Johnson Controls York 366-70488 Instruction Manual

LD12524a
FOR OT/HT MODEL CHILLERS STYLE “B” AND ”C”
CONTROL CENTERS 366-70488, 366-70487 AND 366-73582
LOW PRESSURE CUTOUT CONTROL
P/N 025-45742-000
INSTALLATION AND MAINTENANCE Supersedes: 160.43-NM4 (1206) Form 160.43-NM4 (1112)
035-21593-000
Issue Date:
November 12, 2012

JOHNSON CONTROLS
2
FORM 160.43-NM4
ISSUE DATE: 11/12/2012
This equipment is a relatively complicated apparatus.
During installation, operation maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
materials under pressure, rotating components, and
both high and low voltage. Each of these items has the
potential, if misused or handled improperly, to cause
bodily injury or death. It is the obligation and respon-
sibility of operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure
to comply with any of these requirements could result
in serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that these
individuals possess independent training that will en-
able them to perform their assigned tasks properly and
safely. It is essential that, prior to performing any task
on this equipment, this individual shall have read and
understood this document and any referenced mate-
rials. This individual shall also be familiar with and
comply with all applicable governmental standards and
regulations pertaining to the task in question.
SAFETY 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 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 control 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 accor-
dance 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 warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3
FORM 160.43-NM4
ISSUE DATE: 11/12/2012
MANUAL DESCRIPTION FORM NUMBER
Operation and Maintenance Manuals – OT/HT Style “B” and “C” TURBOPAK Chillers
Electronic Control Center – Part No. 366-70488 160.43-NM1.1
Electronic Control Center – Part No. 366-73582 160.43-NM1.3
Wiring Diagrams – OT/HT Style “B” and “C” TURBOPAK Chillers
Electronic Control Center – Part No. 366-70488 160.43-W1.1
Electronic Control Center – Part No. 366-70488 160.43-W1.2
Electronic Control Center – Part No. 366-70487 160.43-W2.1
Electronic Control Center – Part No. 366-70487 160.43-W2.2
Electronic Control Center – Part No. 366-73582 160.43-W1.3
Renewal Parts – OT/HT Style “B” and “C” TURBOPAK Chillers
Electronic and Pneumatic Control Centers 160.43-RP1.5
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically to
the manual owner. Updated manuals, if applicable, can
be obtained by contacting the nearest Johnson Controls
Service office.
Operating/service personnel maintain responsibility for
the applicability of these documents to the equipment.
If there is any question regarding the applicability of
these documents, the technician should verify whether
the equipment has been modified and if current litera-
ture is available from the owner of the equipment prior
to performing any work on the chiller.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
formation and any other changes in spelling, grammar
or formatting are not included.
ASSOCIATED LITERATURE

JOHNSON CONTROLS
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ISSUE DATE: 11/12/2012
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JOHNSON CONTROLS 5
FORM 160.43-NM4
ISSUE DATE: 11/12/2012
TABLE OF CONTENTS
SECTION 1 - GENERAL...........................................................................................................................................7
Application........................................................................................................................................................7
Operation..........................................................................................................................................................7
SECTION 2 - INSTALLATION ..................................................................................................................................9
Tools Needed ...................................................................................................................................................9
Secure Chiller From Operation.........................................................................................................................9
Remove Pre-Existing LPCO Control ................................................................................................................9
Mounting 025 45742 LPCO Control .................................................................................................................9
Pressure Connection Piping...........................................................................................................................10
Wiring ............................................................................................................................................................. 11
SECTION 3 - TESTING AND ADJUSTMENTS ......................................................................................................13
Tools Needed .................................................................................................................................................13
Secure Chiller From Operation.......................................................................................................................13
Connect LPCO Pressure Connection To A Calibrated Vacuum Source .........................................................13
Cutout Setpoint Testing And Calibration.........................................................................................................14
Switch Deadband Testing And Calibration......................................................................................................14
Reconnect LPCO Evaporator Pressure Connection And Wiring.................................................................... 15
Return Chiller To Service................................................................................................................................15
SECTION 4 - PRODUCT SPECIFICATIONS.......................................................................................................... 17

JOHNSON CONTROLS
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JOHNSON CONTROLS 7
FORM 160.43-NM4
ISSUE DATE: 11/12/2012
1
SECTION 1 - GENERAL
APPLICATION
Low Pressure Cutout (LPCO) controls 025 45742 set
point and deadband settings are factory set for R-11 or
R-123 duty application as:
P/N DESCRIPTION
025 45742 002 CONTROL VACUUM SWITCH R-11 LPCO
Use with R-11 refrigerant
025 45742 003 CONTROL VACUUM SWITCH R-123 LPCO
Use with R-123 refrigerant
LPCO controls 025 45742 are available as retrofit
kits, inclusive of installation hardware, for converting
from the obsolete 225 15443 002 LPCO control used
in Model OT/HT Style “B” and “C” chillers having
Electronic Control Centers 366 70488, 366 70487, 366
73582, as:
P/N DESCRIPTION
325 45742 602 KIT, CONTROL LPCO R-11
VACUUM SWITCH Use with
R-11 refrigerant
325 45742 603 KIT, CONTROL LPCO R-123
VACUUM SWITCH Use with
R-123 refrigerant
OPERATION
The Low Pressure cutout (LPCO) controls 025 45742
are actuated by evaporator pressure. The LPCO control
operates to stop the chiller compressor operation on the
decrease of the evaporator pressure equivalent to a re-
frigerant temperature of 28° F and permits re-starting,
(via the start button) when the evaporator pressure in-
creases equivalent to a refrigerant temperature greater
than 40° F.
LPCO controls 025 45742 set point and deadband set-
tings are factory set for R-11 or R-123 duty applica-
tion. The cutout set point and deadband settings are
field adjustable as described in section III Testing and
Adjustments.
LPCO controls 025 45742 are vacuum switches which
are negative gauge pressure controls that operate at a
predetermined constant pressure below atmospheric.
This means that the absolute pressure of the cutout set-
ting will vary with local atmospheric pressure changes.
LPCO controls 025 45742 require cutout setpoint and
Before installing, the installation and
maintenance instructions provided with
unit must be read and understood.
Before installing, verify the control part
no. matches the refrigerant duty applica-
tion.
For all applications, a factory set safety
control should be tested before use.
To avoid damaging control, proof pressure
and maximum temperature limits stated in
literature and on nameplates must never
be exceeded, even by surges in the system.
Operation of the unit up to maximum
pressure or temperature is acceptable on
a limited basis (e.g., start-up, testing) but
continuous operation must be restricted to
the designated adjustable range. Excessive
cycling at maximum pressure or tempera-
ture limits could reduce sensor life.
Vacuum switches are negative gauge
pressure controls that operate at a pre-
determined constant pressure below at-
mospheric. This means that the absolute
pressure of the cutout setting will vary
with local atmospheric pressure changes.
Vacuum switches require settings verica-
tion at installation and require recalibra-
tion if installed elevation is 300 feet or
more above or below sea level.
Preventative maintenance and periodic
testing is necessary for critical applica-
tions where damage could endanger
property or personnel.
These products do not have any eld re-
placeable parts.

JOHNSON CONTROLS
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FORM 160.43-NM4
ISSUE DATE: 11/12/2012
SECTION 1 - GENERAL
deadband settings verification at installation and re-
quire recalibration if installed elevation is 300 feet or
more above or below sea level. Refer to Section 3 Test-
ing and Adjustments.
LPCO controls 025 45742 are activated when the
bellows sensor responds to a pressure change. This
response actuates a single-pole double-throw snap-
action switch, converting the pressure signal into an
electrical signal.
At atmospheric pressure the switch contacts are made
between the Common and Normally Open terminals
and open between the Common and Normally Closed
terminals. As the pressure falls below the control CUT-
OUT setpoint the switch transfers to be made between
the Common and Normally Closed terminals and open
between the Common and Normally Open terminals.
As the pressure rises above the control CUTIN (CU-
TIN equals cutout plus deadband settings) the switch
transfers to be made between the Common and Nor-
mally Open terminals and open between the Common
and Normally Closed terminals. Refer to Figure 1.
FIGURE 1 - SWITCH CONTACTS
CUTOUT ON PRESSURE FALL
CUTIN ON PRESURE RISE
LD12521

JOHNSON CONTROLS 9
FORM 160.43-NM4
ISSUE DATE: 11/12/2012
2
SECTION 2 - INSTALLATION
TOOLS NEEDED
• Power Drill and a #25 or 9/64 in. drill bit
• Adjustable wrenches; 6 in. and 8 in.
• Open-end wrenches; 3/4 in., 5/8 in. and 9/16 in.
• Screwdrivers; Flat Blade and Phillips
SECURE CHILLER FROM OPERATION
1. Shut off power source feed to the chiller Electron-
ic Control Center (ECC).
2. Lock-Out, Tag-Out the chiller.
3. Pull ECC fuses 1FU, 2FU and 3FU to ensure the
LPCO control wiring is deenergized.
4. Close the evaporator service valve having gauge
piping going to the “Cooler” (evaporator) panel
gauge and LPCO control.
REMOVE PRE-EXISTING LPCO CONTROL
1. Disconnect LPCO control pressure (¼ in. are
nut) connection from the pressure tap behind the
“Cooler” (evaporator) panel gauge.
2. Using a voltage meter, reverify the ECC supply
power and to the LPCO control wiring is deener-
gized.
3. Disconnect the three wires (47, 48 and 49) from
the LPCO control and secure out of the way.
4. Remove the two mounting screws and the LPCO
control from the ECC.
MOUNTING 025 45742 LPCO CONTROL
Install unit where shock, vibration and
ambient temperature uctuations will not
damage unit or affect operation. Orient
unit so that moisture does not enter the
enclosure via the electrical connection.
When appropriate, this entry point should
be sealed to prevent moisture entry.
Do not mount unit in ambient temperature
exceeding Specied limits.
LPCO controls 025 45742 are mounted and operated in
a vertical position with the switch up and pressure con-
nection down. The controls are surface mounted using
two mounting ears, with holes for #10 screws, on either
side of the control bracket plate.
1. Remove enclosure cover rst by removing one
captive screw located on the front of the cover.
2. When replacing a former 225 15443 002 LPCO
control:
a. Select a vertical surface mounting location
on the back wall of the ECC for the replace-
ment LPCO control 025 45742 in the same
general area of the former control. Ensure
that the mounting location allows connection
to the preexisting wiring to the control switch
terminals and for the new capillary tubing to
the “Cooler” (evaporator) panel gauge pres-
sure tap.
b. To reach the LPCO control 025 45742 switch
terminals, the preexisting wires (47, 48 and
49) may need to be relocated through the
cabinet middle conduit fitting containing the
high pressure control wires.
c. Using the LPCO control 025 45742 bracket
plate as a guide, locate and mark the two
mounting holes locations on the ECC back
wall. Ensure that the mounting holes loca-
tions will not interfere with anything within
or outside of the ECC panel.
d. Using a power drill and a #25 or 9/64 in. drill
bit, drill out the two mounting holes.
e. Mount the replacement LPCO control 025
45742 to the back wall of the ECC using
two #10 self tapping screws (YORK p/n 021
14727 000) provided in kit.
3. When replacing a former 025 45742 LPCO con-
trol
a. Mount the replacement LPCO control 025
45742 to the back wall of the ECC where
the former control was located and using
two #10 self tapping screws (YORK p/n 021
14727 000) provided in kit.

JOHNSON CONTROLS
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FORM 160.43-NM4
ISSUE DATE: 11/12/2012
SECTION 2 - INSTALLATION
PRESSURE CONNECTION PIPING
Never use the enclosure for leverage to
hand tighten the pressure connection. Al-
ways use a wrench to tighten the pressure
connection to the piping. To avoid damage
to control, always hold the wrench on the
wrench ats or hex portion of the pres-
sure connection when tightening piping
connections.
1. Installing kit supplied 1/4 Ext. Flare X 1/4 Ext.
Pipe half union tting (YORK p/n 023 00927
000) in 025 45742 LPCO control pressure 1/4 in.
NPTI connection. Refer to Figure 2.
a. Ensure 1/4 in. pipe thread mating surfaces
are clean and free of debris or defect.
b. Use pipe thread sealant YORK p/n 013
03089 000 (Grade 554, Red, 10 ml, for re-
frigerant pipe up to 1/2” dia.) applied to 1/4
in. external pipe threads only. Do not apply
to the first 2 threads of fitting.
c. Apply tightening torque to the fitting only
while holding back on hex portion of the
LPCO control pressure connection. Secure
fitting to pressure connection tight enough to
ensure a leak free seal.
2. Installing kit supplied Capillary Tube (48 in.)
YORK p/n 026 45010 000
a. Ensure 1/4 in. flare mating surfaces are clean
and free of debris or defect.
b. Connect the 1/4 in. flare nut on 90 deg. end
of capillary tube to the 1/4 in. external flare
half union fitting at the LPCO control pres-
sure connection. Apply tightening torque to
the flare nut only while holding back on fit-
ting. Secure flare nut to fitting tight enough
to ensure a leak free seal.
c. Route the capillary tubing across to the right
hand wall of the ECC and up the right hand
wall to the area of the “Cooler” (evaporator)
panel gauge. Coil any excess capillary tubing
near the evaporator pressure tap connection.
FIGURE 2 - PRESSURE CONTROL LEFT SIDE VIEW
LD12524
3. Connect the 1/4 in. are nut on straight end of
capillarytubetothe1/4in.externalareevapora-
tor pressure tap connection, behind the “Cooler”
(evaporator) panel gauge. Apply tightening torque
tothearenutonlywhileholdingbackontting.
Securearenuttottingtightenoughtoensurea
leak free seal.
4. Use kit supplied wire tie-wraps (YORK p/n
025 09607 000) to secure LPCO capillary tubing
as needed.