JOHNSON CONTROLS
8
FORM 201.23-NM2
ISSUE DATE: 09/25/2020
CONDITIONED BASED MAINTENANCE
LIST OF FIGURES
FIGURE 1 - Chiller Control System ........................................................................................................................16
FIGURE 2 - Compressor ........................................................................................................................................16
FIGURE 3 - PWM Current Waveform.....................................................................................................................21
FIGURE 4 - PWM Voltage Waveform .....................................................................................................................21
FIGURE 5 - Pipework Arrangement........................................................................................................................36
FIGURE 6 - Grooved Nozzle ..................................................................................................................................36
FIGURE 7 - Flange Attachment ..............................................................................................................................36
FIGURE 8 - Two Compressor Wiring Diagram With Circuit Breaker ...................................................................... 66
FIGURE 9 - Two Compressor Wiring Diagram With Terminal Block.......................................................................66
FIGURE 10 - Three Compressor Wiring Diagram With Circuit Breaker – Single Point ..........................................67
FIGURE 11 - Three Compressor Wiring Diagram With Terminal Block – Single Point...........................................67
FIGURE 12 - Elementary Control Wiring Diagram 2 Compressor Models ............................................................. 82
FIGURE 13 - Elementary Power Wiring Diagram - YCIV0157-0267 2 Compressor Models..................................84
FIGURE 14 - Power Wiring Connection Diagram - YCIV0157-0267 2 Compressor Models..................................86
FIGURE 15 - Control Wiring Connection Diagram - YCIV0157-0267 2 Compressor Models ...............................88
FIGURE 16 - Power Elementary Wiring Diagram - YCIV0157-0267 2 Compressor Models..................................91
FIGURE 17 - Control Elementary Diagram - YCIV0257-0397 3 Compressor Models............................................96
FIGURE 18 - Power Elementary Diagram - YCIV0257-0397 3 Compressor Models ...........................................100
FIGURE 19 - Control Wiring Connection Diagram - YCIV0257-0397 3 Compressor Models ..............................102
FIGURE 20 - Power Wiring Connection Diagram - YCIV1050-1500 3 Compressor Models................................106
FIGURE 21 - Power Elementary Diagram - YCIV0257-0397 3 Compressor Models ...........................................108
FIGURE 22 - Refrigerant Flow Diagram...............................................................................................................161
FIGURE 23 - Process and Instrumentation Diagram............................................................................................162
FIGURE 24 - Component Locations.....................................................................................................................163
FIGURE 25 - Control and VSD Cabinet Components ..........................................................................................164
FIGURE 26 - Chiller Control Board, Relay Boards, Microgateway, and Optional Circuit Breaker........................165
FIGURE 27 - Chiller Control Board, Relay Boards, and Microgateway, 2 Compressor ......................................166
FIGURE 28 - Chiller Control Board, Relay Boards, and Microgateway, 3 Compressor ......................................167
FIGURE 29 - VSD Logic Board ............................................................................................................................168
FIGURE 30 - VSD Logic Board (Original - Obsolete), P/N 031-02477-000..........................................................169
FIGURE 31 - VSD Logic Board (New), P/N 031-02507-XXX ..............................................................................170
FIGURE 32 - Power Components, 2 Compressor................................................................................................171
FIGURE 33 - Power Components, 3 Compressor................................................................................................172
FIGURE 34 - Fan Contactors and 3T Transformer, 2 Compressor ...................................................................... 173
FIGURE 35 - Fan Contactors, 3 Compressor.......................................................................................................174
FIGURE 36 - VSD Components ...........................................................................................................................175
FIGURE 37 - VSD Components, 2 Compressor...................................................................................................176
FIGURE 38 - VSD Components, 3 Compressor...................................................................................................177
FIGURE 39 - VSD Components, 2 Compressor...................................................................................................178
FIGURE 40 - VSD Components, 3 Compressor...................................................................................................179
FIGURE 41 - Inverter Power Components, 2 Compressor...................................................................................180
FIGURE 42 - Inverter Power Components, 3 Compressor...................................................................................181
FIGURE 43 - Inverter Power Components ...........................................................................................................182
FIGURE 44 - Glycol Pump and Fill Tube Locations..............................................................................................184
FIGURE 45 - Glycol Piping and Fill Tube Location...............................................................................................185
FIGURE 46 - Compressor Components...............................................................................................................186
FIGURE 47 - New Board P/N 031-02507-000......................................................................................................192
FIGURE 48 - Obsolete Board P/N 031-02477-000...............................................................................................192
FIGURE 49 - Chiller Control (Cooling) Range......................................................................................................199
FIGURE 50 - Number of Compressors to Start ....................................................................................................200
FIGURE 51 - Minimum VSD Start Frequency ......................................................................................................200
FIGURE 52 - Minimum VSD Run Frequency .......................................................................................................201
FIGURE 53 - Flash Tank Drain and Feed Valve Controller ..................................................................................208
FIGURE 54 - LED Locations.................................................................................................................................210
FIGURE 55 - Power and Comms LED's ..............................................................................................................210
