York Optiview yk Operating instructions

OPTIVIEW CONTROL CENTER

MODEL YK (THROUGH STYLE G)

CENTRIFUGAL LIQUID CHILLERS

WITH OPTIVIEW CONTROL CENTER

SERVICE INSTRUCTIONS Supersedes: 160.54-M1 (319) Form 160.54-M1 (1019)

Issue Date:

October 25, 2019

This is a company condential document and is for Johnson Controls eyes only.

4/6/2020

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS

This equipment is a relatively complicated apparatus.

During rigging, installation, operation, maintenance,

or service, individuals may be exposed to certain com-

ponents or conditions including, but not limited to:

heavy objects, refrigerants, materials under pressure,

rotating components, and both high and low voltage.

Each of these items has the potential, if misused or

handled improperly, to cause bodily injury or death. It

is the obligation and responsibility of rigging, instal-

lation, and operating/service personnel to identify and

recognize these inherent hazards, protect themselves,

and proceed safely in completing their tasks. Failure

to comply with any of these requirements could result

in serious damage to the equipment and the property in

IMPORTANT!

READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

which it is situated, as well as severe personal injury or

death to themselves and people at the site.

This document is intended for use by owner-authorized

rigging, installation, and operating/service personnel. It

is expected that these individuals possess independent

training that will enable them to perform their assigned

tasks properly and safely. It is essential that, prior to

performing any task on this equipment, this individual

shall have read and understood the on-product labels,

this document and any referenced materials. This in-

dividual shall also be familiar with and comply with

all applicable industry and governmental standards and

regulations pertaining to the task in question.

SAFETY 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.

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL

MANUAL DESCRIPTION FORM NUMBER

Solid State Starter (Mod A) – Operation and Maintenance 160.46-OM3.1

Variable Speed Drive – Operation 160.00-O1

Variable Speed Drive – Service Instructions 160.00-M1

Solid State Starter (Mod B) – Operation and Maintenance 160.00-O2

Service - OptiSpeed Liquid Cooled Variable Speed Drive for Centrifugal Chillers 160.00-M4

Medium Voltage Solid State Starter – Service 160.00-M5

Medium Voltage Variable Speed Drive – Service 160.00-M6

Variable Speed Oil Pump Drive 160.52-M2

YK Style E MaxE Centrifugal Liquid Chillers Installation Instructions 160.54-N1

Operations Manual - OptiView Control Center, Model YK (through Style G), for EMS, SSS, and VSD 160.54-O1

Wiring Diagram – Unit (Style E) With Electromechanical 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

Wiring Diagram – Unit (Style E) (P Compressors) With Electromechanical 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) Variable Speed Drive 160.54-PW10

Wiring Diagram – Field Control Modications for YK Chiller (Style G) 160.75-PW4

Wiring Diagram – YK Chiller (Style G) OptiView Control Center with Remote Low or Medium Voltage EMS 160.75-PW5

Wiring Diagram – YK Chiller (Style G) OptiView Control Center with Unit Mounted Low or

Medium Voltage SSS, Unit Mounted Low Voltage with Modbus, or Remote Medium Voltage VSD 160.75-PW6

Renewal Parts - OptiView Control Center, Model YK (through Style G) 160.54-RP1

Service Information - OptiView Panel Software Enhancement - OptiSave VSD Software Feature SI0068

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for con-

tinuous product improvement, the information con-

tained in this document is subject to change without

notice. Johnson Controls makes no commitment to

update or provide current information automatically

to the manual or product owner. Updated manuals, if

applicable, can be obtained by contacting the nearest

Johnson Controls Service office or accessing the John-

son Controls QuickLIT website at http://cgproducts.

johnsoncontrols.com.

It is the responsibility of rigging, lifting, and operating/

service personnel to verify the applicability of these

documents to the equipment. If there is any question

ASSOCIATED LITERATURE

regarding the applicability of these documents, rig-

ging, lifting, and operating/service personnel should

verify whether the equipment has been modified and

if current literature is available from the owner of the

equipment prior to performing any work on the chiller.

CHANGE 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.

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS

TABLE 1 - CONTROL PANEL APPLICATIONS

PART NUMBER DESCRIPTION

371-02264-101 Electromechanical Starter – NEMA 1

371-02486-101 Electromechanical Starter – CE

371-02448-101 Electromechanical Starter – NEMA 4/12

371-02264-102 Solid State Starter – NEMA 1

371-02486-102 Solid State Starter – CE

371-02448-102 Solid State Starter – NEMA 4/12

371-02264-103 Variable Speed Drive – NEMA 1

371-02486-103 Variable Speed Drive – CE

371-02448-103 Variable Speed Drive – NEMA 4/12

371-02778-101 Electromechanical Starter – NEMA 1 (P Compressors until 8/02)

371-02780-101 Electromechanical Starter – CE (P Compressors until 8/02)

371-02779-101 Electromechanical Starter – NEMA 4/12 (P Compressors until 8/02)

371-02778-102 MOD B Solid State Starter – NEMA 1 (P Compressors until 8/02)

371-02780-102 MOD B Solid State Starter – CE (P Compressors until 8/02)

371-02779-102 MOD B Solid State Starter – NEMA 4/12 (P Compressors until 8/02)

371-02778-103 Variable Speed Drive – NEMA 1-4 (P Compressors until 8/02)

371-02780-103 Variable Speed Drive – CE (P Compressors until 8/02)

371-02779-103 Variable Speed Drive – NEMA 4/12 (P Compressors until 8/02)

371-04118-101 Electromechanical Starter – NEMA 1 (Style F Chillers)

371-04118-102 Style B Solid State Starter – NEMA 1 (Style F Chillers)

371-04118-103 Variable Speed Drive – NEMA 1 (Style F Chillers)

371-04118-110

-111

-112

Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications – no VGD – NEMA 1

Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications and VGD, no J7 compressor – NEMA 1

Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications and VGD, J7 compressor – NEMA 1

371-04119-101 Electromechanical Starter – NEMA 4/12 (Style F Chillers)

371-04119-102 Mod B Solid State Starter – NEMA 4/12 (Style F Chillers)

371-04119-103 Variable Speed Drive – NEMA 4/12 (Style F Chillers)

371-04119-110

-111

-112

Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications – no VGD – NEMA 4-12

Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications and VGD, no J7 compressor – NEMA 4-12

Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications and VGD, J7 compressor – NEMA 4-12

371-04120-101 Electromechanical Starter – CE (Style F Chillers)

371-04120-102 Mod B Solid State Starter – CE (Style F Chillers)

371-04120-103 Variable Speed Drive – CE (Style F Chillers)

371-04120-110

-111

-112

Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications – no VGD – CE

Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications and VGD, no J7 compressor – CE

Mod B Solid State Starter or Variable Speed Drive w/Modbus Communications and VGD, J7 compressor – NEMA 1

NOMENCLATURE

YK KC K4 H9 – CY G

MOTOR CODE

POWER SUPPLY

– for 60Hz

5 for 50Hz

COMPRESSOR CODE*

CONDENSER CODE*

EVAPORATOR CODE*

MODEL*

STYLE (Design Level)

* Refer to YK Engineering Guide (Form 160.75-EG1) for

Shell/Motor/Compressor combinations.

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL

TABLE OF CONTENTS

SECTION 1 - INTRODUCTION...............................................................................................................................15

SECTION 2 - SYSTEM ARCHITECTURE ..............................................................................................................17

SECTION 3 - MICROBOARD 031-01730-000........................................................................................................31

Boot-Up Step and Description........................................................................................................................33

Power Supply ................................................................................................................................................. 38

Service Replacement ..................................................................................................................................... 38

Program Jumpers...........................................................................................................................................42

Program Switches .......................................................................................................................................... 44

SECTION 4 - MICROBOARD 031-02430-000 AND 031-02430-001......................................................................49

Description .....................................................................................................................................................49

Configuration and Setup.................................................................................................................................58

Downloading a Program from a Program Card ..............................................................................................63

Program Jumpers...........................................................................................................................................64

Program Switches .......................................................................................................................................... 65

SECTION 5 - MICROBOARD 031-03630-001........................................................................................................73

Chiller Operating Program..............................................................................................................................74

Program Jumpers...........................................................................................................................................77

Program Switches .......................................................................................................................................... 78

Configuration and Setup.................................................................................................................................84

Downloading a Program from a Program Card ..............................................................................................88

SECTION 6 - I/O BOARD .......................................................................................................................................97

I/O Board ........................................................................................................................................................97

Digital Inputs...................................................................................................................................................97

Digital Outputs................................................................................................................................................97

Triacs..............................................................................................................................................................98

Relay Timing...................................................................................................................................................98

SECTION 7 - LIQUID CRYSTAL DISPLAY ..........................................................................................................107

Backlight Lamp Replacement.......................................................................................................................109

SECTION 8 - DISPLAY INTERFACE BOARD...................................................................................................... 115

SECTION 9 - DISPLAY BACKLIGHT INVERTER BOARD.................................................................................. 119

SECTION 10 - KEYPAD........................................................................................................................................123

SECTION 11 - POWER SUPPLY..........................................................................................................................127

SECTION 12 - CURRENT MODULE (CM-2)........................................................................................................129

SECTION 13 - SOLID STATE STARTERS...........................................................................................................133

Solid State Starters ......................................................................................................................................133

Medium Voltage Solid State Starter .............................................................................................................133

SECTION 14 - ADAPTIVE CAPACITY CONTROL BOARD ................................................................................143

YORK Protocol Configuration.......................................................................................................................143

Modbus Protocol Configuration ...................................................................................................................149

SECTION 15 - PROXIMITY PROBE.....................................................................................................................157

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS

TABLE OF CONTENTS (CONT'D)

SECTION 16 - HIGH SPEED THRUST BEARING LIMIT SWITCH .....................................................................163

SECTION 17 - REFRIGERANT LEVEL CONTROL.............................................................................................165

Automatic Operation.....................................................................................................................................165

Manual Operation.........................................................................................................................................167

Actuators ......................................................................................................................................................167

SECTION 18 - OIL PUMP VARIABLE SPEED DRIVE.........................................................................................171

Automatic Operation.....................................................................................................................................171

Manual Operation.........................................................................................................................................172

Oil Heater Operation .................................................................................................................................... 173

SECTION 19 - COMMUNICATIONS.....................................................................................................................175

SECTION 20 - PRESSURE TRANSDUCERS......................................................................................................177

SECTION 21 - TEMPERATURE THERMISTORS ................................................................................................181

SECTION 22 - REMOTE SETPOINTS..................................................................................................................203

Remote Operating Modes ...........................................................................................................................203

Current Limit.................................................................................................................................................203

Leaving Chilled Liquid Temperature .............................................................................................................205

Leaving Condenser Liquid Temperature (Heat Pump Mode) .......................................................................207

SECTION 23 - HOT GAS BYPASS ...................................................................................................................... 211

Setpoints ...................................................................................................................................................... 211

Operation......................................................................................................................................................212

Hot Gas Operation with Variable Geometry Diffuser (VGD)......................................................................... 213

Manual Control .............................................................................................................................................213

I/O Board ......................................................................................................................................................213

Pre-Rotation Vanes Potentiometer ..............................................................................................................214

SECTION 24 - SMART FREEZE PROTECTION..................................................................................................217

SECTION 25 - SURGE PROTECTION ................................................................................................................ 219

Surge Detection............................................................................................................................................219

Excess Surge Detection ..............................................................................................................................220

Surge Protection...........................................................................................................................................220

Hot Gas Bypass/Compressor Motor Variable Speed Drive (VSD) Applications...........................................221

SECTION 26 - VARIABLE GEOMETRY DIFFUSER............................................................................................223

Stall Detection .............................................................................................................................................. 223

Surge Detection............................................................................................................................................223

Automatic Operation.....................................................................................................................................223

Stall Sensor Validation..................................................................................................................................225

Extreme Stall Monitor ...................................................................................................................................225

Manual Operation.........................................................................................................................................226

Setpoints ......................................................................................................................................................226

Pre-Rotation Vanes Position.........................................................................................................................227

I/O Board ......................................................................................................................................................227

Stall Transducer .......................................................................................................................................... 227

Stall Detector Board ....................................................................................................................................227

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL

TABLE OF CONTENTS (CONT'D)

SECTION 27 - LARGE TONNAGE CHILLER (LTC) I/O BOARD 031-02895-000/001........................................231

Digital Inputs.................................................................................................................................................231

Digital Outputs..............................................................................................................................................233

Analog Inputs ...............................................................................................................................................234

Analog Outputs.............................................................................................................................................235

Auto Detection .............................................................................................................................................236

Diagnostic Screen .......................................................................................................................................236

SECTION 28 - HEAT RECOVERY........................................................................................................................237

Inputs/Outputs ..............................................................................................................................................237

Control..........................................................................................................................................................237

Remote Hot Water Setpoint..........................................................................................................................241

Condenser Flow Switch Open Fault.............................................................................................................241

SECTION 29 - HEAD PRESSURE CONTROL ....................................................................................................243

Inputs/Outputs ..............................................................................................................................................243

Control..........................................................................................................................................................244

Operation when Equipped with Both Heat Recovery and Head Pressure Control ......................................245

SECTION 30 - QUICK START ..............................................................................................................................247

Quick Start Modes........................................................................................................................................247

Setpoints ......................................................................................................................................................247

Operation......................................................................................................................................................249

SECTION 31 - HEAT PUMP DUTY.......................................................................................................................253

Inputs/Outputs ..............................................................................................................................................253

Setpoints ......................................................................................................................................................253

Control..........................................................................................................................................................254

Hot Gas Bypass Control...............................................................................................................................255

Heat Recovery and Head Pressure Control .................................................................................................255

Quick Start....................................................................................................................................................255

Variable Speed Drive....................................................................................................................................255

Condenser Temperature Range ..................................................................................................................255

Condenser High Pressure Warning..............................................................................................................255

GPIC Objects ............................................................................................................................................... 255

SECTION 32 - MOTOR MONITORING ................................................................................................................257

Motor Monitoring Board................................................................................................................................259

Winding Temperatures..................................................................................................................................262

Bearing Temperatures ..................................................................................................................................264

Vibration ....................................................................................................................................................... 265

Cooling Coil Leak Detection .........................................................................................................................267

SECTION 33 - SYSTEM CALIBRATION, SERVICE SETPOINTS, AND RESET PROCEDURES...................... 271

Electromechanical Starter Applications ........................................................................................................271

Solid State Starter Applications ....................................................................................................................272

Compressor Motor Variable Speed Drive Applications................................................................................. 276

Proximity Probe ............................................................................................................................................279

High Speed Thrust Bearing Limit Switch......................................................................................................280

Refrigerant Level Control ............................................................................................................................. 280

Oil Pump Variable Speed Drive....................................................................................................................282

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS

Oil Return Min .............................................................................................................................................. 283

Standby Lubrication......................................................................................................................................283

High Condenser Pressure Warning Threshold.............................................................................................283

Brine Low Evaporator Pressure Cutout........................................................................................................284

Leaving Chilled Liquid Temperature Control Sensitivity ...............................................................................284

Drop Leg Refrigerant Temperature...............................................................................................................284

Smart Freeze Protection ..............................................................................................................................285

Evaporator Refrigerant Temperature............................................................................................................285

Hot Gas Bypass Control...............................................................................................................................285

Chiller Starts and Operating Hours Reset ....................................................................................................286

Service Phone Numbers ..............................................................................................................................286

Surge Protection...........................................................................................................................................287

Sales Order Data..........................................................................................................................................287

Custom User ID and Passwords .................................................................................................................. 288

Record Setpoint Changes ............................................................................................................................289

Chiller Style/Compressor .............................................................................................................................289

Flow Switch .................................................................................................................................................. 292

Microboard 031-02430-000-001 and 031-03630-001 Setup/Configuration ................................................. 293

Variable Geometry Diffuser ..........................................................................................................................293

High Condenser Pressure Fault While Shutdown – Reset Procedure .........................................................295

Motor Lubrication Notification ......................................................................................................................295

Quick Start....................................................................................................................................................298

Heat Pump Duty ..........................................................................................................................................299

Motor Monitoring Software (Version C.Opt.01.22.307 and Later) ................................................................299

Motor Details Screen....................................................................................................................................299

Motor Setpoints Screen................................................................................................................................301

SECTION 34 - DIAGNOSTICS AND TROUBLESHOOTING ...............................................................................305

Diagnostics Screen ...................................................................................................................................... 306

Serial/SD SCreen .........................................................................................................................................307

Main Diagnostics Screen..............................................................................................................................308

Motor Monitoring Board Diagnostic Screen..................................................................................................309

I/O Board (031-02895-000) Diagnostic Screen ............................................................................................ 311

Keypad Test..................................................................................................................................................313

Display Test Main Screen.............................................................................................................................314

Bit Patterns Test Screen...............................................................................................................................316

Serial Inputs/Outputs Test Screen................................................................................................................318

Digital Inputs/Outputs Test Screen ...............................................................................................................320

Analog Inputs Test Screen............................................................................................................................323

SECTION 35 - SYSTEM COMMISSIONING CHECKLIST...................................................................................327

SECTION 36 - SOFTWARE ENHANCEMENTS...................................................................................................333

SI0006 - Software Enhancements Effective May 2001 ...............................................................................333

SI0019 - Software Enhancements Effective March 2002.............................................................................335

SI0034 - Software Enhancements Effective August 2002............................................................................337

TABLE OF CONTENTS (CONT'D)

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL

TABLE OF CONTENTS (CONT'D)

SI0058 - Software Enhancements Effective February 2003 ........................................................................340

SI0062 - Software Enhancements Effective March 2003.............................................................................342

SI0080 - Software Enhancements Effective January 2004 ..........................................................................343

SI0089 - Software Enhancements Effective May 2004 ................................................................................345

SI0148 - Software Enhancements Effective June 2006 ...............................................................................349

SI0158 - Software Enhancements Effective October 2006 ..........................................................................350

SI0164 - Software Enhancements Effective April 2007................................................................................351

SI0186 - Software Enhancements Effective October 2006 ..........................................................................354

SI0201 - Software Enhancements (Ver 19) Effective October 2008 ............................................................356

SI0210 - Software Enhancements (Ver 20) Effective June 2009 .................................................................361

SI0212 - Software Enhancements (Ver 21) Effective June 2009 .................................................................363

SI0224 - Software Enhancements (Ver 22) Effective April 2010 ..................................................................368

SI0252 - Software Enhancements (Ver 23) Effective May 2011...................................................................369

SI0265 - Software Enhancements (Ver 24) Effective May 2012 ..................................................................372

SI0271 - Software Enhancements (Ver 25) Effective August 2013 ..............................................................374

Si0300 - Software Enhancements (Ver 27) Effective June 2015 .................................................................384

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS

LIST OF FIGURES

FIGURE 1 - OptiView Control Center - Electromechanical Starter Applications ..................................................... 22

FIGURE 2 - OptiView Control Center - MOD A Solid State Starter Applications .....................................................23

FIGURE 3 - OptiView Control Center - MOD B Solid State Starter Applications..................................................... 24

FIGURE 4 - OptiView Control Center - Medium Voltage Solid State Starter Applications....................................... 25

FIGURE 5 - OptiView Control Center - Compressor Motor Variable Speed Drive

(YORK Serial Communications Protocol)............................................................................................26

FIGURE 6 - OptiView Control Center - Compressor Motor Variable Speed Drive

(Modbus Serial Communications Protocol) ......................................................................................... 27

FIGURE 7 - OptiView Control Center - Compressor Motor Medium Voltage Variable Speed Drive .......................28

FIGURE 8 - Operation Sequence Timing Diagram

(Electromechanical and Solid State Starter Applications)................................................................ 29

FIGURE 9 - Operation Sequence Timing Diagram (Compressor Motor Variable Speed Drive Applications) .........30

FIGURE 10 - Microboard 031-01730-000 ...............................................................................................................39

FIGURE 11 - Flash Memory Card ...........................................................................................................................40

FIGURE 12 - Microboard (031-01730-000) Power Supply Test Points ...................................................................41

FIGURE 13 - Microboard Lamp Dimmer Circuit......................................................................................................45

FIGURE 14 - Microboard Serial Data Communications Ports.................................................................................46

FIGURE 15 - Congurable Analog and Remote Setpoint Inputs.............................................................................47

FIGURE 16 - BRAM Socket ....................................................................................................................................62

FIGURE 17 - Microboard 031-02430-000 and 031-02430-001...............................................................................66

FIGURE 18 - Program Card 031-02474-001...........................................................................................................67

FIGURE 19 - Microboard (031-02430-000 and 031-02430-001) DC Power Supply Test Points.............................67

FIGURE 20 - Microboard Lamp Dimmer Circuit......................................................................................................68

FIGURE 21 - Microboard Serial Data Communications Ports.................................................................................69

FIGURE 22 - Congurable Analog and Remote Setpoint Inputs.............................................................................70

FIGURE 23 - Congurable Analog and Remote Setpoint Inputs (Heat Pump Duty)...............................................71

FIGURE 24 - Low Voltage Digital Inputs .................................................................................................................72

FIGURE 25 - Microboard 031-03630-001 ...............................................................................................................90

FIGURE 26 - Program Card 031-03601-001...........................................................................................................91

FIGURE 27 - Microboard (031-03630-001) DC Power Supply Test Points .............................................................91

FIGURE 28 - Microboard Lamp Dimmer Circuit......................................................................................................92

FIGURE 29 - Microboard Serial Data Communication Ports...................................................................................93

FIGURE 30 - Congurable Analog and Remote Setpoint Inputs.............................................................................94

FIGURE 31 - Congurable Analog and Remote Setpoint Inputs (Heat Pump Duty)...............................................95

FIGURE 32 - Low Voltage Digital Inputs .................................................................................................................96

FIGURE 33 - I/O Board ........................................................................................................................................101

FIGURE 34 - I/O Board Digital Inputs....................................................................................................................102

FIGURE 35 - I/O Board Typical Optocoupler Circuit .............................................................................................103

FIGURE 36 - I/O Board Typical Field Connections ...............................................................................................103

FIGURE 37 - J1 I/O Board Digital Outputs............................................................................................................104

FIGURE 38 - Display Mounting ............................................................................................................................. 110

FIGURE 39 - Liquid Crystal Display Assembly – Sharp LQ10D367/368 (031-01774-000) Display ...................... 111

FIGURE 40 - Liquid Crystal Display Assembly – Sharp LQ104V1DG61 (031-02886-000) Display...................... 111

FIGURE 41 - Liquid Crystal Display Assembly – LG Semicon LP104V2-W (031-02046-000).............................. 112

FIGURE 42 - Liquid Crystal Display Assembly – Sharp LQ104V1DG81 (031-01771-000)................................... 112

FIGURE 43 - Liquid Crystal Display Typical Control Signal Timing....................................................................... 113

FIGURE 44 - Display (Sharp LQ10D367/368) Lamp Replacement ...................................................................... 113

FIGURE 45 - Display (Sharp LQ104V1DG61 (031-02886-000) and LG LP104V2-W (031-02046-000)) ............. 114

FIGURE 46 - Display Interface Board 031-01765-001 and 031-01765-002 ......................................................... 117

FIGURE 47 - Display Interface Board 031-02887-000.......................................................................................... 118

FIGURE 48 - Display Backlight Inverter Board

(Sharp LQ10D367/368 (031-01774-000) and LG Semicon LP104V2-W (031-02046-000)) ...........120

FIGURE 49 - Display Backlight Inverter Board – Sharp LQ104V1DG61 Display 031-02886-000 ........................ 121

FIGURE 50 - Keypad Interface..............................................................................................................................124

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL

FIGURE 51 - Keypad.............................................................................................................................................125

FIGURE 52 - Power Supply...................................................................................................................................127

FIGURE 53 - Power Supply – DC Power Distribution (Refer To OptiView Control Center

Wiring Diagram for Wire Connections) ............................................................................................128

FIGURE 54 - CM-2 Current Module (Electromechanical Starter Application) .......................................................131

FIGURE 55 - CM-2 Current Module (Electromechanical Starter Applications) .....................................................131

FIGURE 56 - CM-2 Current Module – Interface, Current Transformers, and Variable Resistors ..........................132

FIGURE 57 - Style B Liquid Cooled Solid State Starter (LCSSS) – Interface (YORK Protocol)................................137

FIGURE 58 - Style B Liquid Cooled Solid State Starter (LCSSS) – Interface (YORK Protocol) ........................... 137

FIGURE 59 - Style B Liquid Cooled Solid State Starter (LCSSS) – Interface (Modbus Protocol) ................................... 138

FIGURE 60 - Solid State Starter Logic Board .......................................................................................................138

FIGURE 61 - Mod A Liquid Cooled Solid State Starter (LCSSS) – Interface ........................................................ 141

FIGURE 62 - Compressor Motor Variable Speed Drive (VSD) Adaptive Capacity Control (ACC) Board................ 152

FIGURE 63 - Serial Communications Interface – YORK Protocol ....................................................................... 153

FIGURE 64 - Serial Communications Interface – Modbus Protocol .....................................................................154

FIGURE 65 - Adaptive Capacity Control (ACC) Board..........................................................................................155

FIGURE 66 - Proximity Probe Interface – Probe Part Number 025-30961-000....................................................160

FIGURE 67 - Proximity Probe Interface – Probe Part Number 025-35900-000 and 025-35900-001 ...................160

FIGURE 68 - Proximity Probe Interface – Probe Part Number 025-40496-000....................................................161

FIGURE 69 - Proximity Probe ...............................................................................................................................162

FIGURE 70 - High Speed Thrust Bearing Limit Switch – Interface ....................................................................... 163

FIGURE 71 - High Speed Thrust Bearing Limit Switch ......................................................................................... 164

FIGURE 72 - Refrigerant Liquid Level Sensor ......................................................................................................168

FIGURE 73 - Refrigerant Liquid Level Control – Interface ................................................................................... 169

FIGURE 74 - Oil Pump Variable Speed Drive (VSD) ............................................................................................173

FIGURE 75 - Oil Pump VSD / Oil Heater Control – Interface................................................................................174

FIGURE 76 - Oil Pump VSD Speed Control Signal...............................................................................................174

FIGURE 77 - E-Link Gateway Interface Block Diagram........................................................................................175

FIGURE 78 - Pressure Transducers......................................................................................................................178

FIGURE 79 - Interface, Hot Gas Bypass (Analog I/O Board 371-02514-000) ...................................................... 215

FIGURE 80 - Interface, Hot Gas Bypass (I/O Board 031-02895-000)...................................................................216

FIGURE 81 - Variable Geometry Diffuser Block Diagram ..................................................................................... 228

FIGURE 82 - Variable Geometry Diffuser State Diagram......................................................................................229

FIGURE 83 - LTC I/O Board Basic Block Diagram................................................................................................232

FIGURE 84 - 120 VAC Digital Input.......................................................................................................................232

FIGURE 85 - +5 VDC Digital Input ........................................................................................................................233

FIGURE 86 - Relay Outputs..................................................................................................................................233

FIGURE 87 - Triac Outputs ...................................................................................................................................233

FIGURE 88 - Open Collector.................................................................................................................................234

FIGURE 89 - Analog Inputs...................................................................................................................................234

FIGURE 90 - Analog Outputs ................................................................................................................................235

FIGURE 91 - I/O Board (031-02895-XXX) ............................................................................................................236

FIGURE 92 - Heat Recovery Block Diagram.........................................................................................................238

FIGURE 93 - PID Controller Diagram....................................................................................................................239

FIGURE 94 - Heat Recovery Flow Diagram..........................................................................................................240

FIGURE 95 - Head Pressure Control Block Diagram............................................................................................243

FIGURE 96 - Head Pressure Control Flow Diagram.............................................................................................244

FIGURE 97 - Heat Pump Duty Block Diagram......................................................................................................256

FIGURE 98 - Motor Monitoring Board (031-02893-000/001) ................................................................................ 257

FIGURE 99 - Motor Monitoring Board Basic Block Diagram.................................................................................258

FIGURE 100 - Motor Monitoring Block Diagram ................................................................................................... 260

FIGURE 101 - Winding Temperature – Thermistors..............................................................................................262

FIGURE 102 - Winding and Bearing Temperature – RTD.....................................................................................264

FIGURE 103 - Bearing Vibration Sensor...............................................................................................................265

LIST OF FIGURES (CONT'D)

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS

FIGURE 104 - Motor Cooling Coil Leak Detector – Float Sensor ......................................................................... 267

FIGURE 105 - Motor Cooling Coil Leak Detector – Optical Sensor ...................................................................... 268

FIGURE 106 - Diagnostics Screen........................................................................................................................306

FIGURE 107 - Serial/SD Screen ...........................................................................................................................307

FIGURE 108 - Main Diagnostics ...........................................................................................................................308

FIGURE 109 - Motor Monitoring Board Diagnostic Screen...................................................................................309

FIGURE 110 - I/O Board Diagnostic Screen ......................................................................................................... 311

FIGURE 111 - Keypad Test Screen .......................................................................................................................313

FIGURE 112 - Display Test Main Screen ..............................................................................................................314

FIGURE 113 - Bit Patterns Test Screen ................................................................................................................316

FIGURE 114 - Serial Inputs/Outputs Test Screen .................................................................................................318

FIGURE 115 - Microboard - COM 5 Serial Data Port............................................................................................319

FIGURE 116 - Digital inputs/Outputs Test Screen.................................................................................................320

FIGURE 117 - Analog Inputs Test Screen .............................................................................................................323

FIGURE 118 - Diagnostic Screen..........................................................................................................................377

FIGURE 119 - Head Pressure Control Screen......................................................................................................381

FIGURE 120 - Power Fault Recovery Screen.......................................................................................................382

LIST OF FIGURES (CONT'D)

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL

LIST OF TABLES

TABLE 1 - Control Panel Applications.......................................................................................................................4

TABLE 2 - Boot-up LED Indicators .........................................................................................................................33

TABLE 3 - Addresses and Associated Data............................................................................................................34

TABLE 4 - Diagnostic Display Codes......................................................................................................................50

TABLE 5 - Multiplexer Channels .............................................................................................................................53

TABLE 6 - Summary of Differences ........................................................................................................................62

TABLE 7 - Microboard.............................................................................................................................................62

TABLE 8 - Diagnostic Display Codes......................................................................................................................74

TABLE 9 - Multiplexer Channels .............................................................................................................................79

TABLE 10 - MUX Address.....................................................................................................................................130

TABLE 11 - Microboard Multiplex Channels ........................................................................................................140

TABLE 12 - Proximity Probes ...............................................................................................................................159

TABLE 13 - Pressure Transducer Applications .....................................................................................................179

TABLE 14 - Leaving Chilled Liquid Temperature ..................................................................................................182

TABLE 15 - Leaving Chilled Liquid Temperature (Heat Pump Applications) ........................................................187

TABLE 16 - Return Chilled Liquid Temperature ...................................................................................................188

TABLE 17 - Return Chilled Liquid Temperature (Heat Pump Applications) ..........................................................191

TABLE 18 - Return and Leaving Condensing Water.............................................................................................192

TABLE 19 - Oil and Discharge Temperature.........................................................................................................195

TABLE 20 - Drop Leg Refrigerant Sensor.............................................................................................................200

TABLE 21 - Evaporator Refrigerant Sensor ...........................................................................................................200

TABLE 22 - Leaving and Return Heating Condenser Water Temperature Sensor ...............................................201

TABLE 23 - Control Source Setpoints...................................................................................................................241

TABLE 24 - Compare a Normal Start, Quick Normal Start, and a Quick Restart. ................................................ 250

TABLE 25 - RTD Resistance/Temperature Chart .................................................................................................269

TABLE 26 - Thermistor Resistance/Temperature Chart........................................................................................269

TABLE 27 - Flash Memory Card Version C.MLM.01.07.XXX and C.MLM.01.07A.XXX .......................................290

TABLE 28 - Flash Memory Card Version C.MLM.01.08.XXX .............................................................................. 291

TABLE 29 - Flash Memory Card Version C.MLM.01.08.105A and C.MLM.01.08.206A (and later) ......................291

TABLE 30 - Software Version C.MLM.01.10B.XXX (and later) or C.OPT.01.10B.XXX (and later) ...................... 291

TABLE 31 - Software Version C.OPT.01.16.XXX (and later) ................................................................................292

TABLE 32 - Loop Back Connections.....................................................................................................................371

TABLE 33 - Data Logging .....................................................................................................................................378

TABLE 34 - SI Metric Conversion .........................................................................................................................389

JCI COMPANY CONFIDENTIAL JOHNSON CONTROLSJOHNSON CONTROLS

FORM 160.54-M1

ISSUE DATE: 03/11/2019

THIS PAGE INTENTIONALLY LEFT BLANK

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL

This document explains the operation of the printed cir-

cuit boards and major components of the OptiView™

Control Center to a level that allows a service technician

to troubleshoot and locate the source of a problem.

The overall system architecture is described and illus-

trated with block diagrams, which describes the gener-

al function of each component and provides the system

interface and signal flow, which must be understood

before effective troubleshooting can begin.

The operation of each printed circuit board is described

and illustrated with a block diagram that is a simplified

representation of board circuitry. The expected voltage

level at all inputs and outputs of each board for any

operating condition is provided.

Included in this document are procedures that have to

be performed at chiller commissioning or during ser-

vice. They should not be performed by anyone other

than a service technician. For example, calibration

procedures have to be performed or verified at sys-

tem commissioning or when a component is replaced.

Certain safety shutdowns require special reset pro-

cedures to be performed before the chiller can be re-

started. Since the operating program supplied in each

OptiView Control Center is universal to all applica-

tions, special setpoints, program jumpers and program

switches are required to configure the chiller for local

operating conditions.

A system commissioning checklist is provided as a ref-

erence of items to be performed during chiller com-

missioning.

Chillers that are equipped with Pcompressors have

certain component variances, which are noted in the

appropriate sections of this manual.

In addition to this document, several supporting doc-

uments are required to service the system. OptiView

Control Panel – Operation (Form 160.54-O1) ex-

plains the operation of the OptiView Control Center

keypad, how to enter setpoints and explains all the

messages displayed on the OptiView Control Center

SECTION 1 - INTRODUCTION

display. The appropriate diagrams for each chiller are

shown in the associated literature table in the front

of this manual. These wiring diagrams provide com-

ponent interconnections within the OptiView Control

Center and the connections between these compo-

nents and the motor starter and chiller components.

When the chiller shuts down on a SAFETY or CY-

CLING shutdown or is being prevented from start-

ing, a message is displayed providing the reason for

the shutdown. This message, along with all the chill-

er operating conditions at the instant of the event are

stored in the microboard battery-backed memory. This

history data can be displayed or printed using an op-

tional printer. The OptiView Control Panel – Opera-

tion (Form 160.54-O1) provides a detailed description

of this message, including the conditions required to

produce the message and conditions required to restart

the chiller.

Diagnostic Routines allow service analysis of the fol-

lowing functions:

• Display

• Analog Inputs

• Digital inputs

• Digital Outputs

• Serial Data Ports

Before beginning any troubleshooting, observe the

shutdown message and retrieve the HISTORY data

of that event. Refer to the OptiView Control Panel –

Operation (Form 160.54-O1) for an explanation of the

message. The conditions required to produce the mes-

sage must be clearly understood before proceeding. (If

this is not needed, much time will be wasted). Armed

with knowledge of the overall system architecture and

the function of each printed circuit board and signal

flow provided by this manual, proceed with the appro-

priate wiring diagram listed above to trace the prob-

lem through the system. Use the Diagnostic Routines

where appropriate.

JCI COMPANY CONFIDENTIAL JOHNSON CONTROLSJOHNSON CONTROLS

FORM 160.54-M1

ISSUE DATE: 03/11/2019

THIS PAGE INTENTIONALLY LEFT BLANK

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL

SECTION 2 - SYSTEM ARCHITECTURE

The OptiView Control Center performs the following

functions:

• Controls chiller capacity to chill liquid to the

Chilled Liquid Temperature setpoint.

• Controls chiller solenoid valves, relays, actuators

and motor contactors per the operating program.

• Displays chiller operating conditions, alarms,

shutdown messages and history data.

• Accepts operator-programmed setpoints and con-

trols the chiller accordingly.

• Allows manual control of chiller motor contactors

and actuators.

• Monitors chiller operating conditions and shuts

down chiller when Safety or Cycling thresholds

are exceeded.

• Allows local manual start/stop and accepts start/

stop commands from remote devices, via contact

closures or serial communications.

• Allows setpoints to be changed from a remote loca-

tion via 0 to 10 VDC, 2 to 10 VDC, 0 to 20mA, 4 to

20mA, contact closures or serial communications.

• Provides chiller operating data and status to re-

mote devices via serial communications and con-

tact closures.

• Allows real-time data and history data to be print-

ed on an optional printer.

• Controls the compressor motor starter and con-

tains a printed circuit board logic that supports

Electromechanical Starters, Solid State Starters

and YORK Variable Speed Drives.

The OptiView Control Center is a microprocessor

based control system that receives analog, digital and

serial data inputs and controls analog, digital and serial

data outputs per instructions in the operating program.

A panel mounted display and touch-sensitive keypad

permit local operation.

System pressures are sensed by pressure transducers.

The output of each transducer is a DC voltage that is

analogous to the pressure input. System temperatures

are sensed by thermistors. The output of each thermis-

tor is a DC voltage that is analogous to the temperature

it is sensing. Typical output voltage range of both is 0.5

to 4.5 VDC. These are Analog Inputs to the OptiView

Control Center.

Digital inputs are ON/OFF inputs to the OptiView

Control Center in the form of switch and relay contacts.

These inputs are 115 VAC when the contacts are closed

and 0 VAC when open. These include flow switches,

local start/stop switch, remote cycling and high pres-

sure safety device, etc.

Digital Outputs are ON/OFF outputs from the OptiV-

iew Control Center in the form of relay contacts and

triacs. The relay contacts typically switch 115 VAC and

the triacs typically switch a nominal 30 VAC. Relay

outputs include status/alarm, chiller solenoid valves,

oil heater, oil pump starter and chilled and condenser

water pump starters, etc. Triac outputs include pre-ro-

tation vane control and variable orifice control.

Serial Data is transmitted to and received from devic-

es in RS-232, RS-485 and TX/RX (opto-couple) form.

The OptiView Control Center supports three types of

starters; Electromechanical Starter, Solid State Start-

er and Variable Speed Drive. However, all OptiView

Control Centers contain the following standard compo-

nents, regardless of the starter type applied:

• Microboard

• I/O (input/output) Board

• Keypad

• Display

• Power Supply

In addition to the standard components, the OptiView

Control Center contains a printed circuit board that

provides certain control and interface functions for the

starter type applied. Each starter type requires a differ-

ent board as follows:

• Electromechanical Starter – CM-2 Current Module.

• Solid State Starter (Style A) – Logic Board

Solid State Starter (Style B) – None.

• Variable Speed Drive - Adaptive Capacity Control

Board (except those VSDs that communicate with

the microboard using Modbus protocol).

• Figure 1 on page 22 through 4 are OptiView

Control Center block diagrams of the three starter

types. On each block diagram, the standard com-

ponents are shown, along with the printed circuit

board that supports the applied starter type. Fig-

ure 8 on page 29 and Figure 9 on page 30

are Operation Sequence timing diagrams of the

different starter applications.

FORM 160.54-M1

ISSUE DATE: 10/25/2019

SECTION 2 - SYSTEM ARCHITECTURE

JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS

The microprocessor and all supporting logic circuits,

along with the memory devices containing the operat-

ing program, reside on the microboard. All chiller op-

erating decisions are made here. It receives analog and

digital inputs from the chiller and remote devices. The

analog inputs are connected directly to the microboard.

The Digital inputs are received via the I/O Board (see

description below). Under Program control, the mi-

croboard operates the relays and triacs that are located

on the I/O Board.

The control center will be equipped with one of the fol-

lowing Microboards:

• 031-01730-000 – Shipped in new production

chillers until January 2004. The program resides

in a replaceable Flash memory card. The software

version is C.MLM.01.xx.yzz. It is printed on a la-

bel adhered to the card. The Program can be up-

graded by replacing the card.

• 031-02430-000 – Shipped in new production chill-

ers from January 2004 to 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. This board is backward

compatible to YK chillers presently using the 031-

01730-000 Microboard.

• 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 Sol-

id 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.

• 031-03630-001 – Shipped in new production chill-

ers after June 2015. This new design microboard

has additional features that will be enabled in fu-

ture software revisions. It is a service replacement

for all previous OptiView microboards.

Since the newer versions microboard are backward

compatible to earlier vintage OptiView Control Cen-

ters, earlier chillers could be equipped with a later ver-

sion microboard due to service replacement.

The software versions (C.MLM.01.xx.yzz, C.OPT.01.

xx.yzz) or Y.OPT.01.xx.yzz are alphanumeric codes

that are interpreted as follows. Each time the controls

section or language section is revised, the respective

revision level increments.

• Y or C – Commercial chiller

• MLM – Used on Microboard 031-01730-000

• OPT – Used on Microboard 031-02430-000/-001

• 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 manual, 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.01.09.xxx is of the same controls revision level

as C.MLM.01.09.xxx. From this starting point, both re-

ceive the same updates at each revision. However, be-

ginning with the release of version C.OPT.01.15.011,

C.MLM software will no longer be revised to include

new features. Software upgrades should only be per-

formed by a Service technician.

The I/O Board acts as an input/output device for the

microboard. It conditions the digital input signals for

the microboard and contains relays and triacs that are

controlled by the microboard to control solenoids, mo-

tor contactors and actuators. The 115 VAC digital inputs

from switch and relay contacts are converted to logic

level voltages by optocouplers. The relays have +12

VDC coils that are energized and de-energized by the

microboard. The contacts of these relays control the 115

VAC system solenoids, relays and motor contactors. The

triacs are turned ON and OFF by the microboard. The

outputs of these triacs control actuators.

Chillers equipped with the Variable Geometry Diffuser

(VGD) are supplied with and require I/O Board 031-

01743-002. This board is populated with the required

Triacs Q3 and Q4 that apply the open and close signals

to the Variable Geometry Diffuser ring actuator. See

SECTION 26 - VARIABLE GEOMETRY DIFFUSER.

SECTION 2 - SYSTEM ARCHITECTURE

FORM 160.54-M1

ISSUE DATE: 10/25/2019

JOHNSON CONTROLS JCI COMPANY CONFIDENTIAL

A front panel-mounted keypad allows operator and ser-

vice technician user interface. Membrane keys are used

to display chiller and system parameters, enter set-

points and perform chiller and OptiView Control Cen-

ter diagnostics. It also contains a START-RUN-STOP/

RESET switch that is used to locally start and stop the

chiller and perform manual reset functions.

A front panel mounted liquid crystal display allows

graphic animated display of the chiller, chiller subsys-

tems and system parameters. The chiller and working

components of the chiller are displayed, along with

chiller operating pressures and temperatures. The key-

pad is used to select displays showing increasing levels

of detail of chiller working components.

A self-contained power supply supplies the necessary

DC voltages for all the components within the OptiV-

iew Control Center.

Chillers equipped with Pcompressors and Style F and

later chillers have a different Condenser High Pressure

Safety Cutout Switch (HPCO) than supplied on other

applications. This switch is mounted on the condens-

er shell but has a different wiring interface to the I/O

Board and Motor Controller circuit. For more informa-

tion see SECTION 6 - I/O BOARD of this manual.

Also, P compressor applications and Style F and later

chillers with G, Q and H5-8 compressors are equipped

with a High Speed Thrust Bearing Limit Switch instead

of the proximity probe supplied on other compressors.

This device detects abnormal bearing position through

probe contact instead of distance measurement as per-

formed with the Proximity probe.

Style C (and earlier) chillers are equipped with fixed

speed oil pumps. Style D (and later) chillers are

equipped with variable speed oil pumps.

Style F (and later) chillers require flash memory card

version C.MLM.01.07.xxx and later and are supplied

with factory-mounted flow sensors on the evaporator

and condenser. These are electronic thermal-type sen-

sors.

The operating principle of the sensor is thermal con-

ductivity. It uses the cooling effect of a flowing liquid

to sense flow. The temperature of the heated sensor tip

is sensed by a thermistor located in the tip. A second

thermistor, located higher in the tip in a non-heated

area, is only affected by changes in liquid tempera-

ture. The temperatures sensed by the thermistors are

compared. Flowing liquid carries heat away from the

heated sensor tip, lowering its temperature. The lower

temperature differential between the two thermistors

indicates the liquid is flowing. A higher differential in-

dicates no flow.

These sensors are interfaced to microboard analog

inputs. See the SECTION 3 - MICROBOARD 031-

01730-000 for a detailed explanation of this flow sen-

sor and interface.

If equipped with flash memory card version

C.MLM.01.07.xxx (and later), the chiller style/com-

pressor combination must be entered using the Chiller

Style/Compressor setpoint (See SECTION 27 - LARGE

TONNAGE CHILLER (LTC) I/O BOARD 031-02895-

000/001). Once the applicable chiller style/compres-

sor combination is entered, the program automatically

bundles the functionality and chiller control per the

entered chiller style/compressor requirements. The

various chiller style/compressor combinations are

equipped differently and have different control re-

quirements. The variables include:

• High Speed Thrust Bearing proximity sensing –

Proximity probe or Limit Switch.

• Flow Sensor – Paddle type or factory mounted

Thermal type. The paddle type applies 115 VAC

to the I/O Board Digital inputs TB4-12 (evapora-

tor) and TB4-11 (condenser) (See Figure 34 on

page 102). The factory mounted thermal type

available with Style F (and later) chillers, applies

+5 VDC to the microboard Analog Inputs at J7-

14 (evaporator) and J7-16 (condenser). For more

information, see Figure 15 on page 47.

Flash memory card version C.MLM.01.07.xxx

and C.MLM.01.07A.xxx automatically selects the

flow sensor input, either digital or analog per the

chiller style/compressor setpoint selection.

FORM 160.54-M1

ISSUE DATE: 10/25/2019

SECTION 2 - SYSTEM ARCHITECTURE

JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS

Flash memory card version C.MLM.01.08.xxx

and later allows use of either the Thermal-type

or the Paddle-type flow sensors on Style "F" and

later chillers. With these versions, the actual flow

sensor type present must be entered using the

Flow Switch Setpoint. For more information, see

SECTION 27 - LARGE TONNAGE CHILLER

(LTC) I/O BOARD 031-02895-000/001.

• Oil Heater Outputs – Either TB1-34 or TB1-64 on

I/O Board.

• Refrigerant Level Control Default Period – Either

3.5 seconds or 10.0 seconds.

• “Oil – Variable Speed Pump-Pressure setpoint

Not Achieved” safety shutdown threshold – Ei-

ther 25 psid or 35 psid.

• Standard Coastdown Time (software version

C.OPT.01.16.xxx (and later)) – defaults to either

150 seconds or 240 seconds.

When the compressor motor is driven by an Electro-

mechanical Starter, the OptiView Control Center is

equipped with a CM-2 current module. This printed

circuit board provides current overload and power fault

protection for the compressor motor. Current trans-

formers, located in the compressor motor terminal box,

along with rectifying and calibration circuitry, provide

an analog voltage representing compressor motor cur-

rent to the CM-2 module. This signal is further condi-

tioned and provided to the microboard.

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).

The Style B LCSSS (Figure 3 on page 24) contains

a combination logic/trigger board in the starter cabinet

that has a serial communications interface to the mi-

croboard. Early Style B LCSSS use an Opto-coupled

interface with YORK proprietary protocol. Later Style

B LCSSS (after mid 2008) use Modbus protocol (re-

quires software version C.OPT.01.18.307 or later).

The medium voltage solid state starter (Figure 4 on

page 25) serially communicates with the microboard

using RS-485 Modbus Protocol. Earlier vintage chill-

ers are equipped with the Style A Solid State Starter.

This starter contains a trigger board that interfaces to a

logic board that is installed inside the OptiView Con-

trol Center. The Logic board interfaces the microboard

via a multiplexed data interface.

When the compressor motor is driven by a YORK

Variable Speed Drive, there could be a Variable Speed

Drive (VSD) or a Medium Voltage Variable Speed

Drive (MV VSD) applied.

Early vintage VSDs (Figure 5 on page 26) contain

an adaptive dapacity control (ACC) board that resides

in the OptiView cabinet that interfaces the microboard

using YORK proprietary protocol serial opto-coupled

communications. The ACC board monitors system pa-

rameters and controls the VSD to drive the compressor

at the slowest speed without surging, while maintain-

ing required chiller capacity.

With the later vintage VSD (Figure 6 on page 27),

the ACC functionality resides in the microboard, the

ACC Board is not present and the VSD logic board di-

rectly interfaces the microboard using RS-485 Modbus

protocol serial communications.

The MV VSD (Figure 7 on page 28) is also inter-

faced to the microboard with RS-485 Modbus serial

communications. All Modbus protocol applications re-

quire software version C.OPT.01.16.xxx (or later).

Serial data interface to the Building Automation Sys-

tem (BAS) is through the optional E-Link Gateway.

This printed circuit board monitors the required data

from the microboard and makes it available for the

BAS network. When BAS or ISN communications is

selected as the control source, the microboard will fol-

low the E-Link Gateway commands as well.

Certain compressors are equipped with a VGD, which

is used to reduce rotating stall conditions and associ-

ated stall noise.

Stall may occur at low load conditions with high head.

A mechanical ring, located in the compressor diffuser

passage is operated to open or close the diffuser gap.

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