YMC2 Unit Wiring and Field Control Modifications with...

Supersedes: 160.78-PW2 (813) Form: 160.78-PW2 (1016)

JOB DATA:

CHILLER MODEL NO. YMC2

NO. OF UNITS

Issue Date: October 28, 2016

WIRING DIAGRAMSCONTRACTOR _______________________ PURCHASER ____________________________________________ORDER NO. __________________________ JOB NAME ______________________________________________YORK CONTRACT NO. _________________ LOCATION ______________________________________________YORK ORDER NO. ____________________ ENGINEER _____________________________________________

REFERENCE DATE ______ APPROVAL DATE _______ CONSTRUCTION DATE _______

UNIT WIRING AND FIELD CONTROL MODIFICATIONS

MODEL YMC2 CHILLER WITH M1 COMPRESSOR

JOHNSON CONTROLS2

FORM 160.78-PW2 ISSUE DATE: 10/28/2016

This equipment is a relatively complicated apparatus. During rigging, installation, operation, maintenance, or service, individuals may be exposed to certain com-ponents or conditions including, but not limited to: heavy objects, 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 responsibility of rigging, instal-lation, and 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 rigging, installation, and operating/service personnel. It is expected that these individuals possess 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 the on-product labels, this document and any referenced materials. This in-dividual shall also be familiar with and comply with all applicable industry and governmental standards and regulations pertaining to the task in 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 situa‑tion 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 pollu‑tion if proper care is not taken or instruc‑tions 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 OptiViewTM cabinet. Devices such as relays, switches, transducers 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 improper control signals. Failure to follow this warn‑ing 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 or product owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson Controls Service office or accessing the John-son Controls QuickLIT website at http://cgproducts.johnsoncontrols.com.

It is the responsibility of rigging, lifting, and operating/ service personnel to verify the applicability of these documents to the equipment. If there is any question

regarding the applicability of these documents, rig-ging, lifting, and operating/service personnel should verify whether the equipment has been modified and if current literature is available from the owner of the equipment prior to performing any work on the chiller.

CHANGE BARSRevisions made to this document are indicated with a line along the left or right hand column in the area the revision was made. These revisions are to technical in-formation and any other changes in spelling, grammar or formatting are not included.

ASSOCIATED LITERATURE

Manual Description Form NumberYMC2 Installation 160.78-N1

YMC2 Unit Re-assembly 160.78-N2

YMC2 Field Connections 160.78-PW1

YMC2 Unit Renewal Parts 160.78-RP1

YMC2 OptiView™ Renewal Parts 160.78-RP2

YMC2 Unit Operations and Maintenance Manual 160.78-O1

YMC2 OptiView™ Control Center Operation Manual 160.78-O2

YMC2 Unit Service 160.78-M1

YMC2 OptiView™ Service 160.78-M2

NOMENCLATURE

YORK

Centrifugal Chiller

Magnetic Bearing

Mod Level A

S = Single StageT = Two Stage

Capacity in KW

Refrigerant R-134a

Y AA0050S-2CM

JOHNSON CONTROLS4


TABLE OF CONTENTS

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

SECTION 2 - FIELD CONTROL MODIFICATIONS ................................................................................................39Remote Mode Ready To Start Contacts .........................................................................................................40Cycling Shutdown Contacts ..........................................................................................................................40Safety Shutdown Contacts .............................................................................................................................40Run Contacts .................................................................................................................................................40Anticipatory/Alarm Contacts ...........................................................................................................................41Remote Start And Stop Contacts From Energy Management System ...........................................................41Auxiliary Safety Shutdown ..............................................................................................................................41Remote/Local Cycling Devices ......................................................................................................................41Multi-Unit Sequence .......................................................................................................................................42Chilled lIQUID Pump Starter (TB2-44/45) ......................................................................................................42Condenser Motor Pump Starter (TB2-150/151) ............................................................................................42Condenser Flow Sensors ...............................................................................................................................42Thermal Type Flow Sensor.............................................................................................................................43Paddle Type Flow Sensor...............................................................................................................................43Evaporator Flow Sensors ...............................................................................................................................43Thermal Type Flow Sensor.............................................................................................................................44Paddle Type Flow Sensor...............................................................................................................................44Two Unit Sequence Control ............................................................................................................................44Multiple Units (Two) – Series Operation .........................................................................................................44Multiple Units (Two) – Parallel Operation – Individual Unit Pumps ................................................................46Multiple Units (Two) – Parallel Operation – Single Chilled Water Pump ........................................................46Remote Current Limit Setpoint .......................................................................................................................46Remote Leaving Chilled Liquid Setpoint ........................................................................................................48External Signal For Refrigeration Unit Failure ................................................................................................50Run Contacts/Remote Run Light And Shutdown Indicator Plus Ems ............................................................51Optional Head Pressure Control ....................................................................................................................51

SECTION 3 - ENERGY MANAGEMENT SYSTEMS ..............................................................................................53

JOHNSON CONTROLS 5


LIST OF FIGURES

FIGURE 1 - Unit Device Locations ............................................................................................................................8FIGURE 2 - OptiView Component Layout ...............................................................................................................10FIGURE 3 - Microboard (031-02430-006) Details ................................................................................................... 11FIGURE 4 - Microboard (031-03630-007) Details ...................................................................................................12FIGURE 5 - I/O Board (031-01743) Details .............................................................................................................13FIGURE 6 - OptiView Control Panel TB6 and TB7 Details......................................................................................13FIGURE 7 - LTC I/O Board (031-02895) Details .....................................................................................................14FIGURE 8 - Stall Detector Board (031-02418) Details ............................................................................................15FIGURE 9 - Connector Details ................................................................................................................................15FIGURE 10 - Component Connection Details .........................................................................................................16FIGURE 11 - Power Distribution Diagram 490A and 744A ......................................................................................17FIGURE 12 - Electrical Ground Diagram 490A and 744A .......................................................................................18FIGURE 13 - Run Permissive Circuit ......................................................................................................................19FIGURE 14 - Motor Cooling Valve - Interface (BM1 Model B Only) ........................................................................20FIGURE 15 - OptiView Power Wiring 02430 MICROBOARD .................................................................................21FIGURE 16 - OptiView Power Wiring 03630 MICROBOARD .................................................................................22FIGURE 17 - Low Voltage I/O Wiring Diagram........................................................................................................24FIGURE 18 - I/O Control Wiring ..............................................................................................................................27FIGURE 19 - I/O Control Wiring HYP490VSD ........................................................................................................30FIGURE 20 - I/O Control Wiring HYP744VSD ........................................................................................................32FIGURE 21 - I/O Wiring Options .............................................................................................................................34FIGURE 22 - Motor Connections.............................................................................................................................36FIGURE 23 - MBC Interconnection Diagram...........................................................................................................37FIGURE 24 - Remote Ready To Start Contacts ......................................................................................................40FIGURE 25 - Cycling Shutdown Contacts ...............................................................................................................40FIGURE 26 - Safety Shutdown Contacts ................................................................................................................40FIGURE 27 - Run Contacts .....................................................................................................................................40FIGURE 28 - Anticipatory/Alarm Contacts...............................................................................................................41FIGURE 29 - Remote Start And Stop Contacts From Energy Management System Contacts ...............................41FIGURE 30 - Auxiliary Safety Shutdown .................................................................................................................41FIGURE 31 - Remote/Local Cycling Devices ..........................................................................................................42FIGURE 32 - Multi-Unit Sequence ..........................................................................................................................42FIGURE 33 - Chilled Liquid Pump Starter ...............................................................................................................42FIGURE 34 - Condenser Motor Pump Starter .........................................................................................................42FIGURE 35 - Condenser Flow Switches .................................................................................................................43FIGURE 36 - Evaporator Flow Sensors ..................................................................................................................44FIGURE 37 - Two Unit Sequence Control ...............................................................................................................45FIGURE 38 - Multiple Units (Two) - Series Operation .............................................................................................45FIGURE 39 - Multiple Units (Two) Parallel Operation - Individual Unit Pumps .......................................................46FIGURE 40 - Multiple Units (Two) Parallel Operation - Single Chilled Water Pump ...............................................46FIGURE 41 - Remote Current Limit Setpoint with 0-10VDC or 2-10VDC Signal ....................................................47FIGURE 42 - Remote Current Limit Setpoint with 0-20mA or 4-20mA Signal .........................................................47FIGURE 43 - Remote Current Limit Setpoint with PWM Signal ..............................................................................48FIGURE 44 - Remote Leaving Chilled Liquid Temp. Setpoint With 0-10VDC or 2-10VDC Signal ..........................49FIGURE 45 - Remote Leaving Chilled Liquid Temp. Setpoint With 0-20mA or 4-20mA Signal ...............................50FIGURE 46 - Remote Leaving Chilled Liquid Temp. Setpoint With PWM Signal ....................................................50FIGURE 47 - Run Contacts / Remote Run Light and Shutdown Indicator Plus EMS .............................................51FIGURE 48 - Auxiliary Safety Shutdown Input ........................................................................................................51FIGURE 49 - Optional Head Pressure Control Output ............................................................................................52

JOHNSON CONTROLS6


THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS 7


1SECTION 1 - UNIT WIRING

1. This wiring diagram describes the standard elec-tronic control scheme for use with a YORK Vari-able Speed Drive.

2. Field wiring to be in accordance with the National Electrical Code (N.E.C.) as well as all other appli-cable codes and specifications. See Form 160.78-PW1 for Field Connections. CAUTION: Field wiring contacts may have voltage present when power is removed. Field wiring contacts could be connected to external power sources.

3. Numbers along the left side of diagram are line identification numbers.

4. Main Control Panel Class 1 Field Wiring Termi-nal connection points are indicated by numbers within a rectangle I.E. 15 .

5. To cycle unit ON and OFF automatically with contacts other than those shown, install a cycling device between terminals 1 and 13 (see Note 7). If a cycling device is installed, the jumper must be removed between terminals 1 and 13 .

6. To stop the unit and NOT permit it to start again, install a stop device between terminals 1 and 8 (see Note 7). A remote start-stop switch may be connected to terminals 1 , 7 and 8 (see Note 7). Remote start-stop switch is operative only in the “Remote” operating mode.

7. Device contact rating to be 5 milliamperes at 115 Volts AC.

8. Contact rating is 5A resistive at 120 Volts AC or 240 Volts AC.

9. A jumper is installed between terminals 24 and 25 for normal operation.

10. Solid state motor overload contact is set to trip a 105% FLA.

11. Contacts rating is 5 AMPs resistive at 250 Volts AC and 30 Volts DC, 2 AMP inductive (.4 PF) at 120 Volts AC and 30 Volts DC.

12. Field connected control power supply is not re-quired, as control transformer is supplied on vari-able speed drive.

13. Maximum allowable current draw for the sum of all loads is 2 Amps holding, 10 Amps inrush.

14. Each 115VAC Field-connected inductive load: I.E. Relay Coil, Motor Starter Coil, etc. will have a transient suppressor wired in parallel with its coil, physically located at the coil.

15. Spare transient suppressors and control circuit fuses are supplied in a bag attached to the green ground screw in lower left corner of the control panel.

JOHNSON CONTROLS8

FORM 160.78-PW2 ISSUE DATE: 10/28/2016SECTION 1 - UNIT WIRING

FIGURE 1 - UNIT DEVICE LOCATIONS

LD14644

MagneticBearing

Controller

VariableSpeed Drive

OptiViewControlPanel

LiquidLevel

Sensor

Drop LegRefrigerant

Temperature(RT6)

OrificeValve

Actuator

JOHNSON CONTROLS 9

SECTION 1 - UNIT WIRINGFORM 160.78-PW2 ISSUE DATE: 10/28/2016

1

Stall Detector Pressure

MotorTemperature

DischargeTemperature

(RT2)High

PressureCut-out

CondenserPressure

EvaporatorPressure

Hot GasBypassValve

Leaving Condenser

Liquid Temperature

(RT4)

CondenserFlow Switch

EvaporatorFlow Switch

EnteringCondenser

LiquidTemperature

(RT5)

LeavingChilledLiquid

Temperature(RT1) Entering

Chilled Liquid Temperature

(RT9)

* Pre-rotationalVanes

EvaporatorRefrigerant

Temperature(RT7)

* PRV Position

† Motor Cooling Valve

Motor

VariableGeometryDiffuser

*Vent

* Compressor models ending in “A” only† Compressor models ending in “B” only

FIGURE 1 – UNIT DEVICE LOCATIONS (CONT'D)

LD14643

JOHNSON CONTROLS10


FIGURE 2 - OPTIVIEW COMPONENT LAYOUT

035-22948-013REV A

LD14648b

E-LINK or

SC-EQ

JOHNSON CONTROLS 11


1

FIGURE 3 - MICROBOARD (031-02430-006) DETAILSLD14649

+5V

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GND

SHIELD

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JOHNSON CONTROLS12


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FIGURE 4 - MICROBOARD (031-03630-007) DETAILS

JOHNSON CONTROLS 13


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FIGURE 6 - OPTIVIEW CONTROL PANEL TB6 AND TB7 DETAILS LD14648a

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FIGURE 5 - I/O BOARD (031-01743) DETAILSLD14650A

JOHNSON CONTROLS14


To J

12-3

To C

OM

3 R

S-4

85

To HGBP Actuator J-3

To Level Control Orifice Actuator J-3

To J

12-2

To J

30-5

To 6

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J30

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To 4

FU

}11 12 13 14 15 16

2

2

To TB7-3132

To Motor Housing EEV Control Board

2

3

FIGURE 7 - LTC I/O BOARD (031-02895) DETAILS LD14734

JOHNSON CONTROLS 15


1

FIGURE 8 - STALL DETECTOR BOARD (031-02418) DETAILS

LD14737

TPF

GND -5V +5V

TPE TPD TPK TPL

J2 J2

TB1

HISTD

TB1

TPA

TPJ

SIG IN

OUT2

OUT1

3 1

1

1

TPMTPCTPB

TPG

TPH

031-02418-001REV

J1J1To

Stall DetectorDischarge Pressure

3

2

1

J1

J2{J3

BLACK

WHITE

RED

1

2

3

STDHI

2315

INPUTINPUT

To Microboard031-02430

{

+5 J7-2

INPUT J8-1

GND J7-24

J8-15J7-23

RED

BLACK

GREEN

LD14736

FIGURE 9 - CONNECTOR DETAILS

JOHNSON CONTROLS16


FIGURE 10 - COMPONENT CONNECTION DETAILS LD14735

RED

BLACK

WHT

VGD POTENTIONMETER

To OptiViewControl Panel - Early Release Units

JOHNSON CONTROLS 17


1

FIGURE 11 - POWER DISTRIBUTION DIAGRAM 490A AND 744A

LD21279

092-42636-004

CIRCUIT BREAKER DRIVE AMPS 490 400 744 1200

TRANSFORMER SECONDARY FUSE DRIVE DESIGNATION AMPS 490 11 FU 20 MOD A 490 15 FU 9 MOD B 744 11 FU 20 MOD B

25 FU DRIVE AMPS 490 8 MOD A 490 10 744 16

PRVMOD AONLY

490A MOD B

POWER DISTRIBUTION DIAGRAM

JOHNSON CONTROLS18

FORM 160.78-PW2 ISSUE DATE: 10/28/2016ELECTRICAL GROUND DIAGRAM

ELECTRICAL GROUND DIAGRAM

FIGURE 12 - ELECTRICAL GROUND DIAGRAM 490A AND 744A

LD21280

035-22948-014

MOD AONLY

JOHNSON CONTROLS 19

RUN PERMISSIVE CIRCUITFORM 160.78-PW2 ISSUE DATE: 10/28/2016

1RUN PERMISSIVE CIRCUIT

FIGURE 13 - RUN PERMISSIVE CIRCUIT

035-22948-009REV A

LD14647

JOHNSON CONTROLS20

FORM 160.78-PW2 ISSUE DATE: 10/28/2016RUN PERMISSIVE CIRCUIT

LEGEND1BR 6 AMP CIRCUIT BREAKER1T POWER SUPPLY TRANSFORMERCFS CONDENSER WATER FLOW SWITCHCP CONDENSER PRESSUREEFS EVAPORATOR FLOW SWITCHEP EVAPORATOR PRESSUREFU FUSEHGBP HOT GAS BYPASSHPCO HIGH PRESSURE CUTOUT1R COMPRESSOR MOTOR RELAYLLS CONDENSER LIQUID LEVEL SENSORMBC MAGNETIC BEARING CONTROLLERMOV METAL OXIDE VARISTOROVA LEVEL CONTROL ORIFICE VALVE ACTUATORPRV PRE-ROTATION VANERT1 LEAVING CHILLED WATER TEMPERATURERT2 DISCHARGE TEMPERATURE

RT4 LEAVING CONDENSER WATER TEMPERATURERT5 RETURN CONDENSER WATER TEMPERATURERT6 EVAPORATOR REFRIGERANT TEMPERATURERT7 EVAPORATOR REFRIGERANT TEMPERATURERT9 RETURN CHILLED WATER TEMPERATURESBPV STOP BYPASS VALVESD STALL DETECTORSUPR TRASIENT SUPPRESSORTB TERMINAL BLOCKVGD VARIABLE GEOMETRY DIFFUSERVSD VARIABLE SPEED DRIVE

FIELD INSTALLED WIRINGFACTORY INSTALLED WIRINGFACTORY SYSTEM WIRINGTERMINAL BLOCK CONNECTION POINTCOMPONENT TERMINAL CONNECTIONJACK AND PLUG CONNECTION

MICROBOARD

LTCI/O

BOARD031-02895-000

J12

2

3

J9

4/12

3/11

TB4

2

SERIALCOMMS

(-)

(+)

POSITION SIGNAL0-10VDC

+24VAC

RS-485COM3

3 RETURN

115VAC

2T

1 2

1 2

24VAC

24V-124V-2

+

–

IB2 INTERFACE BOARD

MOTORCOOLING

VALVE

NOTE

J - 1

J - 2

J - 3

J - 4

B

W

G

R

BLK

WHT

GRN

RED

NOTES: 1. IB2 Board Jumper CN2 must be out (only on one pin) for “open on rise” operation. 2. IB2 Board Jumper CN3 must be in (across both pins) for 0-10VDC input signal. 3. IB2 Board Jumper CN4 must be out (only on one pin).

OPTIVIEW PANEL

FIGURE 14 - MOTOR COOLING VALVE - INTERFACE (BM1 MODEL B ONLY)

LD15994

JOHNSON CONTROLS 21

OPTIVIEW POWER WIRINGFORM 160.78-PW2 ISSUE DATE: 10/28/2016

1OPTIVIEW POWER WIRINGMod Level A with 031-02430-006 Microboard

FIGURE 15 - OPTIVIEW POWER WIRING 02430 MICROBOARD

035-22948-004REV B

LD14636a

To Line 903

To Line 702

To Line 702

To Line 903

JOHNSON CONTROLS22

FORM 160.78-PW2 ISSUE DATE: 10/28/2016OPTIVIEW POWER WIRING

OPTIVIEW POWER WIRINGMod Level B with 031-03630-007 Microboard

FIGURE 16 - OPTIVIEW POWER WIRING 03630 MICROBOARD

LD21600

092-42636-006

ISOLATED TRANSFORMER USED WITH IB2 IN MOD LEVEL B UNITS ONLY

JOHNSON CONTROLS 23

OPTIVIEW POWER WIRINGFORM 160.78-PW2 ISSUE DATE: 10/28/2016

1


JOHNSON CONTROLS24

FORM 160.78-PW2 ISSUE DATE: 10/28/2016LOW VOLTAGE I/O WIRING DIAGRAM

LOW VOLTAGE I/O WIRING DIAGRAM

FIGURE 17 - LOW VOLTAGE I/O WIRING DIAGRAM

LD21601a

or 0

2430

JOHNSON CONTROLS 25

LOW VOLTAGE I/O WIRING DIAGRAMFORM 160.78-PW2 ISSUE DATE: 10/28/2016

1

LD21601b

092-42636-007

LOW VOLTAGE I/O WIRING DIAGRAM (CONT'D)

FIGURE 17 – LOW VOLTAGE I/O WIRING DIAGRAM (CONT'D)

JOHNSON CONTROLS26

FORM 160.78-PW2 ISSUE DATE: 10/28/2016LOW VOLTAGE I/O WIRING DIAGRAM


JOHNSON CONTROLS 27

CONTROL I/O WIRINGFORM 160.78-PW2 ISSUE DATE: 10/28/2016

1CONTROL I/O WIRING

FIGURE 18 - I/O CONTROL WIRING

LD21606

092-42636-008

JOHNSON CONTROLS28

FORM 160.78-PW2 ISSUE DATE: 10/28/2016CONTROL I/O WIRING

CONTROL I/O WIRING (CONT'D)

FIGURE 18 – I/O CONTROL WIRING (CONT'D)

LD21602a LD21602b

NO

TE: S

ee D

evic

e D

etai

ls D

raw

ings

.

092-42636-009

JOHNSON CONTROLS 29

CONTROL I/O WIRINGFORM 160.78-PW2 ISSUE DATE: 10/28/2016

1CONTROL I/O WIRING (CONT'D)

FIGURE 18 – I/O CONTROL WIRING (CONT'D)

LD21602b

NO

TE: S

ee D

evic

e D

etai

ls D

raw

ings

.

092-42636-009

490A

on

page

30

744A

on

page

32

JOHNSON CONTROLS30

FORM 160.78-PW2 ISSUE DATE: 10/28/2016I/O CONTROL WIRING HYP490VSD

I/O CONTROL WIRING HYP490VSD

FIGURE 19 - I/O CONTROL WIRING HYP490VSD

LD21603a

JOHNSON CONTROLS 31

I/O CONTROL WIRING HYP490VSDFORM 160.78-PW2 ISSUE DATE: 10/28/2016

1

LD21603a

I/O CONTROL WIRING HYP490VSD (CONT'D)

FIGURE 19 – I/O CONTROL WIRING HYP490VSD (CONT'D)

LD21603b

092-42636-010

JOHNSON CONTROLS32

FORM 160.78-PW2 ISSUE DATE: 10/28/2016I/O CONTROL WIRING HYP744VSD

I/O CONTROL WIRING HYP744VSD

FIGURE 20 - I/O CONTROL WIRING HYP744VSD

LD21604a

JOHNSON CONTROLS 33

I/O CONTROL WIRING HYP744VSDFORM 160.78-PW2 ISSUE DATE: 10/28/2016

1

LD21604a

I/O CONTROL WIRING HYP744VSD (CONT'D)

FIGURE 20 – I/O CONTROL WIRING HYP744VSD (CONT'D)

LD21604b

092-42637-010

JOHNSON CONTROLS34

FORM 160.78-PW2 ISSUE DATE: 10/28/2016I/O WIRING OPTIONS

I/O WIRING OPTIONS

FIGURE 21 - I/O WIRING OPTIONS

LD21605a

JOHNSON CONTROLS 35

I/O WIRING OPTIONSFORM 160.78-PW2 ISSUE DATE: 10/28/2016

1

FIGURE 21 – I/O WIRING OPTIONS (CONT'D)

LD21605b

092-42636-011

I/O WIRING OPTIONS (CONT'D)

JOHNSON CONTROLS36

FORM 160.78-PW2 ISSUE DATE: 10/28/2016MOTOR CONNECTIONS

MOTOR CONNECTIONS

FIGURE 22 - MOTOR CONNECTIONS

LD14806

Z1 MODULE OUTLET

Z2 MODULE OUTLET

MOTOR POWEROUTLET

MOTOR SIGNALOUTLET

JOHNSON CONTROLS 37

MBC INTERCONNECTION DIAGRAMFORM 160.78-PW2 ISSUE DATE: 10/28/2016

1MBC INTERCONNECTION DIAGRAM

FIGURE 23 - MBC INTERCONNECTION DIAGRAM LD14805

MOTOR

Z1 SIDE INTERCONNECTION DIAGRAM

HOUSING GROUND

HOUSING GROUND

SECURITY CABLE

Bla

ck G

roun

d

Bla

ckB

row

nB

lue

Blu

eW

hite

Whi

teG

rey

Whi

te

Bla

ck g

roun

d

Bla

ck

Blu

e

Yello

wB

lack

Bla

ck

Pur

ple

Red

Ora

nge

Yello

wG

reen

Bla

ck

Blu

eW

hite

Whi

te

Bla

ckYe

llow

Whi

teB

lue

Gre

enYe

llow

Ora

nge

Red

Pur

ple

Blu

eB

row

nB

lack

Gre

y

Red

SecurityCable

AXIAL SENSOR

AXIAL SENSOR

RADIAL SENSOR

RADIAL SENSOR

RADIAL BEARING

RADIAL BEARING

TEMPERATURE PROBE

TEMPERATURE PROBE

AXIAL BEARING

AXIAL BEARING

TEMPERATURE PROBE

TEMPERATURE PROBE

Z2 SIDE INTERCONNECTION DIAGRAM

JOHNSON CONTROLS38

FORM 160.78-PW2 ISSUE DATE: 10/28/2016MBC INTERCONNECTION DIAGRAM


JOHNSON CONTROLS 39


2

SECTION 2 - FIELD CONTROL MODIFICATIONS

1. These FIGURES show recommended field control wiring modifications (by others) to the standard OptiView™ 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 OptiView™ Control Center.

7. The OptiView™ Control Center is factory fur-nished for Manual Restart After Power Failure as a standard function. The control center can be field changed from Manual Restart to Auto Re-start after a power failure with a setpoint in the control software setup screen.

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. Lead selector and cycling control to provide simi-lar lead selection and cycling of lag units for three (3) units is available: Kit No. 366-44684D (see Product Drawing Form 160.00-PA1.1) in NEMA I enclosure. Consult your YORK/Johnson Con-trols representative.

10. Sequence control kits (see Figure 37 on page 45) 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 Figure 38 on page 45 and Figure 39 on page 46.

11. Maximum allowable current draw between circuits 24 and 2 for field installed devices is 2 amp hold-ing and 10 amps inrush – see OptiView™ Control Center Wiring Diagram in this manual.

12. For required field wiring connections of the chilled water pump contacts (terminals 44 and 45 on OptiView™ Control Center field wiring terminal block TB2) and chilled water flow switch (termi-nals 1 and 12 on OptiView™ Control Center field wiring terminal board TB2) Refer to YMC2 Field Connections (Form 160.78-PW1).

13. 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.

14. Do not apply voltage on field wiring terminal blocks TB4 and TB6 in YORK OptiView™ Con-trol Center, as 115VAC source is fed from termi-nals 1 and 2 .

JOHNSON CONTROLS40

FORM 160.78-PW2 ISSUE DATE: 10/28/2016SECTION 2 - FIELD CONTROL MODIFICATIONS

REMOTE MODE READY TO START CONTACTSWhen closed, these contacts signify the following:

1. The OptiView™ Control Center is in “digital”, “analog” or “BAS” remote operating mode, al-lowing for energy management system or remote start/stop control.

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

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

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 (Figure 29 on page 41). When the Remote Mode Ready to Start Contacts close, the OptiView™ Control Center will display SYSTEM READY TO START mes-sage.

FIGURE 24 - REMOTE READY TO START CONTACTSLD06820

I/O BOARD

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. YMC2 Operations and Maintenance (Form 160.78-O1) provides a list and ex-planation of all Cycling Shutdowns. While these con-tacts are closed, the OptiView™ Control Center will display CYCLING SHUTDOWN – AUTO RESTART on the System Status Bar and the cause of the shut-down on the System Details bar of the display. Cycling Shutdown contacts function in all operating modes.

FIGURE 25 - CYCLING SHUTDOWN CONTACTSLD06821

I/O BOARD

SAFETY SHUTDOWN CONTACTSWhen closed, these contacts signify the unit is not per-mitted to start due to a SAFETY shutdown condition. Safety shutdowns require a manual reset procedure be performed before the unit can be restarted. YMC2 Op-erations and Maintenance (Form 160.78-O1) provides a list and explanation of all Safety Shutdowns. While these contacts are closed, the OptiView™ Control Cen-ter will display SAFETY SHUTDOWN – MANUAL RESTART 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 con-dition no longer exists and a manual reset is performed by pressing the clear faults key on the control panel. The unit can then be restarted. Safety Shutdown con-tacts function in all operating modes.

FIGURE 26 - SAFETY SHUTDOWN CONTACTSLD06823

I/O BOARD

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

FIGURE 27 - RUN CONTACTSLD06822

I/O BOARD

JOHNSON CONTROLS 41

SECTION 2 - FIELD CONTROL MODIFICATIONSFORM 160.78-PW2 ISSUE DATE: 10/28/2016

2

FIGURE 29 - REMOTE START AND STOP CON-TACTS FROM ENERGY MANAGEMENT SYSTEM CONTACTS

LD06824

I/O BOARD

AUXILIARY SAFETY SHUTDOWNWhen 115 VAC is switched to TB4-31 from a chiller source at TB4-1, a safety shutdown of the chiller is commanded. The contacts must open and a manual re-set performed at the panel to re-start.

FIGURE 30 - AUXILIARY SAFETY SHUTDOWN

I/OBOARDTB4

1 31

LD06824a

REMOTE/LOCAL CYCLING DEVICES The closure of an automatic reset device across this input will permit the unit to operate in all operating modes. Conversely, an opening of the device contacts will inhibit the unit from operating; the OptiView™ Control Center will then display the following mes-sages: CYCLING SHUTDOWN – AUTO RESTART and SYSTEM CYCLING – CONTACTS OPEN.

The OptiView Control Center contains a seven day time clock to select daily sched‑ule Start/Stop times (Sunday through Saturday including one or more holidays in week) up to one full week at a time. So automatic start and stop of the unit on a daily basis, at predetermined times, can be programmed as a standard feature; an additional program timer is not required for this function.

ANTICIPATORY/ALARM CONTACTSThese contacts will close whenever one or more of the WARNING conditions listed in YMC2 OptiView™ Op-eration (Form 160.78-O2) occurs. They will remain closed as long as the condition is in effect. On most warnings, the contacts automatically open when the condition is no longer present. On certain warnings the contacts will open only after the condition is no longer present and the WARNING RESET key is pressed in Operator (or higher) access level.

FIGURE 28 - ANTICIPATORY/ALARM CONTACTSLD04604

I/O BOARD

REMOTE START AND STOP CONTACTS FROM ENERGY MANAGEMENT SYSTEMWhen the OptiView™ Control Center is in the “Digi-tal”, “Analog” remote operating mode with the Remote Stop Contacts open, and the Remote Mode Ready to Start Contacts closed (Figure 24 on page 40), the unit will start via a closure of the Remote Start Con-tacts. A subsequent closure of the Energy Management System Remote Stop Contacts causes the chiller to shut down. The Opti-View™ Control Center will display REMOTE STOP because the Energy Management Sys-tem Remote Stop Contact has commanded the unit to shutdown.

It is recommended that maintained contacts be used for both START and STOP.

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 OptiView™ Control Center and prevent the chiller from restarting. However, the opera‑tor cannot locally start the compressor using “compressor” start switch, when the control center is in the “remote” operating mode.

JOHNSON CONTROLS42


FIGURE 31 - REMOTE/LOCAL CYCLING DEVICES

LD06825

I/O BOARD

MULTI-UNIT SEQUENCEFor multiple chiller installation application, Multi-Unit Sequence contacts are available to start and stop each unit. The maintained closure of a device contacts across terminals 1 and 9 will permit the unit to operate in all the operating modes with the “compressor” switch in the “run” (l) position. Conversely, an opening of the device contacts will inhibit the unit from operating; the OptiView™ Control Center will then display the fol-lowing message: CYCLING SHUTDOWN – AUTO RESTART and MULTIUNIT CYCLING – CON-TACTS OPEN. An accessory sequence control kit for two, three or four units is available from YORK – see Figure 37 on page 45 for Two Unit Sequence Con-trol Kit.

I/O BOARD

FIGURE 32 - MULTI-UNIT SEQUENCELD06828

CHILLED LIQUID PUMP STARTER (TB2-44/45)Dry closure contacts. When the chiller is started, the Contacts close immediately upon entering “MBC Startup”. Normally, they open coincident with receipt of a stop command or a fault other than those below:

A. LEAVING CHILLED LIQUID - LOW TEM-PERATURE cycling shutdown.

B. If Chilled Liquid Pump Operation is set to ENHANCED, MULTIUNIT CYCLING - CONTACTS OPEN or SYSTEM CYCLING - CONTACTS OPEN cycling shutdown.

C. LEAVING CHILLED LIQUID FLOW SWITCH OPEN cycling shutdown.

LD21607

N.O. CONTACTS (IN CONTROL CENTER) RATED 2 AMPSINDUCTION AT 250 VAC, 5 AMPS RESISTIVE AT 250 VAC

TB2 44 45

FIGURE 33 - CHILLED LIQUID PUMP STARTER

CONDENSER MOTOR PUMP STARTER (TB2-150/151) Dry closure contacts. Contacts close coincident with beginning of “MBC Startup”. They open coincident with receipt of a chiller stop command or fault other than CONDENSER-FLOW SWITCH OPEN cycling shutdown.

If it is desired to supply the dry contacts with 115VAC power from the OptiView™ Control Panel to control the Condenser Pump Motor Starter, a field installed wire must be connected from TB5-22 to I/O Board TB2-150. Then connect I/O Board TB2-151 to the Condenser Pump Motor Starter.

FIGURE 34 - CONDENSER MOTOR PUMP STARTERLD21608

N.O. CONTACTS (IN CONTROL CENTER) RATED 2 AMPSINDUCTION AT 250 VAC, 5 AMPS RESISTIVE AT 250 VAC

TB2 150 151

CONDENSER FLOW SENSORSThe Thermal-type Flow Sensor interfaces with the Microboard and Paddle-type Flow Sensor interfaces with the I/O board.

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 OPERATIONS Screen using Service Access Level. Enter “Analog” for Ther-mal-type or “Digital” for Paddle-type. Refer to YMC2 Operations and Maintenance (Form 160.78-O1).

JOHNSON CONTROLS 43


2

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 11 .

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 OptiView™ Control Center will display the following message: CYCLING SHUTDOWN – AUTO RESTART and CONDENSER FLOW SWITCH OPEN.

EVAPORATOR FLOW SENSORSThe Thermal-type Flow Sensor interfaces with the mi-croboard and Paddle-type Flow Sensor interfaces with the I/O board.

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 OPERATIONS Screen using Service the Access Level. Enter “Ana-log” for Thermal-type or “Digital” for Paddle-type. Refer to YMC2 Operations and Maintenance (Form 160.78-O1).

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

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 CONDENSER - FLOW SWITCH OPEN. 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 1 and 11 .

THERMAL TYPE FLOW SENSORWhen the Thermal-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 microboard input J7-16.

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 OptiView™ Control Center will display the following message: CYCLING SHUTDOWN – AUTO RESTART and CONDENSER FLOW SWITCH OPEN.

J14-

MICROBOARD



THERMAL-TYPE FLOW SENSOR

11

1

8

7

TB4

I/O BOARDPADDLE-TYPE FLOW SENSOR

J14-

MICROBOARD



THERMAL-TYPE FLOW SENSOR

11

1

8

7

TB4


I/O BOARD

MIC

RO

BO

AR

D

FIGURE 35 - CONDENSER FLOW SWITCHESLD09133

JOHNSON CONTROLS44


MIC

RO

BO

AR

D

I/O BOARD

J14-

MICROBOARDTHERMAL-TYPE FLOW SENSOR

12

1

TB4


EVAPORATORFLOW SWITCH

CHILLED WATERFLOW SWITCH

5 4

2

1

34

TO 24VA

C S

UP

PLY

FIGURE 36 - EVAPORATOR FLOW SENSORSLD09134

THERMAL TYPE FLOW SENSORWhen the Thermal-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 microboard input J7-14.

When no flow of liquid is sensed, the relay output is turned OFF, this results in less than 1VDC to the mi-croboard input.

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.

TWO UNIT SEQUENCE CONTROLProvides 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 OPERATIONThe supply chilled water temperature to the building is normally determined by the “Chilled Liquid Tempera-ture” setpoint for Unit #2. When lead selector position of sequence control kit (Figure 38 on page 45) is Unit #1, the supply chilled water temperature to the building will be the temperature control setpoint on Unit #1 OptiView™ Control Center. If lower tempera-ture is desired, reprogram the “Chilled Liquid Temper-ature” setpoint for Unit #1.

JOHNSON CONTROLS 45


2

FIGURE 37 - TWO UNIT SEQUENCE CONTROL LD06835

FIGURE 38 - MULTIPLE UNITS (TWO) - SERIES OPERATIONLD06826

See Figure 33

JOHNSON CONTROLS46


MULTIPLE UNITS (TWO) – PARALLEL OPERATION – INDIVIDUAL UNIT PUMPSThis piping arrangement has a chilled water pump as-sociated with each evaporator that are cycled ON and OFF with the unit. This results in reduced chilled water flow rates whenever a single unit can handle the cool-ing load. Because 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 (Figure 37 on page 45) the temperature of the supply chilled water does not change.

FIGURE 39 - MULTIPLE UNITS (TWO) PARALLEL OPERATION - INDIVIDUAL UNIT PUMPS

LD06828

MULTIPLE UNITS (TWO) – PARALLEL OPERATION – SINGLE CHILLED WATER PUMPFor 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 (Figure 37 on page 45), mixed chilled water temperature will rise as a result of uncooled return water flowing through the in-operative unit. For individual unit chilled water pump piping, refer to Figure 39 on page 46.

FIGURE 40 - MULTIPLE UNITS (TWO) PARALLEL OPERATION - SINGLE CHILLED WATER PUMP

LD06830

REMOTE CURRENT LIMIT SETPOINTThe 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, 2-10VDC, 0-20mA, 4-20mA or 1 to 11 second Pulse Width Modulated (PWM) signal to the OptiView™ Control Center. The OptiView™ Control Center must be configured appro-priately to accept the desired signal type as follows:

• The appropriate Remote Mode must be selected: Analog Remote Mode must be selected when us-ing a voltage or current signal input. Digital Re-mote Mode must be selected when using a PWM input.

• If Analog Remote Mode is selected, the Remote Analog Input Range setpoint must be set to “0-10VDC” or “2-10VDC” as detailed below, re-gardless of whether the signal is a voltage or cur-rent input signal type.

• Microboard Program Jumper P23 must be posi-tioned appropriately per the input signal type as detailed below. It is recommended that a qualified Service Technician position this jumper.

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2

Important! The signal type used for Re‑mote Current Limit Setpoint reset and the signal type used for Remote Leaving Chilled Liquid Temperature setpoint re‑set must be the same. For example, if a 0‑10VDC signal is being used for Remote Leaving Chilled Liquid Temperature Re‑set, then a 0‑10VDC signal must be used for Remote Current Limit Reset.

0-10VDC - As shown in Figure 41 on page 47, 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 0-10VDC. This input will only be accepted when Analog Remote Mode is se-lected, 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 Figure 41 on page 47, 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 vari-ous 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%

FIGURE 41 - REMOTE CURRENT LIMIT SETPOINT WITH 0-10VDC OR 2-10VDC SIGNAL

SIGNAL

COMMON 5

1+

J22

LD04498

0-20 mA - As shown in Figure 42 on page 47, con-nect input to Microboard J22-2 (signal) and J2-5 (Gnd). The setpoint varies linearly from 100% to 30% FLA as the input varies from 0-20mA. 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 vari-ous 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 Figure 42 on page 47, con-nect input to Microboard J22-2 (signal) and J2-5 (Gnd). The setpoint varies linearly from 100% to 30% FLA as the input varies from 4-20mA. 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 vari-ous inputs as follows:

SETPOINT (%) = 100 – [(MA – 4) X 4.375]

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%

FIGURE 42 - REMOTE CURRENT LIMIT SETPOINT WITH 0-20MA OR 4-20MA SIGNAL

SIGNAL

COMMON 5

2+

J22

LD04499

JOHNSON CONTROLS48


PWM - The Pulse Width Modulation input is in the form of a 1 to 11 second relay contact closure that ap-plies 115VAC to the I/O Board TB4-20 for 1 to 11 sec-onds. As shown in Figure 43 on page 48, connect dry closure relay contacts between I/O Board TB4-20 (signal) and TB4-1 (115VAC). The setpoint varies lin-early 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 accept-ed in Digital Remote Mode. Calculate the setpoint for various pulse widths as follows:

SETPOINT (%) = 100 – [(PULSE WIDTH IN SECONDS – 1) X 7]

For example, if the relay contacts close for 3 seconds, the setpoint would be set to 86% as follows:

SETPOINT (%) = 100 – [(3 – 1) X 7] = 100 – (2 X 7) = 100 – 14 = 86%

FIGURE 43 - REMOTE CURRENT LIMIT SETPOINT WITH PWM SIGNAL

LD06832

I/O BOARD

REMOTE LEAVING CHILLED LIQUID SETPOINTRemote 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 Control Center. The Leaving Chilled Liquid Tem-perature 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 Tem-perature Base Setpoint value. The setpoint can be re-motely changed over the range of 10° or 20ºF (as per the locally programmed Remote Reset Temperature

Range setpoint) above the Local Leaving Chilled Liq-uid 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 Control Cen-ter must be configured appropriately to accept the de-sired 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.

• If Analog Remote Mode is selected, the Remote Analog Input Range setpoint must be set to “0-10VDC” or “2-10VDC” as detailed below, re-gardless of whether the signal is a voltage or cur-rent signal type.

• Microboard Program Jumper JP24 must be posi-tioned appropriately per the input signal type as detailed below. It is recommended a qualified Ser-vice Technician position this jumper.

Important! The signal type used for Re‑mote 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, then a 0‑10VDC signal must be used for Leaving Chilled Liquid Temperature Reset.

0-10VDC - As shown in Figure 44 on page 49, 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 lin-early between these extremes as the input varies lin-early 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 vari-ous 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

JOHNSON CONTROLS 49


2

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

SETPOINT (°F) = 40 + 5

= 45°F

2-10VDC - As shown in Figure 44 on page 49, 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 2-10VDC. 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 Re-set Temp. Range 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 SETPOINT (°F) = 40 + 3.8 = 43.8°F

FIGURE 44 - REMOTE LEAVING CHILLED LIQUID TEMP. SETPOINT WITH 0-10VDC OR 2-10VDC SIGNAL

SIGNAL

COMMON 5

3+

J22

LD04500

0-20mA - As shown in Figure 45 on page 50, con-nect 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:

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


= 44°F

4-20mA - As shown in Figure 45 on page 50, con-nect 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 0-20mA. 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 TEMP. RESET RANGE) 16


JOHNSON CONTROLS50


For example, if 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

= 40 16

= 2.5°F

SETPOINT (°F) = 40 + 2.5 = 42.5°F

FIGURE 45 - REMOTE LEAVING CHILLED LIQUID TEMP. SETPOINT WITH 0-20MA OR 4-20MA SIGNAL

SIGNAL

COMMON 5

4+

J22

LD04501

PWM - The Pulse Width Modulation input is in the form of a 1 to 11 second relay contact closure that ap-plies 115VAC to the I/O Board TB4-19 for 1-11 sec-onds. As shown in Figure 46 on page 50, 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. Calcu-late the setpoint for various pulse widths as follows:

OFFSET(°F) =

(PULSE WIDTH IN SECONDS)(REMOTE RESET TEMP. RANGE)10


For example, if the relay contacts close for 5 seconds and the Remote Reset Temp. Range setpoint is pro-grammed for 10°F, and the Local Leaving Chilled Liq-uid 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


= 44°F

FIGURE 46 - REMOTE LEAVING CHILLED LIQUID TEMP. SETPOINT WITH PWM SIGNAL

LD06833

EXTERNAL SIGNAL FOR REFRIGERATION UNIT FAILUREWhen the Safety Shutdown Contacts (see Figure 26 on page 40) are not connected to an Energy Manage-ment 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 following safety controls: low oil pressure; high oil pressure; high condenser pres-sure; low evaporator pressure; high oil temperature; high discharge temperature; auxiliary safety; power failure when the Power Restart setpoint on the control panel setup screen is set to manual, which implies that the chiller requires Manual Restart After Failure.

If the unit was shut down because of Cycling Shutdown Contacts (see Fig‑ure on page 40) the alarm will not be energized, but the unit will have been shut down. A closure of the safety alarm contacts means that an operator must manually reset and restart the unit.

JOHNSON CONTROLS 51


2

When the Safety Shutdown contacts close, the Opti-View™ Control Center will display the following mes-sage: SAFETY SHUTDOWN – MANUAL RESTART, and cause of shutdown.

RUN CONTACTS/REMOTE RUN LIGHT AND SHUTDOWN INDICATOR PLUS EMSWhen run contacts are required for a Remote Run Light and/or Shut down Indicator AND Energy Management System (EMS), connect (by others) as shown in the diagram. The EMS, control relay, shutdown and run lights are furnished by others. When the N.O. contacts close, between terminals 35 and 36 on field wiring terminal block TB2 in the OptiView™ Control Center, this indicates that the unit is operating; the remote Run Light will be energized. The unit run contacts open when the unit is shutdown (safety or cycling) and the remote indicator will then be energized. For run con-tacts to EMS only refer to Figure 27 on page 40. When terminals 35 and 36 are not used for an EMS, they may be connected to a remote Run Light. The control relay scheme shown in Figure 43 can also be applied for a remote Run Light AND a Remote Shut-down Indicator, when an EMS is not used.

FIGURE 47 - RUN CONTACTS / REMOTE RUN LIGHT AND SHUTDOWN INDICATOR PLUS EMS

LD06836

The closure of a Momentary or Maintained N.O. Switch or Relay Contacts will cause the unit to shut-down and display: SAFETY SHUTDOWN – MAN-UAL RESTART and AUXILIARY SAFETY – CON-TACTS CLOSED. The unit will not restart until the contacts open and the keypad COM PRESSOR switch is moved to the STOP-RESET position (“O”) and then to the START (“”)position.

FIGURE 48 - AUXILIARY SAFETY SHUTDOWN INPUTLD04399

I/O BOARD

OPTIONAL HEAD PRESSURE CONTROLThe chiller provides optional output for control of sys-tem equipment to maintain condenser temperature for heat recovery on a double-bundle condenser unit or for head pressure control. The output may be used to control a converging or diverting valve, pump VSD, or other suitable equipment. The chiller is equipped with the optional LTC I/O board when output is required to control auxiliary equipment to regulate condenser water temperature or flow for the double-bundle heat recovery option or the head pressure control option. LTC I/O board terminal TB2-2 (VO) to TB2-3 (RTN) will provide 0-10VDC output in proportion to the command from the microprocessor for control. LTC I/O board terminal TB2-1 (IO) to TB2-3 (RTN) will provide 4-20mA output in proportion to the command from the microprocessor for control (see Figure 49 on page 52). The load connected to these terminals must meet the following specification:

• 0-10V - Input resistance should be greater than 1K ohms.

• 4-20mA - Input resistance must be less than or equal 500 ohms.

JOHNSON CONTROLS52


During head pressure control operation in a configura-tion where the means used by the particular site is to throttle flow through the single condenser tube bundle in service, the controlled device should be setup to in-hibit throttling below the minimum required flow rate through the condenser when the control panel output is at minimum so the flow switch requirement is main-tained.

FIGURE 49 - OPTIONAL HEAD PRESSURE CON-TROL OUTPUT

GND

RTN VO I/O

0-10V 4-20mA

1

TB2 LTC I/O BoardLD14346

JOHNSON CONTROLS 53


3

SECTION 3 - ENERGY MANAGEMENT SYSTEMS

YMC2 chiller design allows for ease of interfacing with Energy Management Systems (EMS). The OptiView™ Control Center includes unit status contacts, provisions for remote 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 contacts are factory furnished through a field wiring terminal board in the Optiview™ Control Center. Each set of contacts are single pole, normally open, rated at 5 amperes resistive at 240VAC. Chiller status contacts are provided for unit:

• Remote Mode Ready to Start – See Figure 24 on page 40.

• Cycling Shutdown – See Figure 25 on page 40.

• Safety Shutdown – See Figure 26 on page 40.

• Run (System Operating) – See Figure 27 on page 40.

• Anticipatory/Alarm – See Figure 28 on page 41.

Four sets of inputs are available to the EMS, allow-ing for remote control of unit operation. Input device contact rating shall be 5 milliamperes at 115VAC. Field wiring terminal board (TB4) in the OptiView™ Control Center permits connection for the following operation:

• Remote Stop Contacts – See Figure 29 on page 41.

• Remote Start Contacts – See Figure 29 on page 41.

• Remote/Local Cycling Devices – See Figure 31 on page 42.

• Multi-unit Sequence – See Figure 32 on page 42.

Chiller cycling by the Energy Management System should be minimized. It is possible to limit the compres-sor motor amp draw indirectly or directly by the follow-ing methods:

1. Application of Sequence Control Kit, so only one unit is running, when a single unit can carry the cooling load – see Figure 37 on page 45.

2. When multiple unit installations are controlled by an EMS, remote start and stop con tacts are avail-able to start and stop each chiller per Figure 29 on page 41. Contact rating shall be 5 milliamperes at 115VAC.

3. The OptiView™ Control Center has a program-mable time clock function as a standard feature with holiday capability. This offers one preset automatic Start-Stop per day on a seven day cal-endar basis with the ability to program a single additional holiday start and stop time up to a week in advance. Chilled water pump control contacts (see Note 13) are also provided, allowing for ef-ficient automatic operation of the chilled water pump to reduce energy. Two chilled water pump operating modes are available via the panel Setup Screen . With the Chilled Liquid Pump Operation set to STANDARD, the chilled water pump oper-ates for 30 seconds prior to chiller start, during chiller operation, coastdown, and LOW TEM-PERATURE cycling shutdowns. With the mode set to ENHANCED, the chilled water pump op-erates as above plus it operates during MULTI-UNIT and SYSTEM cycling shutdowns.

4. 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 supplying a 1 to 11 second pulse-width modu-lated signal, refer to Figure 46 on page 50. Through use of the remote temperature control analog input on the microboard, the leaving chilled liquid temperature may be reset via a 0 to 20 or 4 to 20mA D.C. current signal, a 0 to 10 or 2 to 10VDC signal. Refer to Figure 44 on page 49 or Figure 45 on page 50.

5. Current limiting of demand during pulldown may be accomplished by using the standard PULL-DOWN DEMAND LIMIT function provided in the OptiView™ Control Center. The PULLDOWN DEMAND LIMIT key can be programmed to limit compressor motor current from 30 to 100 percent of full load amperes, for 1 to 255 minutes following each compressor start. For more de-tails refer to YMC2 Operations and Maintenance (Form 160.78-O1).

JOHNSON CONTROLS54

FORM 160.78-PW2 ISSUE DATE: 10/28/2016SECTION 3 - ENERGY MANAGEMENT SYSTEMS

6. Controlling the maximum allowable compressor motor amps from 30 to 100% through remote cur-rent limit setpoint. Refer to Figure 43 on page 48 when the remote current limit is accomplished by supplying a 1 to 11 second pulse-width modulated signal in the “remote” operating mode. A jumper configurable analog input is available for remote current limit setpoint via a 0 to 20 or 4 to 20mA D.C. current signal, a 0 to 10 or 2 to 10VDC signal. Refer to Figure 41 on page 47 and Figure 42 on page 47.

7. The Johnson Controls METASYS™ System and other BAS Systems may be interfaced with the chiller OptiView™ Control Center to provide

unified chiller plant system control. The META-SYS™ System directly communicates with the OptiView™ Control Center via the E-Link Gate-way or SC-EQ which may be installed in the Con-trol Center. All temperatures, pressures, safety alarms and cycling information known to the Op-tiView™ Control Center are then available to the METASYS™ System for integrated chiller plant control, data logging, and local and remote opera-tor displays. The E-Link Gateway or SC-EQ also allows the BAS to start, stop, and reset the chill-er’s leaving chilled water setpoint and the current limit setpoint. Standard communication protocols supported are BACnet, Modbus RTU and N2.

JOHNSON CONTROLS 55


NOTES

P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USACopyright © by Johnson Controls 2016 www.johnsoncontrols.com ALL RIGHTS RESERVEDForm 160.78-PW2 (1016)Issue Date: October 28, 2016Supersedes: 160.78-PW2 (813)

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