOARD LAMP DIMMER CIRCUIT ............. 68 FIG........................ 13 – I/O BOARD ............ 88 FIG................ 21 – LIQUID CRYSTAL DISPLAY ASSEMBLY – NEC NL6448AC33-24 DISPLAY ......113 FIG... 27 – DISPLAY (LG SEMICON LP104V2-W (031-02046-000)) LAMP REPLACEMENT ............. 65 FIG......MOD “A” SOLID STATE STARTER APPLICATIONS ....................... 92 FIG............ 15 – I/O BOARD TYPICAL OPTO-COUPLER CIRCUIT .. 79 FIG.......................FORM 160............................. MOUNTING .......... 58 FIG... 77 FIG.... 19 – LIQUID CRYSTAL DISPLAY ASSEMBLY – SHARP LQ10D367/368 (031-01774-000) DISPLAY.... 3 – OPTIVIEW CONTROL CENTER .... 31 FIG.................... 8A – PROGRAM CARD 031-02474-001 ................................... 79 FIG........................... 1 – OPTIVIEW CONTROL CENTER .................................. 43 – ADAPTIVE CAPACITY CONTROL (ACC) BOARD ................................ 89 FIG...... 14 FIG............... 57 FIG..................MODBUS PROTOCOL.................. 20 – LIQUID CRYSTAL DISPLAY ASSEMBLY – SHARP LQ10D421 DISPLAY ..... 84 FIG................ 3A – OPTIVIEW CONTROL CENTER .... 17 – I/O BOARD DIGITAL OUTPUTS ......... 33 – KEYPAD ..... 38 FIG. 76 FIG... 37 – CM-2 CURRENT MODULE (ELECTROMECHANICAL STARTER APPLICATIONS) ................................................. 16 FIG......... 92 FIG.............................. 4B – OPTIVIEW CONTROL CENTER COMPRESSOR MOTOR MEDIUM VOLTAGE VARIABLE SPEED DRIVE ............ 30 – DISPLAY BACKLIGHT INVERTER BOARD (SHARP LQ10D421) ............... 11A – MICROBOARD SERIAL DATA COMMUNICATIONS PORTS ........ 26 – DISPLAY (NEC NL6448AC33-24) LAMP REPLACEMENT........ 98 FIG.............. 38 – CM-2 CURRENT MODULE – INTERFACE.......... 60 FIG..MOD “B” SOLID STATE STARTER APPLICATIONS ..... 59 FIG......... 15 FIG......................................... 97 FIG............ 6 – OPERATION SEQUENCE TIMING DIAGRAM (COMPRESSOR MOTOR VARIABLE SPEED DRIVE APPLICATIONS)....................... 87 FIG............117 6 JOHNSON CONTROLS ...54-M1 (607) LIST OF FIGURES FIG... 21 FIG...... 23 – LIQUID CRYSTAL DISPLAY TYPICAL CONTROL SIGNAL TIMING ..... 11 – MICROBOARD SERIAL DATA COMMUNICATIONS PORTS .......112 FIG..................................... 39 FIG........... 9 – MICROBOARD (031-01730-000) POWER SUPPLY TEST POINTS .................................INTERFACE .................................................. 22 – LIQUID CRYSTAL DISPLAY ASSEMBLY LG SEMICON LP104V2-W (031-02046-000) .................. 17 FIG................ 77 FIG...................ELECTROMECHANICAL STARTER APPLICATIONS ............................................................MEDIUM VOLTAGE SOLID STATE STARTER APPLICATIONS ........................................................................... 39 – MOD “B” LIQUID COOLED SOLID STATE STARTER (LCSSS) .... 12A – CONFIGURABLE ANALOG & REMOTE SETPOINT INPUTS .. 111 FIG.................. 45 – PROXIMITY PROBE INTERFACE-PROBE PART NUMBER 025-30961-000 ........ 66 FIG..... 22 FIG.......... 67 FIG................ CURRENT TRANSFORMERS & VARIABLE RESISTORS .................................................. 28 – DISPLAY INTERFACE BOARD ....... 24 – DISPLAY (SHARP LQ10D367/368) LAMP REPLACEMENT (031-02046-000) .. 86 FIG.......... 32 FIG.................................... 75 FIG....................................................................INTERFACE ........ 83 FIG. 75 FIG.................. 40 – SOLID STATE STARTER LOGIC BOARD .............. 84 FIG.. .117 FIG. 160 FIG................................................ 121 FIG.............................. 54 – OIL PUMP VSD / OIL HEATER CONTROL – INTERFACE .... 199 FIG....... 125 FIG......... 128 FIG.............. HOT GAS BYPASS ............................... 61 – OIL AND DISCHARGE TEMPERATURE .. 52 – REFRIGERANT LIQUID LEVEL CONTROL ........FORM 160...................................54-M1 (607) LIST OF FIGURES (CONT'D) FIG...... 197 FIG................................................................................................. 36 TABLE 3 ...........................................INTERFACE .................. 63 – EVAPORATOR REFRIGERANT SENSOR ...................... 60 – RETURN AND LEAVING CONDENSING WATER ........ 64A – VARIABLE GEOMETRY DIFUSER BLOCK DIAGRAM ...... 130 FIG.................... 59 – RETURN CHILLED LIQUID TEMPERATURE ...................... 70 – MICROBOARD ........... 57 – PRESSURE TRANSDUCERS .............................................. 56 – MICROGATEWAY INTERFACE BLOCK DIAGRAM ...... 135 FIG........MICROBOARD 031-01730-000 PROGRAM SWITCHES....MICROBOARD 031-01730-000 PROGRAM JUMPERS ................................................................... 68 – BIT PATTERNS TEST SCREEN ..... 151 FIG...................................... 204 FIG.. 200 FIG..............MICROBOARD 031-02430-000 PROGRAM SWITCHES.............. 55 JOHNSON CONTROLS 7 ............................. 55 – OIL PUMP VSD SPEED CONTROL SIGNAL .................. 202 FIG....... 53 TABLE 4 .................................. 120 FIG... 151 FIG......... 69 – SERIAL INPUTS / OUTPUTS TEST SCREEN.................. 146 FIG......................................... 203 FIG............... 65 – MAIN DIAGNOSTICS SCREEN ....................................................... 49 – HIGH SPEED THRUST BEARING LIMIT SWITCH ..... 58 – LEAVING CHILLED LIQUID TEMPERATURE .. 51 – REFRIGERANT LIQUID LEVEL SENSOR ....... 208 LIST OF TABLES TABLE 1 .................. 50 – HIGH SPEED THRUST BEARING LIMIT SWITCH ..................................................................................... 46 – PROXIMITY PROBE INTERFACE-PROBE PART NUMBER 025-35900-000 AND 025-35900-001 .....119 FIG. 72 – ANALOG INPUTS TEST SCREEN ................ 33 TABLE 2 ............. 62 – DROP LEG REFRIGERANT SENSOR ................................................................... 129 FIG.... 129 FIG....... 67 – DISPLAY TEST MAIN SCREEN.................. 143 FIG..COM 5 SERIAL DATA PORT.............. 124 FIG.......................... 170 FIG........................ 66 – KEYPAD TEST SCREEN ... 71 – DIGITAL INPUTS / OUTPUTS TEST SCREEN.... 169 FIG............... 140 FIG.. 48 – PROXIMITY PROBE .......................... 132 FIG........MICROBOARD 031-02430-000 PROGRAM JUMPERS .............................. 198 FIG.... 47 – PROXIMITY PROBE INTERFACE – PROBE PART NUMBER 025-40496-000 ......... 53 – OIL PUMP VARIABLE SPEED DRIVE (VSD) ...............118 FIG. 64 – INTERFACE.......INTERFACE .......... 64B – VARIABLE GEOMETRY DIFFUSER STATE DIAGRAM ................. 73-PW3 – (Variable Speed Drive) 8 JOHNSON CONTROLS .54-PW2. In addition to this document.54-PW7 provides details of the interface to remote devices. Chillers that are equipped with “P” Compressors have certain component variances.73-PW2 – (Mod “B” YORK Solid State Starter) • YORK Form 160. The function of each component and signal flow between components must be understood before effective troubleshooting can commence. The operation of each printed circuit board is described and illustrated with a block diagram that is a simplified representation of board circuitry. For example.54-PW1 – Chillers equipped with Electro-Mechanical starter • YORK Form 160. This describes the general function of each component and provides the system interface and signal flow. program jumpers and program switches are required to configure the chiller for local operating conditions. several levels of supporting documentation are required while servicing the system. The following wiring diagrams provide the connections between the printed circuit boards and components within the OptiView Control Center: Chillers Through Style E (Except "P" Compressors): • YORK Form 160. Included in this document are procedures that have to be performed at chiller commissioning or during service. special setpoints.54-M1 (607) SECTION 1 INTRODUCTION This document explains the operation of the printed circuit boards and major components of the OptiView Control Center to a level that allows a Service Technician to troubleshoot and locate the source of a problem. A System Commissioning Checklist is provided as reference of items to be performed during chiller commissioning. Field Control Modifications Diagram 160. how to enter Setpoints and explains all the messages displayed on the OptiView Control Center display.54-O1 explains the operation of the OptiView Control Center Keypad.73-PW1 – (Electro-Mechanical Starter) • YORK Form 160. Since the operating program supplied in each OptiView Control Center is universal to all applications.54-PW8 – Chillers (“P” Compressors) equipped with Electro-Mechanical Starter • YORK Form 160. Operations Manual 160.54-PW2 – Chillers equipped with Mod “A” YORK Solid State Starter • YORK Form 160. The overall system architecture is described and illustrated with block diagrams.1 – Chillers equipped with Mod “B” YORK Solid State Starter • YORK Form 160. They should not be performed by anyone other than a Service Technician. The expected voltage level at all inputs and outputs of each board for any operating condition is provided.54-PW3 – Chillers equipped with YORK Variable Speed Drive Chillers Through Style E ("P" Compressors): • YORK Form 160.54-PW10 – Chillers (“P” Compressors) equipped with YORK Variable Speed Drive Style F Chillers (All Compressors): • YORK Form 160.54-PW9 – Chillers (“P” Compressors) equipped with Mod “B” YORK Solid State Starter • YORK Form 160. calibration procedures have to be performed or verified at system commissioning or when a component is replaced. These variances are noted in the appropriate sections of this book. Certain Safety shutdowns require special reset procedures to be performed before the chiller can be restarted.Introduction FORM 160. FORM 160.54-M1 (607) When the chiller shuts down on a SAFETY or CYCLING shutdown or is being prevented from starting. proceed with the appropriate Wiring Diagram listed above to trace the problem through the system. observe the shutdown message and retrieve the HISTORY data of that event. 1 JOHNSON CONTROLS 9 . a message is displayed providing the reason for the shutdown. including the conditions required to produce the message and conditions required to restart the chiller. The Operations Manual 160. The conditions required to produce the message must be clearly understood before proceeding. Armed with a knowledge of the overall system architecture and the function of each printed circuit board and signal flow provided by this manual. Diagnostic Routines allow service analysis of the following functions: • • • • • Display Analog inputs Digital inputs Digital outputs Serial Data ports Before beginning any troubleshooting. This history data can be displayed or printed using an optional printer. Use the Diagnostic Routines where appropriate. Refer to the Operations Manual for an explanation of the message. This message. along with all the chiller operating conditions at the instant of the event are stored in the Microboard battery-backed memory. (If this is not heeded. much time will be wasted).54-O1 provides a detailed description of this message. • Allows local manual start/stop and accepts start/ stop commands from remote devices. chiller solenoid valves. shutdown messages and history data.5VDC. • Accepts operator-programmed setpoints and controls the chiller accordingly. • Allows setpoints to be changed from a remote location via 0-10VDC. Serial Data is transmitted to and received from devices in RS-232. local start/stop switch. • Monitors chiller operating conditions and shuts down chiller when Safety or Cycling thresholds are exceeded. The relay contacts typically switch 115VAC and the triacs typically switch a nominal 30VAC. 0-20mA. However.System Architecture FORM 160. RS-485 and TX/RX (opto-couple) form.54-M1 (607) SECTION 2 SYSTEM ARCHITECTURE The OptiView Control Center performs the following functions: • Controls chiller capacity to chill liquid to the chilled liquid temperature setpoint. etc. Typical output voltage range of both is 0. System temperatures are sensed by thermistors. the OptiView Control Center contains a printed circuit board that provides certain control and interface functions for the starter type applied. • Allows manual control of chiller motor contactors and actuators.5 to 4. 4-20mA. digital and serial data inputs and controls analog. The output of each thermistor is a DC voltage that is analogous to the temperature it is sensing. • Controls chiller solenoid valves. Triac outputs include pre-rotation vane control and variable orifice control. remote cycling and high pressure safety device. • Allows real-time data and history data to be printed on an optional printer. These are analog inputs to the OptiView Control Center. • Controls the compressor motor starter and contains a printed circuit board logic that supports ElectroMechanical Starters. Solid State Starters and YORK Variable Speed Drive. The OptiView Control Center is a microprocessor based control system that receives analog. • Provides chiller operating data and status to remote devices via serial communications and contact closures. actuators and motor contactors per the operating program. regardless of the starter type applied: • • • • • Microboard I/O (input/output) Board Keypad Display Power Supply In addition to the standard components. Digital Inputs are on/off inputs to the OptiView Control Center in the form of switch and relay contacts. These include flow switches. oil heater. etc. relays. Solid State Starter and Variable Speed Drive. Each starter type requires a different board as follows: 10 JOHNSON CONTROLS . Digital Outputs are on/off outputs from the OptiView Control Center in the form of relay contacts and triacs. System pressures are sensed by pressure transducers The output of each transducer is a DC voltage that is analogous to the pressure input. • Displays chiller operating conditions. Electro-Mechanical Starter. all OptiView Control Centers contain the following standard components. via contact closures or serial communications. Relay outputs include status/alarm. These inputs are 115VAC when the contacts are closed and 0VAC when open. oil pump starter and chilled and condenser water pump starters. alarms. The OptiView Control Center supports three types of starters. digital and serial data outputs per instructions in the operating program. 2-10VDC. A panel mounted display and touch-sensitive keypad permit local operation. contact closures or serial communications. 15. reside on the Microboard. This board is backward compatible with YK chillers presently using the 031-01730-000 or 031-02430000 microboard.xxx is of the same controls revision level as C.xx. This board is backward compatible to YK chillers presently using the 031-01730-000 microboard. Figures 5 and 6 are Operation Sequence timing diagrams of the different starter applications. requires software version C. 3=NEMA/CE ) • zz – language package revision level (00. It conditions the digital input signals for the Microboard and contains relays and triacs that are controlled by the Microboard to control solenoids. • C – Commercial chiller • MLM – Used on Microboard 031-01730-000 • OPT .OPT. The software version is C.None • Variable Speed Drive .MLM. The Program can be upgraded by downloading a new program from a Program Card.OPT.08. Each time the controls section or language section is revised. It is printed on a label adhered to the card.xxx (or later). etc) • y – language package (0=English only. Program Cards are shirt-pocket-size portable memory storage devices available from YORK. and is viewable on the DIAGNOSTICS Screen in SERVICE access level.yzz or C. The triacs are turned on and off by the Microboard. xx.yzz. motor contactors and actuators. The program resides in a replaceable Flash Memory Card. The analog inputs are connected directly to the Microboard. • 031-02430-001 – Shipped in new production chillers after June 2006. The Program can be upgraded by replacing the card. From this starting point. 1=NEMA. earlier vintage chillers could be equipped with a later version Microboard due to service replacement.Used on Microboard 031-02430-000/-001 • 01 – YK chiller • xx . • 031-02430-000 – Shipped in new production chillers from January 2004 to June 2006.xxx).OPT software.01. All chiller operating decisions are made here. The contacts of these relays control the 115VAC system solenoids.01. 2 11 . Under Program control. The I/O Board acts as an input/output device for the Microboard. 2=CE. refer to the controls revision level. The 115VAC digital inputs from switch and relay contacts are converted to logic level voltages by Opto-Couplers. etc) Throughout this manual. Software upgrades should only be performed by a Service Technician. The upgrade is necessary to operate with the Medium Voltage Solid State Starter.MLM. To cross reference C.FORM 160.MLM. 01.01. 01. The microprocessor and all supporting logic circuits. both receive the same updates at each revision.yzz) are alphanumeric codes that are interpreted as follows. along with the printed circuit board that supports the applied starter type. The software version is C.54-M1 (607) • Electro-Mechanical Starter . the respective revision level increments.Adaptive Capacity Control Board (except those VSD that communicate with the microboard using Modbus protocol).xx.xxx. reference is made to functions and features that are only available in certain Flash Memory Card revision levels (C. The digital inputs are received via the I/O Board (see description below).MLM software to C.yzz.01.01. Since the newer versions Microboard are backward compatible to earlier vintage Optiview Control Centers. the Microboard operates the relays and triacs that are located on the I/O Board.01. The relays have +12VDC coils that are energized and de-energized by the Microboard.01.xx. The software versions (C. Figures 1 through 4 are OptiView Control Center block diagrams of the three starter types. This is an upgraded version of the 031-02430-000 microboard.controls revision level (00. The control center will be equipped with one of the following Microboards: • 031-01730-000 – Shipped in new production chillers until January 2004.01. Medium Voltage Variable Speed Drive and those Variable Speed Drives that serially communicate with the microboard using Modbus Protocol.MLM. The upgrade includes a larger JOHNSON CONTROLS BRAM (U38) and an additional RS-485 port on COM2 serial port for Modbus communications.CM-2 Current Module • Solid State Starter (Style A) – Logic Board Solid State Starter (Style B) . It receives analog and digital inputs from the chiller and remote devices.08A.OPT.xx. When used in larger BRAM configuration. Software version C. along with the memory devices containing the operating program. relays and motor contactors. The program resides in non-removable onboard memory.OPT. the standard components are shown. The outputs of these triacs control actuators. On each block diagram. The temperature of the heated sensor tip is sensed by a thermistor located in the tip. along with chiller operating pressures and temperatures.MLM. These sensors are interfaced to Microboard analog inputs. Refer to the I/O Board section of this book. The Keypad is used to select displays showing increasing levels of detail of chiller working components. Style C and earlier chillers are equipped with fixed speed oil pumps. the program automatically bundles the functionality and chiller control per the entered chiller style/compressor requirements.MLM. enter setpoints and perform chiller and OptiView Control Center diagnostics.01.xxx and later and are supplied with factory-mounted Flow Sensors on the evaporator and condenser. The operating principle of the sensor is thermal conductivity. A front panel-mounted Keypad allows Operator and Service Technician user interface. The factory mounted Thermal type (available with Style F and later chillers). the chiller Style/Compressor combination must be entered using the Chiller Style/Compressor Setpoint (refer to SECTION 23). Style F (and later) chillers require Flash Memory card version C. Chillers equipped with “P” compressors and all style “F” and later chillers have a different Condenser High Pressure Safety Cutout Switch (HPCO) than supplied on other compressor applications.07. The lower temperature differential between the two thermistors indicates the liquid is flowing. The chiller and working components of the chiller are displayed. This board is populated with the required Triacs Q3 and Q4 that apply the open and close signals to the Variable Geometry Diffuser ring actuator. A second thermistor. located higher in the tip in a non-heated area. Q” and “H5-8” compressors are equipped with a High Speed Thrust Bearing Limit Switch instead of the Proximity Probe supplied on other compressors.54-M1 (607) Chillers equipped with the Variable Geometry Diffuser are supplied with and require I/O Board 031-01743-002. A front panel mounted liquid crystal Display allows graphic animated display of the chiller. Once the applicable chiller style/compressor combination is entered. It uses the cooling effect of a flowing liquid to sense flow. If equipped with Flash Memory Card version C. A higher differential indicates no flow. These are electronic thermal-type sensors. Style D and later chillers are equipped with Variable Speed Oil Pumps. chiller subsystems and system parameters.xxx (and later).System Architecture FORM 160. The paddle type applies 115Vac to the I/O Board Digital inputs TB4-12 (evaporator) and TB4-11 (condenser) (refer to fig 14). Refer to Variable Geometry Diffuser Section 22A. The variables include: • High Speed Thrust bearing proximity sensing – Proximity Probe or Limit Switch • Flow Sensor – Paddle type or Factory Mounted Thermal Type. A self-contained Power Supply supplies the necessary DC voltages for all the components within the OptiView Control Center. The temperatures sensed by the thermistors are compared. is only affected by changes in liquid temperature. “P” compressor applications and style “F” and later chillers with “G. It also contains a START-RUNSTOP/RESET Switch that is used to locally start and stop the chiller and perform manual reset functions. This switch is mounted on the condenser shell but has a different wiring interface to the I/O Board and Motor Controller circuit. The various chiller style/compressor combinations are equipped differently and have different control requirements.01. This device detects abnormal bearing position through probe contact instead of distance measurement as performed with the Proximity Probe. Refer to the SECTION 3 for a detailed explanation of this flow sensor and interface. Membrane keys are used to display chiller and system parameters. applies +5Vdc to the microboard Analog inputs at J7-14 (evaporator) and J7-16 12 JOHNSON CONTROLS . Also. lowering its temperature. Flowing liquid carries heat away from the heated sensor tip.07. xxx and later allows use of either the Thermal-type or the Paddle-type flow sensors on style F and later chillers. Serial data interface to the YORK ISN Building Automation System is through the optional MicroGateway. located in the compressor motor terminal box.MLM.OPT. This starter contains a Trigger Board that interfaces to a Logic Board that is installed inside the OptiView Control Center.xxx and C. Software version C.54-M1 (607) • • • • (condenser)(refer to fig 12). This board converts the voltage pulsations into an analog voltage that represents the magnitude of the stall noise. Oil Heater Outputs – Either TB1-34 or TB1-64 on I/O Board Refrigerant Level Control Default Period – Either 3.xxx automatically selects the Flow Sensor input. A Pre-rotation Vanes position potentiometer is also required to support this feature. If the chiller is provided with a compressor motor Variable Speed Drive or the optional Hot Gas Bypass.FORM 160.MLM. the OptiView Control center is equipped with a CM-2 Current Module. it is modulated to maintain the most open position possible without stall occurring. JOHNSON CONTROLS . mounted in the discharge scroll of the compressor.MLM. With the later vintage VSD (fig 4A). one of three different Starters could be applied. A mechanical ring. When the compressor motor is driven by a YORK Solid State Starter.xxx (and later)) – defaults to either 150 seconds or 240 seconds. The VGD is pulsed toward the closed position in response to unacceptable stall noise.302 (and later) and I/O Board 03101743-002 is required for this feature. 13 2 When the compressor motor is driven by an ElectroMechanical Starter. Stall may occur at low load conditions with high head.01. A Stall Pressure Transducer. With these versions. the ACC Board is not present and the VSD Logic Board directly interfaces the microboard using RS-485 Modbus Protocol serial communications. xxx (or later). Stall noise is detected as gas pressure pulsations. Certain compressors are equipped with a Variable Geometry Diffuser (VGD). along with rectifying and calibration circuitry.01.10.07.01.xxx (and later) or C. the PRV potentiometer for those features is used. The MV VSD (fig 4B) is also interfaced to the microboard with RS-485 Modbus serial communications. either digital or analog per the Chiller Style/Compressor Setpoint selection. Current Transformers. the actual flow sensor type present must be entered using the Flow Switch Setpoint (refer to SECTION 23). while maintaining required chiller capacity. a PRV potentiometer is provided interfaced to the Microboard.10. the ACC functionality resides in the microboard. located in the compressor diffuser passage is operated to open or close the diffuser gap.01. This signal is further conditioned and provided to the Microboard.OPT. Flash Memory Card version C. provide an analog voltage representing compressor motor current to the CM-2 Module. All Modbus protocol applications require software version C.01. Flash Memory Card version C. The Logic Board interfaces the Microboard via a multiplexed data interface.0 seconds “Oil – Variable Speed Pump-Pressure Setpoint Not Achieved” safety shutdown threshold – Either 25 PSID or 35 PSID Standard Coastdown Time (software version C. This analog voltage is input to the Microboard where it is compared to thresholds that determine if the stall noise is acceptable or unacceptable.01. Early vintage VSD’s (fig 4) contain an Adaptive Capacity Control (ACC) Board that resides in the Optiview cabinet that interfaces the microboard using YORK proprietary protocol serial opto-coupled communications.OPT.07A. The Style B LCSSS use an opto-coupled interface with YORK proprietary protocol. there could be a Variable Speed Drive (VSD) or a Medium Voltage Variable Speed Drive (MV VSD) applied. The ACC board monitors system parameters and controls the VSD to drive the compressor at the slowest speed without surging.01. This printed circuit board provides current overload and power fault protection for the compressor motor.16. It is used to reduce rotating stall conditions and associated stall noise.MLM. The Meduim Voltage Solid State Starter (fig 3A) serially communicates with the microboard using RS-485 Modbus Protocol.16. Later production chillers are equipped with either the Style B Liquid Cooled Solid State Starter (LCSSS) or the Medium Voltage Solid State Starter (MVSSS). Otherwise. When the compressor motor is driven by a YORK Variable Speed Drive. detects the gas pressure pulsations and outputs DC voltage pulsations to the Stall Detector Board.5 seconds or 10. The Style B LCSSS (fig 3) contains a combination Logic/Trigger Board in the starter cabinet that has a serial communications interface to the microboard. Earlier vintage chillers are equipped with the Style “A” Solid State Starter. Otherwise. This printed circuit board requests the required data from the Microboard and makes it available for the ISN network.08. MLM.ELECTRO-MECHANICAL STARTER APPLICATIONS LD09559 .10 VDC. 1 – OPTIVIEW CONTROL CENTER .14 RS-232 / RS-485 SERIAL DATA OIL PUMP VSD SPEED CONTROL CONDENSER REFRIGERANT LEVEL +12 / -12 / +5 VDC PRE-ROTATION VANES POSITION (VARIABLE GEOMETRY DIFFUSER W/O HOT GAS BYPASS) FACTORY-MOUNTED CHILLED AND CONDENSER LIQUID THERMAL-TYPE FLOW SENSORS (STYLE "F" AND LATER CHILLERS) CHILLER TEMPERATURES & PRESSURES HIGH SPEED THRUST BEARING POSITION (NOT APPLICABLE TO "P" COMPRESSORS AND STYLE "F" AND LATER CHILLERS WITH "G" OR "H5-8" COMPRESSORS) + 24 VDC POWER SUPPLY System Architecture REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (0-20mA. Q" OR "H5-8" COMPRESSORS) FORM 160. 2-10VDC) LAMP ADDRESS BACKLIGHT INVERTER BOARD LAMP CONTROL DISPLAY DATA COMPRESSOR MOTOR CURRENT CM-2 CURRENT MODULE LIQUID CRYSTAL DISPLAY DISPLAY INTERFACE BOARD MICROBOARD MULTIPLEXED DATA ROW IN COLUMN OUT KEYPAD MOTOR CONTROLLER SHUTDOWN TO I/O BOARD I / O BOARD TO STARTER DIGITAL IN TRIAC OUT RELAY OUT COMPRESSOR MOTOR START VANE MOTOR SWITCH REMOTE CYCLING HIGH PRESSURE SAFETY LOCAL START / STOP SWITCH OIL PUMP STARTER OIL HEATER ON/OFF CHILLED & CONDENSER WATER PUMP STARTERS STATUS / ALARM CHILLER SOLENOID VALVES CHILLED & CONDENSER WATER FLOW SWITCHES (STYLE "E" AND EARLIER CHILLERS. 4-20 mA / 0 .54-M1 (607) JOHNSON CONTROLS FIG.08.XXX OR LATER VERSIONS) OIL PUMP VSD CYCLING STATUS MOTOR CONTROLLER SHUTDOWN REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (CONTACT CLOSURE) VARIABLE ORIFICE CONTROL VARIABLE GEOMETRY DIFFUSER CONTROL PRE-ROTATION VANE CONTROL HIGH SPEED THRUST BEARING LIMIT SWITCH ("P" COMPRESSORS AND STYLE "F" AND LATER CHILLERS WITH "G. OPTIONAL STYLE F AND LATER CHILLERS WITH FLASH MEMORY CARD VERSION C.01. 2-10VDC) LAMP BACKLIGHT INVERTER BOARD DISPLAY DATA LIQUID CRYSTAL DISPLAY DISPLAY INTERFACE BOARD MICROBOARD MULTIPLEXED DATA ROW IN COLUMN OUT TRIGGER BOARD CONTROL KEYPAD MOTOR CONTROLLER SHUTDOWN TO I/O BOARD I / O BOARD DIGITAL IN TRIAC OUT RELAY OUT COMPRESSOR MOTOR START REMOTE CYCLING STATUS / ALARM CHILLER SOLENOID VALVES OIL PUMP STARTER OIL HEATER ON/OFF CHILLED & CONDENSER WATER PUMP STARTERS VANE MOTOR SWITCH HIGH PRESSURE SAFETY LOCAL START / STOP SWITCH CHILLED & CONDENSER WATER FLOW SWITCHES OIL PUMP VSD CYCLING STATUS MOTOR CONTROLLER SHUTDOWN REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (CONTACT CLOSURE) VARIABLE ORIFICE CONTROL PRE-ROTATION VANE CONTROL LD09037 FORM 160.54-M1 (607) FIG.MOD “A” SOLID STATE STARTER APPLICATIONS 15 2 . 2 – OPTIVIEW CONTROL CENTER .RS-232 / RS-485 SERIAL DATA OIL PUMP VSD SPEED CONTROL CHILLER TEMPERATURES & PRESSURES +12 / -12 / +5 VDC CONDENSER REFRIGERANT LEVEL POWER SUPPLY + 24 VDC COMPRESSOR MOTOR CURRENT JOHNSON CONTROLS LAMP CONTROL ADDRESS TRIGGER BOARD STATUS SOLID STATE STARTER LOGIC BOARD HIGH SPEED THRUST BEARING POSITION REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (0-20mA.10VDC. 4-20mA / 0 . 4-20 mA / 0 . OPTIONAL STYLE F AND LATER CHILLERS WITH FLASH MEMORY CARD VERSION C.XXX OR LATER VERSIONS) OIL PUMP VSD CYCLING STATUS MOTOR CONTROLLER SHUTDOWN REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (CONTACT CLOSURE) VARIABLE ORIFICE CONTROL VARIABLE GEOMETRY DIFFUSER CONTROL HIGH SPEED THRUST BEARING LIMIT SWITCH ("P" COMPRESSORS AND STYLE "F" AND LATER CHILLERS WITH "G.10 VDC. 3 – OPTIVIEW CONTROL CENTER .01.MLM.54-M1 (607) JOHNSON CONTROLS FIG. 2-10VDC) LAMP BACKLIGHT INVERTER BOARD LAMP CONTROL DISPLAY DATA COMPRESSOR MOTOR CURRENT & LINE VOLTAGE SCR CONTROL SOLID STATE STARTER LOGIC/TRIGGER BOARD LIQUID CRYSTAL DISPLAY DISPLAY INTERFACE BOARD MICROBOARD SERIAL DATA ROW IN COLUMN OUT KEYPAD MOTOR CONTROLLER SHUTDOWN TO I/O BOARD I / O BOARD DIGITAL IN TRIAC OUT RELAY OUT COMPRESSOR MOTOR START VANE MOTOR SWITCH REMOTE CYCLING HIGH PRESSURE SAFETY LOCAL START / STOP SWITCH OIL PUMP STARTER OIL HEATER ON/OFF CHILLED & CONDENSER WATER PUMP STARTERS STATUS / ALARM CHILLER SOLENOID VALVES CHILLED & CONDENSER WATER FLOW SWITCHES (STYLE "E" AND EARLIER CHILLERS.08.16 RS-232 / RS-485 SERIAL DATA OIL PUMP VSD SPEED CONTROL CONDENSER REFRIGERANT LEVEL +12 / -12 / +5 VDC PRE-ROTATION VANES POSITION (VARIABLE GEOMETRY DIFFUSER W/O HOT GAS BYPASS) FACTORY-MOUNTED CHILLED AND CONDENSER LIQUID THERMAL-TYPE FLOW SENSORS (STYLE "F" AND LATER CHILLERS) CHILLER TEMPERATURES & PRESSURES HIGH SPEED THRUST BEARING POSITION (NOT APPLICABLE TO "P" COMPRESSORS AND STYLE "F" AND LATER CHILLERS WITH "G" OR "H5-8" COMPRESSORS) + 24 VDC POWER SUPPLY System Architecture REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (0-20mA.MOD “B” SOLID STATE STARTER APPLICATIONS LD09560 . Q" OR "H5-8" COMPRESSORS) PRE-ROTATION VANE CONTROL FORM 160. 54-M1 (607) FIG.MEDIUM VOLTAGE SOLID STATE STARTER APPLICATIONS 17 LD09560A 2 .PRE-ROTATION VANES POSITION (VARIABLE GEOMETRY DIFFUSER W/O HOT GAS BYPASS) RS-232 / RS-485 SERIAL DATA OIL PUMP VSD SPEED CONTROL FACTORY-MOUNTED CHILLED AND CONDENSER LIQUID THERMAL-TYPE FLOW SENSORS (STYLE "F" AND LATER CHILLERS) CHILLER TEMPERATURES & PRESSURES CONDENSER REFRIGERANT LEVEL +12 / -12 / +5 VDC JOHNSON CONTROLS HIGH SPEED THRUST BEARING POSITION (NOT APPLICABLE TO "P" COMPRESSORS AND STYLE "F" AND LATER CHILLERS WITH "G" OR "H5-8" COMPRESSORS) POWER SUPPLY REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (0-20mA. 2-10VDC) LAMP BACKLIGHT INVERTER BOARD LAMP CONTROL DISPLAY DATA LIQUID CRYSTAL DISPLAY DISPLAY INTERFACE BOARD MICROBOARD ROW IN COLUMN OUT RS-485 MODBUS SERIAL DATA MEDIUM VOLTAGE SOLID STATE STARTER KEYPAD MOTOR CONTROLLER SHUTDOWN TO I/O BOARD I / O BOARD DIGITAL IN TRIAC OUT RELAY OUT COMPRESSOR MOTOR START VANE MOTOR SWITCH REMOTE CYCLING HIGH PRESSURE SAFETY LOCAL START / STOP SWITCH OIL PUMP STARTER OIL HEATER ON/OFF CHILLED & CONDENSER WATER PUMP STARTERS STATUS / ALARM CHILLER SOLENOID VALVES CHILLED & CONDENSER WATER FLOW SWITCHES (STYLE "E" AND EARLIER CHILLERS.01. OPTIONAL STYLE F AND LATER CHILLERS WITH FLASH MEMORY CARD VERSION C.MLM.10 VDC. 4-20 mA / 0 . Q" OR "H5-8" COMPRESSORS) PRE-ROTATION VANE CONTROL FORM 160. 3A – OPTIVIEW CONTROL CENTER .08.XXX OR LATER VERSIONS) OIL PUMP VSD CYCLING STATUS MOTOR CONTROLLER SHUTDOWN REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (CONTACT CLOSURE) VARIABLE ORIFICE CONTROL VARIABLE GEOMETRY DIFFUSER CONTROL HIGH SPEED THRUST BEARING LIMIT SWITCH ("P" COMPRESSORS AND STYLE "F" AND LATER CHILLERS WITH "G. 4-20 mA / 0 . OPTIONAL STYLE F AND LATER CHILLERS WITH FLASH MEMORY CARD VERSION C. 2-10VDC) TX/RX LAMP YORK PROTOCOL SERIAL DATA BACKLIGHT INVERTER BOARD LAMP CONTROL DISPLAY DATA SERIAL DATA VSD LOGIC BOARD RX SERIAL DATA LIQUID CRYSTAL DISPLAY DISPLAY INTERFACE BOARD MICRO BOARD EVAP PRESSURE COND PRESSURE COMPRESSOR VSD ADAPTIVE CAPACITY CONTROL BOARD VSD FILTER BOARD VANE POSITION ROW IN COLUMN OUT KEYPAD I / O BOARD DIGITAL IN TRIAC OUT RELAY OUT COMPRESSOR MOTOR START VANE MOTOR SWITCH REMOTE CYCLING HIGH PRESSURE SAFETY LOCAL START / STOP SWITCH OIL PUMP STARTER OIL HEATER ON/OFF CHILLED & CONDENSER WATER PUMP STARTERS STATUS / ALARM CHILLER SOLENOID VALVES TO VARIABLE SPEED DRIVE (VSD) CHILLED & CONDENSER WATER FLOW SWITCHES (STYLE "E" AND EARLIER CHILLERS.01.COMPRESSOR MOTOR VARIABLE SPEED DRIVE (YORK PROPRIETARY SERIAL COMMUNICATIONS PROTOCOL) .54-M1 (607) JOHNSON CONTROLS FIG.MLM. 4 – OPTIVIEW CONTROL CENTER .18 RS-232 / RS-485 SERIAL DATA OIL PUMP VSD SPEED CONTROL CONDENSER REFRIGERANT LEVEL +12 / -12 / +5 VDC FACTORY-MOUNTED CHILLED AND CONDENSER LIQUID THERMAL-TYPE FLOW SENSORS (STYLE "F" AND LATER CHILLERS) CHILLER TEMPERATURES & PRESSURES HIGH SPEED THRUST BEARING POSITION (NOT APPLICABLE TO "P" COMPRESSORS AND STYLE "F" AND LATER CHILLERS WITH "G" AND "H5-8" COMPRESSORS) + 24 VDC POWER SUPPLY System Architecture REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (0-20mA. Q" AND "H5-8" COMPRESSORS) PRE-ROTATION VANE CONTROL LD09561A FORM 160.10 VDC.08.XXX OR LATER VERSIONS) OIL PUMP VSD CYCLING STATUS MOTOR CONTROLLER SHUTDOWN REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (CONTACT CLOSURE) VARIABLE ORIFICE CONTROL VARIABLE GEOMETRY DIFFUSER CONTROL HIGH SPEED THRUST BEARING LIMIT SWITCH ("P" COMPRESSORS AND STYLE "F" AND LATER CHILLERS WITH "G. 2-10VDC) TX/RX LAMP RS-485 MODBUS SERIAL DATA BACKLIGHT INVERTER BOARD LAMP CONTROL DISPLAY DATA SERIAL DATA VSD FILTER BOARD COMPRESSOR VSD LOGIC BOARD LIQUID CRYSTAL DISPLAY DISPLAY INTERFACE BOARD MICRO BOARD (ACC) ROW IN COLUMN OUT KEYPAD I / O BOARD DIGITAL IN TRIAC OUT RELAY OUT COMPRESSOR MOTOR START VANE MOTOR SWITCH REMOTE CYCLING HIGH PRESSURE SAFETY LOCAL START / STOP SWITCH OIL PUMP STARTER OIL HEATER ON/OFF CHILLED & CONDENSER WATER PUMP STARTERS STATUS / ALARM CHILLER SOLENOID VALVES CHILLED & CONDENSER WATER FLOW SWITCHES (STYLE "E" AND EARLIER CHILLERS. 4A – OPTIVIEW CONTROL CENTER . OPTIONAL STYLE F AND LATER CHILLERS WITH FLASH MEMORY CARD VERSION C. 4-20 mA / 0 .MLM. Q" AND "H5-8" COMPRESSORS) PRE-ROTATION VANE CONTROL LD09561B FORM 160.54-M1 (607) FIG.XXX OR LATER VERSIONS) OIL PUMP VSD CYCLING STATUS MOTOR CONTROLLER SHUTDOWN REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (CONTACT CLOSURE) VARIABLE ORIFICE CONTROL VARIABLE GEOMETRY DIFFUSER CONTROL HIGH SPEED THRUST BEARING LIMIT SWITCH ("P" COMPRESSORS AND STYLE "F" AND LATER CHILLERS WITH "G.COMPRESSOR MOTOR VARIABLE SPEED DRIVE (MODBUS SERIAL COMMUNICATIONS PROTOCOL) 19 2 .01.10 VDC.08.RS-232 / RS-485 SERIAL DATA OIL PUMP VSD SPEED CONTROL PRE-ROTATION VANES POSITION (VARIABLE GEOMETRY DIFFUSER W/O HOT GAS BYPASS) FACTORY-MOUNTED CHILLED AND CONDENSER LIQUID THERMAL-TYPE FLOW SENSORS (STYLE "F" AND LATER CHILLERS) +12 / -12 / +5 VDC CHILLER TEMPERATURES & PRESSURES CONDENSER REFRIGERANT LEVEL JOHNSON CONTROLS HIGH SPEED THRUST BEARING POSITION (NOT APPLICABLE TO "P" COMPRESSORS AND STYLE "F" AND LATER CHILLERS WITH "G" AND "H5-8" COMPRESSORS) POWER SUPPLY REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (0-20mA. 08.XXX OR LATER VERSIONS) OIL PUMP VSD CYCLING STATUS MOTOR CONTROLLER SHUTDOWN REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (CONTACT CLOSURE) VARIABLE ORIFICE CONTROL VARIABLE GEOMETRY DIFFUSER CONTROL HIGH SPEED THRUST BEARING LIMIT SWITCH ("P" COMPRESSORS AND STYLE "F" AND LATER CHILLERS WITH "G. OPTIONAL STYLE F AND LATER CHILLERS WITH FLASH MEMORY CARD VERSION C.MLM. 4-20 mA / 0 . 4B – OPTIVIEW CONTROL CENTER .20 RS-232 / RS-485 SERIAL DATA OIL PUMP VSD SPEED CONTROL CHILLER TEMPERATURES & PRESSURES CONDENSER REFRIGERANT LEVEL +12 / -12 / +5 VDC PRE-ROTATION VANES POSITION (VARIABLE GEOMETRY DIFFUSER W/O HOT GAS BYPASS) FACTORY-MOUNTED CHILLED AND CONDENSER LIQUID THERMAL-TYPE FLOW SENSORS (STYLE "F" AND LATER CHILLERS) HIGH SPEED THRUST BEARING POSITION (NOT APPLICABLE TO "P" COMPRESSORS AND STYLE "F" AND LATER CHILLERS WITH "G" AND "H5-8" COMPRESSORS) POWER SUPPLY System Architecture REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT SETPOINTS (0-20mA.10 VDC.01.COMPRESSOR MOTOR MEDIUM VOLTAGE VARIABLE SPEED DRIVE . Q" AND "H5-8" COMPRESSORS) PRE-ROTATION VANE CONTROL LD09561C FORM 160.54-M1 (607) JOHNSON CONTROLS FIG. 2-10VDC) LAMP RS-485 MODBUS SERIAL DATA BACKLIGHT INVERTER BOARD LAMP CONTROL DISPLAY INTERFACE BOARD DISPLAY DATA LIQUID CRYSTAL DISPLAY MEDIUM VOLTAGE VARIABLE SPEED DRIVE MICRO BOARD (ACC) ROW IN COLUMN OUT KEYPAD I / O BOARD DIGITAL IN TRIAC OUT RELAY OUT COMPRESSOR MOTOR START VANE MOTOR SWITCH REMOTE CYCLING HIGH PRESSURE SAFETY LOCAL START / STOP SWITCH OIL PUMP STARTER OIL HEATER ON/OFF CHILLED & CONDENSER WATER PUMP STARTERS STATUS / ALARM CHILLER SOLENOID VALVES CHILLED & CONDENSER WATER FLOW SWITCHES (STYLE "E" AND EARLIER CHILLERS. 6.06. Multi-Unit Sequence (TB4-9).75) (0.75) (0.xxx and later or C. 5. Remote Stop (ISN Serial Port). Operator initiated Soft Shutdown (Flash Memory Card version C. 1.54-M1 (607) TIMING DIAGRAM – CHILLERS EQUIPPED WITH FIXED SPEED OIL PUMP (STYLE C) DISPLAY MESSAGE "SYSTEM RUN" ENERGIZE (OPEN) HIGH SPEED THRUST SOLENOID "SYSTEM PRELUBE" ** "VANES CLOSING BEFORE SHUTDOWN" MAN. Remote/Local Cycling (TB4-13).FORM 160.22) (0. When any of these shutdowns are performed.17) (0.TIME DEPENDENT ON INITIAL VANE POSITION AUTO ZEROING DIFFERENTIAL OIL PRESSURE TRANSDUCERS 2 OIL PRESSURE CHECK "SYSTEM COASTDOWN" OIL PUMP ON "SYSTEM SHUTDOWN" FLOW BYPASS SWITCH 10 13 45 50 65 (0. 4.TIME DEPENDENT ON INITIAL VANE POSITION OIL PRESSURE CHECK "SYSTEM COASTDOWN" OIL PUMP ON "SYSTEM SHUTDOWN" FLOW BYPASS SWITCH 10 13 45 50 (0.MLM. VENT LINE & OIL RETURN SOLENOIDS ** VANES CLOSING . 3.04.22) (0. 5 – OPERATION SEQUENCE TIMING DIAGRAM (ELECTRO-MECHANICAL & SOLID STATE STARTER APPLICATIONS) JOHNSON CONTROLS 21 .83) 110 VANES VANES (1. the vanes are driven fully closed before the starter is de-energized.xxx) "SYSTEM PRELUBE" ** "VANES CLOSING BEFORE SHUTDOWN" MAN.17) (0. OIL PUMP DISABLED ENERGIZE (OPEN) OIL RETURN SOLENOID & LIQUID LINE SOLENOID (J COMPRESSOR ONLY) ** VANES CLOSING .5 MIN) 1800 (30) RESTART 0 START TIME IN SECONDS (MINUTES) LD06502 FIG. When the vane motor switch closes (or 210 seconds from start of vane closure have elapsed).83) START CLOSED TO CLOSE 150 SEC.83) (1. Internal Time Clock.5 MIN) 1800 (30) RESTART LD06501 0 START TIME IN SECONDS (MINUTES) TIMING DIAGRAM – CHILLERS EQUIPPED WITH VARIABLE SPEED OIL PUMP (STYLE D/E/F) DISPLAY MESSAGE "SYSTEM RUN" AUTO ZEROING DIFFERENTIAL OIL PRESSURE TRANSDUCERS **Only applicable to the following shutdowns. OIL PUMP DISABLED ENERGIZE (OPEN) LIQUID LINE.08) 110 VANES VANES (1. Remote Stop (TB4-8).02. Low Water Temperature. the starter is de-energized.01.MLM. (2. (2. 2.83) START CLOSED TO CLOSE 150 SEC. 54-M1 (607) TIMING DIAGRAM – CHILLERS EQUIPPED WITH FIXED SPEED OIL PUMP (STYLE C) DISPLAY MESSAGE "SYSTEM RUN" AUTO ZEROING DIFFERENTIAL OIL PRESSURE TRANSDUCERS ENERGIZE (OPEN) HIGH SPEED THRUST SOLENOID MAN.75) (0. 6 – OPERATION SEQUENCE TIMING DIAGRAM (COMPRESSOR MOTOR VARIABLE SPEED DRIVE APPLICATIONS) 22 JOHNSON CONTROLS .xxx and later or C.TIME DEPENDENT ON INITIAL VANE POSITION "SYSTEM PRELUBE" ** "VANES CLOSING BEFORE SHUTDOWN" OIL PRESSURE CHECK "SYSTEM COASTDOWN" OIL PUMP ON "SYSTEM SHUTDOWN" FLOW BYPASS SWITCH 10 13 45 50 65 (0. Remote Stop (TB4-8).5 MIN) 600 (10) RESTART RESTART (IF FIVE SUCCESSIVE (ONLY AFTER FIFTH RESTARTS HAVE NOT SUCCESSIVE RESTART) OCCURED) LD06503 0 START TIME IN SECONDS (MINUTES) TIMING DIAGRAM – DISPLAY MESSAGE "SYSTEM RUN" * The Liquid Line solenoid will only be energized during this period when the oil temperature reaches > 140°F. Multi-Unit Sequence (TB4-9).08) 110 VANES VANES (1.5 MIN) 600 (10) RESTART RESTART (IF FIVE SUCCESSIVE (ONLY AFTER FIFTH RESTARTS HAVE NOT SUCCESSIVE RESTART) OCCURED) LD06504 0 START TIME IN SECONDS (MINUTES) FIG.83) START CLOSED TO CLOSE 150 SEC.22) (0.22) (0.17) (0.MLM. OIL PUMP DISABLED ENERGIZE (OPEN) LIQUID LINE*. the starter is de-energized. Remote/Local Cycling (TB4-13). OIL PUMP DISABLED ENERGIZE (OPEN) OIL RETURN SOLENOID & LIQUID LINE SOLENOID (J COMPRESSORS ONLY) ** VANES CLOSING .17) (0.System Architecture FORM 160.83) START CLOSED TO CLOSE 150 SEC. 5. the vanes are driven fully closed before the starter is deenergized.01.xxx) OIL PRESSURE TRANSDUCERS "SYSTEM PRELUBE" ** "VANES CLOSING BEFORE SHUTDOWN" MAN. **Only applicable to the following shutdowns. VENT LINE & OIL RETURN SOLENOIDS ** VANES CLOSING .06. 6. 2. (2.TIME DEPENDENT ON INITIAL VANE POSITION OIL PRESSURE CHECK "SYSTEM COASTDOWN" OIL PUMP ON "SYSTEM SHUTDOWN" FLOW BYPASS SWITCH 10 13 45 50 (0. When the vane motor switch closes (or 210 seconds from start VARIABLE SPEED OIL PUMP of vane closure have elapsed).83) (1. 1. Low Water (STYLE D/E/F) Temperature.MLM. It will then be de-energized when the temprature is < 135°F. When any of these shutdowns CHILLERS EQUIPPED WITH are performed. Remote Stop (ISN Serial Port).75) (0. 4.04. Internal Time Clock.83) 110 VANES VANES (1. Operator initiated Soft Shutdown (Flash Memory Card AUTO ZEROING DIFFERENTIAL version C.02. (2. 3. Language selection is performed on the USER Screen following instructions in Operations Manual 160. 01. It must be placed in the “Write Enabled” position in order to allow successful Boot-up. A write protect switch is located on the left edge of the card as shown in Fig. Not all languages are available.12) Microboard 031-01730-000 is supplied in new production chillers until January 2004. and supporting circuits for the Micro. It connects to the Board via an Elastomeric connector that is a silicon rubber strip embedded with silver conductors. 2 = Supplied in new CE (European Community) OptiView Control Centers but can be retrofit to any OptiView Con trol Center. The card is installed by inserting it into the socket/holder and pressing on the surface of the Card until it snaps into place. 2=CE) Controls Revision Level (00.nn. The difference between them is the different languages that can be displayed on the Display Screens. 1=NEMA 1-4. the initialization (boot-up) process will not complete and the chiller will not run! Refer to Renewal Parts List 160. etc. This is a type of non-volatile memory that can be read from or written to. IMPORTANT! – Not all versions of Flash Memory Cards are compatible with revision “E” (and later) Microboards or all BIOS Eproms. 04=YK (“P” compressors before 8/02). the display and peripheral devices. The Program is a set of instructions to control the chiller. The version of the Memory card is an alpha-numeric code that represents the application and revision level.FORM 160. It is stored in a memory device called a flash memory card. Fig. Refer to Renewal Parts List 160.54-RP1 and “Service Replacement” paragraph in this section. The version is printed on a label adhered to the memory card’s surface. The card is located in socket location U46 (Ref. microprocessor (Micro). If an incompatible version is used.54-O1. The Memory card is a replaceable component. 3 There are two Flash Memory Cards available. 1 = Supplied in new NEMA 1-4 OptiView Control Centers but can be retrofit to any OptiView Control Center. The Microboard contains the operating software (Program). JOHNSON CONTROLS 23 .02=YT. With the exception of a write/read sequence that occurs during the Boot-up process explained below. 8. It also contains the Safety and Cycling shutdown thresholds (non changeable) and Display messages and screens.54-M1 (607) SECTION 3 MICROBOARD 031-01730-000 (REFER TO FIG. etc.MLM.54-RP1 for list of available Flash Memory Cards and display languages.nnn Language Package Revision Level (00. 03=YS. The Card can be removed from its socket by using the thumb to press down on the socket’s plastic tension spring. The version code is as follows: C. 7). but requires the locations to be erased before they are written to.) Chiller Type (01=YK (all compressors after 8/02). 7 .) Language Package* (0=English only. 01.54-RP1 for available languages. 05=YR) MaxE™ Chiller Commercial Chiller * Refer to YORK Renewal Parts List 160.54-RP1.nn. Refer to YORK Renewal Parts List Form 160. this device is used primarily as read-only in this application. The Program assembles data in the correct format for transmission through the Serial Data Ports to peripheral devices. retrieves the display from the Program and displays it. the Micro reads the Analog and Digital Inputs to determine the operating conditions and controls Digital Outputs based upon these inputs. During the boot-up process. On the Microboard. 256K or 512K capacity. Similarly.Microboard FORM 160. a Service Information Bulletin is issued that describes the new features.54RP1. It has been superceded by BIOS eprom 031-01796-002. The Micro initiates a Safety shutdown and displays WATCHDOG – SOFTWARE REBOOT message. If the Program has latched-up. are located at the rear of this manual. configure and start operation of certain Microboard components before the main program (stored in the Flash Memory Card) is started. 24 JOHNSON CONTROLS . Depending upon the application. a shutdown is performed and the appropriate message is retrieved from the Program and displayed on the Liquid Crystal Display. The Micro controls the chiller by reading and executing the Program instructions in a sequence determined by the Program. If a step is unsuccessful. MLM. Just prior to the supply decreasing to a level where the Micro and supporting circuits can no longer operate. This eprom is no longer used. Refer to YORK Renewal Parts List Form 160. Increments 01. The EPROM version is an alpha-numeric code that represents the application and revision level. Each time they are revised. This white display screen also lists the BIOS EPROM Version. These inputs are compared to stored thresholds to determine if a Safety or Cycling shutdown is required. The Watchdog circuit also assures that all the Program instructions are being performed and that the Program has not latched-up. IMPORTANT! Eprom 031-01796-002 is not compatible with all versions of Flash Memory Cards. when power is first applied after a power failure.Pass) flashes to indicate the step was successful. There are 5 steps to the boot-up process. the Micro interprets the request. As operating conditions require. Refer to Service Replacement paragraphs in this section. This EPROM is replaceable. the revision level of the affected portion of the program (controls or language) increments. the Micro executes the instructions in the BIOS EPROM program to initialize. status messages are retrieved and displayed.Fail) flashes and the Boot-up process terminates. Also. XX. If a threshold has been exceeded. When an operator presses a key to request a display. The version is printed on a label adhered to the EPROM’s surface. followed by a Pass/Fail status of the step. Revision level. enhancements and program corrections. 00. there is a visual indication as each step is performed. Under Program control. The Program also instructs the Micro to respond to requests from peripheral devices for serial data transmissions. It is located in socket location U45. The Watchdog circuit monitors the +5VDC supply from the external Power Supply to determine when a power failure is occurring. Each time they are revised. it maintains the Micro in a reset state until the +5VDC has returned to a sufficient level. a red LED (CR18 . bypassing important safety thresholds. a green LED (CR17 . shutting down the chiller and retrieving the Power Failure message from the Program and sending it to the Display Controller for display. The execution and Pass/Fail status of steps 3 through 5 are displayed on a white Keypad Display Screen as they are performed. Those bulletins that have been issued to date. When power is applied to the OptiView Control Center following a power failure. below is listed the LED activity associated with each step. Microboard Program Jumper JP38 must be positioned according to the actual EPROM installed. 02 etc. The version code is as follows: C. The Keypad is read as Digital Inputs. The BIOS EPROM (basic input/output system erasable programmable read only memory) is a memory device that contains the bootstrap or power-up program. The steps of the Boot-up process are as follows. the Microboard could be equipped with an EPROM that has either 128K. YM Chiller BIOS EPROM MAXE™ Chiller Commercial Chiller Early vintage chillers were equipped with BIOS eprom 031-01796-001. The Micro responds by de-energizing the run digital output through the FPGA.54-M1 (607) Flash Memory Cards are revised to add new features. it applies a reset signal to the Micro. Refer to Table 1 (Program Jumpers). STEP 1 2 3 4 5 PASS Green on. The Micro stores the setpoints programmed by the Operator or Service Technician. LED INDICATORS When all steps have been completed.Fail) and green (CR17 . in this device. There are 4 rows and 8 columns. First initiate table complete. Keypad Interface The Keypad is read via J18. the day of week. If they are different. it is pass. as long as power is applied. The position of some jumpers can be determined by the Service Technician to meet the desired operation. it is considered pass. History Data and other data that requires preservation. If both values are the same. Red off Green flash once Green flash once Green flash once Green flash once FAIL Watchdog will initiate a re-boot. Registers in the Micro are configured to allow it to perform basic memory read/write functions. time of day and calendar date time-keeping are done here. type or style of components and thus are determined by the YORK factory. If these values are the same. it is considered fail. 5. 3. FPGA configuration. The Program Switches are miniature switches that are placed in either the ON or OFF position.54-RP1. Three red flashes repeating Boot-up process halts. It is located in socket location U52. A location in the Flash Memory Card that contains a code identifying the Manufacturer is compared to other locations that contain the manufacturer’s name. 2. One red flash repeating Boot-up process halts. then the Boot-up process begins in the following sequence. Mini-card checksum. Test data is written to and then read from several memory locations to verify BRAM operation.54-M1 (607) BOOT-UP STEP AND DESCRIPTION 1. it is fail. BRAM quick test. If the calculated value is different than the stored value.Pass) LEDs simultaneously illuminate for 1 second.FORM 160. Others are wire bridges that are either cut or left in place. Program Jumpers/Program Switches The Program Jumpers (Table 1) and Program Switches (Table 2) are used to alter the program operation or configure the Microboard hardware for specific operation. the LED’s will then illuminate or extinguish. Refer to YORK Renewal Parts List Form 160. Refer to Table 3 and 4 for the function of each jumper and switch. The Keypad is a matrix of conductors arranged in rows and columns (ref fig 32 and 33). Also. both the red (CR18 . It is a replaceable part. Boot-up process halts. The Flash Memory Card checksum is calculated and compared to the checksum value that is stored in the Card at the time the Card was initially programmed at the YORK factory. Two red flashes repeating Boot-up process halts. Some jumpers are plastic sleeves with metal inserts that are inserted over 2-prong or 3-prong conductors. The Field Programmable Gate Array (FPGA) is configured to process Digital Inputs and Outputs. Mini-card signature test. 4. Others must be positioned according to the requirements of the size. Four red flashes repeating JOHNSON CONTROLS 25 . This allows the Program and Microboard to be universal for all standard applications. according to the settings of Microboard Program Switches 7 and 8 as follows: Green (CR17) Program SW 7 set to 50 Hz – extinguishes 60 Hz – illuminates Red (CR18) Program SW 8 set to Standard – illuminates Enhanced – extinguishes The BRAM (battery backed random access memory) is a memory device that contains a battery that preserves the data during power failures. When a key 3 When power is applied to the OptiView Control Center. the CM-2 board returns a 0vdc value. The micro determines which board.54-M1 (607) is pressed. J2-7 is TX data to the MicroGateway. temperatures and status from the microboard. A value >0. Since channels 0 through 6 are grounded. J15-1 is TX data to the drive and J15-2 is RX data from the drive. the key corresponding to that coordinate (row. The function of each is in the table below.4vdc indicates the starter is an “A” style Solid State Starter and the micro reads channels 1 through 7. whereupon the printer asserts its Busy signal. It holds it for retrieval by third-party devices. the drive is interfaced to the Microboard via the Opto-Coupled COM 5 serial data port (J15). The microboard sends data to the printer at the selected baud rate until the printer buffer becomes full. Channels 2 through 4 are analog voltages that represent phase A. The highest phase is Channels 5 through 7 are analog voltages that represent phase A. channel 0 indicates the starter size (model) and voltmeter range (300Vac or 600Vac). The MicroGateway polls system pressures. Other printer setup is performed on the PRINTER Screen. A 0-5vdc analog value is returned from each channel.4vdc. Channel 1 is a hardware generated 100% FLA (prevents pre-rotation vanes from further opening) or 104% FLA (closes prerotation vanes until motor current is <102%) current limit override command that overrides normal Prorotation Vanes control. The micro sequentially and continually reads channels 0 through 7. Signal levels are standard RS-232. B and C Line Voltage. creating continuity between the row conductor and the column conductor. If the value is <0. J2-6 is RX data from the Microgateway.Microboard FORM 160. B. Refer to the appropriate section of this book for detailed explanation of each board. the conductors are pressed together at that point. it indicates the starter is an Electro-mechanical (EM) starter and the micro then reads channel 7 to retrieve the peak motor current value. Signal levels are standard RS-232. J2-4 is TX data to the printer. B. The Baud.41vdc to +5vdc. JOHNSON CONTROLS 26 . by the value returned from channel 0. Both boards contain an 8 channel multiplexer. It reads each channel by applying a 3-bit binary address to the multiplexer. Refer to SECTION 8 of this manual for details of the Keypad. CM-2 Board or Style A Solid State Starter Interface The microboard retrieves certain operating parameters (via J10) from the compressor motor starter control board (CM-2 Current Board for Electromechanical starter or Style “A” Solid State Starter Logic Board). The serial data is represented by +5vdc and 0vdc logic levels. J2-2 is the DSR (Data Set Ready or busy) signal from the printer. A 2-4 motor current phase A. Each printer must be setup/configured to operate properly with the microboard. The micro reads the entire keypad by repeating this routine beginning with row 1 and ending with row 4. The data for each channel is shown below: The addresses and associated data are shown below: Mod “A” Solid State Starter Logic Board Address Data starter model / 0 voltmeter range 1 current limit command phase C. The Solid State Starter Logic Board returns a value >0. The keypad is read by applying a logic low to a row while leaving +5vdc pullup on all other rows. Parity and Stop Bits must be programmed on the Comms Screen. and therefore which starter is present. The entire keypad is continually read while the control center is powered.55O1 for details of available printers and printer setup instructions. The micro then reads the 8 columns. MicroGateway Interface An optional Microgateway printed circuit board can be connected to the COM 4B RS-232 serial data port (J2). Data Bits. Refer to YORK manual 160. The microboard suspends data transmission until the printer can accept more data. B and C motor current. C 5-7 line voltage CM-2 Board Address Data 0 thru 6 Gnd 7 Peak Motor Current Style B Solid State Starter or Variable Speed Drive Interface If equipped with either of these drives. If any column has a logic low on it. Printer Interface An optional Printer can be connected to COM1 RS232 serial data port (J2). In the Solid State Starter. Refer to SECTION 15 of this manual. column) is being pressed. Refer to SECTION 11 (Solid State Starter) and SECTION 12 (VSD) for details of this interface. are input from Thermistors.08. the LED display moves to the right. Formulas and graphs are included to calculate the expected transducer output voltage for a given pressure input. They are de-energized by opening the ground path. The contacts of these relays switch 115Vac to system relays and solenoids. As the flow rate increases above the setpoint. When a flow rate less than the setpoint is sensed. The 6 LED’s to the right of the amber reflect flow rates above the setpoint. It turns it off by applying a logic high (>4vdc). Software version C. the output could be unstable. The outputs that control the chilled liquid pump and compressor motor starter have anti-chatter (anti-recycle) timers associated with them.)/second. The output that controls relay K13 is not allowed to change at a rate greater than once every 20 seconds. JOHNSON CONTROLS Style F (and later) chillers are supplied with factorymounted Flow Sensors on the evaporator and condenser (Software version C. is only affected by changes in liquid temperature. Then connect a voltmeter from Microboard J7-14 (evaporator) or J7-16 (condenser) to microboard TP1(ground). resulting in no conduction through the load resistor.xxx (and later) is required for this feature. in the form of analog DC voltages. A 115Vac input to the I/O board is converted to a logic low (<1Vdc). Flowing liquid carries heat away from the heated sensor tip. The microboard controls Actuator motors via Triacs on the I/O Board.FORM 160. The higher the flow rate. There are 11 LED’s on the sensor that reflect the measured flow rate.01.5K ohm microboard load resistor to the +5vdc. The I/O Board contains +12Vdc relays that isolate the microboard low voltage circuits from the 115Vac device coils. To determine the state of the solid state relay. The operating principle of the sensor is thermal conductivity. Lower flow rates remove less heat from the tip allowing a higher tip temperature. Included are tables to convert the expected output voltage for any temperature applied to the thermistor. When the setpoint (or greater) flow rate is sensed. located higher in the tip in a non-heated area. The microboard turns on the Triac by applying a logic low (<1Vdc) to the Triac driver on the I/O Board. Refer to SECTION 16 of this manual. Digital Outputs The microboard controls 115vac relays and solenoids via the I/O Board (via J19). lowering its temperature.xxx (and 3 27 . This applies <1Vdc to the microboard input. there is a thermal warm-up period of up to 20 seconds.MLM. The output that controls relay K0 is not allowed to change at a rate greater than once every 10 seconds. the solid state relay output is turned on causing it to conduct current through the 7. A second thermistor.54-M1 (607) Digital Inputs The I/O Board converts the 115Vac inputs to logic level inputs for the microboard at J19. The sensor operates from a 24Vac power source and has a solid state relay output. Each actuator has an open winding and a close winding. Refer to SECTION 17 of this manual. A 0Vac input to the I/O Board is converted to a logic high (>4Vdc).6 ft. are input from Pressure Transducers. The temperature of the heated sensor tip is sensed by a thermistor located in the tip. System temperatures. The center located amber LED illuminates at the setpoint flow rate (and above). Each winding is controlled by a Triac. Refer to SECTION 4 of this manual for details of the I/O Board. After power is applied. one side of the solid state relay output (pin 2) is connected to the microboard +5Vdc and the other side (pin 4) is Connected to a microboard analog input (refer to fig 12). Current flowing through a winding causes the actuator to rotate in the respective direction. Analog Inputs System pressures. in the form of analog DC voltages.01. The lower the flow. The sensor is vendorcalibrated to turn on” its output at a flow rate of 20cm(0. The 4 LED’s to the left of the amber reflect flow rates below the setpoint. Solid state switching devices are used to control the relays. It uses the cooling effect of a flowing liquid to sense flow. The Triac is turned on to allow current to flow through a winding. This applies >+4Vdc to the microboard input evaporator J7-14. the solid state relay output is turned off. condenser J7-16). The microboard energizes the +12Vdc relays by applying a ground to the coil input.MLM. Refer to SECTION 4 of this manual for details of the I/O Board. This is the setpoint. the LED display moves to the left. the greater the differential between thermistors. During this time.07. On each sensor. As the flow rate decreases from the setpoint. These are electronic thermaltype sensors. first confirm that +5vdc is present at pin 2 of the flow sensor. the lower the tip temperature and therefore a lower differential between thermistors. The temperatures sensed by the thermistors are compared. 5 to +5vdc logic levels. Not used COM3 (J12) – RS-485. The pixels are driven sequentially from left to right. Optional I/O. COM5 logic levels are 0vdc and +5vdc. The greater the binary value. Serial Data Ports The Microboard is equipped with 5 serial data ports (ref fig 11). the drive signals are accompanied by a clock and horizontal and vertical sync signals. Each pixel consists of 3 windows. The LED’s and their functions are as follows: • CR2 RX1 – COM1 serial port receive data.3vdc. Also. 6 for each of the 3 colors. the more light is permitted to pass. 28 JOHNSON CONTROLS . • CR12 TX4 – COM4 serial port transmit data. VSD Adaptive Capacity Control Board or Style B Solid State Starter. they cannot be used simultaneously. the Chiller Style/Compressor Setpoint and Flow Switch Setpoint must be set appropriately (refer to SECTION 23). The data to form these screens is output from J5. a label attached to the display mounting plate lists the required program jumper configuration for that display. Program Jumpers JP2 through JP5 and JP7 and JP8 must be configured to provide the required supply and control voltages to the display and backlight control. A green RX LED illuminates as data is received from another device. • CR16 TX2 – COM2 serial port transmit data. The position of program jumper JP2 determines whether the supply voltage is +5vdc or +3. Refer to Diagnostics SECTION 23 of this manual. To coordinate the drive signals and assure the pixels in each row are driven from left to right and the columns are driven from top to bottom. • CR10 RX5 – COM5 serial port receive data. • CR11 RX2 – COM2 serial port receive data. The position of program jumper JP27 determines which port can be used. Printer COM2 (J13) – RS-232.200 the display pixels arranged in a matrix of 640 columns x 480 rows. The drive signal for each pixel is an 18 bit binary word. • CR13 RX4 – COM4 serial port receive data. green and blue. This data is in the form of red. the program in the BIOS eprom reads wire jumpers PID0 through PID3 on the Display Interface Board to determine the manufacturer of the display. Each port is equipped with two LED’s. The RS-232 voltages are industry standard +5 to +25vdc and -5vdc to -25vdc logic levels.Microboard FORM 160. To assure the program reads the correct input for the flow sensor type present. COM4B – RS-232 Microgateway. Each port is dedicated for a specific function as follows: a. COM1 (J2) – RS-232. • CR15 TX3 – COM3 serial port transmit data. A diagnostic test can be performed on each serial port to confirm proper operation. COM4 (4A-J11). • CR9 TX5 – COM5 serial port transmit data. The RS-485 voltages are industry standard 0vdc and +1. d. red.54-M1 (607) later) allows either the Thermal-Type sensors connected to the Microboard analog inputs or the Paddle-Type sensor connected to the I/O Board digital inputs (refer to the Flow Switch Setpoint in SECTION 23). is permitted to pass to the front of the display. (4B-J2) – This port is actually two ports. During the boot-up. A red TX LED illuminates as data is transmitted to or requested from another device. through which a variable amount of light from the Display Backlight. Display Interface The graphic screens displayed on the liquid Crystal Display are created from the program downloaded from the Program Card and stored in the flash memory chip. Table 3 lists the required program jumper configuration for each display. Each display manufacturer requires a slightly different control. However. COM5 (J15) – Opto-coupled transmit/receive. c. green and blue light allowed to pass. beginning with the top row. • CR14 RX3 – COM3 serial port receive data. Different display manufacturers require different supply and control voltages for their displays and backlights. • CR3 TX1 – COM1 serial port transmit data. b. (refer to table 3). The overall pixel color is a result of the gradient of red. COM4A – RS485 Not used. The drive signals determine the amount of light permitted to pass through each window. The program in the BIOS eprom configures the microboard for correct operation for the actual display installed. e. green and blue drive signals applied to each of the 303. 2-10vdc 0-20Ma or 4-20Ma form. The position of Program Jumper JP3 determines the transition that will occur when the Microboard outputs the Backlight Enable signal. Program Jumpers JP7 and JP8 must be configured to enable the appropriate technique. The +5VDC (fused by 5 Amp fuse F1 on rev “E” and later boards) is input to a +3. The inputs at J22 are configured with Program Jumpers JP23 and JP24 to accept these inputs in either 0-10vdc. these voltages can be monitored at Test Posts TP1 through TP6. CM-2 module. the resistance between J6-6 and J6-7 varies from 0 ohms (0% brightness) to 10K ohms (100% brightness). Refer to Display SECTION 5. the lamp is driven back to full (100%) brightness. depending on position of Program Jumper JP5) to high voltage AC (500 to 1500Vac). Refer to SECTION 3A of this manual. In some displays. the output is a variable resistance.54-RP1. It converts low voltage DC via J6-1 (+12vdc or +5Vdc. The Lamp Dimmer is an integrated circuit that is the electrical equivalent of a 10K ohm potentiometer with 100 positions or steps (ref fig 10A). the microboard controls the backlight brightness via the Lamp Dimmer circuit output at J6-7. JOHNSON CONTROLS Remote Setpoints Remote Leaving Chilled Liquid temperature and Current Limit setpoints can be input via the RS232 Microgateway interface at J2 or directly to the Microboard at J22 (ref fig 12). The output is a 3. If Program Jumpers JP7 and JP8 are installed. SERVICE REPLACEMENT: Replacement part number 331-02430-601 is supplied as service replacement for microboard 031-01730-000.0Vdc (0% brightness). the graphics are still visible. the brightness is driven to 50% after 10 minutes of Keypad inactivity. +5VDC and Ground. At this brightness level. The output of this regulator powers only the Analog circuits. Refer to Table 3 for Program Jumper configurations and SECTION 18 of this manual for details of the Remote Setpoints. A/D converter. The +12VDC (fused by 5 Amp fuse F2 on rev “E” and later boards) is input to a 5VDC regulator. Some display manufacturers require a variable voltage to vary the brightness. Transducers and Thermistors. the voltage between J6-7 and J6-8 can be varied from 0Vdc (100% brightness) to 5. The Lamp Dimmer controls the position of the potentiometer. others turn o when it transitions from high to low. +12VDC. POWER SUPPLY The Microboard receives 3 supply voltages (Microboard J1) from the Power Supply. Replacement part 331-01730-601 (microboard 031-01730-000) is no longer available.FORM 160.3VDC regulator. 3 29 . When Keypad activity is detected (a key is pressed). -12VDC. If configured for variable resistance. This high voltage AC is applied to the lamp to cause it to illuminate. The Display Backlight is the light source for the display. the backlight turns on when this signal transitions from low to high. The lamp Dimmer varies the brightness of the backlight by applying a variable voltage (0-5. This includes the MUX. Mod “A” Solid State Starter Logic Board. In order to extend the life of the Backlight lamp. The Backlight is turned on and off with the “Backlight Enable” signal (J6-5). The position of Program Jumper JP4 determines whether this is a +12Vdc or +5vdc signal. Under program control. If configured for variable voltage output. The +12VDC and +5VDC are input to Voltage Regulators to derive other regulated voltages. JP3 must be positioned according to the display manufacturer’s requirement. As depicted on the Microboard figure. 6 and 7 of this manual for details of the display interface.3VDC regulated voltage. The -12VDC and +12VDC are used directly by various circuits. others require a variable resistance. The Backlight Inverter Board provides a high voltage AC power source for the lamp.54-M1 (607) The microboard controls the Display Backlight via J6. if both are removed. and Replacement Parts List 160.0vdc) or a variable resistance (0-10K ohms) to the Backlight Inverter Board. the lamp Dimmer output is a variable voltage. The Lamp Dimmer outputs “Brightness Control Wiper” (J6-7) to the Backlight Inverter Board. 54-M1 (607) LD07776 FIG.Microboard FORM 160. 7 – MICROBOARD 031-01730-000 30 JOHNSON CONTROLS . 8 – FLASH MEMORY CARD JOHNSON CONTROLS 31 .54-M1 (607) MEMORY CARD SOCKET ELASTOMERIC CONNECTOR MEMORY CARD TOP SURFACE AUGAT R AUGAT R 3 LD06855 TOP SURFACE PRESS DOWN TO RELEASE CARD LD04047 MEMORY CARD RETAINER CLIP MEMORY CARD .FORM 160.SIDE VIEW WRITE ENABLED WRITE DISABLED LD04050 FIG.BOTTOM SURFACE WRITE PROTECT SWITCH (OPTIONAL) (MUST BE IN "ENABLED POSITION") PAD 60 PAD 31 PAD 30 PAD 1 VCC 3V/5V KEY ALIGNMENT NOTCH CINS GND LD04049 MEMORY CARD . Microboard FORM 160.54-M1 (607) TP4 Y *F2 + 12VDC + 12VDC + 5VDC (ANALOG) FROM POWER SUPPLY + 5VDC 5A VOLTAGE REG TP3 Y *F1 5A VOLTAGE REG + 5VDC (DIGITAL) TP2 Y TP1 + 3.3VDC *REV "E" and later boards only. GND -12 VDC Y LD09564 FIG. 9 – MICROBOARD (031-01730-000) POWER SUPPLY TEST POINTS 32 JOHNSON CONTROLS . SHARP LQ10D367.Factory mounted thermal-type flow sensor – evaporator.Display backlight enable signal logic levels.xxx and later). Pins 2-3: +12VDC or +5VDC as determined by position of JP4.Watchdog protection enabled OFF . SHARP LQ10D367/368. JP22 .JP20 . SHARP LQ10D367/368 and LQ10D421. Not Used JP7. Pins 1-2: +12VDC.MLM. OUT: Not Used.07.FPM: (fast page mode) type. Style F and later chillers only (Applies to Flash Memory Card version C. 3 OUT . Determines the power supply voltage applied to the display. LQ10D421 and LG Semicon LP104V2-W displays.Watchdog enable/disable.Display power and logic levels. Determines whether the display brightness is controlled by a variable voltage or variable resistance.01. Jumper must be positioned according to type of RAM used for display memory devices (U25 & U27). JP3 .Not Used JP21 . NEC NL6448AC33-24 and LG Semicon LP104V2-W displays.EDO: (extended data out) type.07. Not Used JP6 . OUT . Pins 2-3: +5VDC/0VDC SHARP LQ10D367/368 NEC NL6448AC33-24 and LG Semicon LP104V2-W displays. xxx and later). Never disable the watchdog protection. OUT:Variable resistance. The position of this jumper. NEC NL6448AC33-24 display. Severe compressor or chiller damage could result. in conjunction with Program switch SW 1 position 12 enables or disables the program Watchdog protection. The ability to disable the watchdog protection is provided for factory testing only!!! IN Watchdog protection enabled. JP9 .0VDC). JP8 . Pins 2-3: Style F and later chillers with factory mounted condenser thermal-type flow sensor. JP5 .Display brightness control technique.Watchdog protection disabled JP2 . Determines the power supply voltage applied to the Display Backlight Inverter Board.Factory mounted thermal-type flow sensor – condenser. Jumper must be positioned according to the voltage level required to turn on the Display Backlight.Permits Program switch SW1 position 12 to enable or disable the program Watchdog protection as follows: Position 12 ON .FORM 160.Display backlight power. JP4 . IN: Variable voltage (0-5. IN . Pins 1-2: +5VDC SHARP LQ10D367/368 and LQ10D421 displays.01. Pins 1-2: Not Used. OUT: Not Used.54-M1 (607) TABLE 1 MICROBOARD 031-01730-000 PROGRAM JUMPERS MICROBOARD PROGRAM JUMPERS JP1 . Pins 1-2: +12VDC/0VDC SHARP LQ10D421 display. Pins 2-3: +3.Display memory type.3VDC NEC NL6448ACCC33-24 and LG Semicon LP104V2-W displays. Style F and later chillers only (applies to Flash Memory Card version C. Determines the logic levels of the Backlight enable signal. Pins 1-2: Not Used. Jumper should be IN.Display backlight enable signal level polarity. JOHNSON CONTROLS 33 .MLM. Pins 2-3: +5VDC. Pins 1-2: 0VDC SHARP LQ10D421 Display. Pins 2-3: Style F and later chillers with factory mounted evaporator thermal-type flow sensor. NEC NL6448AC33-24 and LG Semicon LP104V2-W displays. Assigns selected PC-104 DMA request to PIRQ1 on the microprocessor. Allows an RS-485 connection to Microboard J11 for MultiUnit Communications. 0-20mA or 4-20mA. 2-10VDC. Configures analog input for 0-10VDC.Not Used JP27 . JP36 . 34 JP31 . Pins 1-2: Enables port 4A. Steam Turbine applications. DMA request selections are silk screened on the Microboard adjacent to the program jumper. IN: 150 seconds. Electric motor drive applications.Refrigerant type. OUT: Allows a 0-10VDC or 2-10VDC input on J22-3 Pins 1-2: Allows a 0-20mA or 4-20mA input on J22-4 Pins 2-3: Not Used JP25. Assigns selected PC-104 interrupt request to PIRQ7 on the microprocessor. Not used on YK Chiller applications. Not used on YK chiller applications.Steam Turbine or Electric Motor drive . JP34 .54-M1 (607) JP23 . Not used on YK Chiller applications. Pins 2-3: Enables port 4B. Future modem application.COM 4 serial communications port. Jumper must be positioned according to whether the chiller is cooling water or a brine solution. Assigns selected PC-104 DMA request to PIRQ0 on the microprocessor.Determines the “Coastdown” duration (Oil Pump run duration after shutdown) and whether the “Motor Controller-Loss of Current” Program check is performed while the chiller is running. Configures analog input for 0-10VDC. Not used on YK Chiller applications. Assigns selected PC-104 DMA acknowledge to PDACK1 on the microprocessor. Not used on YK Chiller applications. 0-20mA or 4-20mA.PC-104 Port DMA acknowledge assignment. 2-10VDC. Jumper must be positioned according to the refrigerant type installed in the chiller.PC-104 Port DMA acknowledge assignment. Interrupt request selections are silk screened on the Microboard adjacent to the program jumper. Leaving chilled liquid temperature setpoint range 38ºF (36ºF if Smart Freeze is enabled) to 70ºF. Assigns selected PC-104 DMA acknowledge to PDACK0 on the microprocessor.Remote Current Limit Setpoint (J22) type. DMA acknowledge selections are silk screened on the Microboard adjacent to the program jumper. JP30 . Assigns selected PC-104 interrupt request to PIRQ6 on the microprocessor. OUT: Brine. Leaving chilled liquid temperature setpoint range 10ºF to 70ºF.PC-104 Port DMA assignment.PC-104 Port interrupt assignment. JP28 . JP33 .Remote Leaving Chilled Liquid Temp Setpoint (J22) type. JP29 . DMA request selections are silk screened on the Microboard adjacent to the program jumper. OUT: Allows a 0-10VDC or 2-10VDC input on J22-1 Pins 1-2: Allows a 0-20mA or 4-20mA input on J22-2 Pins 2-3: Not Used JP24 . OUT: 15 minutes.PC-104 Port interrupt assignment. IN: Water. Configures COM 4 port to be either RS-485 for Multi-Unit Communications (COM 4A) or RS-232 for GPIC board (COM4B). IN: R22 OUT: R134a JP35 . DMA acknowledge selections are silk screened on the Microboard adjacent to the program jumper.Microboard FORM 160. Allows an RS-232 connection to Microboard J2 for MicroGateway communications.Water/Brine application. JP26 . JOHNSON CONTROLS . JP32 . “Motor controller-Loss of Current” check is not performed.PC-104 Port DMA assignment. Interrupt request selections are silk screened on the Microboard adjacent to the program jumper. JP39 .New style with integrated Logic/Trigger Board mounted Starter cabinet. Q” and “H5-8” compressors). Jumper must be positioned according to size of U45. JP42 . Configured at the time the board is manufactured and should not require field configuration. It is not a shunt jumper.Compressor Motor starter type.Old style with Logic Board mounted in OptiView Control Center. part number 025-30961-000 or 025-35900-000. Pins 1-2: Type 65548 Pins 2-3: Type 65550 JP41. Configured at the time the board is manufactured and should not require field configuration.54-M1 (607) JP37 .High Speed Thrust Bearing Proximity Probe type (Not applicable to “P” compressors and style F and later chillers with “G. JP44 – Display Controller (U29) type (rev “E” and later boards only).BIOS EPROM U45 size. this jumper must be IN. Note: On Variable speed Drive applications. IN: Not Used OUT: +24VDC Probe. IN: Mod “A” . Refer to Section 13 to determine which Probe is present. OUT: Mod “B” . IN: 256K OUT: 64K or 128K. JP38 . Should be OUT for YK chiller applications.Display Controller (U29) type (rev “E” and later boards only). JP43. JP44 .Solid State Starter style. JP40 .FORM 160. Pins 1-2: Type 65548 Pins 2-3: Type 65550 3 JOHNSON CONTROLS 35 . Must be positioned according to the Display Controller type installed on Microboard. Must be positioned according to the Display Controller type installed on Microboard. Jumper is a 10 Ohm resistor that is soldered to board.Not Used JP43. IN: Electro-Mechanical or Solid State Starter OUT: Variable Speed Drive Program Jumper JP39 must be IN for this application. 54-M1 (607) TABLE 2 MICROBOARD 031-01730-000 PROGRAM SWITCHES SW1 12- Not Used Oil Pump style .Chiller cannot be started at intervals shorter than once every 30 minutes. 7Compressor Motor Variable Speed Drive .Configures the Program to operate the fixed speed Oil Pump and the following Solenoid Valves: TB1-34 Liquid Line. Enables normal chiller operation.Configures the Program to operate the Oil Pump Variable Speed Drive. Prerun . 3- 4- ON: Enables anti-recycle timer. Chillers equipped with the variable speed oil pump have a program controlled oil heater and a different complement of solenoid valves than chillers equipped with a fixed speed oil pump. OFF: Standard prerun. Disables normal chiller operation.Determines the duration of the “System Prelube” period. OFF: Disables anti-recycle timer. Solid State Starter and Electro-mechanical starter applications . ON: Extended prerun. ON: Chiller will automatically restart when power is restored.Enables or disables software diagnostics. ON: 50 Hz OFF: 60 Hz 5- 36 JOHNSON CONTROLS . “System Prelube” period is 50 seconds in duration. The anti-recycle timer must NEVER be disabled unless it is absolutely necessary to do so during troubleshooting. the oil heater and the following Solenoid Valves: Oil Return and Liquid Line (J compressors only) connected in parallel to TB 1-6 1. Auto-restart . Oil Pump runs for 167 seconds. 6Anti-recycle . the chiller can then be restarted by initiating a local start. Chiller can be started at the completion of SYSTEM COASTDOWN. “System Prelube” period is 180 seconds in duration.Configures Program operation for either Variable Speed Drive oil pump or fixed speed oil pump.Determines the course of action required to restart the chiller.Microboard FORM 160. On the 5th shutdown. a 10 minute timer is started and restart is inhibited until the timer has elapsed.Enables or disables the anti-recycle timer. Diagnostics . ON: Enables software diagnostics. regardless of how long the chiller had been running. TB1-61 Oil Return and Vent Line connected in parallel. TB1-62 High Speed Thrust. If in LOCAL mode.Motor/Power Line frequency application. the chiller will restart upon receipt of a remote start signal . OFF: Requires a manual reset after power is restored. if a power failure occurs while the chiller is running. OFF: Disables software diagnostics. The chiller will not start until the operator moves the keypad START-RUN-STOP/ RESET rocker switch to the STOP/RESET position. OFF: (Style C) Fixed Speed Oil Pump . VSD applications (JP37 Out) – Chiller can be started at the completion of SYSTEM COASTDOWN at intervals shorter than once every 10 minutes up to 5 times. If in REMOTE mode. ON: (Style D/E/F) Variable Speed Oil Pump . Oil Pump runs for 37 seconds. OFF: Watchdog protection disabled.FORM 160. 3.C. NEVER disable the watchdog protection! Severe compressor or chiller damage could result. “MULTIUNIT CYCLING . they remain closed. 10 – MICROBOARD LAMP DIMMER CIRCUIT JOHNSON CONTROLS 37 . ON: Enhanced operation. The position of Program Jumpers JP7 & JP8 determine the output at J6-7. this switch setting has no effect.) to Backlight Inverter Board when display is manufactured by Sharp or NEC. Contacts open at completion of System Coastdown after all shutdowns except when chiller shuts down on “LEAVING CHILLED LIQUID . 2. Potentiometer is actually an integrated circuit that is the electrical equivalent of a 10K potentiometer.CONTACTS OPEN” AND “SYSTEM CYCLING . Out = Variable Resistance.C.54-M1 (607) 8- Chilled Water Pump operation . Not Used 10 11 12 - Not Used Not Used Watchdog Protection -Used in conjunction with Program Jumper JP1 (see above) to enable/disable the program watchdog protection. ON: Watchdog protection enabled. Contacts open at completion of System Coastdown after all shutdowns except when it shuts down on “LEAVING CHILLED LIQUID . this switch setting determines whether the watchdog protection is enabled or disabled. On Low Water temp shutdowns.LOW TEMPERATURE” . Refer to Program Jumper Listing in Table 1 for applications.CONTACTS OPEN”.) 10 K 7 BRIGHTNESS CONTROL (WIPER) TO BACKLIGHT INVERTER BOARD 8 BRIGHTNESS CONTROL (-) JP7 NOTES: 1. OFF: Standard operation.0 VDC J6 JP8 6 BRIGHTNESS CONTROL (+) OR (N.Determines Chilled Water Pump control contacts (I/O Board TB2-44/45) operation when chiller shuts down on various CYCLING shutdowns. LD04054 FIG. J6-6 not connected (N. causing the pump to continue to run while the chiller is shutdown. In = Variable Voltage. The ability to disable the watchdog protection is provided for YORK factory testing only. With JP1 OUT. 3 9- 5.LOW TEMPERATURE”. With JP1 IN. Microboard FORM 160.4A. Refer to Fig. 4B. J15-5 Loop-Around Test OUT. Microboard Program Jumper JP27 determines whether COM 4A or 4B can be used. 70 for details. Refer to Table 1. 2. J15-4 Loop-Around Test IN. FIG. 1 & 2 . 11 – MICROBOARD SERIAL DATA COMMUNICATIONS PORTS 38 JOHNSON CONTROLS . 2 & 3.54-M1 (607) TX RX CR3 CR2 R G RS-232 COM 1 COM 4B (NOTE 1) TX RX DTR DSR GTX GRX J2 4 3 5 2 7 6 8 9 PRINTER MICRO MICROGATEWAY TX RX CR12 CR13 RS-485 G R + 3 2 1 J11 3 2 1 4 5 JP27 COM 4A (NOTE 1) -+ 5VDC GND SHIELD NOT MULTI-UNIT USED COMMS TX RX CR16 CR11 R G RS-232 DCD DSR RX RTS TX CTS DTR GND J13 1 2 3 4 5 6 7 9 NOT USED COM 2 UART R TX RX CR15 CR14 G RS-485 COM 3 + -+ 5VDC GND SHIELD J12 3 2 1 4 5 OPTIONAL I/O (HOT GAS BYPASS) TX RX CR9 CR10 R G OPTO-COUPLE COM 5 TX RX COMMON NOTE 2 NOTE 2 J15 VARIABLE SPEED 1 DRIVE 2 3 ADAPTIVE 4 CAPACITY 5 CONTROL 6 BOARD OR MOD "B" SOLID STATE STARTER LD07778 NOTES: 1. 12 – CONFIGURABLE ANALOG & REMOTE SETPOINT INPUTS JOHNSON CONTROLS 39 .FORM 160. FIG.5 K 2 3 1 47K +5V JP21 200 7. 2.xxx and later.54-M1 (607) FACTORY MOUNTED EVAPORATOR THERMAL-TYPE FLOW SENSOR (style F and later chillers) (note 2) 2 4 3 1 J7 2 14 15 13 71. Program Jumpers JP23 – JP24 must be positioned on pins 1-2 or 3-4 according to input signal type. Program Jumpers JP21 and JP22 must be on pins 2-3 on style F and later chillers equipped with factory-mounted thermal-type flow sensors.5 K 24 VAC FACTORY MOUNTED CONDENSER THERMAL-TYPE FLOW SENSOR (style F and later chillers) (note 2) 2 4 3 1 3 4 16 17 3 +5V 2 3 1 JP22 24 VAC MUX J22 0-10 VDC / 2-10 VDC 0-20 mA / 4-20 mA 1 2 2 3 1 REMOTE CURRENT LIMIT SETPOINT JP23 REMOTE LEAVING CHILLED LIQUID TEMP SETPOINT 0-10 VDC / 2-10 VDC 0-20 mA / 4-20 mA 3 4 2 3 1 JP24 REMOTE SETPOINT GND CONNECTIONS 5 LD09565 NOTE: 1.07. Refer to Table 1.01.MLM. Applies to Flash Memory Card version C. The version is as follows: C. During the boot-up.5Vdc Boot-up Program The BIOS (Basic Input Output System) Eprom (U37) contains the boot-up program. Although this board uses a different microprocessor and supporting components. JOHNSON CONTROLS . The board is supplied with +12vdc (J1-3). The progress and pass/fail status of each step is displayed on the microboard 7-segment LED Display (U22 ). 00. The sequence of events in the boot-up process are listed in the table below. -12vdc (J1-4). The YORK part number is 031-02429-001 and is used in both the 031-02430-000 and 031-02430-001 microboards. The part number and version are printed on a label adhered to the surface of the Eprom. Test Points (Ref Fig 9A) The power supply voltages can be measured at following test points: TP1 Gnd TP2 +3.5vdc regulator and used directly by the microboard circuits as the Vcc voltage. OPT. Increments 01. With the VSD Modbus applications. the program in the BIOS Eprom configures the microprocessor and related components and performs testing of certain components to assure those components are operational. BIOS EPROM Optiview Control Center Commercial chiller When power is first applied to the Optiview Control Center. chiller control and operator interface are the same as the previous 031-01730-000 Microboard. Due to the speed at which the boot-up proceeds. It uses the same mounting hole pattern and has the same interface connectors as the previous board.54-M1 (607) SECTION 3A MICROBOARD 031-02430-000 and 031-02430-001 (REFER TO FIG. 5A-10A) Microboard 031-02430-000 is supplied in new production chillers from January 2004 to June 2006 (ref fig 7A). The +12vdc (fused by F2) can be monitored at TP4.Microboard FORM 160. mounting and connections are the same as the 031-02430-000 microboard. • New producton Variable Speed Drives (VSD) after March 2007. NN. The outputs of these regulators are applied to microboard circuits and can be monitored at TP2 and TP5 respectively. After June 2006. The details of the differences between the -000 board and -001 board are described in the respective areas of this section.5Vdc TP10 +2. It is backward compatible to existing YK chillers using the 031-01730-000 or 031-02430-000 microboards and is supplied as service replacement for these boards in kit 331-02430-601. +2. The upgrade includes a larger BRAM (U38) and an additional RS485 port on COM2 serial port (J13) for Modbus serial communications protocol to Variable Speed Drives. The +5vdc (fused by F1) can be monitored at TP3.5vdc value created by 1K Ohm resistors voltage divider circuit as shown. not all steps will be visible during the process. The output of the regulator is the +5vdc (analog) supply that powers all analog circuits and 40 is the source voltage for all transducers and thermistors. 02 etc. It is applied to a +3. This board is an upgraded version of the 031-02430-000 microboard. The version is an alphanumeric code that identifies the application and the program revision level. new production YK chillers will be supplied with microboard 03102430-001. These upgrades are necessary for the following applications that require RS-485 Modbus communications to the microboard: • Medium Voltage Solid State Starter (MV SSS) and Medium Voltage Variable Speed Drive (MV VSD). The -12vdc is not used. Its physical dimensions. It is available from the Baltimore Parts Distribution Center as a replacement part. It is also displayed on the DIAGNOSTICS Screen in Service Access Level. +5vdc (J1-1) and ground (J1-2) from the Power Supply (ref fig 9A). making it backward compatible to all previous YK Optiview Control Centers equipped with the 03101730-000 Microboard. Revision level.3Vdc TP3 +5Vdc TP4 +12Vdc TP5 +2. a white screen is displayed while the boot-up is performed. Not all pass/fail status is displayed on the white screen. It is applied to a +5vdc regulator and used directly by microboard circuits. the Adaptive Capacity Control (ACC) functionality is contained in the microboard and the ACC Board is not used.3vdc regulator. It can be monitored at TP10 as a 2. trying again Flash Checksum Test in progress Application setup in progress CRITICAL CODES LED DISPLAY CODE Ni [] Description NMI handler invoked (should never occur) GPF has occurred (should never occur) Chiller Operating Program The Chiller Operating Program is a set of instructions to control the chiller. The program version that is currently residing in the Microboard Flash Memory chip is displayed on the DIAGNOSTICS Screen in Service Access Level. etc) and each has a unique part number. It contains the Safety and Cycling shutdown thresholds (non-changeable) and display screen messages and graphics. The chiller operating program is stored in a nonremovable Flash Memory chip (U35) that is soldered to the Microboard. The on-board program can be upgraded by downloading the latest version from a Program Card using the procedure in the Service Replacement section of this book.FORM 160. The version is an alpha-numeric code that identifies the chiller model applicability. A label affixed to the Program Card contains the part number and version. YK. language package. YS. YR. It is a portable memory storage device that is programmed with the chiller operating program. This is a 2 1/8 x 3 3/8 x 1/8 inch plastic card weighing 1. language package revision level and chiller operating program revision level.halt & display code = F3 “failed” and halt DISPLAY ON WHITE SCREEN No No No No No No No No No Yes Yes Yes Yes Yes 3A MISCELLANEOUS CODES LED DISPLAY CODE FF CH AP Description FPGA Configuration Failed. The Program Card part number for YK chillers is 03102474-001 and is available from the Baltimore Parts Distribution Center (PDC). Configured Switch to Protected Mode Jump to 32-bit code Low memory test start Low memory test complete Full memory test complete FPGA configuration Display Cont. YD.1oz (ref fig 8A). configured Flash Checksum Test BRAM test Flash Query Test Flash checksum BRAM Test PASS CODE 00 01 02 03 04 P1 P2 05 06 P3 P4 “passed” “passed” “passed” FAIL ACTION watchdog will cause reboot watchdog will cause reboot watchdog will cause reboot watchdog will cause reboot watchdog will cause reboot “F1” on display and halt “F2” on display and halt “P2” will remain on LED display “05” will remain on LED display “F3” will remain on LED display “F4” will remain on LED display “failed” and halt “failed”. JOHNSON CONTROLS Program Card The on-board program can be upgraded by downloading the latest program version from a Program Card. New chillers are supplied programmed with the latest program available at the time of manufacture. There is a Program Card for each chiller type (YT.54-M1 (607) DIAGNOSTIC DISPLAY CODES TEST First init table complete SDRAM regs. 41 . it would apply DC power to an incorrect pin on the 128KB BRAM and the board would not function. it is not necessary to have more than one YK Program Card. MV VSD. For example. The 128KB BRAM is required for MV SSS. Program Jumper JP14 is a non-removable (soldered) wire jumper that connects DC power to the appropriate pin on the BRAM for 32KB operation. Program Jumper JP14 is a removable 2-pin shunt type jumper. All of the programmed Setpoints. language revision level and chiller control revision level. IMPORTANT! The protective cover must be in place at all times when not performing a program download. Italian. and those VSD that communicate with the microboard using Modbus serial communications protocol. time of day and calendar data is stored here. A single YK card can be carried to different locations to re-program other YK Optiview Control Centers. 05=YR. A protective cover prevents dirt from entering this connector.nnn Language Package revision level (00. German and Hungarian languages. 03=YS. The program version that is currently residing in the Microboard Flash memory chip is displayed as the “Controls” Software Version on the DIAGNOSTICS Screen in Service Access Level.1=NEMA. Sales Order Data. It is installed in a 32-pin socket. It is available from the Baltimore Parts Distribution Center as a replacement part. If the shunt is installed on JP14. Simplified and Traditional Chinese. 11=YD) Optiview Control Center Commercial Chiller The Program card is inserted into connector U33 to download a program. It is presently not supported. BRAM (U38) The BRAM (battery backed random access memory) memory device contains a battery that preserves the stored data during power failures. The Program Card for YK chillers has English. Refer to instructions under Service Replacement below. The Program Card obtained from the PDC is programmed with the latest version of the chiller operating program.54-M1 (607) The Program Card is applicable to both NEMA and CE applications. 02=YT. The part number of the BRAM (U38) in the 031-02430– 000 board is 031-02431-000 and its size is 32KB. A Write Protect Switch on the edge of the Program Card prevents inadvertent writing to the Card during program downloading. Spanish. French.nn. The YORK Part number is printed on a label adhered to the surface of the BRAM. etc) Chiller Model (01=YK. Portuguese. Parallel Port Connector Parallel port connector J4 is for future use. re-programming will not be successful. The 128KB BRAM requires the shunt be NOT INSTALLED and the board is supplied in this configuration.Microboard FORM 160. If it does not have this capability. language package. the board will not function.etc) Language Package (0=English only. Handling precautions for the Program Card include: • Do not allow dirt to enter connector • Carry in protective sleeve • Storage temperature range is -20 to 65ºC (-4 to 149ºF) A label adhered to the Program Card contains the version and YORK part number. History Data. The version is an alphanumeric code that identifies the chiller model applicability. 01. A Program Card for a particular chiller type can be used to re-program other chillers of the same type.01. JOHNSON CONTROLS 42 . The version is as follows: C. Program Download Connector U33 A Program Card is inserted into connector U33 to download a program.OPT. The 031-02430–001 board with 128KB BRAM requires software that has “BRAM size detect” capability.nn.2=CE. Program Cards can be reprogrammed. 02. The part number of the BRAM (U52) in the 031-02430– 001 board is 031-02565-000 and its size is 128KB. It is installed in a 28-pin socket.3=NEMA/ CE) Controls Revision Level (00. If dirt accumulates inside this connector. However. If the +5vdc decreases to the threshold of (+4. There are two different watchdog initiated shutdowns.75vdc to 4. There are 4 rows and 8 columns. If any column has a logic low on it. After the re-boot. The Watchdog Circuit also assures that the entire program is being executed and that the program has not latchedup. The micro reads the entire keypad by repeating this routine beginning with row 1 and ending with row 4. Program Jumpers/Program Switches The Program Jumpers (Table 3) and Program Switches (Table 4) are used to alter the program operation or configure the Microboard hardware for specific operation. 43 3A JOHNSON CONTROLS . the chiller shuts down. on-board noise or hardware problem could prevent the watchdog time-out. The Watchdog circuit is a timer that times-out if not given a reset pulse within its time-out period (1 . either of two messages is displayed depending on the type of Watchdog shutdown as explained below. This allows the Program and Microboard to be universal for all standard applications. The keypad is read by applying a logic low to a row while leaving +5vdc pullup on all other rows.8vdc). the microprocessor sends a reset pulse to the Watchdog circuit every time the complete program has been executed. See BRAM transfer exception in Microboard Service Replacement later in this section. column) is being pressed. a reset is issued to the microprocessor and the chiller shuts down. The entire keypad is continually read while the control center is powered. The display momentarily blanks and white screen is displayed while the boot-up program executes as described above. the key corresponding to that coordinate (row.OPT.FORM 160.15. initiating a re-boot. The position of some jumpers can be determined by the Service Technician to meet the desired operation. When the graphic screen is displayed. type or style of components and thus are determined by the YORK factory. if the entire program is not executed or something prevents the microprocessor from sending the reset pulse as described below. The Program Switches are miniature switches that are placed in either the ON or OFF position. “Control Panel – Power Failure” is displayed. MV VSD and VSD Modbus. a “hardware” watchdog initiated shutdown and a “software” watchdog initiated shutdown. the conductors are pressed together at that point. a reboot is initiated and when the graphic screen is displayed. the Watchdog circuit timesout and sends a reset to the microprocessor.2. “Watchdog – Software Reboot” is displayed on the graphic screen. The Keypad is a matrix of conductors arranged in rows and columns (ref fig 32 and 33). the smaller BRAM from the 031-02430-000 board can be transferred to the 031-02430-001 microboard.04 to 2. When replacing a 031-02430-000 microboard with a 031-02430-001 microboard in applications other than MV SSS. When power is restored. the Watchdog circuit doesn’t time-out under normal operation. Watchdog Circuit The Watchdog circuit performs two functions as follows: • Power failure detection • Program latch-up detection/prevention The Watchdog circuit monitors the +5vdc from the power supply and the +3.5vdc) or the +3. To prevent a time-out. the message “Control Panel – Power failure” is displayed. the program intentionally initiates the reboot because it has detected program interruption. If running. Refer to SECTION 8 of this manual for details of the Keypad.54-M1 (607) YK chiller software version C. When a key is pressed. bypassing important safety checks.3vdc decreases to the threshold of (3. In the “hardware” watchdog initiated shutdown. Refer to Table 3 and 4 for the function of each jumper and switch. a program problem. In the “software” watchdog initiated shutdown. The jumpers are plastic sleeves with metal inserts that are inserted over 2-prong or 3-prong conductors.3vdc from the onboard regulator to determine when a power failure is occurring.xxx (and later) has this capability and is required. creating continuity between the row conductor and the column conductor. Others must be positioned according to the requirements of the size.01. The micro then reads the 8 columns. the white screen is displayed and the boot-up is performed as described above. If this occurs. Since it takes less than 1 second to perform the entire program. When the graphic screen is displayed. Keypad Interface The Keypad is read via J18.25 seconds). The data for each channel is shown on the following table: Style B Solid State Starter Interface Prior to June 2006. The micro sequentially and continually reads channels 0 through 7. After March 2007.54-M1 (607) CM-2 Board or Style A Solid State Starter Interface The microboard retrieves certain operating parameters (via J10) from the compressor motor starter control board (CM-2 Current Board for Electromechanical starter or Style “A” Solid State Starter Logic Board). The highest phase is Channels 5 through 7 are analog voltages that represent phase A. COM2 serial port is selectable between RS-232 and RS-485 with Program Jumper JP17. Both boards contain an 8 channel multiplexer. Variable Speed Drive Interface Prior to June 2006. J152 is RX data from the starter. new production starters communicate with microboard 031-02430-000 via the Opto-coupled COM5 serial data port (J15) using YORK proprietary protocol.01. and therefore which starter is present. B and C motor current. it indicates the starter is an Electromechanical (EM) starter and the micro then reads channel 7 to retrieve the peak motor current value. The micro determines which board.4vdc indicates the starter is an “A” style Solid State Starter and the micro reads channels 1 through 7.Microboard FORM 160. Since channels 0 through 6 are grounded. The serial data is represented by +5vdc and 0Vdc logic levels. channel 0 indicates the starter size (model) and voltmeter range (300Vac or 600Vac). A 0-5vdc analog value is returned from each channel. J15-1 is TX data to the starter. by the value returned from channel 0. The function of each is in the table below. MULTIPLEXER CHANNELS 0 1 2 3 4 5 6 7 Peak Motor Current (%FLA) CM-2 Gnd Gnd Gnd Gnd Gnd Gnd Gnd Style A Solid State Starter Starter model/ voltmeter range Current limit command Phase C motor current Phase B motor current Phase A motor current Phase A line voltage Phase B line voltage Phase C line voltage 44 JOHNSON CONTROLS .4vdc. A value >0. the Adaptive Capacity Control (ACC) functionality is contained in the microboard and the ACC Board is not used. new production Variable Speed Drives communicate with microboard 031-02430-001 via COM2 serial data port (J13) using RS-485 Modbus protocol. Refer to the appropriate section of this book for detailed explanation of each board.OPT. The Solid State Starter Logic Board returns a value >0. It reads each channel by applying a 3-bit binary address to the multiplexer. Refer to Figure 11A and Section 11 for details of the solid state starter interface. It must be positioned on pins 1 & 2 to select RS-485 serial port operation. new production starters communicate with microboard 03102430-001 using the same interface/protocol.xxx (or later) is required for COM2 Modbus operation. Software version C. new production VSD communicate with microboard 031-02430-001 using the same interface/protocol. The serial data is represented by +5vdc and 0Vdc logic levels. the CM2 board returns a 0vdc value. new production Variable Speed Drives communicate with microboard 031-02430-000 via the Opto-coupled COM5 serial data port (J15) using a YORK proprietary protocol. Between June 2006 and March 2007. Channel 1 is a hardware generated 100% FLA (prevents pre-rotation vanes from further opening) or 104% FLA (closes pre-rotation vanes until motor current is <102%) current limit override command that overrides normal Pro-rotation Vanes control.16. In the Solid State Starter. With the VSD Modbus applications.41vdc to +5vdc. After June 2006. B and C Line Voltage. Channels 2 through 4 are analog voltages that represent phase A. J15-2 is RX data from the starter. J15-1 is TX data to the starter. If the value is <0. xxx (or later) is required for MV SSS.xxx (or later) is required for MV VSD. It must be positioned on pins 1 & 2 to select RS-485 serial port operation.OPT.54O1 for details of available printers and printer setup instructions.16. The output that controls relay K0 is not allowed to change at a rate greater than once every 10 seconds. The microboard sends data to the printer at the selected baud rate until the printer buffer becomes full.01. The 45 3A . Solid state switching devices are used to control the relays. Signal levels are standard RS-232.01. Software version C. whereupon the printer asserts its Busy signal. Refer to YORK manual 160. The microboard energizes the +12Vdc relays by applying a ground to the coil input. The Baud. The Triac is turned on to allow current to flow through a winding. When the MV SSS or MV VSD is selected on the SETUP Screen. Signal levels are standard RS-232. Refer to SECTION 4 of this manual for details of the I/O Board.xxx (or later).00M5 (MV SSS) and 160. the “Motor Node ID” setpoint must be set to match the setting of the VSD Logic Board Modbus Address Switch SW3. It holds it for retrieval by third-party devices.54-M1 (607) To allow microboard 031-02430-001 to be used as service replacement for 031-01730-000 or 031-02430000 boards non-Modbus applications already in the field.01. When Modbus is selected. The contacts of these relays switch 115Vac to system relays and solenoids. They are de-energized by opening the ground path. They must be both set to “1”. MicroGateway Interface An optional Microgateway printed circuit board can be connected to the COM 4B RS-232 serial data port (J2). Parity and Stop Bits must be programmed on the Comms Screen. Software version C.15.00. The output that controls relay K13 is not allowed to change at a rate greater than once every 20 seconds. Refer to Figure 11A and Section 12 for details of the variable speed drive interface. The MicroGateway polls system pressures. Each actuator has an open winding and a close winding.OPT. Printer Interface An optional Printer can be connected to COM1 RS232 serial data port (J2). The outputs that control the chilled liquid pump and compressor motor starter have anti-chatter (anti-recycle) timers associated with them. Each printer must be setup/configured to operate properly with the microboard. The I/O Board contains +12Vdc relays that isolate the microboard low voltage circuits from the 115Vac device coils.M6 (MV VSD) for details of this interface. temperatures and status from the microboard. J2-4 is TX data to the printer. Microboard 031-02430-001 is required for these applications. COM2 serial port is selectable between RS-232 and RS-485 with Program Jumper JP17. J2-2 is the DSR (Data Set Ready or busy) signal from the printer.16. Refer to SECTION 15 of this manual.FORM 160. J2-7 is TX data to the MicroGateway. The microboard controls Actuator motors via Triacs on the I/O Board. the COM2 serial port with Modbus protocol is automatically enabled. additional Setpoints must be entered on this Screen: The appropriate serial port (COM2-Modbus or COM5-YORK) must be enabled using the “Motor Communications Protocol” Setpoint. Current flowing through a winding causes the actuator to rotate in the respective direction. the Adaptive capacity Control functionality is contained on the microboard. Medium Voltage Solid State Starter (MV SSS) and Medium Voltage Variable Speed Drive Interface (MV VSD) These drives communicate with the Microboard via the COM2 RS-485 Modbus serial port (J13). the COM5 serial port is retained on the 031-02430-001 board. Other printer setup is performed on the PRINTER Screen. J2-6 is RX data from the Microgateway. Refer to figure 11A and YORK Operation and Service manuals 160. Data Bits. when “VSD60Hz” or “VSD-50Hz” is selected on the SETUP Screen. Each winding is controlled by a Triac. Digital Outputs The microboard controls 115vac relays and solenoids via the I/O Board (via J19).OPT. With microboard 031-02430-001 and software version C. The microboard suspends data transmission until the printer can accept JOHNSON CONTROLS more data. A 115Vac input to the I/O board is converted to a logic low (<1Vdc). A 0Vac input to the I/O Board is converted to a logic high (>4Vdc). The selections are “Modbus or “York”. Digital Inputs The I/O Board converts the 115Vac inputs to logic level inputs for the microboard at J19. With the MV VSD. is only affected by changes in liquid temperature. After power is applied. The 6 LED’s to the right of the amber reflect flow rates above the setpoint. COM4 (4A-J11). resulting in no conduction through the load resistor. the greater the differential between thermistors. RS-232 or RS-485. (Refer to table 3). These are electronic thermal-type sensors. The lower the flow. the solid state relay output is turned off. on Microboard 031-02430-001. one side of the solid state relay output (pin 2) is connected to the microboard +5Vdc and the other side (pin 4) is Connected to a microboard analog 46 input (refer to fig 12). COM2 (J13) – RS-232 on Microboard 031-02430000. Flowing liquid carries heat away from the heated sensor tip. As the flow rate increases above the setpoint. The operating principle of the sensor is thermal conductivity. This is the setpoint. This applies >+4Vdc to the microboard input evaporator J7-14. in the form of analog DC voltages. Included are tables to convert the expected output voltage for any temperature applied to the thermistor. Style F (and later) chillers are supplied with factorymounted Flow Sensors on the evaporator and condenser. The RS-232 port is not used. are input from Thermistors. VSD Adaptive Capacity Control Board or Style B Solid State Starter.6 ft. Lower flow rates remove less heat from the tip allowing a higher tip temperature. Medium Voltage Variable Speed Drive and Variable Speed Drives that communicate with the microboard use Modbus serial communications. e. The Software allows either the Thermal-Type sensors connected to the Microboard analog inputs or the Paddle-Type sensor connected to the I/O Board digital inputs (refer to the Flow Switch Setpoint in SECTION 23). Microboard 031-02430-001 is equipped with 7 serial ports. as selected with Program Jumper JP17.Microboard FORM 160. JOHNSON CONTROLS . condenser J7-16). The 4 LED’s to the left of the amber reflect flow rates below the setpoint. the LED display moves to the left. When the setpoint (or greater) flow rate is sensed. It turns it off by applying a logic high (>4vdc). COM3 (J12) – RS-485. It uses the cooling effect of a flowing liquid to sense flow. first confirm that +5vdc is present at pin 2 of the flow sensor. The sensor is vendor-calibrated to turn on” its output at a flow rate of 20cm(0. Refer to figure 11A. System temperatures. On each sensor. COM4A – RS485 not used. the solid state relay output is turned on causing it to conduct current through the 7. lowering its temperature. c. (4B-J2) – This port is actually two ports. Formulas and graphs are included to calculate the expected transducer output voltage for a given pressure input. Analog Inputs System pressures. Refer to SECTION 4 of this manual for details of the I/O Board. This applies <1Vdc to the microboard input. The higher the flow rate. the LED display moves to the right.54-M1 (607) microboard turns on the Triac by applying a logic low (<1Vdc) to the Triac driver on the I/O Board. they cannot be used simultaneously. The center located amber LED illuminates at the setpoint flow rate (and above). are input from Pressure Transducers. During this time. Printer b. A second thermistor. the lower the tip temperature and therefore a lower differential between thermistors. the Switch Setpoint must be set appropriately (refer to SECTION 23). COM5 (J15) – Opto-coupled transmit/receive. The temperature of the heated sensor tip is sensed by a thermistor located in the tip. Serial Data Ports Microboard 031-02430-000 is equipped with 6 serial data ports. The sensor operates from a 24Vac power source and has a solid state relay output. When a flow rate less than the setpoint is sensed. To assure the program reads the correct input for the flow sensor type present. in the form of analog DC voltages.5K ohm microboard load resistor to the +5vdc. Refer to SECTION 17 of this manual. COM1 (J2) – RS-232. The position of program jumper JP27 determines which port can be used. As the flow rate decreases from the setpoint. located higher in the tip in a non-heated area.)/second. Refer to SECTION 16 of this manual. However. To determine the state of the solid state relay. The temperatures sensed by the thermistors are compared. COM4B – RS-232 Microgateway. Then connect a voltmeter from Microboard J7-14 (evaporator) or J7-16 (condenser) to microboard TP1(ground). Each port is dedicated for a specific function as follows: a. There are 11 LED’s on the sensor that reflect the measured flow rate. there is a thermal warm-up period of up to 20 seconds. The RS-485 port is used for Modbus communications to the Medium Voltage Solid State Starter. Hot Gas Bypass d. the output could be unstable. • CR13 TX4 – COM4 serial port transmit data. beginning with the top row. • CR19 RX5 – COM5 serial port receive data. • CR20 TX5 – COM5 serial port transmit data. Under program control. • CR3 TX6 – Not used. Table 3 lists the required program jumper configuration for each display. depending on position of Program Jumper JP5) to high voltage AC (500 to 1500Vac). Future COM6 serial port receive data. Program Jumpers JP7 and JP8 47 3A . • CR14 RX4 – COM4 serial port receive data. The pixels are driven sequentially from left to right. others turn o when it transitions from high to low. A red TX LED illuminates as data is transmitted to or requested from another device. Each display manufacturer requires a slightly different control. the lamp is driven back to full (100%) brightness. 6 for each of the 3 colors. The program in the BIOS eprom configures the microboard for correct operation for the actual display installed. the brightness is driven to 50% after 10 minutes of Keypad inactivity.5 to +5vdc logic levels. through which a variable amount of light from the Display Backlight. a label attached to the display mounting plate lists the required program jumper configuration for that display. In some displays. The microboard controls the Display Backlight via J6. The drive signals determine the amount of light permitted to pass through each window. Different display manufacturers require different supply and control voltages for their displays and backlights. During the boot-up. • CR16 RX3 – COM3 serial port receive data. The Backlight is turned on and off with the “Backlight Enable” signal (J6-5). others require a variable resistance. This high voltage AC is applied to the lamp to cause it to illuminate. green and blue light allowed to pass. • CR18 TX2 – COM2 serial port transmit data. green and blue. Program Jumpers JP2 through JP5 and JP7 and JP8 must be configured to provide the required supply and control voltages to the display and backlight control. the program in the BIOS eprom reads wire jumpers PID0 through PID3 on the Display Interface Board to determine the manufacturer of the display. the microboard controls the backlight brightness via the Lamp Dimmer circuit output at J6-7. red. Also. green and blue drive signals applied to each of the 303. At this brightness level.54-M1 (607) Each port is equipped with two LED’s. the graphics are still visible. The position of Program Jumper JP3 determines the transition that will occur when the Microboard outputs the Backlight Enable signal. The position of Program Jumper JP4 determines whether this is a +12Vdc or +5vdc signal. The RS-485 voltages are industry standard 0vdc and +1. This data is in the form of red. the backlight turns on when this signal transitions from low to high. In order to extend the life of the Backlight lamp. It converts low voltage DC via J6-1 (+12vdc or +5Vdc. Some display manufacturers require a variable voltage to vary the brightness. COM5 logic levels are 0vdc and +5vdc.FORM 160. Refer to Diagnostics SECTION 23 of this manual. JP3 must be positioned according to the display manufacturer’s requirement. The position of program jumper JP2 determines whether the supply voltage is +5vdc or +3. A diagnostic test can be performed on each serial port to confirm proper operation.3vdc. The Backlight Inverter Board provides a high voltage AC power source for the lamp. Future COM6 serial port transmit data. To coordinate the drive signals and assure the pixels in each row are driven from left to right and the columns are driven from top to bottom. The Display Backlight is the light source for the display. The data to form these screens is output from J5. Each pixel consists of 3 windows. Display Interface The graphic screens displayed on the liquid Crystal Display are created from the program downloaded from the Program Card and stored in the flash memory chip. A green RX LED illuminates as data is received from another device. • CR5 TX1 – COM1 serial port transmit data. The greater the binary value. The overall pixel color is a result of the gradient of red. the more light is permitted to pass. the drive JOHNSON CONTROLS signals are accompanied by a clock and horizontal and vertical sync signals. • CR17 RX2 – COM2 serial port receive data. The drive signal for each pixel is an 18 bit binary word. is permitted to pass to the front of the display. The RS-232 voltages are industry standard +5 to +25vdc and -5vdc to -25vdc logic levels.200 the display pixels arranged in a matrix of 640 columns x 480 rows. When Keypad activity is detected (a key is pressed). The LED’s and their functions are as follows: • CR2 RX6 – Not used. • CR4 RX1 – COM1 serial port receive data. • CR15 TX3 – COM3 serial port transmit data. 16.OPT. Refer to Table 3 for Program Jumper configurations and SECTION 18 of this manual for details of the Remote Setpoints. 2-10vdc 0-20Ma or 4-20Ma form. VSD-50Hz – Variable Speed Drive. On this shutdown. 6 and 7 of this manual for details of the display interface. • Motor Drive Type – Configures the program for the applicable compressor motor drive type.54-M1 (607) must be configured to enable the appropriate technique. Refer to entry instructions in SECTION 23 of this manual. The Lamp Dimmer outputs “Brightness Control Wiper” (J6-7) to the Backlight Inverter Board. Standard – Contacts open at completion of “System Coastdown” after all shutdowns except “Leaving Chilled Liquid – Low Temperature”. CAUTION! The Anti-recycle timer must never be disabled unless advised by YORK factory. MV VSD – 50Hz (microboard 031-02430-001 with software version C. Configuration/Setup The following functions are entered as setpoints on the SETUP Screen.xxx (or later) 8. the output is a variable resistance. VSD applications can be started at the completion of “System Coastdown” up to 5 times. If Program Jumpers JP7 and JP8 are installed. On the 5th shutdown. Manual – Requires a manual reset after power is restored. Selections are: 1.01. SSS-Mod B – Style B Solid State Starter 4. Solid state Starters and electromechanical starter applications cannot be started at intervals shorter than once every 30 minutes. The inputs at J22 are configured with Program Jumpers JP23 and JP24 to accept these inputs in either 0-10vdc. The chiller cannot be started until the operator moves the keypad Start-Run-Stop/Reset rocker switch to the stop/reset position. • Power Failure Restart – Determines the course of action required to restart the chiller. regardless of how long the chiller had been running. If configured for variable voltage output. MV VSD – 60Hz (microboard 031-02430-001 with software version C.OPT. SSS-Mod A – Style A Solid State Starter 3.16. 2.01. 60Hz 5. Multi-Unit Cycling. 2. 2. Enhanced – Contacts open at completion of “System 48 Coastdown” after all shutdowns except “Leaving Chilled Liquid – Low Temperature. Enabled – Enables the anti-recycle timer.0vdc) or a variable resistance (0-10K ohms) to the Backlight Inverter Board. • Chilled Liquid Pump Operation – Determines Chilled Liquid Pump control contacts (I/O Board TB2-44/45) operation when chiller shuts down on cycling shutdowns. causing the pump to continue to run while the chiller is shutdown. they remain closed.xxx (or later) • Anti-recycle – Enables or Disables the Anti-recycle timer.0Vdc (0% brightness). the lamp Dimmer output is a variable voltage. 50Hz 6.01. a 10-minute timer is started and restart is inhibited until the timer has elapsed.Microboard FORM 160.Contacts Open” and “System Cycling – Contacts Open”. if a power failure occurs while the chiller is running. Disabled – Disables the anti-recycle timer.xxx (or later) 7. Selections are: 1. Remote Setpoints Remote Leaving Chilled Liquid temperature and Current Limit setpoints can be input via the RS-232 Microgateway interface at J2 or directly to the Microboard at J22 (ref fig 12A). Selections are: 1. Auto – Chiller will automatically restart when power is restored.15. the resistance between J6-6 and J6-7 varies from 0 ohms (0% brightness) to 10K ohms (100% brightness). On these shutdowns. they remain closed. if both are removed. Selections are: 1. The lamp Dimmer varies the brightness of the backlight by applying a variable voltage (0-5. The Lamp Dimmer controls the position of the potentiometer. The Lamp Dimmer is an integrated circuit that is the electrical equivalent of a 10K ohm potentiometer with 100 positions or steps (ref fig 10A). JOHNSON CONTROLS . If configured for variable resistance.OPT. Refer to Display SECTION 5. VSD-60Hz – Variable Speed Drive. Chiller can be started at the completion of “System Coastdown”. EM – Electromechanical Starter 2. the voltage between J6-7 and J6-8 can be varied from 0Vdc (100% brightness) to 5. MV SSS (microboard 031-02430-001 with software version C. causing the pumps to continue to run while the chiller is shutdown. 2. the range is 150 (Default) to 900 Seconds. the range is 240 (Default) to 900 seconds. With Modbus protocol.01. If 49 3A . • Oil Pump Package – Configures the program for either Variable Speed Drive Oil Pump or Fixed Speed Oil Pump. Selections are: 1. 1. Coastdown duration is dependent upon selection made for the CHILLER STYLE/COMPRESSOR Setpoint on the Operations Screen: For style F/J7 and G/K6-K7. Program Jumpers JP14 (BRAM size) and JP17 (COM 2 serial mode) must be configured appropriately per Section 3A Table 3. Used when the Microboard is interfaced to the Variable Speed Drive via the ACC Board. To accommodate both new production and earlier chillers. Extended – “System Prelube” is 180 seconds in duration.OPT. Allows the service technician to enter the Modbus Address of the VSD Logic Board. duration is 150 seconds for all selections. YORK – Enables COM5 (J15) serial port.01. Variable Speed (style D and later) – configures the program to operate the Variable Speed Drive Oil Pump. Whenever the microboard is reading or writing with this board.OPT. this device is the VSD Logic Board. 1. On new production chillers prior to March 2007.Loss of Current” check and anti-recycle function is not performed since there is no motor current. the VSD Adaptive Capacity Control (ACC) Board communicates with the Microboard COM5 serial port using YORK protocol. the Logic Board responds.FORM 160. On VSD applications. the ACC Board is not present and the VSD Logic Board communicates directly with the Microboard COM2 serial port using Modbus protocol. the oil heater (maintains oil temperature 50ºF above condenser saturation temperature) and the following solenoid valves: Oil Return and Liquid Line (J compressors only) connected in parallel to TB1-61. If the transmitted address matches the address assigned. Allows Service Technician to enable the appropriate serial communications port JOHNSON CONTROLS for communications to the Variable Speed Drive (VSD). TB1-62 High Speed Thrust. For software versions C. This is done by placing the VSD Logic Board Modbus Address Switch SW3 position 1 to ON and setting this setpoint to “1”. 2.14. it transmits this address. 2.16. After this date. The address assigned to the VSD Logic Board is “1”.16. MODBUS – Enables COM2 (J13) serial port. “MODBUS” enables COM2 (J13). the device that the microboard serially communicates with is assigned an address. For all others. TB1-61 Oil Return and Vent Line connected in parallel. The chiller must be stopped with the Start-Run-Stop switch in the Stopped position to change this Setpoint. The protocol selection enables the appropriate serial communication port: “YORK” enables COM5 (J15).xxx and later) Only displayed when MOTOR DRIVE TYPE Setpoint above is selected as “VSD-60Hz” or “VSD-50Hz”. • Motor Communications Protocol (Software version C.01. • Motor Node ID (Software version C. Selections are: 1. software version C.xxx and earlier. • Pre-run – Determines the duration of the “System Pre-lube” period. it ignores the command/request.OPT.xxx and later) Only displayed when “Modbus” is selected for the Motor Communications Protocol setpoint above. Standard – “System Prelube” is 50 seconds in duration. Otherwise. Selection required is based on the hardware and interface that is present.MLM/OPT. Enhanced – “Coastdown” is 15 minutes in duration.16. Refer to Section 12 (VSD) to determine which hardware/interface is present. “Motor Controller . Used when the ACC Board is not present and the Microboard is interfaced directly to the Variable Speed Drive Logic Board. microboard 031-02430-001 is required and it must be equipped with the 128K BRAM (031-02565-000). Standard – Electric motor applications. the ACC functionality is contained in the Microboard. Fixed Speed (style C) – Configures the program to operate the fixed speed Oil Pump and the following solenoid valves: TB1-34 Liquid Line. Steam Turbine applications.xxx (or later) allows selection of either YORK or MODBUS protocol. Chillers equipped with the Variable Speed Drive Oil Pump have a program controlled oil heater and a different complement of solenoid valves than chillers equipped with a fixed speed oil pump.54-M1 (607) • Coastdown – Determines the “Coastdown” duration (oil pump run duration after shutdown) and whether the “Motor Controller – Loss of Current” check and anti-recycle function is performed while the chiller is running. In order to select MODBUS. With this microboard. 2. Use the return instructions and return address label provided with the replacement board.xxx (or later) (see BRAM transfer exception below). This board is an upgraded version of the 031-02430-000 microboard and is backward compatible to YK chillers presently using the 031-01730-000 or 031-02430-000 microboards.01. MVVSD.01. Medium Voltage Variable Speed Drive (MV VSD) and Variable Speed Drive (VSD) Modbus applications. The board will not function with incorrect memory components. order part number 331-02430-601.OPT.14.15. Microboard Service Replacement If the microboard is replaced within the warranty period. Not all BRAM devices are compatible with all Microboards. the basic Microboard part number (031-02430-001) and the version of the pre-programmed “Controls” software (for example.Microboard FORM 160. This can be useful when it is desired to transfer a BRAM from one board to another to save stored setpoint. In order to do this. Microboard 031-02430-000 is supplied as replacement part from January 2004 until June 2006. C. It comes equipped with a BRAM (U38) and BIOS Eprom (U37). not all BIOS Eproms are compatible with all Microboards. MVVSD. MV VSD & VSD Modbus require C.OPT. RS-485 is required for MVSSS. it is sometimes desirable to transfer the BRAM from the defective board to the replacement board to save stored Setpoint.xxx or later All including MVSSS.306 or later). Summary of differences between 031-02430-000 and 031-02430-001 Microboards: 031-02430-000 BRAM BRAM Socket Program Jumper JP14 COM2 Serial Port 031-02431-000 (32KB) 28 pin Non-removable wire 031-02430-001 031-02565-000 (128KB) 32 pin 2-pin shunt type w/shunt removed RS-232 or RS485 as selected w/JP17. Transferring a 32KB BRAM from 031-02430–000 Board to 031-02430–001 Board: For applications other than MV SSS. MVVSD and VSD Modbus Communications C. History or Sales Order data.54-RP1. This part number provides an 031-02430-001 Microboard that has been programmed with the latest version of the YK “Controls” software. microboard 031-02430-001 is supplied. the following must be performed: 50 JOHNSON CONTROLS . VSD Modbus When replacing a microboard. History or Sales Order data. Also.OPT.01. To order a replacement Microboard for a YK Chiller. The Microboard is shipped with a label on the outside of the shipping box that lists the part number of the pre-programmed Microboard (331-02430-601).16. Refer to Replacement Parts List 160. The chiller must be stopped with the Start-Run-Stop switch in the Stopped position to change this Setpoint. the 32KB BRAM (031-02431000) from a 031-02430-000 board can be transferred to a 031-02430-001 board. Therefore.54-M1 (607) these two values are not set to the same number. VSD Modbus RS-232 Required “Controls” Software Version Any version Application Except MVSSS. This upgrade is necessary to operate with those motor drives that communicate with the microboard using Modbus communications: Medium Voltage Solid State Starter (MV SSS). (Replacement Microboards cannot be ordered by the basic board part number of 031-02430001). MV VSD and VSD Modbus applications. refer to the following compatibility chart before proceeding: Microboard 031-02430-001 031-02430-000 031-01730-000 BRAM 031-02565-000* 031-02431-000 031-02028-000 BIOS Eprom 031-02429-001 031-02429-001 031-01796-002 *Refer to the following BRAM transfer exception. The upgrade includes a larger BRAM and an additional RS-485 port on COM2 for MODBUS serial communications. before attempting to transfer memory components between boards. the VSD Logic Board will not communicate with the microboard. the defective board must be returned to YORK per the warranty return procedure. After this date. 01. if your chiller is a YK chiller. 03=YS. For example.2=CE. With this configuration. However. once the process is initiated. for example. 11=YD) Optiview Control Center Commercial Chiller 3A JOHNSON CONTROLS 51 . 02. The version is an alpha-numeric code that identifies the chiller model applicability. it automatically proceeds through these steps to completion. since chiller operating programs are occasionally revised.54-M1 (607) 1. 05=YR. 2.301.15.FORM 160. language package and program revision level. 02=YT. etc) Chiller Model (01=YK. The card received from the PDC is programmed with the latest version of the chiller operating program. It cannot be manually terminated before completion. Install a shunt over Program Jumper JP14. Program Cards can be shared among Service Technicians where appropriate.OPT. Once the re-programming process is initiated.3=NEMA/ CE) Controls Revision Level (00. the board can be operated with software versions prior to or later than version C. the chiller will be rendered inoperable until this procedure is repeated using the correct Program Card! A label affixed to the Program Card contains the card version.nn. If a YS chiller program is downloaded into a YK chiller. the existing on-board program will be erased and replaced by the program in the Program Card.1=NEMA. Install 32KB BRAM toward bottom of the BRAM socket (U38) so that there are 4 empty sockets at the top of the BRAM socket as shown.etc) Language Package (0=English only. the Program Card used MUST be for a YK chiller. it is not necessary for an individual Service Technician to have more than one YK Program Card. Program and Verification. Use an unused black plastic shunt from JP9-12 (DO NOT USE JP1). Therefore. Before proceeding. There are 3 steps to the re-programming process: Erase. Program Card Service Replacement Since one YK Program Card can be used to re-program other YK chillers. be absolutely certain the Program Card is applicable to your chiller model.nn. Program Cards can be re-programmed with the latest program version.nnn Language Package revision level (00. DOWNLOADING A PROGRAM FROM A PROGRAM CARD The Program Card Write Protect Switch must be in the “Write Protect” position! LD12566 3. Program Cards (031-02474-001) for YK chillers are available from the Baltimore Parts Distribution Center (PDC).01.OPT. The version is as follows: C. 01. the Service Technician could have a Program Card that does not contain the latest program. Microboard FORM 160. “Er” displayed. 10. 2. c. Otherwise. Reposition Microboard Program Jumper JP6 to pins 2 & 3 (left-hand pins). 9. Do not proceed until you understand the above caution! 7. the program in the Program Card is downloaded into the Microboard Flash memory. “Pr” is displayed. During the Verifying procedure. This assures the integrity of the card before the download procedure can begin. A dialog box appears asking if you want to “Erase Onboard Flash and Re-Program from PcCard?”. the “Optiview Flash Programmer” Screen is displayed. a message in the status box indicates the step that failed. The red LED next to this bar illuminates while this procedure is in progress. b. The following steps will be performed: a. 12. Press START key to start the downloading process. 8. the Microboard is performing a checksum test on the Program Card.54-M1 (607) Download the program as follows: 1. 5. Install protective cover on Microboard connector U33. 52 JOHNSON CONTROLS . The red LED next to this bar illuminates while this procedure is in progress. Restore power to Optiview Control Center. During the Programming procedure. The reprogramming procedure is now complete. a checksum test is performed on the new program in the Microboard Flash Memory. During this procedure. During the Erasing procedure. During this procedure. Remove protective cover from Microboard connector U33. Erasing. the card is defective or corrupted and the download procedure cannot be performed. At the completion of the re-programming process. Remove power from Optiview control center. The red LED next to this bar illuminates while this procedure is in progress. While this is displayed. “Flash Has Been Successfully Programmed” is displayed and “Operation Successful” is displayed in the Status Code box. During this procedure. 4. A green bar reflects the progress of this procedure. if it is successful. Press √ key. A white screen appears displaying “Flash Checksum Test:” and Microboard 7-segment LED (U22) displays “Ch”. 13. Reposition Microboard Program Jumper JP6 to pins 1 & 2 (right-hand pins) pins. A green bar reflects the progress of this procedure. Verifying. Insert Program Card into Microboard connector U33. “Ch” is displayed. A green bar reflects the progress of this procedure. Use the ► key to scroll to YES. Programming. the program in the Microboard Flash Memory will be erased. Remove Program Card from Microboard connector U33. 6. If the checksum test fails. 3. Apply power to Optiview Control Center. 11. If the checksum test passes. Remove power to Optiview Control Center. The Microboard 7-segment LED Display (U22) displays the steps of the programming process while they are in effect. Pins 1-2: +12VDC. Soldered wire jumper.FORM 160. Pins 2-3: +3. NEC NL6448AC33-24 and LG Semicon LP104V2-W (031-02046-000) displays. Pins 1-2: +12VDC/0VDC SHARP LQ10D421 display. SHARP LQ10D367/368 (031-01774-000). JP12 – Not used. JP5 – Display Backlight power. JP10 – Not used. Severe compressor or chiller damage could result. JP8 – Display brightness control technique. JP11 – Not used. NEC NL6448AC3324 display JP9 – Not Used. this jumper must be in the Disable position. Determines whether the boot-up is performed from the Program Card or Eprom U37. Determines the logic levels of the Backlight Enable signal. The ability to disable the watchdog protection is provided for factory testing only. JP7. Pins 2-3: +5VDC. NEC NL644AC33-24 and LG Semicon LP104V2-W (031-02046-000) displays. Determines the power supply voltage applied to the Display Backlight Inverter Board. Must be in this position unless re-programming from the Program Card. IN: – Watchdog enabled OUT: – Watchdog disabled JOHNSON CONTROLS 53 . Pins 2-3: +5VDC/0VDC SHARP LQ10D367/368 (031-01774-000). Pins 2-3: Boots-up from the Program Card. Since the board is presently not populated with a parallel port connector. NEC NL6448AC33-24 and LG Semicon LP104V2-W (031-02046-000) displays. IN: Variable voltage (0-5. JP4 – Display Backlight enable signal logic levels. JP6 – Boot-up source.0VDC). Pins 1-2: 0VDC SHARP LQ10D421 display. OUT: Variable resistance. Must be in this position when re-programming from the Program Card. Jumper must be positioned according to the voltage level required to turn on the Display Backlight. Pins 1-2: +5VDC SHARP LQ10D367/368 (031-01774-000) and LQ10D421 displays. SHARP LQ10D367/368 (031-01774-000) and LQ10D421. Determines whether the display brightness is controlled by a variable resistance or a variable voltage.54-M1 (607) TABLE 3 MICROBOARD 031-02430-000 AND 031-02430-001 PROGRAM JUMPERS JP1 – Parallel Port Enable/Disable. and LG Semicon LP104V2-W (031-02046-000) displays. Used to enable and disable the parallel port in the microprocessor. Must be in this position for correct microboard operation.3VDC NEC NL6448ACC33-24 and LG Semicon LP104V2-W (031-02046-000) displays. JP13 – Watchdog Enable/Disable. 3A Never disable the watchdog protection. JP3 – Display backlight enable signal level polarity. Pins 1-2: Enables Parallel Port Pins 2-3: Disables Parallel Port. JP2 – Display power and logic levels Determines the power supply voltage applied to the display. Pins 2-3: +12VDC or +5VDC as determined by position of JP4. Not used. SHARP LQ10D367/368 (031-01774-000) and LQ10D421. Pins 1-2: Boots-up from Eprom U37. 54 JOHNSON CONTROLS . JP24 – Remote Leaving Chilled Liquid Temperature Setpoint (J22) type.Microboard FORM 160. This function is for future use. Style “F” and later chillers only. PINS 1-2: RS-485 (required for MV SSS. It is presently not supported. Allows an RS-232 connection to microboard J2 for Microgateway communications. JP16 – COM 2 Serial Port modem selection. Pins 1-2: Enables port 4A. IN: 32K (BRAM 031-02431-000) OUT: 128K (BRAM 031-02565-000) (For 031-02430-000 microboards. Configures analog input for 0-10VDC. If either modem is used.54-M1 (607) JP14 – BRAM size (Microboard 031-02430-001 only) – Must be positioned according to the size of the BRAM installed on the board. JP27 – COM 4 serial communications port. JP17 must be configured for modem interface. JP22 – Factory mounted thermal-type flow sensor – condenser. 2-10Vdc. Configures analog input for 0-10VDC. 0-20mA or 4-20mA. 0-20mA or 4-20mA. 2-10Vdc. Pins 2-3: Enables port 4B. this is a non-removable wire jumper soldered in place at time the board is manufactured. IN: – Use external modem OUT: – Use on-board modem JP17 – COM 2 Serial port mode (microboard 03102430-001 only). Pins 1-2: Not Used Pins 2-3: Style F and later chillers with factory mounted evaporator thermal-type flow sensor. Configures port to accept either an external modem connected to J13 or an onboard modem mounted in socket SK1. OUT: Allows 0-10VDC or 2-10VDC input on J22-3 Pins 1-2: Allows a 0-20mA or 4-20mA input on J22-4 Pins 2-3: Not used. MV VSD and those Variable Speed Drives that communicate with the microboard using Modbus protocol. Configures COM 4 port for either RS-485 (COM 4A) or RS232 for MicroGateway board (COM4B). Pins 1-2: Not Used Pins 2-3: Style F and later chillers with factory mounted condenser thermal-type flow sensor. JP23 – Remote Current Limit Setpoint (J22) type. depending on the position of this jumper. Style “F” and later chillers only. Not used. PINS 2-3: RS-232 (not used) JP21 – Factory mounted thermal-type flow sensor – evaporator. It must NOT be removed by field service personnel. OUT: Allows 0-10VDC or 2-10VDC input on J22-1 Pins 1-2: Allows a 0-20mA or 4-20mA input on J22-2 Pins 2-3: Not used. This port can operate in either RS-232 or RS-485 mode. Allows an RS-485 connection to microboard J11. FORM 160. SW1-4 – Not used. Must be set according to whether the chiller is cooling water or brine solution. 3A JOHNSON CONTROLS 55 . Enables normal chiller operation. ON – Brine. Refer to SECTION 24 of this manual.54-M1 (607) TABLE 4 MICROBOARD 031-02430-000 AND 031-02430-001PROGRAM SWITCHES SW1-1 – Refrigerant Selection. OFF – Water. ON – Enables diagnostics. SW1-3 – Diagnostics. Enables or Disables the software diagnostics. Disables normal chiller operation. ON – R134a OFF – R22 SW1-2 – Liquid Type. Leaving Chilled Setpoint range is 10ºF to 70ºF. Leaving Chilled Setpoint range 38ºF (36ºF if Smart Freeze enabled) to 70ºF. Must be set according to the refrigerant type installed in chiller. OFF – Disables diagnostics. Microboard FORM 160.D.54-M1 (607) BRAM BIOS EPROM PROGRAM SWITCHES PROGRAM DOWNLOAD CONNECTOR BOOT-UP LED STATUS DISPLAY = Jumpers = Test Points = L. = Switches LD09254a FIG. 7A – MICROBOARD 031-02430-000 AND 031-02430-001 56 JOHNSON CONTROLS .E. 3 VDC TP1 2.5 VDC GND J1-2 LD09255 FIG.FORM 160.54-M1 (607) SWITCH IN "WRITE" POSITION END OF CARD 031-02474-001 SWITCH IN "WRITE PROTECT" POSITION 3A FIG.5 VDC VOLTAGE REG TP3 J1-1 + 5 VDC F1 5A 3.12 VDC J1-4 + 12 VDC TP10 2.5 VDC 5 VDC VOLTAGE REG TP4 J1-3 + 12 VDC F2 5A + 5 VDC (Analog)(For Transducer and Thermistors) + 5 VDC (VCC) TP5 2. 8A – PROGRAM CARD 031-02474-001 J1-8 Not Used .3 VDC VOLTAGE REG TP2 3. 9A – MICROBOARD (031-02430-000 AND 031-02430-001) DC POWER SUPPLY TEST POINTS JOHNSON CONTROLS 57 . ) 10 K 7 BRIGHTNESS CONTROL (WIPER) TO BACKLIGHT INVERTER BOARD 8 BRIGHTNESS CONTROL (-) JP7 NOTES: 1. LD04054 FIG. J6-6 not connected (N.Microboard FORM 160.0 VDC J6 JP8 6 BRIGHTNESS CONTROL (+) OR (N.C. 3. 10A – MICROBOARD LAMP DIMMER CIRCUIT 58 JOHNSON CONTROLS . Out = Variable Resistance. Potentiometer is actually an integrated circuit that is the electrical equivalent of a 10K potentiometer.C. In = Variable Voltage. Refer to Program Jumper Listing in Table 3 for applications. The position of Program Jumpers JP7 & JP8 determine the output at J6-7.54-M1 (607) 5.) to Backlight Inverter Board when display is manufactured by Sharp or NEC. 2. 4B.54-M1 (607) CR5 CR4 R G TX1 RX1 RS-232 MICRO COM 1 COM 4B (NOTE 1) CR13 CR14 R G TX4 RX4 J2 TX RX DTR DSR GTX GRX 4 3 5 2 7 6 8 9 PRINTER MICROGATEWAY RS-485 + 3 2 1 J11 3 2 1 4 5 MULTI-UNIT COMMS 3A JP27 COM 4A (NOTE 1) -+ 5VDC GND SHIELD CR18 CR17 R G TX2 RX2 COM 2 (NOTE 3) RS-232 DCD DSR RTS CTS DTR RX TX J13 1 2 4 6 7 3 5 UART 3 1 2 CR15 CR16 R G TX3 RX3 JP17 RS-485 (+) (-) GND 8 10 9 . FIG. MODBUS PROTOCOL VSD LOGIC BOARD RS-485 COM 3 + -+ 5VDC GND SHIELD J12 3 2 1 4 5 OPTIONAL I/O (Hot Gas Bypass) CR20 CR19 R G TX5 RX5 OPTO-COUPLE COM 5 TX RX COMMON NOTE 2 NOTE 2 J15 1 2 3 4 5 6 YORK PROTOCOL – VSD ADAPTIVE CAPACITY CONTROL BOARD OR STYLE B LCSSS NOTES: 1. 11A – MICROBOARD SERIAL DATA COMMUNICATIONS PORTS JOHNSON CONTROLS 59 .4A. The COM 2 port has two selectable serial modes. J15-5 Loop-Around Test OUT. J15-4 Loop-Around Test IN. Refer to Table 3. It can operate in either RS-232 or RS-485 mode. The COM 2 RS-485 port is not present on 031-02430-000 microboard. 55 for details. depending upon the position of program jumper JP17 as follows: On pins 1 & 2 for RS-485 operation.FORM 160. LD07788D 3. On Pins 2 & 3 for RS-232 operation. Refer to Table 3. 1 & 2 . MV SSS. 2 & 3. Refer to Fig. Microboard Program Jumper JP27 determines whether COM 4A or 4B can be used. 2.MV VSD. MLM.Microboard FORM 160. 2. FIG. Program Jumpers JP23 – JP24 must be positioned on pins 1-2 or 3-4 according to input signal type.01.5 K 24 VAC FACTORY MOUNTED CONDENSER THERMAL-TYPE FLOW SENSOR (style F and later chillers) (note 2) 2 4 3 1 4 16 17 3 +5V 2 3 1 JP22 24 VAC MUX J22 0-10 VDC / 2-10 VDC 0-20 mA / 4-20 mA 1 2 2 3 1 REMOTE CURRENT LIMIT SETPOINT JP23 REMOTE LEAVING CHILLED LIQUID TEMP SETPOINT 0-10 VDC / 2-10 VDC 0-20 mA / 4-20 mA 3 4 2 3 1 JP24 REMOTE SETPOINT GND CONNECTIONS 5 LD09565 NOTE: 1.xxx and later. Program Jumpers JP21 and JP22 must be on pins 2-3 on style F and later chillers equipped with factory-mounted thermal-type flow sensors. Refer to Table 3. Applies to Flash Memory Card version C.5 K 2 3 1 47K +5V JP21 200 7.07. 12A – CONFIGURABLE ANALOG & REMOTE SETPOINT INPUTS 60 JOHNSON CONTROLS .54-M1 (607) FACTORY MOUNTED EVAPORATOR THERMAL-TYPE FLOW SENSOR (style F and later chillers) (note 2) 2 4 3 1 J7 2 14 15 13 71. 14). The High Pressure safety switch “HP”. The contacts of these +12VDC relays operate the external 115VAC coil devices. Electro-Mechanical starter applications. motor contactors. Refrigerant Level Variable Orifice actuator and Variable Geometry Diffuser actuator (certain compressors only) (ref. Therefore. when the input is 0VAC.54-M1 (607) SECTION 4 I/O BOARD (REFER TO FIG. 17). logic low (<+1VDC) when commanding a relay to energize. Fig. Each winding is controlled by a 4 JOHNSON CONTROLS 61 . are connected to terminal strip TB4 (ref.17). the Microboard energizes and de-energizes these devices. as shown in Fig. K18 cannot be re-energized until K13 is again energized. The 115VAC power source that is switched by the remote contacts is supplied by the I/O Board TB4-1. 15) perform the conversion for each Digital Input. the holding contact of K18. There are conditions external to the I/O Board required to energize relay K18. Field connected Digital Inputs. Fig. Fig. 13 and 14.2 seconds later. It provides the start/stop signal to the Compressor Motor Starter and provides Compressor Run status to remote devices (ref. The Microboard energizes each relay by driving the appropriate input at J19 to logic low voltage level (ground potential). There are multiple TB4-1 terminals located adjacent to the field input connections. the output will be +5VDC. 52 and 64A). and remote cycling/safety devices (ref. must be closed and the RUN Switch “1SS” must be in the RUN position. To stop the compressor motor. this will not occur until after a controlled shutdown has occurred and another start sequence has been initiated. The coils of these devices operate on 115VAC and therefore cannot be directly connected to the Microboard. The contact voltage is 115 VAC when closed and 0VAC when open. Solid State Starter applications or a relay mounted on the Variable Speed Drive Logic Board on Variable Speed Drive applications. the I/O Board converts the 115VAC/0VAC contact voltages to 0VDC/+5VDC logic level inputs for the Microboard. K18 remains energized through K14 contacts and holding contacts of K18. 13. system relays and provide operating status to external devices (ref. Digital Inputs are on/off inputs to the Microboard from relay and switch contacts. When the input is 115VAC. Relay K18 is controlled by DC relays K13 (start) and K14 (stop). energizing K18. Fig. To start the compressor motor. 14). The 115VAC will be present at TB1-16 only if the motor controller contacts “CM” are closed and the circuit between external Terminal Strip TB6-1 and TB6-53 is closed. To prevent sags in Utility Power from chattering K18. The left side of the I/O Board performs the Digital Inputs function. the Microboard energizes K13 and K14 simultaneously. the right side performs the Digital Outputs function. 17. The DC voltage at the appropriate input pin at J19 will be a logic high (>+10VDC) when the Microboard is commanding a relay to de-energize. Fig. start/ stop switch. The 115VAC at TB1-6 is applied to the coil of K18 via K13 contacts. 16.17) The I/O (input/output) Board conditions the Digital Inputs for the Microboard and conditions the Microboard’s Digital Outputs for application to other components and devices. such as those from external devices that cycle the chiller. actuators. The Micro reads the state of these contacts and reacts per the Program instructions. one side of the each of the relay coils is permanently connected to +12VDC at J19-26/27. Triacs are used to control the Pre-rotation Vanes actuator.FORM 160. Current flowing through a winding will cause the actuator shaft to rotate in the respective direction. Approximately 0. such as flow switches. the Microboard de-energizes K14. 13 . Per Program instructions. On the I/O Board. An actuator has an open winding and a close winding. along with the contact of K13. These voltages are not suitable for direct input to the Microboard. Digital Outputs are on/off outputs from the Microboard that control solenoid valves. K13 is de-energized. Fig. the Solid State Starter Logic Board (relay K1). Refer to Fig. The other side of each relay coil is connected to the Microboard via I/O Board connector J19. The “CM” are located on the CM-2 Board (relay K1). it has a 115VAC coil. Individual Opto-coupler circuits (ref. creates an anti-chatter circuit for relay K18. Relay K18 is different from all other relays on the I/O Board. the output will be 0VDC. Once energized. These inputs are in the form of dry contacts connected as shown in Fig. The Digital Outputs section of the I/O Board contains +12VDC coil relays that are driven by the Microboard’s logic level outputs. This actuator has three windings.xxx and later – Excess Surge Detected*. The Pre-rotation Vanes Actuator and Variable Geometry Diffuser actuator are manufactured by Barber-Coleman. As described above. the contacts automatically open when the warning condition is no longer present. when turned on. The Triac Driver responds by opening the short from triac Gate to Triac terminal 2. open and close. The desired rotation is produced by shorting the Actuator common terminal to the appropriate direction terminal.Low Temperature” cycling shutdown occurs. Harmonic Filter-Input Frequency Out Of Range. They remain closed for the duration of the shutdown or until the Keypad COMPRESSOR switch is placed in the Stop-Reset (O) position. Evaporator-Low Pressure Limit. The Triac driver responds by shorting the Triac GATE to Triac terminal 2. Under Program control. K0 . Condenser-High Pressure limit.I / O Board FORM 160. Harmonic Filter-Operation Inhibited. contact rating is 5 amps resistive or 2 Amps inductive @ 250VAC. causing current to flow in the direction winding. they do not open at the completion of “System Coastdown”. the contacts will open only after the warning condition is no longer present and the WARNING RESET key is pressed when logged in at OPERATOR access level or higher. As described above. Vanes Uncalibrated-Fixed Speed. This actuator has two windings. This actuator operates from 24VAC. The following only applies to Flash Memory Card version C. Surge Detected – Excess Surge Limit. They remain closed for the duration of the shutdown or until the Keypad COMPRESSOR switch is placed in the Stop-Reset (O) position. Triacs are turned on to allow current to flow through the appropriate winding to produce the desired rotation. the Microboard drives the Triac Driver input to logic low (<+1VDC) level. 62 JOHNSON CONTROLS . Unless otherwise noted. the Microboard turns the Triacs on and off by applying control signals to the respective Triac Driver. Standby Lube-Low Oil Pressure*. If the OptiView Control Center is retrofit to an existing chiller.Contacts Open” cycling shutdown. On those warnings marked with an asterisk. The Refrigerant Level Variable Orifice Actuator on new production chillers is manufactured by Belimo. Refrigerant Level Out of Range. the Contacts close 13 seconds after the start of “System Prelube”. the relays are energized and de-energized producing contact operation as follows. it could be equipped with a Barber-Coleman Level Actuator that operates as described above.01. One winding produces clockwise rotation and one produces counterclockwise rotation. whereupon they open. Normally. To turn on the Triac. the other produces counterclockwise rotation. When a Triac is turned on. the voltage will be approximately 20 to 30VAC. A voltmeter can be used to determine if a Triac is turned on or off. If Microboard Program Switch SW1-8 is in the ON position. K1 . Setpoint Override*.Contacts Open” or “System Cycling . RELAY TIMING Under Program control. Refer to Variable Geometry Diffuser Section 22A. it will be <10VAC. The Triac Driver is an optocoupler device that isolates the Microboard low voltage circuits from the higher actuator voltages. The 115VAC applied to the Field Winding induces a 20 to 30VAC voltage into each of the direction windings. causing the actuator shaft to rotate. whereupon they open. To turn the Triac off. from Triac terminal 1 to Triac terminal 2. This board is populated with the required Triacs Q3 and Q4 that apply the open and close signals to the Variable Geometry Diffuser ring actuator.MLM. When the chiller is started. When the Triac is turned off. they do not open at the completion of “System Coastdown” when the chiller shuts down on a “Multiunit Cycling . Condenser or Evaporator Transducer Error*. Measure across the Triac. they open coincident with the completion of “System Coastdown” with the following exceptions: a. On most warnings. the Microboard opens its input to the Triac Driver and allows the input to pull up to +12VDC. If a “Leaving Chilled Liquid .05. a Field winding and two direction windings.Chilled Water Pump Starter (TB2-44/45) Dry closure contacts. Chillers equipped with the Variable Geometry Diffuser are supplied with and require I/O Board 03101743-002.54-M1 (607) Triac. Triacs control the current through the open and close windings. b. Harmonic Filter-Data Loss. One direction winding produces clockwise rotation.Anticipatory Alarm (TB2-55/56) Dry closure contacts. Contacts close when one of the following Warning messages is Displayed. Real Time Clock Failure. it permits current to flow through the actuator winding. Compressor Motor Stop (stop) (TB 1-6/16) Contacts close coincident with the beginning of “System Run”.2 seconds and then open. K11 . whereupon they open. K6-K 9 . the contacts will close when the cycling condition clears.07. Then connect I/O Board TB2-151 to the Condenser Pump Motor Starter.Condenser Motor Pump Starter (TB2-150/151) (applies to Flash Memory Card version C. 4 JOHNSON CONTROLS 63 . contacts close 13 seconds after “System Prelube” is initiated. (TB1-61) Contacts close 1minute after “System Run” is initiated. K13 . a field installed wire must be connected from TB5-22 to I/O Board TB2-150. They remain closed for 0. Contacts open at completion of “System Coastdown”. contacts close for 2 minutes every 24 hours since the oil Pump was last automatically or manually run.Compressor Motor Starter (start) (TB1-6/16) Contacts close coincident with the beginning of “System Run”. the contacts will close only after the Safety condition clears.MLM.FORM 160. Liquid Line Solenoid (style D and later chillers . They remain closed until the safety condition clears and a manual reset is performed by placing the COMPRESSOR switch in the Stop-Reset(O) position. fixed or variable speed oil pump). They remain closed until the cycling condition clears. If Standby Lubrication is enabled. The contacts open coincident with any Cycling or Safety shutdown or anytime the Keypad COMPRESSOR switch is placed in the StopReset (O) position.01.xxx or later version) (TB1-64/17) Contacts operate the same as K15. the contacts remain closed at shutdown until all SCR Heatsink temperatures are <105ºF or a maximum of 45 minutes.Oil Heater (“P” compressors and all style F and later chillers equipped with Flash Memory Card version C.Cycling Shutdown Status (TB2-40/41) Dry closure status contacts.54-M1 (607) K2 . They open on chiller shutdown coincident with the beginning of “System Coastdown”. If it is desired to supply the dry contacts with 115VAC power from the OptiView Control Panel to control the Condenser Pump Motor Starter. K12 .Oil Pump Starter (TB 1-29/1) (Style C and earlier chillers) In automatic operation. Vent line Solenoid (style C and earlier chillers. whereupon they open.Oil Return Solenoid (all styles. Analog or ISN Remote mode)(TB2-26/27) Dry closure status contacts that are closed to indicate to a Remote device that the chiller will start upon receipt of a remote start signal. On safety shutdowns.xxx and later) Dry closure contacts.Not Used K10 . They remain closed for the duration of “System Run”. the contacts close for the duration of manual pump operation. They close coincident with a Safety shutdown. They close coincident with a Cycling shutdown.“J” compressor only.04. fixed speed oil pump). variable speed oil pump). K3 . K4 . K14 . a manual reset is performed by placing the COMPRESSOR switch in the Stop-Reset (O) position and then back to the RUN (I) position. They open coincident with the beginning of “System Coastdown”. Anytime the chiller is not in “System Run” or “System Coastdown” and a motor current value of >15%FLA is detected. In manual Oil Pump operation. They open coincident with the beginning of “SYSTEM COASTDOWN” unless the chiller is equipped with the Mod “B” Solid State Starter. the contacts close until motor current is no longer detected. K5 .Safety Shutdown Status (TB2-42/43) Dry closure status contacts. On Cycling shutdowns. Contacts close coincident with beginning of “SYSTEM RUN”.MLM.01. whereupon a complete “System Coastdown” is performed.Remote Mode Ready to Start (only operational in Digital. On Mod “B” Solid State Starter applications. use K5 above) Contacts operate the same as K14. Variable Speed Oil Pump) Contacts are open whenever the Oil Pump is operating. K16 . Liquid Line Solenoid (Style C and earlier chillers.I / O Board FORM 160.(TB1 -34/1)Oil Heater (Style D/E all compressor codes except “P”. fixed speed oil pump) • Electro-Mechanical and Solid State Starter applications: Contacts close 1 minute after “System Run” is initiated.Condenser Motor Pump Starter (TB1164)(If chiller is equipped with Mod “B” Solid State Starter. When the Oil Pump is not operating. K17 . contacts close if oil temperature reaches > 140ºF.Compressor Motor Starter (TB5-22/25) Run Status (TB2-35/36) Contacts operate the same as K14. K18 . • Compressor Motor Variable Speed Drive applications: After chiller has been running for > 1 minute. The contacts close when the Oil Temperature decreases to 4ºF below target value.High Speed Thrust Solenoid (Style C and earlier chillers. They remain closed until the oil temperature decreases to < 135ºF. They open on chiller shutdown coincident with the beginning of “System Coastdown”. whereupon they de-energize. 64 JOHNSON CONTROLS . the contacts are operated to maintain the Oil Temperature at a target value of 50ºF above the Condenser Saturated Temperature from a minimum of 110ºF to a maximum of 160ºF. Fixed Speed Oil Pump)(TB1-62/1) Contacts close 15 sec onds after “System Run” is initiated.54-M1 (607) K15 . open at 3ºF above the target value. 54-M1 (607) 4 LD04055 FIG. 13 – I/O BOARD JOHNSON CONTROLS 65 .FORM 160. 28 TB3 .1 TB4 .80 TB3 .1 TB3 .95 TB4 .1 TB4 .1 TB4 .1 TB4 .1 TB4 .1 LD09566 J1 -19 NOT USED 115VAC 115VAC J1 -20 FIG.8 TB4 .30 FACTORY CONNECTIONS TB3 .11 J1 -15 MULTI-UNIT SEQUENCE AUXILIARY SAFETY SHUTDOWN 115VAC J1 -16 J1 -17 CONDENSER WATER FLOW SWITCH J1 -18 NOT USED 115VAC TB4 .9 TB4 .71 OIL PUMP VSD CYCLING SHUTDOWN VANE MOTOR SWITCH NOT USED HIGH SPEED THRUST BEARING LIMIT SWITCH ("P" compressors and style F and later chillers with "G.18 TB3 . 14 – I/O BOARD DIGITAL INPUTS 66 JOHNSON CONTROLS .19 TB4 .81 115VAC TB4 .1 REMOTE START REMOTE STOP 115VAC TB4 .I / O Board FORM 160.32 OPTOCOUPLER J1 -1 J1 -2 J1 -3 J1 -4 J1 -5 J1 -6 J1 -7 J1 -8 J1 -9 J2 .13 TB4 .20 TB4 .7 J1 -10 J1 -11 TB4 .82 TB4 .54-M1 (607) HIGH PRESSURE SAFETY MOTOR CONTROLLER SHUTDOWN STOP SWITCH (LOCAL) START SWITCH (LOCAL) VGD LIMIT SWITCH (If equipped with Variable Geometry Diffuser) TB3 . Q" and "H5-8" compressors) TB3 .70 TB3 .31 TB4 .1 TB3 .12 REMOTE LEAVING CHILLED LIQUID TEMP SETPOINT (PWM) REMOTE CURRENT LIMIT SETPOINT (PWM) 115VAC J1 -12 J1 -13 FIELD CONNECTIONS CHILLED WATER FLOW SWITCH J1 -14 REMOTE / LOCAL CYCLING 115VAC TB4 . X +5VDC J19 .X OPTOCOUPLER J1 .FORM 160.2 JI .X TB3 .1 TB3 .22/23 LD04057 FIG.54-M1 (607) OPTO-COUPLER TYPICAL (20 CKTS) TB4 . 16 – I/O BOARD TYPICAL FIELD CONNECTIONS JOHNSON CONTROLS 67 .Y 4 NEUTRAL TB3 .Y 115VAC FIELD SUPPLIED DRY CONTACTS (RATED 5MA @ 115VAC) TB4 .21 JI . 15 – I/O BOARD TYPICAL OPTO-COUPLER CIRCUIT TB4 .1 LD04058 FIG. 150 CONDENSER MOTOR PUMP STARTER (Applies to Flash Memory Card version C.64 40 K10 K10 TB1 .44 + 12 VDC CHILLED WATER PUMP STARTER 50 K0 K0 TB2 .41 TB2 .55 ANTICIPATORY ALARM 49 K1 K1 TB2 .153 TB2 .xxx and later) 45 K5 K5 TB2 .40 CYCLING SHUTDOWN 46 K4 K4 TB2 .43 TB2 .01.156 NOT USED 42 K8 K8 TB2 .MLM.165 NOT USED OIL HEATER ON/OFF ("P" compressors and all style F and later chillers equipped with Flash Memory Card version C. 17 – I/O BOARD DIGITAL OUTPUTS 68 LD09042 JOHNSON CONTROLS .17 TB1 .157 TB1 .xxx or later version) OIL PUMP STARTER (Style C and earlier chillers) 41 K9 K9 TB1 .1 TB1 .54-M1 (607) J1 + 12 VDC 26 27 TB2 .56 TB2 .154 NOT USED 43 K7 K7 TB2 .61 OIL RETURN SOLENOID (ALL STYLES) (LIQUID LINE SOLENOID (Style D and later chillers) J-COMPRESSOR ONLY) VENT LINE SOLENOID (Style C and earlier chillers) 38 K12 K12 TB1 .155 TB2 .1 TB1.42 SAFETY SHUTDOWN 47 K3 K3 TB2 .29 39 K11 K11 TB1 .1 FIG.26 REMOTE MODE READY TO START 48 K2 K2 TB2 .I / O Board FORM 160.01.45 TB2 .07.04.151 TB2 .MLM.152 NOT USED 44 K6 K6 TB2 .27 TB2 . 54-M1 (607) (Not applicable to "P" compressors or style F and later chillers)(See Note 3) (See inset below for all others) J1 COMPRESSOR MOTOR STARTER (START) 37 K13 K13 K14 K18 K14 1 TO I/O BOARD TB3-32 START COMPRESSOR MOTOR STARTER (STOP) OIL HEATER ON/OFF (STYLE D/E .ALL COMPRESSORS EXCEPT "P") LIQUID LINE SOLENOID (style C and earlier chillers) NOT USED (style D and later chillers) HIGH SPEED THRUST SOLENOID (style C and earlier chillers) CONDENSER MOTOR PUMP STARTER (All starter applications except Mod "B" Solid State Starter) 36 TB1-6 TB1-16 35 TB1-34 K15 K15 TB1-1 34 TB1-62 K16 K16 TB1-1 TB2-164 K17 K17 (Chillers equipped with "P" compressors and all style "F" and later chillers) (See Note 3) RUN HP STOP TO I/O 16 BOARD J2-1 CM/TM (NOTE 2) 53 1 4 K13 START K14 K18 TB1-6 TB1-16 STOP 16 CM/TM (NOTE 2) 53 TO I/O BOARD J2-1 TB3-32 RUN TB1-33 COMPRESSOR MOTOR STARTER K18 TB1-2 115VAC NEUTRAL K18 K18 TB5-23 NOT USED TB5-22 115 VAC TB5-25 COMPRESSOR MOTOR STARTER TB2-35 TB2-36 RUN STATUS 15 1 HP K18 TB1-3 2 PRV ACTUATOR OPE PRV OPEN J1-33 TRIAC DRIVER Q1 G 1 2 TB1-59 N X G PRV CLOSE J1-32 TRIAC DRIVER 1 Q2 2 3 TB1-58 CL OSE L1 FIELD L2 NOTES: 1. 115VAC LD09043 FIG. Chillers equipped with “P” compressors and all style "F" and later chillers use a different High Pressure (HP) Switch and associated interface than other compressor applications. 3.FORM 160. – – – – – – – indicates wiring external to I/O Board. 2. 17 (CONT’D) – I/O BOARD DIGITAL OUTPUTS JOHNSON CONTROLS 69 . “CM” – Contacts of Relay K1 on Current Module (EM Starter Applications) or Solid State Starter Logic Board (Solid State Starter Applications) or VSD Logic Board (Compressor Motor Variable Speed Drive Applications). 54-M1 (607) TB1-158 VARIABLE GEOMETRY DIFFUSER OPEN VARIABLE GEOMETRY DIFFUSER CLOSE 2 VARIABLE GEOMETRY DIFFUSER ACTUATOR (BARBER-COLEMAN) J1-31 TRIAC DRIVER Q3* G 1 3 TB1-159 OPE N X G J1-30 TRIAC DRIVER 1 Q4* 2 2 TB1-160 CLO SE L1 FIELD L2 * Triacs Q3 and Q4 are present on I/O Board 031-01743-002 only.I / O Board FORM 160. 115VAC TB1-161 2 REFRIGERANT LEVEL CONTROL ACTUATOR (BARBER-COLEMAN) REFRIGERANT LEVEL CONTROL OPEN J1-29 TRIAC DRIVER Q5 G 1 3 TB1-162 OPE N X REFRIGERANT LEVEL CONTROL CLOSE G J1-28 TRIAC DRIVER 1 Q6 2 2 TB1-163 CLO SE L1 FIELD L2 115VAC TB1-161 2 REFRIGERANT LEVEL CONTROL ACTUATOR (BELIMO) 2 OPE N REFRIGERANT LEVEL CONTROL OPEN J1-29 TRIAC DRIVER Q5 G 1 TB1-162 24VAC 1 CLO SE REFRIGERANT LEVEL CONTROL CLOSE G J1-28 TRIAC DRIVER 1 Q6 2 3 TB1-163 115VAC LD09567 FIG. 17 (CONT’D) – I/O BOARD DIGITAL OUTPUTS 70 JOHNSON CONTROLS . the drive signals are applied within each row. Inverter Board interface cable and Program command set. red. the following description is for information only.54-M1 (607) SECTION 5 LIQUID CRYSTAL DISPLAY (REFER TO FIG. In FIXED mode. Displays that could be provided from YORK in new chillers or as replacement parts are: • • • • SHARP LQ10D367/368 (031-01774-000) SHARP LQ10D421 NEC NL6448AC33-24 LG SEMICON LP104V2-W (031-02046-000) the conduction of which determines the amount of light that will pass through the window.FORM 160. green and blue. along with supporting components Display Interface Board and Backlight Inverter Board are mounted on a plate that is attached to the OptiView Control Center door. This kit contains a replacement Display and all compatible supporting components. red green and blue. The next VSYNC pulse causes the above cycle to repeat. Backlight Inverter Board and Inverter ribbon cable provided. The columns of pixels are driven from left to right and the rows are driven top to bottom. Backlight Inverter Board. These are the part numbers of the supporting components that are compatible with the installed display. Each pixel’s drive signal is an 18 bit binary word. through which a variable amount of light from the Display Backlight is permitted to pass through the front of the display. The various display screens are selected for display using the Keypad keys. However. or one every 39. the first pixel drive signal is applied a fixed number 71 5 The YORK part numbers of the Display Interface Board. This continues until all 480 rows have been addressed. Similarly. JOHNSON CONTROLS .18M Hz. the next HSYNC pulse applies drive signals to row 2. The rows are driven from top to bottom. Beginning with the top row. Although there are variations in control signal timing between different display manufacturers. Refer to Fig. The Display provided in the new chiller or from YORK as a service replacement part. Since these control signals occur at rates greater than can be read with a Voltmeter.200 pixels arranged in a 640 columns X 480 rows matrix configuration. A clear plexiglass faceplate prevents display surface damage. Service replacement Displays or supporting components cannot be arbitrarily selected!!! As explained below. 6 bits for each of the 3 colors. These supporting components can be individually replaced. Non-compatibility of components will result in incorrect operation!!! Refer to “Display Interface Board” and “Backlight Inverter Board” sections that follow this section. Total elapsed time to address all 480 rows is approximately 16 milliseconds. an RGB drive signal is applied to the first pixel. The greater the binary value. 23 depicts typical control signals.4 inch color Liquid Crystal Display. beginning with the left most pixel and ending with the right most pixel. Fig. Display replacement kit 331-01771-000 must be ordered as detailed below. The first Horizontal Sync (HSYNC) pulse initiates the sequential application of RGB drive signals to the 640 pixels in row 1. There are 480 horizontal rows of pixels. Each pixel consists of 3 windows. replacement Displays are provided from YORK as kits to assure compatibility of all components. each drive signal contains a horizontal and vertical sync signal. if the Liquid Crystal Display fails. As long as the ENABLE signal is present. 28. Each Display requires a specific Display Interface Board. To coordinate the drive signals and assure the columns are driven from left to right and the rows are driven from top to bottom. The overall pixel color is a result of the gradient of red. System operating parameters are displayed on various color graphic screens. sequentially left to right. could be manufactured by any of several approved manufacturers. Displays can be operated in FIXED mode or DISPLAY ENABLE mode. Typically it takes 31 microseconds to address all 640 pixels. The conduction of each transistor is controlled by a signal from the Display Controller on the Microboard. 18 . are listed on a label attached to the Display mounting plate.27) A 10. Therefore. The Display has 307. Each row contains 640 3-window pixels.72 nanoseconds. Under Program control. the Display Controller on the Microboard sends a drive signal for each pixel to create the image on the display. Imbedded in each window of the pixel is a transistor. the greater the amount of light permitted to pass. The Vertical Sync (VSYNC) pulse starts the scan in the upper left corner. RGB drive signals are then applied to the remaining 639 pixels at the CLK rate of 25. The Display Interface Board receives these display drive signals from the Microboard J5 and applies them to the Display at connector CN1. Upon receipt of the ENABLE signal. green and blue light allowed to pass. • LG SEMICON Display (031-02046-000) does not have the fixed mode feature. in OptiView Control Center applications. The Backlight Lamp provides the illumination for the display. Fig. Microboard Program Jumpers JP3. 4. The lamp is controlled by on/off commands and brightness control signals applied to the Backlight Inverter Board from the Microboard. The Display reads these voltage levels and automatically assumes NORMAL or REVERSE scan operation. as required by the Display manufacturer. 28). the Microboard reads the Panel ID wire jumpers P1D0 . In image reversal applications. Others use two lamps. The actual Display that is installed in the OptiView Control Center of the new chiller is determined by the Display manufacturer contractual agreement in place during the time of OptiView Control Center production. The Microboard Program determines when the lamp is turned on and off and the lamp brightness. there is a different 72 Display Interface Board required for each Display application and each has a unique jumper configuration that identifies the Display. Service replacement lamps are stocked in the YORK Service Parts Distribution Center. beginning with the top row and continuing sequentially through the rows to the last row. 5. 7 and 8 determine the voltage levels of the control signals sent to the Backlight Inverter Board and must be configured per the Display manufacturer’s requirements as listed in Table 1. Refer to replacement parts list for appropriate replacement lamp. As described above. JOHNSON CONTROLS . Also refer to the preceding “Microboard” section for a detailed description of the Lamp Dimmer circuit. The SHARP or NEC Display is placed in the NORMAL or REVERSE scan mode by the voltage levels on the Display Interface Board J1-30 and J1-31 (display connector CN1-30/31). “Program Jumpers”. the Display scan is left to right. when AC control power is first applied to the OptiView Control Center. Refer to DISPLAY INTERFACE BOARD section that follows for jumper configurations. as part of the power-up sequence.3VDC. The ribbon cable that connects the Microboard to the Backlight Inverter Board also varies according to the Display manufacturer’s requirements. it will vary according to the Display manufacturer. Each Display manufacturer specifies the required lamp for their display. Each Display manufacturer specifies the Backlight Inverter Board to be used. These voltage levels are determined by the configuration of Wire jumpers P30 and P31 on the Display Interface Board (ref. The DC power source to operate the Display is provided by the Microboard J5. This signal is typically present 4-48 CLKS after the end of the HSYNC pulse and 2-16 CLKS prior to the next HSYNC pulse. display operates in fixed mode. This illumination voltage is created from a low level DC voltage (+12VDC or +5VDC as required by the Display manufacturer) by the Backlight Inverter Board. Displays by different manufacturers can require different timing and control signals. The lamp is illuminated by applying a high voltage AC (500 to 1500VAC) to it. image reversal is sometimes required. However. All YORK applications operate in the DISPLAY ENABLE mode. Therefore.When ENABLE maintained “low”. Average lamp life is 25000 hours (2. The position of Microboard Program Jumper JP2 determines which of these power sources is supplied to the Display. Some Display manufacturers require +5VDC. Since the Display Interface Board identifies the Display for the Microboard. A detailed description of the operation of this board is in the “Backlight Inverter Board” section that follows. JP2 must be positioned according to the Display manufacturers requirements.9 years).P1D3 on the Display Interface Board and determines which Display is present. The Microboard must know which Display is present in order provide the correct signals. The state of the ENABLE (Display Interface Board J1-27) signal from the Microboard places the Display in the desired mode as follows: • SHARP LQ10D367/368 (031-01774-000) & LDQ10D421 Displays . Some displays use one lamp.54-M1 (607) (48) of clock (CLK) cycles from the end of the HSYNC pulse and the drive signals are terminated a fixed number (16) of CLK cycles prior to the next HSYNC pulse. Lamps are replaceable. beginning with the last row and proceeding to the top row. It can then provide the correct timing and control signals to produce the graphic image. • NEC NL6448AC33-24 Displays . Lamp brightness is controlled by varying the high voltage AC.Liquid Crystal Display FORM 160. A complete explanation of this process is included in the preceding “Microboard” section and the “Display Interface Board” section that follows. the scan is reversed. In DISPLAY ENABLE mode. the scan is right to left. Refer to Fig. display operates in fixed mode. others require +3. the pixel drive signals are applied to the pixels only while ENABLE signal is present. in Display applications other than OptiView Control Centers. Therefore. The greater the voltage the brighter the illumination. Refer to Table 1. but not interchangeable between different displays. 29 to 31.When ENABLE maintained “high” or “open”. 6. 6. BACKLIGHT LAMP REPLACEMENT: SHARP LQ10D367/368 (031-01774-000) Display: (Refer to Fig. Since each Display manufacturer requires a specific Display Interface Board. 4. Electrostatic discharges may damage the display. The display front surface is easily scratched. Microboard Program Jumpers JP2JP8 will have to be configured appropriately for the replacement display. Connecting or disconnecting wires to the display with power applied will damage the display!!! JOHNSON CONTROLS . Grasp Lamp housing and pull until Lamp housing is completely removed from the display. 3. 4. The kit consists of the following items mounted on a Display mounting plate: Display Replacement Kit 331-01771-000: 1. Installation instructions. 4. Installation: Follow instructions above for SHARP 367 Display. Remove protective cover from rear of Display. 3. 5. All mounting hardware 7. Slide new Lamp into Display from left to right until Lamp housing protrusion locks into Display locking tab. the Display received for service replacement may be by a different manufacturer than the one in the OptiView Control Center. Installation: 1. Display Handling: 1. replacement Displays are ordered and supplied as a Display Replacement Kit (YORK Part Number 331-01771-000) to assure component compatibility. 2. Grasp Lamp housing and pull until Lamp housing is completely removed from the Display. 3. Use no water or chemicals. bend the locking tab outward slightly to clear the Lamp housing protrusion. 1. Peel off very slowly to prevent static damage. 29) Removal: The Lamp slides into the Display from left to right and is secured with a locking tab. If soiled. It could break if dropped.54-M1 (607) Displays stocked for Service replacement are a result of that same agreement. Liquid Crystal Display with Lamp Appropriate Display Interface Board for item 1 Appropriate Backlight Inverter Board for item 1 Appropriate ribbon cable (Backlight Inverter Board to Microboard) for item 1 5. 2. 4. 2. Using fingernail or thin flat blade screwdriver. 2. press in on the small black locking tab. The display is made of glass. Remove Control Power from the OptiView Control Center. Backlight Inverter Board and Inverter Ribbon Cable. Grasp Lamp AC power connector and gently pull until Lamp clears locking tab. Therefore. A label attached to the Display mounting plate lists the YORK part numbers of the Display supporting components mounted on the Display mounting plate and the required Microboard Program Jumper (JP2 through 8) configurations. wipe with a dry cotton cloth. Apply Control Power to OptiView Control Center. 3. The items supplied in the kit are compatible with the supplied Display. Disconnect lamp AC power connector from defective lamp. 2. SHARP LQ10D421 Display (refer to Fig. Remove Control power from the OptiView Control Center. Grasp Lamp AC power connector and gently pull until Lamp housing clears locking tab.FORM 160. Disconnect Lamp AC power connector from Backlight Inverter Board. 30) Removal: Both the top and bottom lamps slide into the Display from left to right and are secured with locking tabs. The display is static sensitive. Using a thin flat blade screwdriver. Connect Lamp AC power connector to Backlight Inverter Board. 1. 5. Ribbon cable (Display Interface Board to Microboard) 6. 3. Remove protective cover from rear of display. 73 5 Always remove control power from the OptiView control center before connecting or disconnecting wires to the display. A laminated film is adhered to the display front glass surface to prevent it from being scratched. Slide new Lamp into Display from left to right until Lamp housing is fully inserted. 31) Removal: Not available at this time. 2. Connect Lamp AC power connector to Backlight Inverter Board. Installation: Not available at this time. Disconnect Lamp AC power connector from Backlight Inverter Board. 1. 4. Using small Phillips screwdriver. LG Semicon LP104V2-W (031-02046-000) Display (refer to Fig. 18 – DISPLAY. 3.Liquid Crystal Display FORM 160. Remove protective cover from rear of Display. 2. Installation: 1. Apply AC power to OptiView Control Center. MOUNTING 74 JOHNSON CONTROLS . 5. Secure Lamp with Lamp retaining screw. LD04062 FIG. remove lamp retaining screw. 4. 3. Grasp Lamp AC power connector and gently pull until Lamp housing is completely removed from the Display.54-M1 (607) NEC NL6448AC33-24 Display (refer to Fig. 29) Removal: The Lamp slides into the Display from left to right and is secured with a screw. Remove Control Power from the OptiView Control Center. Configure Microboard Program Jumpers per label. LD05526 DISPLAY CABLE 031-01769-000 5 FIG.54-M1 (607) BACKLIGHT BULB 025-33752-000 LABEL LIQUID CRYSTAL DISPLAY SHARP LQ10D367 DISPLAY INTERFACE BOARD 031-01765-002 MOUNTING PLATE BACKLIGHT INVERTER BOARD 031-01789-000 INVERTER CABLE 031-01770-003 NOTE: 1. LIQUID CRYSTAL DISPLAY SHARP LQ10D421 DISPLAY INTERFACE BOARD (NOT AVAILABLE) LD04064 FIG.FORM 160. 19 – LIQUID CRYSTAL DISPLAY ASSEMBLY – SHARP LQ10D367/368 (031-01774-000) DISPLAY LABEL INVERTER CABLE (NOT AVAILABLE) MOUNTING PLATE CN3 CN1 CH1 CN2 DISPLAY CABLE (NOT AVAILABLE) BACKLIT INVERTER BOARD (NOT AVAILABLE) NOTE: 1. 20 – LIQUID CRYSTAL DISPLAY ASSEMBLY – SHARP LQ10D421 DISPLAY JOHNSON CONTROLS 75 . Configure Microboard Program Jumpers per label. Configure Microboard Program Jumpers per label. 21 – LIQUID CRYSTAL DISPLAY ASSEMBLY – NEC NL6448AC33-24 DISPLAY 76 JOHNSON CONTROLS .54-M1 (607) INVERTER CABLE (NOT AVAILABLE) MOUNTING PLATE CN2 CH1 CN1 CN2 BACKLIT INVERTER BOARD (NOT AVAILABLE) LIQUID CRYSTAL DISPLAY NEC NL6448AC33-24 DISPLAY CABLE (NOT AVAILABLE) DISPLAY INTERFACE BOARD (NOT AVAILABLE) LABEL LD04065 NOTE: 1.Liquid Crystal Display FORM 160. FIG. BP = Back Porch = 4-48 CLKS 2. FP = Front Porch = 2-16 CLKS RGB LD04066 FIG.FORM 160. 22 – LIQUID CRYSTAL DISPLAY ASSEMBLY . Configure Microboard Program Jumpers per label.72 NS DISPLAY PERIOD 640 CLKS DISPLAY PERIOD DISPLAY PERIOD CLK (25. 23 – LIQUID CRYSTAL DISPLAY TYPICAL CONTROL SIGNAL TIMING JOHNSON CONTROLS 77 .54-M1 (607) BACKLIGHT BULB 025-34564-000 LABEL LIQUID CRYSTAL DISPLAY LG SEMICON LP104V2-W DISPLAY INTERFACE BOARD 031-01765-001 MOUNTING PLATE 4564 1 4 BACKLIGHT INVERTER BOARD 031-01789-000 INVERTER CABLE 031-01770-003 NOTE: 1.18 MHz) NOTES: 1.LG SEMICON LP104V2-W (031-02046-000) 480 ROWS 16MS VSYNC 31US HSYNC ROW 1 BP FP ROW 2 ROW 480 640 COLUMNS ENABLE 39. DISPLAY CABLE 031-01769-000 LD05525 5 FIG. 24 – DISPLAY (SHARP LQ10D367/368) LAMP REPLACEMENT (031-02046-000) A BLACK LOCKING TAB FLAT HEAD SCREWDRIVER REAR VIEW LAMP UNIT BLACK LOCKING TAB A B C " ∇ " MARKING AT THE SIDE OF THE LAMP UNIT " " MARKING AT THE METAL PORTION AT THE SIDE OF THE MODULE ∇ REAR VIEW C B LD04068 FIG. 25 – DISPLAY (SHARP LQ10D421) LAMP REPLACEMENT 78 JOHNSON CONTROLS .Liquid Crystal Display FORM 160.54-M1 (607) BEZEL LAMP HOLDER WIRE (white/GND side) PROTRUSION HOLE LOCKING TAB WIRE (pink/HOT side) DIRECTION A DIRECTION B LD04067 DIRECTION C FIG. 27 – DISPLAY (LG SEMICON LP104V2-W (031-02046-000)) LAMP REPLACEMENT JOHNSON CONTROLS 79 .FORM 160. 26 – DISPLAY (NEC NL6448AC33-24) LAMP REPLACEMENT BEZEL LAMP HOLDER WIRE (white/GND side) RETAINING SCREW WIRE (pink/HOT side) DIRECTION B LD05527 DIRECTION C FIG.54-M1 (607) NOT AVAILABLE AT THIS TIME LD04069 5 FIG. beginning with the bottom row and proceeding to the top row. top to bottom The wire jumpers on this board are not field configurable. by providing the Microboard with a means of automatically determining which Display is present.Reverse scan: right to left P31 IN . In image reversal applications.Normal scan. as with typical Program Jumpers.OUT P30 . Each board has the wire jumpers configured appropriately for the display to which it is attached.IN The red. If P31 is IN. If P30 is IN. When P31 is installed. the voltage at J1-30 is +5.3VDC (as determined by position of Microboard Program Jumper JP2). JOHNSON CONTROLS .SHARP LQ10D367/368 (031-01774-000) & LQ10D421 PID0 .Normal scan.OUT PID3 .IN P31 . left to right OUT . The Display reads these voltages and adopts a scan mode as follows: SHARP LQ10D367/368 (031-01774-000) & LQ10D421 Displays: SHARP displays require configuration of both jumpers to achieve total image reversal. 0VDC. 0VDC.3VDC. the Display input (CN1-30) is connected to VCC (+5VDC or +3. image reversal is sometimes required. as shown below. green and blue display drive and control signals are simply passed through the Display Interface Board. beginning with the top row and continuing sequentially through the rows to the bottom row. Since different Display manufacturers require different timing and control signals. P1D0 through P1D3. P30 IN .OUT P30 . top to bottom OUT . if OUT.54-M1 (607) SECTION 6 DISPLAY INTERFACE BOARD (REFER TO FIG. The jumper configurations determine the voltage level at Display Interface Board J1-30 (P30) and J1-31 (P31). The configuration of these jumpers indicates the actual Display that is installed on the OptiView Control Center door. the scan is reversed.IN PID1 .0VDC or +3. The Display Controller on the Microboard is then configured appropriately. as part of the power-up sequence. When P30 is installed. PID0 through PID3. the Display Controller on the Microboard must be configured to meet the requirements of the actual Display installed. when removed. the scan is right to left. the Microboard pulls these signals up to +5VDC. Refer to explanation in “Liquid Crystal Display” section.IN PID2 .Normal scan. bottom to top 80 NEC NL6448AC33-24 Display: P30 Not Used P31 IN or OUT .Reverse scan. when installed. However. There are two variations of the Display Interface Board. 28) The Display Interface Board is located on the Liquid Crystal Display mounting plate and is part of the Microboard interface to the Display. 031-01765-001: Display applicability Jumper configuration LG Semicon LP104V2-W (031-02046-000) & NEC NL6448AC33-24 PID0 . left to right. on the Display Interface Board to determine which Display is present. as determined by the position of Program Jumper JP2 on the Microboard.OUT P31 . connect their respective Microboard (J5) inputs to GND. The value of VCC is either +5VDC or +3. When AC power is applied to the OptiView Control Center. among other items. It permits the use of Displays by different manufacturers. the appropriate Display Interface Board for the Display included in the kit. service replacement Displays are provided as a kit (331-01771-000) that includes. As described in the preceding “Display” section. the Microboard reads the four Panel ID wire jumpers.3VDC as determined by Microboard Program Jumper JP2). In Display applications other than OptiView Control Center applications.OUT 031-01765-002: Display applicability Jumper configuration . Normal scan is left to right.Display Interface Board FORM 160. Normal scan is used in OptiView Control Center applications. if OUT.OUT PID2 . the Display input (CN1-31) is connected to GND.OUT PID3 . the voltage at J1-31 is GND. The YORK part number of the Display Interface Board compatible with the installed Display is listed on a label attached to the Display mounting plate. On Sharp and NEC displays the configuration of wire jumpers P30 and P31 determines whether the Display scan orientation is Normal or Reverse (image reversal) scan. Display Interface Boards are available individually for service replacement.OUT PID1 . 28 – DISPLAY INTERFACE BOARD FORM 160.JOHNSON CONTROLS LG SEMICON LP104V2-W & (031-02046-000) NEC NL6448AC33-24 DISPLAYS 031-01765-001-PID0 IN PID1-3 P30.54-M1 (607) 81 6 . 31 OUT IN OUT IN LD04070 FIG. 3 P30. P31 OUT OUT SHARP LQ10D367/368 (031-01774-000) & LQ10D421 DISPLAYS 031-01765-002 PID0 PID1 PID2. The lamp brightness is controlled by a variable voltage signal. as required by the manufacturer) from the Microboard to a 500 to 1500VAC 60K Hz signal that is applied to the lamp. Other Display manufacturers have only a lamp at the top of the display. These boards are individually available as service replacement parts (the required Backlight Inverter Board part number is listed on the label attached to the Display mounting plate). one at the top and one at the bottom of the display.Display Backlight Inverter Board FORM 160. A label attached to the Display mounting plate lists the required Program Jumper configuration for that particular display. Use extreme caution when working in this area!!! Different Display manufacturers require different Backlight Inverter Boards. The OptiView Control Center could be supplied with any of several approved Displays. turning it off. To increase the average lamp life of 25000 hours. the lamp is turned off. it adjusts the brightness to 100% (maximum). developed by the lamp dimmer circuit (ref. 29). Displays by some manufacturers have two lamps. JP7 and JP8 must be configured to provide the required voltage levels. the brightness control input from the Microboard must be either a variable voltage or a variable resistance. It also adjusts the lamp brightness. the lamp brightness is normally adjusted to 50%. The different board designs require different control voltage inputs. Each Display requires a specific Backlight Inverter Board as specified below and in Figures 29 to 31. the greater the brightness of the lamp. An Inverter converts low level DC voltage (+12VDC or +5VDC.54-M1 (607) SECTION 7 DISPLAY BACKLIGHT INVERTER BOARD (REFER TO FIG. signal turns the lamp on and off. is present at the output of the backlight inverter board. the Microboard generates the control signals that are applied to the Backlight Inverter Board. Depending upon the Display manufacturer. JOHNSON CONTROLS High voltage. the high voltage signal is applied to the lamp.31) The Display Backlight Inverter Board generates a high voltage AC signal that is applied to the backlight lamp. Microboard Program Jumpers JP3 . When CN1-3 is 0VDC. up to 1500VAC. Fig. The magnitude of the signal determines the lamp brightness. service replacement Displays are provided in a kit (YORK P/N 331-01771-000) that includes the appropriate Backlight Inverter Board (refer to “Liquid Crystal Display” Section). This 82 . The Microboard provides the Backlight Enable signal. Refer to Table 1 for required Program Jumper configurations for the various Display applications.0VDC signal. If configured for variable resistance (JP7 and JP8 removed).0VDC range. When the Backlight Enable signal at connector CN1-3 is +5VDC. Program Jumper JP3 must be positioned to provide the required polarity. To accommodate these variations. The lamp dimmer circuit on the Microboard is an IC that is the electrical equivalent of a 10K ohm potentiometer with 100 positions or steps. When configured for variable voltage (JP7 & JP8 installed). When this voltage is not present. 29 . Under Program control. 10). Further. When the Program senses a Keypad key has been pressed. Program Jumper JP4 must be positioned to provide the required voltage. Others require this signal to be 0VDC to turn on the lamp. The Program determines when the lamp is turned on and off. others require +5VDC. Some manufacturers require this signal to be +12VDC. The higher the AC voltage. Microboard Program Jumpers JP7 and JP8 are used to provide the appropriate technique (refer to Fig. causing it to illuminate. some applications require this signal to be a +VDC (+12VDC or +5VDC) to turn on the lamp. The Program adjusts the position of the potentiometer. Fig. This brightness level will still allow the display to be visible. However. Not all applications require the full 5. Microboard Program Jumper JP5 must be positioned to provide the required voltage. The lamp illumination high voltage AC is generated from either +12VDC or +5VDC as required by the manufacturer. Refer to Figures 29 to 31 and locate the output connectors. the output between Microboard J6-7 and J6-8 is a 0 to +5.JP5. the high voltage signal is removed from the lamp. the output between Microboard J6-7 and J6-8 is a 0 to 10K ohm variable resistance. SHARP model LQ10D367/368 (031-01774-000) AND LG Semicon LP104V2-W (031-02046-000) displays require a TDK CXA-LO612-VJL Backlight Inverter Board (YORK P/N 031-01789-000) (ref. These boards generate a lamp illumination high voltage AC from +12VDC. 2 BRIGHTNESS CONTROL (NOTE 2) 1 2 3 4 5 N. 31).FORM 160.C.C. RETURN 500 . When CN1-5 is +12VDC.C. +3.C. The lamp dimmer varies the voltage at CN1-6 over the range of 0 to +2. 0 . 0VDC produces maximum (100%) brightness. Fig. When the “Backlight Enable” signal at connector CN1-5 is 0VDC.1400 VAC BACKLIGHT LAMP DISPLAY BACKLIGHT INVERTER BOARD TYPE: TDK CXA-L0612-VJL PART NUMBER: 031-01789-000 FOR: SHARP LQ10D367/368 (031-01774-000) & LG SEMICON LP104V2-W (031-02046-000) DISPLAYS N.5VDC produces minimum (0%) brightness.10) on the Microboard and applied to connector CN1-6 and CN1-7. NEC model NL6448AC33-24 displays require an NEC 104PWBR1 Backlight Inverter Board (YORK P/N XXXXXXXX-XXX) (refer to Fig. 3 N.C. the high voltage signal is applied to the lamp. 10K Ohms produces maximum (100%) brightness. Refer to Microboard Program Jumpers JP3 & JP4.C. The lamp dimmer varies the resistance between CN3-2 and CN3-3 over the range of 0 to 10K Ohms. INVERTER BOARD CN1 J6 N. 8 7 N. 2. Connector CN2 applies the high voltage lamp illumination signal to the lower lamp. 2. 0VDC = MAX (100%) Brightness. 6 5 4 N.C. developed by the lamp dimmer circuit (ref. The lamp brightness is controlled by a variable resistance. 0VDC produces maximum (100%) lamp brightness. Resistances between these extremes produce linear brightness between 0% and 100%. 29 – DISPLAY BACKLIGHT INVERTER BOARD (SHARP LQ10D367/368 (031-01774-000) & LG SEMICON LP104V2-W (031-02046-000)) 83 JOHNSON CONTROLS . turning it on. These boards generate the lamp illumination high voltage AC from +12VDC.C. The lamp dimmer circuit varies the voltage at CN1-4 over the range of 0 to +3. 10) on the Microboard and applied to connector CN3-2 and CN3-3.0VDC produces minimum (0%) brightness. the high voltage signal is removed from the lamp. Voltages between these values produce a linear brightness 0 and 100%. the high voltage signal is applied to the lamp. The lamp brightness is controlled by a variable voltage signal. SHARP model LQ10D421 displays require a XENTEK LS520 Backlight Inverter Board (YORK P/N XXXXXXXX-XXX) (refer to Fig. N. developed by the lamp dimmer circuit (ref. 3. Fig. 7 3 2 CN2 1 NOTES: 1. turning it on. Refer to Fig. 0 Ohms produces minimum (0%) brightness. OFF = 0VDC. These boards generate the lamp illumination high voltage AC from +12VDC. = No Connection. 10 and Microboard Jumpers JP7 & JP8.0VDC = MIN (0%) Brightness. When the Backlight Enable signal at connector CN3-1 is +5VDC.+3. turning it off.5VDC. CN3 the upper lamp. Voltages between these values produce a linear brightness between 0 and 100%. Refer to Microboard Program Jumper JP5. The Microboard places CN1-7 at ground (GND) potential.C. 4. This display has a lamp at the top of the display and one at the bottom of the display. ON = +5VDC. the high voltage signal is removed from the lamp.0VDC. Connector CN2 applies the high voltage lamp illumination signal. turning it off. Connector CN2 applies the high voltage lamp illumination signal to the lamp. 30). 9 N.54-M1 (607) 10) on the Microboard and applied to connector CN1-4.0VDC. +3. 10 N. When CN3-1 is 0VDC. BACKLIGHT ENABLE (NOTE 1) GND MICRO BOARD + 12 VDC (NOTE 3) 1 INVERTER CABLE 031-01770-003 LD09568 FIG. 0VDC = MAX (100%) Brightness. 2. Refer to Fig. 0 Ohms = MIN (0%) Brightness. Refer to Fig. 0 . Refer to Microboard Program Jumpers JP3 & JP4. Refer to Microboard Program Jumpers JP3 & JP4. FIG.C. 10 INVERTER CABLE (NOT AVAILABLE) LD04073 CN1 4 5 MICRO BOARD CN3 2 3 NOTES: 1. 2.C. 10 and Microboard Program Jumpers JP7 & JP8. 30 – DISPLAY BACKLIGHT INVERTER BOARD (SHARP LQ10D421) BACKLIGHT LAMP 500 . ON = +5VDC.C.1500 VAC GND 1 2 CN2 3 DISPLAY BACKLIGHT INVERTER BOARD TYPE: NEC 104PWBR1 PART NUMBER: NOT AVAILABLE FOR: NEC NL6448AC33-24 DISPLAY J6 1 2 3 +12VDC (NOTE 3) +12VDC (NOTE 3) GND GND N. 4.+2. = No Connection.C. ON = 0VDC. +2.) (NOTE 2) 7 N.C. FIG. = No Connection. N.C.1500 VAC N. 10K Ohms = MAX (100%) Brightness. OFF = 0VDC.10K Ohms. 4.C. OFF = +12VDC.) (GND) 1 2 3 4 5 N.5VDC = MIN (0%) Brightness. 3.Display Backlight Inverter Board FORM 160. 9 INVERTER CABLE (NOT AVAILABLE) N. 10 500 . 10 and Microboard Program Jumpers JP7 & JP8. 6 7 8 CN1 4 5 6 7 MICRO BOARD CN2 1 2 3 LOWER BACKLIGHT LAMP N.C. 8 N. 9 N. Refer to Microboard Program Jumper JP5. DISPLAY BACKLIGHT INVERTER BOARD 3 1 2 CN3 TYPE: XENTEK LS520 PART NUMBER: NOT AVAILABLE FOR: SHARP LQ10D421 DISPLAY J6 1 2 3 +12VDC (NOTE 3) +12VDC (NOTE 3) GND GND BACKLIGHT ENABLE (ON/OFF) (NOTE 1) BRIGHTNESS CONTROL WIPER (NOTE 2) BRIGHTNESS CONTROL ( . Refer to Microboard Program Jumper JP5.C. 3. 31 – DISPLAY BACKLIGHT INVERTER BOARD (NEC NL6448AC33-24) 84 JOHNSON CONTROLS .C. 0 . N.C. N.1500 VAC LD04072 NOTES: 1.5VDC.54-M1 (607) UPPER BACKLIGHT LAMP 500 . 1 2 3 4 5 6 1 BACKLIGHT ENABLE (ON/OFF) (NOTE 1) BRIGHTNESS CONTROL WIPER (NOTE 2) BRIGHTNESS CONTROL ( . When a key is pressed. When a key is not pressed. the contact resistance must be < 100 Ohms. Beginning with row 1 and proceeding through all rows. align the Display and rocker switch openings and apply the Keypad to the door. In order for the Microboard to reliably detect closed and open keys. Under each embossed key area are two conductors. In this example the “1” key is pressed. if column 3 is low. the Microboard senses this continuity as described below and concludes the “1” key is pressed. To check the open and closed contact resistance of any key. The Keypad is attached to the front of the OptiView Control Center door with an adhesive backing. refer to the “Diagnostics and Troubleshooting” Section 23 of this book. start at one corner and slowly peel the Keypad from the door. Since the coordinates of all keys are stored in the Microboard’s Program. a “logic high” (>4VDC) on the remaining rows and reads the columns. each key must meet a closed circuit and open circuit resistance requirement.54-M1 (607) SECTION 8 KEYPAD (REFER TO FIGURES 32 & 33) The Keypad contains touch-sensitive keys that allow the Operator to interface with the OptiView Control Center. The conductors are arranged in a matrix of rows and columns and connected to the Keypad connector as shown in Fig.FORM 160. one on top of the other. it can identify which key is at this coordinate and responds accordingly. the Program places a “logic low” (<1VDC) on a row. If service replacement is required. separated by an air space. 8 JOHNSON CONTROLS 85 . The Microboard Program continuously scans the Keypad to determine if a key is pressed. If the Microboard is not responding to a pressed key. if at the time row 4 is being driven low. Pressing the embossed key area causes contact and electrical continuity between the two conductors. The operation of each key can be checked with an Ohmmeter. The top layer of the Keypad contains embossed areas identifying the keys. Remove the paper backing. then the Micro concludes the key at coordinate of row 4 and column 3 is pressed. The embossed area of each key is located directly over the intersection point of the conductors. For example. 32. the contact resistance must be > 1Meg Ohm. The Operator presses the keys to request the desired screens of information and enter System Setpoints. For example. pressing the “1” key creates continuity between the Keypad connector pin 5 (column 3) and pin 13 (row 4). it could be because the contact resistance requirements are not being met. The rear side of the replacement Keypad is coated with an adhesive covered with a paper backing. or if it’s detecting a closed key when none are pressed. Since this connector is interfaced to the Microboard (J18). A logic low in any column indicates a key in that column and row is pressed. 54-M1 (607) LD04074 CONNECTOR FIG.Keypad FORM 160. 32 – KEYPAD 86 JOHNSON CONTROLS . FORM 160. 33 – KEYPAD JOHNSON CONTROLS 87 .54-M1 (607) LD04075 8 LD04076 FIG. Solid State Starter Logic/Trigger Board (Mod “B” Solid State Starter) or Adaptive Capacity Control (ACC) (Variable Speed Drive applications). the Probe is also powered by this +24VDC. There. Flash Memory Card and other digital circuits. It receives a 102 to 132VAC input from an external power source and provides the following DC outputs: • • • • • -12VDC +12VDC +5VDC +24VDC Ground FIG. To account for losses in wiring and connections and assure sufficient voltage level at the microboard input. As shown in fig 9 (031-01730-000 microboard) and fig 9A (031-01730-000 microboard). All Probes operate from a +5VDC power source.54-M1 (607) SECTION 9 POWER SUPPLY (REFER TO FIG 34 & 35) The Power Supply provides the DC power for the LCD Display and all the printed circuit boards in the OptiView Control Center. is applied to the Display Backlight Inverter Board. Either +5VDC or +3. Solid State Starter Logic Board (Solid State Starter applications) or ACC Board (VSD applications) as shown in the Proximity Probe Section of this book. From the Microboard. these voltages are applied to the circuits requiring the respective voltage. the +12VDC and +5VDC are distributed to other system components requiring these voltages. The power supply requirements are different for these Probes. It is also routed to all Pressure Transducers. These include the MicroGateway. Either +12VDC or +5VDC. the Microboard contains two voltage regulators that create separate +5VDC and +3.1Vdc at the input to the Microboard J1-1. Different Display manufacturers can require different supply voltages for their display and supporting circuits. Proximity Probe and Motor controller Board (CM-2. This permits all Analog circuits to be powered by the same supply. as determined by JP5. Probe 025-30961-000 and Probe 025-35900-000 require a +24VDC source that is tapped off of the supply to the CM-2 Current Module (Electro-Mechanical Starter applications). as determined by JP2.3VDC supply is utilized by the Microprocessor. Solid State Starter Logic Board (Mod “A” Solid State Starter). Temperature Thermistors. The -12VDC. The +5VDC supply is dedicated to all the Microboard Analog circuits and is labeled as the +5VDC (Analog) supply. LCD Display and Display Backlight Inverter Board. 88 JOHNSON CONTROLS .3VDC. VSD Oil Pump. If the Chiller is equipped with Proximity Probe Part number 025-30961-000 or 025-35900-000. The Condor Power supply allows adjustment of the +5Vdc output. I/O Board. 34 – POWER SUPPLY 29136A The +24VDC output provides power to the CM-2 Board (Electro-Mechanical starter applications). +12VDC. depending on the Display manufacturer’s requirements as explained below. To accommodate the different Display manufacturer’s voltage requirements. The +3. Microboard Program Jumpers JP2 and JP5 must be positioned to provide the required supply voltages to the Display and the Display Backlight Inverter Board. It could also be applied to the Backlight Inverter Board. Refer to Table 1 “Microboard Program Jumpers”. +5. Mod “A” Solid State Starter Logic Board or VSD ACC Board). The chiller could be equipped with either of two Proximity Probes. is applied to the Display. the “V AdJ” (R51) potentiometer is adjusted to achieve eliminating any offsets caused by voltage regulator drift. Microboard 031-02430-000 has an additional voltage regulator that provides a 2.Power Supply FORM 160.3VDC supplies. Proximity Probe (025-xxxxx-000 only). Gnd and +5VDC outputs are applied to the Microboard.5Vdc power source. Applications . Logic Board (Mod “A” Solid State Starter). (Not applicable to “P” compressors and style F and later chillers with “G. Logic/Trigger Board (Mod “B” Solid State Starter). +12VDC GND DISPLAY BACKLIGHT INVERTER BOARD 3. +12 or +5VDC as determined by Microboard Program Jumper JP5 & display requirements. 4. 46 & 47 for Proximity Probe Power Connections. +V (NOTE 2) GND 2. Adaptive Capacity Control (VSD). 35 – POWER SUPPLY – DC POWER DISTRIBUTION (REFER TO OPTIVIEW CONTROL CENTER WIRING DIAGRAM FOR WIRE CONNECTIONS) 89 9 . Refer to Fig.3VDC as determined by Microboard Program Jumper JP2 & display requirements.+5VDC (ANALOG) ALL TRANSDUCERS & THERMISTORS . Q” and “H5-8” compressors) LD06509 FORM 160.CM2 (Em Starter).12VDC +12VDC GND +5VDC GND +12VDC +5VDC GND +24VDC JOHNSON CONTROLS MICROGATEWAY DC POWER SUPPLY PROXIMITY PROBE (NOTE 5) +5VDC MICROBOARD GND +12VDC I/O BOARD +12VDC OIL PUMP VSD +5VDC (ANALOG) (NOTE 3) VDD (NOTE 1) GND NOTES: (NOTE 4) CM-2 BOARD or SOLID STATE STARTER LOGIC BOARD or ACC BOARD GND (NOTE 3) LCD DISPLAY 1. Not Applicable to VSD or Mod “B” Solid State Starter applications. 45.54-M1 (607) FIG. REFRIGERANT LIQUID LEVEL SENSOR 5. +5 or +3. an OVERLOAD shutdown is initiated. Relay K1 is normally energized. While the chiller is running. opening its contacts.10VDC) signal to the Current Module at J1-1 and J1-2 when the compressor motor current is at 100% FLA. 290% FLA for 20 seconds or 360% FLA for 10 seconds. opening K1 contacts (CM). Relay K1 remains de-energized until manually reset with RESET switch S2. Simultaneously. Relay K1 and Overload indicator CR4 operate as described immediately above. 38 contains a formula to calculate the resistance of RES required to achieve 1. The Power Fault circuit protects the compressor motor and driveline from transient torque damage. The required turns ratio of the Current Transformers is determined by the system 100% FLA. These are Factory adjusted (field adjusted on service replacements) to provide a nominal 1.15 to 1.Current Module (CM-2) FORM 160. The 100% FLA value is located on a label adhered to the inside of the OptiView Control Center door. The motor current signal input at J1-1 & J1-2 is applied to potentiometer R8. an OVERLOAD shutdown is initiated. They are also connected as a digital input to I/O Board J2-1. Overload detectors and Multiplexer (MUX).0VDC (0. it deenergizes K1. 38) provide 3 phase motor current signals to the Diode Bridge (DB). the OptiView Control Center is equipped with a Current Module. If the motor current remains continuously at >105% FLA for 50 seconds (Nominal).CONTACTS OPEN is displayed. maintaining its contacts in a closed position. a Power Fault shutdown is initiated.0VDC at 100%FLA. This interrupts the circuit to I/O Expansion Board RUN relay coil 1R (K18). the Microboard reads the opening of these contacts via I/O Board J2-1. The chiller cannot be started until RESET switch S2 is manually pressed.38) On applications where the Compressor Motor is controlled by an Electro-Mechanical Starter. It anticipates the transient torque condition by detecting a momentary interruption in motor current and deenergizing the starter before damage can occur. This calibrated voltage is applied to the Power Fault detector. The chiller will automatically restart upon completion of SYSTEM COASTDOWN. A SYSTEM COASTDOWN is initiated and MOTOR CONTROLLER-CONTACTS OPEN is displayed.54-M1 (607) SECTION 10 CURRENT MODULE (CM-2) (REFER TO FIG 36 . If the motor current remains continuously at 245% FLA for 40 seconds. The Power Fault indicator (CR5) is illuminated and remains illuminated until manually reset with RESET switch S2. The Current Module also provides an analog voltage representing the compressor motor current to the Microboard for display and Current Limit control. If the chiller has been running for >75 seconds and the motor current decreases to <10% FLA. A SYSTEM COASTDOWN is initiated and MOTOR CONTROLLER . The Diode Bridge rectifies and combines the three signals into one DC signal that is applied to the parallel Variable Resistors (RES). Three Current Transformers in the Compressor Motor Terminal Box (ref Fig. A SYSTEM COASTDOWN is initiated and POWER FAULT is displayed on the Display. de-energizing it and causing the Starter to shutdown. The Overload indicator (CR4) is illuminated and remains illuminated until manually reset with RESET switch S2. Fig. initiates a SYSTEM COASTDOWN and displays the appropriate message as described below. Whenever the Current Module initiates a chiller shutdown. the Microboard controls the Pre-rotation Vane (PRV) position to limit the motor current to the system 100% Full Load Amp (FLA) value. The contacts of Current Module K1 relay (identified as “CM” contacts on the OptiView Control Center wiring diagram) are interfaced into the Motor Controller initiated shutdown circuit that is located between OptiView Control Center TB6-53 and I/O Board TB1-16 (ref. Relay K1 is de-energized. Fig 17 and 37). The Current Module provides compressor motor Overload and Power Fault protection. Relay K1 is de-energized for 1 second and then returned to the energized state. This is Factory adjusted (field adjusted on service replacements) to illuminate the 105% CURR indicator (CR6) when the compressor motor current reaches 105% FLA. 90 JOHNSON CONTROLS . Relay K1 contacts (CM) open for 1 second and then return to the closed state. 0VDC when the compressor motor current is at 100% FLA. The Microboard reads the MUX outputs at J5-6. manual control is overridden and a close signal is applied to the PRV until the current decreases to 109% FLA. The first time the PRV OPEN key is pressed on the COMPRESSOR Screen after logging in at SERVICE access level. there is no 245% FLA threshold. DECIMAL OUTPUT 1 1 1 7 10 JOHNSON CONTROLS 91 . The 0VDC at channel 0 indicates to the Microboard that this is an Electro-Mechanical Starter application (In all starter applications. allowing the current to rise to 107% FLA before further PRV opening is inhibited. If Switch S1 is in the “Y-Delta/57%” position. When motor current rises to 100% FLA.FORM 160. The Microboard interprets this analog value in terms of %FLA and displays it upon operator keypad request. The Multiplexer (MUX) is an electronic switch with 8 inputs and 1 output. the PRV must be manually operated to achieve 105% FLA compressor motor current. the Microboard prevents any further current rise by inhibiting further Pre-rotation Vanes (PRV) opening until it decreases to 98% FLA. 0VDC = EM starter. a 10 minute window is opened.3. UP for Y-delta or 57% Autotransformer starters. While Current Limit is in effect. If the motor current continues to rise to 104% FLA.0VDC analog signal. It also uses this value to invoke compressor motor Current Limit at 100% FLA and 104% FLA. the normal current limit thresholds of 100% FLA and 104% FLA are applied.2.e. during this procedure. After 10 minutes. LRA/FLA Potentiometer R16 is factory adjusted (field adjusted on service replacements) to the ratio of Locked Rotor Amps to Full Load Amps.0VDC motor current analog signal calibrated on CM-2 board to be +4. Under Program control. the Microboard commands the MUX to route the inputs to the MUX output by applying 3-bit Binary addresses to the MUX address inputs at J5-1. representing motor current over the range of 0 to 100% FLA. to field calibrate Potentiometer R8. the Microboard applies a close signal to the PRV until the motor current decreases to 102% FLA. It then addresses channel 7 (ignoring channels 1 through 6) to read the analog motor current voltage. The address applied to it determines the position of the switch (i. This inhibit is released when the current decreases to 106% FLA. the Micro reads channel 0 to determine the type starter applied.. >0VDC=Solid State Starter). Current Limit is not invoked until 107% FLA and 110% FLA. It first addresses channel 0 to determine the type of starter applied.HIGH CURRENT LIMIT is displayed. MOTOR . Switch S1 must be positioned according to the type of Electro-Mechanical starter present. If the current continues to rise to 110%. Therefore. As detailed in the “System Calibration” section of this book.54-M1 (607) The chiller cannot be restarted until RESET switch is manually pressed. DOWN for all other starters. The voltage level for a logic 1 is +12VDC and logic 0 is 0VDC. The MUX address inputs along with respective outputs are as follows: BINARY J5-1 J5-2 0 0 0 0 1 1 1 0 0 1 1 0 0 1 J5-3 0 1 0 1 0 1 0 0 1 2 3 4 5 6 Ground Ground Ground Ground Ground Ground Ground 0-5. The correct setting is determined by dividing the LRA by the FLA. which input is routed to the output). The input to channel 7 is a 0 to 4. The inputs to channel 0 through 6 are grounded (0VDC) . It is Factory calibrated by Potentiometer R34 to be 4.0VDC at 100% FLA. 37 – CM-2 CURRENT MODULE (ELECTRO-MECHANICAL STARTER APPLICATIONS) 92 JOHNSON CONTROLS .Current Module (CM-2) FORM 160.54-M1 (607) LD04079 FIG. 36 – CM-2 CURRENT MODULE (ELECTRO-MECHANICAL STARTER APPLICATION) 24 LD04080 FIG. 247 (CT RATIO) FLA R = 0.FORM 160.740 (CT RATIO) FLA LD04082 10 FIG.0VDC at FLA. C. 208-600 112-224A 225-829A 830-1790A 11-18C 19-37B R = 1.54-M1 (607) LD04081 MOTOR VOLTAGE FLA 65-111A CT RATIO 200:1 350:1 700:1 1400:1 200:1 200:1 200:1 350:1 700:1 NOTES: RESD (OHMS) A.282 (CT RATIO) FLA R = 0. Requires passing motor lead through current transformer (CT) once before connecting to power supply. Calculates resistance of “RES” to achieve 1. D.370 (CT RATIO) FLA 2300-4160 38-123A 124-264A 265-518A R = 0. CURRENT TRANSFORMERS & VARIABLE RESISTORS JOHNSON CONTROLS 93 . 38 – CM-2 CURRENT MODULE – INTERFACE. Requires passing motor lead through CT twice before connecting to power supply. Requires passing motor lead through CT three times before connecting to power supply. B. If equipped with microboard 031-02430000/001. This communication link transfers start/stop commands to the starter and receives status and operation data from the starter. the Microboard will attempt to establish communications with the Logic/Trigger Board. The Style A LCSSS was in production prior to the Style B LCSSS. Also. With the Style A LCSSS. As shown in Figure 39. A hardwired 115VAC start signal is also applied to the starter via relay 1R (K18) contact closure. The STOP relay contacts on the Logic/Trigger Board assure a positive shutdown on all LCSSS initiated shutdowns.OPT. A Starter Initiated STOP relay. If this communications link does not operate properly. On the SETUP Screen “MVSSS” must be selected for the MOTOR DRIVE TYPE Setpoint.xxx (or later) is required for this application.INVALID CURRENT SCALE SELECTION” is displayed on the System Details line of JOHNSON CONTROLS The Medium Voltage Solid State Starter (MV SSS) communicates with the microboard J13 COM 2 port with RS-485 serial data using Modbus protocol.15.Solid State Starters FORM 160. The Logic/Trigger Board is powered by +24VDC from the OptiView Control Center Power Supply. located in the starter. The Microboard will continue to establish communications until successful. 94 . This board performs the following functions: • Generates the SCR trigger pulses • Receives start/stop commands from the Microboard • Transmits status and fault data to the Microboard • Generates all LCSSS initiated Safety and Cycling shutdowns. Style “B” Serial Interface LCSSS (Refer to Fig. equipped with the 128K BRAM and software C. the starter selection is performed on the SETUP Screen (refer to Section 23). The OptiView Control Center Microboard (J15) communicates with this board via a 1200 baud 0/+5VDC serial data communications link. Refer to SECTION 3A of this manual. Microboard Program Jumpers JP14 and JP17 must be positioned appropriately. If unsuccessful within 10 attempts. The communications link and relay contact interface operate in the same way as described below for the Style B LCSSS. Later vintage chillers are equipped with either the Medium Voltage Solid State Starter (MV SSS) or the Style B Liquid Cooled Solid State Starter (LCSSS).41) SOLID STATE STARTERS The Optiview Control Center will accommodate several different Solid State Starters.00-O2). theory of operation and troubleshooting instructions of this LCSSS are contained in YORK Service Manual 160.01.00-M5. The following describes the interface and interaction of the LCSSS with the OptiView Control Center. opens its contacts whenever the starter initiates a shutdown. theory and operation of this starter are contained in YORK service manual 160.. the Logic/trigger Board initiates a Cycling shutdown and “LCSSS . 39) A complete description. the Logic/Trigger Board reads wire jumpers in its connector J1 to determine the LCSSS model applied (refer to 160. Program Jumper JP39 must be positioned to invoke appropriate microboard operation for the starter applied (Refer to table 1). The MV SSS communicates with the microboard using RS-485 serial data with Modbus protocol. If equipped with microboard 031-01730-000. Microboard 031-02430-001. The Style B LCSSS contains an integrated Logic/Trigger Board located in the starter cabinet that has an opto-coupled interface using YORK proprietary protocol serial communications interface to the microboard. If an invalid jumper configuration is read. the LCSSS contains a single Logic/Trigger printed circuit board. This version communicates with the microboard via a multiplexed data interface.54-M1 (607) SECTION 11 SOLID STATE STARTERS (REFER TO FIG. A complete description.00-O2. 39 . After power has been applied to the system. a Trigger Board resides inside the starter cabinet and a separate Logic Board is located inside the Optiview cabinet. MEDIUM VOLTAGE SOLID STATE STARTER The MV SSS Motor Screen contains information pertinent to the starter. correct Microboard J15 serial port operation can be verified using the Serial Inputs and Outputs diagnostic procedure in the “Diagnostics and Troubleshooting” section of this book. at power-up. the Microboard initiates a Cycling shutdown and displays “LCSSS INITIALIZATION FAILED” on the System Details line of the OptiView Control Center display. Refer to figure 39. the Logic/Trigger Board initiates a cycling shutdown and “LCSSS . There are 4 LCSSS models: 7L. In addition.REQUESTING FAULT DATA” is displayed on the System Details line of the OptiView Control Center display. While this data is being sent. the Logic/Trigger Board will initiate the same Cycling shutdown if it does not receive a data request from the Microboard after 10 successive attempts to send data.STOP CONTACTS OPEN” on the System Details line of the display. While this start inhibit is in effect. the OptiView Control Center sends two start signals simultaneously to the Logic/Trigger Board. If fault data is not returned within 2 seconds. the Microboard will continue to send a request at 2 second intervals until the fault data is returned. Between June 2006 and March 2007. the Logic/Trigger Board responds to each request. The model designation is transmitted to the Microboard for display on the MOTOR Screen. This signals the Microboard that the LCSSS has initiated a shutdown. applying 115VAC to Logic/Trigger Board TB1-24. The open STOP contacts interrupt the circuit to 1R causing it to de-energize. Any additional faults that occur within the 2 second transmission time are also sent and logged on the HISTORY Screen under “LAST TEN FAULTS”. the Microboard sends a data request every 2 seconds. The contacts remain open as long as the condition exists. However. They are programmed on the MOTOR Screen. 95 11 . 14L.54-M1 (607) the OptiView Control Center Display. new production chillers are equipped with microboard 031-01730. Prior to June 2006. it assumes it is not forthcoming and it displays “LCSSS . 26L and 33L. “LCSSS . When the chiller is started.FORM 160. “LCSSS . Communications between the Microboard and Logic/Trigger Board are in the form of master/slave. A snapshot of the LCSSS operating parameters valid at the instant of the fault are also sent. One is transmitted via the serial communications link. The Logic/Trigger Board sends the cause of JOHNSON CONTROLS the shutdown in response to the next data request. This is logged on the HISTORY Screen as the “LAST FAULT WHILE RUNNING”. The Logic/Trigger Board transmits the following parameters over the serial communications link for display on the MOTOR Screen: • Three phase motor current • Three phase line-to-line motor supply voltage • Input Power (KW) • Three phase SCR module temperature • Starter model designation The following are the programmable setpoints associated with the LCSSS. After successful initialization. Refer to figure 39. B. the Microboard reads the opening of the LCSSS STOP contacts via the I/O Board J2. The Logic/Trigger Board sends two types of data to the Microboard: Status data and Fault data.STOPPED” (where X is phase A. Anytime the Logic/Trigger Board initiates a Cycling or Safety shutdown. If these two signals are not received within 5 seconds of one another. Refer to Operation Manual 160. removing the run signal to the LCSSS. The COM5 (J15) serial port on this board communicates with the starter Logic/Trigger Board 031-02001 using YORK protocol.SHUTDOWN . Refer to programming instructions in the “System Calibration. the LCSSS cooling pump will run and the chiller will be inhibited from starting until the temperature has decreased below 109°F. Refer to figure 39. Service Setpoints and Reset Procedures” section of this book. If the temperature of any of the SCR modules are >110°F. Each model has an allowable Full Load Amps (FLA) range and Start Current range as listed below.RUN SIGNAL” is displayed on the System Details line of the display. Normally. The COM5 (J15) serial port on these boards communicates with the starter Logic/Trigger Board 031-02001 using YORK protocol. If none is returned within 10 consecutive requests.000 (early vintage) or 031-02430-000 (later vintage).SERIAL COMMUNICATIONS” on the System Details line of the OptiView Control Center display.54-O1 for description of all Cycling and Safety shutdown messages. new production chillers are equipped with microboard 031-02430-001. or C) is displayed on the System Details line of the display. Simultaneously. new production chillers are equipped with Logic/Trigger Board 031-02505 and Microboard 031-02430-001. the Microboard initiates a Cycling shutdown and displays “LCSSS . The Microboard is the master and the Logic/Trigger Board is the slave. This designation determines the allowable range for the Full Load Amps (FLA) Setpoint and Start Current Setpoint. The chiller can be started if there are no Safety and Cycling conditions. The other is the closure of 1R (K18) Start relay.1.HIGH TEMPERATURE PHASE X . it opens its STOP contacts that are connected in series with the OptiView Control Center’s 1R (K18) RUN relay coil. if the Microboard does not receive a response to 10 consecutive requests. After March 2007. It is the Full Load Amps (FLA) of the chiller. 46. Each model starter has a permissible range over which this setpoint can be programmed as follows: • Supply Line Voltage Range .54-M1 (607) • Full Load Amps .This enables or disables the Open SCR detection Safety protection performed by the Logic/Trigger Board.LOW SUPPLY LINE VOLTAGE” and “LCSSS . 46. Each starter model has a permissible range over which this setpoint can be programmed as follows: LCSSS Model 7L-46. Shutdown and restart thresholds are contained in Operation manual 160.Solid State Starters FORM 160. 46 and 50 Permissible Start Current Range 310 to 700 Amps 620 to 1400 Amps 1150 to 2600 Amps 1460 to 3300 Amps • Start Current .45 x motor Delta Locked Rotor Amps) as listed on the SALES ORDER Screen. 96 JOHNSON CONTROLS . as listed on the SALES ORDER Screen. 58 and 50 14L. 28.17. 28. 58 and 50 33L-17. 46. This protection must never be disabled unless advised by the YORK factory. 28. This setpoint should be programmed to (0. 28. 58 and 50 26L.This setpoint is the line voltage application and establishes the high and low line voltage shutdown thresholds. 58 and 50 26L-17. • Open SCR Enable/Disable . 46 and 50 Permissible FLA 35 to 260 Amps 65 to 510 Amps 125 to 850 Amps 215 to 1050 Amps LCSSS Model 7L-46.The Logic/Trigger Board will limit inrush motor current to this value during starting. 28. 46. 28.54-O1 under the messages “LCSSS .17.This is the maximum allowed motor current at which this chiller is permitted to operate to achieve maximum design capacity. 58 and 50 14L-17. The programmed value is sent to the Logic/Trigger Board over the serial communications link.HIGH SUPPLY LINE VOLTAGE”. 58 and 50 33L-17. the Microboard will close or inhibit opening of the Pre-rotation Vanes (PRV).HIGH SUPPLY LINE VOLTAGE” or “LCSSS . the PRV are inhibited from further opening until the motor current decreases to <98% of the Current Limit setpoint. Each supply voltage application has an allowable upper and lower limit. If the motor current increases to the extent that the “% FULL LOAD AMPS” is 104% of the Current Limit setpoint.54-M1 (607) • Kilowatt Hours (KWH) Reset . by the value programmed for the FULL LOAD AMPS setpoint. received from the Logic/Trigger Board.INTERFACE (YORK PROTOCOL) JOHNSON CONTROLS 97 . While the chiller is running.This allows the accumulated KWH to be set to a desired starting value in the event the BRAM has to be field replaced. the PRV will be driven closed until the “% FULL LOAD AMPS” decreases to 102% of the Current Limit setpoint. the logic trigger Board initiates a Cycling shutdown and displays “LCSSS . to limit the compressor motor current to the Current Limit or Pulldown Demand Limit setpoint (30% to 100% FLA) that is in effect. This must never be arbitrarily performed. The chiller will automatically restart when the line voltage is within the acceptable range.FORM 160. “% FULL LOAD AMPS” is displayed on the MOTOR Screen. If the motor current increases to the extent that the “% FULL LOAD AMPS” reaches 100% of the Current Limit Setpoint. If the supply voltage goes above or below these limits continuously for 20 seconds.LOW SUPPLY LINE VOLTAGE” as appropriate. 39 – STYLE “B” LIQUID COOLED SOLID STATE STARTER (LCSSS) . 13 – “POWER ONE” Power Supply FIG. The PRV opening will then be inhibited until the “% FULL LOAD AMPS” decreases to <98% of the Current Limit setpoint. the Logic/Trigger Board compares the actual 3-phase line voltage to the thresholds established with the Supply Line Voltage Range setpoint. CONTROL CENTER POWER SUPPLY J2 6 GND +24 VDC SOLID STATE STARTER J30 / P30 6 12 5 4 3 2 1 TB2 SERIAL COMMUNICATIONS LCSSS LOGIC / TRIGGER BOARD * J15 3 2 MICRO BOARD 1 GND RX TX 2 MOTOR CONTROLLER SHUTDOWNS 36 37 J19 START STOP J1 2 36 37 25 TB5 TB1 16 J2 1 TB6 24 25 TB6 16 53 15 115VAC TB1 START / STOP 24 I/O BOARD STARTER (MOTOR CONTROLLER) INITIATED SHUTDOWN 16 53 STOP CONTACTS 11 NOTES: LD04648A *9 – “CONDOR” Power Supply. To assure the chiller is not permitted to run for extended periods with the supply line voltage outside of acceptable limits. as required. The Microboard calculates the “% Full Load Amps” (FLA) by dividing the highest phase of the 3-phase motor current. 300 / 600V VOLTMETER SCALE JUMPER K1 RELAY J3 J6 J2 J5 J7 JUMPER P1 / J1 PLUG CONN. theory of operation and troubleshooting instructions of this LCSSS are contained YORK Service Manual 160.Solid State Starters FORM 160. As shown in Fig. the Logic Board of this model starter is mounted inside the OptiView Control Center. 41) A complete description. 40 – SOLID STATE STARTER LOGIC BOARD 98 JOHNSON CONTROLS .46-OM3. 41.54-M1 (607) Mod “A” Multiplexed Data Interface LCSSS (Refer to Fig. LOGIC BOARD INDICATOR LED’S 24672A INTERLOCK JUMPER BETWEEN NO. 1. 7 & 8 PINS R3 R2 R1 RESISTORS J4 START CURRENT POT OVERLOAD CURRENT POT RESET PUSHBUTTON (SWI) FIG. “MOTOR CONTROLLER – CONTACTS OPEN” is displayed. opening its contacts. Phase Rotation/Loss. Relay K1 is normally energized. B and A Power Line Voltages. Fault Current or Half Phase condition is detected. After S1 is pressed. the chiller can be restarted. They are also connected as a digital input to I/O Board J2-1. K1 contacts will open. B and C Compressor Motor Current. Whenever the heatsink temperature increases to 212ºF. Channels 2 though 4 are analog voltages representing Phase C. each time the chiller is shutdown for any reason. and Half Phase Protection for the Compressor Motor. MOTOR CONTROLLER – CONTACTS OPEN is displayed. Power Fault. 11 JOHNSON CONTROLS 99 . MOTOR CONTROLLER – CONTACTS OPEN message is cleared and the chiller will automatically restart. the Microboard reads the opening of these contacts via I/O Board J2-1. This value also determines the Line Voltage display range and Motor current display range. the Microboard sequentially addresses MUX channels 0 through 7. the HIGH TEMP LED is illuminated. Fig. 16 and 37). If the contacts remain open for more than 3 seconds. While it is waiting for the temperature to decrease to this threshold. the chiller can be restarted. When a Power line Phase Rotation/Loss or Trigger Board Out of Lock (OOL) condition is detected. Relay K1 contacts open and remain open for as long as the condition exists. This command is in addition to the Micro’s software current limit feature that’s based on a calculation comparing the highest current phase to the programmed Full Load Amp Setpoint to arrive at an FLA Percentage. Channel 1 is a current limit command that forces the Micro to perform Pre-rotation vanes inhibit and closure at the 100% and 104% FLA. Simultaneously. Rot/Loss or Trig. The voltage output of each channel is listed in the table below. Whenever the Logic Board initiates a chiller shutdown. The respective Ph. if less than 3 seconds. Power Line Voltage. This interrupts the circuit to I/O Board RUN relay coil 1R (K18).54-M1 (607) This board provides Overload. The Program uses this value to limit the Full Load Amps Setpoint range to the maximum allowed value for the Starter size. Under Program control. Relay K1 contacts open for 1 second and then close. The address applied to it determines the position of the switch and therefore the output. initiates a SYSTEM COASTDOWN and displays the appropriate message as described below. The chiller will automatically restart when the contacts close. Fault Current. At the completion of SYSTEM COASTDOWN. Channel 0 is an analog voltage that represents the Starter model and Power Line voltage Voltmeter scale. maintaining its contacts in a closed position. The contacts of Logic Board relay K1 (identified as “CM” contacts on the OptiView Control Center wiring diagram) are interfaced into the Motor Controller initiated shutdown circuit that is located between OptiView Control Center TB6-53 and I/O Board TB1-16 (ref. It also receives SCR High Temp and Trigger Out Of Lock (OOL) shutdown signals from the Starter Trigger Board. it de-energizes K1. The Logic Board illuminates the High Temp LED and opens Relay K1 contacts. When a Power Fault. The contacts remain open and the LED remains illuminated until manually reset with the Logic Board’s S1 RESET switch. POWER FAULT is displayed. Current Limit commands and a Starter Model code to the Microboard. When the temperature is below 110ºF. POWER FAULT is displayed. it provides analog voltages representing Compressor Motor Current. After S1 is pressed. the Trigger Board signals the Logic Board. the LED is extinguished. In routine operation. When the Logic Board detects an Overload condition. the chiller will automatically restart. Relay K1 contacts open and the Overload LED illuminates. Relay K1 contacts are open. OOL LED illuminates and remains illuminated until manu- ally reset with the S1 RESET switch. <1VDC for logic low (0). MOTOR CONTROLLER – CONTACTS OPEN is displayed. The Starter Trigger Board monitors the Starter’s Silicon Controlled Rectifier (SCR) heatsink temperature. The Multiplexer (MUX) is an electronic switch with 8 inputs and 1 output. The LED remains illuminated and the contacts remain open until the temperature decreases to less than 110ºF and manually reset with the Logic Board’s S1 RESET switch. The addresses are +12VDC for logic high (1).FORM 160. and MOTOR CONTROLLER – CONTACTS OPEN is displayed. de-energizing it and causing the Starter to de-energize. Channels 5 through 7 are analog voltages representing Phase A. Finally. it is prevented from restarting until the heatsink temperature decreases to less then 110ºF. The Power Fault LED illuminates and will remain illuminated until manually reset with the S1 RESET switch. 46 to 5.00VDC . Phase “A” AC Power Line voltage Same as Phase “C” above.20VDC .54-M1 (607) The Logic Board MUX address inputs. full scale 2938A 2. full scale 2938A 3. 600VAC.78 to 1.21 to 3.<98% FLA 1. full scale 3672A Current Limit commands 3. max FLA 551.08VDC – 26L.7L.00VDC – 33L. full scale 1574A 1. 0 to +5VDC spanning range in address 0 above. 300VAC. Phase “C” Compressor Motor Current. max FLA 1134. 600VAC. full scale 3672A 3. Same as Phase “C” above.>100% FLA 0.9 600VAC scale = VDC(out) = VAC 135.>104% FLA Phase “C” AC Power Line voltage as follows: 300VAC scale = VDC(out) = VAC 67.88 to 5. 300VAC.87VDC – 33L. max FLA 1134. full scale 1574A 1. 0 to +5VDC spanning range in address 0 above. 0 to +5VDC spanning range in address 0 above.8 0 1 1 1 1 1 0 0 1 1 1 0 1 0 1 3 4 5 6 7 Phase “B” AC Power Line voltage.41 to 0. 300VAC. max FLA 281. Phase “B” Compressor Motor Current.39VDC – 26L.77 to 2. max FLA 551.40 to 3.23 to 1.22VDC – 14L. max FLA 916. Phase “A” Compressor Motor Current.09 to 3. 0 0 1 1 0 1 0 2 100 JOHNSON CONTROLS .77VDC .45VDC .Solid State Starters FORM 160. full scale 787A 0. along with the respective outputs are as follows: BINARY J6-1 J6-2 J6-3 0 0 0 DECIMAL 0 OUTPUT Starter Model/Voltmeter/Ammeter full scale. max FLA 916. 600VAC.76VDC – 14L. 600VAC. max FLA: 0.0 to 1. INTERFACE 11 .S.54-M1 (607) 101 FIG. +5VDC ADDRESS (2 0 ) ADDRESS (2 ) 1 ADDRESS (2 2 ) 1 2 3 J6 4 5 6 MICRO BOARD J19 2 TB6 TB5 25 25 24 TB1 16 16 53 1 TB6 115VAC J2 1 36 37 L.S.S LOGIC PCB (031-00936) 3 1 2 STOP CONTACTS J2 2 36 37 J1 J1-2 = MOTOR CONTROLLER SHUTDOWN J1-36 = STOP J1-37 = START STARTER (MOTOR CONTROLLER) INITIATED SHUTDOWN I/O BOARD LD04649 NOTES: *9 on “CONDOR” Power Supply 13 on “POWER ONE” Power Supply FORM 160. 41 – MOD “A” LIQUID COOLED SOLID STATE STARTER (LCSSS) .C.CONTROL CENTER J/P-30 GND 6 J2 6 +24VDC 12 2 J3 1 SOLID STATE STARTER JOHNSON CONTROLS POWER SUPPLY * 1 2 3 J6 4 5 6 MULTIPLEXED DATA GND. OPT. The COM2 serial port of this board communicates with the MV VSD using Modbus protocol.OPT.16.16. If Modbus is selected. The selections are “Modbus or “York”. The ACC Board performs the following functions: • Acts as a bi-directional serial communications gateway between the Microboard and the VSD Logic Board and VSD Harmonic Filter Logic Board. Logic Board and an optional Harmonic Filter with Harmonic Filter Logic Board. They must be both set to “1”. The VSD consists of a power electronics section. 42 . The 031-002506 VSD Logic Board contains both the Optocoupled YORK protocol serial Port (J11) and an RS-485 Modbus serial port (J16) to allow it to be used as a service replacement part for VSD Logic Board 03101433-xxx and 031-02077-xxx (ref fig 43 & 43A). When using Modbus protocol.01.01. • Tells the VSD Logic Board at what speed (frequency) to operate the compressor motor. all mounted in a cabinet that is either mounted to the compressor motor or floor standing (retrofit applications). when “VSD-60Hz” or “VSD-50Hz” is selected on the SETUP Screen. On new production chillers after March 2007. Between June 2006 and March 2007. motor speed (frequency) and Evaporator/Condenser pressure differential (head) that exists when each surge occurs. Software version C. Refer to Manual 160. In new production chillers shipped prior to March 2007. • Creates a Surge Map in battery backed memory by storing the Pre-rotation Vanes (PRV) position. which resides inside the Optiview Control Center (refer to fig 43). the COM5 serial port is retained on the 031-02430-001 board (ref fig 43 & 43A).xxx (or later). In operation. To allow microboard 031-02430-001 to be used as service replacement for 031-01730-000 or 031-02430-000 board's non-Modbus applications already in the field. • Detects Compressor surge conditions. 160.44) The optional YORK Variable Speed Drive (refer to manuals 160. additional Setpoints must be entered on this Screen: The appropriate serial port (COM2-Modbus or COM5YORK) must be enabled using the “Motor Communications Protocol” Setpoint.) transmits the parameters to the ACC 102 JOHNSON CONTROLS . With microboard 031-02430-001 and software version C. With the Medium Voltage VSD (MV VSD). the ACC board in new production chillers communicate with microboard 031-02430-001 using the same interface/protocol.02430-001 microboard and the ACC Board is not used. the “Motor Node ID” setpoint must be set to match the setting of the VSD Logic Board Modbus Address Switch SW3. this function is performed by the Adaptive Capacity Control Board (031-01782-xxx).00-M4) uses an Adaptive Capacity Control (ACC) function to control the speed of the compressor motor.xxx (or later) is required for COM2 Modbus operation. Prior to June 2006.00-M6 for details of the MV VSD.Adaptive Capacity Control Board FORM 160. the ACC functionality is contained in the 031.00-M1. the 031-02430-001 microboard COM2 (J13) serial port communicates with the VSD Logic Board 031-02506xxx using RS-485 Modbus protocol (ref figure 43B). The description below applies to the ACC Board but also describes the communications between the 03102430-001 microboard and 031-02506-xxx VSD Logic Board when Modbus communications protocol is being used. the ACC functionality resides in the 031-02430-001 microboard. COM2 serial port is selectable between RS-232 and RS-485 operation with program Jumper JP17. Microboard 031-02430-001 must be equipped with 128KB BRAM (031-02565-000) to select “Modbus”. The speed will be the lowest speed between 30 to 60 (50) Hz it can operate without compressor surging. The ACC Board is mounted inside the OptiView Control Center.) monitors power electronics parameters and initiates chiller shutdowns when safety thresholds are exceeded and c. the VSD Logic Board a. b. It must be positioned on pins 1 & 2 to select RS-485 serial port operation.54-M1 (607) SECTION 12 ADAPTIVE CAPACITY CONTROL BOARD (REFER TO FIG.) controls the VSD power electronics to drive the compressor motor at the speed designated by the ACC Board. the COM5 (J15) serial port of Microboard 031-01730-000 (early vintage) or 03102430-000 (later vintage) communicates with this ACC Board using YORK protocol (ref fig 43). which sends the command on to the VSD Logic Board The VSD Logic Board relays the command to the Harmonic Filter Logic Board. a Cycling shutdown is performed and VSD – SERIAL COMMUNICATIONS is displayed. Fault Data Request and Status Data Request. no response is received. Simultaneously.00-M4. Complete operation and service details of the VSD and ACC Board is contained in YORK manual 160. If there have been any faults detected by the VSD Logic or Harmonic Filter Boards since communications were lost. If the VSD Logic and Harmonic Filter Boards respond appropriately to the ACC Board.) transmits these parameters to the ACC Board for transfer to the Microboard for display. To establish communications. The ACC Board passes the command to the VSD Logic Board. During normal communications. The ACC Board returns both the VSD Logic Board’s response and the Harmonic Filter’s response to the Microboard. removing the run signal to the VSD. The communications is in master/slave form. If. The Microboard initiates all communications by sending a command to the ACC Board. It will continue to send this command at 4 second intervals until a response is received. the Microboard dis plays VSD SHUT DOWN – RE QUEST ING FAULT DATA. the Microboard sends a Fault Data Request command. It expects to receive the data listed below in response each of these commands. a Cycling shutdown is performed and VSD –INITIALIZATION FAULT is displayed. the VSD Logic Board opens its VSD Stop Contacts that are connected in series with the OptiView Control Center’s 1R (K18) RUN RELAY coil. they are returned to the Microboard at this time.FORM 160. the Microboard displays a message describing the shutdown (refer to YORK Operation Manual 160.) controls the filter b. a Cycling shutdown is performed and VSD – SERIAL COMMUNICATIONS is displayed. The Microboard sends a Status Data Request command every 2 seconds to the ACC Board which is passed along to the VSD Logic Board and Harmonic Filter Logic Boards as described above. the Microboard will repeat this process to re-establish communications. While this request is being processed. The ACC Board is the center point of communications between the Microboard and the VSD components. it sends a Test and Initialize command to the ACC Board. the Microboard reads the opening of the VSD Stop Contacts via its interface to the OptiView Control Center’s I/O Board input J2-1. if communications are lost with the VSD Logic Board. When a VSD fault condition is detected. There are three different commands issued from the Microboard: Test and Initialize. The VSD Logic Board responds to the command by returning the requested data to the ACC Board and passes the command to the Harmonic Filter logic Board. The VSD Logic Board and Harmonic Filter Logic Boards act as slaves to the ACC and the ACC acts as a slave to the Microboard. This continues until the VSD Logic or Harmonic Filter Boards detect a fault condition. the Microboard establishes serial communications with the ACC. If any of these boards fail to respond to the first command. The Microboard requests the cause of the shutdown by sending a Fault Data Request command. VSD Logic and Harmonic Filter Boards.00-M1 and 160. the ACC Board responds to the Microboard and communications are established.54103 12 . As stated above. after 10 attempts. VSD Logic and Harmonic Filter Logic Boards. VSD Logic Board and the optional Harmonic Filter Logic Board via 0/+5VDC 1200 baud serial communications (Fig. The Microboard will continue to establish communications until successful. commands and data are exchanged every 2 seconds on the serial communications link. If no response is received in 10 attempts. no shutdown is performed. if communications are lost with the Harmonic Filter Logic Board. The Microboard communicates with the ACC Board. the Microboard sends the command again 4 seconds later. 43). Anytime communications have been established and then lost. If there is no response within 2 seconds. When power is first applied to the OptiView Control Center. only WARNING – HARMONIC FILTER – DATA LOSS is displayed.54-M1 (607) Board for transfer to the Microboard for display.) monitors filter parameters and initiates chiller shutdowns when safety thresholds are exceeded and c. This notifies the Microboard that a VSD shutdown has occurred. a Cycling shutdown is performed and VSD – SERIAL COMMUNICATIONS is displayed. The Microboard then begins normal communications with the ACC. However. The optional Harmonic Filter reduces the power line harmonics produced by the VSD. When the cause of the shutdown is received. The VSD Logic and Harmonic Filter Boards send the data listed below to the ACC Board and the ACC Board adds its data to it and returns all the data to the Microboard in one response. This interrupts the circuit to 1R causing it to de-energize. The Harmonic Filter Logic Board a. If a response is not received to 10 consecutive commands. this command is sent at 2 second intervals until a response is received. JOHNSON CONTROLS After communications have been established. The Harmonic Filter Logic Board returns the requested data to the ACC Board. running/stopped • Filter Pre-charge relay – energized/de-energized • Filter Supply Relay . While Manual control is selected. Service Setpoints and Reset Procedures” section of this book. B & C • Filter Heatsink temperature • Filter Operation.Adaptive Capacity Control Board FORM 160. it will automatically be set to 30 Hz and automatically adjusted from this value. the speed can be controlled from the VSD Tuning Screen using Keypad keys. the PRV will simultaneously be driven closed per the following: Speed Increase • 0. • Delta P/P (Head pressure) • Pre-rotation Vanes position • Surge count The compressor motor speed can be controlled either manually in MANUAL mode or automatically in AUTO mode. • 0. and 60 (50) Hz is selected. Via Serial communications. it sends the command every 2 seconds until fault data is returned. it assumes it is not forthcoming and displays VSD – STOP CONTACTS OPEN. JOHNSON CONTROLS .2ºF below the Setpoint and motor current is <80%FLA.0 seconds if PRV position >25% but <50%. PRV Close A close signal of the following durations is applied every 4. surges are not mapped. B & C • Input current TDD – phase A.2 Hz every 19 seconds if none of the above conditions are present. The following VSD status data is transmitted from the VSD Logic Board to the ACC Board for transfer to the Microboard for display: • Output Frequency • Output Voltage • Output Current . B & C • Input Current – phase A.energized/de-energized • Input Phase Rotation – ABC/CBA • Harmonic Filter – present/not present 104 The following ACC status data is transmitted from the ACC Board to the Microboard for display.5 seconds if PRV position <25%. Instructions for manual control are included in the “System Calibration. indicating that surges will not be mapped in the Surge Map.three phase • Input Power KW • KWH • 100% Job FLA • DC Link Voltage • DC Link Current • Internal Ambient Temperature • Inverter Heatsink Temperature – phase A. B & C • Filter current – phase A. If none is returned within 10 requests. if the speed was manually set to <30 Hz. In making the transition from Manual to Auto mode. the speed will be increased as follows. The VSD Logic Board controls the VSD to operate the motor at this frequency.54-M1 (607) O1 for complete listing of messages) and begins sending normal Status Data Request commands. Or.5 seconds: • 3.1 to 10 Hz. where it is passed on to the VSD Logic Board. as explained below.9 seconds if PRV position >50%. The speed can be set to a pre-selected frequency over the range of 10 to 60 (50) Hz. B. VALID POINT LED CR8 is illuminated. the speed command is sent from the Microboard to the ACC Board. If the fault data is not returned to the Microboard within 2 seconds.phase A. B & C • Input voltage THD – phase A. • 1.0 to 60 (50) Hz in increments of 0. B & C • Input Peak voltage – phase A.2 Hz every second if Leaving Chilled Liquid Temperature >0.2ºF below the Setpoint and the motor current is >80% but < 98%FLA. • 0. If not in Current Limit and the actual speed is <60 (50) Hz. it can be increased or decreased over the range of 0.2 Hz every 1 + (%FLA-80) second if Leaving Chilled Liquid Temperature is >0. & C • Converter Heatsink Temperature • Pre-charge Relay energized/de-energized • SCR Gate Drivers enabled/disabled • Water (cooling) Pump on/off • VSD running/stopped • VSD Software version • Motor HP The following Harmonic Filter status data is transmitted from the Harmonic Filter Logic Board to the ACC Board for transfer to the Microboard for display: • Input KVA • Total Power Factor • Filter DC Link Voltage • Input voltage. In MANUAL speed control mode.2ºF. Anytime this LED is illuminated. • 3. If the Leaving Chilled Liquid temperature is within 0. If equipped with an ACC Board. the ACC Board starts a 60 second timer. • Pre-rotation Vanes (PRV) position – The Pre-rotation vanes position. • The Chiller must have been running for >2 minutes.54-M1 (607) In AUTO speed control mode. • The Leaving Chilled Liquid Temperature must be within +0. the ACC Board employs the following: • Delta P/P – This is the chiller Head pressure. The optimum speed is the slowest speed possible that will avoid compressor surge conditions but still allow the chiller to meet capacity requirements. In applications where the ACC functionality is contained in microboard 031-02430-001 (ACC Board not used). the potentiometer is connected to the ACC Board (ref fig 43 & 43A). Surge Map points can be automatically printed to an external printer as they are plotted. When current limit is in effect. In response. Also. In determining the optimum motor speed. • Auto speed control mode must be selected at the Keypad. The Surge Map can be cleared. No speed reduction is permitted if this calibration has not been performed. These parameters are stored as a 3-dimenensional array for each surge. This value is then compared to the programmed Stability Limit Setpoint. VALID POINT LED CR8 will be illuminated and speed decreases are prohibited until the timer has elapsed. the potentiometer is connected to the Microboard (ref fig 43B). The PRV position (0-100%) is displayed on the Optiview display as 0% when fully closed. The Microboard calculates the stability by comparing the Leaving Chilled Liquid Temperature to the Leaving Chilled Liquid Temperature Setpoint to arrive at a rate of change value. If the rate of change exceeds the Stability Limit Setpoint value. This speed is found in an adaptive sense as explained below.FORM 160. is provided by a Potentiometer mounted to the PRV control arm. The potentiometer must be calibrated by a qualified Service technician using a procedure in the “System Calibration. • Motor Speed – This is the actual drive frequency of 30 to 60(50) Hz. • Current Limit must not be in effect. The VSD logic Board controls the VSD to operate the motor at this frequency. the ACC Board controls the speed. It is calculated as (Condenser pressure – Evaporator pressure) / Evaporator pressure.60. PRV position and motor speed that existed at the instant of each previously encountered surge condition. Service Setpoints and Reset Procedures section of this book: The entire Surge Map can be printed by pressing the “Surge Map Print” keypad key. The surge map is stored in the ACC Board’s BRAM battery backed memory.6ºF of the Leaving Chilled Liquid Setpoint. It determines the optimum compressor motor speed (frequency) over the range of 30 to 60(50) Hz and sends this value to the VSD Logic Board via the Serial communications link. The ACC Board calculates this value from evaporator and condenser pressure values received from the Microboard via serial communications link. The following procedures are detailed in the “System Calibration. The following conditions must be met before speed reduction is permitted: • The PRV calibration procedure must have been performed. The potentiometer interface varies according to whether or not the ACC Board is used.00 to 3. the stability timer is started. Valid Point LED CR8 is illuminated. Lowering the speed while this temperature is unstable. as used by the VSD control. would tend to increase the instability. when making the transition from Manual speed control Mode to Auto Mode. It ranges from 0. 100 % when fully open and whole percentage points in between.3 and –0. • Surge Map – This contains the Delta P/P. • The Leaving Chilled Liquid temperature must be stable.xxx. preventing 12 JOHNSON CONTROLS 105 . The Surge Map must never be cleared unless advised by the YORK Factory. The ACC Board returns the calculated Delta P/P value to the Microboard for display over the same link. Service setpoints and Reset Procedures” section of this book. the Microboard sends a flag to the ACC Board. with the microboard connected directly to VSD Logic Board 031-02506. PRV positions in between have linearly scaled maximums. Surge LED CR9 illuminates for 2 seconds. the outputs of the Evaporator and Condenser pressure Transducers are monitored to detect when the difference between these pressures (Delta P) drops transiently toward Zero. • 0.) Delta P must make at least 2 positive transitions. multi-pass evaporators. and b.1 Hz every 9 seconds until it’s to the lowest value allowed by the Surge Map. It also evaluates other chiller conditions to determine if the surge should be plotted on the Surge Map. by a qualified Service Technician using the procedure in the “System Calibration. • Certain applications. Delta P method and DC Link method. Valid Point LED CR8 is illuminated as a visual indication that one or both of these conditions are in effect.4 PSIG for 100 Milliseconds. the speed is lowered until a surge is encountered or a minimum of 30 Hz is reached. • 0. A surge detected by the Delta P method must have all of the following conditions occur within 5 seconds to be considered a valid surge: a.3 and –0. the speed is increased 1.9 seconds at 0% position.04. the speed is brought to 60 Hz. In detecting a surge using the DC Link method. or the Stability Timer is running when a surge occurs. This would be indicative of a surge. the maximum allowed vane pulse is limited to 3.5 PSIG for at least 340 milliseconds. If there are no conditions above that would inhibit speed reduction.xxx and later or “P” compressors with C. PRV Position and motor speed to the 3-dimensional arrays stored in the Surge Map.54-M1 (607) speed reduction for 60 seconds. PRV movement is further reduced during low load conditions with variable speed drive as follows: When the PRV position is < 25% and the Leaving Chilled Liquid Temperature is within + 2. When both these criteria have been met. Surge LED CR9 illuminates for 2 seconds.5 seconds at the 25% PRV position and 0.01. xxx and later. A surge detected by this method must also meet the following requirements to be considered a valid surge: a. The ACC Board uses two different methods of Surge Detection.) At least 6 DC Link surges must occur within 2 minutes. After each surge. the ACC Board compares the real-time Delta P/P.0 Hz but the surge is not plotted on the Surge Map since these conditions would produce an erroneous value. in the following increments: • 0. It will then be decreased 0. the speed will be decreased 0. With Flash Memory Card version C. In detecting a surge using the Delta P method. After it has been running for >2 minutes and the Leaving Chilled Liquid Temperature is within +0. This value is a relative value that represents magnitude of stability. When this criteria is met. The 50% selection reduces the magnitude of PRV movement over the NORMAL selection and the 30% selection reduces it even more.1 Hz every 2 seconds if motor current <80%FLA. C. depending on operating conditions. 106 JOHNSON CONTROLS . This.) Delta P must make a negative transition and exceed 3.MLM. Whenever Valid Point LED CR8 is illuminated.Adaptive Capacity Control Board FORM 160. the speed is increased either 1. and the 50% or 30% sensitivity is selected. is indicative of a surge.1 Hz every 6 seconds until it is within 1 Hz of previously plotted surge condition array in the Surge Map.1 Hz every 2 + (%FLA-80) if motor current >80%FLA but <98%FLA.0 Hz or 0. indicating a valid surge has been detected. If the real-time array does not match any previous surge condition. the VSD’s DC Link Current is monitored to detect when the current drops transiently toward zero. If Current Limit is in effect.MLM. Higher values correspond to decreasing sensitivity. indicating a valid surge has been detected. Surge detection is only enabled while the chiller is running.06.) Delta P must also exceed 3. as explained below. such as short chilled liquid loops. Surges that occur during certain operating conditions are not plotted. The Stability Limit setpoint is programmed over the range of 1000 to 7000. the ACC Board increases the motor speed (up to a maximum of 60(50)HZ) to take the compressor out of surge. When the chiller is started. as the case with Delta P method. surges are not plotted. Each time a Valid Surge is detected.6ºF of the Leaving Chilled Liquid Temperature Setpoint.) At least 3 Delta P surges have occurred within the 2 minute interval. the ACC Board evaluates if the speed can be reduced.5 ºF of Setpoint. Service Setpoints and Reset Procedures” section of this book. parallel chillers and light load conditions can cause excessive Pre-rotation Vane (PRV) movement resulting in leaving chilled liquid temperature control instability. This instability can be reduced by adjusting the SENSITIVITY Setpoint on the Optiview Evaporator Screen. B. If no plotted points are encountered.1 Hz every 20 seconds if motor current >98%FLA.02.8 Hz. 9ºF. a 5 minute time period is entered where the speed is inhibited from decreasing. This serial data is in 0v/+5VDC form.9ºF. is unconditionally plotted as a 3-dimensional array in the Surge Map as a surge condition. this speed is maintained for the next 15 seconds. and Reset Procedures” section of this book. Serial communications with the Harmonic Filter logic Board take place through the microprocessor via the Digital Signal Processor. it would be counted. When the speed has been increased either 1.1 Hz every 8 seconds if Delta T is >0. During this period. The compressor must be surge free for 5 minutes before a speed decrease is permitted or another surge or another surge can be plotted on the Surge map. The microprocessor is the center point of the hardware architecture (Fig. The motor speed. The Surge Margin Adjust Setpoint can be used to add an extra margin of surge prevention.5 and <0.54-M1 (607) Otherwise. The ACC Board counts the surges as they occur and sends a total count to the Microboard for display on the ACC Details Screen (note that the Total Surge Count displayed on the Surge Protection Screen and the Hot Gas Bypass Screen is that which is accumulated by the Surge Protection feature).55 before a speed decrease would be allowed. Also. using the Auto Print keypad key. 42). Surge LED CR9 illuminates for 2 seconds.2 and <0.FORM 160.0 Hz following instructions in the “System Calibration. Service Setpoints. If this were to occur. if there is no Current Limit in effect. but increases are allowed. If the DC Link surge occurred >10 seconds after the Delta P surge. the rate at which new points are printed is also every five minutes.1 Hz every 10 seconds if Delta T is >0. • 0. When the 15 seconds have elapsed. If Delta P/P ever increases to >3. It is programmed over the range of 0. This is usually not required and is to be used only by qualified Service Technicians as a method of plotting a surge event that the ACC Board does not find on its own. The total surge count is not incremented if a different surge type occurs within 10 seconds of the previous surge. 12 JOHNSON CONTROLS 107 . the ACC Board will respond to this point in exactly the same way it responds to automatically plotted surge points. Delta P/P and PRV Position at the instant the point is established.0 Hz or 0. A Surge that occurs within 10 seconds of the previous surge is only counted if it is of the same surge type.8 Hz. the DC Link surge is not counted. A surge point can be manually inserted into the Surge Map using the Manual Surge Point keypad key on the ACC Details screen and switch SW1 on the ACC Board as described in the “System Calibration. At the instant the condition is identified as a surge event. Delta P/P would have to decrease to <3. Similarly. It coordinates the serial data communications between the OptiView Control Center Microboard and the VSD Logic Board and Harmonic Filter Logic Board. the speed is automatically increased at a rate based on the Delta T between the Leaving Chilled Liquid temperature and the Leaving Chilled Liquid temperature Setpoint as follows: • 0. it is not plotted on the Surge Map. Therefore. in Auto speed control mode. new surges are ignored. the surge points can be printed in real-time as they occur. For example. as described above. If a surge is detected within this 5 minute period.60. there is very little PRV movement remaining to compensate for an increasing load condition. VS XMT (CR5) and VS RCV (CR4) LED’s illuminate during serial communications with the VSD Logic Board. This is only to be used for situations in which the automatic surge detection described above does not respond to surge events. • 0. The Default value of 0 should provide proper operation in most applications. the speed is increased 0. if a Delta P surge is detected and a DC Link surge is detected within 10 seconds. and the PRV position reaches >98%.1 Hz every 6 seconds if Delta T is >0. Once plotted. This is repeated as long as the compressor continues to surge. Surge points can be printed from the ACC Details Screen. regardless of whether or not Valid Point LED CR8 is illuminated. Since the maximum rate at which new surges can be plotted is every five minutes. Service Setpoints and Reset Procedures” section of this book. but the speed is increased by the amount as described above. The entire stored Surge Map can be printed using the Surge Map Print keypad key. The motor speed will be automatically increased as described above. When the PRV’s approach their 100% open position. YM XMT (CR7) and YM RCV (CR6) LED’s illuminate during serial communications with the OptiView Control Center Microboard.0 to 25.5ºF. as described above. the speed will be slowly increased to 60 Hz.8 Hz and the surge event is plotted on the Surge Map. The Watchdog circuit maintains the microprocessor in a reset state during low voltage conditions. Switch SW1 is used to manually insert (plot) a surge point in the Surge Map.) Leaving Chilled Liquid Temperature Stability Timer is running.Adaptive Capacity Control Board FORM 160. • TPB: supply voltage ground. Surge LED CR9 illuminates for 2 seconds when a valid surge condition has been detected as explained above. The BRAM is a battery backed memory device where the Surge Map is stored. Although Evaporator and Condenser pressures are transmitted to the ACC Board via the serial communications link for Delta P/P calculation. The Watchdog also assures that the entire Program is executed and that no Program latch-ups occur. Transitions to logic low (<3. Also applied to the MUX. The EPROM contains the operating Program for the ACC Board. Test points are provided as follows: • TPA: +5VDC supply voltage.) Current Limit is in effect b. • TPE: Harmonic Filter Logic Board Frame pulse.5VDC. 108 JOHNSON CONTROLS . is the output of the PRV position Potentiometer.5VDC) during low voltage conditions.) Speed control is in MANUAL mode. • TPC: Watchdog power failure detected. • TPD: Harmonic Filter Logic Board 0/+5VDC 1200 baud serial data. these pressures are also applied directly from the Microboard to the MUX (multiplexer) for Delta P surge detection. these values are input to the microprocessor. This prevents the microprocessor from reading/writing or processing data until it and supporting circuits have sufficient supply voltage.54-M1 (607) This data is accompanied by a Framing pulse and a CLK signal. indicating an unstable control condition c. Valid Point LED CR8 illuminates whenever there is a condition in effect that prevents a Surge from being plotted on the Surge Map. Normally >+4. The RAM serves as the scratch pad memory. Under program control. These conditions are: a. 42 – COMPRESSOR MOTOR VARIABLE SPEED DRIVE (VSD) ADAPTIVE CAPACITY CONTROL (ACC) BOARD JOHNSON CONTROLS 12 109 .54-M1 (607) TPE HARMONIC FILTER FRAME PULSES TPD HARMONIC FILTER DATA MICROBOARD RECEIVE LED TPC (POWER FAIL) VSD TRANSMIT LED MICRO BOARD TRANSMIT LED VSD RECEIVE LED SURGE LED MANUAL SURGE POINT SWITCH MICRO VALID SURGE POINT LED TPB (GND) LD04084 TPA (+5VDC) BRAM EPROM FIG.FORM 160. YORK PROTOCOL 110 JOHNSON CONTROLS .Adaptive Capacity Control Board FORM 160.54-M1 (607) MICROBOARD 031-02430-000 031-01730-000 J8 10 8 J15 1 TX RX GND COND PRESSURE EVAP PRESSURE ADAPTIVE CAPACITY CONTROL BOARD 031-01782 J3 2 3 J10 3 1 2 J18 1 2 3 TX GND RX VSD LOGIC BOARD 031-01433 031-02077 031-02506 J11 1 2 3 COM 5 OPTO-COUPLE 2 3 1 2 3 J4 PRV POSITION LD12567 FIG. 43 – SERIAL COMMUNICATIONS INTERFACE . 43A – SERIAL COMMUNICATIONS INTERFACE .54-M1 (607) MICROBOARD 031-02430-001 J8 10 8 J15 1 TX RX GND COND PRESSURE EVAP PRESSURE ADAPTIVE CAPACITY CONTROL BOARD 031-01782 J3 2 3 J10 3 1 2 J18 1 2 3 TX GND RX VSD LOGIC BOARD 031-01433 031-02077 031-02506 J11 1 2 3 COM 5 OPTO-COUPLE 2 3 J13 10 COM 2 RS-485 1 2 3 J4 8 9 J20 2 PRV POSITION LD12568 FIG.FORM 160.YORK PROTOCOL 12 JOHNSON CONTROLS 111 . MODBUS PROTOCOL 112 JOHNSON CONTROLS . 43B – SERIAL COMMUNICATIONS INTERFACE .Adaptive Capacity Control Board FORM 160.54-M1 (607) MICROBAORD 031-02430-001 ACC J15 1 VSD LOGIC BOARD 031-02506 J11 1 2 3 J16 (-) (+) GND 2 3 4 1 J20 2 +12 VDC COM 5 OPTO-COUPLE 2 3 J13 10 COM 2 RS-485 8 9 22 10 11 J7 PRV POSITION LD12569 FIG. MUX PRV POSITION J4 SURGE REFRESH SW1 MANUAL SURGE POINT CR8 CR9 RED MICRO PRV POT RESET 2 GREEN VALID POINT WATCHDOG / POWER FAIL DETECTOR TPC UNDER VOLTAGE BRAM RAM EPROM TPA TO ALL CKTS +5VDC REG +24VDC REG J6 +24VDC GND 2 1 POWER SUPPLY TPB LD04086 FORM 160.CR6 YM RCV VS RCV GREEN 3 SERIAL DATA 1 J8 RED RED CR7 YM XMT CR5 VS XMT CR4 JOHNSON CONTROLS J10 GREEN 3 MICRO BOARD 1 SERIAL DATA VSD LOGIC BOARD J3 DATA CLK ADDRESS DIGITAL SIGNAL PROCESSOR J9 1 TPD DATA FRAME TPE 2 3 HARMONIC FILTER LOGIC BOARD MICRO BOARD 2 COND PRSS.54-M1 (607) 113 FIG. 44 – ADAPTIVE CAPACITY CONTROL (ACC) BOARD 12 . 3 EVAP PRSS. 10. the Safety shutdown is performed. Therefore. etc.PROXIMITY PROBE CLEARANCE” is displayed.MLM. On chillers equipped with Probe 025-30961-000 and Flash Memory Card version C.HIGH OIL TEMPERAJOHNSON CONTROLS .01. The value is logged on a label adhered to the inside of the OptiView Control Center door.10.MLM. etc. This value is entered at the Keypad as the REFERENCE POSITION Setpoint using the Proximity Probe Calibration Screen.xxx (and later) or C. -26. 45 . The amount of time the +10 threshold has to be exceeded is dependent upon the software version. The output of the Proximity circuit is connected to the Microboard at J8-15 and is a 0 (0.03 or later).5VDC analog voltage corresponding to a measured temperature of 0ºF (-177ºC) to 300ºF (148.4VDC analog voltage corresponding to a measured distance of 10 to 99 mils. 114 field replacement of either of these items requires the Reference Position Setpoint to be programmed again. if the actual Position is 55 mils. If the distance decreases to < -17 mils. If the Reference Position is between 37 and 46 mils. a safety shutdown is performed and “THRUST BEARING .MLM. When the Probe is installed at the time of chiller manufacture. For chillers equipped with “P” compressors. Since this Reference Position value is stored in the BRAM (U52) memory device on the Microboard. With software version C. Q” or “H5-8” compressors. xxx (and later) or C.54-M1 (607) SECTION 13 PROXIMITY PROBE (REFER TO FIG.10. the fault is only detected during those periods. However. The difference between the Reference Position and the actual Position is the PROXIMITY DIFFERENTIAL and is displayed as “High Speed Thrust Bearing Proximity Differential = xx mils” on the Compressor Screen.Proximity Probe FORM 160. the clearance is continually checked.01.) or decreases to > 25 mils (-25. the +10 threshold must be exceeded for 2 continuous seconds to initiate a shutdown.10. With all previous software versions. With software version C. The different vintages of Proximity Probes are shown at the end of this section.01. Distances outside the range of 37 to 79 mils will be rejected. whereupon the calibration procedure must be repeated to establish a new Reference Position. the maximum allowed distance between the tip of the Probe and the surface of the Thrust Collar is 23 mils. a reference position is established.OPT.089VDC) to +4.1ºC).03 or later do not sense the High Speed Drain Line oil temperature.48) The following applies to all applications except “P” compressors and style F and later chillers with “G. This is the PROXIMITY POSITION and is displayed as “High Speed Thrust Bearing Proximity Position = xx mils” on the Proximity Probe Calibration Screen.OPT.01. If the Differential increases to > 10 mils (+10.302 (and later). +11.01.9ºC).01. The output of the 025-30961-000 Probe Temperature circuit is connected to the Microboard at J8-1 and is a 0 to +4.). chillers equipped with Flash Memory Card version C. refer to Section 13A: The Proximity Probe senses the distance between the tip of the Proximity Probe and the surface of the High Speed Thrust collar.02 and earlier. if the Drain Line Temperature increases to >250. It is established using a calibration procedure in the “System Calibration” section of this book. if the Reference Position is 50 mils and the actual Position is 45 mils. The –25 threshold must be exceeded for 2 continuous seconds to initiate a shutdown. a Safety shutdown is performed and “THRUST BEARING . For example. with the same Reference. Any distance between 37 and 79 mils is acceptable.MLM.302 (and later).0ºF (121. when the distance decreases to < 22 mils. With all previous software. regardless of which Probe is installed.MLM. the full -25 mil differential is not allowed. Therefore.01. This value remains the Reference Position until the compressor is rebuilt. regardless of the Differential to the Reference Position. It is the distance between the tip of the Probe and the surface of the High Speed Thrust Collar with a minimum of 25 PSID oil pressure. then the Differential is -5 mils. This is the OIL DRAIN LINE TEMPERATURE and is displayed as “High Speed Thrust Bearing Oil Drain Temperature = xxxºF on the Compressor Screen (not applicable to Flash Memory Card version C.PROXIMITY PROBE OUT OF RANGE” is displayed. during “System Run” and during “Coastdown”. the Differential is +5 mils. An earlier vintage Probe (025-30961-000) also sensed the High Speed Drain Line oil temperature. a Safety shutdown is performed and “THRUST BEARING . the +10 threshold only has to be exceeded for an instant to initiate a shutdown. the clearance is only checked during the last 20 seconds of “System Prelube”. the 0Vdc value will cause the chiller will be locked out on the safety “THRUST BEARING – OIL TEMPERATURE SENSOR” (complete explanation of this message is in Operation Manual 160. When any of the above Thrust Bearing related Safety shutdowns occur. The Probe cannot accurately measure the gap distance if its supply voltage. Refer to Table 1. a Cycling shutdown is performed and “Proximity Probe . 13 JOHNSON CONTROLS 115 . The Proximity Position output of the Probe is measured at the Microboard at J8-15 and is calculated as follows: V = D .5 X V + 18. IMPORTANT! Probes 025-35900-000.FORM 160. Some of these shutdowns also require a thrust bearing inspection.75 Where: V = VDC T = Temp in Deg F The chiller could be equipped with one of several different Probes.54-M1 (607) TURE” is displayed.14 20.OIL TEMPERATURE SENSOR” is displayed. the chiller cannot be restarted until a special reset procedure is performed by a Service technician. a new Flash Card (031-01797) must be ordered at the same time as the probe. refer to part number listed in renewal Parts 160. The chiller will automatically restart when the voltage increases above +19. If the software reads this value. +24VDC.75 62. For service replacement. it is indicative of an open circuit or a broken wire to the Probe and a Safety shutdown is initiated and “THRUST BEARING .5 T = 62. all versions of software do not read this input and therefore meet this requirement.86 X V + 8.54-O1). The value returned from the Probe for this temperature will be 0Vdc. Therefore. Microboard Program Jumpers. 025-35900-001 and 025-40496-000 do not sense the High Speed Drain Temperature.8.Low Supply Voltage” is displayed.01. The reset procedure and bearing inspection criteria is listed in the “System Calibration. If it decreases to <19. For microboards 031-01730-000. The differences are listed below. Service Setpoints and Reset Procedures” section of this book. The Probe differences vary with the vintage. Software versions C. For microboards 031-02430-000/001. If the Temperature signal output of the Probe decreases to 0VDC.03 (and later) do not read this parameter and are required for these probes. If the software does not meet this requirement.18.54-RP1 and 160.MLM. the Microboard monitors the Probe’s 24VDC power source at J9-12 on the Microboard. decreases to <19. To prevent an invalid Proximity gap Safety shutdown due to a Utility Power sag.7VDC.86 D = 20.0VDC. For microboard 031-01730-000.0VDC.14 Where: V = VDC D = distance in Mils The High Speed Drain Temperature output of Probe 025-30961-000 is measured at the Microboard at J8-1 and is calculated as follows: V = T .73-RP3. the software used must be of a later vintage that does not read this parameter. microboard program jumpers JP41 and JP42 must be positioned appropriately to provide proper operation of actual probe installed. +5VDC Description Production until April 2000. Production after March 2006. Does not sense High Speed Drain Temperature. Does not sense High Speed Drain Temperature. Senses proximity only.54-M1 (607) Part Number 025-30961-000 Supply Voltage +24VDC. 025-35900-000 +24VDC.MLM. This design allows the electronics portion of the probe to be replaced separately. Refer to fig 45.Proximity Probe FORM 160. Refer to figure 47 for parts breakout of probe assembly 025-40496-000. Refer to fig 46 Production from March 2003 until March 2006. Does not sense High Speed Drain Temperature. 1-piece integrated design that includes the electronics in the barrel of the probe. Senses Proximity only. Production from April 2000 until March 2003. +5VDC 025-35900-001 +24VDC. Senses Proximity. This probe assembly is a 2-piece design that has the electronics in a module that is separate from the probe. thus eliminating the need to evacuate the chiller refrigerant charge when replacing only the electronics portion of the probe. Refer to fig 46. The probe is connected to the electronics module with a coaxial cable. 1-piece integrated design that includes the electronics in the barrel of the probe. +5VDC 025-40496-000 +24V 116 JOHNSON CONTROLS . Supercedes probe 025-30961-000. Also senses High Speed Drain Line Oil Temperature unless equipped with Flash memory card version C. 1-piece integrated design that includes the electronics in the barrel of the probe. Supercedes probe 025-35900-000. Senses proximity only.01.03 or later. Supercedes all previous probes. 2. FIG.Low Supply Voltage” Cycling Shutdown. Solid State Starter Logic Board or Adaptive Capacity Control Board as determined by the Starter Application. CM-2 Board. +24VDC Reference for “Proximity Probe . CM-2 Board. 45 – PROXIMITY PROBE INTERFACE-PROBE PART NUMBER 025-30961-000 J8 12 2 +5VDC GND PROXIMITY PROBE PROXIMITY 15 +24VDC MICRO BOARD J9 12 +24VDC NOTE 1 J31 1 2 GND +5VDC P31 1 2 JX 2 NOTE 2 J1 2 1 +24VDC POWER SUPPLY LD05532 NOTES: 1.Low Supply Voltage” Cycling Shutdown.54-M1 (607) J8 12 2 1 15 +24VDC +5VDC (DRAIN LINE TEMP) GND DRAIN TEMP PROXIMITY PROXIMITY / TEMP PROBE 13 MICRO BOARD J9 12 +24VDC NOTE 1 J31 1 2 GND +5VDC P31 1 2 JX 2 NOTE 2 LD04090 J1 2 1 +24VDC POWER SUPPLY NOTES: 1. 46 – PROXIMITY PROBE INTERFACE-PROBE PART NUMBER 025-35900-000 and 025-35900-001 JOHNSON CONTROLS 117 . Solid State Starter Logic Board or Adaptive Capacity Control Board as determined by the Starter Application. +24VDC Reference for “Proximity Probe . 2. FIG.FORM 160. CM-2 Board. 5. This pin is for Probe manufacturer’s use only. 2. consisting of: 025-40496-000 probe assembly (ref note 4) 025-37805-000 DIN connector 028-12209-000 O-ring 035-21458-000 instruction drawing FIG. 3. No wire is permitted to be connected to DIN connector Pin3. Connecting a wire to this pin will cause Probe malfunction. use the existing cable and retrofit kit 364-51806-000. +24vdc Reference for “Proximity probe – Low Supply Voltage” Cycling Shutdown. When replacing previous probe versions with this probe. Solid State Starter Logic Board or Adaptive Capacity Control Board.54-M1 (607) J8 2 GND PROXIMITY PROBE ELECTRONICS MODULE GND PROXIMITY PROBE 15 PROXIMITY 2 1 +24VDC MICRO BOARD J9 12 +24VDC NOTE 1 J31 1 2 GND P31 1 2 JX 2 J1 2 1 NOTE 2 +24VDC POWER SUPPLY PROXIMITY PROBE TIP (025-40496-001) LD05532A PROXIMITY PROBE TIP "O RING" (028-12209-000) ELECTRONICS MODULE W/PVC BUSHING (025-40496-002) DIN CONNECTOR (025-37805-000) CONNECTING CABLE (025-40469-003) GND 1 3 NOTE 3 CONNECTING CABLE 025-28701-003 TO OPTIVIEW CONTROL PANEL DIN CONNECTOR (PIN 1) (PIN 2) (GND) NOTES: 1. 4.Proximity Probe FORM 160. Probe assembly 025-40496-000 consists of: Proximity Probe 025-40496-001. as determined by starter application. 47 – PROXIMITY PROBE INTERFACE – PROBE PART NUMBER 025-40496-000 118 JOHNSON CONTROLS 2 +24 VDC POWER SOURCE OUTPUT SIGNAL GROUND LD12570 . Electronics Module with PVC bushing 025-40496-002 and Probe to Electronics Module interconnecting cable 025-40496-003. 54-M1 (607) 13 2.0" + 24VDC PROBE LD05529a YORK PART NUMBER 025-35900-000 and 025-35900-001 FIG. 48 – PROXIMITY PROBE JOHNSON CONTROLS 119 .FORM 160.0" + 24VDC PROBE LD06510 YORK PART NUMBER 025-30961-000 2. a red LED illuminates when the switch is closed. The Microboard reads the state of these contacts through the I/O Board and when they open.INTERFACE 120 115VAC 1 JOHNSON CONTROLS . exposing the pressure switch to the pressure inside the compressor. One side of these contacts is connected to 115VAC. This device detects abnormal bearing position through probe contact instead of distance measurement as performed with the Proximity Probe. 49 – HIGH SPEED THRUST BEARING LIMIT SWITCH . extinguishes when it is open. On the COMPRESSOR Screen. a safety shutdown is performed and “THRUST BEARING – LIMIT SWITCH OPEN” is displayed on the System Details line of the Display. The reset procedure and Bearing inspection criteria is listed in the “System Calibration and Reset Procedures section of this book.54-M1 (607) SECTION 13A HIGH SPEED THRUST BEARING LIMIT SWITCH (REFER TO FIG. followed by a special reset procedure which has been performed by a qualified Service Technician. the chiller cannot be restarted until a Thrust Bearing inspection. The High Speed Thrust Bearing Limit Switch is an assembly consisting of a pressure switch attached to a probe that protrudes into the compressor housing.High Speed Thrust Bearing Limit Switch FORM 160. The other side connects to I/O Board TB3-81. COMPRESSOR CONTROL CENTER TB3 81 1 2 I/O BOARD LD06866 TB6 FIG. After the High Speed Thrust Bearing safety shutdown has occurred. it comes into contact with the probe.50) Chillers that are equipped with “P” compressors and style F and later chillers with “G” or “H5-8” compressors have a High Speed Thrust Bearing Limit Switch (02534535-000) instead of the Proximity Probe described in Section 13. When the bearing position decreases to < the allowed position. 49 . A set of normally closed contacts inside the switch open when the switch is exposed to a pressure of > 15 to 25 PSIG. causing the breakaway probe to detach. 50– HIGH SPEED THRUST BEARING LIMIT SWITCH JOHNSON CONTROLS 121 .FORM 160.54-M1 (607) 13A PRESSURE SWITCH GRD PIN (GRN/YEL) PINS 1 & 2 (BLK) BREAK-AWAY PROBE GRN/YEL LD06860 FIG. the Program modulates the Variable Orifice to maintain the Condenser refrigerant to a programmable Setpoint level. is used to control the refrigerant level in the Condenser.02. the Program operation described here must be ENABLED on those chillers so equipped and DISABLED on all other chillers. The level is at minimum when the when the chiller is shutdown with the orifice in the fully open position. However. if the actual level is greater than the Level Setpoint. This Manual control can also be used to place the Orifice in a fixed position. If Automatic control is selected. The level is expressed as a percentage and is displayed on the Condenser Screen and the Refrigerant Level Control Screen as the “Refrigerant Level Position = xxx%”. the Refrigerant Level close output is energized for the length of the programmable Valve Preset Time Setpoint (0 to 100 seconds. There are different versions of the Level Sensors as shown in figure 50. “RAMP UP TIME REMAINING = XX MIN” is displayed. the ramp value is displayed as “REFRIGERANT LEVEL TARGET = XX%” and replaces the Level Setpoint message on the Condenser Screen. Elevated Evaporator pressure with respect to Condenser pressure could cause the level to be higher. the differences affect the way the sensors are calibrated. These control signals originate at the Microboard. there are two different courses of action taken. the Microboard begins controlling the level to the Level Setpoint.Refrigerant Level Control FORM 160. When a chiller start is initiated. The desired refrigerant level to be maintained in the condenser is the Refrigerant Level Setpoint and is displayed 122 as “Refrigerant Level Setpoint = xxx%” on the Condenser Screen and the Refrigerant level Control Screen. along with the programming of Setpoints described below. This Setpoint is programmed by a Service Technician at chiller commissioning using the Refrigerant Level Control Screen.MLM. This ramp causes the Setpoint to increase from the initial refrigerant level to the programmed Level Setpoint over a period of 15 minutes. If Manual control is selected.MLM. default 50).xxx and earlier or “P” compressors with C. the valve is held in this position until the first 3 minutes of Chiller Run Time has elapsed (Setting the Valve Preset Time to 0 seconds disables this pre-positioning feature).54-M1 (607) SECTION 14 REFRIGERANT LEVEL CONTROL (REFER TO FIG. Service Setpoints and Reset Procedures Programming Procedures” section of this book. While this ramp is in effect. located in the refrigerant liquid line between the Evaporator and Condenser. A Liquid Level Sensor (LLS) detects the Refrigerant Level in the condenser and outputs an analog voltage to the Microboard that represents this level.xxx and later: Upon entering chiller Prelube. After the chiller has JOHNSON CONTROLS . However. while others are equipped with pushbuttons that are used to calibrate the sensor. AUTOMATIC OPERATION While the chiller is shut down. This causes the Condenser refrigerant level to be approximately 0%. It is programmable over the range of 20% to 80%. is performed on the Refrigerant Level Control/Tuning Screen using instructions in the “System Calibration. Since the Level Control feature is optional. Service Setpoints and Reset Procedures” section of this manual. the Variable Orifice can be manually controlled with the Keypad keys.01.07.06. The Level Sensor calibration procedure is in the “System Calibration. Automatic or Manual level control is allowed. During this 3 minute period. The Level Sensor is calibrated so that the refrigerant level is displayed as 0% when the level is at minimum. Levels between these extremes are linearly scaled. If equipped with Flash Memory Card version C. the Refrigerant Level Override displays "Valve Preset" and the Override Time Remaining displays the time remaining in the 3-minute countdown timer. After pre-positioning.MLM. if the actual level is less than the Level Setpoint. A Variable Orifice.xxx and earlier: After the chiller is started. 100% when the level is at maximum. with the sensor fully covered. The level is at maximum when the level is above the site glass. an Open signal is applied to the Actuator. depending on the Flash Memory Card version as follows: If equipped with Flash Memory Card version C. Some sensors are equipped with adjustable potentiometers.04. a linearly increasing ramp is applied to the Level Setpoint. the refrigerant level is controlled to the programmed Level Setpoint. 51 & 52) The chiller can be provided with an optional Condenser Refrigerant Level Control.01. driving the Orifice to the fully open position. It is modulated by an Actuator that is driven by open and close output signals from Triacs on the I/O Board. While the ramp is in effect. when the Vane Motor Switch (VMS) opens after entering SYSTEM RUN. After the 15 minute ramp period has elapsed. This procedure. The operation of the sensors is the same. MLM. If the error is > 9%. This repeats until the chiller is shutdown. However. The result of this comparison determines the signal that will be applied to the actuator at the end of the Level Control Period as explained below. Software version C. At the end of each Level Control Period. After the ramp period has elapsed.54-M1 (607) been running 3 minutes.01. default 8 Proportion Error Deadband . In later versions. the refrigerant level is controlled by the Refrigerant Level Setpoint for the remainder of chiller run. When transitioning from Zone 2 to Zone 1.11. default 8). the Proportion error and Rate of Change are compared to control thresholds Proportion Limit Close.01. as determined by the error relationship of the actual refrigerant level and the Level Setpoint as shown below. The duration of the signal and whether it is an open or close signal depends upon the Proportion Error and the Rate of Change of the actual level compared to the Level Setpoint in a recurring period of time called a Level Control Period. The setpoint values used by the program is determined by the Software vintage. The duration of these periods are programmed as the Level Control Period Setpoint. The duration of the signal determines the magnitude of change to the Orifice position. “Zone Control Off” (if chiller shutdown).OPT. “Zone 2 to Zone 1” is displayed and the “Zone Control Time Remaining” status box displays the amount of time remaining in the 60-second countdown timer. called the Refrigerant Level Target.+3% Rate Error Deadband . This ramp limit allows the level to go from the present level to the Refrigrant Level Setpoint over a period of time programmed as the Ramp-Up Time setpoint (3 to 15 minutes.MLM.xxx (and later) or C. The control thresholds are applied in two different zones.14.5 14 Zone 1 & Zone 2 Level Setpoint 20% to 80%.OPT.FORM 160. is applied to the Refrigerant Level Setpoint. etc. the error must be < 9% for 60 seconds before the Zone 1 parameters are used. the Refrigerant Level Target is used to control the refrigerant level in the condenser and the Refrigerant Level Setpoint message on the Condenser Screen is replaced by “REFRIGERANT LEVEL TARGET = XX%”. In earlier versions.01. “RAMP UP TIME REMAINING = XX MIN” is displayed. The entire chiller run time is divided into Level Control Periods. default 30% Valve Preset Time (setpoint) (seconds) 0 to 100. a linearly increasing ramp limit. The first one begins upon entering SYSTEM RUN and when it ends the next one begins.5 to 30.xxx (and earlier) or C.xxx (and earlier) Level Control Period-3. some control thresholds are fixed while others are programmable. default 50 Ramp Up Time (setpoint) (minutes) 3 to 15.+1% JOHNSON CONTROLS Software version C. While the ramp is in effect. they are fixed and programmable values applied in two different Zones. the values are programmable setpoints as shown below. the Zone 2 parameters are immediately implemented.+0% Rate Error Deadband – +0% *This RATE LIMIT setpoint sets the Rate Limit threshold for refrigerant levels both above (open) and below (close) the Refrigerant Level Setpoint. The Program applies an open or close signal. if the level is greater than or equal to the Refrigerant Level Setpoint. Zone 1 parameters are used when the error is < 9%. it begins controlling to the Setpoint. if it is less than the Refrigerant Level Setpoint.14. During this ramp-up period. The following are the control thresholds: Zone 1 Proportion Limit Open (fixed) 50% Proportion Limit Close (fixed) 45% Rate Limit* (setpoint) 3%-15% default 7% Period (setpoint) (seconds) 8-22 default 15 Zone 2 52% 45% 3%-15% 5% 2.01. the control will operate the same as previous Software versions. Proportion Limit Open and Rate Limit Close and Rate Limit Open. Zone 2 parameters are used when the error is >9%.5-10 2.0 seconds (default 3. On the Refrigerant Level Control Screen.306(and later) In this version. If the Valve Preset Time is set to 0 seconds and the Ramp-Up Time Setpoint is set to 15 minutes. as determined by the error relationship between the actual refrigerant level and the Level Setpoint as shown below. 123 .5) Proportion Limit Open-10% to 50% (default 15) Proportion Limit Close-10% to 50% (default 45) Rate Limit Open-5% to 50% (default 10) Rate Limit Close-5% to 50% (default 10) Proportion Error Deadband . This provides more stable control in certain operating conditions.11. the Zone Control State status box displays which zone of control is being used: “Zone 1”. Zone 2”. as required. as described above. They occur consecutively and continuously. from the Microboard to the actuator to maintain the level to the Level Setpoint. When transitioning from Zone 2 to Zone 1. The orifice valve movement is animated on the Refrigerant Level Control Screen as follows: when 0-20% open. Also. shown as 20% open. Using the Open. Close and Hold keys. If the OptiView Control Center is retrofit to an existing chiller. 40 . the Proportion Error influence in the response will be large. Close. The interface for both actuators is shown in Fig. the more often an output signal is applied to the Variable Orifice Actuator. If the Proportion Error is less than the Limit. close yields larger influence. Open. the Proportion error influence in the response is determined by how close the Proportion Error is to the Limit. Therefore. MANUAL OPERATION The Orifice Actuator can be manually controlled from the Keypad using the Refrigerant Level Control Screen after logging in at SERVICE access level. 80 . Smaller values generally yield greater response for the same level change in the Level control Period. Pressing the Auto key returns Level Control to Automatic operation. To establish the response to the rate of change. the smaller the value programmed for the Level Control Period. The Proportion Error is compared to Setpoints Proportion Limit Open (if level is above setpoint) and Proportion Limit Close (if level is below setpoint).40% open.Refrigerant Level Control FORM 160. the rate influence in the response will be large. shown as 40% open. ACTUATORS New production units use a Belimo actuator that operates from 24VAC. the Variable Orifice can be placed in a fixed position. the rate influence is determined by how close the result is to the Setpoint. The result is the Proportion Error. the chiller could be equipped with a Barber-Coleman actuator that operates from 115VAC. If the Proportion Error exceeds the Limit. shown fully closed.54-M1 (607) At the completion of each Level Control Period. The description of the operation of both actuators is in the “I/O Board” section of this book.100% open. 60 80% open. shown as 80% open. per the above. F/UP MAX MIN OR 1 2 3 E/DN FIG. close yields larger influence. If the result exceeds the Setpoint. further yields smaller influence. further yields smaller influence. shown as 100% open. the amount of change in the Level within the Level Control Period is compared to the Rate Limit Close (if level less than setpoint) and Rate Limit Open (if level greater than setpoint).60% open. the values programmed for Proportion Limit Open/Close and Rate Limit Open/Close determine the sensitivity of the level control. the actual level is compared to the Level Setpoint. 20 . 52. if less than the Setpoint. Hold and Auto keys are used to control the Variable Orifice. 51 – REFRIGERANT LIQUID LEVEL SENSOR 124 LD09256 JOHNSON CONTROLS . 16) LD04092 FORM 160.54-M1 (607) 125 FIG.J8 LEVEL OUTPUT 3 2 1 115VAC LIQUID LEVEL SENSOR 13 GND +12VDC JOHNSON CONTROLS 3 14 MICRO BOARD J1 CLOSE 28 29 I/O BOARD 161 162 (REFER TO FIG. 52 – REFRIGERANT LIQUID LEVEL CONTROL .INTERFACE 14 . 16) 24 VAC 5 BARBER-COLEMAN ACTUATOR 115VAC FIELD L1 L2 J19 TB1 163 OPEN BELIMO ACTUATOR 3 CLO S 28 E 29 1 IT 1 2 2 ORIFICE VALVE ACTUATOR N OPE J1 CLOSE 28 29 I/O BOARD OPEN TB1 163 161 162 ORIFICE VALVE ACTUATOR 2 3 CLOSE X N OPE (REFER TO FIG. xxx (and earlier) or C. This is displayed on the Oil Sump Screen as SETPOINT OIL PRESSURE = XX PSID. a Safety shutdown is performed and OIL . the speed of the VSD is controlled to maintain the programmed Oil Pressure Setpoint (20 to 45 PSID).01. During Oil Pump operation. the oil pump is driven by a Variable Speed Drive (VSD) (Refer to Service Manual 160.MLM. when equipped with the oil pump VSD. the Microboard. After the compressor has been running for 15 seconds.08.0 PSID for “P” compressors equipped with software version C.55) On style D and later chillers.PRESSURE SETPOINT NOT ACHIEVED is displayed. During Automatic operation.54-M1 (607) SECTION 15 OIL PUMP VARIABLE SPEED DRIVE (REFER TO FIG. 126 . These conditions are not checked in MANUAL operation.MLM. 4 and 5 depict chiller operation with the Oil Pump VSD enabled or disabled. The speed command to the VSD is modulated as required to maintain the 45 PSID Target Oil Pressure for the remainder of System Prelube and the first 15 seconds of System Run. The Target Oil Pressure is fixed at 45 PSID. Therefore.05. (If equipped with Flash Memory card version C.xxx (and later). b.xxx (and earlier) for 5 continuous seconds during the last 10 seconds of System Prelube or during the first 15 seconds of System Run. the oil pump speed is automatically controlled to maintain a desired oil pressure.VARIABLE SPEED PUMP . a speed command signal from the Microboard controls the oil pump speed by varying the VSD output frequency. The Microboard (J20-1) then applies a speed command signal to the PWM input of the VSD that ramps the VSD output frequency from 25 Hz (45 Hz on all “P” compressors. if either of the following conditions occur.01. 45 Hz on other compressor applications equipped with Flash Memory Card version C.MLM. the Program operates the oil pump VSD over the range of 25 Hz to 60 Hz to maintain the oil pressure to the target value of 45 PSID. Variable speed oil pump chillers are not equipped with the Liquid Line Solenoid Valve (2SOL). the following minimum and maximum oil pressures are allowed: 1. In normal operation. AUTOMATIC OPERATION When the chiller is started. The speed command is in the form of a Pulse Width Modulation (PWM) Signal as explained below. or High Speed Thrust Solenoid Valve (4SOL). a. when Oil Pump VSD operation is ENABLED with Program Switch SW1-2.OPT. “Microboard Program Switches”. 53 .52-M2 for details of this device). the Program is configured to operate the chiller without these solenoid valves. Operation Sequence Timing Diagrams in Fig. The programming of the Setpoints referred to below is performed on the Oil Sump Screen using instructions in the “System Calibration. Those chillers not equipped with the oil pump VSD must have this operation DISABLED by placing SW1-2 in the OFF position. On those chillers equipped with the oil pump VSD. If the Oil Pressure is < the programmed Oil Pressure Setpoint and the speed command is JOHNSON CONTROLS Under Program control. These Setpoints should not be programmed by anyone other than a qualified Service Technician. Also. the VSD operation as described below must be ENABLED by placing Microboard Program Switch SW1-2 in the ON position. 13 seconds after the System Prelube is initiated.xxx and later) to whatever frequency is required (up to a maximum of 60 Hz) to achieve the Target Oil Pressure. For the remainder of System Run and the Coastdown period.Oil Pump Variable Speed Drive FORM 160. If the Oil Pressure is <35 PSID (< 25.01.01. controls the Oil Heater to maintain a specific oil temperature as described in the “Oil Heater” section below. Refer to Table 2. it operates it over the same frequency range to maintain the pressure to the programmed Oil Pressure Setpoint. it is displayed on the Oil Sump Screen as TARGET OIL PRESSURE = 45 PSID. While this target is in effect. The time remaining that the Target Oil Pressure is in effect is displayed as a countdown timer in the message PULLDOWN TIME REMAINING = XX SEC. The speed can be manually controlled with the Keypad keys using the Oil Sump Screen with Service access level.10A. The speed command is displayed on the Oil Sump Screen as OIL PUMP DRIVE COMMAND FREQUENCY = XX HZ. During the System Prelube period and the first 15 seconds of System Run. under Program control. it is held at 45Hz for 8 seconds before releasing to normal control). the Microboard (J20-3) starts the oil pump by driving the EN (enable) input of the Oil Pump VSD to a Logic Low level (<1VDC). Service Setpoints and Reset Procedures” section of this book.10A. the VSD contains a set of normally open (N. If it remains at a logic high for the entire 0.O.7 second period. To provide an operational status to the Microboard (via I/O Board TB3-70).7 second period. if the error is > + 6 PSID. any time after the first 30 seconds of SYSTEM RUN.HIGH DIFFERENTIAL PRESSURE is displayed.xxx (and later)). They run consecutively and continuously. 2. the next one begins. a Safety shutdown is performed and OIL . If the AUTO key is pressed. the duration of time the signal is at logic low (<1VDC) and logic high (+12VDC) level determines the VSD output frequency between 25 and 60 Hz.DRIVE CONTACTS OPEN. While the chiller is running.5 Hz. the VSD is driven to a specific predetermined frequency. the actual oil pressure is compared to the Oil Pressure Setpoint and the speed command is changed as required to invoke VSD frequency changes to increase or decrease the oil pressure. For example.35 seconds) of the 0. as described above. if the Oil Pressure decreases to < 15 PSID. the value programmed for Control JOHNSON CONTROLS . If the error between the Oil Pressure Setpoint and the actual oil pressure is < +6 PSID. Automatic operation. or smallest increment of change is 0.08A. This allows the output frequency to be changed in 0. the greater the amount of correction above 0.OPT.5 Hz increments. it will automatically turn off after 10 minutes of operation.01.7 seconds.02) + 25 Period Setpoint determines the relative magnitude of correction applied to the VSD output frequency.5 Hz to increase or decrease the oil pressure.3 to 2. Service Setpoints and Reset Procedures” section of this book.3 seconds over the range of 0. when the first one ends.5 Hz steps. if not manually terminated earlier.7 seconds.FORM 160. This permits service analysis of the oil pressure at various oil pump speeds. is resumed. the frequency is increased or decreased 0. manual on/off control. the speed can be manually adjusted over the range of 25 to 60 Hz. Each time the LOWER key is pressed. This frequency is programmed using instructions in the “System Calibration. The RAISE and LOWER keys are used to increase and decrease the VSD output frequency in 0. it is commanding the VSD output frequency to be 25 Hz. this requires the VSD to be manually reset by the removal and restoration of the VSD AC Power.7 second period. The VSD output frequency for any PWM input can be calculated as follows: Frequency in Hz = (On-Time in seconds / 0.5 Hz is applied. except if the VSD experiences a short circuit on the output. displaying OIL .LOW DIFFERENTIAL PRESSURE is displayed.01.5 Hz. The duration of the periods is determined by the Control Period Setpoint. the frequency is increased 0. xxx (and later) or C.) relay contacts that are driven closed as long as all the internal protection circuits are satisfied. or 42. the Oil Sump Screen can be used to monitor the actual oil pressure and the speed command. it would be commanding the VSD to operate at a frequency that is halfway between 25 and 60 Hz.54-M1 (607) at 60 Hz for 5 continuous seconds. The larger the programmed value. etc. At the end of each period. as well as manual speed control is permitted.7 second period. 127 The entire oil pump run time is divided into Oil Pressure Control Periods. This repeats until the oil pump is shutdown. the frequency is decreased 0. During Manual operation. Each time the RAISE key is pressed.7 second period. The signal is applied every 0. it is commanding the VSD output frequency to be 60 Hz. After the pump is manually turned on.0 PSID with software versions C. a Safety shutdown is performed and OIL . The resolution. Within the 0.08. the contacts automatically close.VARIABLE SPEED PUMP . However. When the chiller is not running.01 seconds. After the problem has cleared. Repeated presses of these keys are required to increase or decrease the frequency by greater amounts. The Microboard controls the VSD output frequency by applying a Pulse Width Modulation (PWM) speed command signal to the VSD. Frequencies between these extremes are achieved by driving the signal low for a proportionate amount of time within the 0. If it is low for the entire 0.5 Hz. This Setpoint is programmed in multiples of 0. The opening of these contacts initiate a chiller cycling shutdown. If the SET key is pressed. They open anytime these circuits will not permit the VSD to operate. During Automatic operation.MLM. if the signal is low for 50% (0. If it increases to >90 PSID (120. MANUAL OPERATION 15 The oil pump can be manually operated using the Oil Sump Screen when logged in with SERVICE ACCESS level. “H” or “J” compressors TB1-64 . it is turned off at 3ºF above the target.Style E chillers with “P” compressors and all Style F and later chillers. it defaults to 110ºF.54-M1 (607) OIL HEATER OPERATION On chillers equipped with the oil pump VSD.Oil Pump Variable Speed Drive FORM 160. When the temperature decreases to 4ºF below the target value. the oil heater is controlled by the Microboard via I/O Board The connection to the I/O Board is determined by the chiller style and compressor type as follows: • • TB1-34 . the heater is turned on and off to maintain a target value of 50ºF above the Condenser Saturation Temperature. When the oil pump is not operating. 53 – OIL PUMP VARIABLE SPEED DRIVE (VSD) 128 JOHNSON CONTROLS . the target value defaults to 160ºF. If the calculated target value is > 160ºF. If the calculated target value is < 110ºF.Style D and E chillers with “G”. the heater is turned on. OIL PUMP VSD 28782A FIG. To prevent overheating the oil in the event of an OptiView Control Center failure. thermostat 1HTR opens at 180ºF. 0 Hz OFF ON +12VDC 0VDC "OFF TIME" "ON TIME" 60. 54 – OIL PUMP VSD / OIL HEATER CONTROL – INTERFACE 0.5 Hz OFF ON 0.35 SEC 42.5 Hz OFF ON 0.17 SEC 33.52 SEC 51.0 Hz +12VDC 0VDC OFF ON 0.7 SEC +12VDC 0VDC OFF ON 25.54-M1 (607) 2 I/O BOARD TB3 70 TB1 34 J1 6 35 OIL HEATER ON/OFF 1HTR IM OIL HEATER J19 OIL PUMP VSD STATUS 15 6 35 J20 1 SPEED COMMAND +12VDC START / STOP PWM +V EN 70 STATUS LD04093A MICRO BOARD 2 3 OIL PUMP VSD FIG.FORM 160. 55 – OIL PUMP VSD SPEED CONTROL SIGNAL JOHNSON CONTROLS 129 .0 Hz LD04094 FIG. The COM 4B LoopBack test can be used to verify operation of the Microboard COM 4B communications port. If installed in the OptiView Con trol Center. The MicroGateway is an optional printed circuit board that provides an interface between the OptiView Control Center and YORK ISN (Integrated Systems Network) or other selected networks. MICROGATEWAY J2 G TX G RX 7 6 9 J21 1 2 + 12VDC GND J1 1 2 RS-485 TX RX TB4 RX2 TX2 TB1 2 3 4 LD06511 + TO ISN LAN MICROBOARD FIG. 56) The complete description of the MicroGateway installation and operation is contained in YORK form 450. remote Leaving Chilled Liquid Temperature and/or remote Current Limit Setpoint resets. In operation.FORM 160. temperatures and status to the MicroGateway in response to requests from the MicroGateway.20-NOM1). Similar LEDs on the MicroGateway annunciate data transfer to/from the Microboard (refer to 450. the Control Source must be set to ISN on the OPERATIONS Screen. The MicroGateway communicates with the Microboard COM 4B communications port via an RS-232 interface. Microboard status LEDs illuminate when the Microboard transmits and receives data on COM 4B. Microboard Program Jumper JP 27 must be placed on pins 2 and 3 to allow data to be received from the MicroGateway. Red LED CR12 (TX4) illuminates when data is being transmitted to the MicroGateway. the Microboard provides chiller pressures.20-NOM1. Refer to Diagnostics and Troubleshooting section of this book. the MicroGateway is powered by +12VDC from the Microboard. If there is a communications problem between the Microboard and MicroGateway. use the LEDs described above to analyze the problem. If the remote device that is connected to the MicroGateway is going to provide remote Start/Stop signals. Otherwise. As shown in Figure 11. communications will take place in any Control Source mode. It can be mounted on the upper corner of the left wall of the OptiView Control Center or in its own enclosure in a remote location. 56 – MICROGATEWAY INTERFACE BLOCK DIAGRAM 130 JOHNSON CONTROLS . Green LED CR13 (RX4) illuminates when data is being received from the MicroGateway.54-M1 (607) SECTION 16 MICROGATEWAY (REFER TO FIG. then 1. Condenser. For example. 57. Two wires provide the +5VDC supply voltage and Ground (GND) and the remaining wire connects the transducer output to the Microboard. However. The outputs of the Sump and Pump oil Pressure transducers are displayed individually as PSIG values. The Auto-zeroing will not be performed if either transducer is out of range. this offset is factored with the actual differential pressure to produce the displayed PSID value. the displayed differential value then becomes the actual differential plus or minus the offset that existed during the Auto-Zeroing period. This PSID value is arrived at by subtracting the Sump Oil Pressure transducer value from the Pump Oil Pressure transducer value. This supply voltage is provided from the Power supply via the Microboard. refer to the appropriate formula in Fig. Each of the different transducers has a different YORK part number. During the System Prelube period. Pump Oil (high side) and Sump Oil (low side) pressures are sensed. if the Pump transducer indicates 1. differences can exist. These Saturation Temperatures are displayed and used for Chiller control. The Program converts the transducer output voltage to a pressure value with the appropriate formula in Fig. the output of the Condenser transducer would be read from Microboard J8-21 (signal) to J8-22 (GND). the outputs of the oil Pressure transducers are compared in a process called Auto-Zeroing. to compensate for differences between transducers and assure differential pressure accuracy. due to accuracy tolerances in transducer design. The Evaporator. 57. To convert this output to a pressure. However. the System Oil Pressure is displayed as a differential value in terms of PSID (pounds per square inch differential in gauge).FORM 160. The differential between the Sump and Pump Oil Pressure transducer outputs during a 3 second period beginning 10 seconds after the start of the System Prelube period are compared to determine the offset between them. There are different transducers used to sense these various pressures. The Evaporator and Condenser pressures are converted to Saturation Temperatures per the appropriate refrigerant pressure/temperature conversion table contained in the Program. The transducers output a 0. then 1.5VDC voltage that is analogous to the pressure applied to the device. For example. During this period. If the chiller is equipped with the Variable Geometry Diffuser. since both of the transducers are sensing the same pressure. The operation of the various transducers is identical.0 PSIG greater than the Sump transducer during the Auto-Zeroing period. Similarly. 57. their outputs should indicate the same pressure.54-M1 (607) SECTION 17 PRESSURE TRANSDUCERS (REFER TO FIG. a Stall Detection transducer is located in the discharge scroll of the compressor (refer to Variable Geometry Diffuser Section 22A for details).0 PSIG would be subtracted from the displayed PSID value while the pump is running. 55 lists the transducers and the application of each one.0 PSIG less than the sump transducer during this period. 57) System pressures are sensed by Pressure Transducers. Therefore. The difference between them is simply the pressure range over which they operate.0 PSIG will subtracted from the displayed PSID value while the pump is running. If the pressure is known. These outputs are applied to the Microboard. The actual transducer used is determined by the required pressure range and refrigerant application. Each transducer is connected to the Microboard with three wires. The transducers operate from a +5VDC power source.5 to 4. where this voltage is interpreted as a pressure value in terms of PSIG (pounds per square inch gauge) in English mode or KpaG (Kilo Pascals) in Metric mode. Measurement should be made from the transducer output to Ground (GND). If any of the displayed pressures do not appear to be correct. The voltage output of each transducer can be measured with a Voltmeter at the Microboard. refer to the Diagnostics and Troubleshooting section of this book. The pressures are displayed and used for Chiller control and Safety shutdowns. the transducer output can be predicted with the appropriate formula in Fig. 17 JOHNSON CONTROLS 131 . if the Pump transducer indicates 1. When the oil Pump is turned on following the Auto-zeroing period. Fig. 500 PRESSURE (PSIG) NOMINAL OUTPUT VOLTAGE PRESSURE (PSIG) NOMINAL OUTPUT VOLTAGE EVAPORATOR TRANSDUCER (R22 WATER APPLICATIONS) YORK PART NO.000 PRESSURE (PSIG) NOMINAL OUTPUT VOLTAGE 74 4.500 43.0 0.500 25.5 4 LD05534 OIL PRESSURE (LOW SIDE) (R22 WATER & BRINE APPLICATIONS) YORK PART NO.5 75 V = VOLTS DC LD09969 P = (17 x V) .500 31. 025-28678-004 P + 4.5 2.4.75 x V) .500 0 0.500 300 4.500 1.375 58.5 P = PRESSURE (PSIG) P = (75 x V) . 025-28678-112 025-28678-104 V = P + 2.5 2.500 150 2.75 x V + 15.25 3.2.38 0.25 3.500 300 4.54-M1 (607) MAX ALLOWABLE DEVIATION FROM NOMINAL OUTPUT (MILLIVOLTS) MAX ALLOWABLE DEVIATION FROM NOMINAL OUTPUT (MILLIVOLTS) + 150 + 133 + 116 +100 + 88 + 75 + 44 50 59.75 V= P = (58.5 75 P= (75 x V) + 162. 025-39464-000 025-40088-000 V = P + 37.500 100 4.0 0.5 P = PRESSURE (PSIG) LD05537 MAX ALLOWABLE DEVIATION FROM NOMINAL OUTPUT (MILLIVOLTS) MAX ALLOWABLE DEVIATION FROM NOMINAL OUTPUT (MILLIVOLTS) + 150 * + 100 + 88 + 75 + 30 6 0.15.500 + 100 + 88 + 75 0 0.500 PRESSURE (PSIG) NOMINAL OUTPUT VOLTAGE EVAPORATOR TRANSDUCER R134a WATER & BRINE APPLICATIONS YORK PART NO.25 3. 025-28678-102 025-28678-113 V= (P x 4) .5 2.75 V = VOLTS DC PRESSURE TRANSDUCER YORK PART NO.6 18.500 62.500 225 3.7 1.37.500 142.500 201.500 125 4.5 75 V = VOLTS DC P = 18.500 81.5 P = PRESSURE (PSIG) LD09569a FIG.500 260 4.5 2. 025-28678-103 025-28678-114 V = P .500 150 2.5 17 V = VOLTS DC PRESSURE TRANSDUCER YORK PART NO.37.500 PRESSURE (PSIG) NOMINAL OUTPUT VOLTAGE PRESSURE (PSIG) NOMINAL OUTPUT VOLTAGE EVAPORATOR TRANSDUCER (R22 BRINE APPLICATIONS) YORK PART NO.6 P = PRESSURE (PSIG) LD05535 P = (75 x V) .Pressure Transducers FORM 160. 57 – PRESSURE TRANSDUCERS 132 JOHNSON CONTROLS . 025-28678-001 025-28678-006 V = P + 37.375 P = PRESSURE (PSIG) V = VOLTS DC P = PRESSURE (PSIG) V = VOLTS DC LD04099 MAX ALLOWABLE DEVIATION FROM NOMINAL OUTPUT (MILLIVOLTS) MAX ALLOWABLE DEVIATION FROM NOMINAL OUTPUT (MILLIVOLTS) + 150 + 130 + 110 + 44 25.162.500 106.500 225 3.00 87. HIGH OIL EVAPORATOR EVAPORATOR LOW OIL CONDENSER. Transducers 025-28678-006. 104 have NPTF threads. 17 JOHNSON CONTROLS 133 . -114 and 025-39464-000 and 025-40088-000 have straight threads with O-rings.FORM 160. -102 and -103. -004. -113. HI & LO OIL EVAPORATOR EVAPORATOR STALL DETECTION R22 APPLICATION WATER BRINE X X X X R134a X X X X X X X X X X *Note: Transducers 025-28678-001. -112.54-M1 (607) PRESSURE TRANSDUCER APPLICATIONS CHART TRANSDUCER PART NUMBER* 025-28678-001 025-28678-102 025-28678-113 025-28678-103 025-28678-114 025-28678-004 025-28678-006 025-28678-112 025-28678-104 025-39464-000 025-40088-000 FUNCTION CONDENSER. A +5VDC supply voltage is applied to one side of the thermistor. as the temperature increases.54-RP2. 134 JOHNSON CONTROLS . thus forming a voltage divider network.Temperature Thermistors FORM 160. Drop Leg Refrigerant and Evaporator Temperatures are sensed by 3K Ohm thermistors. Each type has its own YORK part number. Each thermistor is connected to the Microboard with two wires. To convert this voltage to a pressure. One wire supplies the +5VDC voltage and the other is the output of the thermistor. 63 If any of the displayed pressures do not appear to be correct. the Leaving Chilled Liquid Temperature would be read from Microboard J9-20 (output) to Microboard TP1 (Gnd). 62 • Evaporator Refrigerant Temperature – Fig. For example. The resistance value determines the amount of current that will flow through the thermistor and thus the voltage drop across it.63) System temperatures are sensed by Thermistors. As the temperature decreases.000 Ohms at the same temperature. the resistance decreases. Return and Leaving Condenser Liquid. The other side of the thermistor is connected to Ground through a series resistor on the Microboard. The temperature applied to the thermistor determines the resistance value. refer to the “Diagnostics and Troubleshooting” section of this book. This output voltage can be measured with a Voltmeter.54-M1 (607) SECTION 18 TEMPERATURE THERMISTORS (REFER TO FIG. 58 . The thermistors are connected to the Microboard. refer to the appropriate volts/temp chart as follows: • Leaving Chilled Liquid Temperature – Fig. The Return and Leaving Chilled Liquid. 59 • Leaving and Return Condenser Liquid Temperature – Fig. Part numbers are listed in YORK Renewal Parts List 160. Measurement should be made from the thermistor output to Ground (Gnd). Both are negative temperature coefficient devices. 60 • Oil and Discharge Temperature – Fig. The Oil and Compressor Discharge temperatures are sensed by 50K Ohm thermistors. 61 • Drop Leg Refrigerant Temperature – Fig. The Program reads this voltage at the input to the Microboard and converts it to a temperature value. the resistance increases. The 3K Ohm thermistors are defined by the characteristic of being 3000 Ohms at 77ºF (25ºC). There are two different thermistor types used to sense the various system temperatures. That is. Similarly. 58 • Return Chilled Liquid Temperature – Fig. the 50K Ohm thermistors are 50. Both thermistor types vary their resistance as the sensed temperature varies. 8762 1.8396 1.4280 1.8609 1.7725 1.7024 1.45 13.98 -4.5286 1.29 24.9067 1.6505 1.17 -9.37 24.7115 1.8853 1.7085 1.54 18.20 14.4706 1.83 13.6140 1.07 -5.17 -6.06 -12.08 -7.79 21.02 12.5225 1.99 20.60 22.02 -4.6201 1.09 -4.8304 1.82 -5.37 -11.54 11.68 -7.15 -11.9250 1.12 -12.29 10.28 -7.42 -5.75 23.68 -9.68 -11.32 -9.8731 1.26 19.97 11.13 15.86 -8.24 22.44 20.35 17.8152 1.58 23.26 -11.89 Vin 1.4402 1. 58 – LEAVING CHILLED LIQUID TEMPERATURE Temp (°F) Temp (°C) 9.73 -9.59 12.01 14.35 20.6566 1.36 19.81 18.50 12.01 -8.63 17.73 -4.8060 1.15 -10.53 -11.43 16.42 -11.6475 1.78 -9.31 -10.08 18.97 16.68 10.7908 1.33 -7.5835 1.61 16.78 22.41 15.60 15.20 24.76 14.92 14.67 14.00 -9.4889 1.89 16.57 -5.7298 1.6292 1.7634 1.16 11.39 14.61 21.95 15.78 -4.93 -4.44 17.77 -5.26 20.13 -7.37 -5.6170 1.58 -11.06 22.72 -6.7268 1.26 13.6780 1.8243 1.22 15.16 21.55 -8.90 -11.83 -7.07 17.6749 1.54 19.60 -8.7573 1.72 19.99 18.48 -7.47 -5.24 -4.53 20.8365 1.17 -5.7481 1.47 -9.62 -5.5194 1.73 11.5316 1.7390 1.31 -11.8579 1.7207 1.57 -6.8548 1.78 -10.88 -4.21 -11.63 18.4645 1.6414 1.35 11.6688 1.4737 1.49 23.87 10.52 -10.25 11.5530 1.62 -10.5042 1.90 18.7176 1.48 10.7542 1.73 13.5713 1.8518 1.48 -4.80 20.42 22.5682 1.52 21.04 23.38 -7.6963 1.10 -11.14 -4.27 -9.62 Vin 1.7847 1.8182 1.08 -9.16 17.15 16.8945 1.20 -10.35 -8.41 -10.4615 1.8213 1.7359 1.63 -7.43 21.88 -7.5469 1.6353 1.35 13.64 13.90 17.19 -8.87 22.9128 1.16 13.6932 1.06 -9.6627 1.01 -11.8426 1.44 18.34 21.8335 1.28 -12.6871 1.84 23.7817 1.06 11.6902 1.82 -6.4423 1.22 -5.02 24.7695 1.67 23.76 -8.4371 1.80 16.11 14.8457 1.6444 1.8792 1.12 -5.52 -6.4493 1.7512 1.81 -8.17 20.9219 1.5591 1.26 17.98 21.58 -7.6079 1.97 22.89 -10.88 21.77 10.58 10.4767 1.5011 1.7603 Temp (°F) Temp (°C) 20.45 -8.8884 1.62 20.4554 1.6993 1.69 12.6048 1.4463 1.83 11.50 15.05 -10.96 -8.22 -12.47 -10.68 -4.4341 1.84 -9.70 21.90 19.14 -8.5987 1.87 -6.87 15.8030 1.31 12.5377 1.5347 1.72 18.7146 1.99 19.12 12.69 15.73 -7.6018 1.5438 1.53 -4.96 23.54-M1 (607) FIG.47 -6.9189 1.43 -7.7664 1.63 -4.21 12.6719 1.47 -11.8274 1.5133 1.25 -8.73 24.7939 1.98 -7.4859 1.22 -9.40 -8.89 20.22 23.6109 1.7329 1.57 -10.37 -9.8914 1.26 -10.6810 1.96 -11.48 14.8823 1.33 -4.68 -10.09 -8.94 -9.37 -6.50 -8.36 -10.73 -10.42 -6.4584 1.55 24.82 24.52 16.9280 135 18 JOHNSON CONTROLS .19 -4.6262 1.08 19.71 20.4950 1.64 11.09 10.32 -5.32 -6.23 -7.06 16.92 -5.04 -12.12 -6.7786 1.67 -5.10 -10.94 -3.40 12.92 -6.77 -6.98 17.33 22.4676 1.9006 1.5926 Temp (°F) Temp (°C) 15.07 -6.07 21.91 -8.17 18.4310 1.4828 1.02 -6.32 15.83 -4.29 14.15 22.5774 1.04 -3.9097 1.6322 1.78 15.63 -9.9158 1.63 19.31 23.5743 1.5896 1.42 Vin 1.93 -7.40 23.94 -10.00 10.78 -7.6536 1.7878 1.6383 1.04 -7.51 22.99 -3.27 -6.28 -4.58 -9.6658 1.8121 1.7969 1.85 -11.6841 1.8975 1.64 24.8487 1.11 -9.70 16.39 10.7054 1.34 16.07 13.81 19.5072 1.72 -5.18 -7.65 -8.8091 1.93 12.19 10.8000 1.5499 1.97 -6.88 12.5255 1.11 24.67 -6.6231 1.97 13.5957 1.27 -5.00 -10.35 18.53 -9.7756 1.8701 1.70 -8.5103 1.05 -11.90 10.7451 1.17 -12.63 -11.5865 1.38 -4.7237 1.6597 1.25 21.85 14.7420 1.72 17.5652 1.46 24.43 -4.80 -11.53 17.45 19.4432 1.53 -7.89 -9.57 14.17 19.5408 1.99 -6.22 -6.52 -5.9036 1.26 18.4798 1.13 23.8670 1.FORM 160.78 12.87 -5.58 -4.5560 1.8640 1.5804 1.5621 1.83 -10.5164 1.74 -11.45 11.69 22.54 13.97 -5.4981 1.30 -8.81 17.02 -5.24 16.4920 1.91 24.93 24. 1262 2.78 35.18 1.40 1.79 0.47 -2.2360 2.1323 2.82 -2.1902 2.07 33.28 27.2878 2.79 -1.9524 1.06 -1.3762 2.57 -0.73 2.08 28.0439 2.3214 2.82 -0.1354 2.0805 2.86 1.46 27.4159 2.9402 1.96 29.0530 2.54 -1.62 37.91 -2.2695 2.96 -0.04 0.91 34.26 -3.83 36.11 4.57 36.94 34.75 36.47 Vin 2.2787 2.75 29.2177 2.1293 2.40 0.91 3.3183 2.9951 1.57 1.03 3.1780 2.2909 2.05 36.16 Vin 2.23 26.45 32.13 39.1750 2.18 37.92 30.34 35.43 35.80 37.37 -2.02 27.98 3.0195 2.52 -0.9585 1.9433 1.18 -0.12 3.06 2.62 -0.28 -0.1201 2.52 28.11 0.58 31.41 31.64 27.4281 2.1018 2.60 -3.0744 2.4006 2.33 33.1963 2.1994 2.84 31.42 38.79 30.71 1.17 3.3579 2.0073 2.93 -1.01 -0.23 1.77 38.0042 2.23 -2.27 1.88 0.71 37.87 -2.84 -3.81 32.1658 2.53 30.2939 2.69 -1.0988 2.2543 2.9555 1.9738 1.3396 2.0347 2.3335 2.4250 2.86 -0.08 1.78 28.29 2.48 1.62 30.74 -3.28 -2.9372 1.54 0.9707 1.77 -0.0378 2.25 -1.51 38.20 27.0164 2.24 33.27 30.3305 2.67 -2.26 35.11 -3.08 25.03 -1.2726 2.Temperature Thermistors FORM 160.47 34.32 3.22 29.36 30.59 -1.20 2.88 30.1536 2.21 -3.88 2.87 25.3793 2.1445 2.1110 2.69 38.17 25.3884 2.0256 2.47 3.96 1.96 4.62 3.13 29.31 -3.06 -3.30 -1.13 -2.38 -0.36 37.9677 1.9920 1.2970 2.09 -0.11 27.76 26.9494 1.22 3.90 27.2573 2.9829 1.0622 2.2024 2.2299 2.9311 1.3153 2.04 29.79 25.13 -0.49 26.34 28.03 34.19 32.1506 2.3640 2.17 28.1232 2.99 28.10 30.83 136 -3.14 31.72 -0.1811 2.44 2.52 35.4128 2.1140 2.61 25.52 -2.1567 2.92 37.37 1.2146 2.54 37.96 26.22 36.27 37.43 25.24 38.96 -2.54 2.4037 2.21 34.48 29.0835 2.3976 2.67 26.3854 2.57 -2.69 28.06 31.76 1.69 -3.3061 2.06 4.0469 2.45 -1.32 1.99 35.74 -1.23 31.02 32.56 34.4220 2.93 27.43 28.62 -2.04 39.54-M1 (607) FIG.39 2.59 0.1689 2.31 36.22 39.98 1.3457 2.49 31.15 38.84 -1.9859 1.40 26.9798 1.9981 2.0225 2.0683 2.3610 2.71 30.2482 2.59 33.36 -3.3671 2.1079 2.77 -2.52 25.95 39.91 -0.3732 2.0866 2.54 32.06 0.87 28.35 0.1415 2.51 33.64 0.08 -2.17 35.0774 2.0896 2.15 2.23 -0.3274 2.73 27.89 32.25 2.2512 2.95 2.49 2.30 0.64 -1.1933 2.74 0.16 0.2421 2.31 26.72 -2.66 29.82 34.81 27.62 1.66 36.72 32.21 0.52 1.42 -2.13 1.66 1.48 36.61 28.3000 2.81 3.78 2.1476 2.01 30.08 3.38 34.2390 2.43 -0.86 33.0317 2.33 -0.59 2.31 29.3945 2.3427 2.37 32.98 -1.9463 1.3092 2.12 34.39 29.55 27.0012 2.87 35.26 25.0134 2.3031 2.2634 Temp (°F) Temp (°C) 34.45 30.4098 2.0408 2.14 26.64 -1.16 33.33 -2.0713 2.01 -2.98 38.2848 2.1872 2.65 -3.84 26.76 31.2207 2.2817 2.0500 2.0561 2.1049 2.40 36.27 3.45 37.13 36.42 33.84 0.2756 2.1384 2.3244 2.49 0.3488 2.81 1.18 -2.67 -0.37 27.3549 2.34 2.21 Vin 1.42 1.07 38.70 35.35 25.28 32.69 0.3366 2.1841 2.10 37.49 -1.93 32.3701 2.3122 2.32 31.1597 2.33 38.16 -1.2268 2.68 33.0927 2.60 38.9768 1.10 2.18 30.3823 2.42 3.89 37.1171 2.4067 2.01 37.83 2.73 34.10 32.96 36.9646 1.70 25.93 0.63 32.67 3.57 29.2329 2.9341 1.79 -3.01 0.11 -1.35 -1.93 2.08 35.97 31.4311 JOHNSON CONTROLS .55 -3.37 3.86 38.29 34.1628 2.2238 2.2604 2.72 3.48 -0.25 28.16 -3.2055 2.) Temp (°F) Temp (°C) 25.77 33.01 4.76 3.41 -3. 58 – LEAVING CHILLED LIQUID TEMPERATURE (CONT’D.58 26.68 2.50 -3.98 33.91 1.64 2.45 0.0103 2.2085 2.05 26.25 0.1719 2.86 3.67 31.0286 2.2116 2.52 3.3518 2.39 39.30 39.0591 2.9616 1.88 -1.9890 1.57 3.4189 2.45 -3.2665 2.03 1.51 35.2451 2.0652 2.0957 Temp (°F) Temp (°C) 29.3915 2. 14 42.12 43.64 8.7116 2.5043 2.67 42.60 53.7513 2.99 5.5592 2.73 47.08 8.55 9.56 52.39 43.18 45.8976 2.90 51.71 40.7025 2.90 10.43 51.83 7.5836 2.9220 2.87 Vin 2.60 41.36 45.63 11.19 40.64 44.97 10.73 46.33 10.8214 2.46 45.21 12.7726 2.4433 2.24 51.5775 2.6446 2.38 5.7330 2.8245 2.20 49.48 7.6842 2.63 40.4708 2.9281 2.4860 2.12 10.6049 2.12 7.09 5.82 46.11 11.28 6.8854 2.6202 2.69 8.78 7.33 5.00 47.5226 2.8092 2.7299 2.8367 2.7604 2.7208 2.46 54.4586 2.6354 2.65 52.23 5.80 10.5927 2.9129 2.4403 2.45 47.51 41.77 6.86 9.6751 2.43 5.8397 2.31 42.82 44.38 8.06 51.6720 2.04 5.74 48.5805 2.55 44.62 6.5012 2.23 8.89 40.7970 2.68 7.30 9.91 9.27 40.6690 2.48 49.12 50.37 4.6232 2.78 5.82 47.69 41.01 49.84 8.00 12.94 4.5500 2.16 11.8428 2.4952 2.6537 2.22 7.83 43.78 41.7086 2.36 47.85 10.4525 2.5470 2.19 44.4464 2.18 52.10 40.84 49.18 46.57 6.8458 2.00 11.57 39.07 41.8763 2.5256 2.48 12.66 Vin 2.43 10.4555 2.7452 2.6781 2.98 41.40 4.7787 2.27 46.64 47.7879 2.18 5.4830 2.59 4.8549 2.83 39.45 4.6171 2.91 47.32 12.7757 2.5958 2.27 48.5653 2.6385 2.81 9.5409 2.85 11.64 4.55 48.70 53.23 6.5378 2.7696 2.6659 2.76 42.8153 2.79 4.30 4.5348 2.5531 2.04 9.40 42.74 43.88 7.61 9.4494 2.76 9.21 11.7177 2.53 8.4891 2.17 54.6811 2.7909 2.53 5.30 43.16 12.84 52.53 7.6110 2.7238 2.75 52.34 51.38 10.01 40.92 6.87 50.8306 2.13 8.27 7.10 9.46 52.5439 2.8519 2.4616 2.5073 2.09 48.99 52.64 10.64 46.5744 2.7147 2.93 7.03 43.7940 2.18 6.6933 2.4677 2.7482 2.72 6.73 7.4342 2.17 10.) Temp (°F) Temp (°C) 39.5134 2.80 40.8001 2.98 8.6507 2.17 7.22 10.79 53.56 9.33 8.6629 2.4921 2.FORM 160.7360 2.94 43.53 Vin 2.35 9.82 45.32 11.8580 2.37 11.09 47.22 53.55 4.52 51.51 53.06 11.68 50.32 7.6476 2.9312 2.02 7.91 46.8458 2.6141 2.05 42.93 5.7421 2.27 12.8031 2.43 8.89 4.90 11.83 5.47 11.5287 2.8946 2.28 5.98 6.8793 2.54-M1 (607) FIG.21 4.22 50.16 41.28 44.73 5.31 50.5317 2.53 10.7818 2.59 10.28 8.25 9.4982 2.11 49.03 53.54 40.5866 2.9068 2.58 5.42 12.6903 2.73 45.27 11.6598 2.45 9.45 40.5165 2.01 44.8610 2.09 46.48 5.18 48.89 53.7848 2.02 10.46 48.27 54.8732 2.94 50.71 51.92 49.48 43.42 41.33 6. 58 – LEAVING CHILLED LIQUID TEMPERATURE (CONT’D.6994 2.11 12.99 9.6263 2.40 50.58 42.26 4.59 50.9190 2.03 50.57 43.42 11.41 53.74 11.03 6.95 12.53 11.88 5.62 51.82 6.8885 2.49 42.8641 2.08 6.6568 2.65 43.37 7.66 39.55 46.15 9.87 41.79 11.8275 2.00 45.75 10.00 46.28 52.6964 2.47 6.23 42.35 4.45 46.5195 2.09 45.21 43.10 44.28 10.5897 2.07 10.29 49.98 54.20 9.63 5.6324 2.9098 2.8671 2.7665 Temp (°F) Temp (°C) 49.36 40.64 48.96 51.4647 2.9037 2.8702 2.92 44.91 45.38 6.33 41.32 53.48 8.79 8.58 8.9342 18 JOHNSON CONTROLS 137 .48 10.58 11.85 42.64 45.7574 2.27 47.36 54.83 48.97 7.9159 2.84 4.36 46.07 7.13 53.52 6.74 4.69 10.8123 2.55 47.74 8.42 7.5683 2.5104 2.8824 2.03 8.08 54.51 9.50 4.91 48.5988 Temp (°F) Temp (°C) 44.6019 2.7635 2.50 50.68 5.55 45.43 6.18 47.92 40.94 8.8915 2.9007 2.13 5.37 12.96 42.67 6.78 50.46 44.5622 2.06 12.8184 2.13 6.8062 2.73 44.7543 2.4769 2.00 48.5561 2.7055 2.24 41.7269 2.6080 2.74 39.15 51.37 48.57 49.63 7.71 9.8336 2.27 45.75 49.7391 2.66 49.40 9.9251 2.95 11.37 52.89 8.4372 2.38 6.18 8.09 52.5714 2.69 4.4799 2.6872 2.58 7.6415 2.6293 2.94 53.4738 2.68 11.80 51. 78 61.3611 3.64 14.40 18.0745 3.3703 3.26 16.28 62.3215 3.1294 3.9647 2.9373 2.3062 3.1660 3.94 17.4068 3.2452 3.36 57.58 64.54-M1 (607) FIG.66 13.62 21.38 13.45 58.1263 3.3977 3.2971 3.4373 JOHNSON CONTROLS .20 15.12 68.63 18.05 21.27 61.69 Vin 3.25 59.1111 3.36 15.41 55.9525 2.3581 3.03 71.0287 3.16 19.87 21.53 Vin 2.04 18.9891 2.45 69.3093 3.01 70.60 66.12 69.0653 3.36 67.90 65.85 58.1446 3.96 66.0714 3.0836 3.90 12.2696 Temp (°F) Temp (°C) 65.32 16.) Temp (°F) Temp (°C) 54.69 70.63 12.80 62.34 68.82 13.47 15.95 138 12.12 21.92 14. 58 – LEAVING CHILLED LIQUID TEMPERATURE (CONT’D.09 16.1507 3.87 13.22 55.1080 3.2635 3.60 71.79 64.0867 3.1324 3.3733 3.45 18.3885 3.1599 3.0501 3.59 62.39 56.46 60.00 17.3367 3.09 56.34 69.84 54.4190 3.90 56.49 71.2422 3.06 13.4282 3.26 71.97 57.77 19.97 15.82 19.0105 3.31 20.9769 2.78 68.81 21.32 65.37 20.01 63.66 16.66 60.31 14.0074 3.3306 3.3123 3.1172 3.28 13.4007 3.41 19.56 57.87 56.99 21.75 59.58 70.9739 2.3520 3.53 65.79 67.3642 3.0806 3.03 16.0348 3.63 63.4099 3.18 21.80 70.1568 3.06 61.51 55.0958 3.76 57.03 15.48 56.35 19.1873 3.1141 3.2391 3.23 17.26 57.65 59.2147 3.3794 3.23 69.3855 3.39 62.75 65.3946 3.53 63.0227 3.0531 3.47 67.50 13.1538 3.55 59.9922 2.2666 3.57 17.98 19.1965 3.28 66.0044 3.05 60.15 16.08 15.48 14.11 17.0379 3.22 63.87 17.16 64.88 16.25 58.88 61.9495 2.08 62.45 59.74 63.3337 3.15 14.9983 3.01 13.22 19.35 59.37 64.2788 3.75 20.75 14.3824 3.18 62.85 12.23 68.86 60.55 58.03 55.68 67.17 17.37 71.0989 3.9952 2.36 60.65 58.28 17.43 20.9830 2.71 66.69 17.71 16.4221 3.88 19.21 16.46 70.71 19.74 12.60 13.49 66.4129 3.81 14.42 14.56 60.9800 2.3154 3.49 62.74 54.85 65.24 70.3276 3.05 19.68 20.05 59.80 55.37 61.1751 3.0013 3.1019 Temp (°F) Temp (°C) 60.15 58.07 Vin 3.44 13.0592 3.2879 3.22 13.94 22.69 62.2483 3.2117 3.55 16.1629 3.25 21.40 17.2208 3.29 56.2178 3.00 65.75 58.0318 3.1477 3.1812 3.9708 2.58 67.44 21.76 15.64 15.9403 2.58 15.1721 3.35 17.95 20.07 20.2025 3.4160 3.53 14.58 14.95 64.0135 3.3550 3.2818 3.93 55.75 17.11 65.25 67.0623 3.33 13.51 18.65 19.9556 2.26 64.72 18.39 66.35 58.98 16.3763 3.37 21.25 60.57 18.76 60.2361 3.9861 2.93 67.01 69.3428 3.2544 3.64 15.50 20.2849 3.15 71.03 67.90 63.01 68.17 61.61 55.58 56.84 63.21 65.11 63.13 20.2574 3.46 57.9586 2.1202 3.10 18.96 58.46 17.2940 3.1782 3.3398 3.2056 3.85 59.31 15.98 14.45 68.33 18.78 56.47 64.98 18.9617 2.4343 3.42 15.1385 3.1995 3.2269 3.58 19.37 14.56 21.47 61.65 54.37 16.70 55.1690 3.87 15.81 18.60 16.01 20.2757 3.0166 3.1233 3.66 57.71 13.26 14.82 16.69 21.68 64.55 13.48 16.9464 2.0257 3.31 21.0409 3.1355 3.3245 3.0684 3.06 66.77 16.03 14.3184 3.17 57.67 68.9678 2.62 20.0897 3.90 68.96 61.4038 3.25 20.07 57.75 18.2910 3.28 18.67 61.93 20.89 70.58 12.25 15.3916 3.3672 3.00 56.52 17.67 69.3459 3.92 15.05 17.87 18.56 68.68 56.87 20.4312 3.80 12.63 17.78 69.2239 3.00 22.1416 3.90 69.81 20.19 56.69 12.95 59.92 71.92 17.70 15.17 13.2086 3.12 70.09 14.12 13.15 59.46 19.15 60.57 61.3489 3.14 15.98 62.05 64.0928 3.1934 3.20 14.43 16.11 19.19 20.1050 3.50 21.32 63.0440 3.92 18.06 58.22 18.93 13.1843 3.82 66.56 69.0196 3.81 15.2605 3.0562 3.3032 3.2300 3.16 18.43 65.56 20.17 66.12 55.Temperature Thermistors FORM 160.2727 3.86 14.35 70.86 57.3001 3.96 13.32 55.0775 3.81 17.52 19.0470 3.2513 3.1904 3.28 19.75 21.14 67.77 13.4251 3.2330 3.70 14.9403 2.43 63. 11 75.36 27.81 76.76 24.51 22.68 73.49 24.4739 3.20 76.00 27.43 26.85 80.17 78.93 77.92 74.6416 3.69 79.5532 3.65 25.6691 3.7026 18 JOHNSON CONTROLS 139 .32 22.44 76.57 27.6386 3.10 25.56 73.6721 3.5410 3.83 71.6050 Temp (°F) Temp (°C) 78.6752 3.89 82.5562 3.5105 3.11 81.03 25.55 78.6538 3.46 80.72 Vin 3.94 28.80 77.28 74.40 74.4922 3.FORM 160.6599 3.80 78.35 75.41 72.62 24.50 27.10 73.6813 3.20 22.57 26.18 72.5867 3.64 72.80 73.29 27.32 76.36 24.21 26.16 23.04 74.5349 3.43 77.4678 3.58 22.26 22.5258 3.6233 3.96 23.47 75.6325 3.56 24.22 23.21 73.02 24.6630 3.28 82.5197 3.5898 3.6508 3.4953 3.5471 3.86 27.98 73.4770 3.07 27.02 82.4404 3.56 23.50 81.82 79.4526 3.02 23.5837 3.6203 3. 58 – LEAVING CHILLED LIQUID TEMPERATURE (CONT’D.55 77.5441 3.4892 3.5593 3.5684 3.21 27.42 23.5380 3.84 22.6264 3.18 77.5623 3.86 25.20 80.23 75.6569 3.72 27.98 81.6935 3.6172 3.62 23.30 22.43 27.69 24.05 78.92 27.4709 3.6355 3.6477 3.99 75.4495 3.24 81.4861 3.6965 3.78 26.6447 3.4556 3.52 74.36 26.42 24.71 22.14 26.59 80.39 22.6020 3.6874 3.) Temp (°F) Temp (°C) 71.54-M1 (607) FIG.5227 3.5288 3.4800 3.6904 3.6996 3.5136 3.71 26.59 25.36 23.24 25.57 79.82 23.38 25.69 23.18 79.49 23.6843 3.07 26.76 81.84 75.72 75.29 72.5928 3.57 76.44 73.22 24.93 78.06 72.60 75.14 27.87 72.93 79.33 80.5715 3.6294 3.90 22.75 72.52 25.64 26.95 24.68 77.13 22.41 25.5806 3.79 27.5776 3.05 79.96 25.29 23.87 74.65 27.93 26.44 79.89 23.75 74.16 74.67 78.42 78.5166 3.15 82.6660 3.5014 3.29 26.4617 3.4648 3.17 25.95 80.5044 3.01 Vin 3.4465 3.0575 3.6142 3.15 24.90 24.5654 3.05 77.31 79.5989 3.45 22.31 25.95 72.5319 3.83 24.85 26.29 24.77 22.50 26.09 23.75 23.4831 3.37 81.33 73.6782 3.5501 3.00 26.08 76.4587 3.63 81.4983 3.69 76.79 25.96 76.30 77.09 24.6081 3.5959 3.4434 3.64 74.72 80.5745 3.52 72.64 22.45 25.6111 3.08 80. 3047 2.2510 2.9434 1.66 29.70 18.2607 2.1826 2.02 33.71 -5.60 22.3242 2.5967 1.1338 2.71 -2.96 -7.15 20.6211 1.61 15.6455 1.7773 1.9238 1.21 2.38 -1.08 -2.7285 1.09 17.9141 1.41 35.3682 2.11 18.23 37.26 -6.52 2.68 17.2119 2.1680 2.7480 1.8311 1.78 30.46 32.1973 2.57 34.87 21.26 0.64 16.16 15.6309 1.27 1.22 -1.80 0.11 36.04 -3.59 33.8359 1.98 -6.58 -6.83 35.18 -6.3145 2.0020 2.94 -2.2754 2.67 2.9971 2.46 3.29 20.1729 2.8213 1.58 20.33 0.30 33.11 -9.26 18.91 -6.7041 1.27 -4.88 22.69 35.9092 1.0557 2.02 -5.6357 1.88 33.24 29.84 -1.7969 1.74 22.19 -9.13 27.1875 2.31 15.82 17.16 33.54-M1 (607) FIG.91 -4.59 24.2266 2.7188 1.98 28.8115 1.02 -8.51 1.0459 2.8555 Temp (°F) Temp (°C) 23.86 20.8457 1.53 -8.9580 1.20 16.94 -5.1094 2.2412 2.88 -3.04 1.31 -7.0410 2.51 -6.85 34.71 19.27 35.85 26.1924 2.72 0.67 -6.7871 1.18 -3.7334 1.76 15.0068 2.3389 2.80 37.7676 1.6602 1.64 -3.7432 1.61 -8.3438 2.54 28.36 30.30 21.74 23.48 31.7529 1.86 26.23 -7.10 29.97 36.53 36.62 31.10 0.8066 1.13 2.7383 1.87 25.31 -2.9727 1.0264 2.09 37.3096 2.31 23.92 -1.01 15.38 17.15 -7.9922 1.0313 2.88 0.2949 2.2021 2.8408 1.6943 1.27 27.2852 2.45 21.19 1.7578 1.9189 1.02 0.44 25.96 1.59 2.94 38.41 0.10 -3.0850 2.99 -0.72 25.29 34.0215 2.38 3.8506 1.00 -1.96 -3.23 -2.0947 2.34 -6.98 3.20 31.98 -4.18 32.31 22.0801 2.49 -3.46 -1.44 2.91 -0.86 -2.55 -7.34 31.6797 1.19 -4.13 19.74 32.6016 1.53 17.02 24.0166 2.3926 JOHNSON CONTROLS .7920 1.0703 2.22 -5.92 31.13 -0.69 -1.3486 2.11 -6.71 26.99 35.86 -8.12 1.60 -0.76 31.80 29.64 -4.9385 1.38 -5.64 0.3584 2.28 19.6992 1.8701 1.1484 2.6406 1.88 140 -9.57 19.52 29.37 -8.8604 1.21 -0.81 36.70 27.74 1.47 -2.9873 1.1387 2.60 32.86 -5.84 18.6699 1.04 -7.7627 1.2656 2.30 25.8945 1.51 37.53 -1.66 37.43 -4.79 16.07 -0.1582 2.8018 1.74 -6.30 3.62 -5.7090 1. 59 – RETURN CHILLED LIQUID TEMPERATURE Temp (°F) Temp (°C) 15.30 -1.21 -8.6162 1.8799 1.36 -4.16 -2.28 2.72 -3.3633 2.77 -1.13 35.82 1.2070 2.97 18.80 -7.3291 2.83 -4.94 17.8652 1.57 -3.7139 1.68 28.91 16.5058 2.6650 1.37 -0.31 -5.68 -0.1631 2.91 2.Temperature Thermistors FORM 160.6504 1.67 36.01 34.7725 1.6064 1.73 21.8994 1.75 -4.83 -0.52 -0.39 -2.8848 1.1436 2.05 2.95 37.8896 1.28 -8.42 26.27 -9.45 24.2803 2.73 20.12 28.6260 1.66 1.44 -9.04 32.9482 1.99 19.36 -9.96 29.1777 2.16 21.43 34.78 -2.71 34.6895 1.32 32.44 33.22 3.06 31.43 19.0605 2.3193 2.23 17.31 24.28 26.14 3.1289 2.50 16.8750 1.37 37.88 24.26 -3.78 -5.83 2.72 -7.53 Vin 2.99 27.2461 2.36 2.08 30.8262 1.44 20.26 28.6553 1.73 24.0654 2.75 2.0117 2.45 22.2314 2.3877 2.08 38.59 -4.15 34.89 1.17 22.73 33.3535 2.7236 1.55 27.18 0.25 36.40 28.9287 1.9775 1.3828 2.0361 2.1143 2.00 20.16 24.57 0.14 -1.97 2.78 -8.46 -5.7822 1.0898 2.16 25.9531 1.60 23.9629 1.9678 1.47 -7.39 -7.29 -0.01 21.87 34.2705 2.5918 1.56 26.07 Vin 1.12 -8.22 30.41 -3.41 18.46 15.54 -5.6846 1.07 -6.90 32.94 -8.6113 1.82 28.14 -5.41 27.1191 2.61 -1.67 -4.2363 2.03 23.12 -4.00 26.80 -3.50 30.9043 1.51 -4.1240 Temp (°F) Temp (°C) 30.02 22.43 1.35 1.14 26.0752 2.2900 2.84 27.05 16.35 16.3730 2.94 30.2998 2.55 35.49 0.59 21.58 25.45 -8.63 -7.38 29.55 -2.02 -2.2217 2.17 23.88 -7.55 18.1045 2.3340 2.44 -0.83 -6.45 23.70 -8.22 38.42 -6.06 0.63 -2.06 3.76 Vin 1.2168 2.6748 1.3779 2.8164 1.1533 2.01 25.33 -3.36 -0.39 36.2559 2.9824 1.58 1.9336 1.0996 2. 29 6.10 59.5391 2.36 9.5049 2.76 41.43 10.6807 2.8662 2.97 15.0859 3.80 46.27 10.4658 2.9980 3.76 43.87 12.79 14.33 41.08 46.69 11.4316 2.23 51.45 Vin 2.55 8.11 54.7197 2.93 4.42 56.42 15.8809 2.74 49.15 15.62 3.48 50.8516 2.63 50.66 7.22 16.1836 3.18 62.08 4.48 41.91 14.7637 2.96 16.15 49.36 57.04 50.19 44.6611 Temp (°F) Temp (°C) 46.0469 3.1738 3.34 50.50 16.8271 2.36 11.20 40.1787 3.88 14.79 4.22 8.32 16.4609 2.03 5.75 59.86 9.57 13.72 60.59 52.93 7.99 58.4854 2.95 54.34 53.7051 2.11 10.50 7.44 11.77 16.6855 2.22 6.77 15.86 16.95 17.95 56.04 61.19 53.41 7.40 4.87 55.77 44.22 13.0957 3.87 8.17 7.7783 2.40 13.71 4.28 9.1885 3.97 48.04 57.19 50.9639 2.7832 2.22 3.5244 2.7295 2.32 4.66 46.19 41.34 5.69 3.47 8.90 Vin 2.67 62. 59 – RETURN CHILLED LIQUID TEMPERATURE (CONT’D.79 55.82 5.85 10.98 6.6318 2.52 10.1152 3.58 5.27 5.07 39.39 60.06 8.8369 2.6465 2.0150 2.9492 2.33 15.83 13.77 11.1348 3.8320 2.6416 2.8125 2.9199 2.0322 3.48 42.62 12.04 17.13 16.26 7.42 59.48 44.5586 2.72 54.1445 3.5732 2.58 7.93 39.53 47.1055 3.6025 2.5488 2.85 3.48 40.74 52.FORM 160.6709 2.21 39.18 5.46 6.39 47.91 60.03 9.26 56.62 42.7100 2.02 10.50 5.76 42.19 42.78 39.70 48.58 16.68 10.77 9.62 14.86 15.23 17.00 14.51 46.74 13.83 51.68 51.9102 2.9346 2.6221 2.7686 2.38 8.28 12.0029 3.8076 2.7979 2.63 8.9590 2.5879 2.1592 3.4951 2.85 49.31 58.8174 2.08 51.0518 3.48 43.48 13.6123 2.89 50.0811 3.65 53.95 12.69 9.9248 2.09 14.9443 2.94 59.8564 2.60 10.35 39.0225 3.91 41.83 57.78 58.35 10.20 12.0664 3.0127 3.0566 3.89 53.31 8.13 17.93 46.1396 3.62 6.41 48.11 5.62 44.09 47.4072 2.93 51.38 51.55 60.95 47.05 42.0273 3.33 43.7002 2.4414 2.23 15.90 5.4805 2.9688 2.82 47.86 11.8906 2.1201 3.1250 3.5830 2.20 45.54-M1 (607) FIG.1934 3.7393 2.7734 2.48 4.6172 2.4561 2.53 9.15 8.1641 3.49 45.0420 3.9983 2.5537 2.3975 2.7588 2.02 11.6074 2.7344 2.92 40.95 9.5635 2.98 52.59 59.88 61.6514 2.1299 3.6270 2.17 4.5000 2.5146 2.51 38.56 4.76 40.71 14.47 58.0713 3.34 44.69 61.19 43.35 45.5342 2.9297 Temp (°F) Temp (°C) 54.4707 2.68 15.59 49.64 55.48 55.03 12.63 4.26 14.91 44.24 47.35 14.26 48.42 7.7539 2.7246 2.74 5.06 45.57 56.20 9.44 49.0371 3.77 10.8223 2.66 5.05 44.89 57.62 41.1494 3.4268 2.8027 2.53 12.96 13.0078 3.9932 2.1882 141 18 JOHNSON CONTROLS .45 9.27 11.51 57.11 56.9736 2.52 11.61 9.84 63.42 5.8613 2.1543 3.1006 3.71 8.05 41.5098 2.82 7.74 7.41 16.65 13.04 53.20 57.24 4.4121 2.7881 2.62 43.7490 2.8467 2.4170 2.8760 2.12 9.01 63.30 49.51 62.19 10.4023 2.01 4.9785 2.7930 2.7148 2.20 61.56 48.4219 2.37 61.0615 3.31 13.50 53.26 54.86 6.23 60.6904 2.17 14.17 55.90 42.26 59.05 13.53 51.05 16.28 52.7441 2.38 6.4756 2.07 60.93 11.10 7.8955 2.5684 2.68 16.67 57.1104 3.5195 2.4902 2.11 48.79 8.79 45.65 38.9053 2.33 55.56 54.06 40.73 56.4512 2.44 14.62 58.53 14.37 12.18 11.95 5.6953 2.5781 2.6367 2.0176 3.6758 2.33 42.01 7.5439 2.0762 3.71 12.64 45.05 43.90 43.02 62.69 6.5928 2.78 50.6660 2.34 62.50 39.77 3.17 12.61 11.10 11.6563 2.0908 3.98 8.77 6.32 Vin 2.11 12.91 45.) Temp (°F) Temp (°C) 38.80 53.9541 2.62 40.85 62.13 52.4365 2.34 40.9395 2.33 7.13 13.8711 2.4463 2.02 55.53 61.9834 2.06 6.37 46.79 38.60 15.00 49.44 52.87 4.51 15.68 47.5293 2.15 58.8857 2.9004 2.79 12.53 6.06 15.1689 3.14 6.5977 2.94 10.8418 2.64 39. 16 21.3643 3.36 69.2666 3.91 75.58 19.69 17.5156 3.4131 3.5254 3.01 19.51 17.78 19.97 28.19 65.Temperature Thermistors FORM 160.2422 3.71 26.04 78.36 71.44 18.56 21.46 21.12 68.66 68.91 25.3301 3.5596 3.91 19.10 75.47 25.40 27.38 73.4668 Temp (°F) Temp (°C) 73.3398 3.4473 3.2813 3.20 23.6963 3.4033 3.4619 3.2520 3.2031 3.74 23.31 23.48 22.17 22.04 77.4521 3.04 79.2178 3.87 76.6621 3.54-M1 (607) FIG.07 20. 59 – RETURN CHILLED LIQUID TEMPERATURE (CONT’D.2715 3.84 77.6035 3.38 22.69 25.49 24.04 66.6572 3.14 82.2861 3.05 24.84 78.4229 3.2910 3.5059 3.6328 3.90 70.95 74.30 68.5498 3.5791 3.7061 JOHNSON CONTROLS .48 75.3496 3.5303 3.02 25.91 72.37 20.09 72.6377 3.07 80.4424 3.62 27.14 74.41 23.68 63.3545 3.4863 3.41 17.46 20.6230 3.11 19.26 21.06 18.16 18.84 79.25 67.76 21.4326 3.5352 3.6523 3.6914 3.6084 3.76 73.21 66.72 69.6768 3.26 70.40 19.48 26.6670 3.36 25.82 18.60 67.56 22.4570 3.3936 3.84 23.27 24.86 80.53 65.5205 3.25 26.2227 3.3838 3.26 76.81 24.44 78.79 22.51 64.4766 3.59 26.09 Vin 3.66 79.2324 3.5986 3.08 70.85 65.72 81.43 67.58 22.6279 3.28 27.08 67.51 27.2275 3.7012 3.02 65.49 19.6182 3.70 65.88 17.33 74.2959 3.97 20.5645 3.63 18.6426 3.83 142 17.99 23.4814 3.91 67.83 69.5693 3.3252 3.6865 3.86 27.5840 3.52 23.78 17.56 66.4180 3.6133 3.77 67.86 20.68 64.66 20.10 81.25 79.53 74.84 64.52 81.4375 3.87 66.3887 3.66 21.48 68.70 24.3789 3.6816 3.3154 3.01 69.63 70.24 77.28 72.5107 3.2471 3.99 71.6475 3.27 80.27 20.64 72.07 22.3984 3.01 64.2764 3.6719 3.3594 3.97 22.2080 3.14 25.48 80.4277 3.36 65.51 63.60 17.3057 3.73 66.4082 3.65 76.93 82.46 76.89 22.10 23.05 27.29 75.46 72.20 73.) Temp (°F) Temp (°C) 63.64 78.30 19.97 18.27 22.5547 3.59 24.68 19.14 26.74 27.89 81.4961 3.2373 3.63 23.95 24.68 75.45 70.3203 3.34 64.24 78.39 66.54 71.5742 3.4912 3.3447 3.45 79.17 20.06 21.44 77.72 74.80 25.35 18.4717 3.56 20.18 64.5449 3.57 73.81 70.94 27.54 69.3740 3.68 80.58 25.76 20.72 18.72 71.02 26.19 69.5889 3.36 21.2617 3.25 25.2129 3.69 Vin 3.64 77.36 26.34 63.87 19.82 26.16 27.5938 3.07 76.53 18.95 68.31 81.01 73.25 18.3105 3.87 21.3691 3.5400 3.3350 3.17 71.20 19.35 82.2568 3.16 24.3008 3.37 24.91 26.5010 3.96 21. 59 4.86 5.0898 2.0850 2.1289 2.4951 2.3389 2.9092 1.9385 1.36 9.42 52.5977 2.9141 1.9678 1.21 62.86 56.45 46.17 13.78 16.94 42.01 13.2217 2.51 4.97 58.9287 1.3730 Temp (°F) Temp (°C) 56.20 47.3584 2.52 64.8848 1.02 5.90 47.78 50.25 45.81 57.0508 2.44 5.65 47.95 45.61 6.17 59.1582 2.27 40.2070 2.2900 2.4854 2.53 51.12 58.3877 2.48 59.5537 2.36 7.00 61.24 60.3145 2.98 63.59 12.8604 1.69 48.3633 2.0117 2.06 57.85 10.8994 1.44 9.5879 2.1240 2.35 10.77 8.1631 2.98 18.72 58.9727 1.96 55.21 17.0410 2.9482 1.87 16.6318 2.0020 2.12 52.76 61.24 Vin 2.51 12.81 54.33 41.2705 2.36 57.94 48.75 43.68 14.86 6.9824 1.12 17.2998 2.57 58.53 16.53 8.16 56.12 40.38 51.75 46.53 7.94 16.36 54.8701 1.6025 2.4805 2.29 63.0703 2.33 50.00 46.26 55.66 54.59 63.93 5.9873 1.07 18.3047 2.0459 2.76 56.43 10.4414 2.8457 1.0215 2.27 9.01 56.48 41.78 6.2266 2.1045 Temp (°F) Temp (°C) 48.62 53.93 11.80 44.91 57.28 7.03 41.54-M1 (607) FIG.60 46.54 42.76 14.36 62.11 8.60 43.09 14.4609 2.3535 2.67 62.2119 2.11 6.2363 2.38 17.52 5.43 14.81 17.4365 2.03 8.04 17.61 5.0361 2.0264 2.76 11.02 53.8896 1.8799 1.02 Vin 1.1533 2.84 13.26 14.1436 2.51 57.45 61.5342 2.03 7.99 49.84 12.83 13.5000 2.9922 1.02 10.5195 2.66 57.27 10.0313 2.82 62.86 8.20 7.52 15.29 49.11 55.18 5.74 49.5391 2.76 13.36 6.08 51.63 50.1875 2.6270 2.27 58.2510 2.07 18.87 53.2754 2.8555 1.24 4.15 46.39 42.9336 1.95 8.1191 2.0557 2.70 16.8408 1.63 59.11 7.4561 2.1777 2.4658 2.03 50.Temperature Thermistors FORM 160.1680 2.3779 2.27 15.5928 2.3926 2.1826 2.1973 2.60 11.17 53.50 47.18 15.41 55.83 51.26 12.4316 2.42 58.45 16.86 9.02 11.47 53.43 15.4463 2.9531 1.01 15.78 59.8945 1.71 55.1924 2.2412 2.85 4.70 7.92 13.56 55.97 52.21 57.42 13.10 11.54 48.9189 1.4170 2.77 5.61 8.30 46.59 49.45 43.27 5.01 14.15 43.61 9.5146 2.3340 2.03 6.78 7.03 16.23 51.6074 2.60 14.53 6.93 60.4268 2.3438 2.18 50.39 60.3242 2.73 40.68 51.24 42.4756 2.9238 1.64 17.84 48.1268 2.2656 2.6123 2.52 64.2021 2.65 44.0801 2.5830 2.92 14.67 12.09 42.3682 2.28 6.76 12.62 16.91 62.3291 2.61 7.86 15.30 61.4219 2.68 4.51 54.5488 2.52 9.72 17.51 14.72 52.69 9.92 54.31 56.06 64.0068 2.35 44.3096 2.2314 2.1338 2.4072 2.45 8.54 60.9775 1.86 7.55 45.4023 2.77 10.17 14.0947 2.18 10.5684 2.69 15.18 11.39 48.21 54.96 17.68 11.10 12.50 44.18 12.34 13.05 44. 60 – RETURN AND LEAVING CONDENSING WATER Temp (°F) Temp (°C) 40.11 16.10 5.61 61.1094 2.61 15.4707 2.07 54.4902 2.51 13.57 52.27 52.05 47.94 6.06 62.9971 2.09 48.4121 2.1729 2.69 5.94 10.79 41.77 53.5781 2.85 46.28 8.2803 2.5293 2.09 60.28 16.85 61.20 8.9043 1.9580 1.77 9.19 6.35 11.44 63.5586 2.14 49.95 7.09 13.0996 2.11 9.8750 1.35 15.2607 2.6172 2.15 61.69 60.9434 1.5635 2.61 56.9629 1.93 12.5049 2.20 44.8652 1.30 43.77 15.5732 2.51 11.88 41.00 43.85 14.10 10.68 10.36 5.36 8.3193 2.85 43.10 45.67 13.46 9.70 42.93 51.2949 2.44 49.0752 2.70 45.59 Vin 2.43 11.52 10.21 64.6416 143 18 JOHNSON CONTROLS .42 12.36 64.44 6.5439 2.18 41.90 17.3828 2.8506 1.36 16.77 4.0166 2.2461 2.0605 2.33 59.85 11.5098 2.45 7.94 9.35 47.02 59.69 6.40 45.70 8.55 17.1484 2.0654 2.1143 2.30 17.2559 2.64 41.10 15.60 10.58 40.3486 2.89 50.48 50.87 59.90 44.13 63.19 9.6221 2.2852 2.5244 2.93 15.01 12.79 47.1387 2.47 17.42 40.32 53.6367 2.90 64.26 11.75 63.34 14.20 16.3975 2.26 13.4512 2.52 62.34 12. 12 32.9053 2.3203 3.16 91.63 89.7734 2.96 28.96 30.74 24.1641 3.40 79.27 19.7539 2.05 69.8467 2.2617 3.81 22.3594 3.2764 3.32 70.21 87.84 87.8564 2.67 27.10 84.6660 2.74 21.53 74.88 79.9883 2.65 84.03 75.3398 3.3887 3.89 19.0957 3.08 80.52 75.43 80.25 72.26 23.88 30.73 68.36 18.64 81.19 85.6465 2.3789 3.0859 3.54 91.3301 3.06 30.20 78.36 28.9980 3.71 26.0127 3.47 86.0713 3.7197 2.11 21.12 81.48 25.35 29.16 67.10 68.3154 3.4375 3.9004 2.14 26.8955 2.7783 2.75 29.39 87.57 83.7051 2.9688 2.2275 3.2910 3.99 82.8711 2.93 19.05 73.1982 3.95 81.7441 2.89 69.19 76.55 32.9395 2.32 67.9297 2.9346 2.3105 3.05 26.91 22.54 66.76 65.90 22.55 24.64 24.7832 2.99 23.26 89.36 69.32 92.55 29.85 66.88 89.09 24.19 22.01 85.10 27.29 65.1348 3.36 30.05 29.9492 2.8613 2.57 72.19 33.23 32.67 30.93 84.76 20.67 25.41 33.8320 2.85 29.95 26.19 77.74 33.77 71.55 28.80 70.73 85.00 67.71 73.0420 3.50 31.11 28.54 22.7393 2.3447 3.2227 3.7295 2.87 27.41 20.72 23.6807 2.20 74.68 69.83 24.0664 3.3838 3.47 21.53 77.46 84.97 91.6758 2.48 70.78 67.4473 JOHNSON CONTROLS .28 84.8760 2.77 27.57 25.29 81.7002 2.10 22.02 87.7979 2.75 28.33 82.85 28.61 71.10 86.91 66.50 20.76 25.45 65.02 77.49 27.9932 2.47 67.00 70.8076 2.9199 2.72 92.57 68.74 79.71 78.67 18.6709 2.3496 3.51 33.54 23.7686 2.72 22.01 90.8271 2.28 71.01 25.63 23.87 74.46 28. 60 – RETURN AND LEAVING CONDENSING WATER (CONT’D.2959 3.3350 3.54-M1 (607) FIG.01 22.Temperature Thermistors FORM 160.08 Vin 2.65 21.8857 2.0176 3.86 75.91 32.85 76.8906 2.98 31.50 18.13 92.60 80.65 29.29 27.9248 2.7100 2.2373 3.77 30.34 26.9834 2.41 72.58 87.3984 3.73 72.2178 3.75 83.22 66.00 24.69 75.95 88.26 Vin 2.1543 3.0225 3.59 90.4033 3.16 28.4277 3.44 32.19 31.38 73.36 24.58 18.84 70.9736 2.1787 Temp (°F) Temp (°C) 83.69 82.1006 3.26 30.2422 3.38 66.86 23.91 80.10 19.24 26.0078 3.67 20.07 66.6563 2.37 85.20 21.9150 2.07 89.1055 3.18 24.4082 3.05 79.80 19.76 32.39 83.8516 2.7637 2.63 67.7246 2.69 66.9639 2.34 32.98 65.77 80.30 25.8418 2.8027 2.1104 3.1494 3.13 88.7344 2.43 26.54 144 18.65 86.88 19.97 33.81 26.29 31.40 31.17 23.89 73.28 86.02 21.03 78.83 85.56 21.1689 3.58 27.93 72.11 25.3691 3.20 90.36 23.8662 2.45 29.53 19.32 88.4229 3.06 20.0615 3.04 83.60 65.0029 3.15 29.86 25.1836 3.0322 3.37 78.52 76.1934 3.35 76.2324 3.1738 3.52 69.16 82.3008 3.95 Vin 3.2568 3.71 31.86 78.96 71.7148 2.91 27.22 83.9443 2.1592 3.41 68.8223 2.2520 3.38 21.12 71.1201 3.4180 3.44 89.94 21.58 20.09 31.81 81.19 19.19 75.9590 2.08 33.6904 2.1250 3.0811 3.69 76.70 74.91 24.30 33.2666 3.64 70.82 21.23 20.94 68.62 19.46 24.3643 3.45 23.06 28.85 77.7490 2.7588 2.57 79.36 75.3252 3.15 20.2129 3.0518 3.3057 3.8809 2.04 74.9541 2.01 19.44 71.0908 3.47 81.0469 3.02 32.29 21.57 30.) Temp (°F) Temp (°C) 64.92 25.81 31.2861 3.1152 3.63 22.51 82.1885 3.25 29.2715 3.62 33.70 77.35 91.8174 2.87 32.71 19.1445 3.16 30.39 25.82 90.84 33.6953 2.93 92.3740 3.6514 2.27 24.84 18.95 29.02 76.51 88.0371 3.22 79.85 20.2471 3.65 28.0273 3.39 27.54 78.2813 3.0566 3.92 86.52 26.9102 Temp (°F) Temp (°C) 73.32 18.16 70.91 93.74 91.6611 2.8125 2.62 26.8369 2.47 30.97 20.45 22.55 85.7881 2.20 27.9785 2.41 18.2080 3.1299 3.26 68.21 69.0762 3.4326 3.66 32.27 22.76 18.20 25.39 90.36 77.6855 2.76 87.52 92.3936 3.00 27.78 90.2031 3.36 22.09 72.4424 3.32 20.3545 3.1396 3.26 80.22 73.14 65.7930 2.70 88.4131 3.37 74.60 31.81 23. 4814 3.33 40.24 43.09 36.4619 3.7354 3.6768 3.62 37.7451 3.6328 3.33 36.5449 3.55 102.8086 3.68 36.59 97.7939 3.10 94.4912 3.10 38.50 99.33 39.7695 3.61 34.37 43.11 108.11 95.51 43.92 45.08 109.81 111.34 96.5059 3.26 37.5107 3.8818 3.93 100.91 37.6133 3.FORM 160.32 109.5010 3.5840 3.7207 3. 60 – RETURN AND LEAVING CONDENSING WATER (CONT’D.7500 3.5156 3.7402 3.6182 3.43 98.34 112.31 93.4863 3.7305 3.9014 18 JOHNSON CONTROLS 145 .15 42.20 39.18 35.14 100.44 106.6279 3.) Temp (°F) Temp (°C) 93.6865 3.6523 3.31 95.70 93.6377 3.59 108.17 34.56 110.84 34.06 110.88 42.06 44.7744 3.82 112.6621 3.50 105.29 35.6426 3.13 96.4570 3.09 41.45 101.52 35.14 40.7793 3.7598 3.09 44.50 34.5693 3.63 113.04 105.6670 3.5303 3.8037 3.67 106.38 107.8525 3.45 Vin 3.5547 3.27 105.6572 3.6963 3.35 44.55 42.06 34.22 103.90 95.4766 3.14 107.64 Vin 3.8672 3.21 45.8379 3.11 102.93 96.42 42.78 44.20 40.7891 3.6230 3.51 93.37 113.92 44.8330 3.8328 3.36 41.96 97.39 37.71 99.90 94.86 35.80 98.29 99.01 98.50 94.58 40.4668 3.49 44.7842 3.49 45.75 41.67 101.50 37.31 111.33 102.7012 3.8184 3.06 45.96 43.46 38.00 103.6035 3.5791 3.10 43.89 104.29 42.94 40.64 44.96 41.71 38.07 99.35 45.4717 3.4961 3.35 108.7061 3.73 105.79 43.5400 3.67 103.07 40.6914 3.96 106.7158 Temp (°F) Temp (°C) 105.45 103.63 35.62 41.86 108.56 36.95 39.7646 3.59 112.30 94.5742 3.82 110.88 114.98 38.03 37.8721 3.7549 3.57 109.79 101.98 36.79 36.73 34.6719 3.75 96.6084 3.82 39.7256 3.64 98.62 107.83 42.39 34.86 37.21 36.69 42.12 104.91 107.17 97.8770 3.57 39.7988 3.11 113.01 42.72 95.5889 3.6475 3.5352 3.8135 3.06 35.54-M1 (607) FIG.22 38.70 94.84 109.59 38.08 39.36 111.5986 3.89 102.28 34.5498 3.5645 3.6816 3.4521 3.08 112.83 38.8916 3.7109 3.45 39.31 110.70 39.38 97.5254 3.52 95.65 43.5596 3.85 113.54 96.8574 3.58 100.58 104.8232 3.8477 3.8867 3.95 35.20 106.35 104.01 101.22 98.71 40.23 101.8965 3.15 37.81 34.5938 3.8281 3.78 103.84 40.74 37.36 100.34 38.49 41.40 35.44 36.8623 3.05 111.75 35.86 99.5205 3.23 41. 39 62.9570 0.14 75.4395 0.99 28.12 27.58 86.4639 0.79 29.02 88.72 48.82 81.73 63.8984 0.6592 0.7129 0.46 30.24 79.4785 0.06 30.17 11.3467 0.9912 0.3613 0.0352 1.69 22.41 63.11 82.82 28.72 67.37 83.98 76.4004 0.17 70.68 14.80 25.68 68.9375 0.42 7.87 85.9229 0.2979 0.90 25.45 17.4346 0.78 31.64 17.01 0.73 2.74 24.7617 0.20 18.87 83.33 61.3564 0.88 45.86 75.8691 0.6104 0.05 38.0254 1.6006 0.72 30.89 44.12 28.76 6.47 8.50 23.7080 0.10 15.30 87.8496 0.67 71.91 16.5029 0.06 1.39 26.61 85.3076 0.55 72.71 21.8398 0.5615 0.7666 0.59 30.8350 0.9180 0.63 13.7422 0.80 41.31 68.5225 0.51 29.5518 0.25 47.36 3.49 38.2686 0.25 88.2881 0.7471 0.38 84.7715 0.79 47.0645 146 JOHNSON CONTROLS .96 8.8594 0.69 62.20 89.4590 0.4541 0.2930 0.4150 0.30 15.82 20.69 52.03 80.62 84.27 14.57 54.39 44.69 26.7910 0.6055 0.21 21.42 65.2734 0.6348 0.54 12.9619 0.25 31.27 27.17 78.54 26.39 31.05 3.77 71.37 82.8008 0.5420 0.18 39.11 85.7031 0.5371 0.10 16.8545 0.20 25.7373 0.87 12.9766 0.65 25.07 63.3027 0.51 31.04 62.5469 0.93 19.19 30.73 36.0449 1.18 5.0107 1.07 71.3174 0.0205 1.7861 0.98 10.39 1.6152 0.6982 0.43 73.91 37.3955 0.26 72.98 61.9961 1.32 30.18 59.8105 0.70 10.09 65.47 19.65 23.5957 0.37 21.40 66.29 19.62 83.59 24.65 31.49 88.40 2.86 70.73 8.4932 0.9717 0.6738 0.3857 0.8057 0.00 74.97 55.63 49.85 86.32 12.31 57.50 79.82 87.53 76.12 31.40 50.71 1.99 4.2783 0.36 67.27 33.90 60.5859 0.7764 0.36 77.5811 0.02 23.69 7.6787 0.52 49.42 75.83 51.18 48.4980 0.0547 1.3662 0.97 50.0059 1.54 21.0010 1.24 9.90 15.4248 0.62 68.9521 0.8252 0.37 71.5273 Temp (°F) Temp (°C) 58.14 73. 61 – OIL AND DISCHARGE TEMPERATURE Temp (°F) 31.63 60.41 27.3369 0.72 74.63 11.65 29.0596 1.35 20.71 78.5078 0.8447 0.84 26.6201 0.92 57.37 55.6641 0.90 78.12 24.47 70.96 89.9033 0.76 12.7178 0.73 9.07 17.08 66.36 45.26 28.9082 0.48 Vin 0.3271 0.53 52.95 26.24 29.47 5.69 16.8887 0.73 3.37 42.87 22.7568 0.44 24.20 22.7275 0.04 Vin 0.44 78.78 88.4492 0.61 39.8154 0.57 74.22 8.54-M1 (607) FIG.8789 0.5762 0.24 69.4297 0.50 15.17 20.89 5.6299 0.4199 0.09 77.26 17.6836 0.3125 0.12 83.05 6.08 81.36 53.63 77.59 4.5566 0.89 43.42 13.86 30.28 Vin 0.57 18.07 49.62 82.93 69.3809 0.94 53.8740 0.98 27.5127 0.20 13.86 23.8301 0.7520 0.55 69.9131 0.37 22.54 28.39 43.0498 1.35 25.10 29.9668 0.88 84.17 54.30 16.75 18.04 21.7813 0.04 22.11 52.70 27.22 10.88 17.72 40.9326 0.67 3.05 25.81 77.3760 0.4053 0.48 9.8936 0.10 12.Temperature Thermistors FORM 160.9814 0.4688 0.13 84.68 58.99 31.3906 0.34 86.84 73.4883 0.6250 0.86 21.8203 0.33 41.81 23.8643 0.2637 0.77 54.54 56.94 11.70 14.91 32.30 80.6396 0.0303 1.38 18.67 24.36 85.26 40.75 66.84 27.4736 0.29 74.3418 0.43 64.3711 0.00 20.85 14.32 46.04 67.53 22.16 7.33 6.72 88.5908 0.26 51.5176 0.55 27.09 64.76 65.06 14.02 18.26 60.61 6.77 80.3223 0.9863 0.43 89.29 4.07 2.2832 0.96 72.56 80.5713 0.6494 0.92 30.6445 0.3516 0.06 Temp (°C) -0.96 29.7959 Temp (°F) Temp (°C) 75.9473 0.59 81.52 20.0156 1.32 36.11 19.9424 0.70 15.41 11.85 42.88 7.9277 0.3320 0.25 76.97 24.25 26.7227 0.4834 0.63 33.85 82.51 35.5664 0.15 56.7324 0.18 23.76 56.06 87.43 58.00 68.54 59.65 19.37 29.4102 0.6885 0.6689 0.40 28.81 59.34 23.99 32.10 26.69 20.0400 1.98 13.4443 0.46 10.6934 0.84 46.68 28.35 0.6543 0.99 9.75 64.90 34.50 25.33 81.8838 0.50 16.54 87.5322 0.98 79.12 35.10 86.83 18. 67 38.98 37.62 99.93 111.80 117.13 49.12 119.10 46.16 115.88 47.5820 1.4648 1.46 100.4160 1.64 92.4795 1.39 36.87 120.06 97.27 50.65 39.2402 1.30 32.3672 1.05 117.99 108.6846 1.6309 1.74 102.65 122.25 113.35 121.3965 1.3721 1.97 109.3379 1.54 121.49 119.78 108.3477 1.03 49.75 95.32 95.7920 1.6602 1.87 93.3330 Temp (°F) Temp (°C) 101.59 90.5625 1.39 106.6797 1.18 118.28 112.56 98.2891 1.2256 1.42 92.36 103.53 95.19 48.7285 1.6064 1.61 38.4941 1.75 49.18 35.97 115.09 112.90 90.19 92.1719 1.19 107.11 41.61 48.6455 1.31 43.34 49.32 111.26 36.32 93.35 45.71 32.44 41.97 96.6016 Temp (°F) Temp (°C) 112.6504 1.44 40.6992 1.44 34.1865 1.41 96.0938 1.72 121.78 45.30 116.15 38.5869 1.13 90.40 48.99 48.44 49.0889 1.6260 1.51 91.24 120.96 44.39 44.56 34.21 37.64 49.5918 1.25 45.18 108.69 34.1133 1.63 113.3574 1.4844 1.25 100.63 36.4990 1.2842 1.82 48.3916 1.2061 1.42 35.07 44.57 Vin 1.76 42.81 34.74 118.3281 1.06 113.10 93.30 48.82 114.08 39.66 40.20 43.20 99.4453 1.6895 1.50 36.5527 1.57 33.89 42.64 43.19 105.1621 1.54 35.3184 1.12 111.10 95.7676 1.7188 1.4404 1.81 32.37 50.19 39.44 42.6943 1.50 38.1230 1.54-M1 (607) FIG.6553 1.57 37.34 110.3818 1. 61 – OIL AND DISCHARGE TEMPERATURE (CONT’D.2012 1.5234 1.7383 1.4111 1.4063 1.35 115.28 91.4697 1.68 119.31 119.1328 1.95 34.6406 1.44 113.62 117.3867 1.4014 1.8359 1.55 32.0986 1.73 Vin 1.20 114.1426 1.8604 1.04 38.2158 1.2793 1.2695 1.1035 1.45 37.80 37.99 105.39 107.59 106.8457 1.90 112.43 117.85 38.91 36.70 97.92 116.67 45.06 50.0742 1.15 36.00 42.96 92.02 44.41 99.7725 1.Temperature Thermistors FORM 160.99 40.24 117.5576 1.88 101.23 49.2500 1.4355 1.33 42.54 102.33 40.06 33.8408 1.4746 1.57 47.66 41.4551 1.94 47.43 94.92 102.7773 1.0693 1.94 33.3623 1.84 46.30 35.33 41.54 93.4209 1.18 104.69 33.49 116.50 44.67 116.60 44.28 44.86 36.53 43.05 120.25 47.1523 1.33 102.78 104.1572 1.0840 1.7334 1.61 120.76 39.8066 1.15 103.88 95.66 42.58 104.21 94.2207 1.89 41.7871 1.2451 1.10 40.51 48.04 47.7578 1.11 116.30 39.3232 1.1475 1.2744 1.88 39.05 91.99 107.19 33.82 Vin 1.88 42.54 115.39 105.74 43.09 101.8652 1.31 46.86 113.73 110.36 90.85 43.56 103.4307 1.6357 1.58 108.2109 1.92 49.59 107.15 110.3086 1.56 109.70 111.3525 1.8115 1.7432 1.1279 1.99 94.55 41.99 106.78 41.6748 1.43 120.74 36.8701 147 18 JOHNSON CONTROLS .7090 1.2549 1.00 41.3037 1.8555 1.10 122.82 33.2988 1.4502 1.7627 1.7236 1.3428 1.79 107.5088 1.59 114.46 47.5771 1.50 101.22 42.78 40.6113 1.14 45.38 108.01 114.46 45.09 48.79 106.2305 1.3135 1.5479 1.5283 1.63 46.47 50.97 104.10 37.1084 1.42 32.6211 1.99 46.7529 1.17 121.59 105.1182 1.32 34.2354 1.83 100.77 93.6699 1.38 104.71 44.8018 1.49 97.99 43.07 34.73 46.03 36.5723 1.42 43.40 114.55 42.68 32.79 35.67 100.66 35.5039 1.94 35.42 39.84 97.63 96.5674 1.85 49.56 45.31 33.6162 1.1768 1.47 122.55 40.22 41.8213 1.91 122.15 47.8311 1.92 98.19 106.17 109.2598 1.69 37.19 96.73 115.95 50.7139 1.21 40.2646 1.37 109.1914 1.72 48.17 32.78 47.18 44.84 123.44 33.80 105.95 103.4893 1.04 100.7041 1.82 91.34 37.5967 1.28 122.48 112.5381 1.4600 1.52 46.96 39.4258 1.29 101.36 47.86 117.1670 1.93 45.5332 1.80 120.98 121.20 46.19 34.92 38.98 99.) Temp (°F) Temp (°C) 89.1377 1.95 110.5186 1.51 111.13 102.5137 1.56 118.09 43.53 39.8506 1.13 98.7969 1.41 46.27 38.16 50.1963 1.0791 1.2939 1.5430 1.78 114.54 49.54 110.8262 1.11 42.37 118.99 118.74 91.27 97.06 35.1816 1.7480 1.89 45.35 98.3770 1.8164 1.67 47.76 109.6650 1.39 38.77 103.7822 1.65 94.93 119.04 45.77 98. Temperature Thermistors FORM 160.54-M1 (607) FIG. 61 – OIL AND DISCHARGE TEMPERATURE (CONT’D.) Temp (°F) Temp (°C) 123.21 123.39 123.58 123.76 123.94 124.13 124.31 124.50 124.68 124.86 125.05 125.23 125.42 125.60 125.78 125.97 126.15 126.33 126.52 126.70 126.88 127.07 127.25 127.43 127.62 127.80 127.98 128.17 128.35 128.53 128.71 128.90 129.08 129.26 129.44 129.63 129.81 129.99 130.17 130.36 130.54 130.72 130.90 131.09 131.27 131.45 131.63 131.82 132.00 132.18 132.36 132.54 132.73 132.91 133.09 148 50.68 50.78 50.88 50.98 51.08 51.19 51.29 51.39 51.49 51.59 51.70 51.80 51.90 52.00 52.10 52.21 52.31 52.41 52.52 52.62 52.72 52.82 52.92 53.02 53.13 53.23 53.33 53.43 53.53 53.63 53.73 53.84 53.94 54.04 54.14 54.24 54.34 54.44 54.54 54.65 54.75 54.85 54.95 55.05 55.15 55.25 55.35 55.46 55.56 55.66 55.76 55.86 55.97 56.07 56.17 Vin 1.8750 1.8799 1.8848 1.8896 1.8945 1.8994 1.9043 1.9092 1.9141 1.9189 1.9238 1.9287 1.9336 1.9385 1.9434 1.9482 1.9531 1.9580 1.9629 1.9678 1.9727 1.9775 1.9824 1.9873 1.9922 1.9971 2.0020 2.0068 2.0117 2.0166 2.0215 2.0264 2.0313 2.0361 2.0410 2.0459 2.0508 2.0557 2.0605 2.0654 2.0703 2.0752 2.0801 2.0850 2.0898 2.0947 2.0996 2.1045 2.1094 2.1143 2.1191 2.1240 2.1289 2.1338 2.1387 Temp (°F) Temp (°C) 133.27 133.46 133.64 133.82 134.00 134.18 134.37 134.55 134.73 134.91 135.09 135.28 135.46 135.64 135.82 136.01 136.19 136.37 136.55 136.73 136.92 137.10 137.28 137.46 137.65 137.83 138.01 138.19 138.37 138.56 138.74 138.92 139.11 139.29 139.47 139.65 139.84 140.02 140.20 140.39 140.57 140.75 140.94 141.12 141.30 141.49 141.67 141.85 142.04 142.22 142.40 142.59 142.77 142.95 143.14 56.27 56.37 56.47 56.57 56.67 56.77 56.88 56.98 57.08 57.18 57.28 57.38 57.48 57.58 57.68 57.79 57.89 57.99 58.09 58.19 58.29 58.39 58.49 58.59 58.70 58.80 58.90 59.00 59.10 59.20 59.30 59.40 59.51 59.61 59.71 59.81 59.92 60.02 60.12 60.22 60.32 60.42 60.53 60.63 60.73 60.83 60.93 61.03 61.14 61.24 61.34 61.44 61.54 61.64 61.75 Vin 2.1436 2.1484 2.1533 2.1582 2.1631 2.1680 2.1729 2.1777 2.1826 2.1875 2.1924 2.1973 2.2021 2.2070 2.2119 2.2168 2.2217 2.2266 2.2314 2.2363 2.2412 2.2461 2.2510 2.2559 2.2607 2.2656 2.2705 2.2754 2.2803 2.2852 2.2900 2.2949 2.2998 2.3047 2.3096 2.3145 2.3193 2.3242 2.3291 2.3340 2.3389 2.3438 2.3486 2.3535 2.3584 2.3633 2.3682 2.3730 2.3779 2.3828 2.3877 2.3926 2.3975 2.4023 2.4072 Temp (°F) Temp (°C) 143.32 143.51 143.69 143.87 144.06 144.24 144.43 144.61 144.80 144.98 145.17 145.35 145.54 145.72 145.91 146.09 146.28 146.46 146.65 146.84 147.02 147.21 147.39 147.58 147.77 147.95 148.14 148.32 148.51 148.70 148.88 149.07 149.26 149.45 149.63 149.82 150.01 150.20 150.38 150.57 150.76 150.95 151.14 151.33 151.51 151.70 151.89 152.08 152.27 152.46 152.65 152.84 153.03 153.22 153.41 61.85 61.95 62.05 62.15 62.26 62.36 62.47 62.57 62.67 62.77 62.88 62.98 63.08 63.18 63.29 63.39 63.49 63.59 63.70 63.81 63.91 64.01 64.11 64.22 64.32 64.42 64.53 64.63 64.73 64.84 64.94 65.04 65.15 65.26 65.36 65.46 65.57 65.67 65.77 65.88 65.98 66.09 66.19 66.30 66.40 66.51 66.61 66.72 66.82 66.93 67.03 67.14 67.24 67.35 67.46 Vin 2.4121 2.4170 2.4219 2.4268 2.4316 2.4365 2.4414 2.4463 2.4512 2.4561 2.4609 2.4658 2.4707 2.4756 2.4805 2.4854 2.4902 2.4951 2.5000 2.5049 2.5098 2.5146 2.5195 2.5244 2.5293 2.5342 2.5391 2.5439 2.5488 2.5537 2.5586 2.5635 2.5684 2.5732 2.5781 2.5830 2.5879 2.5928 2.5977 2.6025 2.6074 2.6123 2.6172 2.6221 2.6270 2.6318 2.6367 2.6416 2.6465 2.6514 2.6563 2.6611 2.6660 2.6709 2.6758 JOHNSON CONTROLS Temperature Thermistors FORM 160.54-M1 (607) FIG. 61 – OIL AND DISCHARGE TEMPERATURE (CONT’D.) Temp (°F) 153.60 153.79 153.98 154.17 154.36 154.55 154.74 154.94 155.13 155.32 155.51 155.70 155.90 156.09 156.28 156.47 156.67 156.86 157.05 157.25 157.44 157.64 157.83 158.02 158.22 158.41 158.61 158.80 159.00 159.19 159.39 159.59 159.78 159.98 160.18 160.37 160.57 160.77 160.97 161.16 161.36 161.56 161.76 161.96 162.15 162.35 162.55 162.75 162.95 163.15 163.35 163.55 163.75 163.96 164.16 Temp (°C) 67.56 67.67 67.77 67.88 67.98 68.09 68.19 68.31 68.41 68.52 68.62 68.73 68.84 68.94 69.05 69.16 69.27 69.37 69.48 69.59 69.69 69.81 69.91 70.02 70.13 70.23 70.34 70.45 70.56 70.67 70.78 70.89 70.99 71.11 71.22 71.32 71.43 71.54 71.66 71.76 71.87 71.98 72.09 72.21 72.31 72.42 72.53 72.64 72.76 72.87 72.98 73.09 73.20 73.32 73.43 Vin 2.6807 2.6855 2.6904 2.6953 2.7002 2.7051 2.7100 2.7148 2.7197 2.7246 2.7295 2.7344 2.7393 2.7441 2.7490 2.7539 2.7588 2.7637 2.7686 2.7734 2.7783 2.7832 2.7881 2.7930 2.7979 2.8027 2.8076 2.8125 2.8174 2.8223 2.8271 2.8320 2.8369 2.8418 2.8467 2.8516 2.8564 2.8613 2.8662 2.8711 2.8760 2.8809 2.8857 2.8906 2.8955 2.9004 2.9053 2.9102 2.9150 2.9199 2.9248 2.9297 2.9346 2.9395 2.9443 Temp (°F) Temp (°C) 164.36 164.56 164.76 164.96 165.17 165.37 165.57 165.78 165.98 166.19 166.39 166.60 166.80 167.00 167.21 167.42 167.62 167.83 168.04 168.24 168.45 168.66 168.87 169.07 169.28 169.49 169.70 169.91 170.12 170.33 170.54 170.75 170.96 171.18 171.39 171.60 171.81 172.02 172.24 172.45 172.66 172.88 173.10 173.31 173.53 173.74 173.96 174.17 174.39 174.61 174.83 175.04 175.26 175.48 175.70 73.54 73.65 73.76 73.87 73.99 74.10 74.21 74.33 74.44 74.56 74.67 74.78 74.89 75.01 75.12 75.24 75.35 75.47 75.58 75.69 75.81 75.93 76.04 76.16 76.27 76.39 76.51 76.62 76.74 76.86 76.97 77.09 77.21 77.33 77.45 77.56 77.68 77.80 77.92 78.03 78.15 78.27 78.40 78.51 78.63 78.75 78.87 78.99 79.11 79.23 79.36 79.47 79.60 79.72 79.84 Vin 2.9492 2.9541 2.9590 2.9639 2.9688 2.9736 2.9785 2.9834 2.9883 2.9932 2.9980 3.0029 3.0078 3.0127 3.0176 3.0225 3.0273 3.0322 3.0371 3.0420 3.0469 3.0518 3.0566 3.0615 3.0664 3.0713 3.0762 3.0811 3.0859 3.0908 3.0957 3.1006 3.1055 3.1104 3.1152 3.1201 3.1250 3.1299 3.1348 3.1396 3.1445 3.1494 3.1543 3.1592 3.1641 3.1689 3.1738 3.1787 3.1836 3.1885 3.1934 3.1982 3.2031 3.2080 3.2129 Temp (°F) Temp (°C) 175.92 176.14 176.36 176.58 176.80 177.02 177.25 177.47 177.69 177.91 178.14 178.36 178.59 178.81 179.04 179.26 179.49 179.72 179.94 180.17 180.40 180.63 180.86 181.09 181.32 181.55 181.78 182.01 182.24 182.48 182.71 182.94 183.17 183.41 183.65 183.88 184.12 184.36 184.59 184.83 185.07 185.31 185.55 185.79 186.03 186.27 186.51 186.75 186.99 187.24 187.48 187.73 187.97 188.22 188.46 79.96 80.08 80.21 80.33 80.45 80.57 80.70 80.82 80.95 81.07 81.20 81.32 81.45 81.57 81.70 81.82 81.95 82.07 82.20 82.32 82.45 82.58 82.71 82.83 82.96 83.09 83.22 83.35 83.47 83.61 83.73 83.86 83.99 84.12 84.26 84.38 84.52 84.65 84.78 84.91 85.05 85.18 85.31 85.45 85.58 85.71 85.85 85.98 86.11 86.25 86.38 86.52 86.66 86.80 86.93 Vin 3.2178 3.2227 3.2275 3.2324 3.2373 3.2422 3.2471 3.2520 3.2568 3.2617 3.2666 3.2715 3.2764 3.2813 3.2861 3.2910 3.2959 3.3008 3.3057 3.3105 3.3154 3.3203 3.3252 3.3301 3.3350 3.3398 3.3447 3.3496 3.3545 3.3594 3.3643 3.3691 3.3740 3.3789 3.3838 3.3887 3.3936 3.3984 3.4033 3.4082 3.4131 3.4180 3.4229 3.4277 3.4326 3.4375 3.4424 3.4473 3.4521 3.4570 3.4619 3.4668 3.4717 3.4766 3.4814 149 18 JOHNSON CONTROLS Temperature Thermistors FORM 160.54-M1 (607) FIG. 61 – OIL AND DISCHARGE TEMPERATURE (CONT’D.) Temp (°F) Temp (°C) 188.71 188.96 189.21 189.46 189.71 189.96 190.21 190.46 190.71 190.96 191.22 191.47 191.73 191.98 192.23 192.49 192.75 193.01 193.27 193.53 193.79 194.05 194.31 194.57 194.84 195.10 195.37 195.63 195.90 196.16 196.43 196.70 196.97 197.24 197.51 197.78 198.06 198.33 198.61 198.88 199.15 199.43 199.71 199.99 200.27 200.55 200.83 201.11 201.39 201.68 201.97 202.25 202.54 202.82 203.11 150 87.07 87.21 87.35 87.48 87.62 87.76 87.90 88.04 88.18 88.32 88.46 88.60 88.75 88.88 89.02 89.17 89.31 89.46 89.60 89.75 89.89 90.03 90.18 90.32 90.47 90.62 90.77 90.91 91.06 91.21 91.36 91.51 91.66 91.81 91.96 92.11 92.26 92.41 92.57 92.72 92.87 93.02 93.18 93.34 93.49 93.65 93.80 93.96 94.11 94.27 94.44 94.59 94.75 94.91 95.07 Vin 3.4863 3.4912 3.4961 3.5010 3.5059 3.5107 3.5156 3.5205 3.5254 3.5303 3.5352 3.5400 3.5449 3.5498 3.5547 3.5596 3.5645 3.5693 3.5742 3.5791 3.5840 3.5889 3.5938 3.5986 3.6035 3.6084 3.6133 3.6182 3.6230 3.6279 3.6328 3.6377 3.6426 3.6475 3.6523 3.6572 3.6621 3.6670 3.6719 3.6768 3.6816 3.6865 3.6914 3.6963 3.7012 3.7061 3.7109 3.7158 3.7207 3.7256 3.7305 3.7354 3.7402 3.7451 3.7500 Temp (°F) Temp (°C) 203.40 203.69 203.99 204.28 204.57 204.86 205.16 205.46 205.76 206.05 206.35 206.65 206.96 207.26 207.57 207.87 208.17 208.48 208.79 209.10 209.42 209.73 210.04 210.35 210.67 210.99 211.31 211.62 211.94 212.27 212.59 212.92 213.24 213.57 213.90 214.23 214.56 214.89 215.23 215.56 215.90 216.24 216.58 216.92 217.26 217.60 217.95 218.30 218.65 219.00 219.35 219.70 220.06 95.23 95.39 95.56 95.72 95.88 96.04 96.21 96.37 96.54 96.70 96.87 97.04 97.21 97.37 97.55 97.71 97.88 98.05 98.22 98.40 98.57 98.75 98.92 99.09 99.27 99.45 99.62 99.80 99.97 100.16 100.34 100.52 100.70 100.88 101.06 101.25 101.43 101.61 101.80 101.99 102.17 102.36 102.55 102.74 102.93 103.12 103.31 103.51 103.70 103.90 104.09 104.29 104.49 Vin 3.7549 3.7598 3.7646 3.7695 3.7744 3.7793 3.7842 3.7891 3.7939 3.7988 3.8037 3.8086 3.8135 3.8184 3.8232 3.8281 3.8330 3.8379 3.8428 3.8477 3.8525 3.8574 3.8623 3.8672 3.8721 3.8770 3.8818 3.8867 3.8916 3.8965 3.9014 3.9063 3.9111 3.9160 3.9209 3.9258 3.9307 3.9355 3.9404 3.9453 3.9502 3.9551 3.9600 3.9648 3.9697 3.9746 3.9795 3.9844 3.9893 3.9941 3.9990 4.0039 4.0088 JOHNSON CONTROLS Temperature Thermistors FORM 160.54-M1 (607) FIG. 62 – DROP LEG REFRIGERANT SENSOR Temp (°F) Temp (°C) 0.01 3.72 7.21 10.51 13.65 16.65 19.56 22.36 25.09 27.74 30.34 32.89 35.40 37.87 40.31 42.73 45.14 47.53 49.92 52.31 54.70 57.10 59.52 61.95 64.40 66.89 69.40 71.97 74.57 77.23 79.96 82.73 85.60 88.56 91.59 94.75 98.06 101.50 105.10 108.90 112.92 117.17 121.76 -17.77 -15.71 -13.77 -11.94 -10.20 -8.53 -6.91 -5.36 -3.84 -2.37 -0.92 0.49 1.89 3.26 4.62 5.96 7.30 8.63 9.96 11.28 12.61 13.95 15.29 16.64 18.00 19.38 20.78 22.21 23.65 25.13 26.65 28.19 29.78 31.42 33.11 34.86 36.70 38.61 40.61 42.73 44.96 47.32 49.87 Vin 0.753 0.831 0.909 0.987 1.066 1.144 1.222 1.300 1.378 1.456 1.534 1.613 1.691 1.769 1.847 1.925 2.003 2.081 2.160 2.238 2.316 2.394 2.472 2.550 2.628 2.707 2.785 2.863 2.941 3.019 3.097 3.175 3.254 3.332 3.410 3.488 3.566 3.644 3.722 3.801 3.879 3.957 4.035 FIG. 63 – EVAPORATOR REFRIGERANT SENSOR Temp (°F) Temp (°C) 0.04 2.79 5.44 8.02 10.53 12.98 15.39 17.75 20.08 22.38 24.66 26.92 29.17 31.41 33.66 35.90 38.15 40.41 42.69 44.99 47.31 49.67 52.06 54.49 56.96 59.50 62.10 64.77 67.51 70.35 73.29 76.36 79.55 82.89 86.41 90.12 94.07 98.31 102.87 107.81 113.26 119.30 126.10 -17.76 -16.23 -14.76 -13.32 -11.93 -10.57 -9.23 -7.92 -6.62 -5.34 -4.08 -2.82 -1.57 -0.33 0.92 2.17 3.42 4.67 5.94 7.72 8.51 9.82 11.15 12.50 13.87 15.28 16.72 18.21 19.73 21.31 22.94 24.65 26.42 28.27 30.23 32.29 34.49 36.84 39.38 42.12 45.15 48.50 52.28 Vin 1.135 1.214 1.292 1.370 1.448 1.526 1.604 1.683 1.761 1.839 1.917 1.995 2.073 2.151 2.230 2.308 2.386 2.464 2.542 2.620 2.698 2.777 2.855 2.933 3.011 3.089 3.167 3.245 3.324 3.402 3.480 3.558 3.636 3.714 3.792 3.871 3.949 4.027 4.105 4.183 4.261 4.339 4.418 18 JOHNSON CONTROLS 151 2-10VDC. Refer to Table 1 “Microboard Program Jumpers” and explanation below for required configurations. IMPORTANT! . the Program assumes the remote device is defective and defaults the Current Limit Setpoint to 100% and the Leaving Chilled Liquid Temperature Setpoint to the locally programmed Local BASE value. 0-20mA or a 4-20mA signal. 2-10VDC. 12. regardless of whether the signal is a voltage or current input signal type. • Microboard Program Jumper JP23 must be positioned appropriately per the input signal type as detailed below. For example. 0-20mA. It is recommended that a qualified Service Technician position this jumper. Digital Remote Mode or ISN Remote Mode. the REMOTE ANALOG INPUT RANGE setpoint must be set to “0-10VDC” or “2-10VDC” as detailed below. 14 & 17) There are three different Remote operating Modes that can be selected at the Keypad: Analog Remote mode. The PWM input must be received at a frequency of at least once every 30 minutes. Microboard Program Jumpers JP23 and JP24 must be positioned appropriately to receive either a 0-10VDC. 2-10VDC.54-M1 (607) SECTION 19 REMOTE SETPOINTS (See Figs. DIGITAL Remote Mode must be selected when using a PWM input. 0-20mA. The PWM inputs are in the form of a 1 to 11 second Relay contact closure that applies 115VAC to the I/O Board TB4-19 (Leaving Chilled Liquid Temp) and TB4-20 (Remote Current Limit) for 1 to 11 seconds. The OptiView Control Center can receive a remote Current Limit and/or a Remote Leaving Chilled Liquid Temperature Setpoint via the following: Analog Remote Mode • 0-10VDC Analog Input • 2-10VDC Analog Input • 0-20mA Analog Input • 4-20mA Analog Input Digital Remote Mode • Pulse width Modulation (PWM) Input ISN Remote Mode • RS-232 Serial Port via MicroGateway The Analog inputs are connected to the Microboard J22 as shown in Figure 12 and described below.The signal type used for Remote Current Limit setpoint reset and the signal type used for Remote Leaving Chilled Liquid Temperature setpoint reset must be the same.Remote Setpoints FORM 160. if a 0-10VDC signal is being used for Remote Leaving Chilled Liq uid Tem per a ture Reset. • If ANALOG Remote Mode is selected. The source of 115VAC is I/O Board TB4-1. Refer to Figure 14. 4-20mA or 1 to 11 second Pulse Width Modulated (PWM) signal to the OptiView Control Center. 152 JOHNSON CONTROLS . The MicroGateway receives Setpoints from remote external devices and transfers them to the Microboard. The Microboard COM 4B RS-232 Serial Port (J2) receives the Setpoints in serial data form from the MicroGateway located inside the OptiView Control Center enclosure. The OptiView Control Center must be configured appropriately to accept the desired signal type as follows: • The appropriate Remote Mode must be selected: ANALOG Remote Mode must be selected when using a voltage or current signal input. CURRENT LIMIT REMOTE CURRENT LIMIT SETPOINT with 0-10VDC. If not received within this time interval. 4-20mA or Pulse Width Modulation Signal – The Remote Current Limit setpoint can be reset over the range of 100% to 30% Full Load Amps (FLA) by supplying (by others) a 0-10VDC. then a 0-10VDC signal must be used for Remote Current Limit Reset. FORM 160.54-M1 (607) 0-10VDC As shown in Fig. 12, connect input to Microboard J22-1 (signal) and J22-5 (Gnd). The setpoint varies linearly from 100% to 30% FLA as the input varies from 0 to l0VDC. This input will only be accepted when ANALOG Remote Mode is selected, the REMOTE ANALOG INPUT RANGE setpoint is set for “0-10 Volts” and Microboard Program Jumper JP23 has been removed. Calculate the setpoint for various inputs as follows: Setpoint (%) = 100 – (VDC x 7) For example, if the input is 5VDC, the setpoint would be set to 65% as follows: Setpoint (%) = 100 – (5 x 7) = 100 – 35 = 65% 2-10VDC As shown in Fig. 12, connect input to Microboard J22-1 (signal) and J22-5 (Gnd). The setpoint varies linearly from 100% to 30% FLA as the input varies from 2 to 10VDC. This input will only be accepted when ANALOG Remote Mode is selected, the REMOTE ANALOG INPUT RANGE setpoint is set for “2-10 Volts” and Microboard Program Jumper JP23 has been removed. Calculate the setpoint for various inputs as follows: Setpoint (%) = 100 – [(VDC – 2) x 8.75] For example, if the input is 5VDC, the setpoint would be set to 74% as follows: Setpoint (%) = 100 – [(5 - 2) x 8.75] = 100 – [3 x 8.75] = 100 – 26.25 = 74% 0-20mA As shown in Fig. 12, connect input to Microboard J22-2 (signal) and J22-5 (Gnd). The setpoint varies linearly from 100% to 30% FLA as the input varies from 0mA to 20mA. This input will only be accepted when ANALOG remote mode is selected, the REMOTE ANALOG INPUT RANGE setpoint is set for “0-10 Volts” and Microboard Program Jumper JP23 has been placed on pins 1 and 2. Calculate the setpoint for various inputs as follows: Setpoint (%) = 100 – (mA x 3.5) For example, if the input is 8mA, the setpoint would be set to 72% as follows: Setpoint (%) = 100 – (8 x 3.5) = 100 – 28 = 72% 4-20mA As shown in Fig. 12, connect input to Microboard J22-2 (signal) and J22-5 (Gnd). The setpoint varies linearly from 100% to 30% FLA as the input varies from 4mA to 20mA. This input will only be accepted when ANALOG remote mode is selected, the REMOTE ANALOG INPUT RANGE setpoint is set for “2-10 Volts” and Microboard Program Jumper JP23 has been placed on pins 1 and 2. Calculate the setpoint for various inputs as follows: Setpoint (%)100 – [(mA – 4) x 4.3 75] For example, if the input is 8mA, the setpoint would be set to 83% as follows: Setpoint (%) = 100 – [(8–4) x 4.375] = 100 – (4 x 4.375) = 100 – 17.5 = 82.5 = 83% PWM The Pulse Width Modulation input is in the form of a 1 to 11 second relay contact closure that applies 115VAC to the I/O Board TB4-20 for 1 to 11 seconds. As shown in Fig. 14, connect dry closure relay contacts between I/O Board TB4-20 (signal) and TB4-l (115Vac). The setpoint varies linearly from 100% to 30% as the relay contact closure time changes from 1 to 11 seconds. The relay contacts should close for 1 to 11 seconds at least once every 30 minutes to maintain the setpoint to the desired value. If a 1 to 11 second closure is not received within 30 minutes of the last closure, the setpoint is defaulted to 100%. A closure is only accepted at rates not to exceed once every 70 seconds. This input will only be accepted in DIGITAL remote mode. Calculate the setpoint for various pulse widths as follows: Setpoint (%) = 100 – [(pulse width in seconds – 1) x 7] 19 For example, if the relay contacts close for 3 seconds, the setpoint would be set to 86% as follows: JOHNSON CONTROLS 153 Remote Setpoints FORM 160.54-M1 (607) Setpoint (%) = 100 – [(3 –1) x 7] = 100 – (2 x 7) = 100 – 14 = 86% RS-232 As shown in Fig.11, a setpoint can be received in serial data form at Microboard J2 from the GPIC. LEAVING CHILLED LIQUID TEMPERATURE • If ANALOG Remote Mode is selected, the REMOTE ANALOG INPUT RANGE setpoint must be set to “0-10VDC” or “2-10VDC” as detailed below, regardless of whether the signal is a voltage or current signal type. • Microboard Program Jumper JP24 must be positioned appropriately per the input signal type as detailed below. It is recommended a qualified Service Technician position this jumper. REMOTE LEAVING CHILLED LIQUID TEMPERATURE SETPOINT with 0-10VDC, 2-10VDC, 0-20mA, 4-20mA or Pulse Width Modulation Signal – Remote Leaving Chilled Liquid Temperature setpoint reset can be accomplished by supplying (by others) a 0-10VDC, 2-10VDC, 0-20mA, 4-20mA or 1 to 11 second Pulse Width Modulated (PWM) signal to the OptiView Control Center. The LEAVING CHILLED LIQUID TEMPERATURE setpoint is programmable over the range of 38°F to 70°F (water applications); 36°F to 70°F (water applications with Smart Freeze protection enabled); or 10°F to 70°F (brine applications). The Remote input signal changes the setpoint by creating an offset above the locally programmed Leaving Chilled Liquid Temperature Base setpoint value. The setpoint can be remotely changed over the range of 10 or 20°F (as per the locally programmed REMOTE RESET TEMPERATURE RANGE setpoint) above the Local Leaving Chilled Liquid Temperature Setpoint. For example, if the Local setpoint is 40°F and the REMOTE RESET TEMPERATURE RANGE setpoint is programmed for 10°F, the Leaving Chilled Liquid Temperature setpoint can be remotely reset over the range of 40°F to 50°F. The setpoint received through the COM 4B RS-232 serial port is not an offset that is applied to the locally programmed BASE value as described above. Rather, it is an actual Setpoint value. The locally programmed value is not used as a BASE in this application. The OptiView Control Center must be configured appropriately to accept the desired signal type as follows: • The appropriate Remote Mode must be selected: ANALOG Remote Mode must be selected when using a voltage or current signal input. DIGITAL Remote Mode must be selected when using a PWM input. IMPORTANT! - The signal type used for Remote Leaving Chilled Liquid Temperature setpoint reset and the signal type used for Remote Current Limit setpoint reset must be the same. For example, if a 0-10VDC signal is being used for Remote Current Limit setpoint reset, then a 0-10VDC signal must be used for Leaving Chilled Liquid Temperature reset. 0-10VDC As shown in Fig. 12, connect input to Microboard J22-3 (signal) and J22-5 (Gnd). A 0VDC signal produces a 0°F offset. A 10VDC signal produces the maximum offset (10 or 20°F above the Local Setpoint value). The setpoint is changed linearly between these extremes as the input varies linearly over the range of 0VDC to 10VDC. This input will only be accepted when ANALOG Remote mode is selected, the REMOTE ANALOG INPUT RANGE setpoint is set for “0-10VDC” and Microboard Program Jumper JP24 has been removed. Calculate the setpoint for various inputs as follows: Offset (°F) = (VDC)(Remote Reset Temp Range) 10 Setpoint (°F) = Local Setpoint + Offset For example, if the input is 5VDC and the Remote Reset Temp Range setpoint is programmed for 10°F and the Local Leaving Chilled Liquid Temperature setpoint is programmed for 40°F, the setpoint would be set to 45°F as follows: Offset (°F) = 5 x 10 10 = 50 10 = 5°F 154 JOHNSON CONTROLS FORM 160.54-M1 (607) Setpoint = 40 + 5 = 45°F Offset (°F) = (mA)(Remote Reset Temp Range) 20 Setpoint (°F) = Local Setpoint + Offset For example, if the input is 8mA, the Remote Reset Temp Range Setpoint is programmed for 10°F and the Local Leaving Chilled Liquid Temperature setpoint is programmed for 40°F, the setpoint would be set to 44°F as follows: Offset (°F) = (8)(10) 20 = 80 20 = 4°F Setpoint (°F) = 40 + 4 = 44°F 2-10VDC As shown in Fig. 12, connect input to Microboard J22-3 (signal) and J2-5 (Gnd). A 2VDC signal produces a 0°F offset. A 10VDC signal produces the maximum allowed offset (10°F or 20°F above the Local Setpoint value). The setpoint is changed linearly between these extremes as the input varies over the range of 2VDC to 10VDC. This input will only be accepted when ANALOG remote mode is selected, the REMOTE ANALOG INPUT RANGE setpoint is set for “2-10VDC” and the Microboard Program Jumper JP24 has been removed. Calculate the setpoint for various inputs as follows: Offset (°F) = (VDC – 2)(Remote Reset Temp Range) 8 Setpoint (°F) = Local Setpoint + Offset For example, if the input is 5VDC and the Remote Reset Temp Range setpoint is programmed for 10°F and the Local Leaving Chilled Liquid Temperature setpoint is programmed for 40°F, the setpoint would be set to 43.8°F. Offset (°F) = (5 – 2)(10) 8 = (3)(10) 8 = 30 8 = 3.8°F Setpoint (°F) = 40 + 3.8 = 43.8°F 0-20mA As shown in Fig. 12, connect input to Microboard J22-4 (signal) and J22-5 (Gnd). A 0mA signal produces a 0°F offset. A 20mA signal produces the maximum allowed offset (10 or 20°F above the Local setpoint value). The setpoint is changed linearly between these extremes as the input varies over the range of 0-20mA. This input will only be accepted when ANALOG remote mode is selected, the REMOTE ANALOG INPUT RANGE setpoint is set for “0-10VDC” and Microboard Program Jumper J24 has been placed on pins 1 and 2. Calculate the setpoint for various inputs as follows: 4-20mA As shown in Fig. 12, connect input to Microboard J22-4 (signal) and J22-5 (Gnd). A 4mA signal produces a 0°F offset. A 20mA signal produces the maximum allowed offset (10 or 20°F above the Local Setpoint value). The setpoint is changed linearly between these extremes as the input varies over the range of 4-20mA. This input will only be accepted when ANALOG Remote mode is selected, the REMOTE ANALOG INPUT RANGE setpoint is set for “2-10VDC” and Microboard Program Jumper JP24 has been placed on pins 1 and 2. Calculate the setpoint for various inputs as follows: Offset (°F) = (mA–4)(Remote Reset Temp Range) 16 Setpoint (°F) = Local Setpoint + Offset For example, if the input is 8mA, and the Remote Reset Temp Range setpoint is programmed for 10°F and the Local Leaving Chilled Liquid Temperature setpoint is programmed for 40°F, the setpoint would be set to 42.5°F as follows: Offset (°F) = (8–4)(10) 16 = (4)(10) 16 19 JOHNSON CONTROLS 155 Remote Setpoints FORM 160.54-M1 (607) = 40 16 = 2.5°F Setpoint (°F) = 40 + 2.5 = 42.5 Setpoint (F°) = Local Setpoint + Offset For example, if the relay contacts close for 5 seconds and the Remote Reset Temp Range setpoint is programmed to 10°F and the Local Leaving Chilled Liquid Temperature setpoint is programmed for 40°F, the setpoint would be set to 44°F as follows: Offset (°F) = (5 – 1)(10) 10 = (4)(10) 10 = 40 10 = 4°F Setpoint (°F) = 40 + 4 = 44°F RS-232 As shown in Fig. 11, a Setpoint can be received in serial data form at the Microboard COM 4B serial port (J2) from the MicroGateway. PWM The Pulse Width Modulation input is in the form of a 1 to 11 second relay contact closure that applies 115VAC to the I/O Board TB4-19 for 1 to 11 seconds. As shown in Fig. 14, connect dry closure relay contacts between I/O Board TB4-19 (input) and TB4-1 (115VAC). A contact closure time (pulse width) of 1 second produces a 0°F offset. An 11 second closure produces the maximum allowed offset (10 or 20°F above the Local Setpoint value). The relay contacts should close for 1 to 11 seconds at least once every 30 minutes to maintain the setpoint to the desired value. If a 1 to 11 second closure is not received within 30 minutes of the last closure, the setpoint is defaulted to the Local setpoint value. A closure is only accepted at rates not to exceed once every 70 seconds. This input will only be accepted in DIGITAL Remote mode. Calculate the setpoint for various pulse widths as follows: Offset (°F) = (pulse width in seconds – 1)(Remote Reset Temp Range) 10 156 JOHNSON CONTROLS it represents compressor “Head” and is displayed on the Hot Gas Bypass Screen for reference only. The actual valve position is displayed on the HOT GAS BYPASS Screen as 0% to 100%. This position value is sent over the RS-485 serial communications link to the Microboard. A 2.5K Ohm PRV Potentiometer mounted on the Prerotation Vanes (PRV) assembly provides the PRV position (0 to 100%) to the Analog I/O Board. For example. The PRV position is displayed as XX on the COMPRESSOR Screen and “Warning – Vanes Uncalibrated” is displayed on the System Details line of the display until the calibration is performed. The smaller the number. Programmable in 1 minute increments. Surge events are detected by the SURGE PROTECTION feature (Section 21). default 5%) – This is the incremental amount that the Hot Gas valve will be closed at 10 minute intervals after the HOLD PERIOD has elapsed. When a surge is detected. default 0ºF) – This sets the Minimum Load override threshold. Programmable in 0. • Hold Period (30 to 120 minutes. SETPOINTS • Surge Sensitivity (0. The Analog I/O Board converts this command into a 2-10VDC signal and applies it to the Hot Gas Valve Actuator. JOHNSON CONTROLS The Evaporator and Condenser pressure transducers provide these pressure values to the Microboard. The Surge Sensitivity setpoint. These pressures are also used to detect when a surge occurs. the greater the sensitivity. 50% position would be achieved with a 6VDC signal.1 increments. A Hot Gas Bypass Screen. accessed from the COMPRESSOR Screen displays all the applicable parameters and allows a Service Technician to program the applicable setpoints and manually control the Hot Gas valve. If the chiller is equipped with the optional Hot Gas Bypass control. This parameter is indicative of chiller load. Positions between these extremes are linearly scaled. If Disabled. The valve is modulated in response to load and surging conditions. This value is subtracted from the Leaving Chilled Liquid Temperature Setpoint to produce the TEMPERATURE DIFFERENTIAL parameter. it must be Enabled from the OPERATIONS Screen using a procedure in the “System Calibration Service Setpoints and Reset Procedures” section of this book. Refer to HOLD PERIOD above. Although this parameter is not used in the Hot Gas Control. • Close Percentage (5 to 15%. part of the Surge Protection feature. 64) With the optional Hot Gas Bypass feature.3.3) – Determines the surge detection sensitivity. the SURGE DETECTED LED illuminates for 5 seconds and the TOTAL SURGE COUNT increments. Refer to description in Section 22. The Leaving Chilled Liquid Temperature thermistor provides the temperature to the Microboard. • Minimum Load (0ºF to 4ºF. The Microboard uses these values to calculate the DELTA P/P parameter as follows: [(condenser pressure – evaporator pressure) / evaporator pressure]. When the PRV are fully closed.3 to 1. the valve is driven to the fully closed position. To assure accuracy. The Microboard controls the Hot Gas valve by sending a positioning command over the COM 3 RS-485 serial commumications link to the optional Analog I/O Board that is mounted inside the control Center. A 2VDC signal drives the valve fully closed (0% position). the position is display as 0%. is used to modify the surge detection sensitivity. It is the offset below the Leaving Chilled Liquid Temperature 157 20 . Positions between these extremes are linearly scaled. fully open displayed as 100%. A +12VDC source is applied to the potentiometer.54-M1 (607) SECTION 20 HOT GAS BYPASS (REFER TO FIG. a 10VDC signal drives the valve fully open (100% position). the Control Center modulates a valve located in the Hot Gas Bypass connection between the condenser and the evaporator to control the flow of gas to the evaporator.FORM 160. a PRV Calibration procedure must be performed as detailed in the “System Calibration. Service Setpoints and Reset Procedures” section of this book. It will be driven toward the closed position in increments equal to the Close Percentage setpoint at 10 minute intervals until fully closed. default 0. This setpoint is programmed on the Surge Protection Screen and is common to the Surge Protection feature. where it is displayed on the COMPRESSOR Screen. default 30) – This is the period of time after no more surges are detected that the Hot Gas valve closing will begin. the valve is opened to the maximum allowed by the Maximum Open setpoint and “Override” is displayed as the Hot Gas Bypass Control mode on the Hot Gas Bypass Screen. • If Hot Gas valve position is < 35%. After this Minimum Load Override is initiated. the valve is set to one-half of its present position for 10 minutes. If the Pre-Rotation Vanes are more than 95% open and the Leaving Chilled Liquid Temperature is at least 5ºF above the Leaving Chilled Liquid Temperature setpoint. There will be no valve response to surge events in the next 2 minutes. If RS-485 serial communications between the Microboard and the Analog I/O Board are lost continuously for 20 seconds. the Hot Gas valve is opened a certain percentage every few minutes until the surging stops or the valve is fully opened as follows: • If Hot Gas valve is fully closed. The valve is closed accordingly until the temperature delta is 0ºF.5ºF to +25ºF) to (-5. there are some conditions where this probing can actually cause a surge. it is driven to the 50% position. “Warning – External I/O – Serial Communications” is displayed on the System Details line of the Display and the Hot Gas valve will remain at the position when communications were lost.Hot Gas Bypass FORM 160. OPERATION While the chiller is shutdown. until a surge condition is detected. After the 10 minutes have elapsed.54-M1 (607) Setpoint at which the Hot Gas Bypass valve will be opened to the position allowed per the MAXIMUM OPEN setpoint (25% to 100%). the existing safety check that subtracts the evaporator saturation temperature from the leaving chilled liquid temperature changes the range from standard range of (-2. the valve is driven fully closed. the valve is modulated in response to low load. the valve is closed by an amount proportional to the difference between the temperature delta and the minimum Load setpoint. the valve will be positioned to 80% open when the Leaving Chilled Liquid Temperature decreases to more than 4ºF below the Leaving Chilled Liquid Temperature setpoint. as the Leaving Chilled Liquid Temperature rises to the Leaving Chilled Liquid Temperature setpoint. default 100%) – This is the maximum allowed position for the Hot Gas valve during a Minimum Load override condition. • If Hot Gas valve position is > 35% but < 50%. When a surge is detected.0ºF to +25ºF). the Hot Gas Valve is not opened on the first surge or when the VGD is closing. the valve will be positioned to 40% open. this feature is disabled. For example. the Hot Gas Valve will not be opened until a second surge is detected. if the Minimum Load is set for 4ºF and the Maximum Open is set for 80%. If the chiller is equipped with a Variable Speed Drive (VSD). Therefore. it remains there until another surge is detected. to eliminate unnecessary Hot Gas Valve movement. After the chiller has not surged for the period of time programmed as the HOLD PERIOD setpoint. Whenever the Hot Gas valve is partially or fully open. it is driven open another 10%. After it is fully closed. While the chiller is running. high load or surge conditions. In this example. when the Leaving Chilled Liquid Temperature increases to 2ºF below the Leaving Chilled Liquid Temperature setpoint. HOT GAS OPERATION WITH VARIABLE GEOMETRY DIFFUSER (VGD) Since the VGD operates by pulsing the diffuser ring open until stall is detected. the Hot Gas Bypass valve is driven to the fully closed position. When a surge is detected. 158 JOHNSON CONTROLS . this safety check uses the standard values. Allows the user to adjust the quantity of Hot Gas for the local requirements. There will be no valve response to surge events in the next 2 minutes. • Maximum Open (25% to 100%. There will be no valve response to surge events for the next 3. There will be no valve response to surge events for the next 5 minutes. However. the Hot Gas valve is driven to the fully closed position. If “0” is entered for this value.5 minutes. If the Leaving Chilled Liquid Temperature decreases to less than the Minimum Load setpoint. whenever the VSD is running at < full speed (50/60 Hz). If none of the above conditions are in effect. it is driven to the 50% position. manual control can override this operation. the Hot gas Bypass valve is driven to the fully closed position and “Override” is displayed as the Hot gas Bypass Control Mode. • If Hot Gas valve position is >50%. the valve is driven toward the closed position at 10 minute intervals by incremental amounts determined by the CLOSE PERCENTAGE setpoint. Whenever the Hot Gas Bypass valve is closed or not used. it is driven to the 50% position. If a Variable Speed Drive is not present. MANUAL CONTROL The Hot Gas Bypass valve can be manually controlled from the Hot Gas Bypass Screen in Service access level. The scaling of this signal is as described above. the LED in the respective key will illuminate for 2 seconds.FORM 160. Service Setpoints and Reset Procedures” section of this book. ANALOG I/O BOARD If the chiller is equipped with a compressor motor Variable Speed Drive. a calibration procedure must be performed as detailed in the “System Calibration. When the OPEN or CLOSE key is pressed. depending on where the ACC function is performed. This keeps the VGD at a position of similar surge stability when the system head is later lowered and the Hot gas Valve closes. In applications where the ACC functionality is contained in microboard 031-02430-001 (ACC Board not used). The on-board Program Jumpers must be configured as follows: JUMPER J1 J26 J39 POSITION Pins 2 & 3 Pins 2 & 3 Pins 1 & 2 The optional Analog I/O Board mounts inside the Control Center. The Analog I/O Board must be configured properly for the Hot Gas control. Positions between these extremes are linearly scaled. This converts the normal 4-20mA Analog I/O Board output to a 2-10VDC valve positioning output. the PRV potentiometer is connected to the Analog I/O Board P1. Whenever the Hot Gas Valve is not closed. PRV position is displayed on the COMPRESSOR Screen as 0 (closed) to 100% (fully open). The PRV position is transmitted to the Microboard via the RS-485 serial communications link. To assure position accuracy. Positions between these extremes are linearly scaled. 1%. the Pre-rotation Vanes (PRV) potentiometer (2. the potentiometer is connected to the Microboard J7. on the upper right hand side of the Control Center. There must be a 499 Ohm. providing a 0-5vdc voltage from a +12vdc source that represents the PRV position. Valve position is displayed on the HOT GAS BYPASS Screen as 0% (closed) to 100% (fully open). the valve position will be increased or decreased by 5% to a maximum of 100% or minimum of 0%.54-M1 (607) This gives the VGD a chance to close and stabilize the chiller without opening the Hot Gas Valve. Each time either key is pressed. the potentiometer is connected to the ACC Board J4. The Hot Gas Bypass Control Mode will display “Manual”. If the ACC Board is present. the VGD is maintained at the last position. required by the Hot Gas valve actuator. It receives the Hot gas valve positioning command from the Microboard over the RS-485 serial communications link and converts this digital value to a 2-10VDC analog control signal that is applied to the valve actuator. 20 JOHNSON CONTROLS 159 . Manual control has priority over Minimum Load Override. Variable Speed Drive Override and Automatic control. ½ watt resistor connected between P10-2 and P10-5.5K ohms) is connected to either the Adaptive Capacity Control (ACC) Board or the Microboard. If chiller is equipped with a compressor motor Variable Speed Drive. PRESSURE COND. FORM 160. depending on where the ACC function is performed. HOT GAS BYPASS .100% 2. the PRV potentiometer is connected to either the Adaptive Capacity Control Board (J4) or the Microboard J7. PRESSURE OPEN VANE POSITION 0 . Refer to explanation in this section. 64 – INTERFACE.5 K EVAPORATOR TRANSDUCER PRV POTENTIOMETER (NOTE 1) CONDENSER TRANSDUCER LD04563 Notes: 1.54-M1 (607) JOHNSON CONTROLS FIG.160 Hot Gas Bypass MICRO BOARD J12 2 3 P10 2 POSITIONING SIGNAL 2-10 VDC VANE POSITION (+) 11 3 (–) 12 J9 ACTUATOR POSITIONING OPTIONAL ANALOG I/O BOARD RS-485 COM 3 J8 3 P1 2 1 OPTIONAL HOT GAS BYPASS ACTUATOR 18 21 EVAP. this feature allows the Leaving Chilled Liquid temperature Setpoint to be set as low as 36.0ºF.5 PSIG (R22) and 28. If the chiller is equipped with the Evaporator Refrigerant Temperature Sensor (RT7). Unless Smart Freeze protection is activated.54-M1 (607) SECTION 21 SMART FREEZE PROTECTION The Smart Freeze feature prevents nuisance chiller shutdowns due to brief periods of chilled liquid flow fluctuations or other brief operating conditions that would normally cause Low Evaporator Pressure Safety shutdowns. 29. sensor RT7) or 34. This threshold could be lower. the total number of seconds that the evaporator refrigerant temperature is below the freeze threshold is counted. During this period of time.0ºF. Service Setpoints and Reset Procedures” section of this book.7 (freeze threshold–evaporator refrigerant temperature) Thus. loading will be allowed when the pressure increases to 57. it would take 8 minutes and 26 seconds for the chilled liquid to freeze. the chiller is permitted to ride through these temporary conditions. If Smart Freeze is no longer activated due to the Leaving Chilled Liquid Temperature Setpoint being raised to > 38.). if the Evaporator Saturation Temperature is being used as the evaporator refrigerant temperature and that temperature is 26. It cannot be used in Brine cooling mode. Even though Smart Freeze protection is enabled and activated.7ºF) are used. Therefore. the Pre-rotation Vanes Load inhibit still occurs at the same thresholds as with normal operation. by a Service Technician. it requires a certain amount of time for the liquid to change to a solid. are evaluated and the appropriate Low Evaporator Temperature shutdown threshold is applied. The number of seconds it will take the chilled liquid to freeze is based on how far the evaporator refrigerant temperature is below the freeze threshold as follows: Number of seconds to freezing = 4053. the LEAVING CHILLED LIQUID – LOW TEMPERATURE cycling shutdown threshold becomes a minimum of 34. a safety shutdown is performed and “EVAPORATOR – LOW PRESSURE – SMART FREEZE” is displayed on the System details line of the display.0º (evaporator saturation temp. inhibit at 56.3 PSIG. When the total number of seconds the evaporator refrigerant temperature is below the freeze threshold exceeds the “Number of seconds to freezing”.0ºF. The basis of this feature is that the chilled liquid contains an amount of heat.0 PSIG (R134a).0ºF. but not higher than the normal Safety threshold. Otherwise.0 PSIG. the fixed Low Evaporator Pressure Safety thresholds (R22 – 54. then goes below the threshold for 5 seconds.6ºF) (R134a – 25.0ºF.0 (R134a). 21 JOHNSON CONTROLS 161 . the total number of seconds being tracked is set to zero. Thus if the evaporator refrigerant temperature goes below the freeze threshold for 30 seconds. As in normal operation. The pressure is converted to a temperature via the appropriate refrigerant “pressure/temperature lookup table”) is used as the refrigerant temperature. then goes above it for 10 seconds. The count is incremented once for every second the evaporator refrigerant temperature is below the freeze threshold and decremented once for every second it is above the freeze threshold (but is never decremented below zero). the Evaporator Saturation Temperature (as derived from the output of the Evaporator Pressure Transducer.2 PSIG (R22) and 27. and the sensor is enabled using the “System Calibration. If set to < 38. Smart Freeze protection can be enabled or disabled at the Keypad.FORM 160. those parameters that determine when solidification will occur. 28.0ºF. the total number of seconds the evaporator refrigerant temperature was below the freeze threshold was 25 seconds. SMART FREEZE protection is activated only when the feature is enabled AND the Leaving Chilled Liquid Temperature Setpoint is < 38ºF. See Note 1 below. Also. the Leaving Chilled Liquid Temperature Setpoint can be set as low as 36. When Smart Freeze protection is Enabled. Smart Freeze protection uses the Evaporator Refrigerant Temperature as one of the variables to determine when freezing is imminent. Service Setpoints and Reset Procedures” section of this book. Once activated. this value is used as the refrigerant temperature. which cannot be eliminated immediately. With this feature enabled and activated. using a procedure detailed in the “System Calibration. The freeze threshold is 32.8ºF (refrigerant temp. 01.0 PSIG Load Inhibit disable: R22 – 57. 2.MLM.8ºF (refrigerant temperature sensor RT7) or 34.0ºF: 1. R134a – 28. • PRV Load Inhibit: same as Smart Freeze Disabled above.3 PSIG (29. or a minimum of 36.0 PSIG (28.0ºF • If the Leaving Chilled Liquid Temperature Setpoint is >38.0ºF. R134a – 27.0 PSIG SMART FREEZE ENABLED: • Minimum Leaving Chilled Liquid Setpoint: 36.) and the total number of seconds it remains there. R134a – 25.0ºF.0ºF: 1. • Low Evaporator Pressure safety shutdown threshold: R22 . See Note 1 below. as programmed.54.0ºF. Note 1: The freeze threshold evaporation saturation temperature is 32.0ºF (Evaporator Saturation Temperature. Low Evaporator Pressure shutdown threshold: Determined by how far the evaporator refrigerant temperature is below the freeze threshold of 32.Smart Freeze Protection FORM 160. The Low Evaporator Pressure Safety shutdown threshold is the same as Smart Freeze Disabled above.0ºF below the Leaving Chilled Liquid Temperature Setpoint. or a minimum of 36.0ºF • Low Chilled Liquid Temp cycling shutdown threshold: 1º to 34. The Low Leaving Chilled Liquid Temperature Cycling shutdown threshold: 1 to 3.0ºF below the Leaving Chilled Liquid temp Setpoint.5 PSIG.0ºF on Flash Memory Card version C. 162 JOHNSON CONTROLS . • Load Inhibit Disable: same as Smart Freeze Disable above. as programmed. as programmed.54-M1 (607) The following is a summary of the operation with Smart Freeze enabled and disabled: SMART FREEZE DISABLED: • Minimum Leaving Chilled Liquid Setpoint: 38. The Low Leaving Chilled Liquid Temperature Cycling shutdown threshold: 1 to 34.2 PSIG.01 and earlier.0ºF below the Leaving Chilled Liquid Temperature Setpoint. • If the Leaving Chilled Liquid Temperature Setpoint is <38. Refer to explanation above. or a minimum of 34. 2.7ºF) • PRV Load Inhibit: R22 – 56.6ºF). xxx (and later) or C.MLM.xxx and later). Default value is 0.10B.061VDC JOHNSON CONTROLS An excess surge condition is detected by comparing the number of surge events that occur in a selectable time period to a selectable threshold.01.xxx and later) or C.xVDC for > 0. The detection and counting of surges in this feature is completely independent of the surge detection/counting performed by the compressor Variable Speed Drive Adaptive Capacity Control (ACC) Board. If excess surging is detected. If either of the following negative transitions occur in the differential followed by a 0.MLM. It is adjustable over the range of 0.01. When the difference between these pressures decreases transiently and remains so for a period of time described below.OPT.MLM. The SURGE PROTECTION Screen. • If the differential decreases > x.xxx and later. Each time a surge is detected.3.301 (and later)) an excess surge condition has been detected. accessible from the COMPRESSOR Screen. The Evaporator pressure transducer output is subtracted from the Condenser pressure output to determine the differential.260 seconds.22] ÷ 1000 There are two surge counters that count surge events detected by this surge protection feature.3 to 1. the greater the sensitivity. a surge event has been detected.xxx (and later) or C.301 (and later)) exceed the threshold programmed as the COUNT LIMIT setpoint (4 to 20.FORM 160. However. default 4) (default 15 with Software version C.3 in 0. and then makes a positive transition within 7 seconds (90 seconds with software version C. displays all parameters relevant to this feature.10B.09. applies to Flash Memory Card versions C.xxx and later). The TOTAL SURGE COUNT can be cleared using the CLEAR SURGE COUNT key on the Surge Protection Screen following procedure in “System Calibration. The SURGE WINDOW COUNT accumulates the number of surges that occur within the SURGE WINDOW TIME.09.1 increments.01.01. EXCESS SURGE DETECTION Surge events are detected by monitoring the relationship between the Condenser pressure and Evaporator pressure while the chiller is running. the SURGE DETECTED LED on the Surge Protection Screen illuminates for 5 seconds and both counters increment. The smaller the number.10B. SURGE DETECTION positive differential transition within 7 seconds (90 seconds for P and Q compressors with software version C.01. The surge detection sensitivity can be adjusted with the SURGE SENSITIVITY setpoint. a surge event is detected: • If the differential decreases > 0.54-M1 (607) SECTION 22 SURGE PROTECTION This feature applies to all compressor codes.OPT.09. Service Setpoints and Reset Procedures” section of this book.09. If the number of surge events (Surge Window Count) detected in the time period programmed as the COUNT WINDOW setpoint (1 to 5 minutes. default 5) (default 3 with Software version C. The TOTAL SURGE COUNT is the number of surges detected over the lifetime of the chiller.6VDC for > 0.01.01.MLM.OPT.01. The ACC Board detects surges to control the speed of the compressor motor. if compressor code other than “P”.MLM.xxx and later) or C. The surge counts accumulated by this surge protection feature are displayed on the Surge Protection Screen as described below. The surge counts accumulated by the ACC Board are displayed on the ACC Details Screen.OPT. x.10B.05. All setpoints relating to this feature are maintained on this screen. The SURGE PROTECTION feature detects surge events and provides a running count of the events that occur over the lifetime of the chiller (up to a maximum of 65535).390 seconds. it can be configured to shutdown the chiller or initiate a special surge correction/avoidance mode or simply display a warning message.xVDC calculated as [(surge sensitivity setpoint x 300) x 1. 22 163 . • If the SHUTDOWN setpoint is Disabled and the EXTENDED RUN setpoint is Enabled. as explained below. However.Surge Protection FORM 160.xxx (and later) or C. Shutdown mode and Excess Surge Warning message will not implemented unless the Hot Gas valve position is 100% and the VSD output frequency is at maximum.301 (and later) – The Extended Run mode.01.09.xxx (and earlier) or C. the following courses of action are taken: • If the SHUTDOWN setpoint is Enabled. If the chiller is equipped with the Hot Gas Bypass feature and/or a compressor motor Variable Speed Drive (VSD).08A.09. Shutdown mode and Excess Surge Warning message will not be implemented unless the VSD output frequency is at maximum.300 – The Extended Run mode will not be implemented unless the Hot Gas valve position is 100% and the VSD output frequency is at maximum.01. 164 JOHNSON CONTROLS . When the 10 minutes have elapsed.OPT. During the 10-minute period.OPT.xxx (and later) or C.The Extended Run mode will not be implemented unless the VSD output frequency is at maximum. Software version C.OPT. Equipped with both Hot Gas and VSD: Software version C.01. while allowing the chiller to continue to run. SURGE PROTECTION • If both the SHUTDOWN and EXTENDED RUN setpoints are Enabled. HOT GAS BYPASS/COMPRESSOR MOTOR VARIABLE SPEED DRIVE (VSD) APPLICATIONS The Control Center can be configured to take the following courses of action when an excess surge condition has been detected. Equipped with VSD: Software version CMLM. This message will be displayed until manually reset with the Warning Reset key in Operator access level. if the SURGE WINDOW COUNT exceeds the COUNT LIMIT at the end of the 10 minute Extended Run period.xxx (and earlier) or C. Alternating with this message is “Warning – Excess Surge Detected” that is displayed until manually reset with the Warning Reset key in OPERATOR access level.54-M1 (607) Unless the SHUTDOWN or EXTENDED RUN features have been enabled.300 . Software version C. When a surge is detected. the Prerotation Vanes are driven closed for 10 minutes and “Warning – Surge Protection – Excess surge Limit” is displayed.01.MLM. the 10 minute Extended Run period is invoked as above.08.09.MLM. and the EXTENDED RUN setpoint is Disabled. Equipped with Hot Gas: The Hot Gas valve position must be 100% before the Extended Run mode is implemented. The EXTENDED RUN setpoint is used to invoke a special 10 minute surge correction/avoidance mode that temporarily eliminates the conditions causing the surging. the chiller will continue to run under the same conditions displaying “Warning – Excess Surge Detected”.Excess Surge” is displayed.OPT.301 (and later) – The Extended Run mode. if the Surge Window Count is < the Count Limit. certain Hot Gas valve position and VSD speed criteria must be met before the Shutdown or Extended Run functions are performed as explained below.09.MLM. a safety shutdown will be performed and “Surge Protection . The SHUTDOWN setpoint is used to invoke a safety shutdown. a countdown timer on the Surge Protection Screen displays the time remaining in the period. otherwise another 10 minute period is initiated. a safety shutdown is performed and “Surge Protection – Excess Surge” is displayed.08A.08.01. this message and load inhibit are automatically cleared. See Hot Gas Bypass and compressor motor Variable Speed Drive exception above. Stall noise in the compressor discharge is detected as gas pressure pulsations. It is fully open when the chiller is started. During chiller operation. A mechanical ring. located in the diffuser passage after the impeller discharge. In response to a stall condition. Arrows on the diagram indicate actions that move the control from one “State” to another. It is opened (retracted) to open the diffuser gap.5 VDC indicates little or no stall. Software version C. This analog voltage is displayed 22A JOHNSON CONTROLS 165 . A Stall Pressure Transducer (025-39464-000 or 025-40088-000). The VGD Limit Switch indicates when the VGD is fully closed. A signal above 0.8 VDC indicates stall noise is present. If stall occurs.FORM 160. The diffuser ring is also closed in response to surge conditions as described below.10. After a wait period. Stall Reacting. They are Stall Waiting. thereby increasing the gas velocity through the compressor.54-M1 (607) SECTION 22A VARIABLE GEOMETRY DIFFUSER (SEE FIG’S 64A & 64B) Certain York compressors are equipped with a Variable Geometry Diffuser (VGD). This board converts the voltage pulsations into an analog voltage that represents the magnitude of the stall noise. It’s displayed as CLOSED when the VGD is in the full closed position Otherwise. xxx (and later) or C.MLM. An internal actuator end switch prevents travel beyond the fully open or closed positions. Stall may occur at low load conditions with high head.MLM.14.302 (and later) is required for this feature. it is again pulsed open until either a stall occurs or the fully open position is reached. different arrow styles are used for Stall (__). mounted in the discharge scroll of the compressor. The switch closes when the VGD is in the fully closed position. The Variable Geometry Diffuser Screen displays all parameters relevant to this feature. it is driven toward the close position for a selectable period of time. All setpoints related to this feature are maintained on the Variable Geometry Diffuser Setpoints Screen. It is used to reduce rotating stall conditions and associated stall noise. the current state is displayed as the “Control Status” on the Variable Geometry Diffuser Screen. It is closed (extended) to narrow the diffuser gap. In a typical YK chiller.OPT. Surge Waiting and Hot Gas Override. In response to a surge. SURGE DETECTION Surge events are sensed as described in the HOT GAS BYPASS Section 20 and SURGE PROTECTION Section 22 of this manual.OPT. Probing. Surge (__ . it is displayed as OPEN. it is again pulsed open unless another surge occurs.14. __) and Hot Gas (_ _ _ ) response actions. STALL DETECTION (REF FIG 64A) on the Variable Geometry Diffuser Screen as “Stall Detector Voltage” and is input to the Microboard where it is compared to the Low Limit and High Limit setpoint thresholds to determine if the stall noise is acceptable or unacceptable.01.306 (and later)). For clarity. The switch status is displayed on the VGD Screen and VGD setpoints Screen (Software version C. is mechanically operated through linkages via an electric actuator like that used to operate the Pre-rotation vanes. Surge Reacting. The Diffuser Gap Open and Diffuser Gap Close LED’s on the Variable Geometry Diffuser Screen illuminate when the program is initiating the respective output. narrowing the diffuser gap reduces the cross sectional area through which the gas flows. The “States” are shown in circles. a signal below 0. The following describes the operating states: Chiller Off. Since stall is caused by reduced gas flow through the compressor. whereupon the cycle repeats.01. AUTOMATIC OPERATION The VGD operation is illustrated in the STATE DIAGRAM illustrated in figure 64B.xxx (and later) or C.01. the VGD is maintained in the most open position possible that does not allow stall. Prelube or Coastdown: The VGD diffuser gap is driven fully open.10. detects the pressure pulsations and outputs DC voltage pulsations to the Stall Detector Board (031-02418-000 or 031-02418-001). whereupon Hot Gas operation overrides VGD operation and the VGD is held in place. it is driven toward the close position until the stall is eliminated.01. In general. the ring is closed as much as necessary to eliminate the stall. After a wait period. as programmed with the PRV OFFSET setpoint). Therefore. default 0. any stall conditions are ignored and the controls will look for a second surge. Probing will be initiated based on PROBE WAIT time only. the VGD is held in its last position. default 5).5 – 15 minutes. Probing: In this state. Therefore. The pulses are initiated every 10 seconds. stall will be sensed and controlled before a surge occurs. Stall Reacting: If a stall is detected from either the Probing or Stall Waiting states. • A surge is detected. default 0. Opening the diffuser gap may lower the lift capability of the machine. the Probing state is entered. The number of times the Stall Detector Board output goes above the HIGH LIMIT setpoint threshold is displayed on the VGD Setpoints Screen as the “VGD Count”. The Surge Detected LED on the Variable Geometry Diffuser Screen illuminates for 5 seconds each time a surge is detected. A surge is detected as detailed in the “Surge Protection” and “Hot Gas Bypass” sections of this manual. for units with VGD and Hot Gas options. Enters Probing state. Typically. Hot Gas Bypass Override: Applies for units with optional Hot Gas Bypass. If a second surge occurs during. The accumulated time the Stall Detector Board output voltage is greater than the “High Limit” threshold is displayed on the VGD Screen as “VGD Time”. Surge Reacting: The VGD is closed for a specific time period. Note: Setting the PRV OFFSET setpoint to 0% disables this function. default 10). a surge can occur while probing which may be momentary in nature and not evidenced as stall noise.6). This probing continues until the Stall Detector Board output exceeds the HIGH LIMIT setpoint (0. • A stall is detected (stall detector board output goes above the HIGH LIMIT setpoint).54-M1 (607) Stall Waiting: This state is entered on startup. This keeps the VGD at a position of similar surge stability when the system head is later lowered and the hot gas valve closes.5 – 1. the state is changed to Stall Reacting.8) to indicate stall is present or a surge is detected.5 – 15 minutes. Enters Stall Reacting state. as programmed with the PROBE WAIT time setpoint) expires. If there are no other surges detected during this period. The time remaining in the PROBE WAIT time period is displayed on the Variable Geometry Diffuser Screen as “Time Remaining”. default 10.4 – 0. Enters Surge Reacting state. whereupon it enters the Stall Waiting state. This state remains in effect until the Hot Gas Bypass valve position returns to 0%. defined by the SURGE REACT time setpoint (1-30 seconds. the diffuser gap is closed until the Stall Detector 166 Board output drops below the LOW LIMIT setpoint (0. The VGD is held in last position until one of the following occurs: • The PROBE WAIT time period (0. The program looks at a change in the condenser minus evaporator pressures over a short time period to detect a back flow or surge condition of the compressor. When the timer expires. or Hot Gas valve closure. JOHNSON CONTROLS .VARIABLE GEOMETRY DIFFUSER FORM 160.2Vdc. So. default 2). The time remaining in the PROBE WAIT time period is displayed on the Variable Geometry Diffuser Screen as “Time Remaining”. this overrides any of the Stall action states. the VGD mechanism is opened in pulses to open the diffuser gap. the VGD mechanism will be kept at last position. After Stall Reacting.If equipped with the optional Hot Gas Bypass feature and the Hot Gas valve position is greater than 0% when the stall is detected. there are some conditions where the Probing can actually cause a surge. Whenever the Hot Gas Bypass valve position is greater than 0%. During this period. Surge Waiting: The VGD is held in last position for a wait time. This count can be reset using an ADMIN access level.8Vdc. The PRV position is displayed on the Variable Geometry Diffuser Screen as 0% (fully closed) to 100% (fully open). In this state. • The compressor pre-rotation vanes (PRV) position increases more than the PRV OFFSET (1-5%. At higher loads and very high heads or lift. In this case it is likely that simply closing the diffuser gap some amount will stabilize the compressor. default 3. the Hot Gas Bypass valve will not be opened on the first surge or during the time the VGD is closing. It is not driven closed. after a Stall Reaction. normal Hot Gas Bypass Control takes over and Hot Gas Bypass Override state is entered. if a surge is detected. the state returns to Stall Waiting. at lower loads below 70%. the VGD returns to Probing. A surge is generally of more concern and potentially damaging to the compressor than stall. The duration of the pulses are defined by the OPEN PULSE setpoint (1-9 seconds. defined by the PROBE WAIT time Setpoint (0. Control Status displays “PRV Position Override”. whether the chiller is running or not. default 5) .01.14. default 10). While the chiller is running. If the Stall Transducer is not reading accurately. The Hot Gas Minimum Load Override function is not affected by VDG operation. the VGD returns to normal operation. Pressing the OPEN. When the warning is cleared. It can be cleared when the voltages are within the acceptable range of each other and the Warning Reset key is pressed in Service access level.Specifies the duration of the close pulse applied to the VGD in response to a surge.14.306 (and later)) The Variable Geometry Diffuser ring can be damaged by operating in extreme stall for long periods of time.14.xxx (and later) or C. While the chiller is running. the Hot Gas valve will not be opened until a second surge is detected. They require SERVICE access level. The VGD is held in the open position until the warning is manually cleared. The Stall Pressure Transducer unprocessed DC voltage output passes through the Stall Detector Board J2-2 and is connected to the Microboard at J8-1.OPT. Each time the OPEN or CLOSE keys are pressed. While this is in effect. ·While the Pre-rotation vanes position is greater than the PRV VGD INHIBIT Setpoint. CLOSE or HOLD key invokes manual operation and the VGD Control Mode displays MANUAL. MANUAL OPERATION (Software version C. Pressing the HOLD key causes the Hold LED to illuminate and the VGD to be held in its present position. Since both transducers are measuring essentially the same pressure.306 (and later)) This feature verifies the operation of the Stall Pressure Transducer by comparing its voltage output to the voltage output of the Condenser Pressure Transducer. the outputs of the Stall Transducer and Condenser Transducer are compared. a warning message is displayed and the Variable Geometry Diffuser operation is disabled. if the Stall Detector Voltage (output of the Stall Detector Board) exceeds twice the HIGH LIMIT Setpoint.OPT. After it is cleared.FORM 160.01. Pressing the AUTO key invokes automatic operation and AUTO is displayed as the control mode. the VGD is pulsed open per the Open Pulse setpoint. The Extreme Stall condition is not checked under the following conditions: ·While the VGD is in Manual control mode.01. both outputs should be within an acceptable range of each other. the VGD is driven to the full open position and “Warning – Condenser or VGD Sensor Failure” is displayed. STALL SENSOR VALIDATION stall conditions and a warning message is displayed. PRV-VGD Inhibit: If the Pre-rotation Vanes position exceeds the PRV-VGD Inhibit Setpoint (40% to 100%). 22A (Software version C.01. If the difference between them exceeds 0. Press the Warning Reset key in Service access level to clear.14.Enables or Disables the VGD feature. the VGD is driven to the full open position and “Warning – Conditions Override VGD” is displayed. SETPOINTS The following setpoints are entered on the Variable Geometry Diffuser Setpoints Screen. Except that on surge response. The VGD is held in the open position until the warning is manually cleared.MLM. • Surge React (1-30 seconds. It can be cleared after the Stall Detector Voltage returns to less than two times the HIGH LIMIT Setpoint. the respective output is energized and the associated LED illuminates. EXTREME STALL MONITOR The VGD can be manually controlled from the Variable Geometry Diffuser Screen in Service access level.54-M1 (607) Hot Gas Bypass operates as described in the Hot Gas Bypass section 20 of this manual. the VGD is disabled during extreme JOHNSON CONTROLS 167 .MLM. the VGD returns to normal operation. • Enable/Disable . This value is then used for comparison to the condenser transducer. ·While the VGD is fully closed (VGD Limit Switch closed). Default is Disabled. for the duration programmed as the EXTREME STALL DURATION Setpoint (10 to 20 minutes.28 Vdc for 3 continuous minutes.xxx (and later) or C. Chiller must be stopped to change this setpoint. To prevent damage. the potentiometer is connected directly to the Microboard at J7.1 vdc.4-0. the potentiometer is connected to either the Adaptive Capacity Control (ACC) Board or the Microboard. as used by the VGD control. Above this value is unacceptable.01. If the chiller has neither a Variable Speed Drive nor the Hot Gas option. Later chillers are shipped with Stall JOHNSON CONTROLS 168 .OPT. STALL TRANSDUCER Detects stall noise as high frequency pressure fluctuations in the discharge scroll of the commpressor. If the ACC Board is present. In applications where the ACC functionality is contained in microboard 031-02430-001 (ACC Board not used). • High Limit (0. • Open Pulse (1-9 seconds.306 (and later))– Specifies the maximum allowed time an extreme stall condition can exist before the Variable Geometry Diffuser operation is disabled (and driven full open) to protect it from damage. default 95%)(Software version C. depending on where the ACC function is performed.1vdc below the High Limit setpoint.MLM.xxx (and later) or C. If a Low Limit setpoint is entered which is less than 0. default 3) – If the VGD control is in the Stall Waiting state and the Pre-rotation vanes position increases by more than this value. • PRV VGD Inhibit (40% -100%. the Stall Waiting state is performed based only on the “Probe Wait” setpoint interval. the Probing state will be entered. I/O Board 031-01743-001 does not contain required triacs Q3 and Q4. This board is populated with the required triacs Q3 and Q4 that apply the open and close signals to the VGD actuator. default 10) – Specifies how long the VGD control remains in the Stall Waiting or Surge Waiting states before entering the Probing state. • Probe Wait (0.VARIABLE GEOMETRY DIFFUSER FORM 160. the VGD control is inhibited and the VGD will be pulsed open according to the OPEN PULSE Setpoint. Early vintage chillers were shipped with Stall Transducer 025-39464-000.1vdc above the newly entered Low Limit value. The minimum difference between the High Limit setpoint and the Low Limit setpoint is 0. I/O BOARD Chillers equipped with this feature are supplied with and require I/O Board 031-01743-002. PRE-ROTATION VANES POSITION The Pre-rotation Vanes position. the PRV potentiometer is connected to the Analog I/O Board and the PRV position is read from there. Extreme Stall conditions are not checked.8) – Specifies the Stall Detector Board output voltage that represents an acceptable amount of stall noise. If a Low Limit setpoint is entered which is less than 0.306 (and later)) . the potentiometer is connected to the ACC Board J4.01.01.01. is provided by a potentiometer mounted to the PRV control arm. the High Limit setpoint is adjusted so that it is 0. default 0.While the re-rotation vanes position is greater than this setpoint. but is equipped with the Hot Gas Bypass option. It converts the pressure pulsations to DC voltage pulsations and applies them to the Stall Detector Board. default 10 minutes)(Software version C.MLM. the High Limit setpoint is adjusted so that it is 0.1vdc above the newly entered Low Limit value. default 2) – Specifies the length of the open pulse applied to the VGD during 10 second periods while in the Probing state. The minimum difference between the High Limit setpoint and the Low Limit setpoint is 0.54-M1 (607) • PRV Offset (0-5%. default 0. While this is in effect.xxx (and later) or C. The potentiometer interface varies according to how the chiller is equipped as follows: If the chiller is equipped with a compressor motor Variable Speed Drive.8vdc.5-15 minutes. If the chiller is not equipped with a Variable Speed Drive.14.1 vdc. the VGD is driven closed until the Stall Detector Board output voltage decreases to this level. “PRV Position Override” is displayed as Control Status.6) – in the Stall Reacting State.2Vdc.OPT.14.5-1.14. • Extreme Stall Duration (10 to 20 minutes. If the PRV Offset is set to 0%.1vdc below the High Limit setpoint. • Low Limit (0. the potentiometer is connected to the Microboard J7.14. Refer to the Transducer Pin arrangements listed above. There are two versions of the Stall Detector Board as follows: 031-02418-000 Supplied in new production chillers and as replacement part until June 2007.2 to 0. With it in the STANDARD position (on pins 2 & 3). This board contains a filter that removes the noise associated with high gas flow/low head conditions and thus prevents VGD closing in response to conditions that are not true stall conditions. FIG. the filter is engaged.RED pin 2 .+5vdc supply voltage . Does not filter high gas flow/low head noise conditions as described in ENHANCED mode above. stall should be detected before surge occurs.ground . STALL TRANSDUCER STALL DETECTOR BOARD +5 Vdc MICRO BOARD STALL DETECTOR OUTPUT I/O BOARD J1 3 X J1 1 J2 4 J7 23 J19 31 Open J1 31 TB1 158 VGD ACTUATOR 2 O pe n X 1 OUT 2 3 GND 24 30 Close 159 30 160 SEE NOTE 1 1 os e X 2 SEE NOTE 2 GND 3 1 +5 Vdc 12 J8 1 3 Cl 22A 2 STALL TRANSDUCER OUTPUT LD09467b NOTE: 1. When it reaches the value programmed as the HIGH LIMIT Setpoint (typically set to 0. In this mode. Since the filter causes the “Stall Detector Voltage” to typically run 0. The Stall Detector Board (031-02418-000) converts the Stall Transducer DC voltage pulsations to an analog DC voltage output (J2-4) that represents the magnitude of stall noise and applies it to the Microboard (J7-23). These transducers require different wiring connections at the transducer.WHT STALL DETECTOR BOARD 031-02418-001 Supplied in new production chillers and as replacement part after June 2007.3vdc lower than STANDARD mode for the same condition. Ideally. • STANDARD Mode – This mode should not be used unless under the advisement of JCI Tech Support. it may be necessary to lower the HIGH LIMIT and LOW LIMIT Setpoints if valid stall conditions are not being detected or surge occurs before stall is detected.BLK pin 3 . With JP1 in the ENHANCED position (on pins 1&2). since the PRV POSITION – VGD INHIBIT setpoint was the original vehicle to avoid VGD reaction to high gas flow/low head conditions. 64A – VARIABLE GEOMETRY DIFUSER BLOCK DIAGRAM JOHNSON CONTROLS 169 .RED Transducer 025-40088-000 pin 1 . This output is used for the Stall Sensor Validation feature.WHT pin 2 . Provides the same operation as the 031-02418-000 board.FORM 160. Also. Check the part number of the replacement transducer and make connections at the transducer connector as follows: Transducer 025-39464-000 pin 1 .+5vdc supply voltage .8vdc). Requires I/O Board 031-01743-002 Transducer Pin arrangement may vary. 2.BLK pin 3 . This board also provides a path for the Stall Transducer unprocessed DC voltage pulsations output to be connected from J2-2 to the Microboard (J8-1). this setpoint should be set to 95% or 100% to avoid interference when ENHANCED mode is selected.54-M1 (607) Transducer 025-40088-000. the filter is not engaged and would operate the same as the -000 board above.6Vdc).signal out . Use the following guidelines: • ENHANCED Mode – The board is shipped configured in this mode.signal out . it filters the noise associated with high gas flow/low head conditions and thus prevents VGD closing in response to conditions that are not true stall conditions. allowing the VGD to react prior to surge.ground . The presence of this filter could require adjustment of the setpoints as follows: The Stall Detector Board outputs an analog voltage (displayed as “Stall Detector Voltage” on the VGD Screen) that represents the magnitude of stall noise present. Shunt jumper JP1 allows operation with or without the filter. the VGD closes until the voltage decreases to the LOW LIMIT Setpoint (typically set to 0. Default 3) No Stall Chiller Run CHILLER OFF or PRELUBE VGD Open Hot Gas Valve Open Hot Gas Valve Closed Hot Gas Valve Open Hot Gas Valve Open Hot Gas Valve Open HOT GAS OVERRIDE Action Arrow Legend Stall Surge Hot Gas Valve Hold VGD LD09570a FIG.4 to 0..8 V.2 V. 64B – VARIABLE GEOMETRY DIFFUSER STATE DIAGRAM 170 JOHNSON CONTROLS .VARIABLE GEOMETRY DIFFUSER FORM 160.5-15 Min..6) Detect Stall STALL WAITING Probe wait time (0.54-M1 (607) Variable Geometry Diffuser (VGD) STATE DIAGRAM 3/23/05 Vanes open > Setpoint PRV-VGD INHIBIT Vane position > Setpoint Overrides stall or surge reaction or waiting states when vanes near full open position Pulse Open VGD PROBING Pulse VGD Open Until Stall Signal > High Limit (0.5 to 1.8) Pulse Open time (1-5 Sec. Default 10) PRV Offset (0 to 5%. Default 2) Wait timer done Detect Surge Surge Reaction Time Expired SURGE REACTING Close VGD for X second (X = 1-30 Sec... Default 0. Default 0. Default 5) SURGE WAITING Hold VGD for Probe Wait Time Look for 2nd Surge and if occurs set HG Control = True Detect Stall Detect Surge Wait Time Expired or PRV position moved Vanes close below setpoint Detect Surge STALL REACTING Close VGD Until Stall Voltage < Low Limit (0. At the Keypad. SERVICE SETPOINTS AND RESET PROCEDURES The chiller is supplied from the YORK Factory with all factory mounted components fully calibrated. When requesting this password. and C using a clamp-on Ammeter. giving the minimum and maximum allowed values. 2. The ◄ key is a backspace key and causes the entry point to move back one space. use the numeric keys to enter the desired value. Each of these procedures is described below. Log in with the appropriate access level 2. 3. use the 13 pt ◄ and ► keys to select the desired value. as described in a previous chapter of this book. The ADMIN Password changes daily and is valid for 1 calendar day only. This password is obtained by contacting the local YORK service office. Select MOTOR Screen and set Current Limit and Pulldown Demand Limit Setpoints to 100% FLA. Pressing the ▲ key displays the Default value. some of these Setpoints can be used to enable or disable certain features. If the dialog box begins with the word “Enter”. In general. The ◄ key decreases the value. If out of range. the value is not accepted and a message describing why it is not acceptable is displayed momentarily. supply the “Controls” version of software (available on the DIAGNOSTIC Screen) and the calendar day on which you intend to use it. Switch S1 and Potentiometer R16 have to be set appropriately on the CM-2 Module. Although they have been entered at the YORK Factory. In addition to the calibration. the following procedure is used to enter Setpoints in this section: 1. Press the • key to place a decimal point at the appropriate place. The following procedures are used to verify these calibrations or calibrate a component after it has been field replaced. The following procedures can be used to verify the calibration and perform the calibration if necessary. The chiller will begin to operate based on the new value. they can be changed by a field Service Technician. Also. others require the ADMIN (Administration) Access Level. 4.54-M1 (607) SECTION 23 SYSTEM CALIBRATION. CM-2 Settings: 1. Each of these Setpoints is described below. Programming procedures and OptiView Control Center Keypad operation required in the procedures below are detailed in YORK Operation Manual 160. If the BRAM battery backed memory device is field replaced. Select the appropriate Display Screen. A dialog box appears. Most of the following procedures require the Service Technician to be logged in at SERVICE Access Level (Access Code 1 3 8 0).54-O1. Default value and present value. B. If the value is within range. The dialog box can be canceled at any time by pressing the CANCEL (X) key. Read compressor motor current in Phase A. Calibration Verification: 1. 3. These reset procedures require SERVICE access level and should not be performed by anyone other than a Service Technician. Run chiller. Press the desired Setpoint key. ELECTRO-MECHANICAL STARTER AP PLI CA TIONS If the Compressor Motor is driven by an ElectroMechanical Starter. If the CM-2 and/or RES are field replaced. 171 23 . the OptiView Control Center is equipped with a CM-2 Current Module along with supporting components Diode Bridge (DB) and Calibration Resistors (RES). Apply ammeter to highest Phase. If the dialog box begins with “Select”or “Enable”. field calibration is necessary. They will have to be re-entered into the new BRAM. However. Programmable Service Setpoints are used by the Program to control critical chiller operation.FORM 160. JOHNSON CONTROLS 5. log in at SERVICE access level using access code 1 3 8 0. Some Safety shutdowns will not permit the chiller to start until a special reset procedure is performed. Pressing the ▼ key clears the entry. all of the programmed setpoints will be lost. The ► key increases the value. it is accepted and the dialog box disappears. Calculate LRA/FLA ratio by dividing the Motor Lock Rotor Amps by the chiller Full Load Amps (LRA/FLA = ratio) and then adjust Potentiometer R16 to the ratio value. Press the ENTER (✔) key. Place Switch S1 in the appropriate position per the Starter type: UP: Y-Delta or 57% Auto-transformer Starter Down: All others 2. Leading zeroes are not necessary. System Calibration FORM 160.54-M1 (607) 4. Select COMPRESSOR Screen. 5. Manually operate the Pre-rotation Vanes by pressing the OPEN and CLOSE Keypad keys as required to achieve a motor current equivalent to 100% FLA as indicated by the clamp-on Ammeter. The motor current value on the Display should indicate 100% FLA. 6. Manually operate the Pre-rotation Vanes by pressing the OPEN and CLOSE keys as required to achieve a motor current equivalent to 105% FLA as indicated by the clamp-on Ammeter. The 105% LED on the CM-2 Module should illuminate. If the calibration verification does not perform as above, the following Calibration procedure will have to be performed: Calibration: 1. At the Keypad, log in at SERVICE access level using access code 1 3 8 0. 2. Select MOTOR Screen and set Current Limit and Pulldown Demand Limit Setpoints to 100% FLA. 3. Select COMPRESSOR Screen. 4. Run chiller and read compressor motor current in Phase A, B and C using a clamp-on Ammeter. Apply Ammeter to highest Phase. 5. Manually operate the Pre-rotation Vanes by pressing the OPEN and CLOSE Keypad keys as required to achieve a motor current equivalent to 100% FLA as indicated by the clamp-on Ammeter. The voltage across Variable Resistors (RES) should be 0.90 to 1.05VDC. Measure this voltage by connecting a Voltmeter at CM-2 Board J1-2 (+) to J1-1(-). If necessary, adjust RES to achieve this value. Figure 38 contains formulas to calculate the resistance of RES required to achieve this voltage. Adjust both resistors equally such that the combined resistance equals the calculated value. 6. Manually operate the Pre-rotation Vanes by pressing the OPEN, CLOSE and HOLD Keypad keys, as required, to achieve a motor current equivalent to 105% FLA as indicated by the clamp-on Ammeter. Loosen locking nut on Potentiometer R8 on CM-2 and adjust until the CM-2 Module 105% LED illuminates. Counterclockwise increases signal level; Clockwise decreases signal level. Tighten locking nut. 7. Manually operate the Pre-rotation Vanes by pressing the OPEN and CLOSE Keypad keys, as required, to achieve a motor current equivalent to 172 100% FLA as indicated by the clamp-on Ammeter. Loose locking nut on Potentiometer R34 on CM2 and adjust until the motor current value on the Display indicates 100% FLA. Clockwise increases the signal level; Counterclockwise decreases the signal level. Tighten locking nut. SOLID STATE STARTER APPLICATIONS When the compressor motor is driven by a YORK Solid State Starter, one of three different Starters could be applied. Later production chillers are equipped with either the Style B Liquid Cooled Solid State Starter (LCSSS) or the Medium Voltage Solid State Starter (MVSSS). Earlier production vintage chillers are equipped with the Style “A” Solid State Starter. Refer to Section 11 for details of each of these starters. Use the following procedure to select the appropriate motor drive type, then select the appropriate procedure below for the starter type selected. Motor Drive Type Selection: • Microboard 031-1730-000: Position Program Jumpers JP37 and JP39 appropriately per Section 3, Table 1. • Microboard 031-02430-000/001: 1. Chiller must be stopped and RUN switch must be in Stop-Reset position. 2. Select SETUP Screen. 3. Press CHANGE SETTINGS key. 4. A green box will appear around the first changeable setpoint. Use ▲▼ keys to place the box around MOTOR DRIVE TYPE setpoint. 5. Press √ key. A dialog box will appear with the range of settings. Use ◄ ►keys to select “SSS-Mod A”, “SSS-Mod B” or “MV SSS”, as appropriate. 6. Press ENTER (√) key. MOD “B” LIQUID COOLED SOLID STATE STARTER 1. At the Keypad, log in at SERVICE Access level using Password 1 3 8 0. 2. Select MOTOR Screen. 3. Enter the following setpoints using the procedures below: JOHNSON CONTROLS FORM 160.54-M1 (607) Full Load Amps: This is the Full Load Amps (FLA) of the chiller as listed on the Sales Order Screen. The Microboard uses the programmed value to perform Current Limit functions and display compressor motor current in terms of %FLA. 1. Press FULL LOAD AMPS key. 2. Use numeric keypad keys to enter correct value. 3. Press ENTER (✔) key. Start Current: The Logic/Trigger Board will limit compressor motor current to this value during starting. The correct value is (0.45 x Delta Locked Rotor amps), as listed on the SALES ORDER Screen. 1. Press STARTING CURRENT key. 2. Use numeric keypad keys to enter correct value. 3. Press ENTER (✔) key. Voltage Range: This is the compressor motor AC power line application. Selections are 200-208, 220-240, 380, 400, 415, 440480, 550-600 and Disabled. The Microboard uses the programmed value to determine the overvoltage and undervoltage shutdown thresholds for “LCSSS – HIGH SUPPLY LINE VOLTAGE” and “LCSSS – LOW SUPPLY LINE VOLTAGE” cycling shutdowns as described in Operation Manual 160.54-O1. If DISABLED is selected, the shutdown thresholds will be ignored. This check should not be arbitrarily disabled. 1. Press VOLTAGE RANGE key. 2. Use ◄ and ► keys to scroll to desired value. 3. Press ENTER (✔) key. Open SCR Enable/Disable: This allows the Open SCR safety check, performed by the Logic/Trigger Board, to be disabled. This must NEVER be disabled unless advised by the YORK factory. 1. Press OPEN SCR key. 2. Use ◄ and ► keys to select Enable or Disable. 3. Press ENTER (✔) key. Kilowatt Hours (KWH) Reset: This allows the KWH to be set to a desired starting value in the event the BRAM has to be field replaced. This must never be arbitrarily performed. 1. Press KWH RESET key. 2. Use numeric keypad keys to enter desired value. JOHNSON CONTROLS 3. Press ENTER (✔) key. MOD “A” LIQUID COOLED SOLID STATE STARTER The following procedures can be used to verify the calibration and perform the calibration if necessary. If the Logic Board is field replaced, field calibration is necessary. Logic Board Program Jumper JP5 (300V/600V) must be placed in the appropriate position per the compressor motor AC power line. Logic Board Program Jumper: Place Jumper J5 (300V/600V) in appropriate position per the Compressor Motor AC Power Line application as follows: 600V - Place over pins 1 & 2 for 380/400/415, 440/460/480 or 550/575/600 VAC applications. 300V - Place over pins 2 & 3 for 200/208 or 220/230/240 VAC applications. Setpoints: 1. At the Keypad, log in at SERVICE access level using access code 1 3 8 0. 2. Select MOTOR Screen. 3. Enter the following Setpoints using procedures below: Full Load Amps : This is the Full Load Amps (FLA) of the chiller as listed on the Sales Order Screen. The Microboard uses the programmed value to perform Current Limit functions and display compressor motor current in terms of % FLA. 1. Press FULL LOAD AMPS key. 2. Use numeric keypad keys to enter correct value. 3. Press ENTER (✔) key. Voltage Range: This is the AC Power line voltage applied to the Compressor Motor. Selections are: 380, 400, 415, 440-480, 550-600 and Supply Voltage Range Disabled. The Microboard uses the programmed selection to determine the overvoltage and undervoltage thresholds for Starter High Supply Line Voltage and Starter Low Supply Line Voltage. Cycling shutdowns as described in Operator Manual 160.54-O1. If Supply Voltage Range Disabled is selected, the thresholds will be ignored and these shutdowns will not occur. This check should not be arbitrarily disabled. 173 23 System Calibration FORM 160.54-M1 (607) 1. Press VOLTAGE RANGE key. 2. Use ◄ and ► keys to scroll to desired value. 3. Press ENTER (✔) key. Current Unbalance Check Enable/Disable: While the chiller is running, if the compressor Motor current in phase A, B and C becomes unbalanced, a Safety shutdown is performed. Refer to Operator Manual 160.54-O1 for complete description of this check. This Setpoint allows the check to be enabled or disabled. If enabled, the check is performed; if disabled, the check is not performed. 1. Press CURRENT UNBALANCE key. 2. Use ◄ and ► keys to select Enable or Disable. 3. Press ENTER (✔) key. Calibration Verification: At the Keypad, login at SERVICE access level using access code 1 3 8 0. 1. Compressor Motor current display accuracy a. Run chiller. b. Select COMPRESSOR Screen. c. Use the Pre-rotation Vanes HOLD keypad key to stabilize the Compressor Motor current. d. Measure phase A, B and C Compressor Motor current with a clamp-on ammeter. Compare the Ammeter values with displayed motor current values. If displayed values are not within +5% of Ammeter values, refer to Solid State Starter Service Manual 160.46-OM3.1 to troubleshoot Starter. 2. Start Current - Proper starting current is (45% x Delta locked Rotor amps). a. Select COMPRESSOR Screen. b. Start chiller and monitor Compressor Motor starting current in phase A, B and C on the COMPRESSOR Screen. Highest phase should be equivalent to (45% x Delta Locked rotor amps). 3. Overload a. Select COMPRESSOR Screen. b. Run chiller and monitor Compressor Motor current on the COMPRESSOR Screen. c. Manually operate the Pre-rotation Vanes by pressing the OPEN, CLOSE and HOLD keys, as required, until the highest phase indicates a current equivalent to 105% FLA. 174 The Display should indicate 105% and the 105% LED on the Solid State Starter Logic Board should illuminate when the 105% FLA value is reached. If the calibration verification does not perform as above, one or both of the following Calibration procedures will have to be performed: Calibration: At the Keypad, log in at SERVICE access level using access code 1 3 8 0. 1. Start Current a. Select COMPRESSOR Screen. b. Loosen locking nut on Solid State Starter Logic Board Potentiometer R38. c. Start chiller and monitor Compressor Motor starting current in Phase A, B and C on the COMPRESSOR Screen. d. While chiller is starting, adjust START CURRENT potentiometer (R38) on Solid State Starter Logic Board to achieve the proper starting current of (0.45 x Delta Locked rotor Amps) on the highest phase. Turning R38 Clockwise increases current; Counterclockwise decreases current. Multiple starts could be required to achieve the correct calibration. Tighten locking nut. 2. Overload a. Select COMPRESSOR Screen. b. Run Chiller and monitor Compressor Motor current on the COMPRESSOR Screen. c. Manually operate the Pre-rotation Vanes by pressing the OPEN, CLOSE and HOLD keypad keys, as required, until the highest phase indicates a current equivalent to 105% FLA. Adjust OVERLOAD potentiometer (R44) on Solid State Starter Logic Board until the 105% FLA LED illuminates. Clockwise increases signal level; Counterclockwise decreases signal level. Tighten locking nut. Medium Voltage Solid State Starter 1 At the Keypad, log in at SERVICE Access level using password 1 3 8 0. 2. Select MOTOR Screen. 3. Enter the following Setpoints using procedures below: JOHNSON CONTROLS FORM 160.54-M1 (607) Full Load Amps: This is the Full Load Amps (FLA) of the chiller as listed on the Sales Order Screen. The Microboard uses the programmed value to perform Current Limit functions and display compressor motor current in terms of %FLA. 1. Press FULL LOAD AMPS key. 2. Use numeric keypad keys to enter the correct value. 3. Press ENTER Key (√) Key. Start Current: The starter will limit compressor motor current to this value during starting. The correct value is (0.45 x Delta Locked Rotor Amps), as listed on the Sales Order Screen. 1. Press STARTING CURRENT key. 2. Use numeric keypad keys to enter correct value. 3. Press ENTER (√) key. COMPRESSOR MOTOR VARIABLE SPEED DRIVE APPLICATIONS Motor Drive Type: The Variable Speed Drive type applied must be set as follows. Select the procedure based on the microboard that is present. • Microboard 031-1730-000: Position Program Jumpers JP37 and JP39 appropriately per Section 3, Table 1. • Microboard 031-02430-000/001: 1. Chiller must be stopped and RUN switch must be in Stop-Reset position. 2. Select SETUP Screen. 3. Press CHANGE SETTINGS key. 4. A green box will appear around the first changeable setpoint. Use ▲▼ keys to place box around the MOTOR DRIVE TYPE setpoint. 5. Press √ key. A dialog box will appear with the range of settings. Use ◄ ►keys to select “VSD-60Hz”, “VSD-50Hz” or “MV VSD”, as appropriate. 6. Press ENTER (√) key. Motor Communications Protocol: (Software version C.OPT.01.16.xxx and later) Only displayed when Motor Drive Type setpoint above is selected as “VSD-60Hz” or “VSD-50Hz”. The Service Technician must enable the appropriate serial communications port for communications to the Variable Speed Drive (VSD). Entered as “York” to enable COM5 (J15) or “Modbus” to enable COM2 (J13). Selection required is based on the hardware and interface that is present. Refer to Section 12 (VSD) to determine which hardware/ interface is present before making selection. • YORK – Enables COM5 (J15) serial port. Used when the Microboard is interfaced to the Variable Speed Drive via the ACC Board. • MODBUS – Enables COM2 (J13) serial port. Used when the ACC Board is not present and the Microboard is interfaced directly to the Variable Speed Drive Logic Board. In order to select MODBUS, microboard 031-02430-001 is required and it must be equipped with the 128K BRAM (031-02565-000). With this microboard, Program Jumpers JP14 (BRAM size) and JP17 (COM 2 serial mode) must be configured appropriately per Section 3A Table 3. 175 When the compressor motor is driven by a YORK Variable Speed Drive, there could be a Variable Speed Drive (VSD) or a Medium Voltage Variable Speed Drive (MV VSD) applied. Early vintage VSD’s contain an Adaptive Capacity Control (ACC) Board in the Optiview cabinet that interfaces the microboard using YORK Protocol serial communications. With the later vintage VSD, the ACC functionality resides in the microboard, the ACC Board is not present and the VSD Logic Board directly interfaces the microboard directly using RS-485 Modbus Protocol serial communications. The MV VSD is also interfaced to the microboard with RS-485 Modbus serial communications. Refer to Section 12 for the different possible configurations before proceeding. 1. At the Keypad, log in at SERVICE Access level (unless otherwise noted) using password 1 3 8 0. 2. Enter the following Setpoints using procedures below: 23 JOHNSON CONTROLS System Calibration FORM 160.54-M1 (607) 1. Chiller must be stopped and RUN switch must be in Stop-Reset position. 2. Select SETUP Screen. 3. Press CHANGE SETTINGS key. 4. A green box will appear around the first changeable setpoint. Use ▲▼ keys to place box around the MOTOR COMMUNICATIONS PROTOCOL setpoint. 5. Press √ key. A dialog box will appear with the range of settings. Use ◄ ►keys to select “YORK” or “MODBUS”, as appropriate. 6. Press ENTER (√) key. Motor Node ID: (Software version C.OPT.01.16.xxx and later) Only displayed when “Modbus” is selected for the Motor Communications Protocol setpoint above. The Motor Node ID must be set to match the setting of the VSD Logic Board Modbus Address Switch SW3. The address assigned to the VSD Logic Board is “1”. This is done by placing the VSD Logic Board Modbus Address Switch SW3 position 1 to ON and setting this setpoint to “1”. 1. Chiller must be stopped and RUN switch must be in Stop-Reset position. 2. Select SETUP Screen. 3. Press CHANGE SETTINGS key. 4. A green box will appear around the first changeable setpoint. Use ▲▼ keys to place box around the MOTOR NODE ID setpoint. 5. Press √ key. A dialog box will appear with the range of settings. Use numeric keys to set this value to “1”. 6. Press ENTER (√) key. Full Load Amps (VSD): This is the Full Load Amps (FLA) of the chiller as listed on the Sales Order Screen. The Microboard uses the programmed value to perform Current Limit functions and display compressor motor current in terms of %FLA. 1. Place Compressor Start/Stop Switch in the StopReset (O) position. 2. Select VSD DETAILS Screen from the MOTOR Screen. 176 3. Inside the VSD, locate the small trim pot on the VSD Logic Board; (R34) on Logic Board 03102506; (R28) on all other Logic Boards. 4. While monitoring the VSD Full Load Amps 000.0 A message on the VSD DETAILS Screen, adjust this trimpot until the correct Full Load Amps value is displayed. Clockwise will increase the value. Full Load Amps: (MV VSD) This is the Full Load Amps (FLA) of the chiller as listed on the Sales Order Screen. The Microboard uses the programmed value to perform Current Limit functions and display compressor motor current in terms of %FLA. 1. Select MOTOR Screen 2. Press FULL LOAD AMPS Key. 3. Use NUMERIC Keypad keys to enter the correct value. 4. Press ENTER (√) key. Pre-rotation Vanes Position Potentiometer: Refer to the Pre-rotation Vanes Calibration procedure in this section. Adaptive Capacity Control: 1. Select ACC DETAILS Screen 2. The following keys are available: a. Surge Map Clear – Clears all previously established surge points that are stored in memory. When this key is pressed, a dialog box appears requesting the special ACC Map Clear Password. Enter 0 3 6 8 and press the ENTER (√) Key. A message is displayed advising the clearing is in progress. If ACC Board is present, press switch SW1 (for at least 1 second) on the ACC Board within 15 seconds of pressing the ENTER key. Another message is displayed when the clearing has completed. IMPORTANT! – This should not be performed unless advised by YORK factory Service. b. Surge Map Print – Prints the entire array of stored surge points to a printer connected to COM1 serial port. JOHNSON CONTROLS FORM 160.54-M1 (607) c. Auto Map Print – Prints new surge points, as they are established, to a printer connected to COM1 serial port. d. Manual Surge Point – Captures the instantaneous operating conditions and stores them as a surge point. If ACC Board is present, press switch SW1 (for at least 1 second) on the ACC Board within 15 seconds of pressing this key. e. Surge Margin Adjust – Refer to Service manual 160.00-M4. f. Surge Sensitivity – Refer to VSD Service Manual 160.00-M4. Kilowatt Hours: 1. 2. 3. 4. 5. At the Keypad, log in at ADMIN access level. Select MOTOR Screen. Press KWH RESET key. Use numeric keypad keys to enter desired value. Press ENTER (✔) key. Each press of this key increases the frequency by the programmed Amount (0.1 to 10.0 Hz) e. Lower – Places frequency Control in Manual Mode. Decreases the VSD frequency by 0.1 to 10.0 Hz, as programmed with the INCR AMT (increment amount) key. Each press of this key decreases the frequency the programmed amount (0.1 to 10.0 Hz). f. Incr Amt - Programmable Setpoint (0.1 to 10.0 Hz) that determines the amount of increase or decrease in VSD frequency that occurs with each press of the INC or DEC key in Manual frequency control mode. PROXIMITY PROBE Frequency Control: The VSD Frequency can be manually controlled as follows: 1. Select VSD TUNING Screen from the COMPRESSOR Screen. 2. On the VSD Tuning Screen, press the appropriate key as follows: a. Set – Places Frequency Control in Manual Mode. Sets the VSD speed at a specific frequency between 1.0 and 60 (50) Hz. b. Auto – Places the VSD in automatic frequency control. The frequency is determined by the ACC Board to achieve slowest speed possible while avoiding surge. c. Fixed – Sets the VSD frequency at maximum: 60 (50) Hz. d. Raise – Places Frequency Control in Manual Mode. Increases the VSD frequency by 0.1 to 10.0 Hz, as programmed with the INCR AMT (increment amount) key. The following applies to all applications except “P” compressors and Style F and later chillers equipped with “G, Q” or “H5-8” compressors: When the Probe is installed at the time of manufacture or after the compressor is rebuilt in the field, a Reference Position is established. This remains the Reference Position until the Compressor is rebuilt. It is the distance (in mils) between the tip of the Probe and the surface of the High Speed Thrust Collar with a minimum of 25 PSID oil pressure. Any distance between 37 and 79 mils is acceptable. This Reference Position is written on a label that is adhered to the inside of the OptiView Control Center door. It is also stored in the BRAM memory device on the Microboard; if the BRAM is replaced, the original Reference Position value must be programmed using the procedure below. A complete description of the Proximity Probe and the Reference Position is contained in the “Proximity Probe” section of this book. In the procedures below, the Reference Position can be established through a calibration procedure or a previously established Reference Position can be entered, without performing the calibration procedure. Anytime the chiller shuts down on a Thrust Bearing Safety shutdown, there is the potential that Compressor damage has occurred. Therefore, the shutdown must be evaluated by a qualified Service Technician prior to 23 JOHNSON CONTROLS 177 System Calibration FORM 160.54-M1 (607) restarting the chiller. Depending upon the actual shutdown message, the evaluation could require a bearing inspection. To prevent the chiller from restarting without the proper evaluation, restart is inhibited until a special reset procedure is performed. This procedure is listed below and must not be performed by anyone other than a qualified Service Technician. Calibration: Perform this procedure at the time of manufacture or if the compressor is rebuilt in the field. 1. At the Keypad, login at SERVICE access level using access code 1 3 8 0. 2. Place Compressor Start/Stop Switch in the StopReset (O) position. 3. Select PROXIMITY PROBE CALIBRATE Screen from COMPRESSOR Screen. 4. On PROXIMITY PROBE CALIBRATE Screen, press START CALIB key to initiate the calibration. The CALIBRATION IN PROGRESS LED will illuminate and the oil pump will start automatically. The oil pressure is displayed on the Screen. If the CANCEL CALIB key is pressed during the procedure, the oil pump is turned off and the calibration is terminated. 5. When the oil pressure has reached 25 PSID, the Program reads the proximity gap and the START CALIB key label changes to ACCEPT CALIB. 6. Press the ACCEPT CALIB key. The measured gap is entered as the Reference Position. Log this value on the Label adhered to the inside of the OptiView Control Center door. This remains the Reference Position until the Compressor is rebuilt. Reference Position Entry: Perform this procedure if the Reference Position had been previously established, but lost from memory due to replacement of the BRAM (U52) or other event. 1. At the Keypad, login at SERVICE access level using access code 1 3 8 0. 2. Place the Compressor Start/Stop Switch in the Stop-Reset (O) position. 3. Select PROXIMITY PROBE CALIBRATE Screen from COMPRESSOR Screen. 4. On PROXIMITY PROBE CALIBRATE Screen, press the ENTER REFERENCE key. 5. Locate previously established Reference Position that has been logged on label adhered to inside of OptiView Control Center door. Using numeric keypad keys, enter this value. Only values between 37 and 79 mils will be accepted. 6. Press ENTER (✔) key. Safety Shutdown Reset/Inspection Procedure: As explained above, to prevent possible compressor damage, the chiller should not be restarted after a Thrust Bearing safety shutdown until the shutdown has been evaluated. Therefore, to prevent the chiller from being restarted by anyone other than a qualified Service Technician, the chiller cannot be restarted until the special reset procedure below is performed. The evaluation that has to be performed after each shutdown depends on the actual message displayed and the circumstances of the shutdown (refer to HISTORY Screen) as follows: a. THRUST BEARING - PROXIMITY PROBE CLEARANCE - If the shutdown was caused by the gap increasing to > +10 mils from the Reference Position, perform a Bearing inspection. If there is damage, repair compressor. Otherwise, perform reset procedure below and restart chiller. If shutdown was caused by gap decreasing to > 25 mils from the Reference Position, perform the reset procedure below and restart the chiller. b. THRUST BEARING - PROXIMITY PROBE OUT OF RANGE - Perform reset procedure below and restart chiller. c. THRUST BEARING - HIGH OIL TEMPERATURE (Not applicable to chillers equipped with Program version C.MLM.01.03 or higher) - If there have been two consecutive shutdowns, perform a Bearing inspection. Otherwise, perform reset procedure below and restart chiller. d. THRUST BEARING - OIL TEMPERATURE SENSOR (Not applicable to chillers equipped with Program version C.MLM.01.03 or higher) - Perform reset procedure below and restart chiller. Reset Procedure: In order for the following procedure to be successful, the Proximity clearance must be between +10 and –25 mils of the Reference Position and the High Speed Drain Temperature must be >50.0°F and < 179°F. 178 JOHNSON CONTROLS The DEFAULT value is shown in parenthesis. as detailed below. version C. These setpoints are listed below. At the Keypad. 2. Select SETPOINTS Screen.MLM. Select COMPRESSOR Screen.MLM. Select the appropriate procedure per the installed software as follows: Software version C. To prevent the chiller from restarting without the proper bearing evaluation. At the Keypad.OPT. 3. select PROXIMITY PROBE CALIBRATE Screen from COMPRESSOR Screen. Proportion Limit Close . 2. Press ENTER (✔) key.06.10% to 50% (15%) d. Level control operation must be “Enabled”.FORM 160. Use ◄ and ► keys to select Enable or Disable.04.MLM. the Program control must be ENABLED and the Setpoints programmed using the procedure below. 4.01. From SETPOINTS Screen select SETUP Screen. Press FAULT ACKNOWLEDGE key. login at SERVICE access level using access code 1 3 8 0.10% to 50% (45%) The following is only applicable to chillers equipped with “P” compressors and style F and later chillers with “G. JOHNSON CONTROLS 23 179 .20% to 80% (50%) b. it must be “Disabled”. 3.MLM. The refrigerant Level Sensor. If the chiller is equipped with this feature. press FAULT ACKNOWLEDGE Key.5 seconds all other compressors) c. Enable/Disable: If the chiller is equipped with the Refrigerant Level Control. Q” or “H5-8” compressors: Anytime the chiller shuts down on a High Speed Thrust Bearing safety shutdown. 3.xxx (and earlier) or C.01.11. 4. using access code 1 3 8 0.0 to 5. ENTER PASSWORD TO CLEAR FAULT is displayed in a dialog box. log in at SERVICE access level. restart is inhibited until a special reset procedure is performed. After Coastdown is complete. 3. there is the potential that compressor damage has occurred. REFRIGERANT LEVEL CONTROL A complete description of the Condenser refrigerant level control and the Setpoints that affect this control are provided in the “Refrigerant Level Control” section of this book. 3. Therefore.0 seconds “P” compressors.xxx and later and “P” compressors with C.5 to 30 seconds (Flash Memory Card version C.02. displaying the message “THRUST BEARING .xxx and earlier (3. If the Limit Switch is closed. However. The Program uses these setpoints to control the refrigerant to the desired level.xxx).01. 4. The Default value varies depending upon the Flash Memory Card version and compressor application: versions C.1. Enter 1 3 9 7 and press the ENTER (✔) key. HIGH SPEED THRUST BEARING LIMIT SWITCH The refrigerant level can be manually controlled through manual control of the Variable Orifice using the procedure below.01. Level Setpoint . From SETUP Screen select OPERATIONS Screen.5 seconds). login at SERVICE access level using access code 1 3 8 0. this clears the fault and allows the chiller to be started.06. 5. At the Keypad. Place the Keypad Rocker Switch in the Stop-Reset (O) position.07.LIMIT SWITCH OPEN”.xxx (and earlier) a. “Enter Password to Clear Fault” is displayed in a dialog box. The DEFAULT value is the recommended value and should provide proper operation in most applications. 2.01. Enter 1 3 9 7 and press the ENTER (✔) key.xxx and later (10. After Coastdown is complete.54-M1 (607) 1. There are two different setpoint sets used depending upon the software vintage. Proportion Limit Open . Place the COMPRESSOR Switch in the Stop-reset position.0 seconds. Level Control Period .11. 1. a bearing inspection must be performed by a qualified Service Technician prior to restarting the chiller. The procedure below is used to perform this calibration. the Setpoint can be programmed to other values to compensate for local operating conditions. Otherwise. Setpoints: The following are the Setpoints and range of programmable values. 5. must be properly calibrated to accurately detect the refrigerant level in the Condenser.MLM. located in the Condenser. This clears the fault and allows the chiller to be started. Use following procedure: 1. MLM. 100% when the level is at maximum (Refrigerant Level Sensor completely covered). 5. 3. xxx). A green box appears around the first changeable setpoint. 180 . Valve Preset Time – 0 to 100 seconds (50 seconds) (Flash memory Card version C. However. Select the Refrigerant Level Control Screen from the Condenser Screen.◄. “MAX”. log in at SERVICE access level using access code 1 3 8 0. At the Keypad. Others are equipped with calibration pushbuttons labeled “F/UP”. Some sensors are equipped with adjustable potentiometers labeled “S”(span) and “Z”(zero).MLM.MLM.Rate Limit Open .Rate Limit Close .xxx and later) h. The calibration can be verified or performed per the procedure below.▼. Press the appropriate key to select the setpoint to be programmed.xxx and later or C. press the SET ZONES key. Ramp-up Time – 3 to 15 minutes (8 minutes) (Flash Memory Card version C. The REFRIGERANT LEVEL CONTROL Screen is used to manually control the Orifice and the refrigerant level is displayed there. login at SERVICE access level using access code 1 3 8 0. Level Sensor Calibration: The refrigerant level in the condenser is displayed on the CONDENSER Screen and REFRIGERANT LEVEL CONTROL Screen. Press ENTER (✔) key. and “MIN”. A dialog box will appear with the range of settings) 4. Select REFRIGERANT LEVEL CONTROL Screen from the CONDENSER Screen.07.xxx (and later) or C. select the setpoint to be programmed or press the SETPOINTS key for more setpoints 4.14. Remove the cover plate on the Refrigerant Level Sensor to expose the printed circuit board. 5% to 50% (10%) (Flash Memory Card version C. At the Keypad. Using the numeric keypad keys. press the OPEN. Use the ▲. 2. 1.14.54-M1 (607) e.System Calibration FORM 160.306(and later) Zone 1 3% to 15% default 7 8 to 22 default 15 Zone 2 3% to 15% default 5 2. Press ENTER (√) key.04.► keys to place the green box around the desired setpoint to be changed. There are two different versions of the Refrigerant Level Sensors.01. 3.01.5 2.MLM. (If selecting Period or Rate setpoint. xxx) g.04. enter the desired value. log in at SERVICE access Level using access code 1 3 8 0. It should be 0% when the level is at minimum (Refrigerant Level Sensor uncovered).02. 2.+0% Rate Error Deadband – +0% 1. On the REFRIGERANT LEVEL CONTROL Screen.02. Software version C. “E/DN”.10% to 50% (10%) 5% to 50% (10%) (Flash Memory Card version C. CLOSE or HOLD key as required to control the Variable Orifice to achieve the desired refrigerant level.06. Using the numeric keypad keys.01. Press ENTER (√) key.01.OPT.10% to 50% (10%).xxx and later or C. the difference is in the calibration adjustments. f.07. On the REFRIGERANT LEVEL CONTROL Screen.06. At the Keypad.MLM.01. If it is the sensor type JOHNSON CONTROLS Rate Limit Period (seconds) Zone 1 & Zone 2 Level Setpoint 20% to 80% default 30 Valve Preset Time (setpoint) (seconds) 0 to 100 default 50 Ramp Up Time (setpoint) (minutes) 3 to 15 default 8 Proportion Error Deadband . 5. 3.MLM.01.MLM.xxx and later) 1. enter desired value. Pressing the AUTO key invokes automatic operation. The operation of both the sensors is the same. Manual Control: The Variable Orifice can be manually controlled as follows: 1. Locate the calibration adjustments. Select REFRIGERANT LEVEL CONTROL Screen from the CONDENSER Screen.5 to 10 default 2. 5. If equipped with calibration pushbuttons. manually control the orifice from the REFRIGERANT LEVEL CONTROL Screen using the Open. the Oil Pump Speed can be manually controlled using the procedure below.0Vdc at the output of the Probe. the oil pump is driven by a small Variable Speed Drive.43Vdc at the output of the Probe. Manually open the Variable Orifice to the full open position using the keys on the REFRIGERANT LEVEL CONTROL Screen. This will cause the condenser refrigerant level to be at minimum. hold both the “MIN” and “MAX” buttons in and push the “E/DN” button once and hold it for at least 1 second. Close and Hold keys to place the refrigerant level above the site glass. In the following procedure the Probe output is measured with a DC Voltmeter connected to the Probe output as follows: Potentiometer type – terminal 3 (Signal) or Microboard J8-13 terminal 2 (Gnd) or Microboard J8-3 Pushbutton type – terminal “OUT” (Signal) or Microboard J8-13 terminal “V-” (Gnd) or Microboard J8-3 2. Also. the Setpoints can be programmed to other values as required. place the Program Jumper in the “11-18V” position. The procedure varies according to the microboard installed as follows: Microboard 031-01730-000 Program Switch SW1-2 ON – Enabled OFF .43vdc.20 to 45 PSID (35) b. At the keypad. With the level at minimum. hold both the “MIN” and “MAX” buttons in and push the “F/UP” button once and hold it for at least 1 second. b. The output of the Probe will go to 0. Replace Level Sensor cover plate. The Program Variable Speed Drive operation must be ENABLED and the Setpoints programmed using the procedures below. The DEFAULT values (shown in parenthesis) are the recommended values and should provide proper operation in most applications. set the 100% point as follows: a. Shutdown the chiller.0vdc to 0. Start the chiller.54-M1 (607) that is equipped with calibration pushbuttons. With the level at maximum.FORM 160. Enter Setpoints using procedure below: a.0Vdc. 4. If equipped with calibration pushbuttons. Follow procedure later in this section under “Microboard 031-02430-000/-001 Setup/Configuration” Setpoints: The following are the Setpoints and range of programmable values. However. This places the refrigerant level at maximum. Enable/Disable: The Oil Pump Variable Speed Drive Program operation must be enabled.Disabled Microboard 031-02430-000/001 Entered as setpoint on SETUP Screen. If equipped with calibration potentiometers. adjust the “S” calibration screw to achieve 5. b. Control Period – 0. login at SERVICE access level using access code 1 3 8 0. On the REFRIGERANT LEVEL CONTROL Screen.3 second increments. (0. 7. seal with a small amount of sealant to secure the screws. With the chiller running. 6. OIL PUMP VARIABLE SPEED DRIVE On certain model chillers.3 to 2. set the 0% point as follows: a. The Setpoints are listed below.3) 23 JOHNSON CONTROLS 181 . adjust the “Z” calibration screw to achieve 0.7 seconds in 0. A complete description of the Drive operation and the Setpoints that affect this control are provided in the “Oil Pump Variable Speed Drive” section of this book. If equipped with calibration potentiometers.0Vdc to 0. select AUTO level control operation. 3. If equipped with calibration potentiometer screws. Oil Pressure Setpoint . The output of the Probe will go to 5. STANDBY LUBE IN PROCESS. 4. At the keypad. If the Dialog box begins with the word “Enter”. While the Oil Pump is running. the frequency is changed 0. This assures that the oil pump will not be turned on with the shells at atmospheric pressure. LOP < 0 PSIG). at which point another lube cycle will be attempted or b.5 PSIG. log in at SERVICE access Level using access code 1 3 8 0. On the OIL SUMP Screen. Select OIL SUMP Screen. press the appropriate key to select the Setpoint to be programmed. If it begins with “Select”.LOW OIL PRESSURE is displayed and no more standby 182 The condenser pressure at which a High Pressure warning message is displayed and the Pre-rotation Vanes are inhibited from further opening. To Enable or Disable the Standby lubrication cycles. Using numeric keypad keys. 2. HIGH CONDENSER PRESSURE WARNING THRESHOLD To maintain oil seal integrity while the chiller is shutdown. Press SET key. Select OIL SUMP Screen. 2.5 Hz. 2. 4.8 PSIG.) the FAULT ACKNOWLEDGE keypad key is pressed after login at SERVICE access level. enter desired value. Manual Control: The Oil Pump speed can be manually controlled between 25 and 60(50) Hz as follows: 1. use the ◄ and ► keys to select desired value. At the Keypad.54-M1 (607) 1.5 PSIG (R134a). STANDBY LUBRICATION lubrications will occur until a. 3. use the numeric keypad keys to enter the desired value.3 PSIG) for R22 JOHNSON CONTROLS . is programmable over the range of 44. a feature can be enabled that turns on the Oil Pump for 2 minutes every 24 hours if the chiller has not been run in the past 24 hours. Press ENTER (✔) key.System Calibration FORM 160. The speed can be increased and decreased in 0.5 Hz increments using the RAISE and LOWER keys. If the AUTO key is pressed. If the chiller is style “D” equipped with an Oil Pump Variable Speed Drive. When logged in at SERVICE access level. 5. Select CONDENSER Screen. Press ENTER (✔) key. 3. the time remaining until the next Standby lubrication cycle is displayed as NEXT OIL SEAL LUBRICATION = XX HRS on the OIL SUMP Screen. Use the numeric keys to enter the desired value.0 to 54. The Default value for R134a is 162. At the Keypad.0 to 246. Standby lubrication cycles will not be performed if either oil pressure transducer is reading a pressure out of its range (HOP < 6. At the Keypad. 2. If at least 15 PSID of oil pressure is not achieved within 30 seconds of turning on the Oil Pump. the cycle is terminated and WARNING . as they would be during maintenance. On the Condenser Screen. along with a countdown timer displaying the time remaining in the lube cycle is displayed. Press ENTER (✔) key. the Low Evaporator Pressure safety shutdown threshold is programmable over the range of 25.3 PSIG (Default 54. 4. 3. OR The speed can be set to a specific frequency. 2. Each time the key is pressed.) the chiller is started. Proceed as follows to enter this value: 1. Press ENTER (✔) key. log in at SERVICE access level using access code 1 3 8 0. 3. proceed as follows: 1. Use ◄ and ► keys to select Enable or Disable. or 84. The Default for R22 is 246. as programmed by the SET key as follows: 1. automatic speed control is invoked.STANDBY LUBE . BRINE LOW EVAPORATOR PRESSURE CUTOUT On Brine cooling applications. 5.3 PSIG. The Warning message will clear and the PRV inhibit is removed when the pressure decreases to 5 PSIG below the programmed value. press HIGH PRESSURE WARNING THRESHOLD key. Select OIL SUMP Screen. log in at SERVICE access level using access code 1 3 8 0.3 PSIG (R22).9 to 162. 4. 3. log in at SERVICE access level using access code 1 3 8 0. the operating oil pressure will be the programmed Oil Pressure Setpoint. 5. 2. The threshold is logged on an adhesive label attached to the inside of the OptiView Control Center door. Press DROP LEG key. DROP LEG REFRIGERANT TEMPERATURE This Setpoint adjusts the Leaving Chilled Liquid Temperature control sensitivity.06.04.xxx and later or C.9 seconds at 0% position. This selection available with Flash Memory Card ver sion C. LEAVING CHILLED LIQUID TEMPERATURE CONTROL SENSITIVITY the 50% selection. 50% . This provides less overall PRV movement than The chiller can be equipped with a refrigerant temperature sensor in the drop leg between the condenser and evaporator. Press SENSITIVITY key. Longest allowed pulse is 18 seconds in duration. 4.MLM. If “Enabled” with the procedure below. 3. The actual percentage of Brine solution determines this threshold. 23 JOHNSON CONTROLS 183 . Press ENTER (✔) key. It determines the magnitude of Pre-rotation Vanes (PRV) response to correct the error between the Leaving Chilled Liquid Temperature Setpoint and the actual liquid temperature leaving the chiller. 5. Proceed as follows to select this value: 1. Select CONDENSER Screen. log in at SERVICE access level using access code 1 3 8 0. PRV positions in between have linearly scaled maximums.0 PSIG) for R134a Refrigerant. The longest allowed open or close pulse is limited to 30% of the maximum allowed with the NORMAL selection. Using numeric keypad keys. this temperature is displayed on the CONDENSER Screen as the “Drop Leg Temperature”. but that require greater stability.0 to 25. 5. 2. At the Keypad.5 seconds at the 25% PRV position and 0. There are three selections as follows: Normal .Provides standard control operation. Use ◄ and ► keys to select Enable or Disable.02.Provides less sensitivity than the 50% selection. Select EVAPORATOR Screen.54-M1 (607) Refrigerant and 6.FORM 160. the Pre-rotation Vane (PRV) movement is reduced further than described above when the chiller is operating at low load. 2. This selection will reduce PRV instability in short chilled liquid loops. 4. 30% . When the PRV position is < 25% and the Leaving Chilled Liquid Temperature is within + 2. Use ◄ and ► keys to select desired value.Provides less sensitivity than the NORMAL selection. Flash Memory Card version C. Press ENTER (✔) key. The longest allowed open or close pulse is limited to 50% of the maximum allowed with the NORMAL selection. parallel chiller configurations and other applications that cause PRV instability.02. the threshold will have to be programmed in the field. If the BRAM memory device on the Microboard is replaced.01. If the chiller is equipped with the Drop Leg Refrigerant Temperature sensor.xxx and later or C. multi-pass chillers . Select EVAPORATOR Screen. On the EVAPORATOR Screen.xxx have special variable speed low load operation as follows: If the chiller is equipped with the YORK compressor motor Variable Speed Drive and the 50% or 30% Sensitivity is selected. also displayed on the Condenser Screen. It is calculated at the YORK Factory and programmed at the time of manufacture. log in at SERVICE access Level using access code 1 3 8 0. It is subtracted from the Condenser Saturation Temperature to produce “Sub Cooling Temperature”. Press ENTER (✔) key. the values are displayed on the CONDENSER Screen only if enabled with the following procedure.xxx). 3. 3. At the Keypad. press the BRINE LOW EVAPORATOR CUTOUT key. It’s beneficial in the same applications as the 50% selection.01.06.MLM. This selection will provide proper operation in most applications.0 PSIG (Default 25. At the Keypad. Proceed as follows to enter this value: 1. the maximum allowed vane pulse is limited to 3. This provides less overall PRV movement than the NORMAL selection. enter desired value.MLM.MLM. log in at SERVICE access level using access code 1 3 8 0.5 ºF of Setpoint. 4.04. PRV open and close pulses are standard durations for any given error. 1. Manual Control: The Hot Gas Valve can be manually controlled as follows: 1. using password 1 3 8 0. Press ENTER (✔) key. EVAPORATOR REFRIGERANT TEMPERATURE Surge Count can be cleared. enter the desired value. 3. 4. Press SMART FREEZE key. 2. as explained in the “Smart Freeze Protection” section of this book. The DEFAULT value is shown in parentheses. The Hot Gas valve can be manually controlled using the procedure below. operation must be “enabled”. select OPERATIONS Screen. it must be “Disabled”. However. At the keypad. and is also used in the Smart Freeze Protection Low Evaporator Pressure Safety Shutdown threshold calculation. Press ENTER (✔) key. If the chiller is equipped with an Evaporator Refrigerant Temperature sensor. Select HOT GAS BYPASS Screen from the COMPRESSOR Screen. log in at SERVICE access level. 3. Select the appropriate procedure per the installed software as follows: 1. Enable/Disable: If the chiller is equipped with the optional Hot Gas Bypass control. When turned on. The Default value is the recommended value and should provide proper operation in most applications. Otherwise. If the chiller is equipped with this feature. it must be Disabled. If enabled. Otherwise. 4. At the Keypad. Use ◄ and ► keys to select Enable or Disable. Use ◄ and ► keys to select Enabled or Disabled. 5. Shutdown chiller and place COMPRESSOR Start/ stop Switch in the Stop-Reset (O) position. Press ENTER (✔) key. From SETPOINTS Screen. 2. If not equipped with this sensor. log in at SERVICE access level using access code 1 3 8 0. this temperature is displayed on the EVAPORATOR Screen. JOHNSON CONTROLS A complete description of the optional Hot Gas Bypass Control and the Setpoints that affect this control are provided in the “Hot Gas Bypass” section of this book. At the Keypad. 5. 4. log in at SERVICE access level using access code 1 3 8 0. Use ◄ and ► keys to select ON or OFF. 6. it must be “disabled”. 3. this should NOT be arbitrarily performed! Since the Pre-Rotation Vanes (PRV) position is used in the Hot Gas control. log in at SERVICE access level using password 1 3 8 0. Select EVAPORATOR Screen.54-M1 (607) SMART FREEZE PROTECTION This feature is described in the “Smart Freeze Protection” section of this book. The total lifetime 184 . Press ENTER (✔) key. 5. The Smart Freeze Protection feature can be turned ON or OFF using the following procedure: 1. 5. HOT GAS BYPASS CONTROL Setpoints: The following are the Setpoints and range of programmable values. it must be “Enabled” and the setpoints programmed using the procedure below. Select EVAPORATOR Screen. it allows the Leaving Chilled Liquid Temperature Setpoint to be as low as 36ºF for water cooling applications. Select HOT GAS BYPASS Screen from the COMPRESSOR Screen. select SETUP Screen. the PRV position feedback potentiometer must be calibrated with the procedure below. Press REFRIGERANT key. the feature must be Enabled with the procedure below. 2.System Calibration FORM 160. 2. Use the following procedure to Enable or Disable this feature: 1. From SETUP Screen. Use the following procedure: 1. 4. press the appropriate key to select the Setpoint to be programmed. 3. the Setpoint can be programmed to other values to compensate for local operating conditions. Using the numeric Keypad keys. Select SETPOINTS Screen. On the HOT GAS BYPASS Screen. Shutdown the chiller and wait for completion of COASTDOWN. However. login at SERVICE access level using password 1 3 8 0. The Setpoints are listed below. There are two different setpoint sets used depending upon the software vintage. Along with this feature is a correspondingly lower Low Water Temperature Cycling Shutdown threshold and Low Evaporator Pressure Safety Shutdown threshold. At the Keypad. 2. At the Keypad. Use the ▲ and ▼ keys to scroll sequentially through numbers.05. log in at SERVICE access level. xxx and later) Two service phone numbers (Regional and Local). the valve position will be increased or decreased 5%. press the OPEN or CLOSE keys as desired. 4. SURGE PROTECTION The Number of Starts and the Operating Hours can be reset to zero or preset to a desired number. At the keypad. The numeric keypad keys can also be used to enter numbers. Use the following procedure: 1. Using numeric keypad keys. Up to 40 characters/numbers can be entered for each field. The Default value for the Regional number is the “North American Toll Free Number” (1-800-861-1001). Select OPERATIONS Screen. Use the ◄ and ► keys to position the red box over the number character to be changed or entered. Default value is 1-800-861-1001. press ENTER (✔) key. can be displayed on the OPERATIONS Screen. Default value is blank. The Default value for the Local label and number is blank. use the ◄ and ► keys to move the red box to the next value to be changed.05. Field 4 – Local service phone number. However. alphabet characters and punctuation marks to select the desired value. On the HOT GAS BYPASS Screen. 2. The Service Technician enters the Local phone number and label. 6. Pressing the AUTO key invokes automatic operation. Press EDIT PHONE NUMBERS Key. vertically from the top. the Surge Sensitivity setpoint and Total Surge Count clearing require Service access level or higher. Continue this process until all desired values have been entered. However. this should never be arbitrarily performed. At the keypad. CHILLER STARTS AND OPERATING HOURS RESET Field 2 – Regional phone number. In the Dialog box that appears. Use ▲ and ▼ keys to move green selection box to the desired field to be changed. Default value is “York Intl North American Toll Free Number” JOHNSON CONTROLS (Applies to Flash Memory Card version C.01. Press NUMBER of STARTS or OPERATING HOURS key as appropriate. with labels.MLM. Select OPERATIONS screen. Field 1 – Regional phone number label. Field 3 – Local service phone number label. The entry format consists of 4 fields (rows). the label and number can be changed to any desired value. This password changes daily. Each time the key is pressed. Press the ENTER (✔) key. Although most setpoints are entered with Operator access level. Use the following procedure to change any of the fields: 1. 185 23 .MLM. At the Keypad. Select SURGE PROTECTION Screen from COMPRESSOR Screen. 5. login at ADMIN access level. SERVICE PHONE NUMBERS (Applies to Flash Memory Card version C. Press ENTER key (✔) key. 3. 4. 2. enter desired number. 5. using 1 3 8 0. a red box appears over the first changeable value. 7.54-M1 (607) 3. Pre-rotation Vanes Position Potentiometer Calibration: Refer to the Pre-rotation Vanes Calibration procedure in this section. Default value is blank. Contact your local YORK Service Office. When the desired value displayed.01. 2.FORM 160. xxx and later) A complete description of the Surge Protection feature and setpoints that affect this control are provided in the “Surge Protection” section of this book. 3. login at SERVICE access level using access code 1 3 8 0. Surge Sensitivity: 1. After all desired values have been entered in previous step. From the SETPOINTS Screen.Service Technician must use password 1 3 8 0 to enter the Commissioning Date and modify Job Name and Job Location if necessary.3. NAMEPLATE. Using numeric and decimal point keypad keys. If the BRAM battery-backed memory device fails and requires field replacement. 1.01. • Modifying Sales Order Data .3 to 1. 3. Press SURGE SENSITIVITY key. Use the ▲ and ▼ keys to move the green selection box to the desired value to be changed. At the keypad. the Service Technician must use password 0 2 2 8 to enter all Sales Order Data into a new blank BRAM.01 and later. When logged in at this level. DESIGN. SALES ORDER DATA All of the Sales Order Data. Job Name or Location and proceed to step 4. first determine if the BRAM can be transferred before making the transfer. this data can be modified. to change the Sales Order Data as follows: 186 When using this password to enter data into a new blank BRAM. JOHNSON CONTROLS .System Calibration FORM 160. • Chiller Commissioning . 2. select SALES ORDER Screen. Press CHANGE key. etc. log in at ADMIN access level. This password only works with a blank BRAM and is only applicable to chillers equipped with Flash Memory Card Version C. When replacing a microboard. 5.MLM. in the field.2. Use the following procedure to enter data: 1. Programmable over range of 0. 1. The Service Technician must enter the Chiller Commissioning Date and modify the Job Name or Job Location if necessary at the completion of commissioning. Normally. 0. the ability to enter more data will be terminated. SYSTEM) to be entered. press SET ORDER INFO key to enter Commissioning date. Clear Surge Count: This should not be arbitrarily performed.3. depending on the circumstances. it might be desirable to transfer the BRAM from the defective board to the replacement board to save stored Sales Order data. Contact your local YORK Service Office. if there is a change to the chiller design. select SETUP SCREEN. log in at the appropriate Access Level to change the desired values. Default value is 0.If the BRAM is field replaced. At the keypad. Select SURGE PROTECTION Screen from COMPRESSOR Screen. enter desired value. If logged in at SERVICE Access level. • BRAM Replacement . The first changeable area in the selected category will be outlined in a green selection box. There are three different Passwords used. Press ENTER (✔) key.54-M1 (607) 3. 4. Since not all BRAM devices are compatible with all microboards. the FINISH PANEL SETUP procedure (listed at the end of the entry procedure below) must be performed after all data has been entered. From the SETUP Screen. 3. 2.3. all of the data will be lost and will have to be manually programmed. Failure to perform this procedure will result in unreliable OptiView Control Center operation! If this procedure is performed prior to entering all data.) 5. within the category selected. the ACCESS LEVEL shown will be TEST OP. the remainder of the Sales Order Data should never be modified. Press SELECT key to select the data category (ORDER. Refer to the Microboard Service Replacement section of SECTION 3A of this manual. 4. Obtain ADMIN password from local service office. 6. This password changes daily. Use leading zeroes where necessary and place decimal point between first and second digit (ie. This password changes daily. The procedure can be terminated anytime after this by pressing the CANCEL (X) key. Press CLEAR SURGE COUNT key. Press ENTER (✔) key. However. If logged in at ADMIN or TEST OP level.Service Technician must use the ADMIN password. except the “Chiller Commissioning Date” is entered at the YORK Factory at the time of chiller manufacture. However. the user is requested to enter a User ID. Use the ◄ . Use the • key to enter a decimal point. 8. 3. Setpoint Category and new Setpoint value are listed and numbered in reverse order in which they were changed. Each user can be assigned a Password of 0 to 9999 and an access level of VIEW. Press ENTER (✔) key. Enter the appropriate data. c. The comma. If the following procedure is performed prior to entering all of the data. At the Keypad.04. If it is desired to view the details of a particular Setpoint change. The most recent is listed as number 1. select SETUP Screen. OPERATOR. No log in is required for VIEW access level. On SALES ORDER screen. The SECURITY LOG Screen and the SECURITY LOG DETAILS Screen display levels of this information. Each time the ▲ key is pressed. Press ENTER (✔) key. Use the ▲ and ▼ keys to scroll sequentially up and down through the alphabet to enter letters or a comma (.MLM. if desired. From the SETPOINTS Screen. Using numeric Keypad keys. the next higher sequential alphabet letter is displayed. 9.06. This moves to the SECURITY LOG DETAILS Screen. After all values have been entered. 2. 10. enter desired parameter as follows: User ID – 1 to 9999 (numbers cannot be duplicated for more than one user) Password – 0 to 9999 Access Level – 0 = View. followed by a Password. From SETUP Screen. the next lower alphabet letter is displayed. press FINISH PANEL SETUP key.MLM. OPERATOR or SERVICE. slash (/) or minus sign (-). accessible from the HISTORY Screen. Press the ENTER (✔) key. Use ▲ and ▼ keys to select another value to be changed within the same category or press CANCEL (X) key to exit and allow selection of another category.). select the Setpoint change number with the LOG ENTRY key and then press the VIEW DETAILS key. The universal and Default User ID is zero (0). Use the numeric keypad keys to enter numbers. During the entry process. 1 = Operator. Since 15 changes can be displayed at one time. the new Setpoint value and the Access Level and User ID used to make the change are stored. 2 = Service 7. ▲ or ▼ keys to move the green selection box to the desired value to be changed. 4. 5. etc. the Setpoint. ► . the ability to enter more data will be terminated. Press CHANGE USER ATTRIBUTES key. The date and time the Setpoint was changed. 6. On the SECURITY LOG Screen.FORM 160. Press ENTER (✔) key.xxx) This feature provides a record of the last 75 Setpoint changes. multiple pages could be necessary to display all the changes. RECORD SETPOINT CHANGES (Flash memory Card version C. The universal Password to log in at SERVICE access level is 1 3 8 0.01. the ◄ key can be used to backspace and the ► key can be used to forward space. EXTREMELY IMPORTANT! If the procedure above was performed using password 0 2 2 8 to enter data into a new blank BRAM. PAGE-UP and PAGE-DOWN keys are provided to view the entire list. The first changeable area is outlined in a green selection box. Each time the ▼ key is pressed. Use ◄ and ► key to select YES. Up to four Custom Users can be established with User ID’s from 1 to 9999. JOHNSON CONTROLS 23 187 . the following procedure must be performed after all the desired data is entered. A PRINT key allows printing this entire list. When logging in.54-M1 (607) 7. log in at SERVICE access level using 1 3 8 0. b. CUSTOM USER ID AND PASSWORDS Use the following procedure to establish Custom Users: 1. Failure to perform this procedure after all data has been entered will result in unreliable OptiView Control Center Operation! a. the next most recent as number 2. or SERVICE level. slash and minus sign can be selected after scrolling through the entire alphabet. select USER Screen.02. the service technician can establish up to four custom User ID’s and Passwords that can be used by Operations personnel to log in at VIEW. press CANCEL key (X) to exit.xxx and later or C. 8. The universal Password to log in at OPERATOR access level is 9 6 7 5. 3.07. • Oil Heater Outputs – Either TB1-34 or TB1-64 on I/O Board • Refrigerant Level Control Default Period – Either 3.xxx and later are applicable and backward compatible to all YK chiller style/compressor combinations. The various YK chiller style/compressor combinations are equipped differently and have different control requirements. • Flow Sensor – Paddle type or Factory Mounted Thermal Type.01. For correct chiller control.xxx (and later). Once the applicable Chiller/Compressor combination is entered. either Analog or Digital per the Chiller Style/Compressor Setpoint selection.MLM. Minimums and Maximums • Trend Trigger Data • Trend Print Mode • Trend View Mode View the Setpoint changes as follows: 1. They contain all control variables for all combinations. login at SERVICE Access Level using access code 1 3 8 0.xxx and later) If equipped with Flash memory Card version C.07. The paddle type applies 115Vac to the I/O Board DIGITAL inputs TB4-12 (evaporator) and TB4-11 (condenser). The factory mounted thermal type (available with style F chillers). the Chiller Style/Compressor combination must be entered. The Setpoint is selected from the list on the SECURITY LOG Screen as explained in the previous paragraph. This causes a jump to the SECURITY LOG DETAILS Screen where the setpoint change details are displayed. • Setpoint Category • Setpoint • Date and time of change • Access Level and User ID used to make the change • Old Value • New Value The following Setpoint changes are not logged: • Clock Mode • Custom Screen Slot Numbers • Advanced Diagnostics Communication Port Tests • Advanced Diagnostics Secondary Multiplexer Freeze • Soft Shutdown Initiated by Operator • System Language • Display Units • Any Print Report • Cancel any Print Report • Schedule Clear • Schedule Repeat Exception Days • Schedule Start and Stop Times • Log In/Log Out • User Attributes for ID.07A. Variables include the following: • High Speed Thrust bearing proximity sensing – Proximity Probe input at Microboard J8-15 or Limit Switch input at I/O Board TB3-81.MLM.xxx automatically selects the Flow Sensor input. 2.MLM. the actual Flow Sensor type present must be entered using the Flow Switch Setpoint.01. From the HISTORY Screen. With these versions.5 seconds or 10.01. CHILLER STYLE/COMPRESSOR (Flash Memory Card version C.xxx and C.01. At the Keypad. To view the details of a particular setpoint change.07.08. Flash Memory Card version C. Flash Memory Card version C. then press VIEW DETAILS key.01. allows the use of either the Thermal type (Analog) or Paddle-type (Digital) flow sensors in the style F chillers. applies +5Vdc to the microboard ANALOG inputs at J7-14 (evaporator) and J7-16 (condenser). 188 JOHNSON CONTROLS . the correct CHILLER STYLE/COMPRESSOR combination must be entered.System Calibration FORM 160.0 seconds • “Oil – Variable Speed Pump-Pressure Setpoint Not Achieved” safety shutdown threshold – Either 25 PSID or 35 PSID Flash Memory Card version C. the program automatically bundles the functionality and chiller control per the tables below.MLM.01.MLM. select SECURITY LOG Screen to view the complete list of setpoint changes. Password and Level • Trend Start/Stop • Trend Slot Numbers.07. select it with the LOG ENTRY key.MLM.xxx and later.54-M1 (607) The SECURITY LOG DETAILS Screen displays the following Setpoint change details. The program then reads the Proximity Limit Switch at I/O Board TB3-81.5 seconds.5 sec 10.MLM. 23 JOHNSON CONTROLS 189 . enter “Style E/P Compr”. control the Oil Heater from TB1-64. makes the Level Control Period Default 10.MLM.07A. Example 2: If the chiller is a style E and equipped with a P compressor.105A (or later): Example 1: If the chiller is a style F and equipped with a J or H3 compressor.5 sec 35 PSID “Style F/P.5 sec 35 PSID “Style F/J Compr” TB1-64 3.0 seconds.H3 Compr”. make the Level Control Period Default 3. Compr” TB1-64 10.FORM 160. the Oil Pressure safety threshold below is 35 PSID and will read the Flow Sensor inputs at either I/O Board TB4-11/12 or Microboard J7-14/16 as programmed with the FLOW SWITCH Setpoint.0 sec Flow Switch Digital (Paddle Type) Digital (Paddle Type) Analog (thermal type) Analog (thermal type) Analog (thermal type) “Oil-Variable Speed Pump Pressure Setpoint Not Achieved” Threshold* 35 PSID 25 PSID Chiller Style/Compressor “Style CDE/GHJ Compr” “Style E/P Compr” Probe Limit Switch Limit Switch Probe Limit Switch “Style F/GH Compr” TB1-64 3. the Oil Pressure safety threshold below would be 25 PSID and reads the Flow Sensor input at I/O Board TB4-11/12.XXX Proxmity Sense Oil Heater Output* TB1-34 TB1-64 Level Control Period Default 3. enter “Style F/J.07. The program will read the Proximity Probe input at Microboard J815.54-M1 (607) For example.08. FLASH MEMORY CARD VERSION C.0 sec 25 PSID * Not applicable to Style C and earlier chillers.01.01.MLM. if equipped with C.01. controls the Oil Heater from TB1-64.XXX AND C. 01.01.01.5 sec 35 PSID “Style F/J.08.5 sec 10.MLM.0 sec 25 PSID * Not applicable to Style C and earlier chillers FLASH MEMORY CARD VERSION C.54-M1 (607) FLASH MEMORY CARD VERSION C.08.206A (AND LATER) Chiller Style/Compressor Proxmity Sense Oil Heater Output* TB1-34 TB1-64 Level Control Period Default 3.OPT.5 sec 35 PSID “Style F/P.5 sec 35 PSID “Style F/P. Compr” TB1-64 10. H3 Compr” TB1-64 3.0 sec Flow Switch Digital (Paddle Type) Digital (Paddle Type) Programmable (Analog or Digital) Programmable (Analog or Digital) Programmable (Analog or Digital) “Oil-Variable Speed Pump Pressure Setpoint Not Achieved” Threshold* 35 PSID 25 PSID “Style CDE/GHJ Compr” “Style E/P Compr” Probe Limit Switch Limit Switch Probe Limit Switch “Style F/G.0 sec 25 PSID * Not applicable to Style C and earlier chillers SOFTWARE VERSION C.MLM.5 sec 35 PSID “Style F/J Compr” TB1-64 3.105A AND C. H3 Compr” TB1-64 3. H5-8 Compr” TB1-64 3.XXX AND LATER) Chiller Style/Compressor Proxmity Sense Oil Heater Output* TB1-34 TB1-64 Level Control Period Default 3.01.0 sec 35 PSID 190 JOHNSON CONTROLS .10B.5 sec 10.5 sec 35 PSID “Style F/P.0 sec Flow Switch Digital (Paddle Type) Digital (Paddle Type) Programmable (Analog or Digital) Programmable (Analog or Digital) Programmable (Analog or Digital) “Oil-Variable Speed Pump Pressure Setpoint Not Achieved” Threshold* 35 PSID 25 PSID “Style CDE/GHJ Compr” “Style E/P Compr” Probe Limit Switch Limit Switch Probe Limit Switch “Style F/GH Compr” TB1-64 3. Q LH9 Compr” TB1-64 10.0 sec Flow Switch Digital (Paddle Type) Digital (Paddle Type) Programmable (Analog or Digital) Programmable (Analog or Digital) Programmable (Analog or Digital) “Oil-Variable Speed Pump Pressure Setpoint Not Achieved” Threshold* 35 PSID 25 PSID “Style CDE/GHJ Compr” “Style E/P Compr” Probe Limit Switch Limit Switch Probe Limit Switch “Style F/G.5 sec 35 PSID “Style F/J.5 sec 10.08.MLM.MLM.XXX Chiller Style/Compressor Proxmity Sense Oil Heater Output* TB1-34 TB1-64 Level Control Period Default 3.01. H5-8 Compr” TB1-64 3.XXX (AND LATER) OR C. Compr” TB1-64 10.System Calibration FORM 160.10B. the actual sensor type used must be entered at the keypad OPERATIONS Screen using Service Access Level. the program reads the thermal-type flow sensor inputs at Microboard analog inputs J7-14 (evaporator) and J7-16 (condenser) and ignores the Digital inputs.MLM.OPT.XXX (AND LATER) Chiller Style/ Compressor Proxmity Sense Oil Heater Output* TB1-34 TB1-64 Level Control Period Default 3.16.xxx and later) Style F chillers (and later) are provided with factory mounted thermal-type flow sensors for the evaporator and condenser. If Analog is selected. 3. 2 Select SETPOINTS/SETUP/OPERATIONS Screen. The paddle-type sensors interface to the I/O board 115Vac digital inputs at TB4-12 (evaporator) and TB4-11 (condenser). Press ENTER (✔) key.5 sec 35 PSID TB1-64 35 PSID TB1-64 35 PSID Enter the appropriate chiller/compressor combination as follows: 1 At the Keypad.FORM 160. MICROBOARD 031-02430-000/-001 SETUP/ CONFIGURATION (Flash Memory Card version C.0 sec 3. Select SETPOINTS/SETUP/OPERATIONS Screen.08.01. The selections are “Analog” (thermal-type) or “Digital” (paddle-type). Analog or Digital is alternately displayed.5 sec 10. login at SERVICE access level using password 1 3 8 0.H5-8 Compr”. In order for the program to read the appropriate inputs for the flow sensor status. If Digital is selected. Press FLOW SWITCH key. Refer to SECTION 3A for explanation of each setpoint. Flash Memory Card version C.5 sec Flow Switch Digital (Paddle Type) Digital (Paddle Type) Programmable (Analog or Digital) Programmable (Analog or Digital) Programmable (Analog or Digital) Programmable (Analog or Digital) “Oil-Variable Speed Pump Pressure Setpoint Not Achieved” Threshold* 35 PSID 25 PSID Standard Coastdown Time Programmable 150-900 sec Programmable 150-900 sec Programmable 150-900 sec Programmable 150-900 sec Programmable 150-900 sec Programmable 240-900 sec “Style CDE/GHJ Compr” “Style E/P Compr” Probe Limit Switch Limit Switch Probe Limit Switch Probe “Style F/G. Use ◄ or ► keys to select flow sensor type. Default is “Style F/G. 5 Press ENTER (✔) key. FLOW SWITCH If the chiller style in the Chiller Style/Compressor setpoint on the OPERATIONS Screen is set to “F” (any compressor). Enter the applicable flow sensor type as follows: 1. 4 Use ◄ or ►keys to select the appropriate chiller style/compressor combination. H5-8 Compr” “Style F/J1-J5H3 Compr” “Style G/K1-K4 Compr” “Style F & G/PQH9 Compr” “Style F/J7 Compr” “Style G/K6-K7 Compr” TB1-64 35 PSID TB1-64 3. • Chilled Liquid Pump Operation • Motor Drive Type • Anti-recycle 191 23 . the program reads the paddle-type sensor inputs at the I/O Board digital inputs TB4-12 (evaporator) and TB4-11 (condenser) and ignores the Analog inputs. Each time the key is pressed.0 sec 3.xxx and later allow these chillers to use either the thermal-type or field installed paddle-type flow sensor. the “FLOW SWITCH” key appears on the OPERATIONS Screen allowing the flow sensor type to be entered.08. 2. The thermal-type sensors interface to Microboard +5Vdc analog inputs at J7-14 (evaporator) and J7-16 (condenser). 3 Press the CHILLER STYLE/COMPRESSOR key.54-M1 (607) SOFTWARE VERSION C. JOHNSON CONTROLS The following functions are programmed as Setpoints on the 031-02430-000/-001 microboard. 4.01.5 sec 10.01.MLM. login at SERVICE access level using access code 1 3 8 0.54-M1 (607) • • • • Power Failure Restart Coastdown Time Pre-Run Oil Pump Package ers.16. Use the following procedure: 1. At the Keypad. log in at SERVICE access level. Press ✔ key. the range is 240 (Default) to 900 seconds. Use ◄ and ►keys to select Enable or Disable as required. (“Motor Drive Type” requires chiller to be stopped with Compressor Switch in the Stop-Reset position). 5. the PRV must be calibrated per the procedure below. The setpoints are listed below. Press CHANGE SETTINGS key. JOHNSON CONTROLS .01. Press ENTER (✔) key. 4. Select SETPOINTS/SETUP/OPERATIONS screen. 2. The time is programmable over a range based on the selection made for the CHILLER STYLE/COMPRESSOR Setpoint on the Operations Screen: For style F/J7 and G/K6-K7.OPT. Shutdown chiller and place COMPRESSOR start/ Stop Switch in the Stop-reset position. Press ✔ key. the oil pump runs for the duration of the coastdown period. At the keypad. 2. If the compressor is equipped with this feature.01. A green box will appear around the first changeable setpoint. It is the number of times the Stall detector Board output goes above the High Limit setpoint. Use the CHANGE SETTINGS key on the SETUP Screen as described above to enter the desired value.01. This count can be cleared as follows: 1. Otherwise. the COASTDOWN TIME setpoint allows the service technician (in Service Access Level) to enter a coastdown time appropriate for the motor applied. Therefore. xxx (and later) or C. VARIABLE GEOMETRY DIFFUSER Microboard 031-02430-001 only with software version C.10.01. Otherwise it must be Disabled. For all oth192 (Applicable to chillers equipped with Variable Geometry diffuser only. If the chiller is equipped with the compressor motor Variable Speed Drive or the optional Hot Gas Bypass. A dialog box will appear with the range of settings.xxx (or later): • Motor communications Protocol (when VSD-50Hz or VSD-60Hz is selected as Motor Drive Type). it must be enabled and the setpoints programmed using the procedure below. Requires Software version C.10. Microboard 031-02430-001 must be equipped with 128KB BRAM (031-02565-000) to select “Modbus”. the range is 150 (Default) to 900 Seconds. it must be Enabled. • Motor Node ID.OPT. when “Standard” is selected for the COASTDOWN Setpoint on the Setup Screen. Larger motors require a longer coastdown time than the standard 150 seconds. it must be disabled. Program the above setpoints as follows: 1.xxx (and later) To assure bearing lubrication until the compressor motor stops rotating at chiller shutdown. The VGD can be manually controlled using the procedure below. Enable/Disable: If the compressor is equipped with the VGD. 2. (“Power Failure Restart” only requires OPERATOR access level 9 6 7 5). At the keypad. Coastdown Time (Software version C. Select COMPRESSOR/VGD/VGD SETPOINTS Screen. Use ◄► keys to scroll to desired setting. Otherwise. log in at ADMIN access level using access code 1 3 8 0.MLM.OPT. using password 1 3 8 0. 5. 6. 3.System Calibration FORM 160. the Pre-rotation Vanes (PRV) calibration is performed per procedures applicable to those features listed elsewhere in this section. • Coastdown Time (see Coastdown Time Setpoint below).16.302 (and later)) A complete description of the Variable Geometry Diffuser (VGD) operation and setpoints that affect this control is detailed in Section 22A of this book. 4. Select SETUP Screen from SETPOINTS Screen. Use ▲▼ keys to place the box around the setpoint to be changed. 3. VGD Count: The VGD Count is displayed on the VGD Screen. 7. Pre-rotation Vanes Calibration: Refer to the Pre-rotation Vanes Calibration Procedure in this Section.FORM 160. Pressing the AUTO key invokes automatic operation. d. Setpoints: The following are the Setpoints and range of programmable values. Surge Reaction Time . enter desired number.2Vdc (0. 4. The default value is the recommended value and should provide proper operation in most applications. Hot Gas Bypass. the respective output is energized for 2 seconds and the respective LED illuminates for 2 seconds. login at Service access level.8) Low Limit – 0. log in at Service access level using access level code 1 3 8 0. if the endpoints are not established within 10 minutes. e. After a 60 second delay. Each time the OPEN or CLOSED key JOHNSON CONTROLS 23 193 . is pressed. 3. 1.01. Press ENTER (✔) key. However. When the feedback voltage stops decreasing and remains stabilized (so that there is no more than + 0.14.01. “PRV Calibration Unsuccessful” is displayed. “PRV Calibration Successful” is displayed. Otherwise. 4. Select VARIABLE GEOMETRY DIFFUSER Screen from the COMPRESSOR Screen. Select the PRE-ROTATION VANES CALIBRATE screen from the COMPRESSOR screen. enter the desired value. These endpoint voltages are stored in the BRAM as the full open and full closed positions. “PRV Calibration Unsuccessful” is displayed. At the keypad.MLM.025vdc deviation) for 25 continuous seconds.xxx (and later) or C.5vdc.1 to 30 seconds (5) PRV Offset – 0 to 5% (3) Probe Wait Time – 0. Press ENTER (✔) key.01. log in at Service access level using access code 1 3 8 0. CLOSE or HOLD key as desired. 2. 3.306 (and later)) At the keypad. At the keypad. When the feedback voltage stops increasing and remains stabilized (so that there is no more than + 0. Select COMPRESSOR/VGD/VGD SETPOINTS Screen.5 to 1.5 to 15 minutes (10) Open Pulse – 1 to 9 seconds (2) High Limit – 0. Press the START CALIBRATION key to initiate the calibration.01.8Vdc (0. 5. the Setpoint can be programmed to other values to compensate for local operating conditions.14. Use the following procedure: a.025vdc deviation) for 25 continuous seconds. 3.4 to 0. The DEFAULT value is shown in parentheses. Using numeric keypad keys. Pre-rotation Vanes Calibration There is one procedure for all Pre-rotation Vanes (PRV) calibrations. The following procedure applies to the compressor motor Variable Speed Drive (VSD). Place the COMPRESSOR switch in the Stop-reset position (O) and wait until the System Coastdown is complete. On the VGD SETPOINTS Screen. h. the feedback voltage is logged as the 100% position. After a 10 second delay. the program begins evaluating the feedback voltage from the PRV potentiometer.14. Using the numeric keypad keys.54-M1 (607) 3. c. the program begins evaluating the feedback voltage from the PRV potentiometer. The CALIBRATION IN PROGRESS and PRV OPENING LED will illuminate and an open signal is applied to the PRV. the feedback voltage is logged as the 0% position. g.6) Extreme Stall Duration – 10 to 20 minutes (10) (Software version C. Manual Control: The VGD can be manually controlled as follows: 1. press the OPEN. 5. b. press the appropriate key to select the setpoint to be rogrammed. 1.OPT.xxx (and later) or C.306 (and later)) PRV VGD Inhibit – 40% to 100% (95%) (Software version C. On the VARIABLE GEOMETRY DIFFUSER Screen.MLM. 4. Variable Geometry Diffuser and any other PRV calibration. Also. Pressing the HOLD key causes the HOLD LED to illuminate and the VGD to be held in its present position with. 2. If the difference between the endpoint voltages is greater than 0. 2.OPT. f.14. A close signal is then applied to the PRV and illuminates the PRV CLOSING LED. High Condenser Pressure Fault While Shutdown – reset procedure (Software version C. This also clears any motor lubrication warning or safety that is in effect and resets the Operating Hours Since Last Lubrication to zero. name or user ID using the Motor Lube Acknowledge key on the Motor Lubrication Screen. Enter 1 3 9 7 and press the ENTER key (✔). If a “Condenser – High Pressure” fault is detected while the chiller is in Pre-lube. 194 JOHNSON CONTROLS .0 PSIG (R22). “Warning – Motor Bearing Lube Required” and safety shutdown “Motor – Lack of Bearing Lubrication”.14.xxx (and later) or C. they will remain uncalibrated. The entry must be a minimum of 3 characters and a maximum of 8 characters. a safety shutdown is performed when the hours exceed 1400 hours and “Motor – Lack of Bearing Lubrication” is displayed.System Calibration FORM 160. displays information applicable to this feature.01. This entry also resets the Operating Hours Since Last Lubrication to zero.306 (and later)) High temperature condenser water flowing through the condenser while the chiller is shutdown can cause a condenser high pressure condition in the condenser resulting in loss of refrigerant. log in at OPERATOR access level using Password 9 6 7 5. If there is still no response. name or user ID using the following procedure. At the keypad. place COMPRESSOR switch in Stop-reset (O) position. The entry is displayed as the Operator Initials at Last Lubrication. The date and time of this entry is automatically logged as the Date of Last Lubrication and Time of Last Lubrication. This anticipatory fault is only performed while the chiller is stopped. a safety fault occurs and “Condenser – High Pressure Stopped” is displayed.14. If they were not previously calibrated successfully.01. the Operator must acknowledge the lubrication has been performed.OPT. Place the COMPRESSOR switch in the Stop-reset position. 4. System Run or Coastdown. If the PRV were previously calibrated successfully. This anticipatory safety fault annunciates condenser high pressure conditions when the chiller is not running as follows: While the chiller is stopped. Select CONDENSER screen.54-M1 (607) The calibration procedure can be terminated at any time during the procedure by pressing the CANCEL CALIB key. At the keypad. A red box highlights the first changeable location. If there is no response. The date and time of this entry is automatically logged as the Date of Last Motor Lubrication and Time of Last Motor Lubrication. If resetting the safety shutdown “Motor – Lack of Lubrication”. A dialog box appears. it will revert to using the previous calibration values. name or user ID as a 3 to 8 character string. When both motors have been lubricated. 2. .0 PSIG (R22) and a special reset procedure is performed as follows: 1. login at Service access level using code 1 3 8 0. Enter your initials. each indicating an increasing level of urgency. 1. This feature provides an indication when the compressor motor lubrication is required. “Warning – Motor Bearing Lube Required” is displayed when the hours exceed 1200 hours. “Warning – Motor Bearing Lube Suggested” is displayed when the hours exceed 1000 hours. This entry also resets the motor lubrication warning messages: “Warning – Motor Bearing Lube Suggested”.MLM. This is done by entering his/her initials. if the condenser pressure exceeds 160. the fault is handled in the normal way and does not require the special reset procedure. Press the Motor Lube Acknowledge key. MOTOR LUBRICATION NOTIFICATION There are up to three levels of notification.0 (R134a). the Operator enters his/her initials. 2. accessible from the Motor Screen in any access level.0 PSIG (R134a). Press the FAULT ACKNOWLEDGE key on the CONDENSER Screen. The Motor Lubrication Screen. A dialog box appears displaying “Enter Password to Clear Fault”. 5. 3. 240. The lubrication requirement and notification is based on the “Operating Hours Since Last Motor Lubrication”. To provide a record of when a motor lubrication is performed. 240. The chiller can be started after the condenser pressure decreases to less than 160. 6. the next higher sequential alphabet letter or number is displayed. 7. Motor Lube Date: Normally. 2. login at ADMIN access level. With this setting. 8. as it should be when not equipped with the Automatic Motor Lubrication hardware. If disabled. the safety shutdown will occur at the normal 1400 hours. If the AUTO LUBE setpoint is DISABLED. enter the desired date. 3. 4.01. The safety shutdown can be enabled or disabled per the customer’s preference. Use the following procedure: 1. if necessary. Press the AUTO LUBE key. Therefore. Use the ◄ key to backspace. The selection prior to the letter “A” is a blank space. To write over an existing entry or to place a blank space. press the CANCEL (X) key. the motor lubrication warnings and shutdown will occur at the associated elapsed run times. When the desired letter or number is displayed. login at SERVICE Access level using Access Level 1 3 8 0. Each time the ▲ is pressed. 2. use the ► key to forward space the red box for the next entry. 5. scroll to the beginning of the alphabet. 23 JOHNSON CONTROLS 195 . Use the • key to enter a period/decimal point. If Disable is selected in step 4. However. Each time the ▼is pressed. Use the ◄and ►keys to select Enable or Disable as desired per above. select the MOTOR LUBE Screen. From the MOTOR Screen. Press the ENTER (√) key. 3.OPT. Using the number keys. if it is necessary to modify the motor lubrication date after that procedure was performed. the Date of Last Lubrication is automatically recorded when the Operator enters his/her initials. press the ENTER (√) key. when the automatic lubrication hardware is present. 4. a warning will be displayed but the safety shutdown will not occur. Software version C. Since chillers that are equipped with Automatic Motor Lubrication hardware don’t require manual lubrication. no lubrication warnings or shutdown will occur. Press ENTER key. proceed as follows: 1. Use the ◄and ►keys to select Enable or Disable as desired per above. name or user ID with the Motor Lube Acknowledge key in the above procedure.FORM 160. the AUTO LUBE Setpoint must be ENABLED. With this setting. Press the Motor Lube Date key.54-M1 (607) 3. the SHUTDOWN Setpoint can be used to enable or disable the safety shutdown that occurs at 1400 hours since last lubrication. Press ENTER key. the next lower alphabet letter or number is displayed. if it is desired to exit the dialog box and retain the previous entry. When all of the desired characters have been entered. 4.xxx (and later) adds the AUTO LUBE and SHUTDOWN setpoints to the Motor Screen: The AUTO LUBE Setpoint accommodates those chillers that are equipped with Automatic Motor Lubrication hardware that automatically lubricates the motor. At the keypad. During the entry process. At the keypad.16. If enabled. press the SHUTDOWN key. Use the ▲▼keys to scroll sequentially through the alphabet to enter letters or numbers. the motor lubrication warnings (reminders) and safety shutdown are unnecessary. They are described on the following pages. Shown in figures 65 through 72. There are two screens available that allow the Analog Inputs voltage levels and Digital I/O states to be monitored. At the completion of the Boot-up process. Place Compressor Start/Stop switch in the Stop-Reset position (O). Each procedure references the Section and figures of this book that describe the operation of the component being tested. If there is an OptiView Control Center problem. determine the category of the problem. Then perform the applicable Diagnostic. A Watchdog reset will occur and the Boot-up process will commence. BIOS . 196 JOHNSON CONTROLS . Move Microboard Program Switch SW1-4 (microboard 031-01730-000).Software that is part of FLASH Memory Card GUI .Eprom in MicroGateway SSS or VSD – eprom in Solid state Starter or variable Speed Drive (as applicable). it resides in the non-removable Flash Memory chip (U35). These screens are used during the Diagnostics and Troubleshooting process. Ensure the Compressor motor current is 0% FLA. On 031-02430-000 or 03102430-001 microboards. which is entered using the procedure below. They allow output states to be changed. 5. 4. Available when logged in at SERVICE access level.Software that is part of FLASH Memory Card SIO . (Note: if the Program Switch is moved to the ON position before step 4 above is performed. 2. Not shown.Software that controls the chiller. These screens are preceded by a general screen that provides the installed software versions. Access the Diagnostics Main Screen as follows: 1. the Diagnostics Main Screen will appear. On 03101730-000 microboards.Diagnostics & Troubleshooting FORM 160. perform the Troubleshooting procedure to locate the defective component. it resides in the removable Flash Memory Card (U46). Also. If the Diagnostic reveals a malfunction. Log in at SERVICE access level using access code 1 3 8 0. 2.Software that is part of FLASH Memory Card GPIC . SW1-3 (microboard 031-02430-000 or 031-02430001) to the ON position. whether the chiller is running or not. the applicable OptiView Control Center wiring diagram must be used as listed in the REFERENCE INSTRUCTIONS section at the front of this book.54-M1 (607) SECTION 24 DIAGNOSTICS & TROUBLESHOOTING The problems that could be encountered in the OptiView Control Center are in the following categories: • Keypad • Display • Serial Input/Output (I/O) • Digital Input/Output (I/O) • Analog Inputs There is a Diagnostic and associated Troubleshooting procedure for each category. There are several documents that must be referred to while performing the Diagnostics and Troubleshooting procedures. The chiller must be stopped. Each Diagnostic is accessed from the Diagnostics Main Screen.BIOS Eprom on Microboard Kernel . the “LOG IN” key will be displayed and Logging in at SERVICE access level must be performed before the Main Screen is displayed. 3. Accessed from the SETUP screen via the SETPOINTS screen. There are two versions of the Diagnostics screens available as follows: 1. SOFTWARE VERSION Controls . Bit patterns test . The sub-screens are shown indented below: Main screen . from which the next diagnostic can be selected.54-M1 (607) MAIN DIAGNOSTICS SCREEN FIG.All white .All green . After each diagnostic is performed.All red .Keypad test . 24 JOHNSON CONTROLS 197 .Serial 1/0 test .All black .Analog Inputs The ADVANCED SECURITY key is used during the manufacturing process and has no field service use. Press the appropriate key to select the desired diagnostic. return to this MAIN Screen. Some of the diagnostics have sub-screens that are accessed from the selected diagnostic screen.FORM 160.Display test .Digital 1/0 test .All blue . 65 – MAIN DIAGNOSTICS SCREEN 00335VIP Each of the Diagnostics is accessed from this screen. An open circuit would indicate the ribbon Cable is defective. Press the key to be tested. the Keypad is defective. b. Press each keypad key. the Keypad is defective. Refer to Figure 33. 3. If the contact resistance is >100 Ohms. As the key is pressed. e. Release the key. the Microboard is most likely the cause of the problem. Disconnect the ribbon cable from the Keypad. locate the pins of the row/column coordinate of the key of the key to be tested.Diagnostics & Troubleshooting FORM 160. Insert the leads of an Ohmmeter into the pins identified in step “c” above. perform a continuity test on all conductors in the ribbon cable. 2. If the Keypad and Ribbon Cable check OK per the above procedures. 2. the Keypad. If the contact resistance is < 1 Meg Ohm. Refer to description of Keypad operation in Section 8 of this book. Ribbon Cable Using an Ohmmeter. In the Keypad connector. PROCEDURE 1. c. an illuminated LED is displayed corresponding to the key location on the keypad.54-M1 (607) KEYPAD TEST FIG. 198 JOHNSON CONTROLS . 1. 66 – KEYPAD TEST SCREEN 00336VIP This diagnostic is used to verify Keypad operation and the Microboard’s ability to respond to a pressed key. Keypad ribbon cable or Microboard could be defective. d. Microboard There are no checks or measurements to be made on the Microboard. Identify row/column coordinate of the key to be tested. Keypad a. Press the DIAGNOSTICS key to return to the MAIN DIAGNOSTICS Screen. Use the following procedure to locate the defective component. TROUBLESHOOTING If an LED is not displayed when a key is pressed. f. 24 199 . Refer to description of Display operation in Sections 5 through 7 of this book. return to this screen. first ascertain it is not caused by dirt that is lodged between the display surface and the protective plastic cover. All of the red pixels are turned on to create a completely red screen.This test verifies the operation of all of the red pixels. green.This test verifies the operation of all of the green pixels. blue or white dot. PROCEDURE 1. or the red border is not completely visible. 67 – DISPLAY TEST MAIN SCREEN 00337VIP Each of the Display Diagnostics is accessed from this screen. Any pixel that does not turn off will appear as a red. All Blue . from which another test can be selected.This test is used to detect jitter and alignment defects.This test verifies the display’s ability to turn off all pixels to display a completely black screen. If any black dots appear. All of the green pixels are turned on to create a completely green screen. • Bit Patterns . Press the CANCEL (X) or ENTER (✔) key to terminate test and return to DISPLAY TEST MAIN screen. light blue and yellow.FORM 160. from which the next diagnostic can be selected. All of the blue pixels are turned on to create a completely blue screen. It verifies proper operation and compatibility of the Microboard Display Controller with the display. Any pixel that does not turn on will appear as a black dot. Refer to description of “All Red” test above.This test verifies the display’s ability to turn on all pixels to display a completely white screen. They will not be visible on the normal screens displayed outside of this diagnostic mode.This test verifies the operation of all of the blue pixels. It is normal for a small number of randomly spaced pixels to not illuminate. If the vertical bars are not stable or straight. All Green . 2. outlined by a red border are displayed. Refer to description “All Red” test above. However. When all the desired tests have been performed. It is not necessary to replace the display if a small number of black dots appear. press the DIAGNOSTICS key to return to the MAIN DIAGNOSTICS screen. 3. Refer to Figure 66. All Black . Press the appropriate keypad key to perform the desired test from the list below. Any red pixels JOHNSON CONTROLS • • • • that do not turn on will appear as black dots on the display. Refer to description of “All Red” test above. • All Red . All White . then either the Microboard Program Jumpers are not configured correctly for the installed display or the Microboard Display controller is defective. Refer to description of “All Red” test above. After each diagnostic is performed. dark blue. Four vertical bars of green.54-M1 (607) DISPLAY TEST FIG. large black areas would be indicative of a defective display. An open circuit would indicate the ribbon cable is defective. b.0VDC. the Microboard is defective. 2. An through J5-18 and J5-20 through J25 should be <1. J5-13 through J5-18 and J5-20 through J5-25 should be >3. the voltage at Microboard J5-6 through J5-11 (Red drivers bits 0-5). the voltage at Microboard J5-6 through J5-11. the Display is most likely the cause of the problem. as measured to Gnd. perform the applicable procedure below: Test Failed: Bit Patterns . JOHNSON CONTROLS .0VDC. All White or All Black: If these tests do not produce appropriate solid color screens. An open circuit would indicate the Interface Board is defective. All Red. With the “All Blue” test selected. To locate the defective component perform tests in the following order: 1. With the “All Black” test selected. should be >3. perform a continuity test on all conductors in the ribbon cable. the Display Ribbon Cable. Microboard: a. Display Ribbon Cable: Using an Ohmmeter. With the “All Green” test selected.0VDC. the voltage at Microboard J5-6 through J5-1 1. If not. With the “All White” test selected. Display Interface Board and Microboard check OK per the above procedures. 4. as measured to Gnd. should be >3. 68 – BIT PATTERNS TEST SCREEN 00338VIP TROUBLESHOOTING If any of the above tests do not perform correctly as described above. the Microboard is defective. If not. With the “All Red” test selected. either the Microboard Program Jumpers are not configured correctly or for the installed Display or the Microboard is defective.54-M1 (607) FIG. Display Interface Board. e. the voltage at Microboard J5-20 through J5-25 (Blue drivers bits 0-5). as measured to Grid. c.0VDC. All Green. All Blue. If not. the voltage at Microboard J5-13 through J5-18 (Green drivers bits 0-5).If the vertical bars are not straight or if the red border is not completely visible. Display: If the Display Ribbon Cable. the Microboard is defective.0VDC. d. J5-13 Board. should be > 3. the Microboard is defective. 200 3.Diagnostics & Troubleshooting FORM 160. the Microboard is defective. Microboard or Display could be defective. Display Interface Board: Using an Ohmmeter. If not. If not. perform a continuity test on all conductors of the Interface Board. 24 JOHNSON CONTROLS 201 .54-M1 (607) This page intentionally left blank.FORM 160. The TX/RX opto-coupled port (COM 5) is tested by transmitting serial test data from the TX output to the RX input. 2 and 4b) is tested by transmitting serial test data from outputs to inputs of each port. Otherwise. The RS-485 ports (COM 3 and 4a) are tested by transmitting serial test data from one RS-485 port to another.54-M1 (607) SERIAL INPUTS / OUTPUTS TESTS FIG. PROCEDURE COM 2 From J13-5 (TX) J13-7 (DTR) J13-4 (RTS) From J12-3 (+) J12-2 (-) To J13-3 (RX) J13-1(DCD) & J13-2 (DSR) J13-6 (CTS) & J13-8 (RI) To J11-3 (+) J11-2 (-) RS-485 (COM 3 & 4a) Microboard Program Jumper JP27 must be installed in position 1 & 2. indicating the serial port is defective. Using small gauge wire. 69 – SERIAL INPUTS / OUTPUTS TEST SCREEN 00339VIP This diagnostic is used to verify correct operation of the Serial Data Ports. indicating the serial port is OK. From J15-1 (TX) J15-2 (RX) J15-3 (Common) To J15-4 J15-5 J15-6 1. FAIL is displayed. From J2-4 (TX) J2-5 (DTR) To J2-3 (RX) J2-2 (DSR) COM 5 Make individual wire connections or use YORK looparound diagnostic connector 025-33778-000 as depicted in Figure 68 This connector is available from the YORK Parts Distribution Center.Diagnostics & Troubleshooting FORM 160. the Service Technician must install a wire loop-back connection as described below. Both the transmit and receive functions as well as the control lines are tested. Prior to performing each test. Failure to install the loop-back connection or configure the Microboard Program jumper as noted will result in a FAIL outcome for the test. From COM 4b J2-7 (GTX) To J2-6 (GRX) Microboard Program Jumper JP27 must be installed in position 2 & 3. fabricate loop-back connections and install as follows for each port to be tested. Each RS-232 port (COM 1. Refer to Section 3 and Figure 11 of this book for description of the Serial data Ports. There is a test for each of the five Serial Data Ports. COM 1 202 JOHNSON CONTROLS . If the received data matches the transmitted data. PASS is displayed. COM 2 – Three tests are performed. A FAIL result would be indicative of a defective Microboard.54-M1 (607) 2. applying 0/+5VDC pulses from J15-5 to RX (J15-2) input. The following is a description of each test. An LED will illuminate indicating the test is in progress. If either test fails. FAIL is displayed. RTS (J13-4) is set to a Logic High and read at CTS (J13-6) & R1 (J13-8). Test data is then sent from COM 4a to COM 3 at the same rate. Test data is sent from TX (J2-4) to RX (J2-3) at 9600 Baud and DTR (J2-5) is set to a Logic High level and read at DSR (J2-2). 70 – MICROBOARD . DTR (J13-7) is set to a Logic High and read at DSR (J13-2) & DCD (J13-1). Test data is sent from an output to an input as described below. RS-485 (COM 3 & 4a) – Test data is sent from COM 3 RS-485 port to COM 4a RS-485 Port at 19200 Baud. COM 5 – Test data is sent from TX (J15-1) to J15-4 at 1200 Baud. Test data is sent from TX (J13-5) to RX (J13-3) at 19200 Baud. RS-485 tests are terminated. COM 4b – Test data is sent from GTX (J2-7) to GRX (J2-6) at 19200 Baud. After all desired tests have been performed. indicating the Serial Port is defective. press the CANCEL TEST key. If any test fails. At the completion of each test. COM 1 – Two tests are performed. COM 2 tests are terminated. 3. Otherwise. press the DIAGNOSTICS key to return to the MAIN DIAGNOSTICS Screen. TRANSMIT TX RX COMMON IN RECEIVE +5VDC J15 1 2 3 4 5 6 1 2 3 4 5 6 OUT +5VDC LOOP-AROUND DIAGNOSTIC CONNECTOR YORK PIN 025-33778-000 INSTALL TO PERFORM DIAGNOSTIC LOOP-AROUND TEST LD04250 FIG. If any test fails. if the data received matches the data sent. This output turns the Microboard’s loop-around test Transistor on and off. COM 1 tests are terminated.FORM 160.COM 5 SERIAL DATA PORT JOHNSON CONTROLS 24 203 . the Serial Port operates properly and PASS is displayed. press the appropriate key to initiate the desired test. After connecting appropriate loop-back connections above. If it is desired to terminate the test. DIP Switches.) Terminal number on the I/O Board and b. If interpreted as being at a Logic High (>4. The state of the Microboard’s intended drive signals to each of the Relays on the I/O Board is depicted by an LED. 71 – DIGITAL INPUTS / OUTPUTS TEST SCREEN 00340VIP This diagnostic is used to analyze the digital inputs and outputs of the Microboard. is depicted by an LED. The Digital Inputs are listed on this screen according to a. the Microboard is defective. If the intended output is a Logic High level (>10. The state of each Microboard Digital Input.0VDC). the LED is extinguished. 4. 5. the Microboard is defective. If the LED is not extinguished. the Microboard is defective.0VDC). the Microboard is defective. Logic High outputs de-energize the Relays. When all desired tests have been performed. If the LED is not illuminated. PROCEDURE 2. as interpreted by the Microboard. 6. With 115VAC applied to a particular I/O Board Digital Input. If the intended output is a Logic Low level (<1. Refer to description of I/O Board in Section 4 of this book. the applicable LED should be illuminated. the applicable LED should be extinguished. the applicable LED should be illuminated. If the LED is not extinguished. the applicable LED should be extinguished. JOHNSON CONTROLS . 7.) Microboard Program Jumpers and Program 204 8. The state of any output can be manually set to either the ENABLED (Logic Low) or DISABLED (Logic High) state. If the Microboard interprets its input as being at a Logic Low (<1. If the LED is not extinguished. If a Program Switch (DIP) is in the ON position. the applicable LED should be extinguished. Digital Inputs: 1.54-M1 (607) DIGITAL INPUTS / OUTPUTS TESTS FIG. Program Jumper and Program DIP Switch. Tables 1 and 2 list the functions of the Program Jumpers and Switches. If a Program Jumper is not present.Diagnostics & Troubleshooting FORM 160. perform appropriate Troubleshooting procedure below. the LED is illuminated. the applicable LED should be illuminated. perform appropriate Troubleshooting procedure below. press DIAGNOSTICS key to return to MAIN DIAGNOSTICS Screen. If the LED is not illuminated. If the Program Switch (DIP) is in the OFF position.0VDC) level. If the LED is not illuminated. the LED is illuminated. the LED is extinguished. 3. Logic Low outputs energize the Relays. With 0VAC applied to a particular I/O Board Digital Input. If a Program Jumper is present. Figure 14 shows the devices connected to these terminals.0VDC) level. The LED adjacent to the selected output should extinguish. IMPORTANT! . replace ribbon cable. If <11. de-energizing the device it is connected to. Select a relay or triac for manual control by using the ▲ and ▼ keys to place the arrow adjacent to the desired device. If it does not. If a triac is selected. install ribbon cable and proceed to next step. Digital Outputs Troubleshooting: If any of the Digital outputs tests fail to perform as described above. opening its contacts. The Digital Outputs are listed on this Screen according to Relay and Triac number (KI. replace the I/O Board. If the LED is not illuminated. perform appropriate troubleshooting procedure below. An arrow will appear adjacent to Relay KO. If it is not extinguished. perform a continuity test on the cable J1-25 to J19-25. JOHNSON CONTROLS 1. The LED adjacent to the selected output should illuminate. Press SELECT key. 2. 3. 4. perform a continuity check on I/O Board ribbon cable J1-21 to J19-21. Measure the +5VDC supply voltage to the 1/0 Board on 1/0 Board between J1-21 and J1-22. If a defective component is found during any of the steps. If a defective component is found during any of the following steps. Otherwise. 6. select the output that failed the digital Output test above. Press the DISABLE OUTPUT key to disable the selected output. Measure the +12VDC supply voltage to the I/O Board on I/O Board between J1-26 (+12VDC) and J1-25 (Gnd). perform KEYPAD diagnostic test. 2. energizing the device it is connected to. 1. the applicable LED should be extinguished. it will turn off. If >11.0VDC. it should energize. install ribbon cable and proceed to next step. With 0VAC applied to the I/O Board digital input that failed in Procedure above.0VDC. Refer to Figure 17 and applicable wiring diagram referenced at the beginning of Section 23. perform the following steps in sequence.0VDC. If it is <4. it should de-energize. If an open circuit is detected. If < 4. replace the component as instructed and repeat the digital Inputs Procedure above to determine if the problem has been resolved.OVDC). Figure 17 shows the external devices that are connected to these Relays and Triacs and the functions of each one.The following steps cannot be performed until the Motor Controller connection between TB6-1 and TB6-53 has been removed. replace the 1/0 Board. If a triac is selected. This connection could be a jumper or it could be a connection from external devices in the starter. 8. If an open circuit is detected. closing its contacts. Using an Ohmmeter. If the output is at a Logic Low level. If a relay is selected. If <4. Re-install the ribbon cable. With 115VAC (± 10%) applied to the I/O Board digital input that failed in Procedure above. replace ribbon cable. replace the Microboard. 3. Otherwise. proceed to next step. replace the Microboard. replace the component as instructed and repeat the Procedure above to determine if the problem has been resolved. J1-22 to J19-22 and applicable output pin of function that failed in Procedure above. 3. If >4. Refer to Figure 14 and applicable wiring diagram referenced at the beginning of Section 23. etc).5VDC. perform appropriate troubleshooting procedure below.0VDC. the applicable LED should be illuminated. perform the following steps in sequence. the applicable I/O Board output at J1 should be at a Logic low level (<1. If <11. If it does not. replace the Microboard. Q3. Re-install the ribbon cable.FORM 160.0VDC). replace the Microboard. 7. Install Motor Controller connection from TB6-I to TB6-53 removed in step 1. disconnect ribbon cable at I/O Board J1 and repeat the measurement at J1. the applicable I/O Board output at J1 should be at a Logic High level (>4. 5. When all desired tests have been performed. J1-26 to J19-26 and applicable output pin of function that failed in Procedure above. Using the Digital Outputs Procedure above. 2. press DIAGNOSTICS key to return to the MAIN DIAGNOSTICS Screen. disconnect ribbon cable at I/O Board J1 and repeat measurement at JI. Remove I/O Board ribbon cable. perform KEYPAD Diagnostics test.OVDC.54-M1 (607) Digital Outputs: 1. If it is >1. proceed to next step. The Program will prevent manual control of Digital Output devices until this connection is removed. 205 24 . Digital Inputs Troubleshooting: If any of the Digital Inputs tests fail to perform as described above. If the relay does not energize or triac does not turn on. If relay does not de-energize or triac does not turn off. 4. it will turn on. If the output is at a Logic High level. If a relay is selected. Remove 1/0 Board ribbon cable. Press the ENABLE OUTPUT key to enable the selected output.5VDC.5VDC. Using an Ohmmeter. b. The LED adjacent to the selected output will illuminate. See note 1 below for Triac testing. the following should occur: a. With the output at a Logic High level. Press DISABLE OUTPUT key.0VDC) level. If it is >1.0VDC. replace the I/O Board. replace the I/O Board. If it is <10. the Triac should be turned on. Notes: 1. Press ENABLE OUTPUT key. replace the Microboard. the relay contacts should be open. b. The on/off state of the Triac can be determined by measuring across the device (for example. remove the ribbon cable from J1 of the I/O Board. 206 JOHNSON CONTROLS . The LED adjacent to the selected output will extinguish. If a Relay is selected as the output. The appropriate Microboard output pin at J19 for the selected output should be at a Logic Low level (<1. If the resistance is >100 Ohms. the appropriate Microboard output pin at J19 for the selected output should be at a Logic High (>10. With the output at a Logic Low. With the output at a Logic High level. The load (actuator) must be connected across the Triac to determine the on/off state of the Triac. If they are not closed. If the resistance is <100 Ohms. If the Triac is turned off. replace the Microboard. On the I/O Board. a. Hot Gas or Refrigerant Level Control actuator).54-M1 (607) 4. the voltage will be <10VAC. replace the Microboard. TB1-3 to TB1-59 or TB1-58 to TB1-59) with an AC Voltmeter. replace the I/O Board.Diagnostics & Troubleshooting FORM 160. replace the I/O Board. the Triac should be turned off. the voltage will be >100VAC (Slide Valve actuator) or >20VAC (PRV. If a Triac is selected as the output. If a Triac is selected as the output. 5.0VDC.0VDC) level.0VDC. If the Triac has not turned on. the contacts of the relay should be closed. See note 1 below for Triac testing. If it is <10. If they are not open. If the Triac is turned on. measure the resistance from J1-26 to the appropriate pin of J1 on the I/O Board for the selected relay. If the Triac has not turned off. the appropriate Microboard output pin at J19 for the selected output should be at a Logic High (>10.0VDC). If a Relay is selected as the output. replace the I/O Board. 24 JOHNSON CONTROLS 207 .54-M1 (607) This page intentionally left blank.FORM 160. 1 .54-M1 (607) ANALOG INPUTS TEST FIG. The following is a list of the Analog inputs displayed.Section 10. The voltage level of each Analog input. Refer to the appropriate Section of this book for an explanation of each: Pressure Transducers . is displayed. Solid State Starter (Mod “A” only) . as interpreted by the Microboard.Section 18.Section 17. Proximity Probe .Not Used 208 2 3 4 5 6 7 8 9 10 11 12 13 - 14 - 15 16 17 18 19 20 21 - Return Chilled Liquid Temperature Leaving Condenser Liquid Temperature Return Condenser Liquid Temperature Drop Leg Refrigerant Temperature Discharge Temperature Oil Temperature Evaporator Refrigerant Temperature Condenser Pressure Evaporator Pressure Sump Oil Pressure Pump Oil Pressure Proximity Probe DC Voltage Reference (Not applicable to “P” compressors and style F and later chillers with “G.Section 11 and Current Module (CM-2) . Proximity Probe DC Voltage reference or a 0-10VDC Remote Setpoint input at channels 27 and 28. Q” and “H5-8” compressors) Proximity Probe Position (Not applicable to “P” compressors and style F and later chillers with “G. The “Counts” listed for each parameter is the Analog-to-Digital (A/D) converter value and is for manufacturing and engineering use only. 72 – ANALOG INPUTS TEST SCREEN 00341VIP This diagnostic is used to analyze the Analog Inputs to the Microboard. This Screen can be used in the investigation of this problem.+2.Diagnostics & Troubleshooting FORM 160. Microboard TP6. Important! This test does not apply to the Leaving Chilled Liquid Temperature analog input. Thermistors . Q” and “H5-8” compressors) Solid State Starter/CM-2 MUX output Channel 0 Solid State Starter/CM-2 MUX output Channel 1 Solid State Starter/CM-2 MUX output Channel 2 Solid State Starter/CM-2 MUX output Channel 3 Solid State Starter/CM-2 MUX output Channel 4 Solid State Starter/CM-2 MUX output Channel 5 Solid State Starter/CM-2 MUX output Channel 6 JOHNSON CONTROLS .Section 13.Section 14. Refrigerant Level Control . If the chiller is shutting down on an Analog Safety or is prevented from starting because of an Analog input.5VDC Analog supply voltage reference. Channel 0 . there is probably an Analog Input problem. If the measured value is not within +15% of the displayed value. For example.MLM. An open circuit would indicate the cable is defective.MLM.01.5VDC) and TP1 (Gnd).xxx (and later) or C. • Channel 0: Using a Voltmeter.306 (and later)) 25 .Condenser Flow Sensor (style F and later chillers) (Flash Memory Card version C. 1. If voltage is not within +10% of specified voltage.01.10. Troubleshooting : • All Channels except 0. select the analog input that is malfunctioning.302 (and later)) 26 .xxx and later). 15-22. 3. +1 2VDC or +24VDC) to the sensor. 1.Pre-rotation Vanes Potentiometer output (chillers equipped with Variable Geometry Diffuser but not equipped with compressor motor Variable Speed Drive or Hot Gas Bypass) (Software version C.Evaporator Flow Sensor (style F and later chillers) (Flash Memory Card version C. the Power supply is most likely defective.07.10. 2.OPT. • Channels 15-22: Select the desired channel by pressing the SELECT CHANNEL key and using the ▲ and ▼ keys to place the arrow head next to the desired channel. Otherwise. measure the +12VDC supply voltage input at the Microboard J1-3 (+12VDC) to J1-2 (Gnd). Compare this measured value to the displayed value.xxx (and later) or C.MLM. When completed. 24 JOHNSON CONTROLS 209 . Channels 27 and 28 are Remote Setpoint inputs used in Analog Remote mode.xxx (and later) or C.MLM. Make the measurement between the device output and Ground connection to the device. Channel 0 is a reference voltage for the Analog circuits on the Microboard. Disconnect both ends of the cable of the Analog input that is malfunctioning.OPT. Using an Ohmmeter. 2. 6. 30 . Using a Voltmeter. measure the voltage between Microboard TP6 (+2.54-M1 (607) 22 . 28: IMPORTANT! This procedure only applies to 4-20mA inputs. 27. measure the supply voltage (+5VDC.07. measure the output of the Evaporator Transducer at Microboard J8-18 (signal) to J8-9 (Gnd). Channels 15 through 22 are multiplexed outputs from the Solid State Starter (Solid Sate Starter applications) or CM-2 Current Module (Electro-Mechanical Starter applications). All inputs except channel 0. press DIAGNOSTICS key to return the MAIN DIAGNOSTICS Screen. freeze the address of that channel to the Solid State Starter or CM-2 MUX. Refer to Wiring Diagrams listed in front of this Section to identify the device that performs this function and the jack and pin connection to the Microboard.14.Remote Leaving Chilled Liquid Temperature Setpoint (0-20mA or 4-20mA) 28 .Stall Transducer Output (Chillers equipped w/ Variable Geometry Diffuser)(Software version C.01. measure the analog input to the Microboard. Using a Voltmeter.01.10. If wiring is OK.FORM 160.Remote Current Limit Setpoint (0-20mA or 4-20mA) 29 . perform a continuity test on all conductors in the cable. 28: 1. replace the Microboard. Then. 5. press CANCEL FREEZE key.MLM. Compare the measured value in the previous step with the value displayed on the Analog Inputs Screen for that value. Using a Voltmeter. Then measure MUX output at Microboard J10-6 (signal) to J10-5 (Gnd).10.302 (and later)) 27 .01. • All channels except 0.xxx and later) Procedure: 1. check wiring to Power Supply. 15 through 22.5VDC. • Channels 27.01.OPT. 27 and 28 are sensors that connect directly to the Microboard via shielded cable. From the chart above. 15-22: Using a Voltmeter.Refrigerant Level Position 24 .14. When all desired tests have been performed.Solid State Starter/CM-2 MUX output Channel 7 23 . measure the Remote Current Limit setpoint input at J22-2 (signal) or Remote Leaving Chilled Liquid Temperature setpoint input at J22-4 (signal) to J22-5 (Gnd). 3. If voltage is < 11. If the value is not within +10%. proceed to the troubleshooting procedure below to find the cause of the problem. 4.01. It does not apply to 0-10VDC inputs.01. replace the Microboard.Stall Detector Board output (chillers equipped with Variable Geometry Diffuser only) (Software version C. measure the +5VDC supply voltage to the Solid State Starter Logic Board or CM-2 Board. measure the +12VDC supply voltage input at the Microboard J1-3 (+12VDC) to J1-2 (Gnd). If address is not correct. If the address is correct. a Thermistor or Transducer is shorted. Using a Voltmeter. • Channels 15 . 4. If wiring is OK. Press CANCEL FREEZE key. 4. Refer to Table 1 “Microboard Program Jumpers” and verify Program Jumpers JP23 and JP24 are configured correctly for the type of input (0-10VDC or 4-20mA).Diagnostics & Troubleshooting FORM 160. Replace sensor if necessary. J8 and J9 from the Microboard. problem most likely is in the remote device that supplies the remote signal.5VDC. replace the Microboard. Disconnect both ends of the cable of the remote input that is malfunctioning. Make measurement at Microboard J10-4(+5VDC) to J10-5 (Gnd). the voltage supply source (Microboard or Power Supply) is most likely defective. This disconnects all analog devices from the Microboard. 28: 1. Verify sensor accuracy using appropriate test device. If the voltage increases to the correct level. check wiring to Power Supply. perform a continuity check on all conductors in the cable. 210 JOHNSON CONTROLS . If voltage is <4. Disconnect both ends of ribbon cable connected to Microboard J10.5VDC. 5. perform a continuity test on all conductors in the cable. Using a Voltmeter. Using a Voltmeter. the Microboard is most likely the cause of the problem. the Power Supply is most likely defective. Freeze address as described above. 2. Using an Ohmmeter. 2.54-M1 (607) disconnect J7. after disconnecting the connectors the supply voltage is still not within 10% of the specified value. 3. If. If voltage is <11. the Solid State Starter Logic Board or CM-2 Board or input devices to these boards is most likely the cause of the problem. • Channels 27. If steps are OK. An open circuit would indicate the cable is defective. An open circuit would indicate the cable is defective.22: 1. 3. verify the correct address is being sent from the Microboard to the Solid State Starter Logic Board or CM-2 Board. Locate the shorted device and replace. Using an Ohmmeter. COMPRESSOR Screen: (160.14.xxx (and earlier) or C.xxx (and later) or C.54M1) ____ Refrigerant Temp sensor Enable/Disable (160.01. Thresholds. If any of the Setpoints have to be changed.54-M1) ____ Smart Freeze Protection On/Off (160.OPT. An explanation of each setpoint or Calibration Procedure below is contained in the reference document listed in parenthesis adjacent to each item. EVAPORATOR Screen: (160.14. refer to Section 3A Table 3 and 4.01.OPT.54-M1) 3.07.01.01.07.11.14.xxx (and earlier)) ____Proportional Limit Close*(Software version C.OPT.11.xxx (and later)) ____Rate Limit (Software version C. If equipped with Microboard 031-02430-000/-001.xxx (and later)) ____Ramp-up Time (Software version C.OPT. values and calibrations of items marked with an asterisk “*” have been determined and entered/set at the YORK Factory at the time of manufacture.11. login at SERVICE access level before beginning.OPT.01.xxx (and earlier) or C.MLM. To assure access to all Setpoints.MLM.11.xxx (and earlier)) ____Rate Limit Close*(Software version C. If equipped with Microboard 031-01730-000. PRE-ROTATION VANES CALIBRATE Screen: ____ Perform Pre-rotation Vanes calibration (compressor motor VSD and Hot Gas Bypass applications only) VSD TUNING Screen: ____ Select Auto or Manual compressor motor frequency control (compressor motor VSD applications only) 2.MLM. REFRIGERANT LEVEL CONTROL/ TUNING Screen: (160.xxx (and earlier)) ____Manual or Auto control (as desired) ____Verify Refrigerant Level Sensor calibration ____Valve Preset Time (Software version C. use the standard programming procedures in Operation Manual Form 160. PROGRAM JUMPERS/SWITCHES: (160.11.MLM.MLM. 1.xxx (and later)) ____Rate Limit Open*(Software version C.306 (and later)) 4.01.FORM 160.01.11.xxx (and later) or C.OPT.01.xxx (and earlier) or C.54-M1) ____ Brine Low Evaporator Pressure Cutout threshold* (160.01.54-O1.xxx (and earlier) or C.01.MLM.OPT.11. refer to Section 3 Tables 1 and 2.MLM.54-M1) ____ Enter the High Pressure Limit/Warning threshold Setpoint ____ Drop Leg refrigerant Temp Sensor Enable/ Disable 25 JOHNSON CONTROLS 211 .54-O1) Enter the following Setpoints: ____ Leaving Chilled Liquid Temp (except ISN Remote mode) ____ Remote Leaving Chilled Liq uid Temp Setpoint Range (except ISN Remote mode) ____ Low Chilled Liquid Temp cycling shutdown temperature ____ Low Chilled Liquid Temp cycling shutdown Restart temperature ____ Leaving Chilled Liquid Temp control Sensitivity (160. The Setpoints are grouped under the Display Screen in which they appear.14. The indented screens are subscreens of the numbered screens and are accessed from the numbered screens.01.54-M1) Verify the following Setpoints: ____Level Setpoint* ____Control Period* ____Proportional Limit Open*(Software version C.01.01.11. The programming of some of the Setpoints require a SERVICE access level.54-M1 (607) SECTION 25 SYSTEM COMMISSIONING CHECKLIST Use the following checklist during commissioning to assure all Setpoints have been programmed to the desired value and all calibrations have been performed. PROXIMITY PROBE CALIBRATION Screen (except “P” Compressors): ____ Verify that a Proximity Probe Reference Position* had been entered.54-M1) ____ Verify Microboard Program Jumpers and Program Switches are configured appropriately.01. CONDENSER Screen: (160.54-M1) ____ Select Pre-rotation Vanes Manual or Auto control.xxx (and later) or C. 54-M1) Mod “B” Solid State Starter: Verify the following Setpoints have been programmed: ____ Full Load Amps* ____ Start Current* ____ Supply Voltage Range* ____ Enable Open SCR Detection ____ Enable Shorted SCR Detection (Flash Memory Card version C. enable operation on the OPERATIONS Screen and enter the following setpoints: ____ Surge Reaction Time ____ PRV Offset ____ Probe Wait Time ____ Open Pulse ____ High Limit ____ Low Limit ____ Extreme Stall Duration (Software version C.14.01.306 (and later)) ____ Manual or Auto control. VARIABLE GEOMETRY DIFFUSER Screen: (160.xxx and later) ____ Hold Period ____ Close Percentage ____ Minimum Load ____ Manual or Auto Control. enable operation on the OPERATIONS screen and enter the following setpoints: ____ Maximum Open (Flash Memory Card version C.01.MLM.05.System Commissioning Checklist FORM 160.MLM.54-M1 (607) 5.54-M1) ____ Standby Lubrication Enable/Disable If chiller is equipped with the Oil Pump Variable speed Drive. verify the following Setpoints have been entered: ____ Oil Pressure Setpoint* ____ Control Period* ____ Manual or Auto control (as desired) 212 JOHNSON CONTROLS . as desired 6.MLM.54-O1) Solid State Starter Applications: (160.14.306 (and later)) ____ PRV VGD inhibit (Software version C.xxx (and later) or C.01.01.OPT.01.01. SURGE PROTECTION Screen: (160.54-M1) If chiller is equipped with optional Hot Gas Bypass.54-M1) If compressor is equipped with the variable Geometry Diffuser. as desired 8.xxx and later) ____ KWH Reset Medium Voltage Solid State Starter Verify the following setpoints have been programmed: ___Full Load Amps* ___Start Current* Mod “A” Solid State Starter: Verify the following Setpoints have been programmed: ____ Full Load Amps* ____ Supply Voltage Range* ____ Current Unbalance Check .MLM.04.05. HOT GAS BYPASS Screen: (160.xxx and later) ____ Enable/Disable Excess Surge Shutdown feature.01. ____ Enable/Disable Extended Run feature ____ Count Window ____ Count Limit ____ Surge Sensitivity 9.MLM.54-M1) ( Flash Memory Card version C.05.xxx and later) ____ Surge Sensitivity (moved to Surge Protection Screen in Flash Memory Card version C.Enable or Disable* Logic Board: ____ Verify location of 300V/600V Jumper* ____ Verify Start Current calibration* ____ Verify 105% FLA calibration* Electro-Mechanical Starter applications: (160.14. OIL SUMP Screen: (160.MLM.54-M1) Current Module: ____ Verify Switch S1 (Ydelta/57% or all others) setting* ____ Verify Pot R16 (LRA/FLA ratio) setting* ____ Verify slide bar resistor “RES” setting* ____ Verify 105% FLA calibration* ____ Verify 100% FLA display* 7.54-O1) ____ Enter the desired Pulldown Demand Limit and Time Setpoint (160. MOTOR Screen: ____ Enter the desired Current Limit Setpoint (160.14.xxx (and later) or C.OPT.01. 54M1) Enter the following Setpoints: (160.00-M6 (MVVSD) VSD DETAILS Screen: (VSD) ___ Set chiller Full Load Amps (FLA) value by adjusting potentiometer on VSD Logic Board (R34 on logic board 031-02506. The values shown reflect the previously programmed values.FORM 160.OPT.54-O1) With the exception of the “Remote Analog Input Range”. SETPOINTS Screen: (160. ____ Remote Analog Input Range SETUP Screen: ____ Enable Clock ____ Enter CLOCK Time and Date ____ Select 12 or 24 hour display mode Microboard 031-01730-000: ____ The state of Program Jumpers/Switches that affect chiller operation are displayed.01.OPT. 160. ____ Enter chiller START/STOP schedule if required. the setpoints listed here can be changed on this screen if desired. If it is not desired to change any of the listed setpoints.OPT. Confirm they are correct.xxx (or later)) 10.16. the setpoints listed on the SETPOINTS Screen have already been programmed above on Previous Screens. These were configured in step 1 above.54-M1 (607) Variable Speed Drive Applications: (160. ENGLISH or METRIC ____ If desired.01. Printer or ISN Remote application: ____ Chiller ID (identification) 213 25 JOHNSON CONTROLS .16. enter the following parameters as required for each device connected: ____ Baud rate ____ Number of data bits ____ Number of stop bits ____ Parity Enter appropriate number for Modem. R28 on all others).01. xxx (or later) – when “Modbus” is selected as Motor Communications Protocol) ____ Coastdown Time (software version C. MOTOR Screen: (MV VSD) ___Full Load Amps ADAPTIVE CAPACITY CONTROL(ACC) DETAILS Screen: ___Surge Map Clear ___Surge Map Print ___Auto Map Print ___Surge Margin Adjust ___Surge Sensitivity Motor Lubrication Screen: ___Enable/Disable Motor Auto Lubrication (software version C.xxx (or later) . However.54-M1.xxx (or later)) ___Enable/Disable the Motor Lubrication Warning Safety Shutdown (if Motor Lube is disabled) (software version C.16. These were configured in step 1 above.xxx (and Later)) ____ Anti-Recycle ____ Power Failure Restart ____ Coastdown (see Coastdown Time Setpoint below) ____ Pre-run ____ Oil Pump Package SCHEDULE Screen: ____ Enable or Disable Daily start/stop schedule as required.54-M1) ____ Chilled Liquid Pump Operation ____ Motor Drive Type ____ Motor Communications Protocol (software version C. (160. proceed to the SETUP Screen below. USER Screen: ____ Select desired Display language ____ Select desired Display units.54-M1) COMMS Screen: If Modem and or Printer is connected to the Microboard Serial data ports.01. 160.when VSD-50Hz or VSD-60Hz is selected as Motor Drive Type) ____ Motor Node ID (software version C. establish custom USER ID’s and PASSWORDS (160. (160. This screen is used primarily as a central location from which most setpoints can be programmed.01.16.16.00-M4 (VSD).OPT. Confirm they are correct.54-M1 Section 3) Microboard 031-02430-000/-001: ____ The state of Program Switches SW1-1 (Refrigerant Selection) and SW1-2 (Liquid Type) is displayed.OPT. enter the following: ____ Automatic print logging Enable/disable ____ Automatic printer logging start time ____ Automatic print logging interval ____ Printer type ____ Report type.05.xxx and later). LOCAL.54-M1) ____ Select desired Control Source (operating mode).01.xxx and later) ____ Enter Flow Sensor type (Flash Memory Card version C. SETPOINTS.xxx and later) ____ Enter Chiller Style/Compressor (Flash Memory Card version C.08.01. xxx and later) ____ Enter Local phone number (Flash Memory Card version C. DIGITAL Remote or ANALOG Remote ____ Refrigerant Level Control operation Enable/ Disable ____ Hot Gas Bypass Control (optional) Enable/ Disable ____ Variable Geometry Diffuser (Enable/Disable) (Chillers equipped with Variable Geometry Diffuser.54-M1 (607) PRINTER Screen: If Printer is connected to Microboard serial ports.01.10.302 (and Later) ____ Edit Regional phone number if necessary (Flash Memory Card version C. 214 JOHNSON CONTROLS .01.05.MLM. ISN Remote. STATUS.01.MLM.MLM.MLM. SCHEDULE or SALES ORDER SALES ORDER Screen: ____ Enter system commissioning date OPERATIONS Screen: (160.xxx (and later) or C.System Commissioning Checklist FORM 160.01.07.10.MLM.OPT. Software version C. With the TRIGGERED chart type. the valve will be closed proportionately as the Leaving Chilled Liquid Temperature increases to the Leaving Chilled Liquid Temperature Setpoint. The Default value for the Regional number is the North American Toll Free number. If START is selected. Flash Memory Card versions and part numbers are applied as follows: • Nema 1-4 Chillers C. and will stop when all triggers have been satisfied and any selected TRIGGER DELAY has elapsed. the Hot Gas Valve was opened to the 100% position.05A.MLM. If excess surging is detected. the valve will be opened to the position programmed as the “Maximum Open” setpoint (25% to 100%). it can be configured to shutdown the chiller or initiate a special surge correction/avoidance mode or simply display a warning message. Display of Service Phone Numbers Two service phone numbers (Regional and Local). Surge Protection The Surge protection feature detects surge events and provides a running count of the events that occur over the lifetime of the chiller.MLM. data collection can be set to START or STOP based upon the status of up to two Operator selected conditions (TRIGGERS) and a selected TRIGGER DELAY.01. A Surge Protection display Screen displays all parameters relevant to this feature.05A. Data collection will stop at the completion of one screen of data. In this version.FORM 160.01. The Local label and number can also be entered. can be displayed on the OPERATIONS Screen. This is in addition to the ONE SCREEN and CONTINUOUS chart types that can be created in previous Flash Memory Card versions.SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2001 General Beginning May 2001. An excess surge threshold can be programmed to detect excessive surging. This feature is a valuable troubleshooting tool for Service technicians. It allows an event that occurs during unattended hours to be captured for viewing at a later time.54-M1. This allows for better control of the minimum load conditions. data collection will not begin until all triggers have been satisfied and any selected TRIGGER DELAY has elapsed. when the Leaving Chilled Liquid Temperature decreased to the “Minimum Load” setpoint. After the Minimum Load operation is activated. 26 JOHNSON CONTROLS 215 . The trigger event results in a screen of frozen trend data that will remain on the screen until manually cleared. Trend Screen – Triggered Chart A “TRIGGERED” chart can now be created. data collection will begin when manually initiated. However.102 (031-01797-001) • CE Chillers C. Hot Gas Bypass Enhancement In previous Flash Memory Card versions. with labels.54-M1 (607) SECTION 26 SERVICE INFORMATION LETTERS / BULLETINS SI0006 . If STOP is selected. an enhanced Flash Memory Card will be supplied with new production Nema 1-4 and CE chillers.54-O1 and Service Manual 160.203 (031-01797-002) The enhanced flash cards are also available from the Baltimore Parts Distribution Center for retrofit to existing chillers. New features are outlined below and are also included in YORK Operation Manual 160. the label and number can be changed to any desired value. the conditions for this safety shutdown were checked after the first 10 minutes of chiller run. In this version. 2.Service Information Letters / Bulletins FORM 160. in addition to the previous criteria. Therefore. the three Inverter Assemblies are mounted on a single Baseplate instead of three individual Heatsink Assemblies.54-M1 (607) SI0006 . the oil pump VSD starts at 25Hz when turned on during “System Prelube”. In this version. B and C output current to the motor is now displayed on the VSD Tuning Screen. the shutdown conditions are not checked unless Smart Freeze is enabled and the Evaporator Refrigerant Temperature RT7 (if enabled) or Evaporator Saturation Temperature (derived from the evaporator pressure transducer) is < 32º F.SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2001 (CONT'D) “Evaporator-Transducer or Temperature Sensor” Safety Shutdown In Previous Flash Memory Card versions. B and C Temperatures displayed on other models. In this model. The new 351HP VSD is supported. This provides greater reliability in achieving the required 45 PSID Target Oil Pressure at chiller start. Compressor Motor Variable Speed Drive 1. 216 JOHNSON CONTROLS . it starts at 45Hz. The compressor motor VSD phase A. Oil Pump Variable Speed Drive In previous Flash Memory Card versions. Under certain operating conditions this would result in unnecessary shutdowns. as in other models. the VSD Details Screen and the Harmonic Filter Details Screen display a single Baseplate Temperature instead of the Phase A. 100 (031-02073-001) • CE chillers (“P” compressors) .....C. Record Setpoint Changes This feature provides a record of the last 75 Setpoint changes... or if any faults other than the following occur.04... While the chiller is running.......MLM.MLM. The Security Log Screen and the Security Log Details Screen display levels of this information..MLM. “Vanes Closing Before Shutdown” is displayed on the System Status line. The most recent is listed as number 1.C. the new Setpoint value and the Access Level and User ID used to make the change are stored in the BRAM..01...FORM 160... When the Vane Motor Switch (VMS) closes...... multiple pages could be necessary to display all the changes...MLM.100 (031-01797-001) • CE chillers (except “P” compressors) .. JOHNSON CONTROLS 26 217 . whichever occurs first).54-M1 (607) SI0019 ...04.02.. the next most recent as number 2... select the Setpoint change number with the LOG ENTRY key and then press the VIEW DETAILS key. A PRINT key allows printing this entire list.. the Soft Shutdown is terminated and it will immediately enter a normal Coastdown period: • “Leaving Chilled Liquid – Low Temperature” • “Remote Stop” • “Multi-unit Cycling – Contacts Open” • “System Cycling – Contacts Open” • “Control Panel – Schedule” Following an Operator initiated Soft Shutdown..06..02..... a SOFT SHUTDOWN key is available on the Home Screen (when Access Level is Operator or higher).. The date and time the Setpoint was changed.... The new features are outlined below.06.. the Start Signal is removed from the Starter and a normal Coastdown is performed. Pressing this key causes the Pre-rotation Vanes to be driven fully closed... While the Vanes are closing during the Soft Shutdown. Since 15 changes can be displayed at one time...... or higher) to manually initiate a soft shutdown by closing the Pre-rotation Vanes prior to shutting down the chiller....200 (031-01797-002) • Nema 1-4 chillers (“P” compressors) .... While they are closing.. the front panel Rocker Switch must be placed in the Stop/Reset position and then to the Start position in order to start the chiller after a Soft Shutdown has been performed.5 minutes have elapsed.200 (031-02073-002) These versions are also available from the Baltimore Parts Distribution Center for retrofit to existing chillers. Setpoint Category and new Setpoint value are listed and numbered in reverse order in which they were changed... If it is desired to view the details of a particular Setpoint change..01. This moves to the SECURITY LOG DETAILS Screen.... if a standard Local Stop is initiated with the front panel Rocker Switch.. The Flash Memory Card versions and part numbers are as follows: • Nema 1-4 chillers (except “P” compressors) .. On the Security Log Screen... “Local Stop” is displayed on the System Details line... indicating the Vanes have fully closed (or 3. Operator Soft Shutdown This feature allows an Operator (logged in at Operator Access Level.. etc.... the Setpoint. an enhanced Flash Memory Card will be supplied in new production YK Nema 1-4 and CE chillers....C... accessible from the History Screen.... This reduces compressor bearing wear by eliminating compressor backspin at shutdown.....SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2002 General Beginning March 2002.. Both screens are available in Service Access level or higher.... PAGE-UP and PAGE-DOWN keys are provided to view the entire list.C.. minimums and maximums • Trend trigger data • Trend print mode • Trend view mode Leaving Chilled Liquid Temperature Control Sensitivity Setpoint In addition to the NORMAL and 50% selections provided in previous software versions.Service Information Letters / Bulletins FORM 160. Previously. The Setpoint is selected from the list on the Security Log Screen as explained in the previous paragraph. displays the following Setpoint change details. This provides less overall Pre-rotation Vane (PRV) movement than the 50% selection by limiting the longest allowed pulse to 3. Password and Level • Trend start/stop • Trend slot numbers. • Level Control Period Setpoint – Now programmable over the range of 3. • Setpoint Category • Setpoint • Date and time of change • Access Level and User ID used to make the change • Old Value • New Value The following Setpoint changes are not logged: • Clock Mode • Custom Screen slot numbers • Advanced Diagnostics communication port tests • Advanced Diagnostics secondary multiplexer freeze • Soft shutdown initiated by operator • System language • Display units • Any Print report • Cancel any print report • Schedule clear • Schedule repeat exception days • Schedule start and stop times • Log in/log out • User attributes for ID. Refrigerant Level Control The following features provide improved Level Control stability. Previously.0 to 5.SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2002 (CONT'D) The SECURITY LOG DETAILS Screen. it was 1.5 seconds. • Rate Limit Open Setpoint – Now programmable over the range of 5% to 50%.0 seconds. • The message “Warning – Refrigerant Level Out of Range” and the associated Lower signal that opens the valve until the level is within range has been eliminated. a 30% selection has been added to this version. • The Ramp-up feature is now only executed immediately after chiller start.0 seconds.54-M1 (607) SI0019 . Subsequent Ramp functions during chiller run have been eliminated. it was 10% to 50%. A PRINT key is provided to print this information. accessible from the SECURITY LOG Screen.5 to 30. This selection can used when the 50% selection does not reduce the PRV instability to the desired level. 218 JOHNSON CONTROLS . longer Periods would produce longer output pulses for the same error.54-M1 (607) SI0019 . it was 10% to 50%. the maximum Vane pulse is limited to 3. Therefore. • If either the 50% or 30% Leaving Chilled Liquid Temperature SENSITIVITY Setpoint is selected.5 seconds at 25% position and 0.FORM 160. 26 JOHNSON CONTROLS 219 . It is now a fixed percentage of 3. When the Vane position is less than 25% and Leaving Chilled Liquid Temperature is within + 2. This is corrected in this version.9 seconds at 0% position.5 ºF of Setpoint. • Harmonic Filter Currents are now correctly displayed at maximum values. Previously. Hot Gas Bypass The Hot Gas Valve position is now animated on the HOT GAS BYPASS Screen.SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2002 (CONT'D) • Rate Limit Close Setpoint – Now programmable over the range of 5% to 50%. • In previous Flash Memory Card versions. Pre-rotation Vane movement is further reduced when the chiller is operating at low load. it was a percentage of the Period Setpoint. resulting in unstable operation under certain conditions. the SET FREQUENCY Setpoint feature on the VSD TUNING Screen did not correctly set the desired frequency in 50Hz applications. Compressor Motor Variable Speed Drive • The conditions to produce the “Harmonic Filter – Logic Board or Communications” Cycling shutdown must now be present for 10 communication cycles before a shutdown is performed. • The duration of the open or close pulse applied to the Valve Actuator is now independent of the selected Period Setpoint.5 seconds. Previously. Vane positions in between have linearly scaled maximums. History Chiller Run Time is now included on History Details display and print. 0 seconds “Oil – Variable Speed Pump-Pressure Setpoint Not Achieved” safety shutdown threshold – Either 25 PSID or 35 PSID Flash Memory Card version C. they are backward compatible to all previous style YK chiller/compressor combinations. Variables include the following: • • • • • High Speed Thrust bearing proximity sensing – Proximity Probe or Limit Switch Flow Sensor – Paddle type (115Vac digital input) or factory mounted thermal type sensor (+5Vdc analog input) Oil Heater Outputs – Either TB1-34 or TB1-64 on I/O Board Refrigerant Level Control Default Period – Either 3.MLM.07. The enhancements that affect the OptiView Control Center are listed below. an enhanced Flash Memory Card will be supplied in new production YK chillers.xxx and later are applicable and backward compatible to all YK chiller/ compressor combinations. the chiller mod level/compressor size combination must be entered (using Service Access level) using the CHILLER MOD Setpoint key on the OPERATIONS Screen. Part number 031-01797-001 will be supplied in place of 031-02073-001 and 031-01797-002 will be supplied in place of 031-02073-002 .MLM. Q Compr” “Mod CDE – GHJ Compr” “Mod E – P Compr” Once the appropriate chiller/compressor combination is entered. “Mod F – GH Compr” “Mod F – J Compr” “Mod F – P. The new versions are: • • Nema 1-4 chillers (all compressors)……. They supersede all previous versions of the same part number.. The selections are as follows: (Default is “Mod F – GH Compr”) a. c.54-M1 (607) SI0034 (203) .104 (031-01797-001) CE chillers (all compressors)…………….SOFTWARE ENHANCEMENTS EFFECTIVE AUGUST 2002 Flash Memory Card Beginning August 2002. The Cards are also available from the Baltimore Parts Distribution Center as replacement parts.C.07.01. scheduled for future release.5 seconds or 10. For correct control. b. the program automatically bundles the functionality and control per the following table: 220 JOHNSON CONTROLS .01.C. e. The new card supersedes and will be supplied in place of 031-02073-001 and 031-02073-002 Flash Memory Cards that were previously used for “P” compressor applications. The various YK chiller modification level (style)/compressor combinations are equipped differently and have different control requirements.07.MLM. These Cards will accommodate the YK Style “F” chiller. d.205 (031-01797-002) In addition to being used on all YK Style "F" chiller/compressor combinations.Service Information Letters / Bulletins FORM 160. They contain all control variables for all combinations.01. resulting in no conduction through the load resistor. This applies <1Vdc to the microboard input. the solid state relay output is turned off. one side of the solid state relay output (pin 2) is connected to the microboard +5Vdc and the other side (pin 4) is connected to a microboard analog input. The operating principle of the sensor is thermal conductivity. It uses the cooling effect of a flowing liquid to sense flow.0 sec 3.SOFTWARE ENHANCEMENTS EFFECTIVE AUGUST 2002 (CONT'D) Chiller Mod – Compressor “Mod C.5 sec 10. The power source is connected to the sensor as follows: From To Sensor pin 1 TB1-162 (24Vac) pin 3 TB6-5 (Gnd) The sensor outputs are connected to the Microboard as follows: Evaporator: From To Sensor pin 2 Microboard J7-1 (+5Vdc) pin 4 J7-14 (input to Microboard ) Condenser: Sensor pin 2 Microboard J7-15 (+5Vdc) pin 4 J7-16 (input to Microboard) Microboard Program Jumpers JP21 and JP22 must be placed in the positions 2 & 3. To determine the state of the solid state relay. JOHNSON CONTROLS 26 221 .5 sec 3. H Compr” “Mod F – J Compr” “Mod F – P. first confirm that +5vdc is present at pin 2 of the flow sensor. is only affected by changes in liquid temperature. Flowing liquid carries heat away from the heated sensor tip. condenser J7-16). located higher in the tip in a non-heated area. Q Compr” Proxmity Sense Probe Limit Switch Limit Switch Probe Limit Switch Oil Heater Output* TB1-34 TB1-64 TB1-64 TB1-64 TB1-64 Level Control Period Default 3. The lower temperature differential between the two thermistors indicates the liquid is flowing. E – G. Then connect a voltmeter from Microboard J7-14 (evaporator) or J7-16 (condenser) to microboard TP1 (ground). The temperature of the heated sensor tip is sensed by a thermistor located in the tip. When flow is sensed. lowering its temperature.FORM 160. The temperatures sensed by the thermistors are compared. These are electronic thermal-type sensors. A higher differential indicates no flow.54-M1 (607) SI0034 (203) . On each sensor. When no flow is sensed. the solid state relay output is turned on causing it to conduct current through the 7.5 sec 10. Each device operates from a 24Vac power source and has a solid state relay output. H. A second thermistor. This applies >+4Vdc to the microboard input (evaporator J7-14.5K ohm microboard load resistor to the +5vdc. D. J Compr” “Mod E – P Compr” “Mod F – G. Factory Mounted Flow Sensors Style "F" (and later) chillers are supplied with factory-mounted Flow Sensors on the evaporator and condenser.0 sec Flow Switch Paddle Type Paddle Type Factory Mounted Thermal Type Factory Mounted Thermal Type Factory mounted Thermal Type “Oil-Variable Speed Pump Pressure Setpoint Not Achieved” Threshold* 35 PSID 25 PSID 35 PSID 35 PSID 25 PSID * Not applicable to Mod C and earlier chillers. YK chillers equipped with “P” compressors used the High Speed Thrust Bearing Limit Switch and all other compressors used the Proximity Probe. • • Microboards Since the new version Flash Memory Card (as described above) is applicable to all YK chillers with any compressor.Service Information Letters / Bulletins FORM 160. the control will operate as follows: • • While the chiller is stopped. If the VALVE PRESET TIME SETPOINT is set to 0 seconds and the RAMP-UP TIME Setpoint is set to 15 minutes. this control operates as follows: When the chiller enters “System Run”. called the REFRIGERANT LEVEL TARGET. only the “J” compressor will use the Proximity Probe. the valve is held in this position until the first 3 minutes of chiller run time have elapsed. default 8. the Refrigerant Level “Raise” output is energized for the length of the programmable VALVE PRESET TIME setpoint (0 to 100 seconds. Compressors “G”. Service access level). a linearly increasing ramp limit. The standard 331-01730-601 Microboard replacement kit will be supplied when the 331-01730-604 is ordered. “H” and “P” will use the Limit Switch. With Style “F” chillers. the Refrigerant level “Lower” output is energized. During this ramp-up period. In this version. The Control SETPOINT is then used to control the refrigerant level for the remainder of chiller run. After 3 minutes of run time. Refrigerant Level Control In previous Flash Memory Card versions. or if the Level Control is disabled. Refrigerant Level Control will operate exactly the same as previous Flash Memory Card versions. if the Refrigerant Level Position is less than the CONTROL SETPOINT. This ramp limit allows the level to go from the present programmed level to the programmed CONTROL SETPOINT over a period of 15 minutes. In this version. a linearly increasing ramp limit. the REFRIGERANT LEVEL TARGET is used to control the condenser refrigerant level. is applied to the CONTROL SETPOINT. Service access level). This ramp limit allows the level to go from the present level to the CONTROL SETPOINT over a period of time programmed as the RAMP-UP TIME Setpoint (3 to 15 minutes. After pre-positioning. an unlit LED indicates a normal condition and a lit LED indicates a faulted condition. 222 JOHNSON CONTROLS . the Thrust Bearing Limit Switch indication shows a lit LED for a normal condition and unlit for a faulted condition. default 50. is applied to the programmed Control Setpoint. In previous Flash memory card versions.54-M1 (607) SI0034 (203) . called the REFRIGERANT LEVEL TARGET. Setting the VALVE PRESET TIME to 0 seconds disables this pre-positioning feature.SOFTWARE ENHANCEMENTS EFFECTIVE AUGUST 2002 (CONT'D) Proximity Probe/Limit Switch Previously. the Microboard replacement kit 331-01730-604 previously supplied for YK chillers equipped with “P” compressors is no longer required. The CONTROL SETPOINT is used to control the level during the remainder of chiller run. Setting the Valve Preset Time to a value greater than 50 seconds has no effect on the Prelube time. if the Refrigerant Level is less than the CONTROL Setpoint. During these 15 minutes. Upon entering chiller Prelube. the REFRIGERANT LEVEL TARGET is used to control the refrigerant level in the condenser. the “FLOW SWITCH” key appears on the OPERATIONS Screen allowing the flow sensor type to be entered. 26 JOHNSON CONTROLS 223 .FORM 160. However. Oil Pressure Threshold The threshold for “Oil – High Differential Pressure” safety shutdown is changed from 90 PSID to 120 PSID. Press FLOW SWITCH key. this Flash Memory Card version allows Style F chillers to use either the thermal-type or field installed paddle-type flow sensor. the actual sensor type used must be entered at the keypad OPERATIONS Screen using the Service Access Level.206 (p/n 031-01797-002) Flow Sensors Mod (Style) F chillers are provided with factory mounted thermal-type flow sensors for the evaporator and condenser.MLM. 4. Select SETPOINTS/SETUP/OPERATIONS Screen. 60Hz) (419HP. The paddle-type sensors interface to the I/O board 115Vac digital inputs at TB4-12 (evaporator) and TB4-11 (condenser). 2.MLM. Use ◄ or ► keys to select flow sensor type.01. 3. The enhancements are outlined below. B and C Baseplate Temperatures are displayed on the VSD DETAILS Screen and Filter Baseplate Temperature is displayed on the FILTER DETAILS Screen. the program reads the thermal-type flow sensor inputs at Microboard analog inputs J7-14 (evaporator) and J7-16 (condenser) and ignores the Digital inputs. These cards are backward compatible to all previous YK chillers and are available from the Baltimore Parts Distribution Center as replacement parts. Analog or Digital is alternately displayed. The thermal-type sensors interface to Microboard +5Vdc analog inputs at J7-14 (evaporator) and J7-16 (condenser). If Analog is selected.SOFTWARE ENHANCEMENTS EFFECTIVE FEBRUARY 2003 General Beginning February 2003. Press ENTER (✔) key. Display messages unique to this drive are displayed appropriately on the screens as follows: Phase A.08.08. If the chiller Mod (style) level setpoint on the OPERATIONS Screen is set to “F” (any compressor). the program reads the paddle-type sensor inputs at the I/O Board digital inputs TB4-12 (evaporator) and TB4-11 (condenser) and ignores the Analog inputs. the pump speed command is held at 45Hz for the first 8 seconds before releasing to normal control. Each time the key is pressed.54-M1 (607) SI0058 . 50Hz). The selections are “Analog” (thermal-type) or “Digital” (paddle-type). The versions and part numbers are applied as follows: • NEMA 1-4 chillers C. If Digital is selected. Compressor Motor Variable Speed Drive (VSD) This Flash Memory Card version supports VSD part number 371-03789-xxx (503HP. an enhanced Flash memory Card will be supplied in all new production YK chillers. Variable Speed Drive Oil Pump When the oil pump is started during System Prelube.105 (p/n 031-01797-001) • CE chillers C.01. For the program to read the appropriate inputs for the flow sensor status. Enter the applicable flow sensor type as follows: 1. “Harmonic Filter – High Baseplate Temperature” The chiller has shutdown because the Baseplate temperature has increased to >194 ºF. “VSD – High Phase B Inverter Baseplate Temperature” Same as phase A above. In this version. This was incorrect operation. some setpoint changes were not logged in metric mode. the following Safety shutdown messages apply to this VSD: “VSD – High Phase A Inverter Baseplate Temperature” The chiller has shutdown because the Baseplate temperature has increased to >158 ºF. 224 JOHNSON CONTROLS . All setpoint changes are now logged. the following Cycling shutdown messages apply to this VSD: “VSD – Low Phase A Inverter Baseplate Temperature” The chiller has shutdown because the Baseplate temperature has decreased to <37 ºF. In addition to standard VSD Safety shutdown messages. the codes are transmitted into the proper slots in the Microgateway. Security Log Screen In previous Flash Card versions. when in reality. “Start Inhibit” and “Modified Run” codes were transmitted into “Cycling” and “Safety” shutdown slots in the Microgateway. Microgateway In previous Flash Card versions. a Start Inhibit such as Anti-recycle or a Modified Run event such as Current Limit is in effect. “VSD – Low Phase C Inverter Baseplate Temperature” Same as phase A above. “VSD – High Phase C Inverter Baseplate Temperature” Same as phase A above.54-M1 (607) SI0058 . This alarmed external devices that a Cycling or Safety shutdown has occurred.Service Information Letters / Bulletins FORM 160.SOFTWARE ENHANCEMENTS EFFECTIVE FEBRUARY 2003 (CONT'D) In addition to standard VSD Cycling messages. “VSD – Low Phase B Inverter Baseplate Temperature” Same as phase A above. 5 sec 10.0 sec 3.01. The Chiller Style/Compressor selections are shown below. The functionality of this setpoint has changed slightly as follows: The previous choice of “Style F chiller/G. this setpoint key is now labeled “CHILLER STYLE/COMPRESSOR” (English only).5 sec 3. H5-8 compr”. H & J Compr” “Style E/ P Compr” “Style F/ G & H5-8 Compr” “Style F/ J & H3 Compr” “Style F/ P.08. The previous choice of “Style F chiller/J compr” is now “Style F chiller/J.MLM.206A (p/n 031-01797-002) Chiller Style/Compressor Setpoint In previous Flash Memory Card version. H compr” is now “Style F chiller/G.01.08. D & E/ G.FORM 160. H3 compr”. The enhancements are outlined below.SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2003 General Beginning March 2003. For clarity.0 sec “Oil-Variable Speed Pump-Pressure Setpoint Not Achieved” Threshold* 35 PSID 25 PSID 35 PSID 35 PSID 25 PSID Chiller Style/Compressor “Style C. Q Compr” Proxmity Sense Flow Switch Probe Limit Switch Limit Switch Probe Limit Switch Digital (Paddle Type) Digital (Paddle Type) Programmable (Analog or Digital) Programmable (Analog or Digital) Programmable (Analog or Digital) * Not applicable to Style C and earlier chillers 26 JOHNSON CONTROLS 225 .105A (p/n 031-01797-001) • CE chillers C. These cards are backward compatible to all previous YK chillers and are available from the Baltimore Parts Distribution Center as replacement parts. The versions and part numbers are applied as follows: • NEMA 1-4 chillers C. Oil Heater Output* TB1-34 TB1-64 TB1-64 TB1-64 TB1-64 Level Control Period Default 3. this setpoint key (located on OPERATIONS Screen). an enhanced Flash Memory Card will be supplied in all new production YK chillers. was labeled “CHILLER MOD”.5 sec 10.MLM.54-M1 (607) SI0062 . 226 JOHNSON CONTROLS .Service Information Letters / Bulletins FORM 160.54-M1 (607) This page intentionally left blank. but does not affect chiller operation or performance. This data is displayed. the COUNT WINDOW setpoint default is now 3 minutes (was 5 minutes). It calculates the amount of energy that has been saved by having a variable speed drive instead of a constant speed drive. Although this feature is present in this software.09. The COUNT LIMIT setpoint default is now 15 surges (was 4 surges). It is backward compatible to all previous YK chillers.01.SOFTWARE ENHANCEMENTS EFFECTIVE JANUARY 2004 General Beginning January 2004.106 (p/n 031-01797-001) • CE chillers C.MLM. The enhancements are outlined below.09. 26 JOHNSON CONTROLS 227 .207 (p/n 031-01797-002) The versions and part numbers for 031-02430-000 Microboards are as follows: NEMA 1-4 & CE chillers C.54-M1 (607) SI0080 .MLM. enable and setup information. Surge Protection If the chiller is equipped with a compressor motor Variable Speed Drive (VSD): • The surge SHUTDOWN feature. EXTENDED RUN feature and surge warning messages will not be performed unless the VSD output frequency is at maximum. enhanced software will be supplied in all new production YK chillers. If the chiller is equipped with both a VSD and the Hot Gas Bypass feature: • The Hot Gas Valve position must be at 100% AND the VSD output frequency must be at maximum before the above surge features are performed.09.01.01. The resulting difference is the energy savings.FORM 160. The versions and part numbers for 031-01730-000 Microboards are as follows: • NEMA 1-4 chillers C. it is not operational until enabled using a special procedure. The savings is determined by calculating the energy consumption of a constant speed drive and subtracting the measured energy consumption of the variable speed drive. For all applications.301 (p/n 031-02474-001) OptiSave Energy Analyzer Feature This feature reveals the advantage of a compressor motor variable speed drive. It provides all required installation. Refer to Service Information letter SI0068 for a complete description of this feature.OPT. If the PRV were previously calibrated successfully. When the feedback voltage stops increasing and remains stabilized (so that there is no more than + 0. After a 10 second delay. 4.25vdc deviation) for 25 continuous seconds. the program begins evaluating the feedback voltage from the PRV potentiometer. Variable Geometry Diffuser and any other PRV calibration. If they were not previously calibrated successfully. This has been corrected in this version.5vdc. 3. “PRV Calibration Successful” is displayed. If the difference between the endpoint voltages is greater than 0. “PRV Calibration Unsuccessful” is displayed. The CALIBRATION IN PROGRESS and PRV OPENING LED will illuminate and an open signal is applied to the PRV. Place the COMPRESSOR switch in the Stop-reset position (O) and wait until the System Coastdown is complete. Microgateway Induced Reboots With previous Flash Memory Card versions. 5. “PRV Calibration Unsuccessful” is displayed.SOFTWARE ENHANCEMENTS EFFECTIVE JANUARY 2004 (CONT'D) Pre-rotation Vanes Calibration There is now one procedure for all Pre-rotation Vanes (PRV) calibrations. Hot Gas Bypass. 228 JOHNSON CONTROLS . if the endpoints are not established within 10 minutes. the feedback voltage is logged as the 0% position. they will remain uncalibrated. When the feedback voltage stops decreasing and remains stabilized (so that there is no more than + 0. This procedure applies to the compressor motor variable Speed Drive (VSD).54-M1 (607) SI0080 . Press the START CALIBRATION key to initiate the calibration. login at Service access level. The calibration procedure can be terminated at any time during the procedure by pressing the CANCEL CALIB key. the feedback voltage is logged as the 100% position. 1.25vdc deviation) for 25 continuous seconds. After a 60 second delay. the program begins evaluating the feedback voltage from the PRV potentiometer.Stability Limit Setpoint This compressor motor Variable Speed Drive setpoint default is now 7000 (was 4500).Service Information Letters / Bulletins FORM 160. Microgateway communications could cause the Microboard to randomly reboot. 2. A close signal is then applied to the PRV and illuminates the PRV CLOSING LED. At the keypad. These endpoint voltages are stored in the BRAM as the full open and full closed positions. Also. Otherwise. VSD Adaptive Capacity Control . Select the PRE-ROTATION VANES CALIBRATE screen from the COMPRESSOR screen. it will revert to using the previous calibration values. a safety fault occurs and “Condenser – High Pressure .MLM. if the condenser pressure exceeds 160. 26 JOHNSON CONTROLS 229 . an anticipatory safety fault has been created to annunciate condenser high pressure conditions when the chiller is stopped as follows: While the chiller is stopped.0 PSIG (R134a).11. 3.01.0 PSIG (R22).11.SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2004 General Beginning May 2004. the fault data transferred to the Optiview Control Center is a function of the eprom (U16) in the starter Logic/Trigger Board. login at Service access level using code 1 3 8 0. The enhancements are outlined below.01. This anticipatory fault is only performed while the chiller is stopped. 240.OPT. Style B Solid State Starter Faults The following changes apply to faults detected by the Style B Liquid Cooled Solid State Starter (LCSSS): Open SCR (Silicon Controlled Rectifier) Fault When the Solid State Starter initiates a shutdown.MLM.11.0 PSIG (R22) and a special reset procedure is performed as follows: 1. Therefore. Select COMPRESSOR screen. 4.108 (p/n 031-01797-001) • CE chillers C. Place the COMPRESSOR switch in the Stop-reset position.FORM 160. A dialog box appears displaying “Enter Password to Clear Fault”.209 (p/n 031-01797-002) The version and part number for 031-02430-000 Microboards are: • NEMA 1-4 and CE Chillers C. 240. The versions and part numbers for 031-01730-000 Microboards are: • NEMA 1-4 chillers C. At the keypad. If a “Condenser – High Pressure” fault is detected while the chiller is in Pre-lube. Enter 1 3 9 7 and press the ENTER key (√).54-M1 (607) SI0089 . System Run or Coastdown. enhanced software will be supplied in all new production YK chillers.Stopped” is displayed. The chiller can be started after the condenser pressure decreases to less than 160. 2. the fault is handled in the normal way and does not require the special reset procedure. 5.01. Press the FAULT ACKNOWLEDGE key on the COMPRESSOR Screen.0 PSIG (R134a).303 (p/n 031-02474-001) High Condenser Pressure Fault While Shutdown High temperature condenser water flowing through the condenser while the chiller is shutdown can cause a condenser high pressure condition resulting in loss of refrigerant. It is backward compatible to all previous YK chillers. the manual frequency could be changed only when the pump was running. Therefore.SSS. New version C. Therefore.01.SSS.SSS. Start Inhibit Faults The following Start Inhibit Faults are no longer logged on the History Screen.01. 230 JOHNSON CONTROLS . in starters equipped with eprom version C. the fault data returned from the starter did not identify the phase in which the fault occurred. Invalid System Details Messages In previous Flash Memory Card versions.SSS. B or C as appropriate) is displayed when the fault occurs. “LCSSS – Phase X Open SCR” (X replaced by A. This has been corrected in this version.SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2004 (CONT'D) Previously.03 (and later) eprom. The manual frequency can now be changed whether the pump is running or not.01. when this Flash Memory Card version is used with a starter Logic/Trigger Board equipped with version C. They will continue to be displayed on the System Details line of the display and transferred to the MicroGateway.02. when an Open SCR fault occurred. Variable Speed Oil Pump In previous Flash Memory Card versions. B or C as appropriate) Diagnostics Screen The communications error counters now count up to 65535 (was 255). there have certain operating conditions that could cause messages on the System Details line of the display to become “stuck”. “LCSSS – Phase X Heatsink Temperature – Stopped” (X replaced by A. History Data Storage The data capture has been modified to assure that all data is that which is valid at the instant of the event. returns fault data that identifies the phase in which the Open SCR condition is detected.03 eprom now supplied in the starter Logic/Trigger Board.01.Service Information Letters / Bulletins FORM 160.54-M1 (607) SI0089 . This Flash Memory Card version interprets this fault data and displays a message that identifies the defective phase. the message displayed by the Optiview Control Center was “LCSSS – OPEN SCR”.00 through C. The most prevalent one was “Motor – High Current Limit”. enhanced software will be supplied in new production YK chillers. When transitioning from Zone 2 to Zone 1. some control thresholds are fixed while others are programmable. Zone 2 parameters are used when the error is >9%. The Operator enters his/her initials. It is backward compatible to all previous YK chillers. If there is still no response. the VGD is driven to the full open position and “Warning – Conditions Override VGD” is displayed until the Stall Detector Voltage returns to less than two times the HIGH LIMIT Setpoint the warning is manually cleared. a safety shutdown is performed when the hours exceed 1400 hours and “Motor – Lack of Bearing Lubrication” is displayed. the VGD is disabled during extreme stall conditions and a warning message is displayed. The Limit Switch is closed and displayed as CLOSED when the VGD is in the full closed position. for the duration programmed as the EXTREME STALL DURATION Setpoint (10 to 20 minutes). VGD Limit Switch The status of the Variable Geometry Diffuser Limit Switch is now displayed on the VGD Screen and the VGD Setpoints Screen. PRV VGD INHIBIT.OPT. In this version. The notification is based on the “Operating Hours Since Last Motor Lubrication”. “Warning – Condenser or VGD Sensor Failure” is displayed and the Variable Geometry Diffuser (VGD) is driven to the open position until the warning is manually cleared. it is displayed as OPEN. Condenser Refrigerant Level Control In previous software versions.14. all of the control thresholds were programmable. the error must be < 9% for 60 seconds before the Zone 1 parameters are used. While the pre-rotation Vanes position is greater than this setpoint. “Warning – Motor Bearing Lube Suggested” is displayed when the hours exceed 1000 hours. This provides more stable control in certain operating conditions. Extreme Stall Monitor To prevent VGD damage. default 95%. The control thresholds are applied in two different zones. The following are the control thresholds now used for this control: 26 JOHNSON CONTROLS 231 .14. Motor Lubrication Notification This feature provides an indication when the compressor motor lubrication is required. the Zone 2 parameters are immediately implemented. If the Stall Transducer is not reading within an acceptable range of the condenser transducer. “Warning – Motor Bearing Lube Required” is displayed when the hours exceed 1200 hours.212 (031-01797-002) 031-02430-000 Microboard: · NEMA 1-4 and CE chillers C.01. If the error is > 9%.54-M1 (607) SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2005 General Beginning March 2005.MLM. name or user ID to provide a record of when a motor lubrication is performed and clear any motor lubrication warning or safety that is in effect.01.306 (031-02474-001) Stall Sensor Validation This feature verifies the operation of the Stall Pressure Transducer (used for the Variable Geometry Diffuser operation) by comparing its voltage output to the voltage output of the Condenser Pressure Transducer while the chiller is running.FORM 160. The enhancements are outlined below. Otherwise.MLM. This setpoint is programmable over the range of 40% to 100%. While the chiller is running. If there is no response.14. The versions and part numbers are: 031-01730-000 Microboard: · NEMA 1-4 chillers C. if the Stall Detector Voltage (output of the Stall Detector Board) exceeds twice the HIGH LIMIT Setpoint. each indicating an increasing level of urgency. VGD Inhibit Setpoint A new setpoint. the VGD is pulsed open according to the OPEN PULSE Setpoint and “PRV Position Override” is displayed as Control Status.111 (031-01797-001) · CE chillers C. has been added to the Variable Geometry Diffuser operation. as determined by the error relationship between the actual refrigerant level and the Level Setpoint as shown below.01. Zone 1 parameters are used when the error is < 9%. Up to three levels of notification are provided. Service Information Letters / Bulletins FORM 160.54-M1 (607) Zone 1 Zone 2 Proportion Limit Open (fixed) 50% 52% Proportion Limit Close (fixed) 45% 45% Rate Limit (setpoint) 3%-15% 3%-15% default 7 default 5 Period (setpoint) (seconds) 8-22 2. oil foaming when the pump is first turned on results in a sawtooth pressure ramp until it establishes a steady pressure.5 Zone 1 and Zone 2 Level Setpoint 20% to 80% default 30% Valve Preset Time (setpoint) (seconds) 0 to 100 default 50 Ramp Up Time (setpoint) (minutes) 3 to 15 default 8 Compressor Protecton Faults The following compressor protection faults have been added: “Motor – Current >15% FLA” In this version. by the Manual Increment Amount. In this version: “The LOWER key causes a decrease in the command frequency. down to 25/30Hz”. it was not put into effect until the invalid motor current was present for at least 10 seconds. the low oil pressure threshold is not applied until after the first 30 seconds of oil pump operation.5-10 default 15 default 2. 232 JOHNSON CONTROLS . “VSD – FREQUENCY > 0Hz” This new Start Inhibit is set whenever the chiller is shutdown and a compressor motor Variable Speed Drive (VSD) Output Frequency of greater than 0Hz is detected. Variable Speed Oil Pump (manual control) In previous software versions: “The LOWER key causes a decrease in the command frequency by the Manual Increment Amount. “VSD – LOW FREQUENCY DETECTED” This new safety shutdown is set whenever the chiller is running and the compressor motor Variable Speed Drive (VSD) Output Frequency decreases to less than half speed (25Hz for 50Hz units. Although the pressure builds to 15 PSID within seconds at pump turn-on. In this software version. down to the Manual Increment Amount”. a subsequent negative transition below 15 PSID within the first 30 seconds is detected as a Standby Lube failure. 30Hz for 60Hz units) after having reached that speed while starting. This allows sufficient time to establish steady pressure above 15 PSID. Standby Lubrication In low ambient temperature conditions. Previously. Optisave KW Metering Feature This feature provides customers currently employing a solid state starter or electro-mechanical starter with the means to determine their potential savings that would be realized by switching to a variable speed drive. the start inhibit is instantaneously invoked as soon as >15% FLA motor current is detected while the chiller is shutdown. The versions and part numbers are: Microboards 031-02430-000 and 031-02430-001 • NEMA 1-4 and CE chillers C. this shutdown is performed. However. this shutdown is performed: 424HP – 70. It is backward compatible to all previous YK chillers equipped with microboard 031-02430-000 or 031-02430-001. this shutdown is performed. “VSD-HARMONIC FILTER-PRECHARGE-LOW DC BUS VOLTAGE” If the DC Link voltage does not reach at least 60VDC (within 100 milliseconds) or at least 630VDC (within 5 seconds) after the filter precharge command has been received.54-M1 (607) SI0148 . this shutdown is performed. 174.011 (03102474-001) Medium Voltage Solid State Starter This software version is necessary for Medium Voltage Solid State Starter applications. The following Cycling shutdowns apply to 575V/60HZ VSD: “VSD-PRECHARGE-LOW DC BUS VOLTAGE” If the DC Link voltage does not reach at least 60VDC (within 4 seconds) or at least 600VDC (within 20 seconds) after the precharge command has been received. “VSD—PRECHARGE-DC BUS VOLTAGE IMBALANCE” If the Half DC Link voltage does not remain within + 106VDC of the DC Link Voltage divided by 2 during the pre-charge interval.01.4° C Microboard Applicability This software will operate in microboard 31-02430-000 or 031-02430-001. this version (or later versions) are required for microboard 031-02430-001. 575V/60Hz Variable Speed Drive This software version is necessary for 575V/60Hz VSD applications.OPT. The following safety shutdowns apply to 575v/60Hz VSD: “VSD-HARMONIC FILTER-HIGH BASEPLATE TEMPERATURE” If the Baseplate temperature rises above the following limits.2° C 608HP – 88.Refer to Literature Supplement 160. this shutdown is performed. “VSD-LOW DC BUS VOLTAGE” If the DC Link Voltage falls below 600VDC while running.FORM 160. “VSD-HARMONIC FILTER-DC BUS VOLTAGE IMBALANCE” If the Half DC Link Voltage does not remain within + 63 VDC of the DC Link Voltage divided by 2. 190.SOFTWARE ENHANCEMENTS EFFECTIVE JUNE 2006 General Beginning June 2006. enhanced software will be supplied in new production YK chillers. “VSD-DC BUS VOLTAGE IMBALANCE” If the Half DC Link Voltage does not remain within + 106VDC of the DC Link Voltage divided by 2 while running.54-M1 (LS06) 26 JOHNSON CONTROLS 233 . this shutdown is performed. this shutdown is performed.15.0° F. The enhancements are outlined below.0° F. It is backward compatible to all previous YK chillers equipped with microboard 031-02430-000 or 031-02430-0001. This version allows display in English.307 (031-02474-001) Languages Version C. French. enhanced software will be supplied in new production YK chillers. Italian.OPT. The versions and part numbers are: • NEMA 1-4 and CE chillers: C.01.01. German or Hungarian language. 234 JOHNSON CONTROLS . Chinese Traditional.Service Information Letters / Bulletins FORM 160. Chinese simplified. Spanish.15A.011 was released as English only. The enhancements are outlined below.54-M1 (607) SI0158 .15.SOFTWARE ENHANCEMENTS EFFECTIVE OCTOBER 2006 General Beginning October 2006.OPT. xxx and earlier) while the chiller is running. “Condenser – Flow Switch Open” – The condenser flow switch has remained open for 30 continuous seconds (2 continuous seconds with software version JOHNSON CONTROLS Variable Speed Drive – Invalid Current Limit Message In previous software versions. Chilled and Condenser Water – Flow Switch Shutdowns To prevent nuisance flow switch shutdowns due to momentary flow interruption or rapid water temperature changes that can affect Thermal Flow Sensors.16.15A. The versions and part numbers are: • NEMA 1-4 and CE chillers: C.15A. enhanced software will be supplied in new production YK chillers and replacement microboard kit 331-02430-601. the oil pump runs for the duration of the coastdown period. The compressor motor Variable Speed Drive has not yet reached full speed after having been commanded to do so in manual speed control. The enhancements are listed below.xxx and earlier) while the chiller is running or failed to close during the Pre-Lube period. new setpoint COASTDOWN TIME allows the service technician (in Service Access Level) to enter a coastdown time appropriate for the motor applied. The chiller will automatically restart when the flow switch closes.01. The time is programmable over a range based on the selection made for the CHILLER STYLE/ COMPRESSOR Setpoint on the Operations Screen: For style F/J7 and G/K6-K7. “Load Control Mode” is displayed instead of “Motor – High Current Limit” under this condition. This could result in reducing the overall range. Selectable Coastdown Time Setpoint To assure bearing lubrication until the compressor motor stops rotating at chiller shutdown. the software automatically rescaled the Y-axis range (on certain parameters) after the operator had already selected the range. 235 26 . Current Imbalance Messages The safety shutdown messages “Motor or Starter – Current Imbalance” and “LCSSS – Output Current Imbalance” have been combined into one message “Motor or Starter – Output Current Imbalance” for both Variable Speed Drives and Style B Solid State Starters. when operating at <full speed (60Hz/50Hz) and pressing the FIXED key on the VSD Tuning Screen. This software is backward compatible to all previous YK chillers equipped with microboard 031-02430-000 or 031-02430-001. This check is bypassed for the first 30 seconds of “System Run”.FORM 160.OPT. the Pre-rotation Vanes are inhibited from further opening. Larger motors require a longer coastdown time than the standard 150 seconds. While this is displayed.xxx (031-02474-001) C.OPT. In this version.54-M1 (607) SI0164 . For all others.01. While this message was displayed. the message “Motor – High Current Limit” was displayed until the drive reached full speed. New Trend/Custom View Slot Numbers The following slot numbers have been added: 2849 ACC Surge Count 2850 ACC Surge Type 2857 ACC Surge Point Count 2858 ACC Surge Delta P/P 2859 ACC Surge Output Frequency 2860 ACC Surge PRV Position Trend Scaling Error Correction In previous software versions.SOFTWARE ENHANCEMENTS EFFECTIVE APRIL 2007 General Beginning April 2007. the range is 240 (Default) to 900 seconds.OPT. when “Standard” is selected for the COASTDOWN Setpoint on the Setup Screen. the range is 150 (Default) to 900 Seconds. Therefore.01. The Yaxis is now scaled to accommodate the highest value selected. the following extended flow switch delays are implemented for both ANALOG and DIGITAL flow sensor selections: “Leaving Chilled Liquid – Flow Switch Open” – The chilled water flow switch has remained open for 5 continuous seconds (2 continuous seconds with software version C. the PRV are inhibited from opening. select “MODBUS”. Level Control Period = 3. The safety shutdown can be enabled or disabled per the customer’s preference. which is “Condenser – High Pressure Limit”. With this setting.00-M6 for this product. If disabled. the safety shutdown will occur at the normal 1400 hours. these new selections are the same as Style F/J1-J5H3: Proximity Sense = Probe. After this date. microboard 031-02430001 is required (ref SI0155). the ACC functionality is contained in the Microboard and the ACC Board is not present. this software supports the Medium Voltage Variable Speed Drive (MV VSD). With this setting. The new codes sent to the Microgateway are: “Motor-Bearing Lube Suggested” – Warning Code 36 “Motor-Bearing Lube Required” – Warning Code 37 “Motor-Lack of Bearing Lubrication” – Warning Code 38 The following new selections are added on the OPERATIONS Screen: • Style F/J7 compr • • Style G/K1-K4 compr Style G/K6-K7 compr Functionally. the motor lubrication warnings and shutdown will occur at the associated elapsed run times. They send a code 5. select “YORK”.Motor Lubrication Warning Code Correction Previous software versions send an incorrect warning code to the Microgateway for the Motor Lubrication Warning “Motor – Bearing Lube Suggested”.Service Information Letters / Bulletins FORM 160. Otherwise. Motor Lubrication Warnings and Shutdown This software version adds the AUTO LUBE and SHUTDOWN setpoints on the Motor Screen.5 seconds Flow Switch = Programmable (analog or digital). when the automatic lubrication hardware is present. the AUTO LUBE Setpoint must be ENABLED. a warning will be displayed but the safety shutdown will not occur. the VSD Logic Board communicates directly with the Microboard COM2 serial port using Modbus protocol. this software allows selection of either YORK or MODBUS protocol when VSD-50Hz/VSD-60Hz is selected for the Motor Drive Type Setpoint. Report contains only motor run state. This error is corrected in this software version. The protocol selection enables the appropriate serial communication port: “YORK” enables COM5. History Reports do not include snapshot data of shutdowns. H3 compr Style F/J1-J5H3 compr Style F/PQH9 compr compr Style F & G/PQH9 Microgateway .00-O6 and Service Manual 160. Chillers that are equipped with Automatic Motor Lubrication hardware do not require manual lubrication and therefore do not require the motor lubrication warnings (reminders) or the warning safety shutdown. Oil Heater Output = TB1-64.54-M1 (607) New Chiller Style/Compressor Selections The existing selections are changed as follows: Existing Change to Style F/J. the VSD Adaptive Capacity Control (ACC) Board communicates with the Microboard COM5 serial port using YORK protocol. Therefore. the SHUTDOWN Setpoint is used to enable or disable the safety shutdown that occurs at 1400 hours since last lubrication. If enabled. To allow this software to accommodate new production chillers and earlier chillers. no lubrication warnings or shutdown will occur. Refer to YORK Operator Manual 160. When used with Modbus protocol. The hardware present determines which protocol should be selected (ref SI0155): If the ACC Board is used. on new production chillers. 236 JOHNSON CONTROLS . Motor Communications Protocol Setpoint On new production chillers prior to March 2007. PRV position and MV VSD fault code. On these chillers. If the AUTO LUBE setpoint is DISABLED. Variable Speed Drive Oil Pump “Pressure Setpoint not achieved” = 35 PSID Medium Voltage Variable Speed Drive When used with microboard 031-02430-001. Since the MV VSD does not save snapshot data when faulting. as it should be when not equipped with the automatic Motor Lubrication hardware. “MODBUS” enables COM2. “Motor Node ID” Access Level Required: SERVICE Only displayed when “Modbus” is selected for the Motor Communications Protocol Setpoint above. this device is the VSD Logic Board. Allows the Service technician to enter the Modbus Address of the VSD Logic Board. Chiller must be stopped with the Start-Run-Stop switch in the Stopped position to change this Setpoint. select “MODBUS”. A reset counters key is present allowing the error counters to be reset to zero. it ignores the command/request. Chiller must be stopped with the Start-Run-Stop switch in the Stopped position to change this setpoint. the Logic Board responds. If the transmitted address matches the address assigned. Modbus Diagnostics Screen When Modbus Protocol is selected. Microboard 031-02430-001 must be equipped with 128KB BRAM (031-02565-000) to select “Modbus”. This is done by the positioning the VSD Logic Board Modbus Address Switch SW3 position 1 to ON and setting the Motor Node ID setpoint to “1”. Selection is based on hardware and interface. select “YORK”. the device that the microboard serially communicates with is assigned an address. The following new setpoints are programmed on the SETUP Screen: “Motor Communications Protocol” Access Level Required: SERVICE Only displayed when VSD-60Hz or VSD-50Hz is selected for Motor Drive Type Setpoint. If these two values are not set to the same number. Otherwise. the VSD COMMS Screen is replaced by the DIAGNOSTICS VSD (Modbus) Screen.FORM 160. Allows Service Technician to enable the appropriate serial communications port for communications to the Variable Speed Drive. The address assigned to the VSD Logic Board is “1”. If ACC Board is used.54-M1 (607) With Modbus protocol. The following screens are affected by this new protocol selection: Comms Screen When Modbus Comms are selected. Must be set to “1”. Otherwise. The VSD Logic Board Modbus Address switch SW3 must also be set to “1”. Whenever the microboard is reading or writing to this board. On VSD applications. the VSD Logic Board will not communicate with the microboard. This screen displays the following Modbus communications error counters: • • • Panel to VSD VSD to Panel FTR to VSD (if IEE 519 filter present and enabled) 26 JOHNSON CONTROLS 237 . it transmits this address. Entered as “York” to enable COM5 (J15) or “Modbus” to enable COM2 (J13). the COM2 Setup key on the COMMS Screen is not displayed. 54-M1 (607) NOTES 238 JOHNSON CONTROLS .FORM 160. 54-M1 (607) NOTES 27 JOHNSON CONTROLS 239 .FORM 160. Pennsylvania USA 17405-1592 Copyright © by Johnson Controls 2007 Form 160. Printed in USA ALL RIGHTS RESERVED . Box 1592.54-M1 (307) Tele.york. 800-861-1001 www. York.O.P.com Subject to change without notice.54-M1 (607) Supersedes: 160.
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