York YCAV0177 - Fig 14 - Chiller Control Board, Relay Boards, and Microgateway

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138

JOHNSON CONTROLS

FORM 201.21-NM1 (1223)

FIG. 14 - CHILLER CONTROL BOARD, RELAY BOARDS, AND MICROGATEWAY

LD10580

COMPONENT LOCATIONS (CON'T)

TECHNICAL DATA

CHILLER

CONTROL

BOARD

MICROGATEWAY

(OPTIONAL)

RELAY BOARD #1

RELAY BOARD #2

RS-232/485 JUMPER

CLOCK JUMPER (CLK)

JP2

JP4, JP5, & JP6

• • •

▼

▲ ▲

▼

JUMPER POSITION

Main Page

Table of Contents5
Section 1 - General Chiller Information & Safety9
Introduction9
Warranty9
Safety9
Standards for Safety9
Responsibility for Safety10
About this Manual10
Misuse of Equipment10
Suitability for Application10
Structural Support10
Mechanical Strength10
General Access10
Pressure Systems11
Electrical11
Rotating Parts11
Sharp Edges11
Refrigerant & Oils11
High Temperature & Pressure Cleaning11
Emergency Shutdown11
Section 2 - Product Description12
Introduction12
General System Description12
Compressor13
Evaporator14
Condensor15
Flash Tank Feed / Drain Valve15
Oil Separator/Oil System15
Relief Valves15
Oil Cooling16
Capacity Controls16
Power and Control Panel16
Microprocessor & VSD Controls16
Display17
Keypad17
Unit Switch17
Variable Speed Drive (VSD)18
Fig 1 - PWM Current Waveform18
Fig 2 - PWM Voltage Waveform18
Accessories & Options19
Single Point Circuit Breaker19
Building Automation System (BAS) Interface19
Condensor Coil Protection19
DX Cooler Options20
Service Valve Option20
Unit Enclosures20
Fans20
Sound Reduction Options20
Vibration Isolation20
Unit Nomenclature21
Product Identification Number22
Section 3 - Rigging, Handling & Storage26
Delivery and Storage26
Inspection26
Lifting Weights26
Moving the Chiller27
Unit Rigging28
Section 4 - Installation29
Location Requirements29
Outdoor Installation29
Indoor Installation29
Location Clearances30
Vibration Isolators30
Installation30
Shipping Braces30
Chilled Liquid Piping30
General Requirements30
Positions30
Water Treatment32
Connection Types & Sizes32
Cooler Connections32
Option Flanges32
Fig 3 - Pipework Arrangement32
Fig 4 - Victaulic Groove32
Fig 5 - Flange Attachment32
Refrigerant Relief Valve Piping33
Ductwork Connection33
General Requirements33
Electrical Connection33
Power Wiring34
Vac Control Supply Transformer34
Control Panel Wiring34
Volts Free Contacts35
Chilled Liquid Pump Starter35
Run Contact35
Alarm Contact35
System Inputs35
Flow Switch35
Remote Run/Stop35
Optional Remote Setpoint Offset Temp35
Optional Remote Setpoint Offset Sound Limit35
Section 5 - Commissioning36
Preparation36
Preparation - Power off36
Inspection36
Refrigerant Charge36
Service and Oil Line Valves36
Compressor Oil36
Fans36
Isolation / Protection36
Control Panel36
Power Connections37
Grounding37
Water System37
Flow Switch37
Temperature Sensor(S)37
Programmed Options37
Programmed Settings37
Date & Time37
Start / Stop37
Setpoint & Remote Offset37
Interlocks38
Unit Switch38
Start-Up38
Oil Pressure38
Refrigerant Flow38
Loading38
Suction Superheat38
Subcooling38
Condensor & Fan Rotation39
General Operation39
Section 6 - Technical Data40
Water Pressure Drop Charts40
Glycol Correction Factors41
Water Temp. and Flows42
Physical Data44
Electrical Data49
Fig 6 - Single Point Power Supply Connection W/ Field Supplied Circuit Protection49
Fig 7 - Single Point Power Supply Connection W/ Optional Factory Circuit Breaker49
Electrical Notes54
Elementary Wiring Diagram56
Connection Diagram60
Location Label64
Dimensions66
Technical Data (Clearances)122
Weight Dist. & Isolator Mounting124
Fig 8 - Sample Printout Supplied in the Isolator Package & Chiller Panel Literature Packet124
Isolator Mounting Positions125
Seismic Isolator Installation128
Neoprene Isolator Position130
Refrigerant Flow Diagram133
Fig 9 - Refrigerant Flow Diagram133
Process & Instrumentation Diagram134
Fig 10 - Processes and Instrumentation134
Component Locations135
Fig 11 - Component Locations135
Fig 12 - Control and VSD Cabinet Locations136
Fig 13 - Chiller Control Board, Relay Boards, Microgateway, and Optional Circuit Breaker137
Fig 14 - Chiller Control Board, Relay Boards, and Microgateway138
Fig 15 - VSD Logic Board139
Fig 16 - VSD Logic Board140
Fig 17 - Power Components141
Fig 18 - Fan Contactors & 3T Transformers142
Fig 19 - VSD Components143
Fig 20 - VSD Components144
Fig 21 - VSD Components145
Fig 22 - Inverter Power Components146
Fig 23 - Inverter Power Components147
Fig 24 - Inverter Power Components148
Fig 24A - Inverter Power Components148
Fig 25 - Glycol Pump & Fill Tube Locations149
Fig 26 - Glycol Piping & Fill Tube Locations150
Fig 27 - Compressor Components151
Equipment Start-Up Check Sheet152
Unit Checks (no Power)152
Panel Checks154
(Power ON-Both System Switches OFF)154
Programmed Values155
Chilled Liquid Setpoint155
Date/Time, Daily Schedule, & Clock Jumper155
Initial Start-Up156
Check Subcooling & Superheat156
Leak Checking157
Chiller Electronic Components158
Keypad158
Display159
Chiller Control Board160
Relay Output Boards161
VSD (Variable Speed Drive)161
AC to DC Rectifier161
SCR Trigger Board162
DC Link Filter162
1L Line Inductor163
AC to DC Inverter163
Laminated Bus Structure163
VSD Logic Board164
Control Panel to VSD Communications164
IBGT Gate Driver Boards165
Current Transformers165
DV/DT Output Suppression Network166
Flash Tank Feed/Drain Valve Controller166
DC Bus Voltage Isolation Board167
Chiller Circuit Breaker167
Autotransformer167
Chiller Configuration Jumpers168
Number of Compressors Configuration Jumpers168
Vsd Logic to Chiller Microprocessor Board Rs-485 Communication Configuration Jumpers168
Max Vsd Frequency169
Section 7 - Operation170
Operating Controls170
Basic Operating Sequence172
Fig 28 - Chiller Control (Cooling) Range172
Number of Compressors to Start173
General173
Standard IPLV173
Optional Optimized IPLV173
Fig 29 - Number of Compressors to Start173
Minimum Vsd Compressor Start/Run Frequency174
Minimum VSD Start Frequency174
Minimum VSD Run Frequency174
Fig 30 - Minimum VSD Start Frequency174
Fig 31 - Minimum VSD Run174
Acceleration/Deceleration Rate175
Compressors175
VSD Acceleration/ Deceleration Rates175
Standard Iplv Capacity Control176
Fuzzy Logic Control177
Hot Water Starts178
Lag Compressor Operation in Load Limiting178
Optional Iplv Capacity Control179
Fuzzy Logic180
Hot Water Starts181
Load Limiting Control182
Flash Tank Drain/Feed Valve Controller185
Valve Controller & Control Algorithm185
Fig 32 - LED Locations186
Fig 33 - Power, Comms Led's187
Fig 34 - Power, Comms & System Open/Close Led's187
Economizer Control188
Condenser Fan Control189
Fig 35 - Standard IPLV Fan Control190
Fig 36 - High IPLV Fan Control190
Vsd Temperature Control/Fan Control Operation191
Remote Temperature Reset Control 1 9192
Local Current Limit Control193
Pulldown Current Limit Setpoint193
Remote Current Limit Reset194
Sound Limit Controls196
Section 8 - Micropanel198
Vsd Operation & Controls198
VSD Cooling and Cooling Loop200
Vsd Safeties204
IBGT Gate Driver (Hardware) Fault207
Power Supply (Hardware) Fault209
Unit Warnings212
Unit Safeties216
System Safeties218
Status Key224
Unit Data Key228
System Data Key230
Vsd Data Key234
Operating Hours & Start Keys236
History Key237
Unit Data239
VSD Data239
System Data240
Compressor Operating Hours & Starts242
Chilled Liquid & Cooling Setpoints242
Options242
Program Values243
Setpoints Key245
Program Key247
Options Key250
Date/Time & Schedule Key254
Date/Time Key254
Schedule Key255
Unit Operating Schedule256
Sound Limit Schedule257
Manual Override Key258
Print Key259
Operating Data Printout260
History Data Printout261
Service Key262
System Switches Key268
Serial Number Programming269
Enabling Optimized High Iplv Mode271
Unit Setup Mode272
Default Programmable Values274
Serial Port Connections275
Analog Input Connections276
Digital Input Connections278
Analog Output Connections280
Digital Output Connections282
Isn Communications & Transmitted Data284
R-134A Conversion Tables290
Maintenance291
General Requirements291
Maintenance Requirements292
Troubleshooting Guide294
Evacuating a System296
Warranty Policy297
New Equipment297
Reconditioned or Replacement Materials297
All Warranties Are VIOD if297
Sensor Input Voltage Table298
Outside Air Temp Sensor Input Voltage Table299
Pressure Transducer Output Voltage Table300
Motor Temperature Sensor Resistance Table301
Compressor Motor Overload Settings & Maximum Vsd Frequency302
Printer Wiring303
Fig 37 - Print Cable Chiller to Serial Printer303
Okidata 184304
Weigh-Tronix IMP Model 2600304
Seiko304
Operating Log305
Site and Chiller Info305
Programmed Values305
Currents306
System Operating Conditions307
Water System Conditions308
Condensor Conditions308
Recommended Spare Parts309

York YCAV0177 - Fig 14 - Chiller Control Board, Relay Boards, and Microgateway

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