Johnson Controls YORK OM Titan User manual

TITAN™ MULTISTAGE CHILLER WITH
RETROFIT OPTIVIEW CONTROL CENTER KIT
AND ELECTRO-MECHANICAL STARTER
OM TITAN™ MULTI-STAGE CHILLER
OPERATING INSTRUCTIONS NEW RELEASE Form 160.72-O1 (810)

FORM 160.72-O1 (810)
JOHNSON CONTROLS
2
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 this in-
dividual posseses independent training that will enable
them to perform their assigned tasks properly and safe-
ly. It is essential that, prior to performing any task on
this equipment, this individual shall have read and un-
derstood this document and any referenced materials.
This individual shall also be familiar with and comply
with all applicable governmental standards and regula-
tions pertaining to the task in question.
SAFETY SYMBOLS
The 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 not 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.
Identies 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 specied as an optional connection in the manufacturer’s product line, is
not to be connected inside the OptiView 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 specications and must be performed only by a qualied
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 warning
will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3
FORM 160.72-O1 (810)
MANUAL DESCRIPTION FORM NUMBER
Service Instructions for YORK Titan Multi-Stage Chiller with Retrot OptiView Controls 160.72-M1
Renewal Parts for YORK Titan Multi-Stage Chiller with Retrot OptiView Controls 160.72-RP1
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for contin-
uous product improvement, the information contained
in this document is subject to change without notice.
While Johnson Controls makes no commitment to up-
date or provide current information automatically to
the manual owner, that information, if applicable, can
be obtained by contacting the nearest Johnson Controls
Service office.
Operating/service personnel maintains the responsi-
bility of the applicability of these documents to the
competitive equipment the kit is installed on. If there
is any question regarding the applicability of these
documents, the technician should verify whether the
equipment has been modified and if current literature
is available with the owner of the equipment prior to
performing any work on the chiller.
ASSOCIATED LITERATURE
NOMENCLATURE
Nominal Tonnage
Open Drive
Multi-Stage Centrifugal
Compressor
O M 3000

FORM 160.72-O1 (810)
JOHNSON CONTROLS
4
THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS 5
FORM 160.72-O1 (810)
TABLE OF CONTENTS
SECTION 1 - INTRODUCTION.................................................................................................................................7
SECTION 2 - PRINCIPLES OF OPERATION...........................................................................................................9
SECTION 3 - OPTIVIEW CONTROL CENTER ...................................................................................................... 11
Home Screen .................................................................................................................................................19
System Screen ...............................................................................................................................................21
Evaporator Screen .........................................................................................................................................23
Condenser Screen .........................................................................................................................................27
Refrigerant Level Control Screen ...................................................................................................................29
Compressor Screen .......................................................................................................................................31
Compressor Lubrication Screen.....................................................................................................................33
Hot Gas Bypass Screen .................................................................................................................................35
Interstage Valve Screen .................................................................................................................................37
Motor Screen..................................................................................................................................................39
Gearbox Screen .............................................................................................................................................41
Anti-Recycle Setpoints Screen.......................................................................................................................43
Capacity Controls Screen...............................................................................................................................45
PID Tuning Screen .........................................................................................................................................47
Auto / Manual Control Screen ........................................................................................................................49
Setpoints Screen ............................................................................................................................................51
Temperature Setpoints Screen.......................................................................................................................53
Pressure Setpoints Screen.............................................................................................................................55
Time Setpoints Screen ...................................................................................................................................57
Miscellaneous Setpoints Screen ....................................................................................................................59
Setup Screen..................................................................................................................................................61
Configuration Screen......................................................................................................................................63
User Screen ...................................................................................................................................................65
Comms Screen...............................................................................................................................................67
Printer Screen ................................................................................................................................................69
Sales Order Screen........................................................................................................................................71
Operations Screen .........................................................................................................................................73
Options Screen...............................................................................................................................................75
Drive Options Screen .....................................................................................................................................79
Temperature Alarms and Trips Screen ...........................................................................................................81
Pressure Alarms and Trips Screen.................................................................................................................85
Time Alarms and Trips Screen .......................................................................................................................89
Miscellaneous Alarms and Trips Screen ........................................................................................................91
History Screen................................................................................................................................................93
History Details Screen....................................................................................................................................95
Trend Screen..................................................................................................................................................97
Trend Setup Screen .......................................................................................................................................99
Trend Common Slots Screen .......................................................................................................................101
Custom Screen.............................................................................................................................................103
Custom Setup Screen ..................................................................................................................................105
Security Log Screen .....................................................................................................................................107
Security Log Details Screen .........................................................................................................................109
SECTION 3 - OPTIVIEW CONTROL CENTER .................................................................................................... 111
SECTION 4 - GENERAL OPERATING SEQUENCE ........................................................................................... 119
SECTION 5 - SYSTEM COMMISSIONING...........................................................................................................131

FORM 160.72-O1 (810)
JOHNSON CONTROLS
6
FIGURE LIST
TABLE LIST
FIGURE 1 - OptiView Control Center......................................................................................................................13
FIGURE 2 - Home Screen.......................................................................................................................................19
FIGURE 3 - System Screen ....................................................................................................................................21
FIGURE 4 - Evaporator Screen...............................................................................................................................23
FIGURE 5 - Condenser Screen...............................................................................................................................27
FIGURE 6 - Refrigerant Level Control Screen ........................................................................................................29
FIGURE 7 - Compressor Screen.............................................................................................................................31
FIGURE 8 - Compressor Lubrication Screen ..........................................................................................................33
FIGURE 9 - Hot Gas Bypass Screen ......................................................................................................................35
FIGURE 10 - Interstage Valve Screen.....................................................................................................................37
FIGURE 11 - Motor Screen .....................................................................................................................................39
FIGURE 12 - Gearbox Screen.................................................................................................................................41
FIGURE 13 - Anti-Recycle Setpoints Screen ..........................................................................................................43
FIGURE 14 - Capacity Controls Screen..................................................................................................................45
FIGURE 15 - PID Tuning Screen.............................................................................................................................47
FIGURE 16 - Auto / Manual Control Screen............................................................................................................49
FIGURE 17 - Setpoints Screen ...............................................................................................................................51
FIGURE 18 - Temperature Setpoints Screen ..........................................................................................................53
FIGURE 19 - Pressure Setpoints Screen................................................................................................................55
FIGURE 20 - Time Setpoints Screen ......................................................................................................................57
FIGURE 21 - Miscellaneous Setpoints Screen........................................................................................................59
FIGURE 22 - SETUP Screen ..................................................................................................................................61
FIGURE 23 - Conguration Screen.........................................................................................................................63
FIGURE 24 - User Screen.......................................................................................................................................65
FIGURE 25 - Comms Screen..................................................................................................................................67
FIGURE 26 - Printer Screen....................................................................................................................................69
FIGURE 27 - Sales Order Screen ...........................................................................................................................71
FIGURE 28 - Operations Screen.............................................................................................................................73
FIGURE 29 - Options Screen..................................................................................................................................75
FIGURE 31 - Drive Options Screen.........................................................................................................................79
FIGURE 32 - Temperature Alarms and Trips Screen ..............................................................................................81
FIGURE 33 - Temperature Alarms and Trips Screen ..............................................................................................83
FIGURE 34 - Pressure Alarms and Trips Screen ....................................................................................................85
FIGURE 36 - Time Alarms and Trips Screen...........................................................................................................89
FIGURE 37 - Miscellaneous Alarms and Trips Screen............................................................................................91
FIGURE 38 - History Screen ...................................................................................................................................93
FIGURE 39 - History Details Screen .......................................................................................................................95
FIGURE 40 - Trend Screen .....................................................................................................................................97
FIGURE 41 - Trend Setup Screen...........................................................................................................................99
FIGURE 42 - Trend Common Slots Screen ..........................................................................................................101
FIGURE 43 - Custom Screen................................................................................................................................103
FIGURE 44 - Custom Setup Screen......................................................................................................................105
FIGURE 45 - Security Log Screen ........................................................................................................................107
FIGURE 46 - Security Log Details Screen ............................................................................................................109
TABLE 1 - Analog Input Ranges .............................................................................................................................17
TABLE 2 - Master Slot Numbers List For Use With Trend Feature....................................................................... 111
TABLE 3 - Status Line Messages and Colors....................................................................................................... 112
TABLE 4 - Titan OptiView Analog Inputs...............................................................................................................127
TABLE 5 - Titan OptiView Analog Outputs............................................................................................................128
TABLE 6 - Titan OptiView Digital Inputs and Outputs ........................................................................................... 128
TABLE 7 - SI Metric Conversion ...........................................................................................................................137

JOHNSON CONTROLS 7
FORM 160.72-O1 (810)
The following instructions outline the procedures to be
followed for the operation of the YORK OM Titan™
retrofitted with OptiView Controls.
After the installation and during the Initial Start-Up, the
Johnson Controls Start-Up Engineer will instruct the
operators in the operation and necessary maintenance
to be performed to maintain the YORK OM Titan™
retrofitted with OptiView Controls. This instruction
should be thoroughly read by the operators to familiar-
ize themselves with the operation of the unit.
It is important that those responsible for the installation,
operation and maintenance of this system be provided
with a copy of this manual so that they may thoroughly
study its contents. This will help ensure successful op-
eration of the system.
Standard Johnson Controls operating instructions are
included in this manual. Where the specific instruction
is different than the standard instructions, the specific
instruction should be followed. On matters not covered
by the specific instruction, the standard instruction
may be used.
It is suggested that a factory-trained representative of
Johnson Controls supervise any major service or main-
tenance operation. This is especially recommended
should it be necessary to open the compressor or heat
exchangers for any reason.
To obtain a service representative contact:
Your local Johnson Controls Service office at
1-800/524-1330.
SECTION 1 - INTRODUCTION
1

FORM 160.72-O1 (810)
JOHNSON CONTROLS
8
SECTION 1 - INTRODUCTION
THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS 9
FORM 160.72-O1 (810)
SECTION 2 - PRINCIPLES OF OPERATION
The OM Titan Chiller operates under the following
principles:
The fluid (to be cooled) flows through the tube side
(inside the tubes) of the evaporator. Liquid refriger-
ant is located in the shell side of the evaporator, and
is maintained at its saturation temperature by the com-
pressor. The liquid refrigerant is at a lower temperature
than the circulated fluid. Sensible heat flows from the
fluid, through the evaporator tube walls to the refriger-
ant, thereby cooling the fluid. The heat transferred to
the refrigerant causes it to boil.
In order to sustain this process, the refrigerant is held at
the correct saturation temperature by drawing refriger-
ant vapor from the shell side of the evaporator. This is
achieved through the use of the ‘M’ series multistage
centrifugal compressor. The vapor drawn from the
evaporator is compressed by the compressor to a suf-
ficiently high pressure so that the superheated tempera-
ture of the discharge vapor is higher than that of the
condenser water. The high pressure refrigerant is con-
tacted to the condenser water (on the tube side of the
condenser) and is condensed to a high pressure liquid.
This liquid is flashed in one or two stages, cooling each
time and returning back to the evaporator to complete
the cycle. Flashing is the process by which the high
pressure liquid is exposed to a lower pressure causing
the refrigerant to boil, cooling the condensed refrig-
erant liquid. The vapor created in this process (flash
gas) is drawn back into the compressor through the
compressor side load (inter-stage) port or ports and the
colder refrigerant liquid is used to provide cooling.
The M Series multistage compressor operates on the
centrifugal principle. The compressor consists of two
or more impellers which draw gas into the center (suc-
tion) and accelerates the vapor to high velocity (kinetic
energy) at the discharge of the impeller. As the vapor
exits the impeller, the velocity of the gas reduces as it
passes through the diffuser (located around the circum-
ference of the impeller), and the kinetic energy is trans-
formed into potential (pressure) energy. This process
is repeated for each impeller (compression stage). The
compressor shaft is rotated by means of either, an elec-
tric motor (via a speed increasing gearbox), a direct
drive steam turbine, a gas turbine (via a speed reduc-
ing gearbox) or a reciprocating gas engine (via a speed
increasing gearbox).
OM SUBCOOLING
Description and Operation
The OM Titan uses a two or more staged compressor
with flash type intercooler. The liquid is flashed off at
an intermediate pressure, to lower the enthalpy of the
liquid refrigerant as it enters the evaporator, thus pro-
viding a greater refrigeration effect in the evaporator.
The OM Titan utilizes liquid subcooling in addition to
the interstage cooling cycle for better efficiency. By
passing liquid refrigerant over tubes in a subcooler
section, the refrigerant temperature is lowered from
the saturation temperature, to a subcooled temperature
closer to the entering condenser water temperature.
By lowering the refrigerant temperature ahead of the
high stage expansion device, the amount of flash gas in
the intercooler is lowered, thus reducing the gas flow
through the second or possibly third stage impeller and
therefore lowering overall horsepower.
The OM Titan chiller utilizes a subcooler bundle inte-
gral to the main condenser located in the bottom section
of the condenser shell. As liquid refrigerant condenses
in the main condenser, it drains to the bottom of the
main condenser section. At the bottom, the refrigerant
is channeled to the subcooler inlet area, located at the
return water box end of the condenser (opposite from
the water inlet nozzle). Refrigerant liquid enters the
subcooler section from the sides and bottom (there is a
plate blocking the top). Dual subcoolers are utilized in
condensers with tube lengths 20 feet or longer.
The level of refrigerant in the subcooler is adjusted at
full load to provide a liquid level an inch or two above
the subcooler at the inlet area. This level needs to be
sufficient at full load to prevent refrigerant gas from
entering the subcooler. The refrigerant liquid flows
axially down the shell length over the subcooler tubes,
and exits out the bottom at the condenser water inlet
end.
A pneumatic ball valve is mounted in the piping leav-
ing the subcooler. This valve responds to the subcooler
inlet level transmitter signal to maintain the refriger-
ant level above the subcooler tubes. A ball valve was
selected for its ability to control over a wide range of
chiller loads and “head” or differential pressure con-
ditions. The valve is selected to fail open and opens
on chiller shutdown, primarily to drain liquid from the
2

FORM 160.72-O1 (810)
JOHNSON CONTROLS
10
SECTION 2 - PRINCIPLES OF OPERATION
subcooler section. This is a precaution against tube
freezing, by ensuring that liquid refrigerant is not pres-
ent in the subcooler during chiller pump down opera-
tions or if a major leak occurs.
OM INTERCOOLING
Description
There may be one or two stages of liquid intercooling
furnished with the OM Titan chiller in the primary re-
frigeration circuit between the condenser and the evap-
orator. The intercooler performs several functions. The
primary function is to flash the high pressure condensed
refrigerant to an intermediate pressure corresponding
to the M series multistage compressor’s inter-stage
pressure. Flashing the high pressure liquid at the inter-
mediate pressure reduces the horsepower required to
compress the flash gas. This portion of the flash gas is
only compressed from an intermediate pressure (inter-
stage) to condensing pressure rather than from evapo-
rator (low pressure) to condensing pressure. Secondary
functions are the separation of the flash gas from the
liquid refrigerant and providing a liquid seal between
the high and low sides of the system.
The intercooler consists of a pressure vessel with in-
ternally mounted mesh eliminators, a float assembly,
and baffles. The eliminators, located in the top of the
vessel, separate droplets of liquid refrigerant from the
flash gas before it flows to the compressor inter-stage
port. A low pressure rectangular vane type float valve
assembly maintains a liquid seal between the high and
low side of the system. The pressure drop across the
float valve causes the refrigerant to flash to an interme-
diate pressure lowering the refrigerant’s temperature to
the corresponding temperature. A baffle is installed in
the intermediate chamber over the float ball to mini-
mize the effect of turbulence on the float ball and to aid
in maintaining steady float operation.
Sight glasses and a hand operating device are provided
to permit visual float valve inspection and manual float
valve operation. A thermometer well, located near the
float valve, is used for checking liquid temperatures.
A manway with sight glasses allows for access to the
float valve assembly and adjusting arm.
Operation
Liquid refrigerant leaving the level control valve flash-
es to the intercooler pressure (and temperature). Upon
entering the intercooler the liquid refrigerant sepa-
rates from the flash gas. The flash gas returns to the
compressor inter-stage port after passing through the
mist eliminators. The liquid refrigerant, at intermedi-
ate pressure, flows to the float valve. The float valve
will open, maintaining a liquid level in the intercooler,
and allowing refrigerant flow to the evaporator. As the
liquid refrigerant flows through the float valve it is ex-
posed to evaporator pressure and flashes to the corre-
sponding pressure and temperature.
If the OM Titan chiller is equipped with a second stage
intercooler then the liquid leaving first stage intercool-
er is supplied to the second stage intercooler before al-
lowing refrigerant to flow to the evaporator.
Maintenance and Service
Maintenance on intercooler consists primarily of keep-
ing the float valve free to assure steady valve opera-
tion. Service consists of replacing an occasional float
ball and arm assembly.
If the system capacity suddenly decreases as indicated
by an increase in secondary refrigerant temperature,
check float valve operation as follows:
If the low pressure float valve sticks in the open posi-
tion, the liquid seal between the compressor interme-
diate pressure and evaporator pressure will be broken
and gas at intermediate pressure, will flow directly into
the evaporator. This will cause a reduction in capacity
with possible increase in suction pressure and possible
refrigerant carryover back to the compressor and in-
creased current (amperage) readings.
If the float valve sticks, move the float up and down by
means of the hand operation device. If this does not cor-
rect the condition it will be necessary to remove system
refrigerant charge before removing the float through
the manway opening to check the working parts and
mechanisms. Inspect the float ball to be sure it is not
collapsed or leaking. A collapsed or leaking ball (filled
with refrigerant) will cause the valve to remain closed.

JOHNSON CONTROLS 11
FORM 160.72-O1 (810)
SECTION 3 - OPTIVIEW CONTROL CENTER
INTRODUCTION
The Optiview™ Control Center is a microprocessor
based control system for R-22 or R134a centrifugal
chillers. It controls the leaving chilled liquid tempera-
ture via pre-rotation vane controls and has the ability
to limit motor current via control of the pre-rotation
vanes. It is compatible with Electro-mechanical starter
applications.
The panel comes configured with a full screen LCD
Graphic Display mounted in the middle of a keypad
interface. The graphic display allows the presentation
of several operating parameters at once. In addition,
the operator may view a graphical representation of the
historical operation of the chiller as well as the present
operation. For the novice user, the locations of various
chiller parameters are clearly and intuitively marked.
Instructions for specific operations are provided on
many of the screens.
The graphic display also allows information to be rep-
resented in both English (temperatures in °F and pres-
sures in PSIG) and Metric (temperatures in °C and
pressures in kPa) mode.
The Control Center continually monitors the system op-
eration and records the cause of any shutdowns (Safe-
ty, Cycling or Normal). This information is recorded in
memory and is preserved even through a power failure
condition. The user may recall it for viewing at any
time. During operation, the user is continually advised
of the operating conditions by various status and warn-
ing messages. In addition, it may be configured to no-
tify the user of certain conditions via alarms.
There are certain screens, displayed values, program-
mable setpoints and manual control shown in this man-
ual that are for Service Technician use only. They are
only displayed when logged in at SERVICE access
level or higher. The setpoints and parameters displayed
on these screens are explained in detail in the Service
Instructions (Form 160.72-M1). These parameters
affect chiller operation and should NEVER be
modified by anyone other than a qualified Service
Technician. They are shown in this manual for ref-
erence only.
Advanced Diagnostics and troubleshooting informa-
tion for Service Technicians are included in the Service
Instructions (Form 160.72-M1). Also included in the
service manual are detailed descriptions of chiller fea-
tures, such as the Hot Gas Bypass Control, Interstage
Valve control, PID Tuning control, Remote Setpoints,
and Input/Output Sensor tuning.
The control center expands the capabilities of remote
control and communications. By providing a common
networking protocol through the Building Automation
System (BAS), YORK Chillers not only work well in-
dividually, but also as a team. This new protocol al-
lows increased remote control of the chiller, as well
as 24-hour performance monitoring via a remote site.
In addition, compatibility is maintained with the pres-
ent network of BAS communications. The chiller also
maintains the standard digital remote capabilities as
well. Both of these remote control capabilities allow
for the standard Energy Management System (EMS)
interface:
Remote Start•
Remote Stop•
Remote Leaving Chilled Liquid Temperature•
Setpoint adjustment (0-10VDC, 2-10VDC,
0-20mA or 4-20mA) or Pulse Width Modulation
Remote Current Limit Setpoint adjustment•
(0-l0VDC, 2-10VDC, 0-20mA or 4-20mA) or
Pulse Width Modulation
Remote “Ready to Start” Contacts•
Safety Shutdown Contacts•
Cycling Shutdown Contacts•
3

FORM 160.72-O1 (810)
JOHNSON CONTROLS
12
SECTION 3 - OPTIVIEW CONTROL CENTER
THIS PAGE INTENTIONALLY LEFT BLANK

SECTION 3 - OPTIVIEW CONTROL CENTER
JOHNSON CONTROLS 13
FORM 160.72-O1 (810)
The OptiView Control Center display is highlight-
ed by a full screen graphics display. This display is
nested within a standard keypad and is surrounded
by “soft” keys which are redefined based on the cur-
rently displayed screen. Eight buttons are available
on the right side of the panel and are primarily used
for navigation between the system screens. At the
base of the display are 5 additional buttons. The area
to the right of the keypad is used for data entry with
a standard numeric keypad provided for entry of sys-
tem setpoints and limits
The Decimal key provides accurate entry of
setpoint values.
A +/- key has also been provided to allow entry
of negative values and AM/PM selection dur-
ing time entry.
In order to accept changes made to the chiller
setpoints, the Check key is provided as a uni-
versal ‘Enter’ key or ‘Accept’ symbol.
In order to reject entry of a setpoint or dismiss
an entry form, the ‘X’ key is provided as a uni-
versal ‘Cancel’ symbol.
Cursor Arrow keys are pro-
vided to allow movement on
screens which contain a large
amount of entry data. In ad-
dition, these keys can be used
to scroll through history and
event logs.
The Start/Stop control is operated via a three-position
spring loaded selector type switch. When positioned
all the way to the right, it is considered in the STOP/
RESET position. When in the middle position, this is
considered the RUN state.
When moved to the left-most position, it is considered
in the START state. Each state is described in detail
below:
STOP / RESET (• O)
When in this position, the chiller will not run un-
der any condition. For safety reasons, this posi-
tion is required for many maintenance tasks to be
completed (such as proximity probe and vane cal-
ibration). In addition, the switch must be placed
in this state following a safety shutdown before
OPTIVIEW CONTROL CENTER
OPTIVIEW CONTROL CENTERFIGURE 1 -
3

FORM 160.72-O1 (810)
JOHNSON CONTROLS
14
SECTION 3 - OPTIVIEW CONTROL CENTER
the chiller is allowed to restart. This guarantees
that manual intervention has taken place and the
shutdown has been acknowledged
START (• ◄)
The switch can only remain in this position when
being acted upon by a manual force. Once the user
has released the switch, it automatically reverts to
the RUN position. Generally, this state only oc-
curs momentarily as the operator attempts to lo-
cally start the unit. Once this position has been
sensed, if all fault conditions are cleared, the unit
will enter the system prelube (start sequence).
RUN (• ▐ )
When in this position, the chiller is able to oper-
ate. The switch spring-returns to this state after it
has been moved to the START position. When in
this state, the chiller is allowed to function nor-
mally and will also allow the chiller to automati-
cally restart following a cycling shutdown. The
switch must be in this state to receive a valid re-
mote start signal when operating under a remote
control source.
INTERFACE CONVENTIONS OVERVIEW
The new graphical display on each control panel al-
lows a wide variety of information to be presented to
the user. Each screen description in this document will
begin with a section entitled Overview which will de-
scribe the graphical elements on the screen and give
a short summary of the functions available. Each ele-
ment on the screen will then be categorized into three
distinct groups: Display Only, Programmable and Nav-
igation. Below is a short description of what types of
information are included in these groups.
The Programmable values and Navigation commands
are also subject to access level restrictions as described
below. For each of these elements, an indication is
given to show the minimum access level required to
program the value or navigate to the subscreen.
DISPLAY ONLY
Values in this group are read-only parameters of in-
formation about the chiller operation. This type of in-
formation may be represented by a numerical value, a
text string or an LED image. For numerical values, if
the monitored parameter is above the normal operat-
ing range, the high limit value will be displayed along
with the ‘>’ symbol; if it is below the normal operating
range, the low limit value will be displayed along with
the ‘<’ symbol. In some cases, the value may be ren-
dered invalid by other conditions and the display will
use X’s to indicate this.
PROGRAMMABLE
Values in this group are available for change by the
user. In order to program any setpoints on the system,
the user must first be logged in with the appropriate ac-
cess level. Each of the programmable values requires
a specific Access Level which will be indicated beside
the specified value. All of the programmable controls
in the system fall into one of the categories described
below:
Access Level
In order to program any setpoints on the system, the
user must first login with an appropriate access level.
When power is applied to the chiller, the system begins
with an Access Level of VIEW. This will allow the
user to navigate to most screens and observe the val-
ues displayed there. However, the user will not be al-
lowed to change any values. To change any values, the
user must return to the Home Screen (shown by de-
fault when power is applied to the system) and use the
LOGIN button or utilize the CHANGE SETPOINTS
key described below. At this point, the user will be
prompted to enter a User ID and the corresponding
Password. By default, the User ID is zero (0). In order
to gain standard OPERATOR level access, the Pass-
word would be entered as 9 6 7 5, using the numeric
keypad. OPERATOR access reverts to the VIEW lev-
el after 10 continuous minutes without a keypress. If a
custom User ID and Password have been defined (see
User Screen), the user may enter that User ID and the
corresponding Password value.
If the correct password is received, the user is autho-
rized with the appropriate Access Level. If an incorrect
password is entered, the user is notified of the failure
and prompted again. At this point the user may retry
the password entry or cancel the login attempt. The let-
ters Y-O-R-K will display whether the correct or incor-
rect code is entered.
Change Setpoints
On screens containing setpoints programmable at the
OPERATOR access level, a key with this label will be
visible if the present access level is VIEW. This key
brings up the Access Level prompt described above. It
allows the user to login at a higher Access Level with-
out returning to the Home Screen. After login, the user
may then modify setpoints on that screen.

SECTION 3 - OPTIVIEW CONTROL CENTER
JOHNSON CONTROLS 15
FORM 160.72-O1 (810)
Setpoints
The control center uses the setpoint values to control
the chiller and other devices connected to the chiller
system. Setpoints can fall into several categories. They
could be numeric values (such as 45.0°F for the Leav-
ing Chilled Liquid Temperature) or they could Enable
or Disable a feature or function.
Regardless of which setpoint is being programmed, the
following procedure applies:
Press the desired setpoint key. A dialog box ap-1.
pears displaying the present value, the upper and
lower limits of the programmable range and the
default value.
If the dialog box begins with the word ENTER, use2.
the numeric keys to enter the desired value. Lead-
ing zeroes are not necessary. If a decimal point is
necessary,pressthe‘•’key(i.e.45.0).Pressingthe
▲key, sets the entry value to the default for that
setpoint. Pressing the ▼key, clears the present
entry. The ◄key is a backspace key and causes
the entry point to move back one space. If the dia-
log box begins with SELECT, use the ◄and ►
keys to select the desired value. If the previously
defined setpoint is desired, press the ‘X’ (Cancel)
key to dismiss the dialog box.
Press the ‘3. ü’ (Enter) key. If the value is within
range, it is accepted and the dialog box disappears.
The chiller will begin to operate based on the new
programmed value. If out of range, the value will
not be accepted and the user is prompted to try
again.
Manual Controls
Some keys are used to perform manual control func-
tions. These may involve manual control of items such
as the pre-rotation vanes, variable orifice or hot gas by-
pass valve. Other keys in this category are used to initi-
ate/terminate processes such as calibrations or reports.
Free Cursor
On screens containing many setpoints, a specific SOFT
key may not be assigned to each setpoint value. A soft
key will be assigned to enable the cursor arrow keys
below the numeric keypad which are used to HIGH-
LIGHT the desired setpoint field. At this point, the ‘ü’
key is pressed to bring up a dialog prompting the user
to enter a new setpoint value. The ‘X’ key cancels cur-
sor mode.
NAVIGATION
In order to maximize the amount of values which the
panel can display to the user and in order to place those
values in context, multiple screens have been designed
to describe the chiller operation. In order to move from
one screen to the next, navigation keys have been de-
fined. These keys allow the user to either move FOR-
WARD to a subscreen of the present screen or move
BACKWARD to the previous screen. Except for the
Home Screen display, the upper-right SOFT key will
always return the user to the Home Screen. Navigating
with SOFT keys is as simple as pressing the key next
to the label containing the name of the desired screen.
The system will immediately refresh the display with
the graphics for that screen. Following is a layout of all
the screens and how they are connected.
3

FORM 160.72-O1 (810)
JOHNSON CONTROLS
16
SECTION 3 - OPTIVIEW CONTROL CENTER
Home Screen (page 19)
— System Screen (page 21)
— Evaporator Screen (page 23)
— Condenser Screen (page 27)
— Refrigerant Level Control Screen (page 29)
— Compressor Screen (page 31)
— Compressor Lubrication Screen (page 33)
— Hot Gas Bypass Screen (page 35)
— Interstage Valve Screen (page 37)
— Motor Screen (page 39)
— Gearbox Screen (page 41)
— Anti-Recycle Setpoints Screen (page 43)
— Capacity Controls Screen (page 45)
— PID Tuning Screen (page 47)
— Auto/Manual Control Screen (page 49)
— Setpoints Screen (page 51)
— Temperature Setpoints Screen (page 53)
— Pressure Setpoints Screen (page 55)
— Time Setpoints Screen (page 57)
— Miscellaneous Setpoints Screen (page 59)
— Setup Screen (page 61)
— Configuration Screen (page 63)
— User Screen (page 65)
— Comms Screen (page 67)
— Printer Screen (page 69)
— Sales Order Screen (page 71)
— Operations Screen (page 73)
— Options Screen (page 75)
— Drive Options Screen (page 79)
— Alarms/Trips
— Temperature Alarms and Trips Screen
(page 81)
— Pressure Alarms and Trips Screen (page 85)
— Time Alarms and Trips Screen (page 89)
— Miscellaneous Alarms and Trips Screen
(page 91)
— History Screen (page 93)
— History Details Screen (page 95)
— Trend Screen (page 97)
— Trend Setup Screen (page 99)
— Trend Common Slots Screen
(page 101)
— Custom Screen (page 103)
— Custom Setup Screen (page 105)
— Security Log Screen (page 107)
— Security Log Details Screen (page 109)

SECTION 3 - OPTIVIEW CONTROL CENTER
JOHNSON CONTROLS 17
FORM 160.72-O1 (810)
ANALOG INPUT RANGES
The following table indicates the valid display range
for each of the analog input values. In the event that the
input sensor is reading a value outside of these ranges,
the < or > symbols will be displayed beside the mini-
mum or maximum value, respectively.
ANALOG INPUT RANGESTABLE 1 -
ANALOG LOW HIGH UNITS
Analog Input Chilled Liquid Supply Temperature 30 130 °F
Chilled Liquid Return Temperature 30 130 °F
Condenser Water Entering Temperature 30 130 °F
Condenser Water Leaving Temperature 30 130 °F
Evaporator Refrigerant Liquid Temperature 30 130 °F
Condenser Temperature (Compressor Discharge) 30 250 °F
Gear Oil Cooler Leaving Water Temperature 30 130 °F
Compressor Shaft End Oil Return Temperature 30 250 °F
Condenser Refrigerant Temperature 30 130 °F
Compressor Thrust Bearing Oil Return Temperature 30 250 °F
Compressor Oil Cooler Entering Water Temperature 30 130 °F
Compressor Oil Cooler Leaving Water Temperature 30 130 °F
Intercooler Refrigerant Liquid Temperature 30 130 °F
Compressor Main Oil Temperature 30 250 °F
Evaporator Refrigerant Pressure 0 200 PSIG
Compressor Sump Oil Temperature 30 250 °F
Condenser Pressure (Compressor Discharge) 0 300 PSIG
Intercooler Refrigerant Pressure 0 200 PSIG
Compressor Main Oil Pressure 0 300 PSIG
Compressor Sump Oil Pressure 0 200 PSIG
Compressor Thrust Bearing Oil Pressure 0 300 PSIG
Compressor Balance Piston Pressure 0 200 PSIG
Gear Supply Oil Pressure 0 100 PSIG
Compressor Oil Pressure After Filter 0 300 PSIG
Chilled Water Flow 0 12,000 GPM
Compressor Motor Current 0 200 AMPS
Compressor Oil Cooler Water D/P 0 168 "WG
Gear Oil Cooler Water D/P 0 168 "WG
Condenser Oil Cooler Water D/P 0 528 "WG
Gear Supply Oil Temperature 30 250 °F
Chilled Water Entering Pressure 0 300 PSIG
Supply Air Pressure 0 200 PSIG
Condenser Water Entering Pressure 0 200 PSIG
3

FORM 160.72-O1 (810)
JOHNSON CONTROLS
18
SECTION 3 - OPTIVIEW CONTROL CENTER
TABLE 1 - ANALOG INPUT RANGES (CON’T)
ANALOG LOW HIGH UNITS
Condenser Water Leaving Pressure 0 200 PSIG
Condenser Water Flow 0 12,000 GPM
Subcooler Liquid Level 0 100 %
Subcooler Liquid Temperature 30 130 °F
Gear Shaft Pump Oil Pressure 0 100 PSIG
Gear Hi Speed Shaft End Bearing Temperature 30 250 °F
Gear Hi Speed Blind End Bearing Temperature 30 250 °F
Gear Lo Speed Shaft End Bearing Temperature 30 250 °F
Gear Lo Speed Blind End Bearing Temperature 30 250 °F
Motor Shaft End Bearing Temperature 30 250 °F
Motor Blind End Bearing Temperature 30 250 °F
Compressor Oil Temperature After Oil Cooler 30 250 °F
Chilled Water Leaving Pressure 0 300 PSIG
Compressor Motor kW 0 5000 kW

JOHNSON CONTROLS 19
FORM 160.72-O1 (810)
HOME SCREEN
HOME SCREENFIGURE 2 -
OVERVIEW
When the chiller system is powered on, the above de-
fault display appears. The primary values which must
be monitored and controlled are shown on this screen.
The Home Screen display depicts a visual representa-
tion of the chiller itself. Animation indicates chilled
liquid flow.
DISPLAY ONLY
% Full Load Amps
This displays the percentage of full load amps utilized
by the compressor motor.
Operating Hours
Displays the cumulative operating hours of the chiller.
Motor Run (LED)
Is ON when the digital output controlling the Motor
Starter contact is on.
Chilled Liquid Temperature - Leaving
Displays the temperature of the liquid as it leaves the
evaporator.
Chilled Liquid Temperature - Return
Displays the temperature of the liquid as it enters the
evaporator.
Condenser Liquid Temperature - Leaving
Displays the temperature of the liquid as it leaves the
condenser.
Condenser Liquid Temperature - Return
Displays the temperature of the liquid as it enters the
condenser.
PROGRAMMABLE
Login
Access Level Required: VIEW
The Control Center restricts certain operations based
on password entry by the operator. Three different ac-
cess levels are provided as follows: VIEW: The panel
defaults to the lowest access level which is termed
VIEW. In this mode, the chiller operating values and
setpoints can be observed, but no changes can be made.
OPERATOR: The second access level is termed OP-
ERATOR and will allow the customer to change all
of the setpoints required to operate the chiller system.
3

FORM 160.72-O1 (810)
JOHNSON CONTROLS
20
HOME SCREEN
The OPERATOR access level reverts to the VIEW
level after 10 continuous minutes without a keypress.
SERVICE: In the event that advanced diagnostics are
necessary, a SERVICE access level has been provid-
ed. Only qualified service personnel utilize this access
level. This level provides advanced control over many
of the chiller functions and allows calibration of many
of the chiller controls. The access levels are listed
above in hierarchical order beginning with the lowest
level and proceeding to the highest level. Users logged
in under higher access levels may perform any actions
permitted by lower access levels.
The OPERATOR access level is accompanied by a
10-minute timeout. After ten (10) successive minutes
without a keypress, the panel will revert to the VIEW
access level. This prevents unauthorized changes to the
chiller if a user was logged in at a higher access level
and failed to logout. Proper procedure requires that
after making necessary setpoint adjustments the user
return to the Home Screen and logout.
Logout
Access Level Required: OPERATOR
This key is displayed when a user is logged in at any
level other than VIEW. Pressing it will return the ac-
cess level to VIEW.
Print
Access Level Required: VIEW
Use this key to generate a hard-copy report of the
present system status. This provides a snapshot of the
primary operating conditions at the time the key is
pressed. The History page provides enhanced report-
ing capability. (See HISTORY below.)
Message Clear
Access Level Required: SERVICE
When certain safety or cycling conditions have been
detected and the chiller has been shutdown, the main
status display of the chiller will continue to display a
message indicating the cause of the shutdown. Using
this key, the message can be cleared once the condition
has been removed.
NAVIGATION
System
Used to provide additional system information.
Evaporator
A detailed view of all evaporator parameters, including
the programmable Leaving Chilled Liquid Setpoints.
Condenser
A detailed view of all condenser parameters, including
control of the purge functions.
Compressor
A detailed view of all the compressor parameters. This
includes Hot Gas Bypass Control and the compressor
lubrication system.
Motor
A detailed view of the motor controller parameters,
specific to the controller type presently utilized on the
chiller system. This allows programming of the Cur-
rent Limit and the Pulldown Demand Limit values.
Capacity Controls
The primary control of the chiller is shown on this
screen that includes the temperature control, motor lim-
it control, pressure overrides, and anti-surge setpoints.
It also provides access to the majority of setpoints,
alarms, and trips for the system, as well as the PID tun-
ing and calibration of actuators.
Setup
This screen displays the current configuration of the
system and provides for changing options such as tem-
perature sensors, flow transmitters, and valves. It is
also the gateway to many of the general system setup
parameters such as Date/Time, Display Units, Printer
Setup, etc.
History
This screen provides access to a snapshot of system
data at each of the last 10 shutdown conditions, all
trending functions and custom screens.