ykep centrigual liquid chiller unit wiring and field

WIRING DIAGRAMS

CONTRACTOR _______________________ PURCHASER ____________________________________________ ORDER NO. _________________________ JOB NAME ______________________________________________ YORK CONTRACT NO. _________________ LOCATION _____________________________________________ YORK ORDER NO. ____________________ ENGINEER ______________________________________________

REFERENCE DATE ________ APPROVAL DATE ________ CONSTRUCTION DATE ________

Supersedes: 160.77-PW2 (311) Form: 160.77-PW2 (911)

UNIT WIRING AND FIELD CONTROL MODIFICATIONS

MODEL YKEP CHILLER

JOB DATA:

CHILLER MODEL NO. YKEP

NO. OF UNITS

Issue Date: September 23, 2011

JOHNSON CONTROLS2

FORM 160.77-PW2 ISSUE DATE: 9/23/2011

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, 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 respon-sibility 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

IMPORTANT!READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

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 these individual possess independent training that will en-able 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 mate-rials. This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question.

SAFETY SYMBOLSThe following symbols are used in this document to alert the reader to specific situations:

Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken.

Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment if proper care is not taken.

Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution if proper care is not taken or instructions and are not followed.

Highlights additional information useful to the technician in completing the work being performed properly.

External wiring, unless specified as an optional connection in the manufacturer’s product line, is not to be connected inside the cabinet. Devices such as relays, switches, transduc‑ers and controls and any external wiring must not be installed inside the micro panel. All wiring must be in accordance with Johnson Controls’ published specifications and must be performed only by a qualified electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of im‑proper control signals. Failure to follow this warning will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3


CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for con-tinuous product improvement, the information con-tained in this document is subject to change without notice. Johnson Controls makes no commitment to update or provide current information automatically to the manual owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson Controls Service office.

Operating/service personnel maintain responsibility for the applicability of these documents to the equipment. If there is any question regarding the applicability of these documents, the technician should verify whether the equipment has been modified and if current litera-ture is available from the owner of the equipment prior to performing any work on the chiller.

ASSOCIATED LITERATUREMANUAL DESCRIPTION FORM NUMBER

YKEP Installation and Re-Assembly 160.77-N1

YKEP Unit Operation and Maintenance 160.77-O1

YKEP Unit and Control Panel Renewal Parts 160.77-RP1

YKEP Installation Checklist 160.77-CL1

YKEP Startup Checklist 160.77-CL2

YKEP Wiring Diagram - Field Connections 160.77-PW1

YKEP Wiring Diagram - Unit Wiring 160.77-PW3

Liquid Cooled Solid State Starter - Operation 160.00-O2

Medium Voltage Variable Speed Drive (2300v - 6600v) - Operation 160.00-O6

Medium Voltage Variable Speed Drive (10,000v - 13,800v) - Operation 160.00-O8

Unit Mounted Medium Voltage Solid State Starter (2300v - 4160v) - Operation 160.00-07

Liquid Cooled Solid State Starter - Operation 160.00-O2

Long-Term Storage Requirements - General 50.20-NM1

Long-Term Storage Requirements - Field Preparation 50.20-NM5

Long-Term Storage - Periodic Checklist and Logs 50.20-CL5

JOHNSON CONTROLS4


NOMENCLATURE

LD15116

JOHNSON CONTROLS 5


TABLE OF CONTENTS

SECTION 1 - UNIT WIRING ......................................................................................................................................7

SECTION 2 - FIELD CONTROL MODIFICATIONS ................................................................................................39

SECTION 3 - ENERGY MANAGEMENT SYSTEMS ..............................................................................................47

JOHNSON CONTROLS6


LIST OF FIGURES

FIGURE 1 - Unit Device Locations Pressure Transducers ........................................................................................8FIGURE 2 - Unit Device Locations Temperature Sensors .........................................................................................9FIGURE 3 - Control Panel Layout ...........................................................................................................................10FIGURE 4 - Stall Detector Board Details................................................................................................................. 11FIGURE 5 - Compact I/O 1769-IAI6 Digital Input Slot 1 ..........................................................................................12FIGURE 6 - Compact I/O 1769-OW81 Digital Output Slot 2 ...................................................................................13FIGURE 7 - Compact I/O 1769-OA8 Digital Output Slot 3 ......................................................................................14FIGURE 8 - Compact I/O 1769-OW81 Digital Output Slot 4 ...................................................................................15FIGURE 9 - Compact I/O 1769-IF8 Analog Input Slot 5 ..........................................................................................16FIGURE 10 - Compact I/O 1769-IF8 Analog Input Slot 6 ........................................................................................17FIGURE 11 - Compact I/O 1769-IF8 Analog Input Slot 7 ........................................................................................18FIGURE 12 - Compact I/O 1769-IR6 RTD Input Slot 8 ...........................................................................................19FIGURE 13 - Compact I/O 1769-IR6 RTD Input Slot 9 ...........................................................................................20FIGURE 14 - Compact I/O 1769-OF2 Analog Output Slot 10 .................................................................................21FIGURE 15 - Compact I/O 1769-OF4VI Analog Output Slot 11 ..............................................................................22FIGURE 16 - Oil Pump ............................................................................................................................................23FIGURE 17 - Subcooler / Oil Sump .........................................................................................................................24FIGURE 18 - Liquid Cooled Solid State Starter.......................................................................................................24FIGURE 19 - Actuator Wiring ..................................................................................................................................25FIGURE 20 - Connector Details ..............................................................................................................................25FIGURE 21 - Component Connection Details .........................................................................................................26FIGURE 22 - Elementary Diagram ..........................................................................................................................28FIGURE 23 - Compressor Actuators / Stall Detector Boards ..................................................................................29FIGURE 24 - Variable Speed Oil Pump Panel Wiring .............................................................................................30FIGURE 25 - Wiring Diagram ..................................................................................................................................32FIGURE 26 - 120VAC and Low Voltage Connection Diagram ................................................................................34FIGURE 27 - Connection Diagram ..........................................................................................................................36FIGURE 28 - Variable Speed Oil Pump Panel ........................................................................................................38FIGURE 29 - Remote Ready To Start Contacts ......................................................................................................40FIGURE 30 - Cycling Shutdown Contacts ...............................................................................................................40FIGURE 31 - Safety Shutdown Contacts ................................................................................................................40FIGURE 32 - Run Contacts .....................................................................................................................................40FIGURE 33 - Anticipatory/Alarm Contacts ..............................................................................................................41FIGURE 34 - Remote Start and Stop Contacts From Energy Management System Contacts ...............................41FIGURE 35 - Chilled Water Pump Starter ...............................................................................................................41FIGURE 36 - Condenser Motor Pump Starter .........................................................................................................42FIGURE 37 - Condenser Flow Switches .................................................................................................................42FIGURE 38 - Evaporator Flow Sensors ..................................................................................................................43FIGURE 39 - Two Unit Sequence Control ...............................................................................................................44FIGURE 40 - Multiple Units (Two) - Series Operation .............................................................................................44FIGURE 41 - Multiple Units (Two) Parallel Operation - Individual Unit Pumps .......................................................45FIGURE 42 - Multiple Units (Two) Parallel Operation - Single Chilled Water Pump ...............................................45FIGURE 43 - Remote Hardwired Analog Temperature Setpoint .............................................................................45FIGURE 44 - Demand Limit Hardwired Remote......................................................................................................46

JOHNSON CONTROLS 7


1SECTION 1 - UNIT WIRING

1. All wiring shall be in accordance with the national electric code as well as all other applicable codes and specifications.

2. An underlined contact location signifies a nor-mally closed contact. Numbers within parenthesis (beneath contacts) indicate line number location of relay or timer coil.

3. Numbers adjacent to circuit lines are the circuit identification.

4. The primary compressor motor may be supplied with a UMMVSSS (Per R-1157), MVVSD (Per R-1150) or electomechanical (Per R-787) starter. Run interlock is only used on remote mounted electromechanical starter. All interface wiring for the remote mounted MVSSS, MVVSD and elec-tromechical starters is supplied and installed by others.

5. Ground control panel cabinet.

6. Identify all control panel wiring using heat shrink-able type wire markers.

7. For wiring other than pre-wired cables for PLC I/O modules. Use appropriate wire size depending on AMP rating of circuit breaker protecting the conductor: Derated for 50 degree C/122 degree F using YORK/Johnson Controls C-10 standard.

30 AMPS - #10 AWG20 AMPS - #12 AWG15 AMPS - #14 AWG10 AMPS - #16 AWG

All wire material must be per YORK/Johnson Controls C-10 standard. Unless otherwise noted all panel wiring to be 16 AWG. Unless otherwise noted wire color coding to be as follows:

115 VAC Hot - Black115 VAC Neutral - White+/- 5 VDC - Dark Blue+/- 24 VDC - Dark BlueGround - Green/Yellow3 Phase - Black

Field wiring must be sized by the installing con-tractor using appropriate derating factors for am-bient conditions and number of conductors in con-duit as required by 2008 NEC article 310.

8. Three phase oil pump must be properly phased. IL1, IL2 and IL3 corresponding to phase sequence A, B and C.

9. A coil transient suppressor must be installed on every coil or inductive load connected to the 129 VAC output module unless otherwise noted. Sup-pressors are supplied with control panel for field installation if needed.

10. Install 1 each flow sensor in each of the heat ex-changer's outlet nozzle. Use the 1/2" coupling best suited for sensor installation.

11. Secure conduits and cables together with cable straps.

12. Provide “Drip Loops” to 120 volt or greater wire harnesses to prevent water from entering junction boxes, panels, etc.

13. Assemble wires to existing harness in panel and solid state starter with Item 61.

14. Pack insulation into motor terminal box after con-nection of motor leads.

JOHNSON CONTROLS8

FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING

FIGURE 1 - UNIT DEVICE LOCATIONS PRESSURE TRANSDUCERS

CONTROL PANEL

Economizer Level Valve Actuator

Economizer Refrigerant Pressure Transducer

Subcooler Level Valve Actuator

Primary Compressor Pre-Rotation Vane Motor

Primary Compressor Liquid Injection Solenoid Valve

Primary Compressor Oil Return Solenoid Valve

Evaporator Pressure Transducer

Primary Compressor Oil Pump Pressure Transducer

Primary Compressor Stall Detector Pressure Transducer Condenser

Pressure Transducer

Economizer Compressor Thrust Switch

Economizer Compressor Pre-Rotation Vane Motor

Economizer Compressor VGD Position

Economizer Compressor Oil Pump Pressure Transducer

Economizer Compressor Stall Detector Pressure Transducer

LD15723

JOHNSON CONTROLS 9

SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011

1

CONTROL PANEL

Condenser Flow Sensor

Economizer Compressor PRV Closed Limit Switch

Economizer Compressor Variable Geometry Diffuser

Entering Condenser Water Sensor

Leaving Condenser Water Sensor

Evaporator Flow Sensor

Leaving Chilled Water Sensor

Economizer Level Sensor

Economizer Compressor Discharge Sensor

Evaporator Refrigerant Liquid Temperature Sensor

Subcooler Refrigerant Level Sensor

Primary Compressor Variable Geometry Diffuser

Primary Compressor Discharge Temperature Sensor

Leaving Chilled Water Sensor

Primary Compressor PRV Closed Limit Switch

FIGURE 2 - UNIT DEVICE LOCATIONS TEMPERATURE SENSORSLD15723a

JOHNSON CONTROLS10


FIGURE 3 - CONTROL PANEL LAYOUTLD14648

JOHNSON CONTROLS 11


1

PS

1 (c

omm

on)

TB2-

3

PS

2 (5

VD

C)

TB2-

1

TPF

GND -5V +5V

TPE TPD TPK TPL

J2 J2

TB1

HISTD

TPA

TPJ

SIG IN

OUT2

OUT1

3 1

1

1

TPMTPCTPB

TPG

TPH

031-02418-001REV

J1J1

To EconomizerStall Detector

Discharge Pressure(PE -149B)

3

2

1

J1

J2{J3

BLACK

WHITE

RED

1

2

4

3

+5 194

INPUT 209

213

GND 195

RED

BLACK

GREEN

WHITE

TPF

GND -5V +5V

TPE TPD TPK TPL

J2 J2

TB1

HISTD

TPA

TPJ

SIG IN

OUT2

OUT1

3 1

1

1

TPMTPCTPB

TPG

TPH

031-02418-001REV

J1J1To Primary

Stall DetectorDischarge Pressure

(PE -149A)

3

2

1

J1

J2{J3

BLACK

WHITE

RED

1

2

4

3

+5 194

INPUT 171

201

GND 195

RED

BLACK

GREEN

WHITE

BLA

CK

BLA

CK

RE

D

RE

D

J2-3

J2-1

J2-3

J2-1

{ {To P

rimar

yS

tall

Det

ecto

rD

isch

arge

Pre

ssur

e(P

E -1

49A

)

To E

cono

miz

erS

tall

Det

ecto

rD

isch

arge

Pre

ssur

e(P

E -1

49B

)

FIGURE 4 - STALL DETECTOR BOARD DETAILSLD15814

JOHNSON CONTROLS12


EMERGENCY STOP

PRIMARY COMPRESSOR PRV CLOSED LIMIT SWITCH

ECONOMIZER COMPRESSOR PRV CLOSED LIMIT SWITCH

PRIMARY COMPRESSOR MOTOR STARTER SAFETY FAULT LOCKOUT RELAY (SEE NOTE 4)

ECONOMIZER COMPRESSOR MOTOR STARTER SAFETY FAULT LOCKOUT RELAYPRIMARY COMPRESSOR MOTOR STARTER RUN INTERLOCK (SEE NOTE 4)

SPARE

PRIMARY COMPRESSOR MAIN OIL PUMP DRIVE FAULTED (OPEN ON FAULT)

ECONOMIZER COMPRESSOR MAIN OIL PUMP DRIVE FAULTED (OPEN ON FAULT)

ECONOMIZER COMPRESSOR THRUST SWITCH

REMOTE HARDWARE START/STOP (RSS)

HARDWARE SAFETY

PRIMARY COMPRESSOR HIGH DISCHARGE PRESSURE CUTOUT

ECONOMIZER COMPRESSOR HIGH DISCHARGE PRESSURE CUTOUT

CHILLED LIQUID LOW FLOW OR DIFFERENTIAL PRESSURE SWITCH (OPTIONAL)

CONDENSER WATER LOW FLOW OR DIFFERENTIAL PRESSURE SWITCH (OPTIONAL)

FIGURE 5 - COMPACT I/O 1769-IAI6 DIGITAL INPUT SLOT 1

LD15816

075-94164-000 SHT 1 Rev.

JOHNSON CONTROLS 13


1

COMPRESSOR OIL HEATER CONTRACTOR

PRIMARY COMPRESSOR MOTOR START/STOP RELAY (SEE NOTE 4)

ECONOMIZER COMPRESSOR MOTOR START/STOP RELAY

PRIMARY COMPRESSOR LIQUID INJECTION SOLENOID VALVE

OIL RETURN SOLENOID VALVE

PRIMARY COMPRESSOR VSOP ENABLE

ECONOMIZER COMPRESSOR VSOP ENABLE

REMOTE READY TO START (RMRS)

FIGURE 6 - COMPACT I/O 1769-OW81 DIGITAL OUTPUT SLOT 2

LD15817

075-94164-000 SHT 1 Rev.

JOHNSON CONTROLS14


TCV-100A OPEN PRIMARY COMPRESSOR PRVTCV-100A CLOSE PRIMARY COMPRESSOR PRVTCV-100B OPEN ECONOMIZER COMPRESSOR PRVTCV-100B CLOSE ECONOMIZER COMPRESSOR PRV

PCV-112A OPEN PRIMARY COMPRESSOR VGDPCV-112A CLOSE PRIMARY COMPRESSOR VGDPCV-112B OPEN ECONOMIZER COMPRESSOR VGDPCV-112B CLOSE ECONOMIZER COMPRESSOR VGD

FIGURE 7 - COMPACT I/O 1769-OA8 DIGITAL OUTPUT SLOT 3

LD15818

075-94164-000 SHT 2 Rev.

JOHNSON CONTROLS 15


1

CONDENSER WATER PUMP RUN (R103)

CHILLED LIQUID PUMP RUN (R100)

SAFETY SHUTDOWN (RS)

CYCLING SHUTDOWN(RC)

ALARM (RA)

RESET(RST)

VSD BYPASSENABLE (RBE)

LCSSS TRIGGER BOARD CONTROL POWER

FIGURE 8 - COMPACT I/O 1769-OW81 DIGITAL OUTPUT SLOT 4

LD15819a

075-94164-000 SHT 2 Rev. C

JOHNSON CONTROLS16


PE-111EVAPORATORREFRIGERANTPRESSURE6-74 PSIG

PE-113CONDENSERREFRIGERANTPRESSURE0-300 PSIG

PE-116ECONOMIZERREFRIGERANTPRESSURE0-300 PSIG

PE-140OIL SUMPPRESSURE0-300 PSIG

PE-141APRIMARY COMPRESSOR OILPUMP PRESSURE0-300 PSIG

PE-141BECONOMIZER COMPRESSOR OILPUMP PRESSURE0-300 PSIG

(DO NOT CONNECT EXCEPT FOR EM STARTER) IT-160A PRIMARY MOTOR CURRENT 4-20mA 0-125% FLA

PE-149APRIMARY COMPRESSOR DISCHARGEPRESSURE0-300 PSIG

FIGURE 9 - COMPACT I/O 1769-IF8 ANALOG INPUT SLOT 5

LD15820

075-94164-000 SHT 2 Rev.

JOHNSON CONTROLS 17


1

XE-149APRIMARY COMPRESSOR VGD STALL BOARD SIGNAL/NOISE0-5V

ZE-149APRIMARY COMPRESSOR VGD POSITION0-100%

PE-149BECONOMIZER COMPRESSOR DISCHARGE PRESSURE0-300 PSIG

XE-149BECONOMIZER COMPRESSOR VGD STALL BOARD SIGNAL/NOISE0-5V

ZE-149BECONOMIZER COMPRESSOR VGDPOSITION0-100%

LE-114SUBCOOLER REFRIGERANTLEVEL SENSOR0-100%

LE-116ECONOMIZERLEVEL SENSOR0-100%

ZE-142APRIMARY COMPRESSORAXIAL THRUST POSITION-0.865 TO 112.428 MILS0-5VDC


LD15826

075-94164-000 SHT 2 Rev.

JOHNSON CONTROLS18


+5VDC REFERENCE

ZE-100APRIMARY COMPRESSOR PRV0-100%

ZE-100BECONOMIZER COMPRESSOR PRV0-100%

RST-100LEAVING CHILLED LIQUID REMOTE SET POINT

RST-160DEMAND LIMITREMOTE

FSLL-100EVAPORATOR CHILLEDLIQUID FLOW

FSLL-103CONDENSER WATER FLOW

SPARE


LD15827

075-94164-000 SHT 3 Rev.

JOHNSON CONTROLS 19


1

TE-100LEAVING CHILLEDLIQUID TEMPERATURE

TE-101ENTERING CHILLEDLIQUID TEMPERATURE

TE-102ENTERING CONDENSER WATER TEMPERATURE

TE-103LEAVING CONDENSER WATER TEMPERATURE

TE-111EVAPORATOR REFRIGERANT LIQUID TEMPERATURE

TE-114SUBCOOLED REFRIGERANT LIQUID TEMPERATURE

FIGURE 12 - COMPACT I/O 1769-IR6 RTD INPUT SLOT 8

LD15828

075-94164-000 SHT 3 Rev.

JOHNSON CONTROLS20


TE-140OIL SUMPTEMPERATURE

TE-112PRIMARY COMPRESSORDISCHARGETEMPERATURE

TE-113ECONOMIZER COMPRESSORDISCHARGETEMPERATURE

SPARE

SPARE

SPARE

FIGURE 13 - COMPACT I/O 1769-IR6 RTD INPUT SLOT 9

LD15829

075-94164-000 SHT 3 Rev.

JOHNSON CONTROLS 21


1

PRIMARY COMPRESSOR OIL PUMP SPEED

ECONOMIZER COMPRESSOR OIL PUMP SPEED

NOTE:FOR SLOT 10 SET EXTERNAL POWER SWITCH TO DOWN POSITION.

FIGURE 14 - COMPACT I/O 1769-OF2 ANALOG OUTPUT SLOT 10

LD15830

075-94164-000 SHT 3 Rev.

JOHNSON CONTROLS22


SUBCOOLER LEVEL VALVE ACTUATOR 0-10VDC

ECONOMIZER LEVEL VALVE ACTUATOR0-10VDC

HOT GAS VALVE ACTUATOR0-10VDC

+10VDCVSD POWER SUPPLY

FIGURE 15 - COMPACT I/O 1769-OF4VI ANALOG OUTPUT SLOT 11

LD15831

075-94164-000 SHT 3 Rev.

JOHNSON CONTROLS 23


1

FIGURE 16 - OIL PUMP

Oil Sump Temperature Sensor

Oil Sump Pressure Transducer

To Control Panel

To Control Panel

(VSOP)

To Control Panel

(Hole D)

To Control Panel

(Hole A and H)

To VS Oil Pump Panel

LD15774

JOHNSON CONTROLS24


FIGURE 17 - SUBCOOLER / OIL SUMP

FIGURE 18 - LIQUID COOLED SOLID STATE STARTER

Subcooler Level Valve Actuator

Subcooled Refrigerant Liquid Temperature Sensor

Oil Sump Temperature Sensor

Oil Sump Pressure Transducer

LD15776

LD15775

JOHNSON CONTROLS 25


1

FIGURE 19 - ACTUATOR WIRING

FIGURE 20 - CONNECTOR DETAILS

WHITE

BLACK

RED

LD15724a

LD15777

JOHNSON CONTROLS26


FIGURE 21 - COMPONENT CONNECTION DETAILS

Actuator Details

Chilled and CondenserWater Flow Switches

(FSLL-100 and FSLL-103)

Liquid Level SensorStall Detector Pressure Transducer

LD15725

JOHNSON CONTROLS 27


1LEGEND

CB CIRCUIT BREAKERFLA FULL LOAD AMPSFU FUSEHTRIA/B 3 PHASE THERMOSTATICALLY

CONTROLLED 3000W OIL HEATERLCSSS LIQUID COOLED SOLID STATE STARTERMIA/B OIL HEATER CONTACTORMOV METAL OXIDE VARISTORMVVSD MEDIUM VOLTAGE VARIABLE SPEED

DRIVE (REMOTE MOUNTED)MVSSS MEDIUM VOLTAGE SOLID STATE

STARTER (REMOTE MOUNTED)OL MOTOR STARTER OVERLOADPRV PRE-ROTATION VANE MOTORPS POWER SUPPLYR RELAYRES RESISTORSSR SOLID STATE RELAYSUPR TRANSIENT SUPPRESSORTB TERMINAL BASETS TEMPERATURE SWITCHUMMVSSS UNIT MOUNTED MEDIUM VOLTAGE

SOLID STATE STARTER

VSDA/B VARIABLE SPEED OIL PUMP DRIVE FAULT CONTACT

ZS LIMIT SWITCHFIELD WIRINGFACTORY WIRINGCIRCUIT BOARD OR ENCLOSURE BOUNDARYFACTORY SYSTEM WIRING

SHIELDED CABLE

METAL OXIDE VARISTOR

TERMINAL CONNECTION POINT ON COMPONENTTERMINAL CONNECTION POINT IN MAIN CONTROL POINTTERMINAL CONNECTION POINT IN VS OIL PUMP PANELTERMINAL CONNECTION POINT IN PRIMARY COMPR. MOTOR STARTERTERMINAL CONNECTION POINT IN LCSSSINCOMING/OUTCOMING WIRE THRU PANEL MOUNT RECEPTACLE

JOHNSON CONTROLS28


FIGURE 22 - ELEMENTARY DIAGRAM

ELEMENTARY DIAGRAM

LD15762

075-94164-000 SHT 1 Rev. C

JOHNSON CONTROLS 29


1

PRIMARY COMPRESSOR

COMPRESSOR ACTUATORS

ECONOMIZER COMPRESSOR

FIGURE 23 - COMPRESSOR ACTUATORS / STALL DETECTOR BOARDSLD15770

JOHNSON CONTROLS30


VSOP PANEL WIRING

FIGURE 24 - VARIABLE SPEED OIL PUMP PANEL WIRINGLD15771

JOHNSON CONTROLS 31


1

THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS32


WIRING DIAGRAM

FIGURE 25 - WIRING DIAGRAMLD15772

JOHNSON CONTROLS 33


1WIRING DIAGRAM (CONT'D)

FIGURE 25 - WIRING DIAGRAM (CONT'D)LD15773

075-94164-000 SHT 5 Rev. C

JOHNSON CONTROLS34


FIGURE 26 - 120VAC AND LOW VOLTAGE CONNECTION DIAGRAM

120VAC AND LOW VOLTAGE CONNECTION DIAGRAM

LD15778

BOTTOM OF ENCLOSURE

JOHNSON CONTROLS 35


1

INSIDE OF PANEL DOORBOTTOM OF ENCLOSURE

120VAC AND LOW VOLTAGE CONNECTION DIAGRAM (CONT'D)

FIGURE 26 - 120VAC AND LOW VOLTAGE CONNECTION DIAGRAM (CONT'D)LD15779

075-94164-000 SHT 6 Rev.

JOHNSON CONTROLS36


INSIDE BOTTEM OF CONTROL PANEL


CONNECTION DIAGRAM

FIGURE 27 - CONNECTION DIAGRAMLD15780

JOHNSON CONTROLS 37


1

INSIDE BOTTEM OF CONTROL PANEL


CONNECTION DIAGRAM (CONT'D)

FIGURE 27 - CONNECTION DIAGRAM (CONT'D)LD15781

075-94164-000 SHT 7 Rev.

JOHNSON CONTROLS38


VARIABLE SPEED OIL PUMP PANEL

FIGURE 28 - VARIABLE SPEED OIL PUMP PANEL

LD15782

075-94164-000 SHT 8 Rev.

VS OIL PUMP PANEL POWER SUPPLY

VOLTS-PH-HZPANEL

MAXIMUM FLA

MINIMUM CIRCUIT

AMPACITY

MAXIMUM DUAL

ELEMENT FUSE SIZE

200-3-60 22.24 24 30208-3-60 21.86 24 30220-3-60 20.24 22 25230-3-60 19.90 22 25240-3-60 19.53 22 25380-3-60 11.86 13 15416-3-60 11.41 13 15440-3-60 10.15 11 12460-3-60 9.95 11 12480-3-60 9.77 11 12550-3-60 8.03 9 10575-3-60 7.88 9 10600-3-60 7.73 9 10

346-3-50 13.20 15 20380-3-50 11.86 13 15400-3-50 11.60 13 15415-3-50 11.42 13 15

JOHNSON CONTROLS 39


2

SECTION 2 - FIELD CONTROL MODIFICATIONS

1. These FIGURES show recommended field con-trol wiring modifications (by others) to the stan-dard Control Center Wiring Diagram.

2. If more than one of these modifications is to be utilized with a particular unit, additional consid-eration must be given to the application to insure proper functioning of the control system. Consult your YORK/Johnson Controls representative.

3. The additional controls and wiring for these modi-fications are to be furnished and installed in the field by others (see Warnings on page 2).

4. The controls specified are recommended for use, but other controls of equal specifications are ac-ceptable.

5. All wiring shall be in accordance with the Nation-al Electrical Code, and applicable State and Local Codes.

6. Each 115VAC field connected inductive load, i.e. relay coil, motor starter coil, etc., shall have a transient suppressor wired (by others) in parallel with its coil, physically located at the coil. Spare transient suppressors are furnished in a bag in the Control Center.

7. The Control Center is factory furnished for Manu-al Restart After Power Failure as a standard func-tion.

8. Two (2) unit controls schemes are suitable for 8° – 12°F water range. Constant chilled water flow is assumed at all loads. For other requirements con-tact your YORK/Johnson Controls representative.

9. Sequence control kits (see Figure 36 on Page 42) assume a constant chilled water flow and a constant leaving chilled water temperature to sense the cooling load. Sequence control kits are not designed for variable chilled water flow or with reset of the leaving chilled water tempera-ture – see Figures 29 to 32.

10. Maximum allowable current draw between cir-cuits 24 and 2 for field installed devices is 2 amp holding and 10 amps inrush – see Control Center Wiring Diagram in this manual.

11. For required field wiring connections of the chilled water pump contacts (terminals B3 and 2 on Control Center field wiring terminal block IFM4) and chilled water flow switch (terminals 1 and 65 on Control Center field wiring terminal)(see Wiring Diagram Field Connections Form 160.77-PW2).

12. The Chilled Water Flow Switch is a safety con-trol. It must be connected to prevent operation of the chiller whenever chilled water flow is stopped. The use of the chilled water flow switch for pur-poses other than protection of the chiller may be accomplished in several ways. Two flow switches, a flow switch and a relay or separate contacts on the same flow switch.

13. Do not apply voltage on field wiring terminal blocks IFM2 and IFM4 in YORK Control Center, as 115VAC source is fed from terminals 1 and 2 .

JOHNSON CONTROLS40

FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 2 - FIELD CONTROL MODIFICATIONS

REMOTE MODE READY TO START CONTACTS

When closed, these contacts signify the following:

1. All chiller safety cutout controls are in the normal position, so they will allow the unit to start.

2. All chiller cycling cutout controls are in the nor-mal position, so they will allow the unit to start.

3. The Control Center chiller start Green pushbutton on the house screen Graphics display page illu-minated.

4. Any applicable anti-recycle timer has timed out. A closure of the Remote Mode Ready to Start Con-tacts then signifies that the unit shall start when the Energy Management System maintains the Remote Stop Contact open and momentarily clos-es the Remote Start Con tact. When the Remote Mode Ready to Start Contacts close, the Control Center will display READY TO START message.

IFM2 1 B9

1 90

TO ENERGY MANAGEMENT SYSTEM FROM CHILLER

FIELD WIRING TERMINAL BLOCK IN CONTROL CENTER

POWERED OUTPUT (IN CONTROL CENTER) RATED 2 AMPS INDUCTIVE @ 120VAC

FIGURE 29 - REMOTE READY TO START CONTACTSLD15832

CYCLING SHUTDOWN CONTACTS

When closed, these contacts signify the unit is not per-mitted to start due to a CYCLING shutdown condition. The unit will automatically restart after the cycling condition is no longer present. YKEP Unit Operation and Maintenance (Form 160.77-O1) provides a list and explanation of all Cycling Shutdowns. While these contacts are closed, the Control Center will display STOPPED – CYCLED OFF on the System Status Bar and the cause of the shutdown on the System Details bar of the display. Cycling Shutdown contacts function in all operating modes.

FIGURE 30 - CYCLING SHUTDOWN CONTACTS

IFM4 1 B5

1 134




LD15833

SAFETY SHUTDOWN CONTACTS

When closed, these contacts signify the unit is not permit-ted to start due to a SAFETY shutdown condition. Safety shutdowns require a manual reset procedure be performed before the unit can be restarted. YKEP Unit Operation and Maintenance (Form 160.77-O1) provides a list and explanation of all Safety Shutdowns. While these con-tacts are closed, the Control Center will display SYSTEM TRIPPED on the System Status Bar and the cause of the shutdown on the System Details Bar of the display. These contacts will remain closed until the safety condition no longer exists and a manual reset is performed by press-ing the clear faults key on the control panel. The unit can then be restarted. Safety Shutdown contacts function in all operating modes.

FIGURE 31 - SAFETY SHUTDOWN CONTACTS

IFM4 1 B4

1 132




LD15834

RUN CONTACTS

When closed, these contacts signify that the unit is op-erating. The Control Center will display a System Run Message.

FIGURE 32 - RUN CONTACTS

IFM4 1 B2

1 128



POWERED OUTPUT (IN CONTROL CENTER) RATED 2 AMPS RESISTIVE @ 120VAC

LD15835

JOHNSON CONTROLS 41

SECTION 2 - FIELD CONTROL MODIFICATIONSFORM 160.77-PW2 ISSUE DATE: 9/23/2011

2

ANTICIPATORY/ALARM CONTACTS

These contacts will close whenever one or more of the following WARNING conditions occurs. They will re-main closed as long as the condition is in effect. On most warnings, the contacts automatically open when the condition is no longer present. On those warnings marked with an asterisk, the contacts will open only after the condition is no longer present and the WARN-ING RESET key is pressed in Operator (or higher) ac-cess level.

Real time clock failure, Condenser or Evaporator Transducer Error*, Setpoint Override*, Condenser-High Pressure Limit, Evaporator-Low Pressure Limit.

FIGURE 33 - ANTICIPATORY/ALARM CONTACTS

IFM4 1 B6

1 136


POWERED OUTPUT (IN CONTROL CENTER) RATED 2 AMPS INDUCTION @ 120VAC

LD15836

REMOTE START AND STOP CONTACTS FROM ENERGY MANAGEMENT SYSTEM

When the Control Center is in the remote operating mode and the compressor switch is in the “run” (l) po-sition, with the Remote Stop Contacts open, and the Remote Mode Ready to Start Contacts closed (see Fig-ure 29 on Page 40), the unit will start via a closure of the Remote Start Contacts. A subsequent opening of the Energy Management System Remote Start Con-tacts causes the chiller to shut down. The Control Cen-ter will display REMOTE STOP because the Energy Management System Remote Stop Contact has com-manded the unit to shutdown.

Even when the chiller is applied with Re‑mote Start‑Stop (when the Control Center is in the “Remote Operating Mode"), an EMERGENCY STOP by an operator or others can STOP the compressor from the Control Center and prevent the chiller from restarting. However, the operator cannot locally start the compressor using “start” button, when the control center is in the “remote” operating mode.

FIGURE 34 - REMOTE START AND STOP CON-TACTS FROM ENERGY MANAGEMENT SYSTEM CONTACTS

2 62 1FIELD WIRING TERMINAL BLOCK IN CONTROL CENTER

STARTCONTACT RATING 5 mA @ 115VAC

LD15837

CHILLED WATER PUMP STARTER (IFM4-B3 AND 1)When the chiller is started, the Contacts close immedi-ately upon entering “Startup”. Normally, they open co-incident with the completion of “System Coastdown” with the following exceptions:

If a LEAVING CHILLED LIQUID - LOW TEMPER-ATURE cycling shutdown occurs, they do not open at the completion of “System Coastdown”. They remain closed for the duration of the shutdown or until Stop is selected at the keypad, whereupon they open.

If LEAVING CHILLED LIQUID FLOW SWITCH OPEN cycling shutdown occurs, they remain closed until the chiller is giveen a stop command or another fault oc-curs.

FIGURE 35 - CHILLED WATER PUMP STARTER

IFM4 1 B3

1 130




LD15838

JOHNSON CONTROLS42


CONDENSER MOTOR PUMP STARTER (IFM4-B2 AND 1)

Contacts close coincident with beginning of “Startup”. They open after postlube sequence.

FIGURE 36 - CONDENSER MOTOR PUMP STARTER

IFM4 1 B2

1 128




LD15839

CONDENSER FLOW SENSORS

The Effector-type Flow Sensor interfaces with the Analog Input and Paddle-type Flow Sensor interfaces with the digital input module.

For the program to read the appropriate inputs for the flow sensor status, the actual flow sensor type used must be entered at the keypad FACTORY SETUP Screen using Service Access Level.

When flow is sensed, the flow sensor contacts are closed. Opening of the flow sensor contacts (no flow) for 30 continuous seconds causes a cycling shutdown displaying “LOW CONDENSER WATER FLOW”. The flow sensor status is bypassed for the first 30 sec-onds of “System Run”.

If Paddle-type (Digital) is selected and no condenser flow sensor is used, a jumper must be installed be-tween terminals 252 and 194 .

Condenser Effector Type Flow SensorWhen the Effector-type Flow Switch is used, the flow switch uses the cooling effect of liquid to sense flow.

When the flow of liquid is sensed, the solid state relay output is turned on conducting current through the mi-croboard load resistor to the +5VDC applying greater than +4VDC to the input Slot 7, Channel 6.

When no flow of liquid is sensed, the solid state re-

lay output is turned off, this results in less than 1VDC to the microboard input and the Control Center will display the following message: LOW CONDENSER WATER FLOW.

FIGURE 37 - CONDENSER FLOW SWITCHES

I/O BOARD PADDLE-TYPE FLOW SENSOR

EFFECTOR-TYPE FLOW SENSORSLOT 7

CHILLED LIQUID

CONDENSER

LD15840

Condenser Paddle Type Flow SensorIf desired, a Condenser Water Flow Interlock can be applied. Flow Switch – McDonnel type FS8W, max. 150 psi (YORK Part No. 024-15793) available at ad-ditional cost. If Condenser Water Flow Switch is not used, a jumper must be installed between terminals 1 and 68 .

When condenser water is flowing, the flow switch con-tact will close. Opening of the Condenser Water Flow Switch Contacts for 2 continuous seconds will cause unit shutdown. The flow switch status is checked 30 seconds into “System Run” and continuously thereaf-ter. The Control Center will display the following mes-sage: LOW CONDENSER WATER FLOW.

EVAPORATOR FLOW SENSORS

The Effector-type Flow Sensor interfaces with the Analog Input and Paddle-type Flow Sensor interfaces with the digital input module.

For the program to read the appropriate inputs for the flow sensor status, the actual flow sensor type used must be entered at the keypad FACTORY SETUP Screen using Service the Access Level.

JOHNSON CONTROLS 43


2

TWO UNIT SEQUENCE CONTROL

Provides that cycling thermostat RWT will automati-cally cycle either #1 or #2 unit. Timer 3TR is an addi-tional feature which prevents simultaneous starting of lead and lag unit following a power failure and elimi-nates nuisance starting of lag unit due to periodic fluc-tuations in temperature. For two unit sequence control kit, order YORK Accessory Kit No. 466-61597T for controls as specified with NEMA 1 enclosure.

RWT has 20°F to 80°F range with adjustable differen-tial of 3-1/2 to 14°F; 6 ft. of capillary with 3/8" x 5" bulb and 1/2" NPT brass well (maximum liquid DWP 300 psig). The thermostat is drawn to indicate its oper-ation closes on rise. A 1/2" pipe coupling in the return chilled water line from the building must be furnished (by others) for RWT control well.

MULTIPLE UNITS (TWO) - SERIES OPERATION

The supply chilled water temperature to the building is normally determined by the “Chilled Liquid Temp.” setpoint for Unit #2. When lead selector position of se-quence control kit (Refer to Figure 39 on Page 44) is Unit #1, the supply chilled water temperature to the building will be the temperature control setpoint on Unit #1 Control Center. If lower temperature is de-sired, reprogram the “Chilled Liquid Temp.” setpoint for Unit #1.

When flow is sensed, the flow sensor contacts are closed. Opening of the flow sensor contacts (no flow) for 2 continuous seconds causes a shutdown displaying “LOW CHILLED WATER FLOW”. The flow sensor status is bypassed for the first 25 seconds of “System Prelube”.

FIGURE 38 - EVAPORATOR FLOW SENSORS

I/O BOARD PADDLE-TYPE FLOW SENSOR

EFFECTOR-TYPE FLOW SENSORSLOT 7

CHILLED LIQUID

CONDENSER

LD15840

Evaporator Effector Type Flow SensorWhen the Effector-type Flow Switch is used, the flow switch uses the cooling effect of liquid to sense flow.

When the flow of liquid is sensed, the relay output is turned on conducting current through the microboard load resistor to the +5VDC applying greater than +4VDC to the input Slot 7, Channel 5.

When no flow of liquid is sensed, the relay output is turned off, this results in less than 1VDC to the input Slot 7, Channel 5.

Evaporator Paddle Type Flow SensorWhen Evaporator Water is flowing, the flow switch con tact will close. If the flow switch opens for 2 sec-onds, the unit shuts down.

If desired, a Condenser Water Flow Interlock can be applied. Flow Switch – McDonnel type FS8W, max. 150 psi (YORK Part No. 024-15793) available at ad-ditional cost. If Condenser Water Flow Switch is not used, a jumper must be installed between terminals 1 and 65 .

JOHNSON CONTROLS44


FIGURE 39 - TWO UNIT SEQUENCE CONTROLLD15842

FIELD CONNECTION DIAGRAM

ELEMENTARY DIAGRAM

TERMINAL BOARD IN SEQUENCING CONTROL BOX

2 131 130 13-1 14-113-2 14-2GRD. SCREWS

RWT

SEE NOTE AASEE NOTE CC

SELECTOR SWITCH NOTE FF

FIELD WIRING

LEAD UNIT

1

13-1

14-1

13-2

14-2

2

133

UNIT #1 UNIT #2

FIELD WIRING TERMINAL BLOCKS IN CONTROL CENTER

2 2 62 162 1

130RWT

3TR

131 3TR

NOTE EE

NOTE 6

SUPR.

2

NOTES:AA. RWT - RETURN WATER THERMOSTAT BY YORK.CC. ALL REMOTE WIRING (BY OTHERS) TO BE #14 AWG COPPER CLASS 1 N.E.C. CONTROL WIRE.DD. ALL CONTACTS HAVE A MAXIMUM RATING OF 125 VA @ 125VAC 50/60 HZ.EE. 3TR - TIME DELAY RELAY, 100 SEC., “ON” DELAY.FF. 4 POLE, DOUBLE THROW SNAP SWITCH (TOGGLE)

TWO UNIT SEQUENCE CONTROL - PARALLEL OR SERIES WATER FLOW - LEAD SELECTOR AND CYCLING THERMOSTAT (NOTES 2, 6, 8, 9, 10 AND 11)

FIGURE 40 - MULTIPLE UNITS (TWO) - SERIES OPERATIONLD15842a

RWT LOCATION (IF USED)

RWT

COOLER

UNIT #1

COOLER

UNIT #2

TEMPERATURE CONTROL FUNCTION IN CONTROL CENTER

CHILLED WATER PIPING SCHEMATIC

T.S. = TEMPERATURE SENSING UNITS

T.S. T.S.

JOHNSON CONTROLS 45


2

MULTIPLE UNITS (TWO) – PARALLEL OPERATION – INDIVIDUAL UNIT PUMPS

This piping arrangement is the same as Figure 36 on Page 42, except that the chilled water pumps associ-ated with each evaporator are cycled ON and OFF with the unit. This results in reduced chilled water flow rates whenever a single unit can handle the cooling load. Be-cause no chilled water flows through the inoperative unit, the mixed water temperature peculiar to using a single pump is avoided. When one unit is cut-out by the sequence control (refer to Figure 39 on Page 44) the temperature of the supply chilled water does not change.

FIGURE 41 - MULTIPLE UNITS (TWO) PARALLEL OPERATION - INDIVIDUAL UNIT PUMPS


TEMPERATURE CONTROL FUNCTION IN CHILLER CONTROL CENTER

COOLER

T.S.

T.S.

SUPPLYCHILLED


UNIT # 1

COOLERUNIT # 2

CHILLED WATER PIPING SCHEMATIC

MULTIPLE UNITS - PARALLEL OPERATION: IN THIS ARRANGEMENTS, THE INDIVIDUAL CHILLED WATER PUMP IS STOPPED WHEN THE ONE UNIT IS SHUT DOWN AT APPROXIMATELY 40% SYSTEM LOAD. LEAVING CHILLED WATER TEMPERATURE IS CONSTANT (± 1/2°F) AT ALL LOADS. (NOTES 8 and 11)

WATER TO SYSTEM


LD15845

MULTIPLE UNITS (TWO) – PARALLEL OPERATION – SINGLE CHILLED WATER PUMP

For this piping arrangement, each chiller’s water sen-sor is located in its own leaving water nozzle. This produces a constant “mixed” chilled water tempera-ture when both units are operating. When either unit is cycled off by the sequence control (see Figure 39 on Page 44), mixed chilled water temperature will rise as a result of uncooled return water flowing through the inoperative unit. For individual unit chilled water pump piping, refer to Figure 42 on .

FIGURE 42 - MULTIPLE UNITS (TWO) PARALLEL OPERATION - SINGLE CHILLED WATER PUMP



COOLER

T.S.

T.S.

SUPPLY CHILLEDWATER TO SYSTEM


UNIT # 1

COOLERUNIT # 2

CHILLED WATER PIPING SCHEMATICMULTIPLE UNITS - PARALLEL OPERATION: IN THIS ARRANGEMENTS, WHEN ONE UNIT IS SHUT DOWN AT APPROXIMATELY 40% LOAD, THE CHILLED WATER TEMPERATURE SUPPLY TO THE SYSTEM RISES TO THE MIXED TEMPERATURE OF THE CHILLED WATER LEAVING BOTH UNITS, FOR ALL LOADS DOWN TO MINIMUM CAPACITY. LEAVING CHILLED WATER TEMPERATURE IS CONSTANT (± 1/2°F) AS LONG AS BOTH UNITS ARE IN OPERATION. (NOTES 8 and 11)


LD15845a

REMOTE LEAVING CHILLED LIQUID SETPOINT

Remote Leaving Chilled Liquid Temperature Setpoint Reset can be accomplished by supplying (by others) 4-20mA or Control Center. The Leaving Chilled Liq-uid 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 Re-mote 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 20ºF (as per the locally programmed Remote Reset Tem-perature Range setpoint) above the Local Leaving Chilled Liquid Temperature Setpoint. For example, if the Local Setpoint is 40°F and the Remote Reset Tem-perature 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.

{+0°F to +10°F = 4-20mA setpoint above programmable level setpoint

Channel 3 Slot 7

246

245

247

FIGURE 43 - REMOTE HARDWIRED ANALOG TEMPERATURE SETPOINT

LD15844

JOHNSON CONTROLS46


DEMAND LIMIT REMOTE

Remote Demand Limit can be accomplished by sup-plying (by others) 4-20mA or Control Center. The De-mand Limit is programmable over the range of 40% - 100%. The Remote Input Signal changes the setpoint when set for remote setpoint on the SETPOINTS SCREEN refer to YKEP Unit Operation and Mainte-nance (Form 160.77-O1). The setpoint can be remote-ly changed over the range of 40% - 100%.

{To EMS 4-20 mA = 40% to 100% load

Channel 4 Slot 7

249

251

250

FIGURE 44 - DEMAND LIMIT HARDWIRED REMOTELD15843

EXTERNAL SIGNAL FOR REFRIGERATION UNIT FAILURE

When the Safety Shutdown Contacts (see Safety Shut-down Contacts on Page 40) are not connected to an Energy Management System they may be employed to energize a local or remote safety alarm (by others). When the normally open Safety Shutdown Contacts close, the alarm will indicate shutdown of the unit. The cause of shutdown will be one or more of the follow-ing safety controls: low oil pressure; high oil pressure; high condenser pressure; low evaporator pressure; high oil temperature; high discharge temperature; auxiliary safety; power failure.

If the unit was shut down because of Cycling Shutdown Contacts (see Figure 20) the alarm will not be energized, but the unit will have been shut down. A clo‑sure of the safety alarm contacts means that an operator must manually reset and restart the unit.

JOHNSON CONTROLS 47


3

SECTION 3 - ENERGY MANAGEMENT SYSTEMS

YKEP chiller design allows for ease of interfacing with Energy Management Systems (EMS). The Control Center includes unit status contacts, provisions for re-mote control inputs and provisions for remote setpoint reset of leaving chilled liquid temperature and current limit for EMS interfacing (see Note 7).

Five sets of unit status outputs are factory furnished through a field wiring terminal board in the Control Center. Each set of contacts are 170VAC power out-puts, rated at 2 amperes resistive at 120VAC. Chiller status contacts are provided for unit:

• Remote Mode Ready to Start – See Figure 29 on Page 40.

• Cycling Shutdown – See Figure 30 on Page 40.

• Safety Shutdown – See Figure 31 on Page 40.

• Run (System Operating) – See Figure 32 on Page 40.

• Anticipatory/Alarm – See Figure 33 on Page 41.

One input is available to the EMS, allowing for remote control of unit operation. Input device contact rating shall be 5 milliamperes at 115VAC. Field wiring termi-nal 62 in the Control Center permits connection for the following operation Remote Start/Stop Contacts – See Figure 24.

Chiller cycling by the Energy Management System should be minimized. It is possible to limit the com-pressor motor amp draw indirectly or directly by the following methods:

1. Application of Sequence Control Kit, so only one unit is running, when a single unit can carry the cooling load – see Figure 26 on Page 34.

2. Reduce the compressor-motor kW input (and thus amps), by raising the leaving chilled liquid tempera ture through remote temperature control setpoint in the “remote” operating mode. When remote tem perature reset is accomplished by sup-plying a 4-20 mA signal, refer to Figure 43 on Page 45. Through use of the remote tempera-ture control analog input on Slot 7, Channel 3, the leaving chilled liquid temperature may be reset via a 4 to 20mA D.C. current signal.

3. Current limiting of demand during pulldown may be accomplished by using the standard PULL-DOWN DEMAND LIMIT function provided in the Control Center. The “Pulldown Demand Limit” key can be programmed to limit compres-sor motor current from 40 to 100 percent of full load amperes, for 1 to 255 minutes following each compressor start. For more details refer to YKEP Unit Operation and Maintenance (Form 160.77-O1).

4. Controlling the maximum allowable compressor motor amps from 40 to 100% through remote cur-rent limit setpoint. Refer to Figure 44 on Page 46 when the remote current limit is accom-plished by supplying a 4-20 mA the “remote” op-erating mode. Remote current limit setpoint via a 4 to 20mA D.C. current signal.

5. The Johnson Controls METASYS™ System may be interfaced with the chiller Control Center to provide unified chiller plant system control. The METASYS™ System directly communicates with the Control Center via the E-Link Gateway card which may be installed in the Control Cen-ter. All temperatures, pressures, safety alarms and cycling information known to the Control Center are then available to the METASYS™ System for integrated chiller plant control, data logging, and local and remote operator displays. The META-SYS™ E-Link Gateway card also allows the Mol-bus RTU to start, stop, and reset the chiller’s leav-ing chilled water and current limit setpoints.

Modbus RTU via RS-485 is available to commu-nicate directly to the chiller Control Center with-out an E-Link.

JOHNSON CONTROLS48


NOTES

JOHNSON CONTROLS 49


The following factors can be used to convert from English to the most common SI Metric values.

TEMPERATURE

To convert degrees Fahrenheit (°F) to degrees Celsius (°C), subtract 32° and multiply by 5/9 or 0.5556.

Example: (45.0°F - 32°) x 0.5556 = 27.2°C

To convert a temperature range (i.e., a range of 10°F) from Fahrenheit to Celsius, multiply by 5/9 or 0.5556.

Example: 10.0°F range x 0.5556 = 5.6 °C range

TABLE 1 - SI METRIC CONVERSION

MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT

Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW)

Power Horsepower 0.7457 Kilowatts (kW)

Flow Rate Gallons / Minute (gpm) 0.0631 Liters / Second (l/s)

LengthFeet (ft) 304.8 Meters (m)

Inches (in) 25.4 Millimeters (mm)

Weight Pounds (lbs) 0.4538 Kilograms (kg)

Velocity Feet / Second (fps) 0.3048 Meters / Second (m/s)

Pressure DropFeet of Water (ft) 2.989 Kilopascals (kPa)

Pounds / Square Inch (psi) 6.895 Kilopascals (kPa)

P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USACopyright © by Johnson Controls 2011 ALL RIGHTS RESERVEDForm 160.77-PW2 (911)Issue Date: September 23, 2011 Supersedes: 160.77-PW2 (311)

800-861-1001www.johnsoncontrols.com

ykep centrigual liquid chiller unit wiring and field

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