Johnson Controls YORK YK MaxE User manual

OPERATION MANUAL
OPTIVIEWTM CONTROL CENTER
MAXETM CENTRIFUGAL LIQUID CHILLERS
Supersedes: 160.54-O1 Form 160.54-O1
MODEL YK (THROUGH STYLE G)
R-134a COOLING ONLY
WITH OPTIVIEWTM CONTROL CENTER
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER
& VARIABLE SPEED DRIVE
29420A

JOHNSON CONTROLS
2
FORM 160.54-O1
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, materials under pressure, rotating components, and
both high and low voltage. Each of these items has the
potential, if misused or handled improperly, to cause
bodily injury or death. It is the obligation and 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 possesses independent training that will enable
them to perform their assigned tasks properly and safely.
It is essential that, prior to performing any task on this
equipment, this individual shall have read and under-
stood this document and any referenced materials. This
individual shall also be familiar with and comply with
all applicable governmental standards and regulations
pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or se-
rious injury.
DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or serious
injury.
CAUTION identies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instruction will be given, together with
a brief explanation.
External wiring, unless specied as an optional connection in the manufacturer’s product
line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the micro panel. NO external wiring
is allowed to be run through the micro panel. All wiring must be in accordance with YORK’s
published specications and must be performed ONLY by qualied YORK/Johnson Controls
personnel. Johnson Controls will not be responsible for damages/problems resulting from
improper connections to the controls or application of improper control signals. Failure to
follow this will void the manufacturer’s warranty and cause serious damage to property or
injury to persons.
NOTE is used to highlight additional
information which may be helpful to
you.

FORM 160.54-O1
3
JOHNSON CONTROLS
NOMENCLATURE
REFERENCE INSTRUCTIONS
DESCRIPTION FORM NO.
SOLID STATE STARTER (MOD “A”) – OPERATION & MAINTENANCE 160.46-OM3.1
SOLID STATE STARTER (MOD “B”) – OPERATION & MAINTENANCE 160.00-O2
MEDIUM VOLTAGE SOLID STATE STARTER – OPERATION 160.00-O5
MEDIUM VOLTAGE SOLID STATE STARTER – SERVICE 160.00-M5
VARIABLE SPEED DRIVE – OPERATION 160.00-O1
VARIABLE SPEED DRIVE – SERVICE INSTRUCTIONS 160.00-M4
MEDIUM VOLTAGE VARIABLE SPEED DRIVE – OPERATION 160.00-O6
MEDIUM VOLTAGE VARIABLE SPEED DRIVE – SERVICE 160.00-M6
VARIABLE SPEED OIL PUMP DRIVE 160.52-M2
INSTALLATION 160.54-N1
OPTIVIEW CONTROL CENTER - SERVICE INSTRUCTIONS 160-54-M1
WIRING DIAGRAM – UNIT STYLE E WITH ELECTRO-MECHANICAL STARTER 160.54-PW1
WIRING DIAGRAM – UNIT STYLE E WITH MOD “A” SOLID STATE STARTER 160.54-PW2
WIRING DIAGRAM – UNIT STYLE E WITH MOD “B” SOLID STATE STARTER 160.54-PW2.1
WIRING DIAGRAM – UNIT STYLE E WITH VARIABLE SPEED DRIVE 160.54-PW3
RENEWAL PARTS – UNIT 160.49-RP4
RENEWAL PARTS – OPTIVIEW CONTROL CENTER 160.54-RP1
WIRING DIAGRAM – UNIT STYLE E (P Compressors) with ELECTRO-MECHANICAL STARTER 160.54-PW8
WIRING DIAGRAM – UNIT STYLE E (P Compressors) with MOD “B” SOLID STATE STARTER 160.54-PW9
WIRING DIAGRAM – UNIT STYLE E (P Compressors) with VARIABLE SPEED DRIVE 160.54-PW10
WIRING DIAGRAM – UNIT STYLE F (all compressors) WITH ELECTRO-MECHANICAL STARTER 160.73-PW1
WIRING DIAGRAM – UNIT STYLE F (all compressors) WITH MOD “B” SOLID STATE STARTER 160.73-PW2
WIRING DIAGRAM – UNIT STYLE F (all compressors) WITH VARIABLE SPEED DRIVE 160.73-PW3
WIRING DIAGRAM – UNIT (STYLE F) (all compressors) WITH MEDIUM VOLTAGE VSD OR MEDIUM VOLTAGE SSS 160.73-PW5
WIRING DIAGRAM – FIELD CONTROL MODIFICATIONS (STYLE G) 160.75-PW4
WIRING DIAGRAM – UNIT STYLE G WITH ELECTRO-MECHANICAL STARTER 160.75-PW5
WIRING DIAGRAM – UNIT STYLE G WITH SSS, LV VSD WITH MODBUS & MV VSD 160.75-PW6
YK CB CB G4 – CM E
MOTOR CODE
POWER SUPPLY
– for 60 Hz
5 for 50 Hz
COMPRESSOR CODE
CONDENSER CODE
EVAPORATOR CODE
MODEL
STYLE (Design Level)

JOHNSON CONTROLS
4
FORM 160.54-O1
SECTION 1 Description of System and Fundamentals of Operation ................... 7
SECTION 2OptiView Control Center ................................................................. 11
SECTION 3Printers..........................................................................................167
TABLE OF CONTENTS
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for continu-
ous 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 ofce.
It is the responsibility of operating/service personnel
as to the applicability of these documents to the equip-
ment in question. If there is any question in the mind
of operating/service personnel as to the applicability of
these documents, then, prior to working on the equip-
ment, they should verify with the owner whether the
equipment has been modied and if current literature
is available.

FORM 160.54-O1
5
JOHNSON CONTROLS
LIST OF FIGURES
FIG. 1 – MODEL YK MAXE™ CHILLER ............................. 6
DETAIL A – COMPRESSOR PREROTATION
VANES.................................................................. 7
FIG. 2 – REFRIGERANT FLOW-THROUGH CHILLER..... 8
FIG. 3 – OPTIVIEW CONTROL CENTER.........................11
FIG. 4 – HOME SCREEN................................................. 16
FIG. 5 – SYSTEM SCREEN............................................. 19
FIG. 6 – EVAPORATOR SCREEN ................................... 21
FIG. 7 – CONDENSER SCREEN..................................... 24
FIG. 7A – HEAT RECOVERY SCREEN ............................. 26
FIG. 7B – HEAD PRESSURE SCREEN............................. 30
FIG. 8 – REFRIGERANT LEVEL CONTROL SCREEN
(Flash Memory Card version C.MLM.01.06.XXX
and earlier) ......................................................... 32
FIG. 8A – REFRIGERANT LEVEL CONTROL SCREEN
(Software Version C.MLM.01.07.xxx to
C.MLM.01.10D.xxx or C.OPT.01.10D and earlier) .. 34
FIG 8B – REFRIGERANT LEVEL CONTROL SETPOINTS
SCREEN (Software Version C.MLM.01.07.xxx to
C.MLM.01.10D.xxx or C.OPT.01.10D
(and earlier)) ....................................................... 36
FIG 8C – REFRIGERANT LEVEL CONTROL SCREEN
(Software version C.MLM.01.14.xxx (and later) or
C.OPT.01.14.306 (and later)) ............................. 38
FIG. 9 – COMPRESSOR SCREEN
(All “P” Compressors and Style F chillers with
G, Q or H5-8 compressors) ................................ 40
FIG. 9A – COMPRESSOR SCREEN (Style E and earlier
chillers with G, H or J compressors and Style F
and later chillers with J or H3 compressors)....... 42
FIG. 10 – PROXIMITY PROBE CALIBRATION SCREEN
(Style E and earlier chillers with G, H and J
compressors and Style F and later chillers with
J or H3 compressors) ......................................... 44
FIG. 11 – HOT GAS BYPASS SCREEN ............................ 46
FIG. 12 – SURGE PROTECTION SCREEN ...................... 48
FIG. 12A – VARIABLE GEOMETRY DIFFUSER SCREEN.. 52
FIG. 12B – VARIABLE GEOMETRY DIFFUSER SETPOINTS
SCREEN............................................................. 54
FIG. 13 – PRE-ROTATION VANES CALIBRATION
SCREEN............................................................. 56
FIG. 14 – VSD TUNING SCREEN ..................................... 58
FIG. 15 – OIL SUMP SCREEN........................................... 60
FIG. 16 – ELECTRO-MECHANICAL STARTER SCREEN.... 64
FIG. 17 – MOD “A” SOLID STATE STARTER SCREEN .... 66
FIG. 18 – MOD “B” SOLID STATE STARTER SCREEN .... 68
FIG. 18A – MEDIUM VOLTAGE SOLID STATE STARTER
SCREEN............................................................. 70
FIG. 19 – VARIABLE SPEED DRIVE SCREEN ................. 72
FIG. 19A – MEDIUM VOLTAGE VARIABLE SPEED DRIVE
SCREEN (Software Version C.OPT.01.16.xxx
and Later) ........................................................... 74
FIG. 20 – VARIABLE SPEED DRIVE DETAILS SCREEN
(Style D VSD and VSD with part number
371-03789-xxx (503 HP 60 Hz; 419 HP 50 Hz).. 78
FIG. 21 – VARIABLE SPEED DRIVE DETAILS SCREEN
(VSD with Part Number 371-02767-XXX
(60 Hz) or 371-03700-XXX (50 HZ))................... 80
FIG. 22 – ADAPTIVE CAPACITY CONTROL SCREEN
(software version C.OPT.01.18.307 and earlier) 82
FIG. 22A – ADAPTIVE CAPACITY CONTROL SCREEN
(YORK protocol conguration)
(software version C.OPT.01.19.307 and later) ... 84
FIG. 22B – ADAPTIVE CAPACITY CONTROL SCREEN
(Modbus protocol conguration)
(software version C.OPT.01.19.307 and later) ... 86
FIG. 22C – SURGE MAP SCREEN - TABLE VIEW
(software version C.OPT.01.19.307 and later) ... 90
FIG. 22D – SURGE MAP SCREEN - LIST VIEW
(software version C.OPT.01.19.307 and Later) .. 92
FIG. 23 – HARMONIC FILTER DETAILS SCREEN
(Style D VSD and VSD with part number
371-03789-xxx (503 HP 60 Hz; 419 HP 50 Hz).. 94
FIG. 24 – HARMONIC FILTER DETAILS SCREEN
(VSD with Part Number 371-02767-XXX (60 Hz)
or 371-03700-XXX (50 Hz)) ............................... 96
FIG. 25 – MOTOR LUBRICATION SCREEN (Software version
C.MLM.01.14.xxx (and later) or C.OPT.01.14.306
(and later)) .......................................................... 98
FIG. 26 – SETPOINTS SCREEN ..................................... 100
FIG. 27 – SETUP SCREEN.............................................. 104
FIG. 27A – QUICK START SCREEN.................................. 108
FIG. 28 – SCHEDULE SCREEN .......................................112
FIG. 29 – USER SCREEN.................................................114
FIG. 30 – COMMS SCREEN.............................................116
FIG. 31 – PRINTER SCREEN...........................................118
FIG. 32 – SALES ORDER SCREEN ................................ 120
FIG. 33 – OPERATIONS SCREEN .................................. 122
FIG. 34 – HISTORY SCREEN.......................................... 124
FIG. 35 – HISTORY DETAILS SCREEN .......................... 126
FIG. 36 – SECURITY LOG SCREEN............................... 127
FIG. 37 – SECURITY LOG DETAILS SCREEN ............... 128
FIG. 38 – CUSTOM VIEW SCREEN................................ 129
FIG. 39 – CUSTOM VIEW SETUP SCREEN
................... 130
FIG. 40 – TREND SCREEN ............................................. 132
FIG. 41 – TREND SETUP SCREEN ................................ 134
FIG. 42 – ADVANCED TREND SETUP SCREEN............ 136
FIG. 43 – COMMON SLOTS SCREEN ............................ 138
FIG. 44 – PRINTERS ....................................................... 164
FIG. 45 – SAMPLE PRINTOUT (STATUS)....................... 170
FIG. 46 – SAMPLE PRINTOUT (SETPOINTS)................ 172
FIG. 47 – SAMPLE PRINTOUT (SCHEDULE)................. 174
FIG. 48 – SAMPLE PRINTOUT (SALES ORDER)........... 175
FIG. 49 – SAMPLE PRINTOUT (HISTORY) .................... 176
FIG. 50 – SAMPLE PRINTOUT (SECURITY LOG).......... 178
FIG. 51 – SAMPLE PRINTOUT (TREND)........................ 178
FIG. 52 – SAMPLE PRINTOUT – (CUSTOM SCREEN).. 179
FIG. 53 – SAMPLE PRINTOUT – (ADAPTIVE CAPACITY
CONTROL NEW MAP POINT)......................... 179
FIG. 54 – SAMPLE PRINTOUT (ADAPTIVE CAPACITY
CONTROL EXISTING MAP POINTS) .............. 179

JOHNSON CONTROLS
6
FORM 160.54-O1
Description of System and Fundamentals of Operation
THIS PAGE INTENTIONALLY LEFT BLANK

FORM 160.54-O1
7
JOHNSON CONTROLS
When the compressor motor is driven by a YORK Solid
State Starter, one of three different Starters could be ap-
plied. Later production chillers are equipped with either
the Style B Liquid Cooled Solid State Starter (LCSSS)
or the Medium Voltage Solid State Starter (MVSSS).
Earlier vintage chillers are equipped with the Mod “A”
Solid State Starter. This starter contains a Trigger Board
that interfaces to a Logic Board that is installed inside of
the Control Center.
When the compressor motor is driven by a YORK Vari-
able Speed Drive, there could be a Variable Speed Drive
(VSD) or a Medium Voltage Variable Speed Drive (MV
VSD) applied.
In operation, a liquid (water or brine to be chilled) ows
through the cooler, where boiling refrigerant absorbs heat
from the liquid. The chilled liquid is then piped to fan
coil units or other air conditioning terminal units, where
it ows through nned coils, absorbing heat from the
air. The warmed liquid is then returned to the chiller to
complete the chilled liquid circuit.
SECTION 1
DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION
00611vip
CONDENSER
CONTROL
CENTER
COMPRESSOR
MOTOR
EVAPORATOR
FIG. 1 – MODEL YK MaxE™ CHILLER
SYSTEM OPERATION DESCRIPTION (SEE FIG. 2)
The YORK Model YK MaxE™ Chiller is commonly ap-
plied to large air conditioning systems, but may be used on
other applications. The chiller consists of an open motor
mounted to a compressor (with integral speed increasing
gears), condenser, evaporator and variable ow control.
The chiller is controlled by a modern state of the art Mi-
crocomputer Control Center that monitors its operation.
The Control Center is programmed by the operator to suit
job specications. Automatic timed start-ups and shut-
downs are also programmable to suit nighttime, week-
ends, and holidays. The operating status, temperatures,
pressures, and other information pertinent to operation
of the chiller are automatically displayed and read on
a graphic display. Other displays can be observed by
pressing the keys as labeled on the Control Center. The
chiller with the OptiView Control Center is applied with
an electro-mechanical starter, YORK Solid State Starter
(optional), or Variable Speed Drive (optional).

JOHNSON CONTROLS
8
FORM 160.54-O1
The refrigerant vapor, which is produced by the boiling
action in the cooler, ows to the compressor where the
rotating impeller increases its pressure and temperature
and discharges it into the condenser. Water owing
through the condenser tubes absorbs heat from the refrig-
erant vapor, causing it to condense. The condenser water
is supplied to the chiller from an external source, usu-
ally a cooling tower. The condensed refrigerant drains
from the condenser into the liquid return line, where the
variable orice meters the ow of liquid refrigerant to the
cooler to complete the refrigerant circuit.
The major components of a chiller are selected to handle
the refrigerant, which would be evaporated at full load
design conditions. However, most systems will be called
upon to deliver full load capacity for only a relatively
small part of the time the unit is in operation.
7619A(D)
DETAIL A – COMPRESSOR PREROTATION VANES
CAPACITY CONTROL
The major components of a chiller are selected for full
load capacities, therefore capacity must be controlled
to maintain a constant chilled liquid temperature leav-
ing the cooler. Prerotation vanes (PRV), located at the
entrance to the compressor impeller, compensate for
variation in load (See Detail A).
The position of these vanes is automatically controlled
through a lever arm attached to an electric motor located
outside the compressor housing. The automatic adjust-
ment of the vane position in effect provides the perfor-
mance of many different compressors to match various
load conditions from full load with vanes wide open to
minimum load with vanes completely closed.
Description of System and Fundamentals of Operation

FORM 160.54-O1
9
JOHNSON CONTROLS
1
FIG. 2 – REFRIGERANT FLOW-THRU CHILLER
PREROTATION VANES
(See Detail A)
SUCTION
EVAPORATOR
ELIMINATOR
OIL COOLER
LD00924
FLOW CONTROL
ORIFICE
SUB-COOLER
CONDENSER
DISCHARGE
BAFFLE
DISCHARGE
COMPRESSOR

JOHNSON CONTROLS
10
FORM 160.54-O1
OptiView Control Center
THIS PAGE INTENTIONALLY LEFT BLANK

FORM 160.54-O1
11
JOHNSON CONTROLS
SECTION 2
OPTIVIEW CONTROL CENTER
INTRODUCTION
The YORK OptiView Control Center is a micropro-
cessor based control system for R-22 or R134a cen-
trifugal chillers. It controls the leaving chilled liquid
temperature via pre-rotation vane controls and has the
ability to limit motor current via control of the pre-ro-
tation vanes. It is compatible with YORK Solid State
Starter (optional), Variable Speed Drive (optional), and
Electro-Mechanical starter applications.
The panel comes congured 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 specic operations are provided on
many of the screens.
The graphic display also allows information to be repre-
sented in both English (temperatures in °F and pressures
in PSIG) and Metric (temperatures in °C and pressures in
kPa) mode. The advantages are most apparent, however,
in the ability to display many languages.
The Control Center continually monitors the system op-
eration and records the cause of any shutdowns (Safety,
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 warning
messages. In addition, it may be congured to notify the
user of certain conditions via alarms. A complete listing
of shutdown, status, and warning messages is attached
in the Display Messages section of this book.
There are certain screens, displayed values, program-
mable Setpoints and manual control shown in this book
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 YORK Service
Manual 160.54-M1. These parameters affect chiller
operation and should NEVER be modied by anyone
other than a qualied Service Technician. They are
shown in this book for reference only.
Advanced Diagnostics and troubleshooting information
for Service Technicians are included in YORK Service
Manual 160.54-M1. Also included in the Service man-
ual are detailed descriptions of chiller features, such
as the Refrigerant Level Control, Variable Speed Drive
Oil Pump, Hot Gas Bypass, High Speed Thrust Bear-
ing Proximity Probe, Remote Setpoints, Smart Freeze
Protection, and Standby Lubrication.
The control center expands the capabilities of remote
control and communications. By providing a common
networking protocol through the ISN, YORK Chillers
not only work well individually, but also as a team. This
new protocol allows increased remote control of the
chiller, as well as 24-hour performance monitoring via a
remote site. In addition, compatibility is maintained with
the present network of ISN 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:
1. Remote Start
2. Remote Stop
3. Remote Leaving Chilled Liquid Temperature
Setpoint adjustment (0-10VDC, 2-10VDC, 0-20mA
or 4-20mA) or Pulse Width Modulation
4. Remote Current Limit Setpoint adjustment
(0-10VDC, 2-10VDC, 0-20mA or 4-20mA) or Pulse
Width Modulation
5. Remote “Ready to Start” Contacts
6. Safety Shutdown Contacts
7. Cycling Shutdown Contacts
2

JOHNSON CONTROLS
12
FORM 160.54-O1
The chiller operating program resides in the Optiview
control center Microboard. The control center could be
equipped with either of the following Microboards:
•031-01730-000 – shipped in new production chill-
ers until January 2004. The program resides in a
replaceable Flash Memory Card. The software ver-
sion (C.MLM.01.xx.yzz) is printed on label adhered
to card. Program can be upgraded by replacing the
card.
•031-02430-000 – shipped in new production chill-
ers between January 2004 and June 2006. The pro-
gram resides in non-removable onboard memory.
The software version is C.OPT.01.xx.yzz, and is
viewable on the DIAGNOSTICS Screen in SER-
VICE access level. The program can be upgraded
by downloading a new program from a Program
Card. Program Cards are shirt-pocket-size portable
memory storage devices available from YORK.
•031-02430-001 – Shipped in new production chill-
ers after June 2006. This is an upgraded version
of the 031-02430-000 microboard. The upgrade
is necessary to operate with the Medium Voltage
Solid State Starter, Medium Voltage Variable Speed
Drive and those Variable Speed Drives and Style B
Solid State Starters that serially communicate with
the microboard using Modbus Protocol. Variable
Speed Drive Modbus applications require Software
version C.OPT.01.16.307 (or later). Style B Solid
State Starter Modbus applications require Software
version C.OPT.01.18.307 (or later).
The upgrade includes a larger BRAM (U38) and
an additional RS-485 port on COM2 serial port
for Modbus communications. When used in larger
BRAM conguration, requires software version
C.OPT.01.15.xxx (or later). This board is backward
compatible with YK chillers presently using the
031-01730-000 or 031-02430-000 microboard.
Earlier vintage chillers could be equipped with a later
Microboard due to service replacement.
Software versions (C.MLM.01.xx.yzz or C.OPT.01.
xx.yzz) are alpha-numeric codes that represent the appli-
cation, language package and revision levels per below.
Each time the controls portion or language section is
revised, the respective revision level increments.
•C – Commercial chiller
•MLM – Used on Microboard 031-01730-000
•OPT - Used on Microboard 031-02430-000
•01 – YK chiller
•xx - controls revision level (00, 01, etc)
•y – language package (0=English only, 1=NEMA,
2=CE, 3=NEMA/CE )
•zz – language package revision level (00, 01, etc)
Throughout this book, reference is made to functions
and features that are only available in certain Flash
Memory Card revision levels (C.MLM.01.xx.xxx). To
cross reference C.MLM software to C.OPT software,
refer to the controls revision level. Software version
C.OPT.01.08A.300 is of the same controls revision
level as C.MLM.01.08.105A/.206A. From this starting
point, both receive the same updates at each revision.
Software upgrades should only be performed by a Ser-
vice Technician.
OptiView Control Center

FORM 160.54-O1
13
JOHNSON CONTROLS
When in this position, the chiller will not run under
any condition. For safety reasons, this position is
required for many maintenance tasks to be completed
(such as proximity probe and vane calibration). In
addition, the switch must be placed in this state
following a Safety shutdown before the chiller is
allowed to restart. This guarantees that manual inter-
vention has taken place and the shutdown has been
acknowledged.
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 occurs
momentarily as the operator attempts to locally start
the unit. Once this position has been sensed, if all
fault conditions are cleared, the unit will enter the
system prelube (start sequence).
When in this position, the chiller is able to operate.
The switch spring-returns to this state after it has
been toggled to the START position. When in this
state, the chiller is allowed to function normally, and
will also allow the chiller to automatically restart fol-
lowing a Cycling shutdown. The switch must be in
this state to receive a valid remote start signal when
operating under a remote control source.
OPTIVIEW CONTROL CENTER
The OptiView™ Control Center display is highlighted
by a full screen graphics display. This display is nested
within a standard keypad, and is surrounded by “soft”
keys which are redened based on the currently dis-
played 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 key-
pad is used for data entry with a standard numeric keypad
provided for entry of system 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 during
time entry.
In order to accept changes made to the chiller
setpoints, the Check key is provided as a univer-
sal ‘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
rocker switch. When toggled 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
toggled to the left-most position, it is considered in the
START state. Each state is described in detail below:
•STOP / RESET (O)
• START (◄ )
•RUN ( ▀ )
29348A
FIG. 3
2

JOHNSON CONTROLS
14
FORM 160.54-O1
OVERVIEW
The new graphical display on each control panel allows
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 describe
the graphical elements on the screen and give a short
summary of the functions available. Each element on
the screen will then be categorized into three distinct
groups: Display Only, Programmable, and Navigation.
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 sub-screen.
DISPLAY ONLY
Values in this group are read-only parameters of infor-
mation about the chiller operation. This type of infor-
mation 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 operating
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 rendered
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 rst be logged in with the appropriate access level.
Each of the programmable values requires a specic Ac-
cess Level which will be indicated beside the specied
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 rst 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 navi-
gate to most screens and observe the values displayed
there. However, the user will not be allowed to change
any values. To change any values, the user must return to
the Home Screen (shown by default when power is ap-
plied 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 Password would be entered as 9 6 7 5,
using the numeric keypad. OPERATOR access reverts
to the VIEW level after 10 continuous minutes without
a keypress. If a custom User ID and Password have been
dened (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 notied of the failure
and prompted again. At this point the user may retry the
password entry, or cancel the login attempt.
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 higherAccess Level without
returning to the Home Screen. After login, the user may
then modify setpoints on that screen.
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 Leaving Chilled
Liquid Temperature), or they could Enable or Disable a
feature or function.
Regardless of which setpoint is being programmed, the
following procedure applies:
1. Press the desired setpoint key. A dialog box appears
displaying the present value, the upper and lower
limits of the programmable range, and the default
value.
INTERFACE CONVENTIONS
OptiView Control Center

FORM 160.54-O1
15
JOHNSON CONTROLS
Home Screen (page 16)
System Screen (page 19)
Evaporator (page 21)
Condenser (page 24)
Level Control (page 24-31)
Heat Recovery (page 26)
Head Pressure Control (page 30)
Compressor (page 42)
Proximity Probe Calibration (Style E and earlier
chillers with G, H, or J compressors and Style F and
later chillers with J or H3 Compressors)(page 36)
Hot Gas Bypass (page 46)
Surge Protection Screen (page 48)
Variable Geometry Diffuser (page 52)
Vane Calibration (page 56)
VSD Tuning (page 58)
Oil Sump (page 60)
Motor (page 60)
EM Starter Version (page 64)
Mod “A” Solid State Starter (page 66)
Mod “B” Solid State Starter (page 68)
Medium Voltage Solid State Starter (page 70)
VSD (page 72)
VSD Details (page 76 78)
ACC Details (page 80, 82, 84)
Surge Map (page 86, 88)
Harmonic Filter Details (page 92, 94)
Motor Lubrication (page 96)
Setpoints (page 98)
Setup (page 100)
Schedule (page 106)
User (page 108)
Comms (page 110)
Printer (page 112)
Sales Order (page 114)
Operations (page 116)
Diagnostics (Refer to YORK
Service Manual 160.54-M1)
Quick Start (page 104)
History (page 120)
History Details (page 120)
Security Log Screen (page 121)
Security Log Details Screen (page 122)
Custom View (page 123)
Custom Setup (page 124)
Trend (page 126)
Trend Setup (page 128)
Advanced Trend Setup (page 130)
Common Slots (page 132)
2. If the dialog box begins with the word “ENTER”,
use the numeric keys to enter the desired value.
Leading 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 pres-
ent entry. The ◄ key is a backspace key and causes
the entry point to move back one space.
If the dialog box begins with “SELECT”, use the
◄ and ► keys to select the desired value.
If the previously dened setpoint is desired, press
the ‘X’ (Cancel) key to dismiss the dialog box.
3. Press the ‘’ (Enter) key.
If the value is within range, it is accepted and the
dialog box disappears. The chiller will begin to op-
erate 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 orice or oil pump
speed. Other keys in this category are used to initiate/
terminate processes such as calibrations or reports.
Free Cursor
On screens containing many setpoints, a specic “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 “highlight”
the desired setpoint eld. At this point, the ‘’ key is
pressed to bring up a dialog prompting the user to enter
a new setpoint value. The ‘X’ key cancels cursor mode.
(See the Schedule Screen for an example.)
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ned.
These keys allow the user to either move “forward” to
a sub-screen 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.
2

JOHNSON CONTROLS
16
FORM 160.54-O1
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 minimum or maxi-
mum value, respectively.
*Saturation temperatures are calculated values. They will display XXX if the pressure used for the calculation is out of range.
**Not applicable to chillers equipped with Flash Memory Card version C.MLM.01.03 and later.
***7.5 PSIG Flash Memory Card Version C.MLM.01.04 and later.
ANALOG INPUT ENGLISH RANGE METRIC RANGE
LOW HIGH UNITS LOW HIGH UNITS
Leaving Chilled Liquid Temperature 0.0 82.0 °F -17.7 27.7 °C
Return Chilled Liquid Temperature 0.0 94.1 °F -17.7 34.5 °C
Leaving Condenser Liquid Temperature 8.0 133.5 °F -13.3 56.3 °C
Return Condenser Liquid Temperature 8.0 133.5 °F -13.3 56.3 °C
Evaporator Refrigerant Temperature (Optional) 0.0 126.1 °F -17.7 52.3 °C
Discharge Temperature 31.8 226.3 °F -0.1 107.9 °C
Oil Temperature 31.8 226.3 °F -0.1 107.9 °C
Condenser Pressure (R22 and R134a) ***0.0 315.0 PSIG 0.0 2172.4 KPAG
Condenser Temperature (R22)* -122.1 130.9 °F -85.6 54.9 °C
Condenser Temperature (R134a)* -98.7 160.1 °F -72.6 71.7 °C
Evaporator Pressure (R22 – water) 49.4 128.8 PSIG 340.6 888.2 KPAG
Evaporator Pressure (R22 – brine) 25.0 100.0 PSIG 172.4 689.6 KPAG
Evaporator Pressure (R134a) 5.5 77.4 PSIG 37.9 533.7 KPAG
Evaporator Temperature (R22 – water)* 13.0 67.0 °F -10.5 19.4 °C
Evaporator Temperature (R22 – brine)* -18.0 51.4 °F -27.7 10.7 °C
Evaporator Temperature (R134a)* -44.9 64.7 °F -42.7 18.1 °C
Oil Sump Pressure (R22) 23.2 271.8 PSIG 160.0 1874.4 KPAG
Oil Sump Pressure (R134a) 0.0 315.0 PSIG 0.0 2172.4 KPAG
Oil Pump Pressure (R22 and R134a) 0.0 315.0 PSIG 0.0 2172.4 KPAG
High Speed Thrust Bearing Proximity Position
(Style E and earlier chillers with G, H, or J 8.0 99.0 Mils -7.1 148.8 °C
compressors and Style F and later chillers with
J or H3 compressors)
High Speed Thrust Bearing 19.1 300.0 °F -7.1 148.8 °C
Drain Temperature**
Refrigerant Level 0.0 100.0 % 0.0 100.0 %
Drop Leg Refrigerant Temperature 0.0 121.7 °F -17.7 49.8 °C
LANGUAGES
The Screens can be displayed in various languages.
Language selection is done on the USER Screen. The
desired language is selected from those available. Not all
languages are available. English is the default language.
If a language other than English is being displayed, an
English-only speaking person should navigate to the
USER Screen using the preceding Navigation chart
and select English per the USER Screen instructions
in this book.
OptiView Control Center

FORM 160.54-O1
17
JOHNSON CONTROLS
2
THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS
18
FORM 160.54-O1
OVERVIEW
When the chiller system is powered on, the above default
display appears. The primary values which must be mon-
itored and controlled are shown on this screen. The Home
Screen display depicts a visual representation of the chiller
itself. Animation indicates chilled liquid ow.
DISPLAY ONLY
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.
Motor Run (LED)
Is ON when the digital output controlling the Motor
Starter contact is on.
Input Power (kW)
Available only if the chiller system is utilizing a Variable
Speed drive (VSD), Medium Voltage Variable Speed
Drive (MV VSD), Mod “B” Solid state Starter or Me-
dium Voltage Solid State Starter motor controller. This
displays the total input power used by the system.
% Full Load Amps
This displays the percentage of full load amps utilized
by the system.
Operating Hours
Displays the cumulative operating hours of the chiller.
Heating Condenser Liquid Temperature - Leaving
(Software version C.OPT.01.21.307 and later)
Displays the temperature of the liquid as it leaves the
heating condenser tube bundle. Only appears when the
Heat Recovery is enabled.
Heating Condenser Liquid Temperature – Return
(Software version C.OPT.01.21.307 and later)
Displays the temperature of the liquid as it enters the
heating condenser tube bundle. Only appears when the
Heat Recovery is enabled.
LD14331
FIG. 4
OptiView Control Center

FORM 160.54-O1
19
JOHNSON CONTROLS
PROGRAMMABLE
Login
Access Level Required: VIEW
The OptiView Panel 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.
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 provided.
Only qualied 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 access
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 reporting capability.
(See HISTORY below.) This option will not be present
if the chiller is presently congured to log any incoming
Adaptive Capacity Control map points. (See the Adap-
tive Capacity Control Details screen.)
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.
Warning Reset
Access Level Required: OPERATOR
Use of this key acknowledges a warning condition and
resets the message display associated with it.
Soft Shutdown
(Flash Memory Card version C.MLM.01.06.xxx and
later)
Access Level Required: Operator
This key, available only when the compressor is running,
is used to initiate a Soft Shutdown. A Soft Shutdown
fully closes the Pre-rotation Vanes prior to shutting
down the compressor. This reduces bearing wear by
eliminating compressor backspin at shutdown. Press-
ing this key causes the Vanes to be driven to the fully
closed position. While the vanes are closing, “VANES
CLOSING BEFORE SHUTDOWN” is displayed on
the System Status line. When the Vane Motor Switch
(VMS) closes, indicating the vanes have fully closed (or
3.5 minutes have elapsed, whichever occurs rst), the
Run signal is removed from the compressor motor starter
and a “SYSTEM COASTDOWN” is performed. While
the vanes are closing, if a Local Stop is initiated with the
Compressor Switch or any fault other than “LEAVING
CHILLED LIQUID TEMP – LOW TEMPERATURE”,
“REMOTE STOP”, “MULTI-UNIT CYCLING – CON-
TACTS OPEN”, SYSTEM CYCLING – CONTACTS
OPEN” or “CONTROL PANEL – SCHEDULE” oc-
cur, it will immediately enter “System Coastdown”.
To restart the chiller after an operator initiated Soft
shutdown, the Compressor Switch must be placed in the
Stop/Reset position (O) and then the Start position (3).

JOHNSON CONTROLS
20
FORM 160.54-O1
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 liquid level functions.
Compressor
A detailed view of all the compressor parameters. This in-
cludes pre-rotation vane control, Hot Gas Bypass Control,
Proximity Probe calibration, and PRV calibration.
Oil Sump
A detailed view of all the oil pump and oil sump pa-
rameters. This includes the Variable Speed Oil Pump
when installed. It also controls the Seal Lubrication
functionality.
Motor
A detailed view of the motor controller parameters, spe-
cic to the controller type presently utilized on the chiller
system. This allows programming of the Current Limit
and the Pulldown Demand Limit values. For a VSD
system, the Adaptive Capacity Control and Harmonic
Filter information is controlled under this screen.
Setpoints
This screen provides a single location to program the most
common system setpoints. It is also the gateway to many
of the general system setup parameters such as Date/Time,
Display Units, Scheduling, Printer Setup, etc.
History
This screen provides access to a snapshot of system data
at each of the last 10 shutdown conditions.
OptiView Control Center