MILLENNIUM ®

ROTARY SCREW LIQUID CHILLERS

SERVICE INSTRUCTIONS Supersedes: 160.80-M1 (604) Form 160.80-M1 (307)

OPTIVIEW™ CONTROL CENTER

371-02459-101 (ELECTRO-MECHANICAL STARTER - NEMA 1)
371-02579-101 (ELECTRO-MECHANICAL STARTER - CE)
371-02578-101 (ELECTRO-MECHANICAL STARTER - NEMA 4/12)
371-02459-102 (SOLID STATE STARTER - NEMA 1)
371-02578-102 (SOLID STATE STARTER - CE)
371-02448-102 (SOLID STATE STARTER - NEMA 4/12)

MODEL YS (STYLE E)

00200VIP

m
Metric Conversions
 FORM 160.80-M1 (307)

IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES

This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or
During installation, operation, maintenance or service, death to themselves and people at the site.
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants, This document is intended for use by owner-authorized
oils, materials under pressure, rotating components, and operating/service personnel. It is expected that this in-
both high and low voltage. Each of these items has the dividual possesses independent training that will enable
potential, if misused or handled improperly, to cause them to perform their assigned tasks properly and safely.
bodily injury or death. It is the obligation and respon- It is essential that, prior to performing any task on this
sibility of operating/service personnel to identify and equipment, this individual shall have read and under-
recognize these inherent hazards, protect themselves, stood this document and any referenced materials. This
and proceed safely in completing their tasks. Failure individual shall also be familiar with and comply with
to comply with any of these requirements could result all applicable governmental standards and regulations
in serious damage to the equipment and the property in pertaining to the task in question.

SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:

DANGER indicates an imminently CAUTION identifies a hazard which

hazardous situation which, if not could lead to damage to the machine,
avoided, will result in death or serious damage to other equipment and/or
injury. environmental pollution. Usually an
instruction will be given, together with
a brief explanation.

WARNING indicates a potentially NOTE is used to highlight additional

haz ard ous sit u a tion which, if not information which may be helpful to
avoided, could result in death or se- you.
rious injury.

External wiring, unless specified as an optional connection in the manufacturer’s product

line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the micro panel. NO external wiring
is allowed to be run through the micro panel. All wiring must be in accordance with YORK’s
published specifications and must be performed ONLY by qualified YORK personnel. YORK
will not be responsible for damages/problems resulting from improper connections to the
controls or application of improper control signals. Failure to follow this will void the
manufacturer’s warranty and cause serious damage to property or injury to persons.

2 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

CHANGEABILITY OF THIS DOCUMENT

In complying with YORK’s policy for continuous It is the responsibility of operating/service personnel
product improvement, the information contained in as to the applicability of these documents to the equip-
this document is subject to change without notice. ment in question. If there is any question in the mind
While YORK makes no commitment to update or of operating/service personnel as to the applicability of
pro vide current in for ma tion automatically to the these documents, then, prior to working on the equip-
manual owner, that information, if applicable, can ment, they should verify with the owner whether the
be obtained by contacting the nearest YORK Applied equipment has been modified and if current literature
Systems Service office. is available.

REFERENCE INSTRUCTIONS
DESCRIPTION FORM NO.
SOLID STATE STARTER (MOD “A”) – OPERATION & MAINTENANCE 160.46-OM3.1
SOLID STATE STARTER (MOD “B”) – OPERATION & MAINTENANCE 160.00-O2
INSTALLATION 160.80-N1
OPERATION 160.80-O1
WIRING DIAGRAM – UNIT WITH ELECTRO-MECHANICAL STARTER 160.80-PW1
WIRING DIAGRAM – UNIT WITH MOD “B” SOLID STATE STARTER 160.80-PW2
RENEWAL PARTS – UNIT 160.80-RP1
RENEWAL PARTS – OPTIVIEW CONTROL CENTER 160.80-RP3

NOMENCLATURE
YS CB CB S4 – CM E
DESIGN LEVEL (E)

MOTOR CODE
60 Hz 50 Hz
POWER SUPPLY
CF 5CC
– for 60 Hz
CG 5CD
5 for 50 Hz
CH 5CE
CJ 5CF
COMPRESSOR CODE
CK 5CG
S0, S1, S2, S3, S4, S5
CL 5CH
CM 5CI
CN 5CJ
CONDENSER CODE
CP 5CK
BA, BB, CA, CB, DA, DB, EA, EB, FA, FB
CR 5CL
CS 5CM
CT 5CN
CU 5CO
COOLER CODE
CV
BA, BB, CA, CB, DA, DB, DC
EA, EB, EC, FA, FB, FC

MODEL

JOHNSON CONTROLS 3
 FORM 160.80-M1 (307)

TABLE OF CONTENTS
SECTION 1 INTRODUCTION ......................................................................................8

SECTION 2 SYSTEM ARCHITECTURE ......................................................................9

FIG. 1 – CONTROL CENTER - ELECTRO-MECHANICAL STARTER APPLICATIONS ................... 11
FIG. 2 – CONTROL CENTER - MOD “A” SOLID STATE STARTER APPLICATIONS ...................... 12
FIG. 3 – CONTROL CENTER - MOD “B” SOLID STATE STARTER APPLICATIONS ....................... 13
FIG. 4 –OPERATION SEQUENCE TIMING DIAGRAM ....................................................................... 14
(ELECTRO-MECHANICAL & SOLID STATE STARTER APPLICATIONS) .......................... 14

SECTION 3 MICROBOARD 031-01730-000 .............................................................15

FIG. 5 – MICROBOARD 031-01730-000 ................................................................................................. 22
FIG. 6 – FLASH MEMORY CARD ........................................................................................................... 23
FIG. 7 – MICROBOARD (031-01730-000) POWER SUPPLY TEST POINTS ....................................... 24
TABLE 1 – MICROBOARD 031-01730-000 PROGRAM JUMPERS ..................................................... 25
TABLE 2 – MICROBOARD 031-01730-000 PROGRAM SWITCHES................................................... 27
FIG. 8 – MICROBOARD LAMP DIMMER CIRCUIT ............................................................................. 28
FIG. 9 – MICROBOARD SERIAL DATA COMMUNICATIONS PORTS .............................................. 29
FIG. 10 – CONFIGURABLE ANALOG & REMOTE SETPOINT INPUTS ........................................... 30

SECTION 3A MICROBOARD 031-02430-000 ..........................................................31

TABLE 3 – MICROBOARD 031-02430-000 PROGRAM JUMPERS ..................................................... 40
TABLE 4 – MICROBOARD 031-02430-000 PROGRAM SWITCHES................................................... 42
FIG. 5A – MICROBOARD 031-02430-000 ............................................................................................... 43
FIG. 6A – PROGRAM CARD 031-02488-001 .......................................................................................... 44
FIG. 7A – MICROBOARD (031-02430-000) DC POWER SUPPLY TEST POINTS ............................. 44
FIG. 8A – MICROBOARD LAMP DIMMER CIRCUIT .......................................................................... 45
FIG. 9A – MICROBOARD SERIAL DATA COMMUNICATIONS PORTS ............................................ 46
FIG. 10A – CONFIGURABLE ANALOG & REMOTE SETPOINT INPUTS ......................................... 47

SECTION 4 I/O BOARD............................................................................................48

FIG. 11 – I/O BOARD ................................................................................................................................ 51
FIG. 12 – I/O BOARD DIGITAL INPUTS ................................................................................................ 52
FIG. 13 – I/O BOARD TYPICAL OPTO-COUPLER CIRCUIT .............................................................. 53
FIG. 14 – I/O BOARD TYPICAL FIELD CONNECTIONS ..................................................................... 53
FIG. 15 – I/O BOARD DIGITAL OUTPUTS ............................................................................................ 54

SECTION 5 LIQUID CRYSTAL DISPLAY.................................................................58

FIG. 16 – DISPLAY, MOUNTING ............................................................................................................ 61
FIG. 17 – LIQUID CRYSTAL DISPLAY ASSEMBLY – SHARP LQ10D367/368
(031-01774-000) DISPLAY........................................................................................................ 62
FIG. 18 – LIQUID CRYSTAL DISPLAY ASSEMBLY – SHARP LQ10D421 DISPLAY........................ 62
FIG. 19 – LIQUID CRYSTAL DISPLAY ASSEMBLY – NEC NL6448AC33-24 DISPLAY .................. 63
FIG. 20 – LIQUID CRYSTAL DISPLAY ASSEMBLY - LG SEMICON LP104V2-W
(031-02046-000) ......................................................................................................................... 64
FIG. 21– LIQUID CRYSTAL DISPLAY TYPICAL CONTROL SIGNAL TIMING ............................... 64
FIG. 22 – DISPLAY (SHARP LQ10D367) LAMP REPLACEMENT ...................................................... 65

4 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

FIG. 23 – DISPLAY (SHARP LQ10D367/368 [031-01774-000]) LAMP REPLACEMENT ................... 65

FIG. 24 – DISPLAY (NEC NL6448AC33-24) LAMP REPLACEMENT ................................................. 66
FIG. 25 – DISPLAY (LG SEMICON LP104V2-W [031-02046-000]) LAMP REPLACEMENT ............ 66

SECTION 6 DISPLAY INTERFACE BOARD .............................................................67

FIG. 26 – DISPLAY INTERFACE BOARD .............................................................................................. 68

SECTION 7 DISPLAY BACKLIGHT INVERTER BOARD .........................................69

FIG. 27 – DISPLAY BACKLIGHT INVERTER BOARD (SHARP LQ10D367/368
(031-01774-000) & LG SEMICON LP104V2-W) (031-02046-000) ........................................ 70
FIG. 28 – DISPLAY BACKLIGHT INVERTER BOARD (SHARP LQ10D421) ..................................... 71
FIG. 29 – DISPLAY BACKLIGHT INVERTER BOARD (NEC NL6448AC33-24) ............................... 71

SECTION 8 KEYPAD .................................................................................................72

FIG. 30 – KEYPAD .................................................................................................................................... 73
FIG. 31 – KEYPAD .................................................................................................................................... 74

SECTION 9 POWER SUPPLY ...................................................................................75

FIG. 32 – POWER SUPPLY ....................................................................................................................... 75
FIG. 33 – POWER SUPPLY – DC POWER DISTRIBUTION ................................................................ 76

SECTION 10 CURRENT MODULE (CM-2) ...............................................................77

FIG. 34 – CM-2 CURRENT MODULE (ELECTRO-MECHANICAL STARTER APPLICATION) ....... 79
FIG. 35 – CM-2 CURRENT MODULE (ELECTRO-MECHANICAL STARTER APPLICATIONS)..... 79
FIG. 36 – CM-2 CURRENT MODULE – INTERFACE, CURRENT TRANSFORMERS &
VARIABLE RESISTORS ........................................................................................................... 80

SECTION 11 SOLID STATE STARTERS ..................................................................81

FIG. 37 – MOD “B” SOLID STATE STARTER (LCSSS) - INTERFACE............................................... 83
FIG. 38 – SOLID STATE STARTER LOGIC BOARD ............................................................................ 84
FIG. 39 – MOD “A” LIQUID COOLED SOLID STATE STARTER (LCSSS) - INTERFACE ............... 87
FIG. 40 – MOD “A” SOLID STATE STARTER LOGIC BOARD............................................................ 88

SECTION 12 VARIABLE ORIFICE CONTROL .........................................................89

SECTION 13 MICROGATEWAY ................................................................................90

FIG. 41 – MICROGATEWAY INTERFACE BLOCK DIAGRAM ........................................................... 90

SECTION 14 PRESSURE TRANSDUCERS ............................................................91

FIG. 42 – PRESSURE TRANSDUCERS ................................................................................................... 93

JOHNSON CONTROLS 5
 FORM 160.80-M1 (307)

SECTION 15 TEMPERATURE THERMISTORS .......................................................94

FIG. 43 – LEAVING CHILLED LIQUID TEMPERATURE..................................................................... 95
FIG. 44 – RETURN CHILLED LIQUID TEMPERATURE ................................................................... 100
FIG. 45 – RETURN AND LEAVING CONDENSING WATER ............................................................. 103
FIG. 46 – OIL AND DISCHARGE TEMPERATURE ............................................................................. 106
FIG. 47 – EVAPORATOR REFRIGERANT SENSOR............................................................................ 111

SECTION 16 REMOTE SETPOINTS ....................................................................... 112

SECTION 17 HOT GAS BYPASS............................................................................ 117

FIG. 48 – FUTURE ................................................................................................................................... 117

SECTION 18 SMART FREEZE PROTECTION ....................................................... 118

SECTION 19 STANDBY CHILLER FREEZE PROTECTION ..................................120

SECTION 20 OIL RECOVERY FEATURE ...............................................................121

SECTION 21 SYSTEM CALIBRATION, SERVICE SETPOINTS AND RESET

PROCEDURES ..................................................................................122
ELECTRO-MECHANICAL STARTER APPLICATIONS ...................................................................... 122
SOLID STATE STARTER APPLICATIONS ........................................................................................... 123
MOD “B” SOLID STATE STARTER ................................................................................................. 123
MOD “A” SOLID STATE STARTER ................................................................................................. 124
SLIDE VALVE POSITION....................................................................................................................... 125
HIGH CONDENSER PRESSURE WARNING THRESHOLD .............................................................. 126
BRINE LOW EVAPORATOR PRESSURE CUTOUT THRESHOLD ................................................... 126
SMART FREEZE PROTECTION ............................................................................................................ 127
EVAPORATOR REFRIGERANT TEMPERATURE ............................................................................... 127
VARIABLE ORIFICE CONTROL .......................................................................................................... 127
HOT GAS BYPASS CONTROL .............................................................................................................. 127
TRANSDUCER AUTO ZERO ................................................................................................................. 128
SEAL OIL PRESSURE TRANSDUCER ................................................................................................ 128
MAXIMUM LOAD LIMIT ...................................................................................................................... 128
MINIMUM LOAD CONTROL SOURCE .............................................................................................. 128
STANDBY CHILLER FREEZE PROTECTION ..................................................................................... 129
LEAVING CHILLED LIQUID TEMPERATURE CONTROL SENSITIVITY ...................................... 129
ICE STORAGE MODE ............................................................................................................................ 129
MANUAL SLIDE VALVE CONTROL.................................................................................................... 130
SERVICE PHONE NUMBERS ................................................................................................................ 130
CHILLER STARTS AND OPERATING HOURS RESET ...................................................................... 130
SALES ORDER DATA............................................................................................................................. 130
CUSTOM USER ID AND PASSWORDS ............................................................................................... 131
RECORD SETPOINT CHANGES ........................................................................................................... 132
MICROBOARD 031-02430-000 SETUP/CONFIGURATION .............................................................. 133
HIGH CONDENSER PRESSURE FAULT WHILE SHUTDOWN – RESET PROCEDURE ............ 133

6 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

SECTION 22 DIAGNOSTICS & TROUBLESHOOTING .........................................134

MAIN DIAGNOSTICS SCREEN ............................................................................................................ 136
FIG. 49 – MAIN DIAGNOSTICS SCREEN ........................................................................................ 136
KEYPAD TEST ........................................................................................................................................ 137
FIG. 50 – KEYPAD TEST SCREEN .................................................................................................... 137
DISPLAY TEST ........................................................................................................................................ 138
FIG. 51 – DISPLAY TEST MAIN SCREEN ........................................................................................ 138
FIG. 52 – BIT PATTERNS TEST SCREEN ......................................................................................... 139
SERIAL INPUTS / OUTPUTS TESTS .................................................................................................... 140
FIG. 53 – SERIAL INPUTS / OUTPUTS TEST SCREEN .................................................................. 140
FIG. 54 – MICROBOARD - COM 5 SERIAL DATA PORT ............................................................... 141
DIGITAL INPUTS / OUTPUTS TESTS .................................................................................................. 142
FIG. 55 – DIGITAL INPUTS / OUTPUTS TEST SCREEN ................................................................ 142
ANALOG INPUTS TEST ........................................................................................................................ 145
FIG. 56 – ANALOG INPUTS TEST SCREEN..................................................................................... 145

SECTION 23 SYSTEM COMMISSIONING CHECKLIST ........................................148

SECTION 24 SERVICE INFORMATION LETTERS / BULLETINS .........................150

SI0007 - SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2001 .................................................... 150
SI0024 - SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2002 .............................................. 151
SI0091 - SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2004 .................................................... 152

JOHNSON CONTROLS 7
 Introduction
FORM 160.80-M1 (307)

SECTION 1
INTRODUCTION
This document explains the operation of the printed the connections between the printed circuit boards and
circuit boards and major components of the Control components within the Control Center:
Center to a level that allows a Service Technician to
troubleshoot and locate the source of a problem. • YORK Form 160.80-PW1 – Chillers equipped
with Electro-Mechanical starter
The overall system architecture is described and illus-
trated with block diagrams. This describes the general • YORK Form 160.80-PW2 – Chillers equipped
function of each component and provides the system in- with Mod “B” YORK Solid State Starter
terface and signal flow. The function of each component
and signal flow between components must be understood When the chiller shuts down on a SAFETY or CY-
before effective troubleshooting can commence. CLING shutdown or is being prevented from starting,
a message is displayed providing the reason for the shut-
The operation of each printed circuit board is described down. This message, along with all the chiller operating
and illustrated with a block diagram that is a simplified conditions at the instant of the event are stored in the
representation of board circuitry. The expected voltage Microboard battery-backed memory. This history data
level at all inputs and outputs of each board for any can be displayed or printed using an optional printer.
operating condition is provided. The Operations Manual 160.80-O1 provides a detailed
description of this message, including the conditions
Included in this document are procedures that have to be required to produce the message and conditions required
performed at chiller commissioning or during service. to restart the chiller.
They should not be performed by anyone other than
a Service Technician. For example, calibration proce- Diagnostic Routines allow service analysis of the fol-
dures have to be performed or verified at system com- lowing functions:
missioning or when a component is replaced. Certain • Display
Safety shutdowns require special reset procedures to be • Analog inputs
performed before the chiller can be restarted. Since the
• Digital inputs
operating program supplied in each Control Center is
universal to all applications, special setpoints, program • Digital outputs
jumpers and program switches are required to configure • Serial Data ports
the chiller for local operating conditions.
Before beginning any troubleshooting, observe the shut-
A System Commissioning Checklist is provided as down message and retrieve the HISTORY data of that
reference of items to be performed during chiller com- event. Refer to the Operations Manual for an explanation
missioning. of the message. The conditions required to produce the
message must be clearly understood before proceeding.
In addition to this document, several levels of sup- (If this is not heeded, much time will be wasted). Armed
porting documentation are required while servicing the with a knowledge of the overall system architecture and
system. Field Control Modifications Diagram 160.80- the function of each printed circuit board and signal flow
PW5 provides details of the interface to remote devices. provided by this manual, proceed with the appropri-
Operations Manual 160.80-O1 explains the operation ate Wiring Diagram listed above to trace the problem
of the Control Center Keypad, how to enter Setpoints through the system. Use the Diagnostic Routines where
and explains all the messages displayed on the Control appropriate.
Center display. The following wiring diagrams provide

8 JOHNSON CONTROLS
 FORM 160.80-M1 (307)
SECTION 2
SYSTEM ARCHITECTURE
The Control Center performs the following functions: Digital Outputs are on/off outputs from the Control
• Controls chiller capacity to chill liquid to the Center in the form of relay contacts and triacs. The re-
chilled liquid temperature setpoint. lay contacts and triacs typically switch 115VAC. Relay
• Controls chiller solenoid valves, relays, actuators outputs include status/alarm, chiller solenoid valves, oil 2
and motor contactors per the operating program. heater, and chilled and condenser water pump starters,
etc. Triac outputs include slide valve control.
• Displays chiller operating conditions, alarms,
shutdown messages and history data.
Serial Data is transmitted to and received from devices
• Accepts operator-programmed setpoints and con- in RS-232, RS-485 and TX/RX (opto-couple) form.
trols the chiller accordingly.
• Allows manual control of chiller motor contactors The Control Center supports three types of starters;
and actuators. Electro-Mechanical Starter, Mod “A” Solid State Starter
• Monitors chiller operating conditions and shuts and Mod “B” Solid State Starter. However, all Control
down chiller when Safety or Cycling thresholds Centers contain the following standard components,
are exceeded. regardless of the starter type applied:
• Allows local manual start/stop and accepts start/ • Microboard
stop commands from remote devices, via contact
closures or serial communications. • I/O (input/output) Board
• Allows setpoints to be changed from a remote lo- • Keypad
cation via 0-10VDC, 2-10VDC, 0-20mA, 4-20mA, • Display
contact closures or serial communications.
• Power Supply
• Provides chiller operating data and status to remote
devices via serial communications and contact clo- In addition to the standard components, the Control
sures. Center contains a printed circuit board that provides
• Allows real-time data and history data to be printed certain control and interface functions for the starter
on an optional printer. type applied. Each starter type requires a different board
• Controls the compressor motor starter and contains as follows:
a printed circuit board logic that supports Electro- • Electro-Mechanical Starter - CM-2 Current Mod-
Mechanical Starters, and Solid State Starters. ule
The Control Center is a microprocessor based control • Solid State Starter (Mod “A” only) - Logic Board
system that receives analog, digital and serial data Figures 1 through 3 are Control Center block diagrams
inputs and controls analog, digital and serial data out- of the three starter types. On each block diagram, the
puts per instructions in the operating program. A panel standard components are shown, along with the printed
mounted display and touch-sensitive keypad permit circuit board that supports the applied starter type. Figure
local operation. 4 is an Operation Sequence timing diagram.
System pressures are sensed by pressure transducers
The microprocessor and all supporting logic circuits,
The output of each transducer is a DC voltage that is
along with the memory devices containing the oper-
analogous to the pressure input. System temperatures are
ating program, reside on the Microboard. All chiller
sensed by thermistors. The output of each thermistor
operating decisions are made here. It receives analog
is a DC voltage that is analogous to the temperature
and digital inputs from the chiller and remote de-
it is sensing. Typical output voltage range of both is
vices. The analog inputs are connected directly to the
0.5 to 4.5VDC. These are analog inputs to the Control
Microboard. The digital inputs are received via the I/O
Center.
Board (see description below). Under Program control,
Digital Inputs are on/off inputs to the Control Center the Microboard operates the relays and triacs that are
in the form of switch and relay contacts. These inputs located on the I/O Board.
are 115VAC when the contacts are closed and 0VAC
The control center could be equipped with either of the
when open. These include flow switches, local start/
following Microboards:
stop switch, remote cycling and high pressure safety
device, etc. • 031-01730-000 – Shipped in new production
JOHNSON CONTROLS 9
 System Architecture
FORM 160.80-M1 (307)

chillers until March 2004. The program resides in logic level voltages by Opto-Couplers. The relays have
a replaceable Flash Memory Card. The software +12VDC coils that are energized and de-energized by
version is C.MLM.03.xx.yzz. It is printed on a the Microboard. The contacts of these relays control the
label adhered to the card. The Program can be 115VAC system solenoids, relays and motor contactors.
upgraded by replacing the card. The triacs are turned on and off by the Microboard.
• 031-02430-000 – Shipped in new production A front panel-mounted Keypad allows Operator and
chillers after March 2004. The program resides Service Technician user interface. Membrane keys are
in non-removable onboard memory. The software used to display chiller and system parameters, enter
version is C.OPT.03.xx.yzz, and is viewable on the setpoints and perform chiller and Control Center diag-
DIAGNOSTICS Screen in SERVICE access level. nostics. It also contains a START-RUN-STOP/RESET
The Program can be upgraded by downloading a Switch that is used to locally start and stop the chiller
new program from a Program Card. Program Cards and perform manual reset functions.
are shirt-pocket-size portable memory storage de-
vices available from YORK. A front panel mounted liquid crystal Display allows
graphic animated display of the chiller, chiller subsys-
Since the newer version Microboard is backward com- tems and system parameters. The chiller and working
patible to earlier vintage Optiview Control Centers, components of the chiller are displayed, along with
earlier vintage chillers could be equipped with a later chiller operating pressures and temperatures. The Key-
version Microboard due to service replacement. pad is used to select displays showing increasing levels
of detail of chiller working components.
The software versions (C.MLM.03.xx.yzz or A self-contained Power Supply supplies the necessary
C.OPT.03.xx.yzz) are alphanumeric codes that are DC voltages for all the components within the Control
interpreted as follows. Each time the controls section Center.
or language section is revised, the respective revision
level increments. When the compressor motor is driven by an Electro-
Mechanical Starter, the Control center is equipped with
• C – Commercial chiller
a CM-2 Current Module. This printed circuit board
• MLM – Used on Microboard 031-01730-000 provides current overload and power fault protection
• OPT - Used on Microboard 031-02430-000 for the compressor motor. Current Transformers, located
• 03 – YS chiller in the compressor motor terminal box, along with recti-
• xx - controls revision level (00, 01, etc) fying and calibration circuitry, provide an analog volt-
age representing compressor motor current to the CM-2
• y – language package (0=English only, 1=NEMA, Module. This signal is further conditioned and provided
2=CE, 3=NEMA/CE ) to the Microboard.
• zz – language package revision level
(00, 01, etc) When the compressor motor is driven by the YORK
Solid State Starter, there could be either of two different
Throughout this book, reference is made to functions Solid State Starters applied. New production chillers are
and features that are only available in certain Flash equipped with the Mod “B” Solid State Starter. This
Memory Card revision levels (C.MLM.03.xx.xxx). To starter contains a combination Logic/Trigger Board that
cross reference C.MLM software to C.OPT software, interfaces the Microboard via a serial communications
refer to the controls revision level. Software version link. Earlier vintage chillers, such as those encountered
C.OPT.03.03A.xxx is of the same controls revision in Control Center retrofit applications, are equipped
level as C.MLM.03.03.xxx. From this starting point, with the Mod “A” Solid State Starter. This starter con-
both receive the same updates at each revision. Soft- tains a Trigger Board that interfaces to a Logic Board
ware upgrades should only be performed by a Service that is installed inside the Control Center. The Logic
Technician. Board interfaces the Microboard via a multiplexed data
interface.
The I/O Board acts as an input/output device for the
Microboard. It conditions the digital input signals for Serial data interface to the YORK ISN Building Auto-
the Microboard and contains relays and triacs that are mation System is through the optional MicroGateway,
controlled by the Microboard to control solenoids, mounted inside the Control Center. This printed circuit
motor contactors and actuators. The 115VAC digital board requests the required data from the Microboard
inputs from switch and relay contacts are converted to and makes it available for the ISN network.
10 JOHNSON CONTROLS
 RS-232 / RS-485 SERIAL DATA

+12 / -12 / +5 VDC POWER

CHILLER TEMPERATURES & PRESSURES
SUPPLY
SLIDE VALVE POSITION

JOHNSON CONTROLS
REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT + 24 VDC
SETPOINTS (0-20 mA, 4-20mA, 0-10VDC, 2 - 10 VDC)

BACKLIGHT
LAMP LAMP ADDRESS COMPRESSOR
INVERTER
CONTROL MOTOR
BOARD
CURRENT
LIQUID CM-2
CRYSTAL CURRENT
DISPLAY DISPLAY DATA
DISPLAY MODULE
INTERFACE MICRO BOARD
BOARD MULTIPLEXED DATA

ROW IN
KEYPAD COLUMN OUT

MOTOR CONTROLLER
SHUTDOWN TO I/O BOARD

I / O BOARD
TO STARTER
DIGITAL TRIAC RELAY
IN OUT OUT
COMPRESSOR
MOTOR START

REMOTE CYCLING STATUS / ALARM

HIGH PRESSURE SAFETY CHILLER SOLENOID VALVES
LOCAL START / STOP SWITCH
HOT GAS BYPASS (OPTIONAL)
CHILLED & CONDENSER WATER FLOW SWITCHES
VARIABLE ORIFICE
SEPARATOR OIL LEVEL SWITCH STATUS
MOTOR CONTROLLER SHUTDOWN OIL HEATER ON/OFF

REMOTE LEAVING CHILLED WATER TEMP & CURRENT CHILLED & CONDENSER WATER PUMP STARTERS
LIMIT SETPOINTS (PULSE WIDTH MODULATION)

SLIDE VALVE CONTROL

FIG. 1 – CONTROL CENTER - ELECTRO-MECHANICAL STARTER APPLICATIONS LD04954

11
FORM 160.80-M1 (307)

2
 RS-232 / RS-485 SERIAL DATA

12
+12 / -12 / +5 VDC POWER
CHILLER TEMPERATURES & PRESSURES
SUPPLY
SLIDE VALVE POSITION

REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT + 24 VDC

SETPOINTS (0-20 mA, 4-20mA, 0-10VDC, 2 - 10 VDC)
COMPRESSOR
MOTOR
System Architecture

BACKLIGHT CURRENT
LAMP LAMP
INVERTER ADDRESS
CONTROL
BOARD
TRIGGER
SOLID
LIQUID BOARD
STATE
CRYSTAL STATUS
DISPLAY DISPLAY DATA STARTER
DISPLAY INTERFACE LOGIC
MICRO BOARD BOARD TRIGGER
BOARD MULTIPLEXED DATA BOARD
CONTROL
ROW IN
KEYPAD COLUMN OUT

MOTOR CONTROLLER
SHUTDOWN TO I/O BOARD

I / O BOARD
DIGITAL TRIAC RELAY
IN OUT OUT
COMPRESSOR
MOTOR START

REMOTE CYCLING STATUS / ALARM

HIGH PRESSURE SAFETY CHILLER SOLENOID VALVES
LOCAL START / STOP SWITCH
HOT GAS BYPASS (OPTIONAL)
CHILLED & CONDENSER WATER FLOW SWITCHES
VARIABLE ORIFICE
SEPARATOR OIL LEVEL SWITCH STATUS
MOTOR CONTROLLER SHUTDOWN OIL HEATER ON/OFF
REMOTE LEAVING CHILLED WATER TEMP & CURRENT CHILLED & CONDENSER WATER PUMP STARTERS
LIMIT SETPOINTS (PULSE WIDTH MODULATION)

SLIDE VALVE CONTROL

FIG. 2 – CONTROL CENTER - MOD “A” SOLID STATE STARTER APPLICATIONS LD04955

JOHNSON CONTROLS
FORM 160.80-M1 (307)
 RS-232 / RS-485 SERIAL DATA

+12 / -12 / +5 VDC POWER

CHILLER TEMPERATURES & PRESSURES
SUPPLY
SLIDE VALVE POSITION
REMOTE LEAVING CHILLED WATER TEMP & CURRENT LIMIT

JOHNSON CONTROLS
SETPOINTS (0-20 mA, 4-20mA, 0-10VDC, 2 - 10 VDC)
+ 24 VDC

BACKLIGHT
LAMP LAMP COMPRESSOR
INVERTER
CONTROL MOTOR
BOARD
CURRENT &
SOLID
LIQUID LINE VOLTAGE
STATE
CRYSTAL DISPLAY STARTER
DISPLAY DATA
DISPLAY INTERFACE LOGIC/TRIGGER
MICRO BOARD BOARD SCR
BOARD SERIAL DATA CONTROL

ROW IN
KEYPAD COLUMN OUT

MOTOR CONTROLLER
SHUTDOWN TO I/O BOARD

I / O BOARD
DIGITAL TRIAC RELAY
IN OUT OUT
COMPRESSOR
MOTOR START

REMOTE CYCLING STATUS / ALARM

HIGH PRESSURE SAFETY CHILLER SOLENOID VALVES
LOCAL START / STOP SWITCH
HOT GAS BYPASS (OPTIONAL)
CHILLED & CONDENSER WATER FLOW SWITCHES
VARIABLE ORIFICE
SEPARATOR OIL LEVEL SWITCH STATUS
MOTOR CONTROLLER SHUTDOWN OIL HEATER ON/OFF

REMOTE LEAVING CHILLED WATER TEMP & CURRENT CHILLED & CONDENSER WATER PUMP STARTERS
LIMIT SETPOINTS (PULSE WIDTH MODULATION)

SLIDE VALVE CONTROL

FIG. 3 – CONTROL CENTER - MOD “B” SOLID STATE STARTER APPLICATIONS LD04956

13
FORM 160.80-M1 (307)

2
 System Architecture
FORM 160.80-M1 (307)

DISPLAY
MESSAGE

"SYSTEM RUN"

CHECK OIL
PRESSURE

"START SEQUENCE
INITIATED"
DISCHARGE
AUTO-ZEROING
SUPERHEAT
OIL FILTER
CHECK
AND DIFF. OIL
TRANSDUCERS

CHECK DIFFERENTIAL
OIL FILTER PRESS.

"SYSTEM SHUTDOWN"
2-MINUTE
FLOW SWITCH LOCKOUT
BYPASS DELAY

0 15 25 30 45 210 1800
START (0.25) (0.42) (0.5) (0.75) (3.5) (30)
RESTART
TIME IN SECONDS (MINUTES)

LD04957
FIG. 4 – OPERATION SEQUENCE TIMING DIAGRAM
(ELECTRO-MECHANICAL & SOLID STATE STARTER APPLICATIONS)

14 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

SECTION 3
MICROBOARD
031-01730-000
(REFER TO FIG. 5 - 10)

Microboard 031-01730-000 is supplied in new produc- There are two Flash Memory Cards available. The dif-
tion chillers until March 2004. ference between them is the different languages that can
be displayed on the Display Screens. Language selection
The Microboard contains the operating software (Pro- is performed on the USER Screen following instructions
gram), microprocessor (Micro), and supporting circuits in Operations Manual 160.80-O1. Not all languages
for the Micro. are available. Refer to Renewal Parts List 160.80-RP3
for list of available Flash Memory Cards and display 3
The Program is a set of instructions to control the languages. IMPORTANT! – Not all versions of Flash
chiller, the display and peripheral devices. It also Memory Cards are compatible with revision “E” (and
contains the Safety and Cycling shutdown thresholds later) Microboards or all BIOS Eproms. If an incompat-
(non changeable) and Display messages and screens. ible version is used, the initialization (boot-up) process
It is stored in a memory device called a flash memory will not complete and the chiller will not run! Refer to
card. This is a type of nonvolatile memory that can be Renewal Parts List 160.80-RP3 and “Service Replace-
read from or written to, but requires the locations to be ment” paragraph in this section.
erased before they are written to. With the exception of
a write/read sequence that occurs during the Boot-up The Micro controls the chiller by reading and executing
process explained below, this device is used primarily the Program instructions in a sequence determined by
as read-only in this application. A write protect switch the Program. Under Program control, the Micro reads
is located on the left edge of the card as shown in Fig. the Analog and Digital Inputs to determine the oper-
6. It must be placed in the “Write Enabled” position in ating conditions and controls Digital Outputs based
order to allow successful Boot-up. The card is located upon these inputs. These inputs are compared to stored
in socket location U46 (ref. Fig. 5). It connects to the thresholds to determine if a Safety or Cycling shutdown
Board via an Elastomeric connector that is a silicon rub- is required. If a threshold has been exceeded, a shutdown
ber strip embedded with silver conductors. The Card is performed and the appropriate message is retrieved
can be removed from its socket by using the thumb to from the Program and displayed on the Liquid Crystal
press down on the socket’s plastic tension spring. The Display. As operating conditions require, status mes-
card is installed by inserting it into the socket/holder and sages are retrieved and displayed. The Keypad is read as
pressing on the surface of the Card until it snaps into Digital Inputs. When an operator presses a key to request
place. The Memory card is a replaceable component. a display, the Micro interprets the request, retrieves the
Refer to YORK Renewal Parts List Form 160.80-RP3. display from the Program and displays it. The Program
The version of the Memory card is an alphanumeric assembles data in the correct format for transmission
code that represents the application and revision level. through the Serial Data Ports to peripheral devices. The
The version is printed on a label adhered to the memory Program also instructs the Micro to respond to requests
card’s surface. The version code is as follows: from peripheral devices for serial data transmissions.
C.MLM.nn.nn.nnn
The Watchdog circuit monitors the +5VDC supply from
Language Package Revision Level (00, 01, etc.)
Language Package* (0=English only, 1=NEMA 1-4,2=CE) the external Power Supply to determine when a power
Controls Revision Level (00, 01, etc.) failure is occurring. Just prior to the supply decreasing
Chiller Type (01=YK, 02=YT, 03=YS, 05=YR) to a level where the Micro and supporting circuits can no
MILLENNIUM Chiller longer operate, it applies a reset signal to the Micro.
Commercial Chiller
* Refer to YORK Renewal Parts List 160.80-RP3 for available lan- The Micro responds by de-energizing the run digital out-
guages.
put, shutting down the chiller and retrieving the Power
1 = Supplied in new NEMA 1-4 OptiView Control Centers but can
be retrofit to any OptiView Control Center. Failure message from the Program and sending it to the
2 = Supplied in new CE (European Community) OptiView Control Display Controller for display. Similarly, when power is
Centers but can be retrofit to any OptiView Control Center. first applied after a power failure, it maintains the Micro
in a reset state until the +5VDC has returned to a suffi-

JOHNSON CONTROLS 15
 Microboard
FORM 160.80-M1 (307)

cient level. The Watchdog circuit also assures that all the started. Depending upon the application, the Microboard
Program instructions are being performed and that the could be equipped with an EPROM that has either 128K,
Program has not latched-up, bypassing important safety 256K or 512K capacity. Microboard Program Jumper
thresholds. If the Program has latched-up, The Micro JP38 must be positioned according to the actual EPROM
initiates a Safety shutdown and displays WATCHDOG installed. Refer to Table 1 (Program Jumpers). There
– SOFTWARE REBOOT message. are 5 steps to the boot-up process. During the boot-up
process, there is a visual indication as each step is per-
The BIOS EPROM (basic input/output system erasable formed, followed by a Pass/Fail status of the step. On
programmable read only memory) is a memory device the Microboard, a green LED (CR17 - Pass) flashes to
that contains the bootstrap or power-up program. It is indicate the step was successful. If a step is unsuccessful,
located in socket location U45. This EPROM is replace- a red LED (CR18 - Fail) flashes and the Boot-up process
able. Refer to YORK Renewal Parts List Form 160.80- terminates. The execution and Pass/Fail status of steps
RP3. The EPROM version is an alphanumeric code that 3 through 5 are displayed on a white Keypad Display
represents the application and revision level. The version Screen as they are performed. This white display screen
is printed on a label adhered to the EPROM’s surface. also lists the BIOS EPROM Version. The steps of the
The version code is as follows: Boot-up process are as follows. Also, below is listed the
LED activity associated with each step.
C. MLM. 00. XX.
BOOT-UP STEP AND DESCRIPTION
Revision level. Increments 01, 02 etc. 1. First initiate table complete.
YS Chiller BIOS EPROM Registers in the Micro are configured to allow it to per-
form basic memory read/write functions.
MILLENNIUM Chiller
Commercial Chiller 2. FPGA configuration.
The Field Programmable Gate Array (FPGA) is con-
figured to process Digital Inputs and Outputs.
There are two different BIOS Eproms. Eprom 031-
01796-001 can only be used in revision “A” through 3. Mini-card signature test.
“D” Microboards. Eprom 031-01796-002, although it A location in the Flash Memory Card that contains a code
can be used in revision “A” through “D” Microboards, identifying the Manufacturer is compared to other locations
is required in revision “E” and later Microboards to that contain the manufacturer’s name. If these values are
support the use of either 65548 or 65550 Display Con- the same, it is pass. If they are different, it is fail.
trollers (U29). IMPORTANT! Eprom 031-01796-002 4. Mini-card checksum.
is NOT compatible with all versions of Flash Memory The Flash Memory Card checksum is calculated and
Cards. If an incompatible Flash Memory Card version is compared to the checksum value that is stored in the
used with this BIOS, the initialization (boot-up) process Card at the time the Card was initially programmed at
will not complete and the chiller will not run! (refer to the YORK factory. If both values are the same, it is
Renewal Parts List 160.80-RP3 and “Service Replace- considered pass. If the calculated value is different than
ment” paragraph in this section. the stored value, it is considered fail.
When power is applied to the Control Center following 5. BRAM quick test.
a power failure, the Micro executes the instructions in Test data is written to and then read from several memory
the BIOS EPROM program to initialize, configure and locations to verify BRAM operation.
start operation of certain Microboard components before
the main program (stored in the Flash Memory Card) is

16 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

LED INDICATORS determined by the YORK factory. Some jumpers are

plastic sleeves with metal inserts that are inserted over
When power is applied to the Control Center, both the 2-prong or 3-prong conductors. Others are wire bridges
red (CR18 - Fail) and green (CR17 - Pass) LEDs si- that are either cut or left in place. The Program Switches
multaneously illuminate for 1 second, then the Boot-up are miniature switches that are placed in either the ON
process begins in the following sequence. or OFF position.

STEP PASS FAIL Keypad Interface

Watchdog will The Keypad is read via J18. The Keypad is a matrix of
1 Green on, Red off
initiate a re-boot conductors arranged in rows and columns (ref fig 32
Boot-up process halts. and 33). There are 4 rows and 8 columns. When a key
2 Green flash once
One red flash repeating is pressed, the conductors are pressed together at that
Boot-up process halts. point, creating continuity between the row conductor and 3
3 Green flash once
Two red flashes repeating the column conductor. The keypad is read by applying
4 Green flash once
Boot-up process halts. a logic low to a row while leaving +5vdc pullup on all
Three red flashes repeating other rows. The micro then reads the 8 columns. If any
5 Green flash once
Boot-up process halts. column has a logic low on it, the key corresponding
Four red flashes repeating to that coordinate (row, column) is being pressed. The
micro reads the entire keypad by repeating this routine
When all steps have been completed, the LED's will beginning with row 1 and ending with row 4. The entire
then illuminate or extinguish, as long as power is ap- keypad is continually read while the control center is
plied, according to the settings of Microboard Programs powered. Refer to SECTION 8 of this manual for details
Switches 7 and 8 as follows: of the Keypad.

GREEN (CR17) CM-2 Board or Style A Solid State Starter Inter-

Program SW 7 set to ON - extinguishes face
OFF - illuminates The microboard retrieves certain operating parameters
(via J10) from the compressor motor starter control board
RED (CR18) (CM-2 Current Board for Electromechanical starter or
Program SW 8 set to Standard - illuminates Style “A” Solid State Starter Logic Board). Refer to the
Enhanced - extinguishes appropriate section of this book for detailed explanation
of each board. Both boards contain an 8 channel mul-
The BRAM (battery backed random access memory) is tiplexer. The micro sequentially and continually reads
a memory device that contains a battery that preserves channels 0 through 7. It reads each channel by applying a
the data during power failures. It is a replaceable part. 3-bit binary address to the multiplexer. A 0-5vdc analog
Refer to YORK Renewal Parts List Form 160.80-RP3. value is returned from each channel. The function of
It is located in socket location U52. The Micro stores each is in the table below. The micro determines which
the setpoints programmed by the Operator or Service board, and therefore which starter is present, by the value
Technician, History Data and other data that requires returned from channel 0. Since channels 0 through 6 are
preservation, in this device. Also, the day of week, time grounded, the CM-2 board returns a 0vdc value. The
of day and calendar date timekeeping are done here. Solid State Starter Logic Board returns a value >0.41vdc
to +5vdc. If the value is <0.4vdc, it indicates the starter
Program Jumpers/Program Switches is an Electro-mechanical (EM) starter and the micro then
The Program Jumpers (Table 1) and Program Switches reads channel 7 to retrieve the peak motor current value.
(Table 2) are used to alter the program operation or A value >0.4vdc indicates the starter is an “A” style Solid
configure the Microboard hardware for specific opera- State Starter and the micro reads channels 1 through 7.
tion. This allows the Program and Microboard to be In the Solid State Starter, channel 0 indicates the starter
universal for all standard applications. Refer to Table size (model) and voltmeter range (300Vac or 600Vac).
3 and 4 for the function of each jumper and switch. Channel 1 is a hardware generated 100% FLA (prevents
The position of some jumpers can be determined by pre-rotation vanes from further opening) or 104% FLA
the Service Technician to meet the desired operation. (closes pre-rotation vanes until motor current is <102%)
Others must be positioned according to the requirements current limit override command that overrides normal
of the size, type or style of components and thus are Pro-rotation Vanes control. Channels 2 through 4 are

JOHNSON CONTROLS 17
 Microboard
FORM 160.80-M1 (307)

analog voltages that represent phase A, B and C motor Digital Inputs

current. The highest phase is Channels 5 through 7 are The I/O Board converts the 115Vac inputs to logic
analog voltages that represent phase A, B and C Line level inputs for the microboard at J19. A 115Vac input
Voltage. The data for each channel is shown below: to the I/O board is converted to a logic low (<1Vdc).
A 0Vac input to the I/O Board is converted to a logic
The addresses and associated data are shown below.
high (>4Vdc). Refer to SECTION 4 of this manual for
Mod “A” details of the I/O Board.
CM-2 Board
Solid State Starter Logic Board
Address Data Address Data
Digital Outputs
starter model / The microboard controls 115vac relays and solenoids via
0 thru 6 Gnd 0 the I/O Board (via J19). The I/O Board contains +12Vdc
voltmeter range
1 current limit command relays that isolate the microboard low voltage circuits
Peak phase C, B, A from the 115Vac device coils. Solid state switching
2-4 devices are used to control the relays. The microboard
7 Motor motor current
Current phase A, B, C energizes the +12Vdc relays by applying a ground to
5-7 the coil input. They are de-energized by opening the
line voltage
ground path. The contacts of these relays switch 115Vac
Style B Solid State Starter Interface to system relays and solenoids. The outputs that control
If equipped with either of these drives, the drive is in- the chilled liquid pump and compressor motor starter
terfaced to the Microboard via the Opto-Coupled COM have anti-chatter (anti-recycle) timers associated with
5 serial data port (J15). The serial data is represented by them. The output that controls relay K0 is not allowed to
+5vdc and 0vdc logic levels. J15-1 is TX data to the drive change at a rate greater than once every 10 seconds. The
and J15-2 is RX data from the drive. Refer to SECTION output that controls relay K13 is not allowed to change
11 (Solid State Starter) for details of this interface. at a rate greater than once every 20 seconds.

Printer Interface The microboard controls Actuator motors via Triacs on

An optional Printer can be connected to COM1 RS-232 the I/O Board. Each actuator has an open winding and a
serial data port (J2). J2-4 is TX data to the printer. J2-2 is close winding. Current flowing through a winding causes
the DSR (Data Set Ready or busy) signal from the print- the actuator to rotate in the respective direction. Each
er. Signal levels are standard RS-232. The microboard winding is controlled by a Triac. The Triac is turned on to
sends data to the printer at the selected baud rate until allow current to flow through a winding. The microboard
the printer buffer becomes full, whereupon the printer turns on the Triac by applying a logic low (<1Vdc) to
asserts its Busy signal. The microboard suspends data the Triac driver on the I/O Board. It turns it off by ap-
transmission until the printer can accept more data. Each plying a logic high (>4vdc). Refer to SECTION 4 of
printer must be setup/configured to operate properly with this manual for details of the I/O Board.
the microboard. The Baud, Data Bits, Parity and Stop
Bits must be programmed on the Comms Screen. Other Analog Inputs
printer setup is performed on the PRINTER Screen. Re- System pressures, in the form of analog DC voltages,
fer to YORK manual 160.80-O1 for details of available are input from Pressure Transducers. Refer to SECTION
printers and printer setup instructions. 16 of this manual. Formulas and graphs are included to
calculate the expected transducer output voltage for a
MicroGateway Interface given pressure input.
An optional Microgateway printed circuit board can
System temperatures, in the form of analog DC volt-
be connected to the COM 4B RS-232 serial data port
ages, are input from Thermistors. Refer to SECTION
(J2). J2-7 is TX data to the MicroGateway. J2-6 is RX
17 of this manual. Included are tables to convert the
data from the Microgateway. Signal levels are standard
expected output voltage for any temperature applied to
RS-232. The MicroGateway polls system pressures,
the thermistor.
temperatures and status from the microboard. It holds
it for retrieval by third-party devices. Refer to SECTION
15 of this manual.

18 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

Serial Data Ports of the gradient of red, green and blue light allowed to
The Microboard is equipped with 5 serial data ports (ref pass. The drive signal for each pixel is an 18 bit binary
fig 11). Each port is dedicated for a specific function as word; 6 for each of the 3 colors. The greater the binary
follows: value, the more light is permitted to pass. The pixels are
driven sequentially from left to right, beginning with
a. COM1 (J2) – RS-232. Printer the top row. To coordinate the drive signals and assure
b. COM2 (J13) – RS-232. Not used the pixels in each row are driven from left to right and
c. COM3 (J12) – RS-485. Optional I/O. the columns are driven from top to bottom, the drive
d. COM4 (4A-J11), (4B-J2) – This port is actually two signals are accompanied by a clock and horizontal and
ports. However, they cannot be used simultaneously. vertical sync signals.
The position of program jumper JP27 determines
which port can be used. (refer to table 3). COM4A– During the boot-up, the program in the BIOS eprom
reads wire jumpers PID0 through PID3 on the Display 3
RS485 Not used. COM4B – RS-232 Microgateway.
Interface Board to determine the manufacturer of the
e. COM5 (J15) – Opto-coupled transmit/receive. Style display. Each display manufacturer requires a slightly
B Solid State Starter. different control. The program in the BIOS eprom
configures the microboard for correct operation for the
Each port is equipped with two LED’s. A red TX LED actual display installed.
illuminates as data is transmitted to or requested from
another device. A green RX LED illuminates as data Different display manufacturers require different supply
is received from another device. The RS-232 voltages and control voltages for their displays and backlights.
are industry standard +5 to +25vdc and -5vdc to -25vdc Program Jumpers JP2 through JP5 and JP7 and JP8 must
logic levels. The RS-485 voltages are industry standard be configured to provide the required supply and control
0vdc and +1.5 to +5vdc logic levels. COM5 logic levels voltages to the display and backlight control. Table 3 lists
are 0vdc and +5vdc. A diagnostic test can be performed the required program jumper configuration for each dis-
on each serial port to confirm proper operation. Refer to play. Also, a label attached to the display mounting plate
Diagnostics SECTION 23 of this manual. lists the required program jumper configuration for that
display. The position of program jumper JP2 determines
The LED’s and their functions are as follows: whether the supply voltage is +5vdc or +3.3vdc.
• CR2 RX1 – COM1 serial port receive data.
• CR3 TX1 – COM1 serial port transmit data. The microboard controls the Display Backlight via J6.
• CR12 TX4 – COM4 serial port transmit data. The Display Backlight is the light source for the display.
• CR13 RX4 – COM4 serial port receive data. The Backlight Inverter Board provides a high voltage
• CR15 TX3 – COM3 serial port transmit data. AC power source for the lamp. It converts low voltage
• CR14 RX3 – COM3 serial port receive data. DC via J6-1 (+12vdc or +5Vdc, depending on position
• CR11 RX2 – COM2 serial port receive data. of Program Jumper JP5) to high voltage AC (500 to
• CR16 TX2 – COM2 serial port transmit data. 1500Vac). This high voltage AC is applied to the lamp
• CR10 RX5 – COM5 serial port receive data. to cause it to illuminate. The Backlight is turned on
• CR9 TX5 – COM5 serial port transmit data. and off with the “Backlight Enable” signal (J6-5). The
position of Program Jumper JP4 determines whether
Display Interface this is a +12Vdc or +5vdc signal. In some displays, the
The graphic screens displayed on the liquid Crystal Dis- backlight turns on when this signal transitions from low
play are created from the program downloaded from the to high; others turn o when it transitions from high to
Program Card and stored in the flash memory chip. The low. The position of Program Jumper JP3 determines the
data to form these screens is output from J5. This data is transition that will occur when the Microboard outputs
in the form of red, green and blue drive signals applied the Backlight Enable signal. JP3 must be positioned ac-
to each of the 303,200 the display pixels arranged in a cording to the display manufacturer’s requirement.
matrix of 640 columns x 480 rows. Each pixel consists
of 3 windows; red, green and blue, through which a Under program control, the microboard controls the
variable amount of light from the Display Backlight, is backlight brightness via the Lamp Dimmer circuit
permitted to pass to the front of the display. The drive output at J6-7. In order to extend the life of the Back-
signals determine the amount of light permitted to pass light lamp, the brightness is driven to 50% after 10
through each window. The overall pixel color is a result minutes of Keypad inactivity. At this brightness level,

JOHNSON CONTROLS 19
 Microboard
FORM 160.80-M1 (307)

the graphics are still visible. When Keypad activity is Power Supply
detected (a key is pressed), the lamp is driven back to The Microboard receives 3 supply voltages (Microboard
full (100%) brightness. Some display manufacturers J1) from the Power Supply; +12VDC, -12VDC, +5VDC
require a variable voltage to vary the brightness; others and Ground. The -12VDC and +12VDC are used directly
require a variable resistance. Program Jumpers JP7 and by various circuits. The +12VDC and +5VDC are input
JP8 must be configured to enable the appropriate tech- to Voltage Regulators to derive other regulated volt-
nique. The Lamp Dimmer is an integrated circuit that ages. The +5VDC (fused by 5 Amp fuse F1 on rev “E”
is the electrical equivalent of a 10K ohm potentiometer and later boards) is input to a +3.3VDC regulator. The
with 100 positions or steps (ref fig 10A). The Lamp output is a 3.3VDC regulated voltage. The +12VDC
Dimmer controls the position of the potentiometer. The (fused by 5 Amp F2 on rev “E” and later boards) is input
lamp Dimmer varies the brightness of the backlight by to a 5VDC regulator. The output of this regulator powers
applying a variable voltage (0-5.0vdc) or a variable re- only the Analog circuits. This includes the MUX, A/D
sistance (0-10K ohms) to the Backlight Inverter Board. converter, CM-2 module, Solid State Starter (Mod “A”)
If Program Jumpers JP7 and JP8 are installed, the Logic Board, Transducers and Thermistors. As depicted
lamp Dimmer output is a variable voltage; if both are on Fig. 5, these voltages can be monitored at Test Posts
removed, the output is a variable resistance. The Lamp TP1 through TP6.
Dimmer outputs “Brightness Control Wiper” (J6-7) to
the Backlight Inverter Board. If configured for variable Service Replacement
voltage output, the voltage between J6-7 and J6-8 can Replacement part number 331-02430-603 is supplied
be varied from 0Vdc (100% brightness) to 5.0Vdc (0% as service replacement for microboard 031-01730-000.
brightness). If configured for variable resistance, the Refer to Section 3A of this manual and Replacement
resistance between J6-6 and J6-7 varies from 0 ohms Parts List 160.80-RP3 Replacement part 331-01730-603
(0% brightness) to 10K ohms (100% brightness). (microboard 031-01730-000) is no longer available.

Refer to Display SECTION 5, 6 and 7 of this manual

for details of the display interface.

Revision “A” through “D” Microboards are equipped with

Display Controller (U29) type 65548. Revision “E” and
later boards could be equipped with either a 65548 or
65550 Display Controller. To accommodate the use of
either device, BIOS Eprom part number 031-01796-002
is required on revision “E” and later Microboards. Also,
Program Jumpers JP43 and JP44 (refer to Table 1) must
be configured according to the actual Display Controller
installed on the board. These jumpers are positioned ap-
propriately at the time the board is manufactured and
should not require field configurationn
Remote Setpoints
Remote Leaving Chilled Liquid temperature and Cur-
rent Limit setpoints can be input via the RS-232 Micro-
gateway interface at J2 or directly to the Microboard at
J22 (ref fig 12). The inputs at J22 are configured with
Program Jumpers JP23 and JP24 to accept these inputs
in either 0-10vdc, 2-10vdc 0-20Ma or 4-20Ma form.
Refer to Table 3 for Program Jumper configurations and
SECTION 18 of this manual for details of the Remote
Setpoints.

20 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

This page intentionally left blank.

JOHNSON CONTROLS 21
 Microboard
FORM 160.80-M1 (307)

LD07786

FIG. 5 – MICROBOARD 031-01730-000

22 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

MEMORY CARD SOCKET

ELASTOMERIC MEMORY CARD -
CONNECTOR
TOP SURFACE

AUGAT R
AUGAT R

LD04958

TOP SURFACE

PRESS DOWN LD04047 MEMORY CARD

TO RELEASE CARD RETAINER CLIP

MEMORY CARD - BOTTOM SURFACE

WRITE PROTECT SWITCH (OPTIONAL)

(MUST BE IN "ENABLED POSITION")

PAD 60 PAD 31

PAD 30 PAD 1

VCC CINS GND

3V/5V ALIGNMENT
KEY NOTCH

LD04049

MEMORY CARD - SIDE VIEW

WRITE ENABLED

WRITE DISABLED
LD04050

FIG. 6 – FLASH MEMORY CARD

JOHNSON CONTROLS 23
 Microboard
FORM 160.80-M1 (307)

TP4
Y + 12VDC
*
+ 12VDC F2 VOLTAGE
5A + 5VDC (ANALOG)
FROM REG
POWER TP3 Y + 5VDC (DIGITAL)
SUPPLY *
+ 5VDC F1 VOLTAGE TP2 Y
+ 3.3VDC
5A REG

TP1
GND Y

* Rev "E" and later boards only

LD09475

FIG. 7 – MICROBOARD
(031-01730-000) POWER SUPPLY TEST POINTS

24 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

TABLE 1
MICROBOARD 031-01730-000 PROGRAM JUMPERS

MICROBOARD PROGRAM JUMPERS JP5 - Display backlight power. Determines the power
supply voltage applied to the Display Backlight
JP1 - Watchdog enable/disable. The position of this Inverter Board.
jumper, in conjunction with Program switch SW Pins 1-2: +12VDC. SHARP LQ10D367 and
1 position 12 enables or disables the program LQ10D421, NEC NL6448AC33-24 and LG
Watchdog protection. Semicon LP104V2-W displays.

Never disable the watchdog protection. Pins 2-3: +5VDC. Not Used
Severe compressor or chiller damage 3
JP6 - Display memory type. Jumper must be po-
could result. The ability to disable the
sitioned according to type of RAM used for
watchdog protection is provided for display memory devices (U25 & U27).
factory testing only!!!
IN - EDO: (extended data out) type. Jumper
IN - Watchdog protection enabled. should be IN.
OUT - FPM: (fast page mode) type. Not used
OUT - Permits Program switch SW1 position 12 to at this time.
enable or disable the program
JP7, JP8 - Display brightness control technique. Deter-
Watchdog protection as follows:
mines whether the display brightness is controlled
Position 12 ON - Watchdog protection enabled
by a variable voltage or variable resistance.
OFF - Watchdog protection disabled
IN: Variable voltage (0-5.0VDC). SHARP
JP2 - Display power and logic levels. Determines the LQ10D367, LQ10D421 and LG Semicon
power supply voltage applied to the display. LP104V2-W displays.
Pins 1-2: +5VDC SHARP LQ10D367 and OUT: Variable resistance. NEC
LQ10D421 displays. NL6448AC33-24 display.

Pins 2-3: +3.3VDC NEC NL6448ACCC33-24 JP9 - JP20 - Not Used

and LG Semicon LP104V2-W displays.
JP21 - Configurable Analog input (J7-2 & J7-14) type.
JP3 - Display backlight enable signal level polarity. Configures analog input for 0-10VDC, 4-20mA,
Jumper must be positioned according to the thermistor (temperature) or transducer (pressure)
voltage level required to turn on the Display input.
Backlight.
OUT: Allows a 0-10VDC input on J7-2 or a
Pins 1-2: 0VDC SHARP LQ10D421 Display. transducer input on J7-14.
Pins 2-3: +12VDC or +5VDC as determined Pins 1-2: Allows a 4-20mA input on J7-14.
by position of JP4. SHARP LQ10D367, NEC Pins 2-3: Allows a thermistor input on J7-14.
NL6448AC33-24 and LG Semicon LP104V2-
W displays. JP22 - Configurable Analog input (J7-4 & J7-16) type.
Configures analog input for 0-10VDC, 4-20mA,
JP4 - Display backlight enable signal logic levels. thermistor (temperature) or transducer (pressure)
Determines the logic levels of the Backlight input.
enable signal.
OUT: Allows a 0-10VDC input on J7-4 or a
Pins 1-2: +12VDC/0VDC SHARP LQ10D421 transducer input on J7-16.
display.
Pins 1-2: Allows a 4-20mA input on J7-16.
Pins 2-3: +5VDC/0VDC SHARP LQ10D367,
NEC NL6448AC33-24 and LG Semicon Pins 2-3: Allows a thermistor input on J7-16.
LP104V2-W displays.

JOHNSON CONTROLS 25
 Microboard
FORM 160.80-M1 (307)

JP23 - Remote Current Limit Setpoint (J22) type. Con- JP32 - PC-104 Port DMA acknowledge assignment.
figures analog input for 0-10VDC, 2-10VDC, Assigns selected PC-104 DMA acknowledge
0-20mA or 4-20mA. to PDACK0 on the microprocessor. DMA ac-
OUT: Allows a 0-10VDC or 2-10VDC input on knowledge selections are silk screened on the
J22-1 Microboard adjacent to the program jumper. Not
used on YS Chiller applications.
Pins 1-2: Allows a 0-20mA or 4-20mA input on
J22-2 JP33 - PC-104 Port DMA acknowledge assignment.
Assigns selected PC-104 DMA acknowledge
Pins 2-3: Not Used to PDACK1 on the microprocessor. DMA ac-
JP24 - Remote Leaving Chilled Liquid Temp Setpoint knowledge selections are silk screened on the
(J22) type. Configures analog input for Microboard adjacent to the program jumper. Not
0-10VDC, 2-10VDC, 0-20mA or 4-20mA. used on YS Chiller applications.
OUT: Allows a 0-10VDC or 2-10VDC input JP34 - Refrigerant type. Jumper must be positioned
on J22-3 according to the refrigerant type installed in the
chiller.
Pins 1-2: Allows a 0-20mA or 4-20mA input on
J22-4 IN: R22
Pins 2-3: Not Used OUT: R134a
JP25, JP26 - Not Used JP35 - Water/Brine application. Jumper must be posi-
tioned according to whether the chiller is cooling
JP27 - COM 4 serial communications port. Configures water or a brine solution.
COM 4 port to be either RS-485 for Multi-Unit IN: Water. Leaving chilled liquid temperature
Communications (COM 4A) or RS-232 for setpoint range 38°F (36°F if Smart Freeze is
GPIC board (COM 4B). enabled) to 70°F.
Pins 1-2: Enables port 4A. Allows an RS-485 OUT: Brine. Leaving chilled liquid temperature
connection to Microboard J11 for Multi-Unit setpoint range 20°F to 70°F.
Communications.
JP36, JP37 - Not Used
Pins 2-3: Enables port 4B. Allows an RS-232
connection to Microboard J2 for GPIC commu- JP38 - BIOS EPROM U45 size. Jumper must be posi-
nications. tioned according to size of U45. Jumper is a 10
Ohm resistor that is soldered to board. It is not
JP28 - PC-104 Port interrupt assignment. Assigns se- a shunt jumper.
lected PC-104 interrupt request to PIRQ7 on the IN: 256K
microprocessor. Interrupt request selections are
silk screened on the Microboard adjacent to the OUT: 64K or 128K. Should be OUT for YS
program jumper. Not used on YS chiller appli- chiller applications.
cations. JP39 - Solid State Starter style.
JP29 - PC-104 Port interrupt assignment. Assigns se- IN: Mod “A” Starter - Old style with Logic
lected PC-104 interrupt request to PIRQ6 on the Board mounted in Control Center.
microprocessor. Interrupt request selections are OUT: Mod “B” Starter - New style with inte-
silk screened on the Microboard adjacent to the grated Logic/Trigger Board mounted Starter
program jumper. Future modem application. cabinet.
JP30 - PC-104 Port DMA assignment. Assigns selected JP40, JP41, JP42 - Not Used
PC-104 DMA request to PIRQ0 on the micropro-
JP43, JP44 - Display Controller (U29) type (rev “E”
cessor. DMA request selections are silk screened
and later boards only). Must be positioned ac-
on the Microboard adjacent to the program jumper.
cording to the Display Controller type installed
Not used on YS Chiller applications.
on Microboard. Configured at the time the
JP31 - PC-104 Port DMA assignment. Assigns selected board is manufactured and should not require
PC-104 DMA request to PIRQ1 on the micropro- field configuration.
cessor. DMA request selections are silk screened
on the Microboard adjacent to the program jumper. Pins 1-2: Type 65548
Not used on YS Chiller applications. Pins 2-3: Type 65550
26 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

TABLE 2
MICROBOARD 031-01730-000 PROGRAM SWITCHES

SW1 7- Not Used

1- Not Used
8- Chilled Water Pump operation - Determines
2- Not Used Chilled Water Pump control contacts (I/O Board
TB2-44/45) operation when chiller shuts down
3- Not Used on various CYCLING shutdowns.
4- Diagnostics - Enables or disables software diag- ON: Enhanced operation. Contacts open at 3
nostics completion of System Lockout Delay after
ON: Enables software diagnostics. Disables all shutdowns except when it shuts down on
normal chiller operation “LEAV ING CHILLED LIQUID - LOW
TEM PER A TURE”, “MULTI-UNIT CY-
OFF: Disables software diagnostics. Enables CLING - CONTACTS OPEN” AND “SYS-
normal chiller operation. TEM CYCLING - CONTACTS OPEN”.
5- Auto-restart - Determines the course of action OFF: Standard operation. Contacts open at
required to restart the chiller, if a power failure completion of System Lockout Delay after
occurs while the chiller is running. all shutdowns except when chiller shuts down
on “LEAVING CHILLED LIQUID - LOW
ON: Chiller will automatically restart when TEMPERATURE”. On Low Water temp shut-
power is restored. downs, they remain closed, causing the pump to
OFF: Requires a manual reset after power is continue to run while the chiller is shutdown.
restored. The chiller will not start until the op-
erator moves the keypad START-RUN-STOP/ 9- Not Used
RESET rocker switch to the STOP/RESET
position. If in LOCAL mode, the chiller can 10 - Not Used
then be restarted by initiating a local start. If in
REMOTE mode, the chiller will restart upon 11 - Not Used
receipt of a remote start signal.
12 - Watchdog Protection -Used in conjunction with
6- Anti-recycle - Enables or disables the anti-recy- Program Jumper JP1 (see above) to enable/dis-
cle timer. able the program watchdog protection. With JP1
IN, this switch setting has no effect. With JP1
The anti-recycle timer must OUT, this switch setting determines whether the
NEVER be disabled unless it watchdog protection is enabled or disabled.
is absolutely necessary to do so
during troubleshooting. NEVER disable the watchdog
protection! Severe compressor
or chiller damage could result.
ON: Enables anti-recycle timer. Solid State The ability to disable the watch-
Starter and Electro-Mechanical starter appli-
dog protection is provided for
cations - Chiller cannot be started at intervals
YORK factory testing only.
shorter than once every 30 minutes.
OFF: Disables anti-recycle timer. Chiller can be
started at the completion of SYSTEM LOCK- ON: Watchdog protection enabled.
OUT DELAY, regardless of how long the chiller OFF: Watchdog protection disabled.
had been running.

JOHNSON CONTROLS 27
 Microboard
FORM 160.80-M1 (307)

5.0 VDC

J6
JP8

6 BRIGHTNESS CONTROL (+) OR (N.C.)

TO
10 K 7 BRIGHTNESS CONTROL (WIPER)
BACKLIGHT
INVERTER
BOARD

8 BRIGHTNESS CONTROL (-)

JP7 LD04054

NOTES:
1. J6-6 not connected (N.C.) to Backlight Inverter Board when display is manufactured by Sharp or NEC.
2. The position of Program Jumpers JP7 & JP8 determine the output at J6-7; In = Variable Voltage; Out = Variable Resistance. Refer to Program
Jumper Listing in Table 1 for applications.
3. Potentiometer is actually an integrated circuit that is the electrical equivalent of a 10K potentiometer.

FIG. 8 – MICROBOARD LAMP DIMMER CIRCUIT

28 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

CR3 CR2
R G
TX1 RX1
RS-232 J2
TX 4
RX 3 PRINTER
MICRO COM 1 DTR 5
DSR 2

COM 4B GTX 7
(NOTE 1) GRX MICROGATEWAY
6
8
CR12 CR13 9
R G
TX4 RX4
RS-485
+
J11 3
3
3
JP27 COM 4A NOT USED
MULTI-UNIT
-- 2
2 1 (NOTE 1) COMMS
+ 5VDC 1
GND
4
SHIELD
CR16 CR11 5
R G
TX2 RX2

RS-232 J13
DCD 1
DSR 2
RX 3
RTS NOT USED
4
COM 2 TX 5
CTS 6
DTR 7

CR15 CR14 GND 9

R G
UART TX3 RX3

RS-485 J12
+ 3
-- 2
+ 5VDC
OPTIONAL I/O
COM 3 1
GND 4
SHIELD 5

CR9 CR10
R G
TX5 RX5

OPTO-COUPLE
J15
TX
1
RX MOD "B"
2
COM 5 COMMON
3
SOLID STATE
NOTE 2 STARTER
4
NOTE 2
5
6

LD07788

NOTES:
1. Microboard Program Jumper JP27 determines whether COM 4A or 4B can be used. 1 & 2 - 4A, 2 & 3, 4B. Refer to Table 1.
2. J15-4 Loop-Around Test IN. J15-5 Loop-Around Test OUT. Refer to Fig. 55 for details.

FIG. 9 – MICROBOARD SERIAL DATA COMMUNICATIONS PORTS

JOHNSON CONTROLS 29
 Microboard
FORM 160.80-M1 (307)

J7
71.5 K
TRANSDUCER 0 10 VDC 2
OR THERMISTOR
NOT USED 14 2
4 - 20 MA 1 47K

1 JP21
+5V 3

13
7.5 K 200

TRANSDUCER 0-10 VDC 4

OR THERMISTOR
NOT USED 2
16 1
4 - 20 MA
15 JP22
+5V 3

MUX
J22
REMOTE CURRENT 0-10 VDC / 1
LIMIT SETPOINT 2-10 VDC
2 2 1
0 - 20 MA /
4 - 20 MA
3 JP23

REMOTE LEAVING 0-10 VDC / 3

CHILLED LIQUID 2-10 VDC
TEMP SETPOINT
0 - 20 MA / 4 2 1
4 - 20 MA
3 JP24

REMOTE SETPOINT 5
GND CONNECTIONS

LD04636

NOTE:
1. Program Jumpers JP21 – JP24 must be positioned on pins 1-2 or 3-4 according to input signal type. Refer to Table 1.

FIG. 10 – CONFIGURABLE ANALOG & REMOTE SETPOINT INPUTS

30 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

SECTION 3A
MICROBOARD
031-02430-000
(REFER TO FIG 5A – 10A)
Beginning March 2004, new production YS chillers will Boot-up Program
be supplied with Microboard part number 031-02430- The BIOS (Basic Input Output System) Eprom (U37)
000 (ref fig 5A). Although this board uses a different contains the boot-up program. It is a replaceable part.
microprocessor and supporting components, chiller con- The YORK part number is 031-02429-001. It is avail-
trol and operator interface are the same as the previous able from the Baltimore Parts Distribution Center as a
031-01730-000 Microboard. It uses the same mounting replacement part. The version is an alphanumeric code
hole pattern and has the same interface connectors as the that identifies the application and the program revision 3A
previous board, making it backward compatible to all level. The part number and version are printed on a
previous YS Optiview Control Centers equipped with label adhered to the surface of the Eprom. It is also
the 031-01730-000 Microboard. displayed on the DIAGNOSTICS Screen in Service
Access Level.
The board is supplied with +12vdc (J1-3), -12vdc (J1-4),
+5vdc (J1-1) and ground (J1-2) from the Power Supply The version is as follows:
(ref fig 9A). The -12vdc is not used. The +5vdc (fused by
C. OPT. 00. NN.
F1) can be monitored at TP3. It is applied to a +3.3vdc
regulator, +2.5vdc regulator and used directly by the
microboard circuits as the Vcc voltage. The outputs Revision level. Increments 01, 02 etc.
of these regulators are applied to microboard circuits BIOS EPROM
and can be monitored at TP2 and TP5 respectively.
Optiview Control Center
The +12vdc (fused by F2) can be monitored at TP4.
It is applied to a +5vdc regulator and used directly by Commercial chiller
microboard circuits. The output of the regulator is the
+5vdc (analog) supply that powers all analog circuits and When power is first applied to the Optiview Control
is the source voltage for all transducers and thermistors. Center, a white screen is displayed while the boot-up
It can be monitored at TP10 as a 2.5vdc value created by is performed. During the boot-up, the program in the
1K Ohm resistors voltage divider circuit as shown. BIOS Eprom configures the microprocessor and related
components and performs testing of certain components
Test Points (Ref Fig 7A) to assure those components are operational.
The power supply voltages can be measured at following
test points: The sequence of events in the boot-up process are listed
in the table below. The progress and pass/fail status of
TP1 Gnd each step is displayed on the microboard 7-segment
TP2 +3.3Vdc LED Display (U22 ). Due to the speed at which the
TP3 +5Vdc boot-up proceeds, not all steps will be visible during
TP4 +12Vdc the process. Not all pass/fail status is displayed on the
TP5 +2.5Vdc white screen.
TP10 +2.5Vdc

JOHNSON CONTROLS 31
 Microboard
FORM 160.80-M1 (307)

DIAGNOSTIC DISPLAY CODES

PASS DISPLAY ON
TEST FAIL ACTION
CODE WHITE SCREEN

First init table complete 00 watchdog will cause reboot No

SDRAM regs. Configured 01 watchdog will cause reboot No
Switch to Protected Mode 02 watchdog will cause reboot No
Jump to 32-bit code 03 watchdog will cause reboot No
Low memory test start 04 watchdog will cause reboot No
Low memory test complete P1 “F1” on display and halt No
Full memory test complete P2 “F2” on display and halt No
FPGA configuration 05 “P2” will remain on LED display No
Display Cont. configured 06 “05” will remain on LED display No
Flash Checksum Test P3 “F3” will remain on LED display Yes
BRAM test P4 “F4” will remain on LED display Yes
Flash Query Test “passed” “failed” and halt Yes
Flash checksum “passed” “failed”,halt & display code = F3 Yes
BRAM Test “passed” “failed” and halt Yes
MISCELLANEOUS CODES
LED DISPLAY CODE Description
FF FPGA Configuration Failed, trying again
CH Flash Checksum Test in progress
AP Application setup in progress
CRITICAL CODES
LED DISPLAY CODE Description
Ni NMI handler invoked (should never occur)
[] GPF has occurred (should never occur)

Chiller Operating Program Program Card

The Chiller Operating Program is a set of instructions The on-board program can be upgraded by downloading
to control the chiller. It contains the Safety and Cycling the latest program version from a Program Card. This
shutdown thresholds (non-changeable) and display is a 2 1/8 x 3 3/8 x 1/8 inch plastic card weighing 1.1oz
screen messages and graphics. (ref fig 6A). It is a portable memory storage device that
is programmed with the chiller operating program. The
The chiller operating program is stored in a non-remov- Program Card part number for YS chillers is 031-02488-
able Flash Memory chip (U35) that is soldered to the 001 and is available from the Baltimore Parts Distribu-
Microboard. New chillers are supplied programmed with tion Center (PDC). There is a Program Card for each
the latest program available at the time of manufacture. chiller type (YT, YK, YS, YR, YD, etc) and each has a
The program version that is currently residing in the unique part number. A label affixed to the Program Card
Microboard Flash Memory chip is displayed on the contains the part number and version. The version is an
DIAGNOSTICS Screen in Service Access Level. alpha-numeric code that identifies the chiller model ap-
plicability, language package, language package revision
The on-board program can be upgraded by downloading level and chiller operating program revision level.
the latest version from a Program Card using the proce-
dure in the Service Replacement section of this book.

32 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

The Program Card is applicable to both NEMA and The Program card is inserted into connector U33 to
CE applications. The Program Card for YS chillers has download a program. Refer to instructions under Ser-
English, Simplified and Traditional Chinese, French, vice Replacement below.
Spanish, Portuguese, Italian, German and Hungarian
languages. Program Download Connector U33
A Program Card is inserted into connector U33 to down-
The program version that is currently residing in the load a program. A protective cover prevents dirt from
Microboard Flash memory chip is displayed on the DI- entering this connector. IMPORTANT! The protective
AGNOSTICS Screen in Service Access Level. cover must be in place at all times when not performing
a program download. If dirt accumulates inside this con-
The Program Card obtained from the PDC is pro- nector, re-programming will not be successful.
3A
grammed with the latest version of the chiller operating
program. Program Cards can be reprogrammed. Parallel Port Connector
Parallel port connector J4 is for future use. It is presently not
A Program Card for a particular chiller type can be supported.
used to re-program other chillers of the same type. For
example, it is not necessary to have more than one YS BRAM (U38)
Program Card. A single YS card can be carried to differ- The BRAM (battery backed random access memory)
ent locations to re-program other YS Optiview Control memory device contains a battery that preserves the
Centers. stored data during power failures. All of the programmed
Setpoints, Sales Order Data, History Data, time of day
A Write Protect Switch on the edge of the Program Card and calendar data is stored here. It is a replaceable part.
prevents inadvertent writing to the Card during program The YORK Part number is 031-02431-000 and is printed
downloading. on a label adhered to the surface of the BRAM. It is
available from the Baltimore Parts Distribution Center
Handling precautions for the Program Card include: as a replacement part.
• Do not allow dirt to enter connector
• Carry in protective sleeve Watchdog Circuit
• Storage temperature range is -20 to 65ºC (-4 to The Watchdog circuit performs two functions as fol-
149ºF) lows:
• Power failure detection
A label adhered to the Program Card contains the ver- • Program latch-up detection/prevention
sion and YORK part number. The version is an alphanu-
meric code that identifies the chiller model applicability, The Watchdog circuit monitors the +5vdc from the
language package, language revision level and chiller power supply and the +3.3vdc from the onboard regu-
control revision level. The version is as follows: lator to determine when a power failure is occurring.
If the +5vdc decreases to the threshold of (+4.75vdc
to 4.5vdc) or the +3.3vdc decreases to the threshold of
C.OPT.nn.nn.nnn (3.04 to 2.8vdc), a reset is issued to the microprocessor
Language Package revision level and the chiller shuts down. When power is restored,
(00,01,etc)
the white screen is displayed and the boot-up is per-
Language Package (0=English
formed as described above. When the graphic screen is
only,1=NEMA,2=CE,3=NEMA/
CE) displayed, the message “Control Panel – Power failure”
Controls Revision Level (00, 01,
is displayed.
02, etc)
Chiller Model (01=YK, 02=YT, The Watchdog Circuit also assures that the entire pro-
03=YS, 05=YR, 11=YD) gram is being executed and that the program has not
Optiview Control Center latched-up, bypassing important safety checks. The
Commercial Chiller
Watchdog circuit is a timer that times-out if not given a
reset pulse within its time-out period (1 - 2.25 seconds).
To prevent a time-out, the microprocessor sends a reset

JOHNSON CONTROLS 33
 Microboard
FORM 160.80-M1 (307)

pulse to the Watchdog circuit every time the complete Keypad Interface
program has been executed. Since it takes less than 1 The Keypad is read via J18. The Keypad is a matrix of
second to perform the entire program, the Watchdog conductors arranged in rows and columns (ref fig 30
circuit doesn’t time-out under normal operation. How- and 31). There are 4 rows and 8 columns. When a key
ever, if the entire program is not executed or something is pressed, the conductors are pressed together at that
prevents the microprocessor from sending the reset pulse point, creating continuity between the row conductor and
as described below, the Watchdog circuit times-out and the column conductor. The keypad is read by applying
sends a reset to the microprocessor, initiating a re-boot. a logic low to a row while leaving +5vdc pullup on all
If running, the chiller shuts down. The display momen- other rows. The micro then reads the 8 columns. If any
tarily blanks and white screen is displayed while the column has a logic low on it, the key corresponding
boot-up program executes as described above. When the to that coordinate (row, column) is being pressed. The
graphic screen is displayed, either of two messages is micro reads the entire keypad by repeating this routine
displayed depending on the type of Watchdog shutdown beginning with row 1 and ending with row 4. The entire
as explained below. keypad is continually read while the control center is
powered. Refer to SECTION 8 of this manual for details
There are two different watchdog initiated shutdowns; of the Keypad.
a “hardware” watchdog initiated shutdown and a “soft-
ware” watchdog initiated shutdown. CM-2 Board or Style A Solid State Starter Inter-
face
In the “hardware” watchdog initiated shutdown, a pro- The microboard retrieves certain operating parameters
gram problem, on-board noise or hardware problem (via J10) from the compressor motor starter control board
could prevent the watchdog time-out. If this occurs, a (CM-2 Current Board for Electromechanical starter or
re-boot is initiated and when the graphic screen is dis- Style “A” Solid State Starter Logic Board). Refer to the
played, “Control Panel – Power Failure” is displayed. appropriate section of this book for detailed explanation
of each board. Both boards contain an 8 channel mul-
In the “software” watchdog initiated shutdown, the tiplexer. The micro sequentially and continually reads
program intentionally initiates the reboot because it channels 0 through 7. It reads each channel by applying a
has detected program interruption. After the re-boot, 3-bit binary address to the multiplexer. A 0-5vdc analog
“Watchdog – Software Reboot” is displayed on the value is returned from each channel. The function of
graphic screen. each is in the table below. The micro determines which
board, and therefore which starter is present, by the value
Program Jumpers/Program Switches returned from channel 0. Since channels 0 through 6 are
The Program Jumpers (Table 3) and Program Switches grounded, the CM-2 board returns a 0vdc value. The
(Table 4) are used to alter the program operation or Solid State Starter Logic Board returns a value >0.41vdc
configure the Microboard hardware for specific opera- to +5vdc. If the value is <0.4vdc, it indicates the starter
tion. This allows the Program and Microboard to be is an Electro-mechanical (EM) starter and the micro
universal for all standard applications. Refer to Table then reads channel 7 to retrieve the peak motor current
3 and 4 for the function of each jumper and switch. value. A value >0.4vdc indicates the starter is an “A”
The position of some jumpers can be determined by style Solid State Starter and the micro reads channels 1
the Service Technician to meet the desired operation. through 7. In the Solid State Starter, channel 0 indicates
Others must be positioned according to the require- the starter size (model) and voltmeter range (300Vac or
ments of the size, type or style of components and thus 600Vac). Channel 1 is a hardware generated 100% FLA
are determined by the YORK factory. The jumpers are (prevents pre-rotation vanes from further opening) or
plastic sleeves with metal inserts that are inserted over 104% FLA (closes pre-rotation vanes until motor current
2-prong or 3-prong conductors. The Program Switches is <102%) current limit override command that overrides
are miniature switches that are placed in either the ON normal Pro-rotation Vanes control. Channels 2 through
or OFF position. 4 are analog voltages that represent phase A, B and C
motor current. The highest phase is Channels 5 through
7 are analog voltages that represent phase A, B and C
Line Voltage. The data for each channel is shown on the
following table:
34 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

MULTIPLEXER CHANNELS

0 1 2 3 4 5 6 7

Peak
CM-2 Gnd Gnd Gnd Gnd Gnd Gnd Gnd Motor Current
(%FLA)

STYLE A Starter model/ Current Phase C Phase B Phase A Phase A Phase B

Phase C
Solid State voltmeter limit motor motor motor line line
line voltage
Starter range command current current current voltage voltage

3A
Style B Solid State Starter Digital Inputs
If equipped with either of these drives, the drive is in- The I/O Board converts the 115Vac inputs to logic
terfaced to the Microboard via the Opto-Coupled COM level inputs for the microboard at J19. A 115Vac input
5 serial data port (J15). The serial data is represented by to the I/O board is converted to a logic low (<1Vdc).
+5vdc and 0vdc logic levels. J15-1 is TX data to the drive A 0Vac input to the I/O Board is converted to a logic
and J15-2 is RX data from the drive. Refer to SECTION high (>4Vdc). Refer to SECTION 4 of this manual for
11 (Solid State Starter) for details of this interface. details of the I/O Board.

Printer Interface Digital Outputs

An optional Printer can be connected to COM1 RS-232 The microboard controls 115vac relays and solenoids via
serial data port (J2). J2-4 is TX data to the printer. J2-2 is the I/O Board (via J19). The I/O Board contains +12Vdc
the DSR (Data Set Ready or busy) signal from the print- relays that isolate the microboard low voltage circuits
er. Signal levels are standard RS-232. The microboard from the 115Vac device coils. Solid state switching
sends data to the printer at the selected baud rate until devices are used to control the relays. The microboard
the printer buffer becomes full, whereupon the printer energizes the +12Vdc relays by applying a ground to
asserts its Busy signal. The microboard suspends data the coil input. They are de-energized by opening the
transmission until the printer can accept more data. Each ground path. The contacts of these relays switch 115Vac
printer must be setup/configured to operate properly with to system relays and solenoids. The outputs that control
the microboard. The Baud, Data Bits, Parity and Stop the chilled liquid pump and compressor motor starter
Bits must be programmed on the Comms Screen. Other have anti-chatter (anti-recycle) timers associated with
printer setup is performed on the PRINTER Screen. Re- them. The output that controls relay K0 is not allowed to
fer to YORK manual 160.80-O1 for details of available change at a rate greater than once every 10 seconds. The
printers and printer setup instructions. output that controls relay K13 is not allowed to change
at a rate greater than once every 20 seconds.
MicroGateway Interface
An optional Microgateway printed circuit board can The microboard controls Actuator motors via Triacs on
be connected to the COM 4B RS-232 serial data port the I/O Board. Each actuator has an open winding and a
(J2). J2-7 is TX data to the MicroGateway. J2-6 is RX close winding. Current flowing through a winding causes
data from the Microgateway. Signal levels are standard the actuator to rotate in the respective direction. Each
RS-232. The MicroGateway polls system pressures, winding is controlled by a Triac. The Triac is turned on to
temperatures and status from the microboard. It holds allow current to flow through a winding. The microboard
it for retrieval by third-party devices. Refer to SECTION turns on the Triac by applying a logic low (<1Vdc) to
13 of this manual. the Triac driver on the I/O Board. It turns it off by ap-
plying a logic high (>4vdc). Refer to SECTION 4 of
this manual for details of the I/O Board.

JOHNSON CONTROLS 35
 Microboard
FORM 160.80-M1 (307)

Analog Inputs The LED’s and their functions are as follows:

System pressures, in the form of analog DC voltages, • CR2 RX6 – Not used. Future COM6 serial port
are input from Pressure Transducers. Refer to SECTION receive data.
14 of this manual. Formulas and graphs are included to • CR3 TX6 – Not used. Future COM6 serial port
calculate the expected transducer output voltage for a transmit data.
given pressure input. • CR4 RX1 – COM1 serial port receive data.
• CR5 TX1 – COM1 serial port transmit data.
System temperatures, in the form of analog DC volt- • CR13 TX4 – COM4 serial port transmit data.
ages, are input from Thermistors. Refer to SECTION • CR14 RX4 – COM4 serial port receive data.
15 of this manual. Included are tables to convert the • CR15 TX3 – COM3 serial port transmit data.
expected output voltage for any temperature applied to • CR16 RX3 – COM3 serial port receive data.
the thermistor. • CR17 RX2 – COM2 serial port receive data.
• CR18 TX2 – COM2 serial port transmit data.
Serial Data Ports • CR19 RX5 – COM5 serial port receive data.
The Microboard is equipped with 5 serial data ports (ref • CR20 TX5 – COM5 serial port transmit data.
fig 9A). Each port is dedicated for a specific function
as follows: Display Interface
The graphic screens displayed on the liquid Crystal Dis-
a. COM1 (J2) – RS-232. Printer play are created from the program downloaded from the
b. COM2 (J13) – RS-232. Not used Program Card and stored in the flash memory chip. The
c. COM3 (J12) – RS-485. Optional I/O. data to form these screens is output from J5. This data is
d. COM4 (4A-J11), (4B-J2) – This port is actu- in the form of red, green and blue drive signals applied
ally two ports. However, they cannot be used to each of the 303,200 the display pixels arranged in a
simultaneously. The position of program jumper matrix of 640 columns x 480 rows. Each pixel consists
JP27 determines which port can be used. (refer of 3 windows; red, green and blue, through which a
to table 3). COM4A – RS485 Not used. COM4B variable amount of light from the Display Backlight, is
– RS-232 Microgateway. permitted to pass to the front of the display. The drive
e. COM5 (J15) – Opto-coupled transmit/receive. signals determine the amount of light permitted to pass
Style B Solid State Starter. through each window. The overall pixel color is a result
of the gradient of red, green and blue light allowed to
Each port is equipped with two LED’s. A red TX LED pass. The drive signal for each pixel is an 18 bit binary
illuminates as data is transmitted to or requested from word; 6 for each of the 3 colors. The greater the binary
another device. A green RX LED illuminates as data value, the more light is permitted to pass. The pixels are
is received from another device. The RS-232 voltages driven sequentially from left to right, beginning with
are industry standard +5 to +25vdc and -5vdc to -25vdc the top row. To coordinate the drive signals and assure
logic levels. The RS-485 voltages are industry standard the pixels in each row are driven from left to right and
0vdc and +1.5 to +5vdc logic levels. COM5 logic levels the columns are driven from top to bottom, the drive
are 0vdc and +5vdc. A diagnostic test can be performed signals are accompanied by a clock and horizontal and
on each serial port to confirm proper operation. Refer to vertical sync signals.
Diagnostics SECTION 22 of this manual.
During the boot-up, the program in the BIOS eprom
reads wire jumpers PID0 through PID3 on the Display
Interface Board to determine the manufacturer of the
display. Each display manufacturer requires a slightly
different control. The program in the BIOS eprom
configures the microboard for correct operation for the
actual display installed.

36 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

Different display manufacturers require different supply be varied from 0Vdc (100% brightness) to 5.0Vdc (0%
and control voltages for their displays and backlights. brightness). If configured for variable resistance, the
Program Jumpers JP2 through JP5 and JP7 and JP8 must resistance between J6-6 and J6-7 varies from 0 ohms
be configured to provide the required supply and control (0% brightness) to 10K ohms (100% brightness).
voltages to the display and backlight control. Table 3 lists
the required program jumper configuration for each dis- Refer to Display SECTION 5, 6 and 7 of this manual
play. Also, a label attached to the display mounting plate for details of the display interface.
lists the required program jumper configuration for that
display. The position of program jumper JP2 determines Remote Setpoints
whether the supply voltage is +5vdc or +3.3vdc. Remote Leaving Chilled Liquid temperature and Cur-
rent Limit setpoints can be input via the RS-232 Micro-
The microboard controls the Display Backlight via J6. gateway interface at J2 or directly to the Microboard at
The Display Backlight is the light source for the display. J22 (ref fig 10A). The inputs at J22 are configured with 3A
The Backlight Inverter Board provides a high voltage Program Jumpers JP23 and JP24 to accept these inputs
AC power source for the lamp. It converts low voltage in either 0-10vdc, 2-10vdc 0-20Ma or 4-20Ma form.
DC via J6-1 (+12vdc or +5Vdc, depending on position Refer to Table 3 for Program Jumper configurations and
of Program Jumper JP5) to high voltage AC (500 to SECTION 16 of this manual for details of the Remote
1500Vac). This high voltage AC is applied to the lamp Setpoints.
to cause it to illuminate. The Backlight is turned on
and off with the “Backlight Enable” signal (J6-5). The Configuration/Setup
position of Program Jumper JP4 determines whether The following functions are entered as setpoints on the
this is a +12Vdc or +5vdc signal. In some displays, the SETUP Screen. Refer to entry instructions in SECTION
backlight turns on when this signal transitions from low 21 of this manual.
to high; others turn o when it transitions from high to
low. The position of Program Jumper JP3 determines the • Chilled Liquid Pump Operation – Determines
transition that will occur when the Microboard outputs Chilled Liquid Pump control contacts (I/O Board
the Backlight Enable signal. JP3 must be positioned ac- TB2-44/45) operation when chiller shuts down on
cording to the display manufacturer’s requirement. cycling shutdowns. Selections are:
1. Standard – Contacts open at completion of “Sys-
Under program control, the microboard controls the tem Lockout Delay” after all shutdowns except
backlight brightness via the Lamp Dimmer circuit “Leaving Chilled Liquid – Low Temperature”.
output at J6-7. In order to extend the life of the Back- On this shutdown, they remain closed, causing
light lamp, the brightness is driven to 50% after 10 the pump to continue to run while the chiller is
minutes of Keypad inactivity. At this brightness level, shutdown.
the graphics are still visible. When Keypad activity is 2. Enhanced – Contacts open at completion of
detected (a key is pressed), the lamp is driven back to “System Lockout Delay” after all shutdowns
full (100%) brightness. Some display manufacturers except “Leaving Chilled Liquid – Low Tem-
require a variable voltage to vary the brightness; oth- perature, Multi-Unit Cycling- Contacts Open”
ers require a variable resistance. Program Jumpers JP7 and “System Cycling – Contacts Open”. On
and JP8 must be configured to enable the appropriate these shutdowns, they remain closed, causing
technique. The Lamp Dimmer is an integrated circuit the pumps to continue to run while the chiller
that is the electrical equivalent of a 10K ohm potentiom- is shutdown.
eter with 100 positions or steps (ref fig 8A). The Lamp
Dimmer controls the position of the potentiometer. The • Motor Drive Type – Configures the program for the
lamp Dimmer varies the brightness of the backlight by applicable compressor motor drive type. Selections
applying a variable voltage (0-5.0vdc) or a variable re- are:
sistance (0-10K ohms) to the Backlight Inverter Board. 1. EM – Electromechanical Starter
If Program Jumpers JP7 and JP8 are installed, the 2. SSS-Mod A – Style A Solid State Starter
lamp Dimmer output is a variable voltage; if both are 3. SSS-Mod B – Style B Solid State Starter
removed, the output is a variable resistance. The Lamp • Anti-recycle – Enables or Disables the Anti-re-
Dimmer outputs “Brightness Control Wiper” (J6-7) to cycle timer. CAUTION! The Anti-recycle timer
the Backlight Inverter Board. If configured for variable must never be disabled unless advised by YORK
voltage output, the voltage between J6-7 and J6-8 can factory. Selections are:

JOHNSON CONTROLS 37
 Microboard
FORM 160.80-M1 (307)

1. Enabled – Enables the anti-recycle timer. Solid Microboard BRAM BIOS Eprom
state Starters and electromechanical starter ap- 031-02430-000 031-02431-000 031-02429-001
plications cannot be started at intervals shorter 031-01730-000 031-02028-000 031-01796-002
than once every 30 minutes.
2. Disabled – Disables the anti-recycle timer. Program Card Service Replacement
Chiller can be started at the completion of Since one YS Program Card can be used to re-program
“System Lockout Delay”, regardless of how other YS chillers, it is not necessary for an individual
long the chiller had been running. Service Technician to have more than one YS Program
Card. Program Cards can be shared among Service
• Power Failure Restart – Determines the course of ac- Technicians where appropriate.
tion required to restart the chiller, if a power failure
occurs while the chiller is running. Selections are: However, since chiller operating programs are occasion-
1. Manual – Requires a manual reset after power ally revised, the Service Technician could have a Program
is restored. The chiller cannot be started until Card that does not contain the latest program. Program
the operator moves the keypad Start-Run-Stop/ Cards (031-02488-001) for YS chillers are available
Reset rocker switch to the stop/reset position. from the Baltimore Parts Distribution Center (PDC).
2. Auto – Chiller will automatically restart when The card received from the PDC is programmed with
power is restored. the latest version of the chiller operating program.

Microboard Service Replacement Program Cards can be re-programmed with the latest
If the microboard is replaced within the warranty period, program version.
the defective board must be returned to YORK per the
warranty return procedure. Use the return instructions DOWNLOADING A PROGRAM FROM A PRO-
and return address label provided with the replacement GRAM CARD
board.
The Program Card Write Protect Switch
To order a replacement Microboard for a YS Chiller, must be in the “Write Protect” position!
order part number 331-02430-603. This part number
provides an 031-02430-000 Microboard that has been
programmed with the latest version of the YS “Con-
trols” software. It comes equipped with a BRAM (U38)
and BIOS Eprom (U37). (Replacement Microboards
cannot be ordered by the basic board part number of
There are 3 steps to the re-program-
031-02430-000) ming process: Erase, Program and
Verification. Once the re-program-
The Microboard is shipped with a label on the outside ming process is initiated, it automati-
of the shipping box that lists the part number of the cally proceeds through these steps to
pre-programmed Microboard (331-02430-603), the completion. It cannot be manually ter-
basic Microboard part number (031-02430-000) and the minated before completion. Therefore,
version of the pre-programmed “Controls” software (for once the process is initiated, the exist-
example, C.OPT.03.04.301 or later). ing on-board program will be erased
and replaced by the program in the
If replacing a 2430 microboard with a 2430 microboard,
Program Card. Before proceeding, be
the BRAM can be transferred from the defective board
to the replacement board to avoid re-programming the
absolutely certain the Program Card is
Sales Order Data. applicable to your chiller model. For
example, if your chiller is a YS chiller,
BIOS Eproms and BRAMS cannot be the Program Card used MUST be for
interchanged between the 031-01730- a YS chiller. If a YK chiller program
000 and 031-02430-000 microboards. is downloaded into a YS chiller, for
The boards will not function with an example, the chiller will be rendered
incorrect component. Refer to the fol- inoperable until this procedure is
lowing table for applicability: repeated using the correct Program
38 Card! JOHNSON CONTROLS
 FORM 160.80-M1 (307)

A label affixed to the Program Card contains the card 8. Press √ key. The following steps will be performed:
version. The version is an alpha-numeric code that iden- a. Erasing. During this procedure, the program in
tifies the chiller model applicability, language package the Microboard Flash Memory will be erased. A
and program revision level. The version is as follows: green bar reflects the progress of this procedure.
The red LED next to this bar illuminates while this
C.OPT.nn.nn.nnn procedure is in progress.
Language Package revision level
b. Programming. During this procedure, the pro-
(00,01,etc) gram in the Program Card is downloaded into the
Language Package (0=English Microboard Flash memory. A green bar reflects
only,1=NEMA,2=CE,3=NEMA/ the progress of this procedure. The red LED next
CE) to this bar illuminates while this procedure is in
3A
Controls Revision Level (00, 01, progress.
02, etc) c. Verifying. During this procedure, a checksum test is
Chiller Model (01=YK, 02=YT, performed on the new program in the Microboard
03=YS, 05=YR, 11=YD) Flash Memory. A green bar reflects the progress
Optiview Control Center of this procedure. The red LED next to this bar
Commercial Chiller illuminates while this procedure is in progress.

Download the program as follows: The Microboard 7-segment LED Display (U22) dis-
1. Remove power to Optiview Control Center. plays the steps of the programming process while they
are in effect. During the Erasing procedure, “Er” is
2. Remove protective cover from Microboard connec- displayed. During the Programming procedure, “Pr”
tor U33. is displayed. During the Verifying procedure, “Ch”
3. Reposition Microboard Program Jumper JP6 to pins is displayed.
2 & 3 (left-hand pins).
At the completion of the re-programming process, if
4. Insert Program Card into Microboard connector it is successful, “Flash Has Been Successfully Pro-
U33. grammed” is displayed and “Operation Successful” is
5. Restore power to Optiview Control Center. A white displayed in the Status Code box. Otherwise, a mes-
screen appears displaying “Flash Checksum Test:” sage in the status box indicates the step that failed.
and Microboard 7-segment LED (U22) displays “Ch”.
While this is displayed, the Microboard is performing 9. Remove power from Optiview control center.
a checksum test on the Program Card. This assures 10. Remove Program Card from Microboard connector
the integrity of the card before the download proce- U33.
dure can begin. If the checksum test fails, the card is 11. Install protective cover on Microboard connector
defective or corrupted and the download procedure U33.
cannot be performed. If the checksum test passes, the 12. Reposition Microboard Program Jumper JP6 to pins
“Optiview Flash Programmer” Screen is displayed. 1 & 2 (right-hand pins) pins.
6. Press START key to start the downloading process. A 13. Apply power to Optiview Control Center. The re-
dialog box appears asking if you want to “Erase On- programming procedure is now complete.
board Flash and Re-Program from PcCard?”. Do not
proceed until you understand the above caution!
7. Use the ► key to scroll to YES.

JOHNSON CONTROLS 39
 Microboard
FORM 160.80-M1 (307)

TABLE 3
MICROBOARD 031-02430-000 PROGRAM JUMPERS

JP1 – Not Used. JP6 – Boot-up source. Determines whether the boot-up
is performed from the Program Card or Eprom
JP2 – Display power and logic levels Determines the U37.
power supply voltage applied to the display.
Pins 1-2: +5VDC SHARP LQ10D367/368 Pins 1-2: Boots-up from Eprom U37. Must be
(031-01774-000) and LQ10D421 displays. in this position unless re-programming from the
Pins 2-3: +3.3VDC NEC NL6448ACC33-24 Program Card.
and LG Semicon LP104V2-W (031-02046-000)
displays. Pins 2-3: Boots-up from the Program Card. Must
be in this position when re-programming from
JP3 – Display backlight enable signal level polarity. the Program Card.
Jumper must be positioned according to the
voltage level required to turn on the Display JP7, JP8 – Display brightness control technique.
Backlight. Determines whether the display brightness is
controlled by a variable resistance or a variable
Pins 1-2: 0VDC SHARP LQ10D421 display. voltage.

Pins 2-3: +12VDC or +5VDC as determined IN: Variable voltage (0-5.0VDC). SHARP
by position of JP4. SHARP LQ10D367/368 LQ10D367/368 (031-01774-000) and
(031-01774-000), NEC NL644AC33-24 and LQ10D421, and LG Semicon LP104V2-W
LG Semicon LP104V2-W (031-02046-000) (031-02046-000) displays.
displays.
OUT: Variable resistance. NEC NL6448AC33-24
JP4 – Display Backlight enable signal logic levels. display
Determines the logic levels of the Backlight
Enable signal. JP9 – Not Used.

Pins 1-2: +12VDC/0VDC SHARP LQ10D421 JP10 – Not used.

display.
JP11 – Not used.
Pins 2-3: +5VDC/0VDC SHARP LQ10D367/
368 (031-01774-000), NEC NL6448AC33-24 JP12 – Not used.
and LG Semicon LP104V2-W (031-02046-000)
displays. JP13 – Watchdog Enable/Disable. Soldered wire
jumper.
JP5 – Display Backlight power. Determines the power
supply voltage applied to the Display Backlight Never disable the watchdog protection.
Inverter Board. Severe compressor or chiller damage
could result. The ability to disable the
Pins 1-2: +12VDC. SHARP LQ10D367/ watchdog protection is provided for
368 (031-01774-000) and LQ10D421, NEC factory testing only!!!
NL6448AC33-24 and LG Semicon LP104V2-
W (031-02046-000) displays. In – Watchdog enabled
Out – Watchdog disabled
Pins 2-3: +5VDC. Not used.

40 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

JP14 – BRAM size. Soldered wire jumper. Cannot JP27 – COM 4 serial communications port. Configures
be re-positioned by field personnel. Factory COM 4 port for either RS-485 (COM 4A) or RS-
positioned according to size of the on-board 232 for MicroGateway board (COM4B).
BRAM (U38).
Pins 1-2: Enables port 4A. Allows an RS-485
In - 32K x 8. Installed for present production. connection to microboard J11. Not used.
Out – 128K x 8
Pins 2-3: Enables port 4B. Allows an RS-232
JP16 – COM 2 Serial Port modem selection. Configures connection to microboard J2 for Microgateway
port to accept either an external modem con- communications.
nected to J13 or an onboard modem mounted in 3A
socket SK1. If either modem is used, JP17 must
be configured for modem interface. This function
is for future use. It is presently not supported.

In – Use external modem

Out – Use on-board modem

JP17 – COM 2 Serial Port configuration. Configures

port for either RS-232 modem interface or RS-
485 interface. This port is for future use. It is
presently not supported.

Pins 1-2 – RS-485

Pins 2-3 – RS-232 (modem)

JP21 – Not Used

JP22 – Not Used

JP23 – Remote Current Limit Setpoint (J22) type. Con-

figures analog input for 0-10VDC, 2-10Vdc, 0-
20mA or 4-20mA.

OUT: Allows 0-10VDC or 2-10VDC input on J22-1

Pins 1-2: Allows a 0-20mA or 4-20mA input on

J22-2

Pins 3-4: Not used.

JP24 – Remote Leaving Chilled Liquid Temperature

Setpoint (J22) type. Configures analog input for
0-10VDC, 2-10Vdc, 0-20mA or 4-20mA.

OUT: Allows 0-10VDC or 2-10VDC input on J22-1

Pins 1-2: Allows a 0-20mA or 4-20mA input on

J22-2

Pins 3-4: Not used.

JOHNSON CONTROLS 41
 Microboard
FORM 160.80-M1 (307)

TABLE 4
MICROBOARD 031-02430-000 PROGRAM SWITCHES

SW1-1 – Refrigerant Selection. Must be set according

to the refrigerant type installed in chiller.

ON – R134a

OFF – R22

SW1-2 – Liquid Type. Must be set according to

whether the chiller is cooling water or brine
solution.

ON – Brine. Leaving Chilled Setpoint range is

20ºF to 70ºF.

OFF – Water. Leaving Chilled Setpoint range

38ºF (36ºF if Smart Freeze enabled) to 70ºF.

SW1-3 – Diagnostics. Enables or Disables the soft-

ware diagnostics. Refer to SECTION 22 of
this manual.

ON – Enables diagnostics. Disables normal

chiller operation.

OFF – Disables diagnostics. Enables normal

chiller operation.

SW1-4 – Not used.

42 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

3A

BRAM

BIOS
PROGRAM EPROM
SWITCHES

PROGRAM
DOWNLOAD
CONNECTOR

BOOT-UP
LED STATUS
DISPLAY

LD09254

FIG. 5A – MICROBOARD 031-02430-000

JOHNSON CONTROLS 43
 Microboard
FORM 160.80-M1 (307)

SWITCH IN "WRITE" POSITION

END OF CARD

031-02488-001

SWITCH IN "WRITE PROTECT" POSITION

FIG. 6A – PROGRAM CARD 031-02488-001

J1-8

Not Used
- 12 VDC
J1-4

+ 12 VDC

TP10
TP4 2.5 VDC
J1-3
+ 12 VDC F2 5 VDC + 5 VDC (Analog)(For Transducer
5A VOLTAGE and Thermistors)
REG

+ 5 VDC (VCC)
TP5
2.5 VDC
VOLTAGE 2.5 VDC
REG

TP3
TP2
J1-1
+ 5 VDC F1 3.3 VDC 3.3 VDC
5A VOLTAGE
REG TP1

GND
J1-2

LD09255

FIG. 7A – MICROBOARD (031-02430-000) DC POWER SUPPLY TEST POINTS

44 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

3A
5.0 VDC

J6
JP8

6 BRIGHTNESS CONTROL (+) OR (N.C.)

TO
10 K 7 BRIGHTNESS CONTROL (WIPER)
BACKLIGHT
INVERTER
BOARD

8 BRIGHTNESS CONTROL (-)

JP7

NOTES:
1. J6-6 not connected (N.C.) to Backlight Inverter Board when display is manufactured by Sharp or NEC.
2. The position of Program Jumpers JP7 & JP8 determine the output at J6-7; In = Variable Voltage; Out = Variable Resistance. Refer to Program
Jumper Listing in Table 3 for applications.
3. Potentiometer is actually an integrated circuit that is the electrical equivalent of a 10K potentiometer.

LD04054

FIG. 8A – MICROBOARD LAMP DIMMER CIRCUIT

JOHNSON CONTROLS 45
 Microboard
FORM 160.80-M1 (307)

CR3 CR2
R G
TX1 RX1
RS-232 J2
TX 4
RX 3 PRINTER
MICRO COM 1 DTR 5
DSR 2

COM 4B GTX 7
(NOTE 1) GRX MICROGATEWAY
6
8
CR12 CR13 9
R G
TX4 RX4
RS-485
J11
+ 3
3
JP27 COM 4A NOT USED
MULTI-UNIT
-- 2
2 1 (NOTE 1) COMMS
+ 5VDC 1
GND
4
SHIELD
CR16 CR11 5
R G
TX2 RX2

RS-232 J13
DCD 1
DSR 2
RX 3
RTS NOT USED
4
COM 2 TX 5
CTS 6
DTR 7

CR15 CR14 GND 9

R G
UART TX3 RX3

RS-485 J12
+ 3
-- 2
+ 5VDC
OPTIONAL I/O
COM 3 1
GND 4
SHIELD 5

CR9 CR10
R G
TX5 RX5

OPTO-COUPLE
J15
TX
1
RX MOD "B"
2
COM 5 COMMON
3
SOLID STATE
NOTE 2 STARTER
4
NOTE 2
5
6

LD07788

NOTES:
1. Microboard Program Jumper JP27 determines whether COM 4A or 4B can be used. 1 & 2 - 4A, 2 & 3, 4B. Refer to Table 3.
2. J15-4 Loop-Around Test IN. J15-5 Loop-Around Test OUT. Refer to Fig. 55 for details.

FIG. 9A – MICROBOARD SERIAL DATA COMMUNICATIONS PORTS

46 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

J7
71.5 K
TRANSDUCER 0 10 VDC 2
OR THERMISTOR
NOT USED 14 2
4 - 20 MA 1 47K

1 JP21
+5V 3

13
7.5 K 200

3A
TRANSDUCER 0-10 VDC 4
OR THERMISTOR
NOT USED 2
16 1
4 - 20 MA
15 JP22
+5V 3

MUX
J22
REMOTE CURRENT 0-10 VDC / 1
LIMIT SETPOINT 2-10 VDC
2 2 1
0 - 20 MA /
4 - 20 MA
3 JP23

REMOTE LEAVING 0-10 VDC / 3

CHILLED LIQUID 2-10 VDC
TEMP SETPOINT
0 - 20 MA / 4 2 1
4 - 20 MA
3 JP24

REMOTE SETPOINT 5
GND CONNECTIONS

LD04636

NOTE:
1. Program Jumpers JP21 – JP24 must be positioned on pins 1-2 or 3-4 according to input signal type. Refer to Table 3.

FIG. 10A – CONFIGURABLE ANALOG & REMOTE SETPOINT INPUTS

JOHNSON CONTROLS 47
 I / O Board
FORM 160.80-M1 (307)

SECTION 4
I/O BOARD
(REFER TO FIG. 11 - 15)
The I/O (input/output) Board conditions the Digital In- relay to de-energize; logic low (<+1VDC) when com-
puts for the Microboard and conditions the Microboard’s manding a relay to energize.
Digital Outputs for application to other components and
devices. The left side of the I/O Board performs the Digi- Relay K18 is different from all other relays on the I/O
tal Inputs function; the right side performs the Digital Board; it has a 115VAC coil. It provides the start/stop
Outputs function. Refer to Fig. 11. signal to the Compressor Motor Starter and provides
Compressor Run status to remote devices (ref.
Digital Inputs are on/off inputs to the Microboard from Fig.15). Relay K18 is controlled by DC relays K13
relay and switch contacts, such as flow switches, start/ (start) and K14 (stop). To start the compressor motor,
stop switch, and remote cycling/safety devices (ref. Fig. the Microboard energizes K13 and K14 simultane-
12). The Micro reads the state of these contacts and re- ously. The 115VAC at TB1-6 is applied to the coil of
acts per the Program instructions. The contact voltage is K18 via K13 contacts, energizing K18. Approximately
115VAC when closed and 0VAC when open. These volt- 0.2 seconds later, K13 is de-energized. K18 remains
ages are not suitable for direct input to the Microboard. energized through K14 contacts and holding contacts
Therefore, the I/O Board converts the 115VAC/0VAC of K18. To stop the compressor motor, the Microboard
contact voltages to 0VDC/+5VDC logic level inputs for de-energizes K14. To prevent sags in Utility Power from
the Microboard. Individual Opto-coupler circuits (ref. chattering K18, the holding contact of K18, along with
Fig. 13) perform the conversion for each Digital Input. the contact of K13, creates an anti-chatter circuit for
When the input is 115VAC, the output will be 0VDC; relay K18. Once energized, K18 cannot be reenergized
when the input is 0VAC, the output will be +5VDC. until K13 is again energized; this will not occur until
after a controlled shutdown has occurred and another
Field connected Digital Inputs, such as those from ex- start sequence has been initiated.
ternal devices that cycle the chiller, are connected to
terminal strip TB4 (ref. Fig.12). These inputs are in the There are conditions external to the I/O Board required
form of dry contacts connected as shown in Fig. 14. The to energize relay K18. The 115VAC will be present at
115VAC power source that is switched by the remote TB1-16 only if the motor controller contacts “CM” are
contacts is supplied by the I/O Board TB4-1. There are closed and the circuit between external Terminal Strip
multiple TB4-1 terminals located adjacent to the field TB6-1 and TB6-53 is closed. The “CM” are located on
input connections, as shown in Fig. 11 and 12. the CM-2 Board (relay K1), Electro-Mechanical starter
applications, the Solid State Starter Logic Board (relay
Digital Outputs are on/off outputs from the Microboard K1), Solid State Starter applications. The High Pressure
that control solenoid valves, motor contactors, actuators, safety switch “HP”, must be closed and the RUN Switch
system relays and provide operating status to external “1SS” must be in the RUN position.
devices (ref. Fig. 15). Per Program instructions, the
Microboard energizes and de-energizes these devices. Triacs are used to control the Slide Valve 4-way solenoid
The coils of these devices operate on 115VAC and there- valve. This Solenoid Valve is controlled by 115VAC
fore cannot be directly connected to the Microboard. power. It has a Load coil and an Unload coil that are
The Digital Outputs section of the I/O Board contains energized by current flow through them. The Load triac
+12VDC coil relays that are driven by the Microboard’s is turned on to allow current flow through the Load coil.
logic level outputs. The contacts of these +12VDC relays This diverts high pressure oil through the solenoid valve
operate the external 115VAC coil devices. On the I/O and into the load side of the Slide Valve cylinder, moving
Board, one side of the each of the relay coils is perma- it in the Load direction. The Unload Triac is turned on to
nently connected to +12VDC at J19-26/27. The other allow current flow through the Unload side of the Slide
side of each relay coil is connected to the Microboard Valve cylinder, moving it in the Unload direction. Under
via I/O Board connector J19. The Microboard energizes Program control, the Microboard turns the Triacs on and
each relay by driving the appropriate input at J19 to logic off to control the Leaving Chilled Liquid Temperature
low voltage level (ground potential). The DC voltage to the Leaving Chilled Liquid Temperature Setpoint or
at the appropriate input pin at J19 will be a logic high limit compressor motor current. At appropriate intervals,
(>+10VDC) when the Microboard is commanding a a Triac is turned on for up to 3 seconds, as required,

48 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

to move the Slide Valve in the desired direction. The K1 - Anticipatory Alarm (TB2-55/56)
magnitude of Slide Valve movement for each Load or Dry closure contacts. Contacts close when one of the
Unload pulse is determined by the oil pressure and the following Warning messages is Displayed. On most
duration of time the Triac is turned on. The Microboard warnings, the contacts automatically open when the
turns the Triacs on and off by applying control signals to warning condition is no longer present. On those warn-
the respective Triac Driver. The Triac Driver is an opto- ings marked with an asterisk, the contacts will open only
coupler device that isolates the Microboard low voltage after the warning condition is no longer present and the
circuits from the higher actuator voltages. To turn on the WARNING RESET key is pressed when logged in at
Triac, the Microboard drives the Triac Driver input to OPERATOR access level or higher.
logic low (<+1VDC) level. The Triac driver responds
by shorting the Triac GATE to Triac terminal 2. To turn Freeze Threat From Operating Chiller, Low Discharge
the Triac off, the Microboard opens its input to the Triac Superheat Detected*, Low Discharge superheat limit,
Driver and allows the input to pull up to +12VDC. The Oil-Dirty Filter, Oil High Temperature, Real Time Clock
Triac Driver responds by opening the short from triac failure, Setpoint Override*, Slide Valve Uncalibrated,
Gate to Triac terminal 2. A voltmeter can be used to de- External I/O – Serial Communications, Condenser
termine if a Triac is turned on or off. Measure across the – High Pressure Limit, Evaporator – Low Pressure
Triac; from Triac terminal 1 to Triac terminal 2. When Limit.
the Triac is turned off, the voltage will be approximately
115VAC; when turned on, it will be <10VAC. K2 - Remote Mode Ready to Start (only operational

RELAY TIMING
in Digital, Analog or ISN Remote mode)(TB2-26/ 4
27)
Under Program control, the relays are energized and Dry closure status contacts that are closed to indicate to
de-energized producing contact operation as follows. a Remote device that the chiller will start upon receipt
Unless otherwise noted, contact rating is 5 amps resistive of a remote start signal. The contacts open coincident
or 2 Amps inductive @ 250VAC. with any Cycling or Safety shutdown or anytime the
Keypad COMPRESSOR switch is placed in the Stop-
K0 - Chilled Water Pump Starter (TB2-44/45) Reset (O) position. On Cycling shutdowns, the contacts
Dry closure contacts. When the chiller is started, the will close when the cycling condition clears. On safety
Contacts close 4 seconds after the start of “Start Se- shutdowns, the contacts will close only after the Safety
quence Initiated”. Normally, they open coincident with condition clears, a manual reset is performed by plac-
the completion of SYSTEM LOCKOUT DELAY with ing the COMPRESSOR switch in the Stop-Reset (O)
the following exceptions: position and then back to the RUN (I) position.
a. If a LEAVING CHILLED LIQUID - LOW
K3 - Safety Shutdown Status (TB2-42/43)
TEM PER ATURE cy cling shutdown occurs,
they do not open at the completion of SYSTEM Dry closure status contacts. They close coincident with
LOCKOUT DELAY. They remain closed for a Safety shutdown. They remain closed until the safety
the duration of the shutdown or until the Keypad condition clears and a manual reset is performed by
COMPRESSOR switch is placed in the Stop-Reset placing the COMPRESSOR switch in the Stop-Reset
(O) position, whereupon they open. (O) position, whereupon they open.

b. If Microboard Program Switch SW1-8 is in the K4 - Cycling Shutdown Status (TB2-40/41)

ON position, they do not open at the completion of
Dry closure status contacts. They close coincident with a
SYSTEM LOCKOUT DELAY when the chiller
shuts down on a MULTI-UNIT CY CLING ‡ Cycling shutdown. They remain closed until the cycling
condition clears, whereupon they open.
- CONTACTS OPEN or SYSTEM CYCLING
- CONTACTS OPEN cycling shutdown. They
remain closed for the duration of the shutdown K5 – Condenser Pump Starter (TB2-151)
or until the Keypad COMPRESSOR switch is Contacts close to start the condenser pump coincident
placed in the Stop-Reset (O) position, whereupon with the beginning of “System Run”. They remain closed
they open. as long as the chillers running. They open coincident with

JOHNSON CONTROLS 49
 I / O Board
FORM 160.80-M1 (307)

the beginning of “System Lockout delay”. If equipped K12 – Hot Gas Bypass Solenoid (TB1-61)
with Flash Memory Card version C.MLM.03.01 or later Contacts control the optional Hot Gas Bypass valve
and Mod “B” Solid State Starter, the contacts remain per description in the “Hot Gas Bypass” section of this
closed at shutdown until all SCR Heatsink temperatures book.
are < 105°F or a maximum of 45 minutes.
K13 - Compressor Motor Starter (start) -
If the Freeze Warning feature has been enabled, the (TB1-6/16) Contacts close coincident with the beginning
contacts will be controlled per the condenser saturation of “System Run”. They remain closed for 0.2 seconds
temperature while the chiller is shutdown as follows: and then open.

a. At chiller shutdown, the contacts remain closed un- K14 - Compressor Motor Stop (stop) (TB 1-6/16)
til the condenser saturation temperature increases Contacts close coincident with the beginning of “System
to >35.0°F, whereupon they open. Run”. They remain closed for the duration of “System
Run”. They open coincident with the beginning of “Sys-
b. During shutdown, if the condenser saturation tem Coastdown”.
temperature decreases to <30.0°F, the contacts
are closed until the temperature rises to >35.0°F, K15 - Not Used
whereupon they open.
K16 - Oil Line Solenoid (TB1-62)
125 - 400 TR chillers only. Contacts close for the first
If it is desired to supply the dry contacts with 115VAC
15 seconds and open for the last 15 seconds of “Start
power from the OptiView Control Center to control the
Sequence Initiated”. They then close coincident with the
Condenser Pump Motor Starter, a field installed wire
beginning of “System Run” and remain closed until the
must be connected from TB5-22 to I/O Board TB2-150.
chiller is shutdown, whereupon they open coincident
Then connect I/O Board TB2-151 to the Condenser
with the beginning of “System Lockout delay”. They
Pump Motor Starter.
remain open while the chiller is shutdown.

K6-K9 – Not Used K17 - Not Used

K10 – Oil Heater (TB1-64) K18 - Compressor Motor Starter (TB5-22/25)

Contacts close coincident with the beginning of “System Run Status (TB2-35/36)
Lockout Delay”. They remain closed as long as the chiller Contacts operate the same as K14.
is shutdown unless the Separator Oil Level Switch is open,
indicating insufficient oil level in the Separator. This allows
the oil heater thermostat to control the oil heater while the
chiller is shutdown. The contacts open coincident with the
beginning of “System Run”. They remain open as long
as the chiller is running. This prevents the oil heater from
being turned on during compressor run.

K11 – Refrigerant Level Solenoid (TB1-29)

Contacts control the Refrigerant Level Solenoid valve
for variable orifice control, per description in “Variable
Orifice Control” section of this book.

50 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

LD04055

FIG. 11 – I/O BOARD

JOHNSON CONTROLS 51
 I / O Board
FORM 160.80-M1 (307)

TB3 - 32 OPTO-
HIGH PRESSURE SAFETY J1 -1
COUPLER

J2 - 1
MOTOR CONTROLLER SHUTDOWN J1 -2

TB3 - 30
STOP SWITCH (LOCAL) J1 -3
FACTORY CONNECTIONS

TB3 - 28
START SWITCH (LOCAL) J1 -4

TB3 - 71
NOT USED J1 -5

TB3 - 70
NOT USED J1 -6

TB3 - 18
SEPARATOR OIL LEVEL J1 -7

TB3 - 80 J1 -8
NOT USED

TB3 - 81
NOT USED J1 -9

TB4 - 1
115VAC

TB4 - 7
REMOTE START J1 -10

TB4 - 8
REMOTE STOP J1 -11
TB4 - 1
115VAC

REMOTE LEAVING CHILLED LIQUID TB4 - 19

J1 -12
TEMP SETPOINT (PWM)
REMOTE CURRENT LIMIT TB4 - 20
J1 -13
SETPOINT (PWM)
FIELD CONNECTIONS

TB4 - 1
115VAC
TB4 - 12
CHILLED WATER FLOW SWITCH J1 -14

TB4 - 13
REMOTE / LOCAL CYCLING J1 -15
TB4 - 1
115VAC
TB4 - 9
MULTI-UNIT SEQUENCE J1 -16

TB4 - 31
AUXILIARY SAFETY SHUTDOWN J1 -17
TB4 - 1
115VAC
TB4 - 11
CONDENSER WATER FLOW SWITCH J1 -18

TB4 - 82
NOT USED J1 -19
TB4 - 1
115VAC

TB4 - 95
NOT USED J1 -20
TB4 - 1
115VAC
TB3 - 1
115VAC
LD04961

FIG. 12 – I/O BOARD DIGITAL INPUTS

52 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

OPTO-COUPLER +5VDC
TYPICAL (20 CKTS) J19 - 21
TB4 - X
TB3 - X

JI - Y

NEUTRAL
TB3 - 2
JI - 22/23

LD04057

FIG. 13 – I/O BOARD TYPICAL OPTO-COUPLER CIRCUIT

TB4 - X
OPTO-
COUPLER J1 - Y

115VAC
FIELD SUPPLIED TB4 - 1 TB3 - 1
DRY CONTACTS
(RATED 5MA @ 115VAC)
LD04058

FIG. 14 – I/O BOARD TYPICAL FIELD CONNECTIONS

JOHNSON CONTROLS 53
 I / O Board
FORM 160.80-M1 (307)

J1
+ 12 VDC
26

27
+ 12 VDC

TB2 - 44
50
CHILLED WATER PUMP STARTER K0 K0
TB2 - 45
TB2 - 55
49
ANTICIPATORY ALARM K1 K1
TB2 - 56
TB2 - 26
48
REMOTE MODE READY TO START K2 K2
TB2 - 27
TB2 - 42
47
SAFETY SHUTDOWN K3 K3
TB2 - 43
TB2 - 40
46
CYCLING SHUTDOWN K4 K4
TB2 - 41
TB2 - 150
45
CONDENSER PUMP STARTER K5 K5
TB2 - 151
TB2 - 152
44
NOT USED K6 K6
TB2 - 153
TB2 - 154
43
NOT USED K7 K7
TB2 - 155
TB2 - 156
42
NOT USED K8 K8
TB2 - 157
TB1 - 165
41
NOT USED K9 K9
TB1 - 1
TB1 - 64
40
OIL HEATER K10 K10
TB1 - 17
TB1 - 29
39
REFRIGERANT LEVEL K11 K11
SOLENOID VALVE TB1 - 1
TB1- 61
38
HOT GAS SOLENOID VALVE K12 K12
(OPTIONAL) TB1 - 1
FIG. 15 – I/O BOARD DIGITAL OUTPUTS LD04962

54 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

J1

K13
COMPRESSOR MOTOR 37
K13
STARTER (START)
START
K14 K18 HP
COMPRESSOR MOTOR 36 TB1-6 RUN
K14
STARTER (STOP)
TB1-16
STOP
TB1-34
35 16 TO I/O
NOT USED K15 K15
TB1-1 BOARD J2-1
CM (NOTE 2)
TB1-62
OIL LINE SOLENOID VALVE 34 53
K16 K16
(125 - 400 TR CHILLER ONLY) TB1-1
1
TB1-164
NOT USED K17 K17 115VAC

TB2-164

TB1-33 TB5-23
COMPRESSOR MOTOR NOT USED
STARTER K18 TB5-22 4
K18 115 VAC
TB1-2 K18 TB5-25
115VAC NEUTRAL COMPRESSOR MOTOR STARTER

TB2-35

K18 RUN STATUS

TB2-36

SLIDE VALVE
ACTUATOR 2
TB1-3

2 LOAD
J1-33 TRIAC
SLIDE VALVE Q1
LOAD DRIVER
G 1
TB1-59
1 115 VAC
1
G
J1-32 TRIAC Q2
SLIDE VALVE
DRIVER
UNLOAD 2
TB1-58

UNLOAD

NOTES:
1. – – – – – – – indicates wiring external to I/O Board.
2. “CM” – Contacts of Relay K1 on Current Module (EM Starter Applications) or Solid State Starter Logic
Board (Solid State Starter Applications).
LD04963

FIG. 15 – (CONT’D) – I/O BOARD DIGITAL OUTPUTS

JOHNSON CONTROLS 55
 I / O Board
FORM 160.80-M1 (307)

TB1-158

2
J1-31 TRIAC
NOT USED Q3
DRIVER
G 1
TB1-169

1
G
J1-30 TRIAC Q4
NOT USED
DRIVER
2
TB1-160

TB1-161

2
J1-29 TRIAC
NOT USED Q5
DRIVER
G 1
TB1-162

1
G
J1-28 TRIAC Q6
NOT USED
DRIVER
2
TB1-163

LD04964

FIG. 15 – (CONT’D) – I/O BOARD DIGITAL OUTPUTS

56 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

This page intentionally left blank.

JOHNSON CONTROLS 57
 Liquid Crystal Display
FORM 160.80-M1 (307)

SECTION 5
LIQUID CRYSTAL DISPLAY
(REFER TO FIG. 16 - 25)

A 10.4 inch color Liquid Crystal Display, along with that will pass through the window. The conduction of
supporting components Display Interface Board and each transistor is controlled by a signal from the Display
Backlight Inverter Board are mounted on a plate that Controller on the Microboard. The overall pixel color
is attached to the OptiView Control Center door. A clear is a result of the gradient of red, green and blue light
plexiglass faceplate prevents display surface damage. allowed to pass.
System operating parameters are displayed on various
color graphic screens. The various display screens are Under Program control, the Display Controller on the
selected for display using the Keypad keys. Microboard sends a drive signal for each pixel to create
the image on the display. Each pixel’s drive signal is an
The Display provided in the new chiller or from YORK 18 bit binary word; 6 bits for each of the 3 colors, red
as a service replacement part, could be manufactured by green and blue. The greater the binary value, the greater
any of several approved manufacturers. Each Display the amount of light permitted to pass. The columns of
requires a specific Display Interface Board, Backlight pixels are driven from left to right and the rows are
Inverter Board, Inverter Board interface cable and Pro- driven top to bottom. To coordinate the drive signals
gram command set. Therefore, Service replacement and assure the columns are driven from left to right
Displays or supporting components cannot be ar- and the rows are driven from top to bottom, each drive
bitrarily selected!!! As explained below, replacement signal contains a horizontal and vertical sync signal. The
Displays are provided from YORK as kits to assure Display Interface Board receives these display drive
compatibility of all components. Non-compatibility signals from the Microboard J5 and applies them to the
of components will result in incorrect operation!!! Display at connector CN1. Refer to Fig. 26.
Refer to “Display Interface Board” and “Backlight In-
verter Board” sections that follow this section. Displays Although there are variations in control signal timing
that could be provided from YORK in new chillers or between different display manufacturers, Fig. 21 depicts
as replacement parts are: typical control signals. Since these control signals occur
at rates greater than can be read with a Voltmeter, the
• SHARP LQ10D367/368 (031-01774-000)
following description is for information only. There are
• SHARP LQ10D421 480 horizontal rows of pixels. Each row contains 640
• NEC NL6448AC33-24 3-window pixels. Beginning with the top row, the drive
• LG SEMICON LP104V2-W (031-02046-000) signals are applied within each row, sequentially left
to right, beginning with the left most pixel and ending
The YORK part numbers of the Display Interface with the right most pixel. The rows are driven from top
Board, Backlight Inverter Board and Inverter ribbon to bottom. The Vertical Sync (VSYNC) pulse starts the
cable provided, are listed on a label attached to the scan in the upper left corner. The first Horizontal Sync
Display mounting plate. These are the part numbers of (HSYNC) pulse initiates the sequential application of
the supporting components that are compatible with the RGB drive signals to the 640 pixels in row 1. Upon
installed display. These supporting components can be receipt of the ENABLE signal, an RGB drive signal
individually replaced. However, if the Liquid Crystal is applied to the first pixel. As long as the ENABLE
Display fails, Display replacement kit 331-01771-000 signal is present, RGB drive signals are then applied to
must be ordered as detailed below. This kit contains the remaining 639 pixels at the CLK rate of 25.18MHz,
a replacement Display and all compatible supporting or one every 39.72 nanoseconds. Typically it takes 31
components. microseconds to address all 640 pixels. Similarly, the
next HSYNC pulse applies drive signals to row 2. This
The Display has 307,200 pixels arranged in a 640 col- continues until all 480 rows have been addressed. Total
umns X 480 rows matrix configuration. Each pixel con- elapsed time to address all 480 rows is approximately 16
sists of 3 windows; red, green and blue, through which milliseconds. The next VSYNC pulse causes the above
a variable amount of light from the Display Backlight cycle to repeat. Displays can be operated in FIXED
is permitted to pass through the front of the display. mode or DISPLAY ENABLE mode. In FIXED mode,
Imbedded in each window of the pixel is a transistor, the first pixel drive signal is applied a fixed number
the conduction of which determines the amount of light (48) of clock (CLK) cycles from the end of the HSYNC

58 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

pulse and the drive signals are terminated a fixed num- Display Interface Board required for each Display ap-
ber (16) of CLK cycles prior to the next HSYNC pulse. plication and each has a unique jumper configuration
In DISPLAY ENABLE mode, the pixel drive signals that identifies the Display. A complete explanation of
are applied to the pixels only while ENABLE signal is this process is included in the preceding “Microboard”
present. This signal is typically present 4-48 CLKS after section and the “Display Interface Board” section that
the end of the HSYNC pulse and 2-16 CLKS prior to follows.
the next HSYNC pulse. All YORK applications oper-
The DC power source to operate the Display is provided
ate in the DISPLAY ENABLE mode. The state of the
by the Microboard J5. Some Display manufacturers re-
ENABLE (Display Interface Board J1-27) signal from
quire +5VDC; others require +3.3VDC. The position of
the Microboard places the Display in the desired mode
Microboard Program Jumper JP2 determines which of
as follows:
these power sources is supplied to the Display. JP2 must
be positioned according to the Display manufacturers
• SHARP LQ10D367/368 (031-01774-000) & requirements. Refer to Table 1, “Program Jumpers”.
LDQ10D421 Displays - When ENABLE main-
tained “low”, display operates in fixed mode.
The Backlight Lamp provides the illumination for the
• NEC NL6448AC33-24 Displays - When ENABLE
display. Average lamp life is 25000 hours (2.9 years).
maintained “high” or “open”, display operates in
Some displays use one lamp. Others use two lamps.
fixed mode.
Lamps are replaceable, but not interchangeable between
• LG SEMICON Display (031-02046-000) does not different displays. Each Display manufacturer specifies
have the fixed mode feature. the required lamp for their display. Refer to replacement
parts list for appropriate replacement lamp. Service
As described above, in OptiView Control Center appli- replacement lamps are stocked in the YORK Service
cations, the Display scan is left to right, beginning with Parts Distribution Center. The lamp is illuminated by
the top row and continuing sequentially through the applying a high voltage AC (500 to 1500VAC) to it.
rows to the last row. However, in Display applications This illumination voltage is created from a low level DC
other than OptiView Control Centers, image reversal voltage (+12VDC or +5VDC as required by the Display
is sometimes required. In image reversal applications, manufacturer) by the Backlight Inverter Board. Lamp
the scan is reversed; the scan is right to left, beginning brightness is controlled by varying the high voltage AC.
with the last row and proceeding to the top row. The The greater the voltage the brighter the illumination. 5
SHARP or NEC Display is placed in the NORMAL The lamp is controlled by on/off commands and bright-
or REVERSE scan mode by the voltage levels on the ness control signals applied to the Backlight Inverter
Display Interface Board J1-30 and J1-31 (display con- Board from the Microboard. The Microboard Program
nector CN1-30/31). These voltage levels are determined determines when the lamp is turned on and off and the
by the configuration of Wire jumpers P30 and P31 on lamp brightness. Each Display manufacturer specifies
the Display Interface Board (ref. Fig. 26). The Display the Backlight Inverter Board to be used. Therefore,
reads these voltage levels and automatically assumes it will vary according to the Display manufacturer.
NORMAL or REVERSE scan operation. Refer to DIS- The ribbon cable that connects the Microboard to the
PLAY INTERFACE BOARD section that follows for Backlight Inverter Board also varies according to the
jumper configurations. Display manufacturer’s requirements. Refer to Fig. 22
to 25. Microboard Program Jumpers JP3, 4, 5, 7 and 8
Displays by different manufacturers can require different determine the voltage levels of the control signals sent to
timing and control signals. The Microboard must know the Backlight Inverter Board and must be configured
which Display is present in order provide the correct per the Display manufacturer’s requirements as listed
signals. Therefore, when AC control power is first in Table 1. A detailed description of the operation of
applied to the OptiView Control Center, as part of the this board is in the “Backlight Inverter Board” section
power-up sequence, the Microboard reads the Panel ID that follows. Also refer to the preceding “Microboard”
wire jumpers P1D0 - P1D3 on the Display Interface section for a detailed description of the Lamp Dimmer
Board and determines which Display is present. It can circuit.
then provide the correct timing and control signals to
produce the graphic image, as required by the Display
manufacturer. Since the Display Interface Board iden-
tifies the Display for the Microboard, there is a different

JOHNSON CONTROLS 59
 Liquid Crystal Display
FORM 160.80-M1 (307)

The actual Display that is installed in the OptiView Always remove control power from the
Control Center of the new chiller is determined by the OptiView control center before con-
Display manufacturer contractual agreement in place necting or disconnecting wires to the
during the time of OptiView Control Center production. display. Connecting or disconnecting
Displays stocked for Service replacement are a result of wires to the display with power applied
that same agreement. Therefore, the Display received for
will damage the display!!!
service replacement may be by a different manufacturer
than the one in the OptiView Control Center. Since each BACKLIGHT LAMP REPLACEMENT:
Display manufacturer requires a specific Display In-
terface Board, Backlight Inverter Board and Inverter SHARP LQ10D367/368 (031-01774-000) Display:
Ribbon Cable, replacement Displays are ordered and (Refer to Fig. 22)
supplied as a Display Replacement Kit (YORK Part
Removal:
Number 331-01771-000) to assure component compati-
bility. The items supplied in the kit are compatible with The Lamp slides into the Display from left to right and
the supplied Display. The kit consists of the following is secured with a locking tab.
items mounted on a Display mounting plate: 1. Remove Control Power from the OptiView Control
Center.
Display Replacement Kit 331-01771-000: 2. Remove protective cover from rear of Display.
1. Liquid Crystal Display with Lamp 3. Disconnect Lamp AC power connector from Back-
2. Appropriate Display Interface Board for item 1 light Inverter Board.
3. Appropriate Backlight Inverter Board for item 1 4. Using fingernail or thin flat blade screwdriver, bend
4. Appropriate ribbon cable (Backlight Inverter Board the locking tab outward slightly to clear the Lamp
to Microboard) for item 1 housing protrusion.
5. Ribbon cable (Display Interface Board to 5. Grasp Lamp AC power connector and gently pull
Microboard) until Lamp housing clears locking tab.
6. All mounting hardware 6. Grasp Lamp housing and pull until Lamp housing
is completely removed from the Display.
7. Installation instructions. A label attached to the Dis-
play mounting plate lists the YORK part numbers Installation:
of the Display supporting components mounted 1. Slide new Lamp into Display from left to right until
on the Display mounting plate and the required Lamp housing protrusion locks into Display locking
Microboard Program Jumper (JP2 through 8) con- tab.
figurations. Microboard Program Jumpers JP2 2. Connect Lamp AC power connector to Backlight
- JP8 will have to be configured appropriately Inverter Board.
for the replacement display.
3. Apply Control Power to OptiView Control Center.
Display Handling: SHARP LQ10D421 Display (refer to Fig. 23)
1. The display is made of glass. It could break if Removal:
dropped. Both the top and bottom lamps slide into the Display
2. The display front surface is easily scratched. If from left to right and are secured with locking tabs.
soiled, wipe with a dry cotton cloth. Use no water 1. Remove Control power from the OptiView Control
or chemicals. Center.
3. The display is static sensitive. Electrostatic dis- 2. Remove protective cover from rear of display.
charges may damage the display.
3. Disconnect lamp AC power connector from de-
4. A laminated film is adhered to the display front fective lamp.
glass surface to prevent it from being scratched.
4. Using a thin flat blade screwdriver, press in on the
Peel off very slowly to prevent static damage.
small black locking tab.
5. Grasp Lamp AC power connector and gently pull
until Lamp clears locking tab.
6. Grasp Lamp housing and pull until Lamp housing
is completely removed from the display.
60 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

Installation: 2. Remove protective cover from rear of Display.

Follow instructions above for SHARP 367 Display. 3. Disconnect Lamp AC power connector from Back-
light Inverter Board.
NEC NL6448AC33-24 Display (refer to Fig. 24)
4. Using small Phillips screwdriver, remove lamp
Removal: retaining screw.
Not available at this time. 5. Grasp Lamp AC power connector and gently pull
until Lamp housing is completely removed from
Installation: the Display.
Not available at this time.
Installation:
LG Semicon LP104V2-W (031-02046-000) Display 1. Slide new Lamp into Display from left to right until
(refer to Fig. 25) Lamp housing is fully inserted.
2. Secure Lamp with Lamp retaining screw.
Removal:
3. Connect Lamp AC power connector to Backlight
The Lamp slides into the Display from left to right and Inverter Board.
is secured with a screw.
4. Apply AC power to OptiView Control Center.
1. Remove Control Power from the OptiView Control
Center.

LD04062

FIG. 16 – DISPLAY, MOUNTING

JOHNSON CONTROLS 61
 Liquid Crystal Display
FORM 160.80-M1 (307)

BACKLIGHT BULB DISPLAY INTERFACE MOUNTING

025-33752-000 LIQUID CRYSTAL DISPLAY BOARD 031-01765-002 PLATE
SHARP LQ10D367
LABEL

BACKLIGHT
INVERTER
BOARD
031-01789-000
DISPLAY CABLE
INVERTER CABLE 031-01769-000
031-01770-003

NOTE:
LD05563
1. Configure Microboard Program Jumpers per label.

FIG. 17 – LIQUID CRYSTAL DISPLAY ASSEMBLY – SHARP LQ10D367/368 (031-01774-000) DISPLAY

INVERTER CABLE MOUNTING PLATE

LABEL (NOT AVAILABLE)

CN3

CN1

CH1

CN2

DISPLAY CABLE
(NOT AVAILABLE)

BACKLIT INVERTER
BOARD (NOT AVAILABLE)
LIQUID CRYSTAL DISPLAY DISPLAY INTERFACE
NOTE: SHARP LQ10D421 BOARD (NOT AVAILABLE)
1. Configure Microboard Program Jumpers per label.
LD04064

FIG. 18 – LIQUID CRYSTAL DISPLAY ASSEMBLY – SHARP LQ10D421 DISPLAY

62 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

INVERTER CABLE
(NOT AVAILABLE) MOUNTING PLATE

CN2

CH1
CN1

CN2

BACKLIT DISPLAY CABLE

INVERTER (NOT AVAILABLE)
BOARD
(NOT AVAILABLE)

LIQUID CRYSTAL DISPLAY DISPLAY INTERFACE

NEC NL6448AC33-24 BOARD (NOT AVAILABLE)
LABEL

LD04065

NOTE:
1. Configure Microboard Program Jumpers per label.

FIG. 19 – LIQUID CRYSTAL DISPLAY ASSEMBLY – NEC NL6448AC33-24 DISPLAY

JOHNSON CONTROLS 63
 Liquid Crystal Display
FORM 160.80-M1 (307)

BACKLIGHT BULB DISPLAY INTERFACE MOUNTING

025-34564-000 LIQUID CRYSTAL DISPLAY BOARD 031-01765-001 PLATE
LG SEMICON LP104V2-W
LABEL

4564

4
BACKLIGHT
INVERTER
BOARD
031-01789-000
DISPLAY CABLE
INVERTER CABLE 031-01769-000
031-01770-003

LD05525

NOTE:
1. Configure Microboard Program Jumpers per label.

FIG. 20 – LIQUID CRYSTAL DISPLAY ASSEMBLY - LG SEMICON LP104V2-W (031-02046-000)

480 ROWS
16MS
VSYNC

31US
HSYNC
ROW 1 ROW 2 ROW 480

BP FP
640
COLUMNS

ENABLE DISPLAY DISPLAY DISPLAY

PERIOD PERIOD PERIOD
39.72 NS
640 CLKS

CLK NOTES:
(25.18 1. BP = Back Porch = 4-48 CLKS
MHz)
2. FP = Front Porch = 2-16 CLKS

RGB LD04066

FIG. 21– LIQUID CRYSTAL DISPLAY TYPICAL CONTROL SIGNAL TIMING

64 JOHNSON CONTROLS
 Liquid Crystal Display
FORM 160.80-M1 (307)

BEZEL
LAMP HOLDER

WIRE PROTRUSION
(white/GND side)

HOLE

LOCKING TAB
WIRE
(pink/HOT side)

DIRECTION A

DIRECTION B

LD04067

DIRECTION C

FIG. 22 – DISPLAY (SHARP LQ10D367) LAMP REPLACEMENT

5
A

BLACK LOCKING TAB

REAR
FLAT HEAD VIEW
BLACK LOCKING TAB SCREWDRIVER

LAMP UNIT

C REAR
" ∇ " MARKING AT THE VIEW
SIDE OF THE LAMP UNIT
∇
" " MARKING AT THE
METAL PORTION AT THE SIDE
OF THE MODULE C

LD04068
FIG. 23 – DISPLAY (SHARP LQ10D367/368 [031-01774-000]) LAMP REPLACEMENT

JOHNSON CONTROLS 65
 Liquid Crystal Display
FORM 160.80-M1 (307)

NOT AVAILABLE AT THIS TIME

LD04069

FIG. 24 – DISPLAY (NEC NL6448AC33-24) LAMP REPLACEMENT

BEZEL
LAMP HOLDER

WIRE
(white/GND side)

RETAINING SCREW

WIRE
(pink/HOT side)

DIRECTION B

LD05565

DIRECTION C
FIG. 25 – DISPLAY (LG SEMICON LP104V2-W [031-02046-000]) LAMP REPLACEMENT

66 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

SECTION 6
DISPLAY INTERFACE BOARD
(REFER TO FIG. 26)
The Display Interface Board is located on the Liq- NEC NL6448AC33-24 Display:
uid Crystal Display mounting plate and is part of the P30 Not used
Microboard interface to the Display. It permits the use P31 IN or OUT - Normal scan; left to right, top to
of Displays by different manufacturers, by providing the
bottom
Microboard with a means of automatically determining
which Display is present. The wire jumpers on this board are not field configu-
rable, as with typical Program Jumpers. There are two
Since different Display manufacturers require different variations of the Display Interface Board. Each board
timing and control signals, the Display Controller on has the wire jumpers configured appropriately for the
the Microboard must be configured to meet the require- display to which it is attached, as shown below. Display
ments of the actual Display installed. When AC power Interface Boards are available individually for service
is applied to the OptiView Control Center, as part of the replacement. The YORK part number of the Display
power-up sequence, the Microboard reads the four Panel Interface Board compatible with the installed Display is
ID wire jumpers, P1D0 through P1D3, on the Display listed on a label attached to the Display mounting plate.
Interface Board to determine which Display is present. However, service replacement Displays are provided as
The configuration of these jumpers indicates the actual a kit (331-01771-000) that includes, among other items,
Display that is installed on the OptiView Control Center the appropriate Display Interface Board for the Dis-
door. The Display Controller on the Microboard is then play included in the kit. Refer to explanation in “Liquid
configured appropriately. Crystal Display” section.
031-01765-001:
On Sharp and NEC displays the configuration of wire Display applicability - LG Semicon LP104V2-W
jumpers P30 and P31 determines whether the Display (031-02046-000) &
scan orientation is Normal or Reverse (image reversal) NEC NL6448AC33-24
scan. As described in the preceding “Display” section, Jumper configuration - PID0 - IN
Normal scan is left to right, beginning with the top row PID1 - OUT
and continuing sequentially through the rows to the PID2 - OUT
bottom row. Normal scan is used in OptiView Control PID3 - OUT
P30 - OUT
Center applications. In Display applications other than
P31 - OUT
OptiView Control Center applications, image reversal
is sometimes required. In image reversal applications, 031-01765-002:
Display applicability - SHARP LQ10D367/368
the scan is reversed; the scan is right to left, beginning
(031-01774-000) &
with the bottom row and proceeding to the top row. The
LQ10D421
jumper configurations determine the voltage level at Dis- Jumper configuration - PID0 - OUT
play Interface Board J1-30 (P30) and J1-31 (P31). If P30 PID1 - IN
is IN, the voltage at J1-30 is +5.0VDC or +3.3VDC (as PID2 - OUT
determined by position of Microboard Program Jumper PID3 - OUT
JP2); if OUT, 0VDC. If P31 is IN, the voltage at J1-31 is P30 - IN
6
GND; if OUT, 0VDC. The Display reads these voltages P31 - IN
and adopts a scan mode as follows: The red, green and blue display drive and control signals
are simply passed through the Display Interface Board.
SHARP LQ10D367/368 (031-01774-000) & The value of VCC is either +5VDC or +3.3VDC, as
LQ10D421 Displays: determined by the position of Program Jumper JP2 on
SHARP displays require configuration of both jumpers the Microboard. PID0 through PID3, when installed,
to achieve total image reversal. connect their respective Microboard (J5) inputs to GND;
when removed, the Microboard pulls these signals up
P30 IN - Normal scan; left to right to +5VDC. When P30 is installed, the Display input
OUT - Reverse scan: right to left (CN1-30) is connected to VCC (+5VDC or +3.3VDC
P31 IN - Normal scan; top to bottom as determined by Microboard Program Jumper JP2).
OUT - Reverse scan; bottom to top When P31 is installed, the Display input (CN1-31) is
connected to GND.
JOHNSON CONTROLS 67
 68
Display Interface Board

FIG. 26 – DISPLAY INTERFACE BOARD

LG SEMICON LP104V2-W (031-02046-000)
NEC NL6448AC33-24 DISPLAY
031-01765-001 - PID0 IN
PID1-3 OUT
P30, P31 OUT
SHARP LQ10D367/368 (031-01774-000) & LQ10D421 DISPLAYS
031-01765-002 - PID0 OUT
PID1 IN
PID2, 3 OUT
P30, 31 IN LD04070

JOHNSON CONTROLS
FORM 160.80-M1 (307)
 FORM 160.80-M1 (307)

SECTION 7
DISPLAY BACKLIGHT INVERTER BOARD
(REFER TO FIG. 27- 29)
7
The Display Backlight Inverter Board generates a signal turns the lamp on and off. Some manufacturers re-
high voltage AC signal that is applied to the backlight quire this signal to be +12VDC, others require +5VDC.
lamp, causing it to illuminate. The magnitude of the Program Jumper JP4 must be positioned to provide the
signal determines the lamp brightness. Displays by some required voltage. Further, some applications require this
manufacturers have two lamps; one at the top and one at signal to be a +VDC (+12VDC or +5VDC) to turn on
the bottom of the display. Other Display manufacturers the lamp. Others require this signal to be 0VDC to turn
have only a lamp at the top of the display. on the lamp. Program Jumper JP3 must be positioned
to provide the required polarity.
An Inverter converts low level DC voltage (+12VDC
or +5VDC, as required by the manufacturer) from the Depending upon the Display manufacturer, the bright-
Microboard to a 500 to 1500VAC 60KHz signal that ness control input from the Microboard must be either
is applied to the lamp. The higher the AC voltage, the a variable voltage or a variable resistance. Microboard
greater the brightness of the lamp. When this voltage is Program Jumpers JP7 and JP8 are used to provide the
not present, the lamp is turned off. appropriate technique (refer to Fig. 8). The lamp dimmer
circuit on the Microboard is an IC that is the electrical
High voltage, up to 1500VAC, is equivalent of a 10K ohm potentiometer with 100 posi-
present at the output of the backlight tions or steps. The Program adjusts the position of the
inverter board. Refer to Figures 27 to potentiometer. When configured for variable voltage
29 and locate the output connectors. (JP7 & JP8 installed), the output between Microboard
J6-7 and J6-8 is a 0 to +5.0VDC signal. Not all applica-
Use extreme caution when working in
tions require the full 5.0VDC range. If configured for
this area!!!
variable resistance (JP7 and JP8 removed), the output
Different Display manufacturers require different Back- between Microboard J6-7 and J6-8 is a 0 to 10K ohm
light Inverter Boards. The different board designs require variable resistance.
different control voltage inputs. To accommodate these
variations, Microboard Program Jumpers JP3 - JP5, The OptiView Control Center could be supplied with
JP7 and JP8 must be configured to provide the required any of several approved Displays. Each Display re-
voltage levels. A label attached to the Display mounting quires a specific Backlight Inverter Board as speci-
plate lists the required Program Jumper configuration fied below and in Figures 27 to 29. These boards are
for that particular display. Refer to Table 1 for required individually available as service replacement parts (the
Program Jumper configurations for the various Display required Backlight Inverter Board part number is listed
applications. on the label attached to the Display mounting plate).
However, service replacement Displays are provided
Under Program control, the Microboard generates the in a kit (YORK P/N 331-01771-000) that includes the
control signals that are applied to the Backlight Inverter appropriate Backlight Inverter Board (refer to “Liquid
Board. The Program determines when the lamp is turned Crystal Display” Section).
on and off. It also adjusts the lamp brightness. To in-
crease the average lamp life of 25000 hours, the lamp SHARP model LQ10D367/368 (031-01774-000) AND
brightness is normally adjusted to 50%. This brightness LG Semicon LP104V2-W (031-02046-000) displays
level will still allow the display to be visible. When the require a TDK CXA-LO612-VJL Backlight Inverter
Program senses a Keypad key has been pressed, it adjusts Board (YORK P/N 031-01789-000) (ref. Fig. 27). These
the brightness to 100% (maximum). boards generate a lamp illumination high voltage AC
from +12VDC. When the Backlight Enable signal at
The lamp illumination high voltage AC is generated connector CN1-3 is +5VDC, the high voltage signal is
from either +12VDC or +5VDC as required by the applied to the lamp. When CN1-3 is 0VDC, the high
manufacturer. Microboard Program Jumper JP5 must voltage signal is removed from the lamp, turning it off.
be positioned to provide the required voltage. The The lamp brightness is controlled by a variable voltage
Microboard provides the Backlight Enable signal. This signal, developed by the lamp dimmer circuit (ref. Fig.
8) on the Microboard and applied to connector CN1-4.

JOHNSON CONTROLS 69
 Display Backlight Inverter Board
FORM 160.80-M1 (307)

The lamp dimmer circuit varies the voltage at CN1-4 100%. This display has a lamp at the top of the display
over the range of 0 to +3.0VDC. 0VDC produces maxi- and one at the bottom of the display. Connector CN2
mum (100%) brightness; +3.0VDC produces minimum applies the high voltage lamp illumination signal to the
(0%) brightness. Voltages between these values produce lower lamp; CN3 the upper lamp.
a linear brightness 0 and 100%. Connector CN2 applies
the high voltage lamp illumination signal to the lamp. NEC model NL6448AC33-24 displays require an NEC
104PWBR1 Backlight Inverter Board (YORK P/N XXX-
SHARP model LQ10D421 displays require a XENTEK XXXXX-XXX) (refer to Fig. 29). These boards generate
LS520 Backlight Inverter Board (YORK P/N XXX- the lamp illumination high voltage AC from +12VDC.
XXXXX-XXX) (refer to Fig. 28). These boards generate When the Backlight Enable signal at connector CN3-1
the lamp illumination high voltage AC from +12VDC. is +5VDC, the high voltage signal is applied to the lamp,
When the “Backlight Enable” signal at connector turning it on. When CN3-1 is 0VDC, the high voltage
CN1-5 is 0VDC, the high voltage signal is applied to signal is removed from the lamp, turning it off. The
the lamp, turning it on. When CN1-5 is +12VDC, the lamp brightness is controlled by a variable resistance,
high voltage signal is removed from the lamp, turning developed by the lamp dimmer circuit (ref. Fig. 8) on
it off. The lamp brightness is controlled by a variable the Microboard and applied to connector CN3-2 and
voltage signal, developed by the lamp dimmer circuit CN3-3. The lamp dimmer varies the resistance between
(ref. Fig.8) on the Microboard and applied to connector CN3-2 and CN3-3 over the range of 0 to 10K Ohms. 0
CN1-6 and CN1-7. The Microboard places CN1-7 at Ohms produces minimum (0%) brightness; 10K Ohms
ground (GND) potential. The lamp dimmer varies the produces maximum (100%) brightness. Resistances be-
voltage at CN1-6 over the range of 0 to +2.5VDC. 0VDC tween these extremes produce linear brightness between
produces maximum (100%) lamp brightness; 2.5VDC 0% and 100%. Connector CN2 applies the high voltage
produces minimum (0%) brightness. Voltages between lamp illumination signal.
these values produce a linear brightness between 0 and

RETURN
BACKLIGHT DISPLAY BACKLIGHT INVERTER BOARD
500 - 1400 VAC LAMP TYPE: TDK CXA-L0612-VJL
PART NUMBER: 031-01789-000
N.C.

FOR: SHARP LQ10D367 &

NOTES: LG SEMICON LP104V2-W DISPLAYS
3 2 1 1. OFF = 0VDC; ON = +5VDC. Refer to
CN2 Microboard Program Jumpers JP3 & JP4.
2. 0 - +3.0VDC. 0VDC = MAX (100%) Bright-
ness; +3.0VDC = MIN (0%) Brightness.
Refer to Fig. 8 and Microboard Jumpers J6
INVERTER JP7 & JP8.
3. Refer to Microboard Program Jumper JP5.
N.C. 10
BOARD
4. N.C. = No Connection. N.C. 9
N.C. 8
CN1 BRIGHTNESS CONTROL (NOTE 2)
7 MICRO
1 2 3 4 5 N.C. 6 BOARD
N.C. BACKLIGHT ENABLE (NOTE 1)
5
GND
4
N.C. 3
N.C. 2
+ 12 VDC (NOTE 3)
1

INVERTER CABLE 031-01770-003 LD05566

FIG. 27 – DISPLAY BACKLIGHT INVERTER BOARD (SHARP LQ10D367/368 (031-01774-000) & LG SEMICON
LP104V2-W) (031-02046-000)
70 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

UPPER
BACKLIGHT 500 - 1500 VAC
LAMP N.C. DISPLAY BACKLIGHT INVERTER BOARD
1 2 3 TYPE: XENTEK LS520
CN3
PART NUMBER: NOT AVAILABLE 7
FOR: SHARP LQ10D421 DISPLAY
J6
+12VDC (NOTE 3) 1
1
+12VDC (NOTE 3) 2
2
GND 3
3
GND
MICRO
CN1 4
4 BOARD
BACKLIGHT ENABLE (ON/OFF) (NOTE 1) 5
5
BRIGHTNESS CONTROL WIPER (NOTE 2)
6 N.C. 6
BRIGHTNESS CONTROL ( - ) (GND) 7
7

8
CN2 N.C. 9
1 2 3 INVERTER CABLE
N.C. (NOT AVAILABLE) N.C. 10
LOWER
BACKLIGHT 500 - 1500 VAC
LAMP LD04072
NOTES:
1. ON = 0VDC; OFF = +12VDC. Refer to Microboard Program Jumpers JP3 & JP4.
2. 0 - +2.5VDC. 0VDC = MAX (100%) Brightness; +2.5VDC = MIN (0%) Brightness.
Refer to Fig. 8 and Microboard Program Jumpers JP7 & JP8.
3. Refer to Microboard Program Jumper JP5.
4. N.C. = No Connection.

FIG. 28 – DISPLAY BACKLIGHT INVERTER BOARD (SHARP LQ10D421)

BACKLIGHT 500 - 1500 VAC DISPLAY BACKLIGHT INVERTER BOARD

LAMP GND
TYPE: NEC 104PWBR1
1 2 3 PART NUMBER: NOT AVAILABLE
CN2 FOR: NEC NL6448AC33-24 DISPLAY
J6
+12VDC (NOTE 3) 1
1
+12VDC (NOTE 3) 2
2
GND 3
3
GND
MICRO
CN1 4
4 BOARD
5 N.C. 5

6
BACKLIGHT ENABLE (ON/OFF) (NOTE 1) 7
1
BRIGHTNESS CONTROL WIPER (NOTE 2)
CN3 2 N.C. 8
BRIGHTNESS CONTROL ( - ) (NOTE 2) N.C. 9
3

N.C. 10

INVERTER CABLE
(NOT AVAILABLE)
LD04073

NOTES:
1. ON = +5VDC; OFF = 0VDC. Refer to Microboard Program Jumpers JP3 & JP4.
2. 0 - 10K Ohms. 0 Ohms = MIN (0%) Brightness; 10K Ohms = MAX (100%) Brightness.
Refer to Fig. 8 and Microboard Program Jumpers JP7 & JP8.
3. Refer to Microboard Program Jumper JP5.
4. N.C. = No Connection.

FIG. 29 – DISPLAY BACKLIGHT INVERTER BOARD (NEC NL6448AC33-24)

JOHNSON CONTROLS 71
 Keypad
FORM 160.80-M1 (307)

SECTION 8
KEYPAD
(REFER TO FIGURES 30 & 31)

The Keypad contains touch-sensitive keys that allow concludes the key at coordinate of row 4 and column 3
the Operator to interface with the Control Center. The is pressed. Since the coordinates of all keys are stored
Operator presses the keys to request the desired screens in the Microboard’s Program, it can identify which key
of information and enter System Setpoints. is at this coordinate and responds accordingly. In this
example the “1” key is pressed.
The top layer of the Keypad contains embossed areas
identifying the keys. Under each embossed key area In order for the Microboard to reliably detect closed
are two conductors, one on top of the other, separated and open keys, each key must meet a closed circuit
by an air space. The conductors are arranged in a ma- and open circuit resistance requirement. When a key
trix of rows and columns and connected to the Keypad is pressed, the contact resistance must be < 100 Ohms.
connector as shown in Fig. 31. The embossed area of When a key is not pressed, the contact resistance must
each key is located directly over the intersection point be > 1 Meg Ohm. If the Microboard is not responding
of the conductors. Pressing the embossed key area to a pressed key, or if it’s detecting a closed key when
causes contact and electrical continuity between the none are pressed, it could be because the contact resis-
two conductors. For example, pressing the “1” key tance requirements are not being met. The operation of
creates continuity between the Keypad connector pin each key can be checked with an Ohmmeter. To check
5 (column 3) and pin 13 (row 4). Since this connector the open and closed contact resistance of any key, refer
is interfaced to the Microboard (J18), the Microboard to the “Diagnostics and Troubleshooting” Section 21
senses this continuity as described below and concludes of this book.
the “1” key is pressed.

The Microboard Program continuously scans the Key- The Keypad is attached to the front of the Control Center
pad to determine if a key is pressed. Beginning with door with an adhesive backing. If service replacement is
row 1 and proceeding through all rows, the Program required, start at one corner and slowly peel the Keypad
places a “logic low” (<1VDC) on a row, a “logic high” from the door. The rear side of the replacement Keypad
(>4VDC) on the remaining rows and reads the columns. is coated with an adhesive covered with a paper backing.
A logic low in any column indicates a key in that column Remove the paper backing, align the Display and rocker
and row is pressed. For example, if at the time row 4 switch openings and apply the Keypad to the door.
is being driven low, if column 3 is low, then the Micro

72 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

LD04074

CONNECTOR

FIG. 30 – KEYPAD

JOHNSON CONTROLS 73
 Keypad
FORM 160.80-M1 (307)

LD04075

LD04076
FIG. 31 – KEYPAD

74 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

SECTION 9
POWER SUPPLY
(REFER TO FIG 32 & 33)

The Power Supply provides the DC power for the LCD

Display and all the printed circuit boards in the Con-
trol Center. It receives a 102 to 132VAC input from an
external power source and provides the following DC
outputs:
• -12VDC
• +12VDC
• +5VDC 29136A
9
FIG. 32 – POWER SUPPLY
• +24VDC
• Ground

The +24VDC output provides power to the CM-2 Board labeled as the +5VDC (Analog) supply. It is also routed
(Electro-Mechanical starter applications), Solid State to all Pressure Transducers, Temperature Thermistors,
Starter Logic Board (Mod “A” SSS) or Solid State and Motor controller Board (CM-2, Solid State Starter
Starter Logic/Trigger Board (Mod “B” SSS). Logic Board [Mod “A” SSS]). This permits all Analog
circuits to be powered by the same supply, eliminating
The -12VDC, +12VDC, Gnd and +5VDC outputs are any offsets caused by voltage regulator drift. Microboard
applied to the Microboard. There, these voltages are 031-02430-000 has an additional voltage regulator that
applied to the circuits requiring the respective voltage. provides a 2.5Vdc power source. The +3.3VDC supply
From the Microboard, the +12VDC and +5VDC are is utilized by the Microprocessor, Flash Memory Card
distributed to other system components requiring these and other digital circuits. It could also be applied to the
voltages. These include the GPIC, I/O Board, LCD Backlight Inverter Board, depending on the Display
Display and Display Backlight Inverter Board. manufacturer’s requirements as explained below.

The Condor Power supply allows adjustment of the Different Display manufacturers can require different
+5Vdc output. To account for losses in wiring and supply voltages for their display and supporting circuits.
connections and assure sufficient voltage level at the To accommodate the different Display manufacturer’s
microboard input, the “VAdJ” (R51) potentiometer is ad- voltage requirements, Microboard Program Jumpers
justed to achieve +5.1Vdc at the input to the Microboard JP2 and JP5 must be positioned to provide the required
J1-1. supply voltages to the Display and the Display Back-
light Inverter Board. Either +5VDC or +3.3VDC, as
As shown in Fig 7 (031-01730-000 microboard) and determined by JP2, is applied to the Display. Either
Fig 7A (031-01730-000 microboard), the Microboard +12VDC or +5VDC, as determined by JP5, is applied
contains two voltage regulators that create separate to the Display Backlight Inverter Board. Refer to Table
+5VDC and +3.3VDC supplies. The +5VDC supply is 1 “Microboard Program Jumpers”.
dedicated to all the Microboard Analog circuits and is

JOHNSON CONTROLS 75
 76
+5VDC (ANALOG)
ALL TRANSDUCERS & THERMISTORS

+5VDC
- 12VDC
+12VDC
+12VDC MICROGATEWAY
GND
Power Supply

DC GND
POWER
SUPPLY +5VDC

+5VDC

MICROBOARD +12VDC I/O

GND
BOARD

+24VDC
GND

(NOTE 4)
CM-2 BOARD
or +5VDC (ANALOG)
(NOTE 3) VDD (NOTE 1)
SOLID STATE
GND (NOTE 3) LCD
STARTER GND DISPLAY

+V (NOTE 2)
DISPLAY BACKLIGHT
NOTES: GND INVERTER BOARD
1. +5 or +3.3VDC as determined by Microboard Program Jumper JP2
& display requirements.
2. +12 or +5VDC as determined by Microboard Program Jumper JP5 & LD06483
display requirements.
3. Not Applicable to Mod “B” Solid State Starter Applications.
4. Applications - CM2 (Em Starter) Logic/Trigger Board (Mod “B” Solid
State Starter).

FIG. 33 – POWER SUPPLY – DC POWER DISTRIBUTION (REFER TO CONTROL CENTER WIRING DIAGRAM FOR WIRE CONNECTIONS)

JOHNSON CONTROLS
FORM 160.80-M1 (307)
 FORM 160.80-M1 (307)

SECTION 10
CURRENT MODULE (CM-2)
(REFER TO FIG 34 - 36)

On applications where the Compressor Motor is con- The motor current signal input at J1-1 & J1-2 is applied
trolled by an Electro-Mechanical Starter, the Control to potentiometer R8. This is Factory adjusted (field ad-
Center is equipped with a Current Module. The Cur- justed on service replacements) to illuminate the 105%
rent Module provides compressor motor Overload CURR indicator (CR6) when the compressor motor
and Power Fault protection. The Current Module also current reaches 105% FLA. This calibrated voltage is
provides an analog voltage representing the compressor applied to the Power Fault detector, Overload detectors
motor current to the Microboard for display and Cur- and Multiplexer (MUX).
rent Limit control. While the chiller is running, the
Microboard controls the Slide Valve position to limit The Power Fault circuit protects the compressor motor
the motor current to the system 100% Full Load Amp and driveline from transient torque damage. It anticipates
(FLA) value. the transient torque condition by detecting a momentary
interruption in motor current and de-energizing the
The contacts of Current Module K1 relay (identified as starter before damage can occur. If the chiller has been 10
“CM” contacts on the Control Center wiring diagram) running for >75 seconds and the motor current decreases
are interfaced into the Motor Controller initiated shut- to <10% FLA, a Power Fault shutdown is initiated.
down circuit that is located between Control Center TB6- The Power Fault indicator (CR5) is illuminated and
53 and I/O Board TB1-16 (ref. Fig 15 and 35). They are remains illuminated until manually reset with RESET
also connected as a digital input to I/O Board J2-1. Relay switch S2. Relay K1 is de-energized for 1 second and
K1 is normally energized, maintaining its contacts in a then returned to the energized state. Relay K1 contacts
closed position. Whenever the Current Module initiates (CM) open for 1 second and then return to the closed
a chiller shutdown, it de-energizes K1, opening its con- state. A SYSTEM LOCKOUT DELAY is initiated
tacts. This interrupts the circuit to I/O Expansion Board and POWER FAULT is displayed on the Display. The
RUN relay coil 1R (K18), de-energizing it and causing chiller will automatically restart upon completion of
the Starter to shutdown. Simultaneously, the Microboard SYSTEM LOCKOUT DELAY.
reads the opening of these contacts via I/O Board J2-1,
initiates a SYSTEM LOCKOUT DELAY and displays If the motor current remains continuously at >105%
the appropriate message as described below. FLA for 50 seconds (Nominal), an OVERLOAD
shutdown is initiated. The Overload indicator (CR4)
Three Current Transformers in the Compressor Mo- is illuminated and remains illuminated until manually
tor Terminal Box (ref Fig. 36) provide 3 phase motor reset with RESET switch S2. Relay K1 is de-ener-
current signals to the Diode Bridge (DB). The required gized, opening K1 contacts (CM). Relay K1 remains
turns ratio of the Current Transformers is determined de-energized until manually reset with RESET switch
by the system 100% FLA. The Diode Bridge rectifies S2. A SYSTEM LOCKOUT DELAY is initiated and
and combines the three signals into one DC signal that MOTOR CONTROLLER-CONTACTS OPEN is
is applied to the parallel Variable Resistors (RES). displayed. The chiller cannot be started until RESET
These are Factory adjusted (field adjusted on service switch S2 is manually pressed.
replacements) to provide a nominal 1.0VDC (0.15 to
1.10VDC) signal to the Current Module at J1-1 and J1-2 If the motor current remains continuously at 245% FLA
when the compressor motor current is at 100% FLA. Fig. for 40 seconds, 290% FLA for 20 seconds or 360% FLA
36 contains a formula to calculate the resistance of RES for 10 seconds, an OVERLOAD shutdown is initiated.
required to achieve 1.0VDC at 100%FLA. The 100% Relay K1 and Overload indicator CR4 operate as de-
FLA value is located on a label adhered to the inside of scribed immediately above. A SYSTEM LOCKOUT
the Control Center door. DELAY is initiated and MOTOR CONTROLLER
- CONTACTS OPEN is displayed. The chiller cannot

JOHNSON CONTROLS 77
 Current Module (CM-2)
FORM 160.80-M1 (307)

be restarted until RESET switch is manually pressed. the motor current continues to rise to 104% FLA, the
LRA/FLA Potentiometer R16 is factory adjusted (field Microboard applies an unload signal to the Slide Valve
adjusted on service replacements) to the ratio of Locked until the motor current decreases to 102% FLA. While
Rotor Amps to Full Load Amps. The correct setting is Current Limit is in effect, “MOTOR - HIGH CUR-
determined by dividing the LRA by the FLA. If Switch RENT LIMIT” is displayed.
S1 is in the “Y-Delta/57%” position, there is no 245%
FLA threshold. Switch S1 must be positioned accord- As detailed in the “System Calibration” section of this
ing to the type of Electro-Mechanical starter present; book, to field calibrate Potentiometer R8, the slide valve
UP for Y-delta or Autotransformer starters, DOWN for must be manually operated to achieve 105% FLA com-
Across-the-Line starters. pressor motor current. Therefore, during this procedure,
Current Limit is not invoked until 107% FLA and 110%
The Multiplexer (MUX) is an electronic switch with 8 FLA. The first time the SLIDE VALVE LOAD key is
inputs and 1 output. The address applied to it determines pressed on the COMPRESSOR Screen after logging
the position of the switch (ie, which input is routed to the in at SERVICE access level, a 10 minute window is
output). The inputs to channel 0 through 6 are grounded opened, allowing the current to rise to 107% FLA before
(0VDC) . The input to channel 7 is a 0 to 4.0VDC analog further slide valve loading is inhibited. This inhibit is
signal, representing motor current over the range of 0 released when the current decreases to 106% FLA. If
to 100% FLA. It is Factory calibrated by Potentiometer the current continues to rise to 110%, manual control is
R34 to be 4.0VDC when the compressor motor current is overridden and an unload signal is applied to the slide
at 100% FLA. Under Program control, the Microboard valve until the current decreases to 109% FLA. After
commands the Mux to route the inputs to the Mux output 10 minutes, the normal current limit thresholds of 100%
by applying 3-bit Binary addresses to the Mux address FLA and 104% FLA are applied.
inputs at J5-1, 2, 3. The voltage level for a logic 1 is
+12VDC and logic 0 is 0VDC. The Microboard reads The Mux address inputs along with respective outputs
the Mux outputs at J5-6. It first addresses channel 0 are as follows:
to determine the type of starter applied. The 0VDC at BINARY
channel 0 indicates to the Microboard that this is an J5-1 J5-2 J5-3
DECIMAL OUTPUT

Electro-Mechanical Starter application (In all starter ap-

0 0 0 0 Ground
plications, the Micro reads channel 0 to determine the
0 0 1 1 Ground
type starter applied; 0VDC = EM starter, >0VDC=Solid
0 1 0 2 Ground
State Starter). It then addresses channel 7 (ignoring
0 1 1 3 Ground
channels 1 through 6) to read the analog motor current
1 0 0 4 Ground
voltage. The Microboard interprets this analog value in 1 0 1 5 Ground
terms of %FLA and displays it upon operator keypad 1 1 0 6 Ground
request. It also uses this value to invoke compressor 0-5.0VDC motor current
motor Current Limit at 100% FLA and 104% FLA. analog signal calibrated on
When motor current rises to 100% FLA, the Microboard 1 1 1 7 CM-2 board to be +4.0VDC at
100% FLA.
prevents any further current rise by inhibiting further
Slide Valve loading until it decreases to 98% FLA. If

78 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

10

LD04079

FIG. 34 – CM-2 CURRENT MODULE (ELECTRO-MECHANICAL STARTER APPLICATION)

LD04080

FIG. 35 – CM-2 CURRENT MODULE (ELECTRO-MECHANICAL STARTER APPLICATIONS)

JOHNSON CONTROLS 79
 Current Module (CM-2)
FORM 160.80-M1 (307)

LD04081

NOTES:
MOTOR CT
FLA RESD (OHMS) A. Requires passing motor lead through current transformer (CT)
VOLTAGE RATIO
once before connecting to power supply.
65-111A 200:1 B. Requires passing motor lead through CT twice before connecting
112-224A 350:1 R = 1.282 (CT RATIO) to power supply.
208-600
225-829A 700:1 FLA C. Requires passing motor lead through CT three times before con-
830-1790A 1400:1 necting to power supply.

R = 0.247 (CT RATIO) D. Calculates resistance of “RES” to achieve 1.0 VDC at FLA.
11-18C 200:1
FLA
R = 0.370 (CT RATIO)
19-37B 200:1
FLA
2300-4160
38-123A 200:1
R = 0.740 (CT RATIO)
124-264A 350:1
FLA
265-518A 700:1

LD04082

FIG. 36 – CM-2 CURRENT MODULE – INTERFACE, CURRENT TRANSFORMERS & VARIABLE RESISTORS

80 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

SECTION 11
SOLID STATE STARTERS
(REFER TO FIGS. 37 - 40)

SOLID STATE STARTERS procedure in the “Diagnostics and Troubleshooting”

section of this book. The STOP relay contacts on the
The Control Center will accommodate either of two dif- Logic/Trigger Board assure a positive shutdown on all
ferent YORK Liquid Cooled Solid State Starters (LC- LCSSS initiated shutdowns.
SSS). New production chillers after October 1999, are
equipped with the Mod “B” LCSSS. This style LCSSS After power has been applied to the system, the
contains the Silicon Controlled Rectifier (SCR) assem- Microboard will attempt to establish communications
blies, an integrated Logic/Trigger Board and interfaces with the Logic/Trigger Board. If unsuccessful within 10
the Control Center via a serial data communications attempts, the Microboard initiates a Cycling shutdown
link and hardwired relay contacts. The Control Center and displays “LCSSS INITIALIZATION FAILED”
can be retrofit to earlier vintage chillers equipped with on the System Details line of the Control Center dis-
the previous version LCSSS that interfaces the Control play. The Microboard will continue to establish com-
Center via a multiplexed data interface and hardwired munications until successful. Also, at power-up, the
relay contacts. The earlier vintage LCSSS houses the Logic/Trigger Board reads wire jumpers in its con-
SCR assemblies and Trigger board; a separate Logic nector J1 to determine the LCSSS model applied (refer
Board is located inside the Control Center. Microboard to 160.00-O2). If an invalid jumper configuration is
Program Jumper JP39 must be positioned to invoke read, the Logic/trigger Board initiates a Cycling shut-
the appropriate Microboard/Program operation for the 11
down and “LCSSS - INVALID CURRENT SCALE
starter applied (refer to Table 1). SELECTION” is displayed on the System Details line
of the Control Center Display. The model designation
Mod “B” Serial Interface LCSSS is transmitted to the Microboard for display on the MO-
(Refer to Fig. 37) TOR Screen. This designation determines the allowable
A complete description, theory of operation and trou- range for the Full Load Amps (FLA) Setpoint and Start
bleshooting instructions of this LCSSS are contained Current Setpoint. There are 4 LCSSS models: 7L, 14L,
in YORK Service Manual 160.00-O2. The following 26L and 33L. Each model has an allowable Full Load
describes the interface and interaction of the LCSSS Amps (FLA) range and Start Current range as listed
with the Control Center. below.

As shown in Figure 37, the LCSSS contains a single Communications between the Microboard and Logic/
Logic/Trigger printed circuit board. This board performs Trigger Board are in the form of master/slave. The
the following functions: Microboard is the master and the Logic/Trigger Board
is the slave. The Logic/Trigger Board sends two types
• Generates the SCR trigger pulses
of data to the Microboard: Status data and Fault data.
• Receives start/stop commands from the After successful initialization, the Microboard sends
Microboard a data request every 2 seconds. Normally, the Logic/
• Transmits status and fault data to the Microboard Trigger Board responds to each request. However, if
the Microboard does not receive a response to 10 con-
• Generates all LCSSS initiated Safety and Cycling
secutive requests, the Microboard initiates a Cycling
shutdowns.
shutdown and displays “LCSSS - SERIAL COMMU-
NICATIONS” on the System Details line of the Control
The Logic/Trigger Board is powered by +24VDC from
Center display. In addition, the Logic/Trigger Board will
the Control Center Power Supply. The Control Center
initiate the same Cycling shutdown if it does not receive
Microboard (J15) communicates with this board via a
a data request from the Microboard after 10 successive
1200 baud 0/+5VDC serial data communications link.
attempts to send data.
If this communications link does not operate properly,
correct Microboard J15 serial port operation can be
verified using the Serial Inputs and Outputs diagnostic Anytime the Logic/Trigger Board initiates a Cycling or
Safety shutdown, it opens its STOP contacts that are

JOHNSON CONTROLS 81
 Solid State Starter Logic Board
FORM 160.80-M1 (307)

connected in series with the Control Center’s 1R (K18) • Three-phase SCR module temperature
RUN relay coil. The contacts remain open as long as the • Starter model designation
condition exists. The open STOP contacts interrupt the
circuit to 1R causing it to de-energize, removing the run The following are the programmable setpoints asso-
signal to the LCSSS. Simultaneously, the Microboard ciated with the LCSSS. They are programmed on the
reads the opening of the LCSSS STOP contacts via the MOTOR Screen. Refer to programming instructions in
I/O Board J2- 1. This signals the Microboard that the the “System Calibration, Service Setpoints and Reset
LCSSS has initiated a shutdown. The Logic/Trigger Procedures” section of this book.
Board sends the cause of the shutdown in response to
• Full Load Amps - This is the maximum allowed
the next data request. This is logged on the HISTORY
motor current at which this chiller is permitted
Screen as the “LAST FAULT WHILE RUNNING”.
to operate to achieve maximum design capacity.
A snapshot of the LCSSS operating parameters valid
It is the Full Load Amps (FLA) of the chiller,
at the instant of the fault are also sent. Any additional
as listed on the SALES ORDER Screen. Each
faults that occur within the 2 second transmission time
starter model has a permissible range over which
are also sent and logged on the HISTORY Screen under
this setpoint can be programmed as follows:
“LAST TEN FAULTS”. Refer to Operation Manual
160.80-O1 for description of all Cycling and Safety shut- LCSSS Model Permissible FLA
down messages. While this data is being sent, “LCSSS 7L-46, 58 and 50 35 to 260 Amps
- SHUTDOWN - REQUESTING FAULT DATA” 14L-17, 28, 46, 58 and 50 65 to 510 Amps
is displayed on the System Details line of the Control
26L-17, 28, 46, 58 and 50 125 to 850 Amps
Center display. If fault data is not returned within 2
seconds, the Microboard will continue to send a request 33L-17, 28, 46 and 50 215 to 1050 Amps
at 2 second intervals until the fault data is returned. If • Start Current - The Logic/Trigger Board will limit
none is returned within 10 consecutive requests, it as- inrush motor current to this value during starting.
sumes it is not forthcoming and it displays “LCSSS The programmed value is sent to the Logic/Trigger
- STOP CONTACTS OPEN” on the System Details Board over the serial communications link. This
line of the display. setpoint should be programmed to (0.45 x mo-
tor Delta Locked Rotor Amps) as listed on the
The chiller can be started if there are no Safety and Cy- SALES ORDER Screen. Each model starter has
cling conditions. If the temperature of any of the SCR a permissible range over which this setpoint can
modules are >110°F, the LCSSS cooling pump will run be programmed as follows:
and the chiller will be inhibited from starting until the Permissible Start
LCSSS Model
temperature has decreased below 109°F. While this start Current Range
inhibit is in effect, “LCSSS - HIGH TEMPERATURE 7L-46, 58 and 50 310 to 700 Amps
PHASE X - STOPPED” (where X is phase A, B, or C)
14L- 17, 28, 46, 58 and 50 620 to 1400 Amps
is displayed on the System Details line of the display.
When the chiller is started, the Control Center sends 26L- 17, 28, 46, 58 and 50 1150 to 2600 Amps
two start signals simultaneously to the Logic/Trigger 33L-17, 28, 46 and 50 1460 to 3300 Amps
Board. One is transmitted via the serial communications • Supply Line Voltage Range - This setpoint is
link. The other is the closure of 1R (K18) Start relay, the line voltage application and establishes the
applying 115VAC to Logic/Trigger Board TB1-24. If high and low line voltage shutdown thresholds.
these two signals are not received within 5 seconds of Shutdown and restart thresholds are contained in
one another, the Logic/Trigger Board initiates a cycling Operation manual 160.80-O1 under the messages
shutdown and “LCSSS - RUN SIGNAL” is displayed “LCSSS - LOW SUPPLY LINE VOLTAGE”
on the System Details line of the display. and “LCSSS - HIGH SUPPLY LINE VOLT-
AGE”.
The Logic/Trigger Board transmits the following pa-
rameters over the serial communications link for display • Open SCR Enable/Disable - This enables or dis-
on the MOTOR Screen: ables the Open SCR detection Safety protection
performed by the Logic/Trigger Board. This pro-
• Three-phase motor current tection must never be disabled unless advised by
• Three-phase line-to-line motor supply voltage the YORK factory.
• Input Power (kW)

82 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

• Kilowatt Hours (KWH) Reset - This allows While the chiller is running, the Microboard will unload
the accumulated KWH to be set to a desired or inhibit loading of the Slide Valve, as required, to limit
starting value in the event the BRAM has to be the compressor motor current to the Current Limit or
field replaced. This must never be arbitrarily per- Pulldown Demand Limit setpoint (30% to 100% FLA)
formed. that is in effect. The Microboard calculates the “% Full
Load Amps” (FLA) by dividing the highest phase of the
To assure the chiller is not permitted to run for ex- 3-phase motor current, received from the Logic/Trigger
tended periods with the supply line voltage outside of Board, by the value programmed for the FULL LOAD
acceptable limits, the Logic/Trigger Board compares AMPS setpoint. “% FULL LOAD AMPS” is displayed
the actual 3-phase line voltage to the thresholds estab- on the MOTOR Screen. If the motor current increases
lished with the Supply Line Voltage Range setpoint. to the extent that the “% FULL LOAD AMPS” reaches
Each supply voltage application has an allowable up- 100% of the Current Limit Setpoint, the slide valve is
per and lower limit. If the supply voltage goes above inhibited from further loading until the motor current
or below these limits continuously for 20 seconds, the decreases to <98% of the Current Limit setpoint. If the
logic trigger Board initiates a Cycling shutdown and motor current increases to the extent that the “% FULL
displays “LCSSS - HIGH SUPPLY LINE VOLTAGE” LOAD AMPS” is 104% of the Current Limit setpoint,
or “LCSSS - LOW SUPPLY LINE VOLTAGE” as the slide valve will be unloaded until the “% FULL
appropriate. The chiller will automatically restart when LOAD AMPS” decreases to 102% of the Current Limit
the line voltage is within the acceptable range. setpoint. The slide valve loading will then be inhibited
until the “% FULL LOAD AMPS” decreases to <98%
of the Current Limit setpoint.
11

CONTROL CENTER SOLID STATE STARTER

J30 / P30
GND 5
POWER 6 6
J2 +24 VDC
SUPPLY 12 4
* 3
2
J15 1
3 GND
2 RX TB2
MICRO 1 TX
BOARD SERIAL COMMUNICATIONS

LCSSS
LOGIC / TRIGGER
2 36 37 J19 BOARD
CONTROLLER
SHUTDOWNS
MOTOR

START
STOP

TB1
– TB6 –
J1 2 36 37 START / STOP 24
25 25 24
TB5
I/O TB1 TB6
STARTER (MOTOR CONTROLLER) INITIATED SHUTDOWN
BOARD 16 16 16
STOP CONTACTS
53 53
J2 1 1 115VAC

NOTE:
9 – “CONDOR” Power Supply; 13 – “POWER ONE” Power Supply LD04648

FIG. 37 – MOD “B” SOLID STATE STARTER (LCSSS) - INTERFACE

JOHNSON CONTROLS 83
 Solid State Starter Logic Board
FORM 160.80-M1 (307)

Mod “A” Multiplexed Data Interface LCSSS

(Refer to Figs. 38 - 40)
A complete description, theory of operation and trou-
bleshooting instructions of this LCSSS are contained
YORK Service Manual 160.46-OM3. 1.
As shown in Fig. 38, the Logic Board of this model
starter is mounted inside the Control Center.

300 / 600V
VOLTMETER
SCALE K1
JUMPER RELAY

J3

J6
J2
J5

J7
JUMPER

P1 / J1
PLUG LOGIC
CONN. BOARD
INDI-
CATOR
LED’S

24672

INTERLOCK R3 R2 R1 J4 START OVERLOAD RESET

JUMPER RESISTORS CURRENT CURRENT PUSHBUTTON
BETWEEN POT POT (SWI)
NO. 7 & 8
PINS

FIG. 38 – SOLID STATE STARTER LOGIC BOARD

84 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

This board provides Overload, Power Fault, Fault POWER FAULT is displayed. The respective Ph.
Current, Phase Rotation/Loss, and Half Phase Pro- Rot/Loss or Trig. OOL LED illuminates and remains
tection for the Compressor Motor. It also receives SCR illuminated until manually reset with the S1 RESET
High Temp and Trigger Out Of Lock (OOL) shutdown switch. The chiller will automatically restart when the
signals from the Starter Trigger Board. Finally, it pro- contacts close.
vides analog voltages representing Compressor Motor
Current, Power Line Voltage, Current Limit commands The Starter Trigger Board monitors the Starter’s Sil-
and a Starter Model code to the Microboard. icon Controlled Rectifier (SCR) heatsink temperature.
Whenever the heatsink temperature increases to 212°F,
The contacts of Logic Board relay K1 (identified as the Trigger Board signals the Logic Board. MOTOR
“CM” contacts on the Control Center wiring diagram) CONTROLLER – CONTACTS OPEN is displayed.
are interfaced into the Motor Controller initiated shut- The Logic Board illuminates the High Temp LED and
down circuit that is located between Control Center opens Relay K1 contacts. The LED remains illuminated
TB6-53 and I/O Board TB1-16 (ref. Fig. 15 and 36). and the contacts remain open until the temperature de-
They are also connected as a digital input to I/O Board creases to less than 110°F and manually reset with the
J2-1. Relay K1 is normally energized, maintaining its Logic Board’s S1 RESET switch. After S1 is pressed,
contacts in a closed position. Whenever the Logic Board the chiller can be restarted. In routine operation, each
initiates a chiller shutdown, it de-energizes K1, opening time the chiller is shutdown for any reason, it is pre-
its contacts. This interrupts the circuit to I/O Board RUN vented from restarting until the heatsink temperature
relay coil 1R (K18), de-energizing it and causing the decreases to less then 110°F. While it is waiting for the
Starter to de-energize. Simultaneously, the Microboard temperature to decrease to this threshold, the HIGH
reads the opening of these contacts via I/O Board J2-1, TEMP LED is illuminated, Relay K1 contacts are open, 11
initiates a SYSTEM LOCKOUT DELAY and displays and MOTOR CONTROLLER – CONTACTS OPEN
the appropriate message as described below. is displayed. When the temperature is below 110°F, K1
contacts will open, the LED is extinguished, MOTOR
When the Logic Board detects an Overload condition, CONTROLLER – CONTACTS OPEN message is
Relay K1 contacts open and the Overload LED illu- cleared and the chiller will automatically restart.
minates. MOTOR CONTROLLER – CONTACTS
OPEN is displayed. The contacts remain open and the The Multiplexer (MUX) is an electronic switch with 8
LED remains illuminated until manually reset with the inputs and 1 output. The address applied to it determines
Logic Board’s S1 RESET switch. After S1 is pressed, the position of the switch and therefore the output. Under
the chiller can be restarted. Program control, the Microboard sequentially addresses
MUX channels 0 through 7. The voltage output of each
When a Power Fault, Fault Current or Half Phase channel is listed in the table below. Channel 0 is an
condition is detected, Relay K1 contacts open for 1 sec- analog voltage that represents the Starter model and
ond and then close. The Power fault LED illuminates Power Line voltage Voltmeter scale. The Program uses
and will remain illuminated until manually reset with this value to limit the Full Load Amps Setpoint range
the S1 Reset switch. POWER FAULT is displayed. At to the maximum allowed value for the Starter size. This
the completion of SYSTEM LOCKOUT DELAY, the value also determines the Line Voltage display range and
chiller will automatically restart. Motor current display range. Channel 1 is a current limit
command that forces the Micro to perform slide valve
When a Power line Phase Rotation/Loss or Trigger inhibit and unload at the 100% and 104% FLA. This
Board Out of Lock (OOL) condition is detected, Relay command is in addition to the Micro’s software current
K1 contacts open and remain open for as long as the limit feature that’s based on a calculation comparing
condition exists. If the contacts remain open for more the highest current phase to the programmed Full Load
than 3 seconds, MOTOR CONTROLLER – CON- Amp Setpoint to arrive at an FLA Percentage. Channels
TACTS OPEN is displayed; if less than 3 seconds, 2 though 4 are analog voltages representing Phase C, B

JOHNSON CONTROLS 85
 Solid State Starter Logic Board
FORM 160.80-M1 (307)

and A Power Line Voltages. Channels 5 through 7 are

analog voltages representing Phase A, B and C Com-
pressor Motor Current. The addresses are +12VDC for
logic high (1). <1VDC for logic low (0).

The Logic Board MUX address inputs, along with the

respective outputs are as follows:

BINARY DECIMAL OUTPUT

J6-1 J6-2 J6-3
0 0 0 0 Starter Model/Voltmeter/Ammeter full scale, max FLA:
0.41 to 0.77VDC – 7L, 600VAC, max FLA 281, full scale 787A
0.78 to 1.22VDC – 14L, 300VAC, max FLA 551, full scale 1574A
1.23 to 1.76VDC – 14L, 600VAC, max FLA 551, full scale 1574A
1.77 to 2.39VDC – 26L, 300VAC, max FLA 916, full scale 2938A
2.40 to 3.08VDC – 26L, 600VAC, max FLA 916, full scale 2938A
3.09 to 3.87VDC – 33L, 300VAC, max FLA 1134, full scale 3672A
3.88 to 5.00VDC – 33L, 600VAC, max FLA 1134, full scale 3672A
0 0 1 1 Current Limit commands
3.46 to 5.00VDC – <98% FLA
1.21 to 3.45VDC – >100% FLA
0.0 to 1.20VDC – >104% FLA
0 1 0 2 Phase “C” AC Power Line voltage as follows:
300VAC scale = VDC(out) = VAC
67.9
600VAC scale = VDC(out) = VAC
135.8
0 1 1 3 Phase “B” AC Power Line voltage. Same as Phase “C” above.
1 0 0 4 Phase “A” AC Power Line voltage Same as Phase “C” above.
1 0 1 5 Phase “A” Compressor Motor Current. 0 to +5VDC spanning range in address 0 above.
1 1 0 6 Phase “B” Compressor Motor Current. 0 to +5VDC spanning range in address 0 above.
1 1 1 7 Phase “C” Compressor Motor Current. 0 to +5VDC spanning range in address 0 above.

86 JOHNSON CONTROLS
 CONTROL CENTER SOLID STATE STARTER
J/P-30
GND
POWER 6 6 1
SUPPLY J2 J3
+24VDC
12 2

JOHNSON CONTROLS
*
ADDRESS (2 2 )
1 1
MICRO 1
ADDRESS (2 )
BOARD 2 2
ADDRESS (2 0 )
3 3
J6 J6
4 +5VDC 4
GND.
5 5
MULTIPLEXED DATA
6 6
J19
2 36 37 L.C.S.S.S
LOGIC PCB
TB6
(031-00936)
TB5
2 36 37
25 25 24 3
J1 J2
J1-2 = MOTOR CONTROLLER SHUTDOWN
TB1
J1-36 = STOP STARTER (MOTOR CONTROLLER) INITIATED SHUTDOWN
J1-37 = START 16 16 1

J2 53 STOP
2 CONTACTS
1 1 115VAC
I/O BOARD
TB6

LD04649
NOTES:

* 9 on “CONDOR” Power Supply

13 on “POWER ONE” Power Supply

FIG. 39 – MOD “A” LIQUID COOLED SOLID STATE STARTER (LCSSS) - INTERFACE

87
FORM 160.80-M1 (307)

11
 Solid State Starter Logic Board
FORM 160.80-M1 (307)

LD04083

FIG. 40 – MOD “A” SOLID STATE STARTER LOGIC BOARD

88 JOHNSON CONTROLS
 Variable Orifice Control
FORM 160.80-M1 (307)

SECTION 12
VARIABLE ORIFICE CONTROL

A solenoid valve (2SOL), located in a line parallel with 27.0 PSIG (R134a), DELTA P control is overridden and
the refrigerant orifice, is opened and closed to create the solenoid valve is opened. While this condition is in
a variable orifice. Opening the parallel line allows a effect, “WARNING - EVAPORATOR – LOW PRES-
greater refrigerant flow to the evaporator. The solenoid SURE LIMIT” is displayed and the Low Evaporator
valve is driven from the I/O Board TB1-29. Under Pro- Pressure Override LED is illuminated on the Variable
gram control, it is energized to open the parallel line and Orifice Control Screen. The solenoid will remain open
de-energized to close the parallel line. until the Low Pressure limit condition is no longer in
effect (> 57.5 PSIG R22; >28.0 PSIG R134a, whereupon
When the chiller is not running, the solenoid valve is the Low Pressure override is released.
opened during the 2-minute “SYSTEM LOCKOUT
DELAY”, closed thereafter. During run, the Solenoid
Valve is primarily controlled by DELTA P control. If the Discharge Superheat (Discharge temp – Condenser
However, Low Evaporator Pressure and Discharge Saturation temp) is < 15.0°F (R22) or < 10.0°F (R134a),
Superheat conditions can override DELTA P control as DELTA P control or any Low Evaporator Pressure over-
explained below. ride (as explained above) that is in effect is overridden
and the solenoid valve is closed. While this condition
During run, the solenoid valve is opened and closed is in effect, the Superheat Override LED is illumi-
per the DELTA P Setpoint that has been programmed nated. The solenoid valve will remain closed until the
by a qualified Service Technician. The setpoint is pro- Discharge Superheat increases to > 20.0°F (R22) or >
grammed over the range of 25 to 150 PSIG (R22) or 15 15.0°F (R134a), whereupon the Discharge Superheat
to 110 PSIG (R134a). The system Delta P is the differ- override is released.
ential between the condenser and evaporator pressure,
calculated as Delta P = condenser pressure – evaporator
pressure. If the system Delta P decreases to < the DELTA The Variable Orifice Control Screen, accessed from
P setpoint, the solenoid valve is opened. It will remain the CONDENSER Screen in SERVICE access level,
open until the system Delta P increases to (DELTA P displays all of the applicable Variable Orifice control pa-
Setpoint + 10), whereupon it will close. rameters and allows a Service technician to program the
DELTA P Setpoint. The Low Evaporator Pressure and 12
If the evaporator pressure decreases to the Low Evapo- Superheat Override LEDs are located on this screen.
rator Pressure Warning threshold of 56.2 PSIG (R22) or

JOHNSON CONTROLS 89
 MicroGateway
FORM 160.80-M1 (307)

SECTION 13
MICROGATEWAY
(REFER TO FIG. 41)

The complete description of the MicroGateway in- be set to ISN on the OPERATIONS Screen. Otherwise,
stallation and operation is contained in YORK form communications will take place in any Control Source
450.20-NOM1. mode.

The MicroGateway is an optional printed circuit board

In operation, the Microboard provides chiller pressures,
that provides an interface between the OptiView Control
temperatures and status to the MicroGateway in response
Center and YORK ISN (Integrated Systems Network) or
to requests from the MicroGateway. Microboard status
other selected networks. It can be mounted on the upper
LEDs illuminate when the Microboard transmits and
corner of the left wall of the OptiView Control Center
receives data on COM 4B. Green LED CR13 (RX4)
or in its own enclosure in a remote location.
illuminates when data is being received from the Mi-
croGateway. Red LED CR12 (TX4) illuminates when
If installed in the OptiView Control Center, the
data is being transmitted to the MicroGateway. Similar
MicroGateway is powered by +12VDC from the
LEDs on the MicroGateway annunciate data transfer
Microboard.
to/from the Microboard (refer to 450.20-NOM1).
The MicroGateway communicates with the Microboard
COM 4B communications port via an RS-232 interface If there is a communications problem between the
(ref. Fig. 41). As shown in Figure 9, Microboard Pro- Microboard and MicroGateway, use the LEDs described
gram Jumper JP 27 must be placed on pins 2 and 3 to above to analyze the problem. The COM 4B LoopBack
allow data to be received from the MicroGateway. test can be used to verify operation of the Microboard
COM 4B communications port. Refer to Diagnostics
If the remote device that is connected to the MicroGate- and Troubleshooting section of this book.
way is going to provide remote Start-Stop signals, re-
mote Leaving Chilled Liquid Temperature and/or remote
Current Limit Setpoint resets, the Control Source must

MICROGATEWAY
J2 TB4
GTX 7 TX
1 RX2
GRX 6 RX
2 TX2
9 TB1
+
J21 J1 2 TO ISN
+ 12VDC RS-485 -
1 3 LAN
1
GND
2 2 4

MICROBOARD

LD06484

FIG. 41 – MICROGATEWAY INTERFACE BLOCK DIAGRAM

90 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

SECTION 14
PRESSURE TRANSDUCERS
(REFER TO FIG. 42)

System pressures are sensed by Pressure Transducers. ferential value are compared to determine the offset
There are different transducers used to sense the various between them. Since system pressures should be equal-
system pressures. The actual transducer used is deter- ized during this period, both transducers will be sensing
mined by the required pressure range and refrigerant the same pressure and their outputs should indicate the
application. The operation of the various transducers is same pressure. However, due to accuracy tolerances in
identical. The difference between them is simply the pres- transducer design, differences can exist. Therefore, to
sure range over which they operate. Each of the different compensate for differences between transducers and as-
transducers has a different YORK part number. Figure sure differential pressure accuracy, this offset is added
44 lists the transducers and the application of each one. or subtracted from the actual differential pressure, at
The Transducers are as follows: completion of the Auto-zeroing period, to produce
the displayed PSID value. The displayed differential
Pressure Location Pressure value is the actual differential value plus or minus the
Transducer Sensed
offset that existed during the Auto-zeroing period. For
Evaporator Evaporator Evaporator
example, if the Oil Pressure Transducer indicates 1.0
Condenser Condenser Condenser
PSIG greater than the Evaporator Transducer during the
Filter Oil Separator Oil Filter Input Auto-zeroing period, then 1.0 PSIG will be subtracted
Oil Compressor SB-2 Compressor oil from the displayed PSID value during “System Run”.
input / Oil Filter
Similarly, if the Oil Pressure Transducer indicates 1.0
output
PSIG less than the Evaporator Transducer during this
Seal Oil Compressor SB-3 Seal oil period, then 1.0 PSIG is added to the displayed value
during “System Run”.
The output of each transducer is displayed on the appro-
priate screen as a discrete pressure value in terms of PSIG
(pounds per square inch gauge) in English mode or KpaG The Auto Zeroing feature can be Enabled or Disabled
(Kilo Pascals) in Metric mode. In addition, some pressure following a procedure in the “System calibration,
values are subtracted from other pressure values to create Service Setpoints and Reset Procedures” section of
“differential” pressures displayed as PSID (pounds per this book. Normally, the Auto Zeroing feature should
square inch differential, in either PSIG or KpaG). These be Enabled. However, certain local conditions could
differential pressures are as follows: require the Auto-Zeroing feature be disabled. For ex-
ample, standby chillers, configured in series or parallel
“Differential Oil Pressure” = piping arrangements, can experience large evaporator/
condenser pressure differentials while not running. This
Oil Pressure – Evaporator Pressure
differential is created by the cold evaporator chilled
liquid and/or warm condenser water from the running 14
“Differential Filter pressure” =
chiller flowing through the standby chiller. The exis-
Filter Oil Pressure – Oil Pressure
tence of this differential during the Auto Zeroing period
produce large artificial offsets that are not a result of
“Differential Seal Pressure” =
transducer tolerances. Therefore, in these installations,
Seal Oil Pressure – Evaporator Pressure the Auto Zeroing should be Disabled.
To compensate for transducer differences and assure
differential pressure accuracy, the transducers that are The Evaporator and Condenser pressures are converted
involved in the creation of a differential value are com- to Saturation Temperatures per the appropriate refrig-
pared in a process called Auto-Zeroing. During the first erant pressure/temperature conversion table contained
15 seconds of the “Start Sequence Initiated” period, the in the Program. These Saturation Temperatures are
output of both transducers that are creating the dif- displayed and used for Chiller control.

JOHNSON CONTROLS 91
 Pressure Transducers
FORM 160.80-M1 (307)

The transducers output a 0.5 to 4.5VDC voltage that is J8-21 (signal) to J8-22 (Gnd). To convert this output to
analogous to the pressure applied to the device. These a pressure, refer to the appropriate formula in Figure 42.
outputs are applied to the Microboard, where this voltage If the pressure is known, the transducer output can be
is interpreted as a pressure value. The Program converts predicted with the appropriate formula in Figure 42.
the transducer output voltage to a pressure value with
the appropriate formula in Figure 42. The pressures New production chillers are equipped with the Seal
are displayed and used for Chiller control and Safety Oil Pressure Transducer. Previous vintage chillers,
shutdowns. such as those encountered in retrofit applications are
not equipped with this transducer. Therefore, Seal Oil
The transducers operate from a +5VDC power source. Pressure Transducer operation must be Enabled or Dis-
This supply voltage is provided from the Power supply abled as required for the application. This procedure is
via the Microboard. Each transducer is connected to in the “System Calibration, Service Setpoints and Reset
the Microboard with three wires. Two wires provide Procedures” section of this book.
the +5VDC supply voltage and Ground (Gnd) and the
remaining wire connects the transducer output to the
Microboard. The voltage output of each transducer If any of the displayed pressures do not appear to be
can be measured with a Voltmeter at the Microboard. correct, refer to the Diagnostics and Troubleshooting
Measurement should be made from the transducer out- section of this book.
put to Ground (Gnd). For example, the output of the
Condenser transducer would be read from Microboard

92 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

MAX ALLOWABLE DEVIATION

MAX ALLOWABLE DEVIATION

FROM NOMINAL OUTPUT

FROM NOMINAL OUTPUT

+ 150
+ 100
+ 133
+ 88

(MILLIVOLTS)
(MILLIVOLTS)
+ 116
+ 75

+ 44
0 150 225 300
0.500 2.500 3.500 4.500
50 59.38 87.5 106.25 125
0.500 1.00 2.500 3.500 4.500 PRESSURE (PSIG)
NOMINAL OUTPUT VOLTAGE
PRESSURE (PSIG)
NOMINAL OUTPUT VOLTAGE

PRESSURE TRANSDUCER
EVAPORATOR TRANSDUCER
YORK PART NO. 025-28678-006
(R22 WATER APPLICATIONS)
YORK PART NO. 025-28678-113

V = P + 37.5 P = (75 x V) - 37.5

V = (P x 4) - 162.5 P = (75 x V) + 162.5 75
75 4
V = VOLTS DC P = PRESSURE (PSIG)
LD04994 LD04995
V = VOLTS DC P = PRESSURE (PSIG)
MAX ALLOWABLE DEVIATION
FROM NOMINAL OUTPUT

+ 150
+ 130 PRESSURE TRANSDUCER APPLICATIONS CHART
(MILLIVOLTS)

+ 110
R22
TRANSDUCER
FUNCTION APPLICATION
PART NUMBER
+ 44
WATER BRINE
CONDENSER, OIL,
25.0 43.7 62.5 81.25 100 025-28678-006 X X
0.500 1.500 2.500 3.500 4.500 FILTER, SEAL
PRESSURE (PSIG) 025-28678-113 EVAPORATOR X
NOMINAL OUTPUT VOLTAGE
025-28678-114 EVAPORATOR X
R134a
EVAPORATOR TRANSDUCER
(R22 BRINE APPLICATIONS) CONDENSER, OIL
025-28678-006 X X
YORK PART NO. 025-28678-114 FILTER, SEAL
025-28678-112 EVAPORATOR X X
V = P - 15.6 P = 18.75 x V + 15.6
18.75

V = VOLTS DC P = PRESSURE (PSIG) LD04996

MAX ALLOWABLE DEVIATION

+ 150
FROM NOMINAL OUTPUT

14
(MILLIVOLTS)

+ 30
All transducers have
straight threads with neo-
6 31.5 74
0.500 2.000 4.500 prene O-rings.
PRESSURE (PSIG)
NOMINAL OUTPUT VOLTAGE

EVAPORATOR TRANSDUCER
R134a WATER & BRINE APPLICATIONS
YORK PART NO. 025-28678-112

V = P + 2.5 P = (17 x V) - 2.5

17

V = VOLTS DC P = PRESSURE (PSIG)

LD04102

FIG. 42 – PRESSURE TRANSDUCERS

JOHNSON CONTROLS 93
 Temperature Thermistors
FORM 160.80-M1 (307)

SECTION 15
TEMPERATURE THERMISTORS
(REFER TO FIG. 43 - 47)

System temperatures are sensed by Thermistors. that will flow through the thermistor and thus the volt-
There are two different thermistor types used to sense age drop across it. The Program reads this voltage at the
the various system temperatures. Each type has its own input to the Microboard and converts it to a temperature
YORK part number. Part numbers are listed in YORK value.
Renewal Parts List 160.80-RP3. The Return and Leaving
Chilled Water, Return and Leaving Condenser Water, Each thermistor is connected to the Microboard with two
Condenser Liquid, and Evaporator Refrigerant Tem- wires. One wire supplies the +5VDC voltage and the
peratures are sensed by 3K Ohm thermistors. The Oil other is the output of the thermistor. This output voltage
and Compressor Discharge temperatures are sensed by can be measured with a Voltmeter. Measurement should
50K Ohm thermistors. be made from the thermistor output to Ground (Gnd). For
example, the Leaving Chilled Liquid Temperature would
The 3K Ohm thermistors are defined by the charac- be read from Microboard J9-20 (output) to Microboard
teristic of being 3000 Ohms at 77°F (25°C). Similarly, TP1 (Gnd). To convert this voltage to a pressure, refer
the 50K Ohm thermistors are 50,000 Ohms at the same to the appropriate volts/temp chart as follows:
temperature. Both thermistor types vary their resistance • Leaving Chilled Liquid Temperature – Fig. 43
as the sensed temperature varies. Both are negative tem-
perature coefficient devices. That is, as the temperature • Return Chilled Liquid Temperature – Fig. 44
increases, the resistance decreases. As the temperature • Leaving and Return Condenser Liquid Temperature
decreases, the resistance increases. – Fig. 45
• Oil and Discharge Temperature – Fig. 46
The thermistors are connected to the Microboard. A
+5VDC supply voltage is applied to one side of the • Evaporator Refrigerant Temperature – Fig. 47
thermistor. The other side of the thermistor is connected
to Ground through a series resistor on the Microboard, If any of the displayed pressures do not appear to be
thus forming a voltage divider network. The temperature correct, refer to the “Diagnostics and Troubleshooting”
applied to the thermistor determines the resistance value. section of this book.
The resistance value determines the amount of current

94 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

FIG. 43 – LEAVING CHILLED LIQUID TEMPERATURE

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
9.90 -12.28 1.4280 15.13 -9.37 1.5957 20.17 -6.57 1.7634
15
10.00 -12.22 1.4310 15.22 -9.32 1.5987 20.26 -6.52 1.7664
10.09 -12.17 1.4341 15.32 -9.27 1.6018 20.35 -6.47 1.7695
10.19 -12.12 1.4371 15.41 -9.22 1.6048 20.44 -6.42 1.7725
10.29 -12.06 1.4402 15.50 -9.17 1.6079 20.53 -6.37 1.7756
10.39 -12.01 1.4432 15.60 -9.11 1.6109 20.62 -6.32 1.7786
10.48 -11.96 1.4463 15.69 -9.06 1.6140 20.71 -6.27 1.7817
10.58 -11.90 1.4493 15.78 -9.01 1.6170 20.80 -6.22 1.7847
10.68 -11.85 1.4423 15.87 -8.96 1.6201 20.89 -6.17 1.7878
10.77 -11.80 1.4554 15.97 -8.91 1.6231 20.98 -6.12 1.7908
10.87 -11.74 1.4584 16.06 -8.86 1.6262 21.07 -6.07 1.7939
10.97 -11.68 1.4615 16.15 -8.81 1.6292 21.16 -6.02 1.7969
11.06 -11.63 1.4645 16.24 -8.76 1.6322 21.25 -5.97 1.8000
11.16 -11.58 1.4676 16.34 -8.70 1.6353 21.34 -5.92 1.8030
11.25 -11.53 1.4706 16.43 -8.65 1.6383 21.43 -5.87 1.8060
11.35 -11.47 1.4737 16.52 -8.60 1.6414 21.52 -5.82 1.8091
11.45 -11.42 1.4767 16.61 -8.55 1.6444 21.61 -5.77 1.8121
11.54 -11.37 1.4798 16.70 -8.50 1.6475 21.70 -5.72 1.8152
11.64 -11.31 1.4828 16.80 -8.45 1.6505 21.79 -5.67 1.8182
11.73 -11.26 1.4859 16.89 -8.40 1.6536 21.88 -5.62 1.8213
11.83 -11.21 1.4889 16.98 -8.35 1.6566 21.97 -5.57 1.8243
11.93 -11.15 1.4920 17.07 -8.30 1.6597 22.06 -5.52 1.8274
12.02 -11.10 1.4950 17.16 -8.25 1.6627 22.15 -5.47 1.8304
12.12 -11.05 1.4981 17.26 -8.19 1.6658 22.24 -5.42 1.8335
12.21 -11.00 1.5011 17.35 -8.14 1.6688 22.33 -5.37 1.8365
12.31 -10.94 1.5042 17.44 -8.09 1.6719 22.42 -5.32 1.8396
12.40 -10.89 1.5072 17.53 -8.04 1.6749 22.51 -5.27 1.8426
12.50 -10.83 1.5103 17.63 -7.98 1.6780 22.60 -5.22 1.8457
12.59 -10.78 1.5133 17.72 -7.93 1.6810 22.69 -5.17 1.8487
12.69 -10.73 1.5164 17.81 -7.88 1.6841 22.78 -5.12 1.8518
12.78 -10.68 1.5194 17.90 -7.83 1.6871 22.87 -5.07 1.8548
12.88 -10.62 1.5225 17.99 -7.78 1.6902 22.96 -5.02 1.8579
12.97 -10.57 1.5255 18.08 -7.73 1.6932 23.04 -4.98 1.8609
13.07 -10.52 1.5286 18.17 -7.68 1.6963 23.13 -4.93 1.8640
13.16 -10.47 1.5316 18.26 -7.63 1.6993 23.22 -4.88 1.8670
13.26 -10.41 1.5347 18.35 -7.58 1.7024 23.31 -4.83 1.8701
13.35 -10.36 1.5377 18.44 -7.53 1.7054 23.40 -4.78 1.8731
13.45 -10.31 1.5408 18.54 -7.48 1.7085 23.49 -4.73 1.8762
13.54 -10.26 1.5438 18.63 -7.43 1.7115 23.58 -4.68 1.8792
13.64 -10.20 1.5469 18.72 -7.38 1.7146 23.67 -4.63 1.8823
13.73 -10.15 1.5499 18.81 -7.33 1.7176 23.75 -4.58 1.8853
13.83 -10.10 1.5530 18.90 -7.28 1.7207 23.84 -4.53 1.8884
13.92 -10.05 1.5560 18.99 -7.23 1.7237 23.93 -4.48 1.8914
14.01 -10.00 1.5591 19.08 -7.18 1.7268 24.02 -4.43 1.8945
14.11 -9.94 1.5621 19.17 -7.13 1.7298 24.11 -4.38 1.8975
14.20 -9.89 1.5652 19.26 -7.08 1.7329 24.20 -4.33 1.9006
14.29 -9.84 1.5682 19.36 -7.02 1.7359 24.29 -4.28 1.9036
14.39 -9.78 1.5713 19.45 -6.97 1.7390 24.37 -4.24 1.9067
14.48 -9.73 1.5743 19.54 -6.92 1.7420 24.46 -4.19 1.9097
14.57 -9.68 1.5774 19.63 -6.87 1.7451 24.55 -4.14 1.9128
14.67 -9.63 1.5804 19.72 -6.82 1.7481 24.64 -4.09 1.9158
14.76 -9.58 1.5835 19.81 -6.77 1.7512 24.73 -4.04 1.9189
14.85 -9.53 1.5865 19.90 -6.72 1.7542 24.82 -3.99 1.9219
14.95 -9.47 1.5896 19.99 -6.67 1.7573 24.91 -3.94 1.9250
15.04 -9.42 1.5926 20.08 -6.62 1.7603 24.99 -3.89 1.9280

JOHNSON CONTROLS 95
 Temperature Thermistors
FORM 160.80-M1 (307)

FIG. 43 – LEAVING CHILLED LIQUID TEMPERATURE (CONT’D)

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
25.08 -3.84 1.9311 29.92 -1.16 2.0988 34.73 1.52 2.2665
25.17 -3.79 1.9341 30.01 -1.11 2.1018 34.82 1.57 2.2695
25.26 -3.74 1.9372 30.10 -1.06 2.1049 34.91 1.62 2.2726
25.35 -3.69 1.9402 30.18 -1.01 2.1079 34.99 1.66 2.2756
25.43 -3.65 1.9433 30.27 -0.96 2.1110 35.08 1.71 2.2787
25.52 -3.60 1.9463 30.36 -0.91 2.1140 35.17 1.76 2.2817
25.61 -3.55 1.9494 30.45 -0.86 2.1171 35.26 1.81 2.2848
25.70 -3.50 1.9524 30.53 -0.82 2.1201 35.34 1.86 2.2878
25.79 -3.45 1.9555 30.62 -0.77 2.1232 35.43 1.91 2.2909
25.87 -3.41 1.9585 30.71 -0.72 2.1262 35.52 1.96 2.2939
25.96 -3.36 1.9616 30.79 -0.67 2.1293 35.51 1.95 2.2970
26.05 -3.31 1.9646 30.88 -0.62 2.1323 35.70 2.06 2.3000
26.14 -3.26 1.9677 30.97 -0.57 2.1354 35.78 2.10 2.3031
26.23 -3.21 1.9707 31.06 -0.52 2.1384 35.87 2.15 2.3061
26.31 -3.16 1.9738 31.14 -0.48 2.1415 35.96 2.20 2.3092
26.40 -3.11 1.9768 31.23 -0.43 2.1445 36.05 2.25 2.3122
26.49 -3.06 1.9798 31.32 -0.38 2.1476 36.13 2.29 2.3153
26.58 -3.01 1.9829 31.41 -0.33 2.1506 36.22 2.34 2.3183
26.67 -2.96 1.9859 31.49 -0.28 2.1536 36.31 2.39 2.3214
26.76 -2.91 1.9890 31.58 -0.23 2.1567 36.40 2.44 2.3244
26.84 -2.87 1.9920 31.67 -0.18 2.1597 36.48 2.49 2.3274
26.93 -2.82 1.9951 31.76 -0.13 2.1628 36.57 2.54 2.3305
27.02 -2.77 1.9981 31.84 -0.09 2.1658 36.66 2.59 2.3335
27.11 -2.72 2.0012 31.93 -0.04 2.1689 36.75 2.64 2.3366
27.20 -2.67 2.0042 32.02 0.01 2.1719 36.83 2.68 2.3396
27.28 -2.62 2.0073 32.10 0.06 2.1750 36.92 2.73 2.3427
27.37 -2.57 2.0103 32.19 0.11 2.1780 37.01 2.78 2.3457
27.46 -2.52 2.0134 32.28 0.16 2.1811 37.10 2.83 2.3488
27.55 -2.47 2.0164 32.37 0.21 2.1841 37.18 2.88 2.3518
27.64 -2.42 2.0195 32.45 0.25 2.1872 37.27 2.93 2.3549
27.73 -2.37 2.0225 32.54 0.30 2.1902 37.36 2.98 2.3579
27.81 -2.33 2.0256 32.63 0.35 2.1933 37.45 3.03 2.3610
27.90 -2.28 2.0286 32.72 0.40 2.1963 37.54 3.08 2.3640
27.99 -2.23 2.0317 32.81 0.45 2.1994 37.62 3.12 2.3671
28.08 -2.18 2.0347 32.89 0.49 2.2024 37.71 3.17 2.3701
28.17 -2.13 2.0378 32.98 0.54 2.2055 37.80 3.22 2.3732
28.25 -2.08 2.0408 33.07 0.59 2.2085 37.89 3.27 2.3762
28.34 -2.03 2.0439 33.16 0.64 2.2116 37.98 3.32 2.3793
28.43 -1.98 2.0469 33.24 0.69 2.2146 38.07 3.37 2.3823
28.52 -1.93 2.0500 33.33 0.74 2.2177 38.15 3.42 2.3854
28.61 -1.88 2.0530 33.42 0.79 2.2207 38.24 3.47 2.3884
28.69 -1.84 2.0561 33.51 0.84 2.2238 38.33 3.52 2.3915
28.78 -1.79 2.0591 33.59 0.88 2.2268 38.42 3.57 2.3945
28.87 -1.74 2.0622 33.68 0.93 2.2299 38.51 3.62 2.3976
28.96 -1.69 2.0652 33.77 0.98 2.2329 38.60 3.67 2.4006
29.04 -1.64 2.0683 33.86 1.03 2.2360 38.69 3.72 2.4037
29.13 -1.59 2.0713 33.94 1.08 2.2390 38.77 3.76 2.4067
29.22 -1.54 2.0744 34.03 1.13 2.2421 38.86 3.81 2.4098
29.31 -1.49 2.0774 34.12 1.18 2.2451 38.95 3.86 2.4128
29.39 -1.45 2.0805 34.21 1.23 2.2482 39.04 3.91 2.4159
29.48 -1.40 2.0835 34.29 1.27 2.2512 39.13 3.96 2.4189
29.57 -1.35 2.0866 34.38 1.32 2.2543 39.22 4.01 2.4220
29.66 -1.30 2.0896 34.47 1.37 2.2573 39.30 4.06 2.4250
29.75 -1.25 2.0927 34.56 1.42 2.2604 39.39 4.11 2.4281
29.83 -1.21 2.0957 34.64 1.47 2.2634 39.48 4.16 2.4311
96 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

FIG. 43 – LEAVING CHILLED LIQUID TEMPERATURE (CONT’D)

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
39.57 4.21 2.4342 44.46 6.92 2.6019 49.48 9.71 2.7696
15
39.66 4.26 2.4372 44.55 6.97 2.6049 49.57 9.76 2.7726
39.74 4.30 2.4403 44.64 7.02 2.6080 49.66 9.81 2.7757
39.83 4.35 2.4433 44.73 7.07 2.6110 49.75 9.86 2.7787
39.92 4.40 2.4464 44.82 7.12 2.6141 49.84 9.91 2.7818
40.01 4.45 2.4494 44.91 7.17 2.6171 49.94 9.97 2.7848
40.10 4.50 2.4525 45.00 7.22 2.6202 50.03 10.02 2.7879
40.19 4.55 2.4555 45.09 7.27 2.6232 50.12 10.07 2.7909
40.27 4.59 2.4586 45.18 7.32 2.6263 50.22 10.12 2.7940
40.36 4.64 2.4616 45.27 7.37 2.6293 50.31 10.17 2.7970
40.45 4.69 2.4647 45.36 7.42 2.6324 50.40 10.22 2.8001
40.54 4.74 2.4677 45.46 7.48 2.6354 50.50 10.28 2.8031
40.63 4.79 2.4708 45.55 7.53 2.6385 50.59 10.33 2.8062
40.71 4.84 2.4738 45.64 7.58 2.6415 50.68 10.38 2.8092
40.80 4.89 2.4769 45.73 7.63 2.6446 50.78 10.43 2.8123
40.89 4.94 2.4799 45.82 7.68 2.6476 50.87 10.48 2.8153
40.98 4.99 2.4830 45.91 7.73 2.6507 50.96 10.53 2.8184
41.07 5.04 2.4860 46.00 7.78 2.6537 51.06 10.59 2.8214
41.16 5.09 2.4891 46.09 7.83 2.6568 51.15 10.64 2.8245
41.24 5.13 2.4921 46.18 7.88 2.6598 51.24 10.69 2.8275
41.33 5.18 2.4952 46.27 7.93 2.6629 51.34 10.75 2.8306
41.42 5.23 2.4982 46.36 7.98 2.6659 51.43 10.80 2.8336
41.51 5.28 2.5012 46.45 8.03 2.6690 51.52 10.85 2.8367
41.60 5.33 2.5043 46.55 8.08 2.6720 51.62 10.90 2.8397
41.69 5.38 2.5073 46.64 8.13 2.6751 51.71 10.95 2.8428
41.78 5.43 2.5104 46.73 8.18 2.6781 51.80 11.00 2.8458
41.87 5.48 2.5134 46.82 8.23 2.6811 51.90 11.06 2.8458
41.96 5.53 2.5165 46.91 8.28 2.6842 51.99 11.11 2.8519
42.05 5.58 2.5195 47.00 8.33 2.6872 52.09 11.16 2.8549
42.14 5.63 2.5226 47.09 8.38 2.6903 52.18 11.21 2.8580
42.23 5.68 2.5256 47.18 8.43 2.6933 52.28 11.27 2.8610
42.31 5.73 2.5287 47.27 8.48 2.6964 52.37 11.32 2.8641
42.40 5.78 2.5317 47.36 8.53 2.6994 52.46 11.37 2.8671
42.49 5.83 2.5348 47.45 8.58 2.7025 52.56 11.42 2.8702
42.58 5.88 2.5378 47.55 8.64 2.7055 52.65 11.47 2.8732
42.67 5.93 2.5409 47.64 8.69 2.7086 52.75 11.53 2.8763
42.76 5.98 2.5439 47.73 8.74 2.7116 52.84 11.58 2.8793
42.85 6.03 2.5470 47.82 8.79 2.7147 52.94 11.63 2.8824
42.94 6.08 2.5500 47.91 8.84 2.7177 53.03 11.68 2.8854
43.03 6.13 2.5531 48.00 8.89 2.7208 53.13 11.74 2.8885
43.12 6.18 2.5561 48.09 8.94 2.7238 53.22 11.79 2.8915
43.21 6.23 2.5592 48.18 8.99 2.7269 53.32 11.85 2.8946
43.30 6.28 2.5622 48.27 9.04 2.7299 53.41 11.90 2.8976
43.39 6.33 2.5653 48.37 9.10 2.7330 53.51 11.95 2.9007
43.48 6.38 2.5683 48.46 9.15 2.7360 53.60 12.00 2.9037
43.57 6.43 2.5714 48.55 9.20 2.7391 53.70 12.06 2.9068
43.65 6.47 2.5744 48.64 9.25 2.7421 53.79 12.11 2.9098
43.74 6.52 2.5775 48.74 9.30 2.7452 53.89 12.16 2.9129
43.83 6.57 2.5805 48.83 9.35 2.7482 53.98 12.21 2.9159
43.92 6.62 2.5836 48.92 9.40 2.7513 54.08 12.27 2.9190
44.01 6.67 2.5866 49.01 9.45 2.7543 54.17 12.32 2.9220
44.10 6.72 2.5897 49.11 9.51 2.7574 54.27 12.37 2.9251
44.19 6.77 2.5927 49.20 9.56 2.7604 54.36 12.42 2.9281
44.28 6.82 2.5958 49.29 9.61 2.7635 54.46 12.48 2.9312
44.37 6.87 2.5988 49.38 9.66 2.7665 54.55 12.53 2.9342
JOHNSON CONTROLS 97
 Temperature Thermistors
FORM 160.80-M1 (307)

FIG. 43 – LEAVING CHILLED LIQUID TEMPERATURE (CONT’D)

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
54.65 12.58 2.9373 60.05 15.58 3.1050 65.75 18.75 3.2727
54.74 12.63 2.9403 60.15 15.64 3.1080 65.85 18.81 3.2757
54.84 12.69 2.9403 60.25 15.70 3.1111 65.96 18.87 3.2788
54.93 12.74 2.9464 60.36 15.76 3.1141 66.06 18.92 3.2818
55.03 12.80 2.9495 60.46 15.81 3.1172 66.17 18.98 3.2849
55.12 12.85 2.9525 60.56 15.87 3.1202 66.28 19.05 3.2879
55.22 12.90 2.9556 60.66 15.92 3.1233 66.39 19.11 3.2910
55.32 12.96 2.9586 60.76 15.98 3.1263 66.49 19.16 3.2940
55.41 13.01 2.9617 60.86 16.03 3.1294 66.60 19.22 3.2971
55.51 13.06 2.9647 60.96 16.09 3.1324 66.71 19.28 3.3001
55.61 13.12 2.9678 61.06 16.15 3.1355 66.82 19.35 3.3032
55.70 13.17 2.9708 61.17 16.21 3.1385 66.93 19.41 3.3062
55.80 13.22 2.9739 61.27 16.26 3.1416 67.03 19.46 3.3093
55.90 13.28 2.9769 61.37 16.32 3.1446 67.14 19.52 3.3123
56.00 13.33 2.9800 61.47 16.37 3.1477 67.25 19.58 3.3154
56.09 13.38 2.9830 61.57 16.43 3.1507 67.36 19.65 3.3184
56.19 13.44 2.9861 61.67 16.48 3.1538 67.47 19.71 3.3215
56.29 13.50 2.9891 61.78 16.55 3.1568 67.58 19.77 3.3245
56.39 13.55 2.9922 61.88 16.60 3.1599 67.68 19.82 3.3276
56.48 13.60 2.9952 61.98 16.66 3.1629 67.79 19.88 3.3306
56.58 13.66 2.9983 62.08 16.71 3.1660 67.90 19.95 3.3337
56.68 13.71 3.0013 62.18 16.77 3.1690 68.01 20.01 3.3367
56.78 13.77 3.0044 62.28 16.82 3.1721 68.12 20.07 3.3398
56.87 13.82 3.0074 62.39 16.88 3.1751 68.23 20.13 3.3428
56.97 13.87 3.0105 62.49 16.94 3.1782 68.34 20.19 3.3459
57.07 13.93 3.0135 62.59 17.00 3.1812 68.45 20.25 3.3489
57.17 13.98 3.0166 62.69 17.05 3.1843 68.56 20.31 3.3520
57.26 14.03 3.0196 62.80 17.11 3.1873 68.67 20.37 3.3550
57.36 14.09 3.0227 62.90 17.17 3.1904 68.78 20.43 3.3581
57.46 14.15 3.0257 63.01 17.23 3.1934 68.90 20.50 3.3611
57.56 14.20 3.0287 63.11 17.28 3.1965 69.01 20.56 3.3642
57.66 14.26 3.0318 63.22 17.35 3.1995 69.12 20.62 3.3672
57.76 14.31 3.0348 63.32 17.40 3.2025 69.23 20.68 3.3703
57.86 14.37 3.0379 63.43 17.46 3.2056 69.34 20.75 3.3733
57.96 14.42 3.0409 63.53 17.52 3.2086 69.45 20.81 3.3763
58.06 14.48 3.0440 63.63 17.57 3.2117 69.56 20.87 3.3794
58.15 14.53 3.0470 63.74 17.63 3.2147 69.67 20.93 3.3824
58.25 14.58 3.0501 63.84 17.69 3.2178 69.78 20.99 3.3855
58.35 14.64 3.0531 63.95 17.75 3.2208 69.89 21.05 3.3885
58.45 14.70 3.0562 64.05 17.81 3.2239 70.01 21.12 3.3916
58.55 14.75 3.0592 64.16 17.87 3.2269 70.12 21.18 3.3946
58.65 14.81 3.0623 64.26 17.92 3.2300 70.24 21.25 3.3977
58.75 14.86 3.0653 64.37 17.98 3.2330 70.35 21.31 3.4007
58.85 14.92 3.0684 64.47 18.04 3.2361 70.46 21.37 3.4038
58.95 14.97 3.0714 64.58 18.10 3.2391 70.58 21.44 3.4068
59.05 15.03 3.0745 64.68 18.16 3.2422 70.69 21.50 3.4099
59.15 15.08 3.0775 64.79 18.22 3.2452 70.80 21.56 3.4129
59.25 15.14 3.0806 64.90 18.28 3.2483 70.92 21.62 3.4160
59.35 15.20 3.0836 65.00 18.33 3.2513 71.03 21.69 3.4190
59.45 15.25 3.0867 65.11 18.40 3.2544 71.15 21.75 3.4221
59.55 15.31 3.0897 65.21 18.45 3.2574 71.26 21.81 3.4251
59.65 15.36 3.0928 65.32 18.51 3.2605 71.37 21.87 3.4282
59.75 15.42 3.0958 65.43 18.57 3.2635 71.49 21.94 3.4312
59.85 15.47 3.0989 65.53 18.63 3.2666 71.60 22.00 3.4343
59.95 15.53 3.1019 65.64 18.69 3.2696 71.72 22.07 3.4373
98 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

FIG. 43 – LEAVING CHILLED LIQUID TEMPERATURE (CONT’D)

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
71.83 22.13 3.4404 78.42 25.79 3.6081
15
71.95 22.20 3.4434 78.55 25.86 3.6111
72.06 22.26 3.4465 78.67 25.93 3.6142
72.18 22.32 3.4495 78.80 26.00 3.6172
72.29 22.39 3.4526 78.93 26.07 3.6203
72.41 22.45 3.4556 79.05 26.14 3.6233
72.52 22.51 3.4587 79.18 26.21 3.6264
72.64 22.58 3.4617 79.31 26.29 3.6294
72.75 22.64 3.4648 79.44 26.36 3.6325
72.87 22.71 3.4678 79.57 26.43 3.6355
72.98 22.77 3.4709 79.69 26.50 3.6386
73.10 22.84 3.4739 79.82 26.57 3.6416
73.21 22.90 3.4770 79.95 26.64 3.6447
73.33 22.96 3.4800 80.08 26.71 3.6477
73.44 23.02 3.4831 80.20 26.78 3.6508
73.56 23.09 3.4861 80.33 26.85 3.6538
73.68 23.16 3.4892 80.46 26.92 3.6569
73.80 23.22 3.4922 80.59 27.00 3.6599
73.92 23.29 3.4953 80.72 27.07 3.6630
74.04 23.36 3.4983 80.85 27.14 3.6660
74.16 23.42 3.5014 80.98 27.21 3.6691
74.28 23.49 3.5044 81.11 27.29 3.6721
74.40 23.56 3.0575 81.24 27.36 3.6752
74.52 23.62 3.5105 81.37 27.43 3.6782
74.64 23.69 3.5136 81.50 27.50 3.6813
74.75 23.75 3.5166 81.63 27.57 3.6843
74.87 23.82 3.5197 81.76 27.65 3.6874
74.99 23.89 3.5227 81.89 27.72 3.6904
75.11 23.95 3.5258 82.02 27.79 3.6935
75.23 24.02 3.5288 82.15 27.86 3.6965
75.35 24.09 3.5319 82.28 27.94 3.6996
75.47 24.15 3.5349 82.41 28.01 3.7026
75.60 24.22 3.5380
75.72 24.29 3.5410
75.84 24.36 3.5441
75.96 24.42 3.5471
76.08 24.49 3.5501
76.20 24.56 3.5532
76.32 24.62 3.5562
76.44 24.69 3.5593
76.57 24.76 3.5623
76.69 24.83 3.5654
76.81 24.90 3.5684
76.93 24.96 3.5715
77.05 25.03 3.5745
77.18 25.10 3.5776
77.30 25.17 3.5806
77.43 25.24 3.5837
77.55 25.31 3.5867
77.68 25.38 3.5898
77.80 25.45 3.5928
77.93 25.52 3.5959
78.05 25.59 3.5989
78.17 25.65 3.6020
78.30 25.72 3.6050

JOHNSON CONTROLS 99
 Temperature Thermistors
FORM 160.80-M1 (307)

FIG. 44 – RETURN CHILLED LIQUID TEMPERATURE

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
15.01 -9.44 1.5918 23.03 -4.98 1.8604 30.78 -0.68 2.1289
15.16 -9.36 1.5967 23.17 -4.91 1.8652 30.92 -0.60 2.1338
15.31 -9.27 1.6016 23.31 -4.83 1.8701 31.06 -0.52 2.1387
15.46 -9.19 1.6064 23.45 -4.75 1.8750 31.20 -0.44 2.1436
15.61 -9.11 1.6113 23.60 -4.67 1.8799 31.34 -0.37 2.1484
15.76 -9.02 1.6162 23.74 -4.59 1.8848 31.48 -0.29 2.1533
15.91 -8.94 1.6211 23.88 -4.51 1.8896 31.62 -0.21 2.1582
16.05 -8.86 1.6260 24.02 -4.43 1.8945 31.76 -0.13 2.1631
16.20 -8.78 1.6309 24.16 -4.36 1.8994 31.90 -0.06 2.1680
16.35 -8.70 1.6357 24.31 -4.27 1.9043 32.04 0.02 2.1729
16.50 -8.61 1.6406 24.45 -4.19 1.9092 32.18 0.10 2.1777
16.64 -8.53 1.6455 24.59 -4.12 1.9141 32.32 0.18 2.1826
16.79 -8.45 1.6504 24.73 -4.04 1.9189 32.46 0.26 2.1875
16.94 -8.37 1.6553 24.87 -3.96 1.9238 32.60 0.33 2.1924
17.09 -8.28 1.6602 25.01 -3.88 1.9287 32.74 0.41 2.1973
17.23 -8.21 1.6650 25.16 -3.80 1.9336 32.88 0.49 2.2021
17.38 -8.12 1.6699 25.30 -3.72 1.9385 33.02 0.57 2.2070
17.53 -8.04 1.6748 25.44 -3.64 1.9434 33.16 0.64 2.2119
17.68 -7.96 1.6797 25.58 -3.57 1.9482 33.30 0.72 2.2168
17.82 -7.88 1.6846 25.72 -3.49 1.9531 33.44 0.80 2.2217
17.97 -7.80 1.6895 25.86 -3.41 1.9580 33.59 0.88 2.2266
18.11 -7.72 1.6943 26.00 -3.33 1.9629 33.73 0.96 2.2314
18.26 -7.63 1.6992 26.14 -3.26 1.9678 33.87 1.04 2.2363
18.41 -7.55 1.7041 26.28 -3.18 1.9727 34.01 1.12 2.2412
18.55 -7.47 1.7090 26.42 -3.10 1.9775 34.15 1.19 2.2461
18.70 -7.39 1.7139 26.56 -3.02 1.9824 34.29 1.27 2.2510
18.84 -7.31 1.7188 26.71 -2.94 1.9873 34.43 1.35 2.2559
18.99 -7.23 1.7236 26.85 -2.86 1.9922 34.57 1.43 2.2607
19.13 -7.15 1.7285 26.99 -2.78 1.9971 34.71 1.51 2.2656
19.28 -7.07 1.7334 27.13 -2.71 2.0020 34.85 1.58 2.2705
19.43 -6.98 1.7383 27.27 -2.63 2.0068 34.99 1.66 2.2754
19.57 -6.91 1.7432 27.41 -2.55 2.0117 35.13 1.74 2.2803
19.71 -6.83 1.7480 27.55 -2.47 2.0166 35.27 1.82 2.2852
19.86 -6.74 1.7529 27.70 -2.39 2.0215 35.41 1.89 2.2900
20.00 -6.67 1.7578 27.84 -2.31 2.0264 35.55 1.97 2.2949
20.15 -6.58 1.7627 27.98 -2.23 2.0313 35.69 2.05 2.2998
20.29 -6.51 1.7676 28.12 -2.16 2.0361 35.83 2.13 2.3047
20.44 -6.42 1.7725 28.26 -2.08 2.0410 35.97 2.21 2.3096
20.58 -6.34 1.7773 28.40 -2.00 2.0459 36.11 2.28 2.3145
20.73 -6.26 1.7822 28.54 -1.92 2.5058 36.25 2.36 2.3193
20.87 -6.18 1.7871 28.68 -1.84 2.0557 36.39 2.44 2.3242
21.01 -6.11 1.7920 28.82 -1.77 2.0605 36.53 2.52 2.3291
21.16 -6.02 1.7969 28.96 -1.69 2.0654 36.67 2.59 2.3340
21.30 -5.94 1.8018 29.10 -1.61 2.0703 36.81 2.67 2.3389
21.45 -5.86 1.8066 29.24 -1.53 2.0752 36.95 2.75 2.3438
21.59 -5.78 1.8115 29.38 -1.46 2.0801 37.09 2.83 2.3486
21.73 -5.71 1.8164 29.52 -1.38 2.0850 37.23 2.91 2.3535
21.88 -5.62 1.8213 29.66 -1.30 2.0898 37.37 2.98 2.3584
22.02 -5.54 1.8262 29.80 -1.22 2.0947 37.51 3.06 2.3633
22.17 -5.46 1.8311 29.94 -1.14 2.0996 37.66 3.14 2.3682
22.31 -5.38 1.8359 30.08 -1.07 2.1045 37.80 3.22 2.3730
22.45 -5.31 1.8408 30.22 -0.99 2.1094 37.94 3.30 2.3779
22.60 -5.22 1.8457 30.36 -0.91 2.1143 38.08 3.38 2.3828
22.74 -5.14 1.8506 30.50 -0.83 2.1191 38.22 3.46 2.3877
22.88 -5.07 1.8555 30.64 -0.76 2.1240 38.36 3.53 2.3926
100 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

FIG. 44 – RETURN CHILLED LIQUID TEMPERATURE (CONT’D)

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
38.51 3.62 2.3975 46.37 7.98 2.6660 54.56 12.53 2.9346
15
38.65 3.69 2.4023 46.51 8.06 2.6709 54.72 12.62 2.9395
38.79 3.77 2.4072 46.66 8.15 2.6758 54.87 12.71 2.9443
38.93 3.85 2.4121 46.80 8.22 2.6807 55.02 12.79 2.9492
39.07 3.93 2.4170 46.95 8.31 2.6855 55.17 12.87 2.9541
39.21 4.01 2.4219 47.09 8.38 2.6904 55.33 12.96 2.9590
39.35 4.08 2.4268 47.24 8.47 2.6953 55.48 13.05 2.9639
39.50 4.17 2.4316 47.39 8.55 2.7002 55.64 13.13 2.9688
39.64 4.24 2.4365 47.53 8.63 2.7051 55.79 13.22 2.9736
39.78 4.32 2.4414 47.68 8.71 2.7100 55.95 13.31 2.9785
39.92 4.40 2.4463 47.82 8.79 2.7148 56.11 13.40 2.9834
40.06 4.48 2.4512 47.97 8.87 2.7197 56.26 13.48 2.9983
40.20 4.56 2.4561 48.11 8.95 2.7246 56.42 13.57 2.9932
40.34 4.63 2.4609 48.26 9.03 2.7295 56.57 13.65 2.9980
40.48 4.71 2.4658 48.41 9.12 2.7344 56.73 13.74 3.0029
40.62 4.79 2.4707 48.56 9.20 2.7393 56.89 13.83 3.0078
40.76 4.87 2.4756 48.70 9.28 2.7441 57.04 13.91 3.0127
40.91 4.95 2.4805 48.85 9.36 2.7490 57.20 14.00 3.0176
41.05 5.03 2.4854 49.00 9.45 2.7539 57.36 14.09 3.0225
41.19 5.11 2.4902 49.15 9.53 2.7588 57.51 14.17 3.0273
41.33 5.18 2.4951 49.30 9.61 2.7637 57.67 14.26 3.0322
41.48 5.27 2.5000 49.44 9.69 2.7686 57.83 14.35 3.0371
41.62 5.34 2.5049 49.59 9.77 2.7734 57.99 14.44 3.0420
41.76 5.42 2.5098 49.74 9.86 2.7783 58.15 14.53 3.0469
41.90 5.50 2.5146 49.89 9.94 2.7832 58.31 14.62 3.0518
42.05 5.58 2.5195 50.04 10.02 2.7881 58.47 14.71 3.0566
42.19 5.66 2.5244 50.19 10.11 2.7930 58.62 14.79 3.0615
42.33 5.74 2.5293 50.34 10.19 2.7979 58.78 14.88 3.0664
42.48 5.82 2.5342 50.48 10.27 2.8027 58.94 14.97 3.0713
42.62 5.90 2.5391 50.63 10.35 2.8076 59.10 15.06 3.0762
42.76 5.98 2.5439 50.78 10.43 2.8125 59.26 15.15 3.0811
42.90 6.06 2.5488 50.93 10.52 2.8174 59.42 15.23 3.0859
43.05 6.14 2.5537 51.08 10.60 2.8223 59.59 15.33 3.0908
43.19 6.22 2.5586 51.23 10.68 2.8271 59.75 15.42 3.0957
43.33 6.29 2.5635 51.38 10.77 2.8320 59.91 15.51 3.1006
43.48 6.38 2.5684 51.53 10.85 2.8369 60.07 15.60 3.1055
43.62 6.46 2.5732 51.68 10.93 2.8418 60.23 15.68 3.1104
43.76 6.53 2.5781 51.83 11.02 2.8467 60.39 15.77 3.1152
43.91 6.62 2.5830 51.98 11.10 2.8516 60.55 15.86 3.1201
44.05 6.69 2.5879 52.13 11.18 2.8564 60.72 15.96 3.1250
44.19 6.77 2.5928 52.28 11.27 2.8613 60.88 16.05 3.1299
44.34 6.86 2.5977 52.44 11.36 2.8662 61.04 16.13 3.1348
44.48 6.93 2.6025 52.59 11.44 2.8711 61.20 16.22 3.1396
44.62 7.01 2.6074 52.74 11.52 2.8760 61.37 16.32 3.1445
44.77 7.10 2.6123 52.89 11.61 2.8809 61.53 16.41 3.1494
44.91 7.17 2.6172 53.04 11.69 2.8857 61.69 16.50 3.1543
45.06 7.26 2.6221 53.19 11.77 2.8906 61.85 16.58 3.1592
45.20 7.33 2.6270 53.34 11.86 2.8955 62.02 16.68 3.1641
45.35 7.42 2.6318 53.50 11.95 2.9004 62.18 16.77 3.1689
45.49 7.50 2.6367 53.65 12.03 2.9053 62.34 16.86 3.1738
45.64 7.58 2.6416 53.80 12.11 2.9102 62.51 16.95 3.1787
45.79 7.66 2.6465 53.95 12.20 2.0150 62.67 17.04 3.1836
45.93 7.74 2.6514 54.11 12.28 2.9199 62.84 17.13 3.1885
46.08 7.82 2.6563 54.26 12.37 2.9248 63.01 17.23 3.1934
46.22 7.90 2.6611 54.41 12.45 2.9297 63.17 17.32 3.1882

JOHNSON CONTROLS 101

 Temperature Thermistors
FORM 160.80-M1 (307)

FIG. 44 – RETURN CHILLED LIQUID TEMPERATURE (CONT’D)

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
63.34 17.41 3.2031 73.01 22.79 3.4717
63.51 17.51 3.2080 73.20 22.89 3.4766
63.68 17.60 3.2129 73.38 22.99 3.4814
63.84 17.69 3.2178 73.57 23.10 3.4863
64.01 17.78 3.2227 73.76 23.20 3.4912
64.18 17.88 3.2275 73.95 23.31 3.4961
64.34 17.97 3.2324 74.14 23.41 3.5010
64.51 18.06 3.2373 74.33 23.52 3.5059
64.68 18.16 3.2422 74.53 23.63 3.5107
64.85 18.25 3.2471 74.72 23.74 3.5156
65.02 18.35 3.2520 74.91 23.84 3.5205
65.19 18.44 3.2568 75.10 23.95 3.5254
65.36 18.53 3.2617 75.29 24.05 3.5303
65.53 18.63 3.2666 75.48 24.16 3.5352
65.70 18.72 3.2715 75.68 24.27 3.5400
65.87 18.82 3.2764 75.87 24.37 3.5449
66.04 18.91 3.2813 76.07 24.49 3.5498
66.21 19.01 3.2861 76.26 24.59 3.5547
66.39 19.11 3.2910 76.46 24.70 3.5596
66.56 19.20 3.2959 76.65 24.81 3.5645
66.73 19.30 3.3008 76.84 24.91 3.5693
66.91 19.40 3.3057 77.04 25.02 3.5742
67.08 19.49 3.3105 77.24 25.14 3.5791
67.25 19.58 3.3154 77.44 25.25 3.5840
67.43 19.68 3.3203 77.64 25.36 3.5889
67.60 19.78 3.3252 77.84 25.47 3.5938
67.77 19.87 3.3301 78.04 25.58 3.5986
67.95 19.97 3.3350 78.24 25.69 3.6035
68.12 20.07 3.3398 78.44 25.80 3.6084
68.30 20.17 3.3447 78.64 25.91 3.6133
68.48 20.27 3.3496 78.84 26.02 3.6182
68.66 20.37 3.3545 79.04 26.14 3.6230
68.83 20.46 3.3594 79.25 26.25 3.6279
69.01 20.56 3.3643 79.45 26.36 3.6328
69.19 20.66 3.3691 79.66 26.48 3.6377
69.36 20.76 3.3740 79.86 26.59 3.6426
69.54 20.86 3.3789 80.07 26.71 3.6475
69.72 20.96 3.3838 80.27 26.82 3.6523
69.90 21.06 3.3887 80.48 26.94 3.6572
70.08 21.16 3.3936 80.68 27.05 3.6621
70.26 21.26 3.3984 80.89 27.16 3.6670
70.45 21.36 3.4033 81.10 27.28 3.6719
70.63 21.46 3.4082 81.31 27.40 3.6768
70.81 21.56 3.4131 81.52 27.51 3.6816
70.99 21.66 3.4180 81.72 27.62 3.6865
71.17 21.76 3.4229 81.93 27.74 3.6914
71.36 21.87 3.4277 82.14 27.86 3.6963
71.54 21.97 3.4326 82.35 27.97 3.7012
71.72 22.07 3.4375 82.56 28.09 3.7061
71.91 22.17 3.4424
72.09 22.27 3.4473
72.28 22.38 3.4521
72.46 22.48 3.4570
72.64 22.58 3.4619
72.83 22.69 3.4668

102 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

FIG. 45 – RETURN AND LEAVING CONDENSING WATER

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
40.12 4.51 1.8408 48.39 9.11 2.1094 56.61 13.67 2.3779
15
40.27 4.59 1.8457 48.54 9.19 2.1143 56.76 13.76 2.3828
40.42 4.68 1.8506 48.69 9.27 2.1191 56.91 13.84 2.3877
40.58 4.77 1.8555 48.84 9.36 2.1240 57.06 13.92 2.3926
40.73 4.85 1.8604 48.99 9.44 2.1289 57.21 14.01 2.3975
40.88 4.93 1.8652 49.14 9.52 2.1338 57.36 14.09 2.4023
41.03 5.02 1.8701 49.29 9.61 2.1387 57.51 14.17 2.4072
41.18 5.10 1.8750 49.44 9.69 2.1436 57.66 14.26 2.4121
41.33 5.18 1.8799 49.59 9.77 2.1484 57.81 14.34 2.4170
41.48 5.27 1.8848 49.74 9.86 2.1533 57.97 14.43 2.4219
41.64 5.36 1.8896 49.89 9.94 2.1582 58.12 14.51 2.4268
41.79 5.44 1.8945 50.03 10.02 2.1631 58.27 14.60 2.4316
41.94 5.52 1.8994 50.18 10.10 2.1680 58.42 14.68 2.4365
42.09 5.61 1.9043 50.33 10.18 2.1729 58.57 14.76 2.4414
42.24 5.69 1.9092 50.48 10.27 2.1777 58.72 14.85 2.4463
42.39 5.77 1.9141 50.63 10.35 2.1826 58.87 14.93 2.4512
42.54 5.86 1.9189 50.78 10.43 2.1875 59.02 15.01 2.4561
42.70 5.94 1.9238 50.93 10.52 2.1924 59.17 15.10 2.4609
42.85 6.03 1.9287 51.08 10.60 2.1973 59.33 15.18 2.4658
43.00 6.11 1.9336 51.23 10.68 2.2021 59.48 15.27 2.4707
43.15 6.19 1.9385 51.38 10.77 2.2070 59.63 15.35 2.4756
43.30 6.28 1.9434 51.53 10.85 2.2119 59.78 15.43 2.4805
43.45 6.36 1.9482 51.68 10.93 2.1268 59.93 15.52 2.4854
43.60 6.44 1.9531 51.83 11.02 2.2217 60.09 15.61 2.4902
43.75 6.53 1.9580 51.97 11.10 2.2266 60.24 15.69 2.4951
43.90 6.61 1.9629 52.12 11.18 2.2314 60.39 15.77 2.5000
44.05 6.69 1.9678 52.27 11.26 2.2363 60.54 15.86 2.5049
44.20 6.78 1.9727 52.42 11.35 2.2412 60.69 15.94 2.5098
44.35 6.86 1.9775 52.57 11.43 2.2461 60.85 16.03 2.5146
44.50 6.95 1.9824 52.72 11.51 2.2510 61.00 16.11 2.5195
44.65 7.03 1.9873 52.87 11.60 2.2559 61.15 16.20 2.5244
44.80 7.11 1.9922 53.02 11.68 2.2607 61.30 16.28 2.5293
44.95 7.20 1.9971 53.17 11.76 2.2656 61.45 16.36 2.5342
45.10 7.28 2.0020 53.32 11.85 2.2705 61.61 16.45 2.5391
45.25 7.36 2.0068 53.47 11.93 2.2754 61.76 16.53 2.5439
45.40 7.45 2.0117 53.62 12.01 2.2803 61.91 16.62 2.5488
45.55 7.53 2.0166 53.77 12.10 2.2852 62.06 16.70 2.5537
45.70 7.61 2.0215 53.92 12.18 2.2900 62.21 16.78 2.5586
45.85 7.70 2.0264 54.07 12.26 2.2949 62.36 16.87 2.5635
46.00 7.78 2.0313 54.21 12.34 2.2998 62.52 16.96 2.5684
46.15 7.86 2.0361 54.36 12.42 2.3047 62.67 17.04 2.5732
46.30 7.95 2.0410 54.51 12.51 2.3096 62.82 17.12 2.5781
46.45 8.03 2.0459 54.66 12.59 2.3145 62.98 17.21 2.5830
46.60 8.11 2.0508 54.81 12.67 2.3193 63.13 17.30 2.5879
46.75 8.20 2.0557 54.96 12.76 2.3242 63.29 17.38 2.5928
46.90 8.28 2.0605 55.11 12.84 2.3291 63.44 17.47 2.5977
47.05 8.36 2.0654 55.26 12.92 2.3340 63.59 17.55 2.6025
47.20 8.45 2.0703 55.41 13.01 2.3389 63.75 17.64 2.6074
47.35 8.53 2.0752 55.56 13.09 2.3438 63.90 17.72 2.6123
47.50 8.61 2.0801 55.71 13.17 2.3486 64.06 17.81 2.6172
47.65 8.70 2.0850 55.86 13.26 2.3535 64.21 17.90 2.6221
47.79 8.77 2.0898 56.01 13.34 2.3584 64.36 17.98 2.6270
47.94 8.86 2.0947 56.16 13.42 2.3633 64.52 18.07 2.6318
48.09 8.94 2.0996 56.31 13.51 2.3682 64.52 18.07 2.6367
48.24 9.02 2.1045 56.46 13.59 2.3730 64.83 18.24 2.6416

JOHNSON CONTROLS 103

 Temperature Thermistors
FORM 160.80-M1 (307)

FIG. 45 – RETURN AND LEAVING CONDENSING WATER (CONT’D)

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
64.98 18.32 2.6465 73.71 23.17 2.9150 83.04 28.36 3.1836
65.14 18.41 2.6514 73.87 23.26 2.9199 83.22 28.46 3.1885
65.29 18.50 2.6563 74.04 23.36 2.9248 83.39 28.55 3.1934
65.45 18.58 2.6611 74.20 23.45 2.9297 83.57 28.65 3.1982
65.60 18.67 2.6660 74.37 23.54 2.9346 83.75 28.75 3.2031
65.76 18.76 2.6709 74.53 23.63 2.9395 83.93 28.85 3.2080
65.91 18.84 2.6758 74.70 23.72 2.9443 84.10 28.95 3.2129
66.07 18.93 2.6807 74.86 23.81 2.9492 84.28 29.05 3.2178
66.22 19.01 2.6855 75.03 23.91 2.9541 84.46 29.15 3.2227
66.38 19.10 2.6904 75.19 24.00 2.9590 84.65 29.25 3.2275
66.54 19.19 2.6953 75.36 24.09 2.9639 84.83 29.35 3.2324
66.69 19.27 2.7002 75.52 24.18 2.9688 85.01 29.45 3.2373
66.85 19.36 2.7051 75.69 24.27 2.9736 85.19 29.55 3.2422
66.00 18.89 2.7100 75.85 24.36 2.9785 85.37 29.65 3.2471
67.16 19.53 2.7148 76.02 24.46 2.9834 85.55 29.75 3.2520
67.32 19.62 2.7197 76.19 24.55 2.9883 85.73 29.85 3.2568
67.47 19.71 2.7246 76.35 24.64 2.9932 85.92 29.96 3.2617
67.63 19.80 2.7295 76.52 24.74 2.9980 86.10 30.06 3.2666
67.78 19.88 2.7344 76.69 24.83 3.0029 86.28 30.16 3.2715
67.94 19.97 2.7393 76.85 24.92 3.0078 86.47 30.26 3.2764
68.10 20.06 2.7441 77.02 25.01 3.0127 86.65 30.36 3.2813
68.26 20.15 2.7490 77.19 25.11 3.0176 86.84 30.47 3.2861
68.41 20.23 2.7539 77.36 25.20 3.0225 87.02 30.57 3.2910
68.57 20.32 2.7588 77.53 25.30 3.0273 87.21 30.67 3.2959
68.73 20.41 2.7637 77.70 25.39 3.0322 87.39 30.77 3.3008
68.89 20.50 2.7686 77.86 25.48 3.0371 87.58 30.88 3.3057
69.05 20.58 2.7734 78.03 25.57 3.0420 87.76 30.98 3.3105
69.21 20.67 2.7783 78.20 25.67 3.0469 87.95 31.09 3.3154
69.36 20.76 2.7832 78.37 25.76 3.0518 88.13 31.19 3.3203
69.52 20.85 2.7881 78.54 25.86 3.0566 88.32 31.29 3.3252
69.68 20.94 2.7930 78.71 25.95 3.0615 88.51 31.40 3.3301
69.84 21.02 2.7979 78.88 26.05 3.0664 88.70 31.50 3.3350
70.00 21.11 2.8027 79.05 26.14 3.0713 88.88 31.60 3.3398
70.16 21.20 2.8076 79.22 26.24 3.0762 89.07 31.71 3.3447
70.32 21.29 2.8125 79.40 26.34 3.0811 89.26 31.81 3.3496
70.48 21.38 2.8174 79.57 26.43 3.0859 89.44 31.91 3.3545
70.64 21.47 2.8223 79.74 26.52 3.0908 89.63 32.02 3.3594
70.80 21.56 2.8271 79.91 26.62 3.0957 89.82 32.12 3.3643
70.96 21.65 2.8320 80.08 26.71 3.1006 90.01 32.23 3.3691
71.12 21.74 2.8369 80.26 26.81 3.1055 90.20 32.34 3.3740
71.28 21.82 2.8418 80.43 26.91 3.1104 90.39 32.44 3.3789
71.44 21.91 2.8467 80.60 27.00 3.1152 90.59 32.55 3.3838
71.61 22.01 2.8516 80.77 27.10 3.1201 90.78 32.66 3.3887
71.77 22.10 2.8564 80.95 27.20 3.1250 90.97 32.76 3.3936
71.93 22.19 2.8613 81.12 27.29 3.1299 91.16 32.87 3.3984
72.09 22.27 2.8662 81.29 27.39 3.1348 91.35 32.97 3.4033
72.25 22.36 2.8711 81.47 27.49 3.1396 91.54 33.08 3.4082
72.41 22.45 2.8760 81.64 27.58 3.1445 91.74 33.19 3.4131
72.57 22.54 2.8809 81.81 27.67 3.1494 91.93 33.30 3.4180
72.73 22.63 2.8857 81.99 27.77 3.1543 92.13 33.41 3.4229
72.89 22.72 2.8906 82.16 27.87 3.1592 92.32 33.51 3.4277
73.05 22.81 2.8955 82.33 27.96 3.1641 92.52 33.62 3.4326
73.22 22.90 2.9004 82.51 28.06 3.1689 92.72 33.74 3.4375
73.38 22.99 2.9053 82.69 28.16 3.1738 92.91 33.84 3.4424
73.54 23.08 2.9102 82.86 28.26 3.1787 93.11 33.95 3.4473
104 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

FIG. 45 – RETURN AND LEAVING CONDENSING WATER (CONT’D)

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
93.31 34.06 3.4521 105.04 40.58 3.7207
15
93.51 34.17 3.4570 105.27 40.71 3.7256
93.70 34.28 3.4619 105.50 40.84 3.7305
93.90 34.39 3.4668 105.73 40.96 3.7354
94.10 34.50 3.4717 105.96 41.09 3.7402
94.30 34.61 3.4766 106.20 41.23 3.7451
94.50 34.73 3.4814 106.44 41.36 3.7500
94.70 34.84 3.4863 106.67 41.49 3.7549
94.90 34.95 3.4912 106.91 41.62 3.7598
95.11 35.06 3.4961 107.14 41.75 3.7646
95.31 35.18 3.5010 107.38 41.88 3.7695
95.52 35.29 3.5059 107.62 42.01 3.7744
95.72 35.40 3.5107 107.86 42.15 3.7793
95.93 35.52 3.5156 108.11 42.29 3.7842
96.13 35.63 3.5205 108.35 42.42 3.7891
96.34 35.75 3.5254 108.59 42.55 3.7939
96.54 35.86 3.5303 108.84 42.69 3.7988
96.75 35.98 3.5352 109.08 42.83 3.8037
96.96 36.09 3.5400 109.32 42.96 3.8086
97.17 36.21 3.5449 109.57 43.10 3.8135
97.38 36.33 3.5498 109.82 43.24 3.8184
97.59 36.44 3.5547 110.06 43.37 3.8232
97.80 36.56 3.5596 110.31 43.51 3.8281
98.01 36.68 3.5645 110.56 43.65 3.8330
98.22 36.79 3.5693 110.81 43.79 3.8379
98.43 36.91 3.5742 111.05 43.92 3.8328
98.64 37.03 3.5791 111.31 44.06 3.8477
98.86 37.15 3.5840 111.36 44.09 3.8525
99.07 37.26 3.5889 111.82 44.35 3.8574
99.29 37.39 3.5938 112.08 44.49 3.8623
99.50 37.50 3.5986 112.34 44.64 3.8672
99.71 37.62 3.6035 112.59 44.78 3.8721
99.93 37.74 3.6084 112.85 44.92 3.8770
100.14 37.86 3.6133 113.11 45.06 3.8818
100.36 37.98 3.6182 113.37 45.21 3.8867
100.58 38.10 3.6230 113.63 45.35 3.8916
100.79 38.22 3.6279 113.88 45.49 3.8965
101.01 38.34 3.6328 114.14 45.64 3.9014
101.23 38.46 3.6377
101.45 38.59 3.6426
101.67 38.71 3.6475
101.89 38.83 3.6523
102.11 38.95 3.6572
102.33 39.08 3.6621
102.55 39.20 3.6670
102.78 39.33 3.6719
103.00 39.45 3.6768
103.22 39.57 3.6816
103.45 39.70 3.6865
103.67 39.82 3.6914
103.89 39.94 3.6963
104.12 40.07 3.7012
104.35 40.20 3.7061
104.58 40.33 3.7109
104.81 40.45 3.7158

JOHNSON CONTROLS 105

 Temperature Thermistors
FORM 160.80-M1 (307)

FIG. 46 – OIL AND DISCHARGE TEMPERATURE

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
31.99 -0.01 0.2637 58.43 14.68 0.5322 75.98 24.44 0.8008
32.63 0.35 0.2686 58.81 14.90 0.5371 76.25 24.59 0.8057
33.27 0.71 0.2734 59.18 15.10 0.5420 76.53 24.74 0.8105
33.90 1.06 0.2783 59.54 15.30 0.5469 76.81 24.90 0.8154
34.51 1.39 0.2832 59.90 15.50 0.5518 77.09 25.05 0.8203
35.12 1.73 0.2881 60.26 15.70 0.5566 77.36 25.20 0.8252
35.73 2.07 0.2930 60.63 15.91 0.5615 77.63 25.35 0.8301
36.32 2.40 0.2979 60.98 16.10 0.5664 77.90 25.50 0.8350
36.91 2.73 0.3027 61.33 16.30 0.5713 78.17 25.65 0.8398
37.49 3.05 0.3076 61.69 16.50 0.5762 78.44 25.80 0.8447
38.05 3.36 0.3125 62.04 16.69 0.5811 78.71 25.95 0.8496
38.61 3.67 0.3174 62.39 16.88 0.5859 78.98 26.10 0.8545
39.18 3.99 0.3223 62.73 17.07 0.5908 79.24 26.25 0.8594
39.72 4.29 0.3271 63.07 17.26 0.5957 79.50 26.39 0.8643
40.26 4.59 0.3320 63.41 17.45 0.6006 79.77 26.54 0.8691
40.80 4.89 0.3369 63.75 17.64 0.6055 80.03 26.69 0.8740
41.33 5.18 0.3418 64.09 17.83 0.6104 80.30 26.84 0.8789
41.85 5.47 0.3467 64.43 18.02 0.6152 80.56 26.98 0.8838
42.37 5.76 0.3516 64.76 18.20 0.6201 80.82 27.12 0.8887
42.89 6.05 0.3564 65.09 18.38 0.6250 81.08 27.27 0.8936
43.39 6.33 0.3613 65.42 18.57 0.6299 81.33 27.41 0.8984
43.89 6.61 0.3662 65.75 18.75 0.6348 81.59 27.55 0.9033
44.39 6.88 0.3711 66.08 18.93 0.6396 81.85 27.70 0.9082
44.88 7.16 0.3760 66.40 19.11 0.6445 82.11 27.84 0.9131
45.36 7.42 0.3809 66.72 19.29 0.6494 82.37 27.99 0.9180
45.84 7.69 0.3857 67.04 19.47 0.6543 82.62 28.12 0.9229
46.32 7.96 0.3906 67.36 19.65 0.6592 82.87 28.26 0.9277
46.79 8.22 0.3955 67.68 19.82 0.6641 83.12 28.40 0.9326
47.25 8.47 0.4004 68.00 20.00 0.6689 83.37 28.54 0.9375
47.72 8.73 0.4053 68.31 20.17 0.6738 83.62 28.68 0.9424
48.18 8.99 0.4102 68.62 20.35 0.6787 83.88 28.82 0.9473
48.63 9.24 0.4150 68.93 20.52 0.6836 84.13 28.96 0.9521
49.07 9.48 0.4199 69.24 20.69 0.6885 84.38 29.10 0.9570
49.52 9.73 0.4248 69.55 20.86 0.6934 84.62 29.24 0.9619
49.97 9.98 0.4297 69.86 21.04 0.6982 84.87 29.37 0.9668
50.40 10.22 0.4346 70.17 21.21 0.7031 85.11 29.51 0.9717
50.83 10.46 0.4395 70.47 21.37 0.7080 85.36 29.65 0.9766
51.26 10.70 0.4443 70.77 21.54 0.7129 85.61 29.79 0.9814
51.69 10.94 0.4492 71.07 21.71 0.7178 85.85 29.92 0.9863
52.11 11.17 0.4541 71.37 21.87 0.7227 86.10 30.06 0.9912
52.53 11.41 0.4590 71.67 22.04 0.7275 86.34 30.19 0.9961
52.94 11.63 0.4639 71.96 22.20 0.7324 86.58 30.32 1.0010
53.36 11.87 0.4688 72.26 22.37 0.7373 86.82 30.46 1.0059
53.77 12.10 0.4736 72.55 22.53 0.7422 87.06 30.59 1.0107
54.17 12.32 0.4785 72.84 22.69 0.7471 87.30 30.72 1.0156
54.57 12.54 0.4834 73.14 22.86 0.7520 87.54 30.86 1.0205
54.97 12.76 0.4883 73.43 23.02 0.7568 87.78 30.99 1.0254
55.37 12.98 0.4932 73.72 23.18 0.7617 88.02 31.12 1.0303
55.76 13.20 0.4980 74.00 23.34 0.7666 88.25 31.25 1.0352
56.15 13.42 0.5029 74.29 23.50 0.7715 88.49 31.39 1.0400
56.54 13.63 0.5078 74.57 23.65 0.7764 88.72 31.51 1.0449
56.92 13.85 0.5127 74.86 23.81 0.7813 88.96 31.65 1.0498
57.31 14.06 0.5176 75.14 23.97 0.7861 89.20 31.78 1.0547
57.68 14.27 0.5225 75.42 24.12 0.7910 89.43 31.91 1.0596
58.06 14.48 0.5273 75.70 24.28 0.7959 89.67 32.04 1.0645
106 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

FIG. 46 – OIL AND DISCHARGE TEMPERATURE (CONT’D)

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
89.90 32.17 1.0693 101.92 38.85 1.3379 112.86 44.93 1.6064
15
90.13 32.30 1.0742 102.13 38.96 1.3428 113.06 45.04 1.6113
90.36 32.42 1.0791 102.33 39.08 1.3477 113.25 45.14 1.6162
90.59 32.55 1.0840 102.54 39.19 1.3525 113.44 45.25 1.6211
90.82 32.68 1.0889 102.74 39.30 1.3574 113.63 45.35 1.6260
91.05 32.81 1.0938 102.95 39.42 1.3623 113.82 45.46 1.6309
91.28 32.94 1.0986 103.15 39.53 1.3672 114.01 45.56 1.6357
91.51 33.06 1.1035 103.36 39.65 1.3721 114.20 45.67 1.6406
91.74 33.19 1.1084 103.56 39.76 1.3770 114.40 45.78 1.6455
91.96 33.31 1.1133 103.77 39.88 1.3818 114.59 45.89 1.6504
92.19 33.44 1.1182 103.97 39.99 1.3867 114.78 45.99 1.6553
92.42 33.57 1.1230 104.18 40.10 1.3916 114.97 46.10 1.6602
92.64 33.69 1.1279 104.38 40.21 1.3965 115.16 46.20 1.6650
92.87 33.82 1.1328 104.58 40.33 1.4014 115.35 46.31 1.6699
93.10 33.95 1.1377 104.78 40.44 1.4063 115.54 46.41 1.6748
93.32 34.07 1.1426 104.99 40.55 1.4111 115.73 46.52 1.6797
93.54 34.19 1.1475 105.19 40.66 1.4160 115.92 46.63 1.6846
93.77 34.32 1.1523 105.39 40.78 1.4209 116.11 46.73 1.6895
93.99 34.44 1.1572 105.59 40.89 1.4258 116.30 46.84 1.6943
94.21 34.56 1.1621 105.80 41.00 1.4307 116.49 46.94 1.6992
94.43 34.69 1.1670 105.99 41.11 1.4355 116.67 47.04 1.7041
94.65 34.81 1.1719 106.19 41.22 1.4404 116.86 47.15 1.7090
94.88 34.94 1.1768 106.39 41.33 1.4453 117.05 47.25 1.7139
95.10 35.06 1.1816 106.59 41.44 1.4502 117.24 47.36 1.7188
95.32 35.18 1.1865 106.79 41.55 1.4551 117.43 47.46 1.7236
95.53 35.30 1.1914 106.99 41.66 1.4600 117.62 47.57 1.7285
95.75 35.42 1.1963 107.19 41.78 1.4648 117.80 47.67 1.7334
95.97 35.54 1.2012 107.39 41.89 1.4697 117.99 47.78 1.7383
96.19 35.66 1.2061 107.59 42.00 1.4746 118.18 47.88 1.7432
96.41 35.79 1.2109 107.79 42.11 1.4795 118.37 47.99 1.7480
96.63 35.91 1.2158 107.99 42.22 1.4844 118.56 48.09 1.7529
96.84 36.03 1.2207 108.18 42.33 1.4893 118.74 48.19 1.7578
97.06 36.15 1.2256 108.38 42.44 1.4941 118.93 48.30 1.7627
97.27 36.26 1.2305 108.58 42.55 1.4990 119.12 48.40 1.7676
97.49 36.39 1.2354 108.78 42.66 1.5039 119.31 48.51 1.7725
97.70 36.50 1.2402 108.97 42.76 1.5088 119.49 48.61 1.7773
97.92 36.63 1.2451 109.17 42.88 1.5137 119.68 48.72 1.7822
98.13 36.74 1.2500 109.37 42.99 1.5186 119.87 48.82 1.7871
98.35 36.86 1.2549 109.56 43.09 1.5234 120.05 48.92 1.7920
98.56 36.98 1.2598 109.76 43.20 1.5283 120.24 49.03 1.7969
98.77 37.10 1.2646 109.95 43.31 1.5332 120.43 49.13 1.8018
98.98 37.21 1.2695 110.15 43.42 1.5381 120.61 49.23 1.8066
99.20 37.34 1.2744 110.34 43.53 1.5430 120.80 49.34 1.8115
99.41 37.45 1.2793 110.54 43.64 1.5479 120.98 49.44 1.8164
99.62 37.57 1.2842 110.73 43.74 1.5527 121.17 49.54 1.8213
99.83 37.69 1.2891 110.93 43.85 1.5576 121.35 49.64 1.8262
100.04 37.80 1.2939 111.12 43.96 1.5625 121.54 49.75 1.8311
100.25 37.92 1.2988 111.32 44.07 1.5674 121.72 49.85 1.8359
100.46 38.04 1.3037 111.51 44.18 1.5723 121.91 49.95 1.8408
100.67 38.15 1.3086 111.70 44.28 1.5771 122.10 50.06 1.8457
100.88 38.27 1.3135 111.90 44.39 1.5820 122.28 50.16 1.8506
101.09 38.39 1.3184 112.09 44.50 1.5869 122.47 50.27 1.8555
101.29 38.50 1.3232 112.28 44.60 1.5918 122.65 50.37 1.8604
101.50 38.61 1.3281 112.48 44.71 1.5967 122.84 50.47 1.8652
101.71 38.73 1.3330 112.67 44.82 1.6016 123.02 50.57 1.8701

JOHNSON CONTROLS 107

 Temperature Thermistors
FORM 160.80-M1 (307)

FIG. 46 – OIL AND DISCHARGE TEMPERATURE (CONT’D)

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
123.21 50.68 1.8750 133.27 56.27 2.1436 143.32 61.85 2.4121
123.39 50.78 1.8799 133.46 56.37 2.1484 143.51 61.95 2.4170
123.58 50.88 1.8848 133.64 56.47 2.1533 143.69 62.05 2.4219
123.76 50.98 1.8896 133.82 56.57 2.1582 143.87 62.15 2.4268
123.94 51.08 1.8945 134.00 56.67 2.1631 144.06 62.26 2.4316
124.13 51.19 1.8994 134.18 56.77 2.1680 144.24 62.36 2.4365
124.31 51.29 1.9043 134.37 56.88 2.1729 144.43 62.47 2.4414
124.50 51.39 1.9092 134.55 56.98 2.1777 144.61 62.57 2.4463
124.68 51.49 1.9141 134.73 57.08 2.1826 144.80 62.67 2.4512
124.86 51.59 1.9189 134.91 57.18 2.1875 144.98 62.77 2.4561
125.05 51.70 1.9238 135.09 57.28 2.1924 145.17 62.88 2.4609
125.23 51.80 1.9287 135.28 57.38 2.1973 145.35 62.98 2.4658
125.42 51.90 1.9336 135.46 57.48 2.2021 145.54 63.08 2.4707
125.60 52.00 1.9385 135.64 57.58 2.2070 145.72 63.18 2.4756
125.78 52.10 1.9434 135.82 57.68 2.2119 145.91 63.29 2.4805
125.97 52.21 1.9482 136.01 57.79 2.2168 146.09 63.39 2.4854
126.15 52.31 1.9531 136.19 57.89 2.2217 146.28 63.49 2.4902
126.33 52.41 1.9580 136.37 57.99 2.2266 146.46 63.59 2.4951
126.52 52.52 1.9629 136.55 58.09 2.2314 146.65 63.70 2.5000
126.70 52.62 1.9678 136.73 58.19 2.2363 146.84 63.81 2.5049
126.88 52.72 1.9727 136.92 58.29 2.2412 147.02 63.91 2.5098
127.07 52.82 1.9775 137.10 58.39 2.2461 147.21 64.01 2.5146
127.25 52.92 1.9824 137.28 58.49 2.2510 147.39 64.11 2.5195
127.43 53.02 1.9873 137.46 58.59 2.2559 147.58 64.22 2.5244
127.62 53.13 1.9922 137.65 58.70 2.2607 147.77 64.32 2.5293
127.80 53.23 1.9971 137.83 58.80 2.2656 147.95 64.42 2.5342
127.98 53.33 2.0020 138.01 58.90 2.2705 148.14 64.53 2.5391
128.17 53.43 2.0068 138.19 59.00 2.2754 148.32 64.63 2.5439
128.35 53.53 2.0117 138.37 59.10 2.2803 148.51 64.73 2.5488
128.53 53.63 2.0166 138.56 59.20 2.2852 148.70 64.84 2.5537
128.71 53.73 2.0215 138.74 59.30 2.2900 148.88 64.94 2.5586
128.90 53.84 2.0264 138.92 59.40 2.2949 149.07 65.04 2.5635
129.08 53.94 2.0313 139.11 59.51 2.2998 149.26 65.15 2.5684
129.26 54.04 2.0361 139.29 59.61 2.3047 149.45 65.26 2.5732
129.44 54.14 2.0410 139.47 59.71 2.3096 149.63 65.36 2.5781
129.63 54.24 2.0459 139.65 59.81 2.3145 149.82 65.46 2.5830
129.81 54.34 2.0508 139.84 59.92 2.3193 150.01 65.57 2.5879
129.99 54.44 2.0557 140.02 60.02 2.3242 150.20 65.67 2.5928
130.17 54.54 2.0605 140.20 60.12 2.3291 150.38 65.77 2.5977
130.36 54.65 2.0654 140.39 60.22 2.3340 150.57 65.88 2.6025
130.54 54.75 2.0703 140.57 60.32 2.3389 150.76 65.98 2.6074
130.72 54.85 2.0752 140.75 60.42 2.3438 150.95 66.09 2.6123
130.90 54.95 2.0801 140.94 60.53 2.3486 151.14 66.19 2.6172
131.09 55.05 2.0850 141.12 60.63 2.3535 151.33 66.30 2.6221
131.27 55.15 2.0898 141.30 60.73 2.3584 151.51 66.40 2.6270
131.45 55.25 2.0947 141.49 60.83 2.3633 151.70 66.51 2.6318
131.63 55.35 2.0996 141.67 60.93 2.3682 151.89 66.61 2.6367
131.82 55.46 2.1045 141.85 61.03 2.3730 152.08 66.72 2.6416
132.00 55.56 2.1094 142.04 61.14 2.3779 152.27 66.82 2.6465
132.18 55.66 2.1143 142.22 61.24 2.3828 152.46 66.93 2.6514
132.36 55.76 2.1191 142.40 61.34 2.3877 152.65 67.03 2.6563
132.54 55.86 2.1240 142.59 61.44 2.3926 152.84 67.14 2.6611
132.73 55.97 2.1289 142.77 61.54 2.3975 153.03 67.24 2.6660
132.91 56.07 2.1338 142.95 61.64 2.4023 153.22 67.35 2.6709
133.09 56.17 2.1387 143.14 61.75 2.4072 153.41 67.46 2.6758
108 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

FIG. 46 – OIL AND DISCHARGE TEMPERATURE (CONT’D)

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
153.60 67.56 2.6807 164.36 73.54 2.9492 175.92 79.96 3.2178 15
153.79 67.67 2.6855 164.56 73.65 2.9541 176.14 80.08 3.2227
153.98 67.77 2.6904 164.76 73.76 2.9590 176.36 80.21 3.2275
154.17 67.88 2.6953 164.96 73.87 2.9639 176.58 80.33 3.2324
154.36 67.98 2.7002 165.17 73.99 2.9688 176.80 80.45 3.2373
154.55 68.09 2.7051 165.37 74.10 2.9736 177.02 80.57 3.2422
154.74 68.19 2.7100 165.57 74.21 2.9785 177.25 80.70 3.2471
154.94 68.31 2.7148 165.78 74.33 2.9834 177.47 80.82 3.2520
155.13 68.41 2.7197 165.98 74.44 2.9883 177.69 80.95 3.2568
155.32 68.52 2.7246 166.19 74.56 2.9932 177.91 81.07 3.2617
155.51 68.62 2.7295 166.39 74.67 2.9980 178.14 81.20 3.2666
155.70 68.73 2.7344 166.60 74.78 3.0029 178.36 81.32 3.2715
155.90 68.84 2.7393 166.80 74.89 3.0078 178.59 81.45 3.2764
156.09 68.94 2.7441 167.00 75.01 3.0127 178.81 81.57 3.2813
156.28 69.05 2.7490 167.21 75.12 3.0176 179.04 81.70 3.2861
156.47 69.16 2.7539 167.42 75.24 3.0225 179.26 81.82 3.2910
156.67 69.27 2.7588 167.62 75.35 3.0273 179.49 81.95 3.2959
156.86 69.37 2.7637 167.83 75.47 3.0322 179.72 82.07 3.3008
157.05 69.48 2.7686 168.04 75.58 3.0371 179.94 82.20 3.3057
157.25 69.59 2.7734 168.24 75.69 3.0420 180.17 82.32 3.3105
157.44 69.69 2.7783 168.45 75.81 3.0469 180.40 82.45 3.3154
157.64 69.81 2.7832 168.66 75.93 3.0518 180.63 82.58 3.3203
157.83 69.91 2.7881 168.87 76.04 3.0566 180.86 82.71 3.3252
158.02 70.02 2.7930 169.07 76.16 3.0615 181.09 82.83 3.3301
158.22 70.13 2.7979 169.28 76.27 3.0664 181.32 82.96 3.3350
158.41 70.23 2.8027 169.49 76.39 3.0713 181.55 83.09 3.3398
158.61 70.34 2.8076 169.70 76.51 3.0762 181.78 83.22 3.3447
158.80 70.45 2.8125 169.91 76.62 3.0811 182.01 83.35 3.3496
159.00 70.56 2.8174 170.12 76.74 3.0859 182.24 83.47 3.3545
159.19 70.67 2.8223 170.33 76.86 3.0908 182.48 83.61 3.3594
159.39 70.78 2.8271 170.54 76.97 3.0957 182.71 83.73 3.3643
159.59 70.89 2.8320 170.75 77.09 3.1006 182.94 83.86 3.3691
159.78 70.99 2.8369 170.96 77.21 3.1055 183.17 83.99 3.3740
159.98 71.11 2.8418 171.18 77.33 3.1104 183.41 84.12 3.3789
160.18 71.22 2.8467 171.39 77.45 3.1152 183.65 84.26 3.3838
160.37 71.32 2.8516 171.60 77.56 3.1201 183.88 84.38 3.3887
160.57 71.43 2.8564 171.81 77.68 3.1250 184.12 84.52 3.3936
160.77 71.54 2.8613 172.02 77.80 3.1299 184.36 84.65 3.3984
160.97 71.66 2.8662 172.24 77.92 3.1348 184.59 84.78 3.4033
161.16 71.76 2.8711 172.45 78.03 3.1396 184.83 84.91 3.4082
161.36 71.87 2.8760 172.66 78.15 3.1445 185.07 85.05 3.4131
161.56 71.98 2.8809 172.88 78.27 3.1494 185.31 85.18 3.4180
161.76 72.09 2.8857 173.10 78.40 3.1543 185.55 85.31 3.4229
161.96 72.21 2.8906 173.31 78.51 3.1592 185.79 85.45 3.4277
162.15 72.31 2.8955 173.53 78.63 3.1641 186.03 85.58 3.4326
162.35 72.42 2.9004 173.74 78.75 3.1689 186.27 85.71 3.4375
162.55 72.53 2.9053 173.96 78.87 3.1738 186.51 85.85 3.4424
162.75 72.64 2.9102 174.17 78.99 3.1787 186.75 85.98 3.4473
162.95 72.76 2.9150 174.39 79.11 3.1836 186.99 86.11 3.4521
163.15 72.87 2.9199 174.61 79.23 3.1885 187.24 86.25 3.4570
163.35 72.98 2.9248 174.83 79.36 3.1934 187.48 86.38 3.4619
163.55 73.09 2.9297 175.04 79.47 3.1982 187.73 86.52 3.4668
163.75 73.20 2.9346 175.26 79.60 3.2031 187.97 86.66 3.4717
163.96 73.32 2.9395 175.48 79.72 3.2080 188.22 86.80 3.4766
164.16 73.43 2.9443 175.70 79.84 3.2129 188.46 86.93 3.4814

JOHNSON CONTROLS 109

 Temperature Thermistors
FORM 160.80-M1 (307)

FIG. 46 – OIL AND DISCHARGE TEMPERATURE (CONT’D)

Temp (°F) Temp (°C) Vin Temp (°F) Temp (°C) Vin
188.71 87.07 3.4863 203.40 95.23 3.7549
188.96 87.21 3.4912 203.69 95.39 3.7598
189.21 87.35 3.4961 203.99 95.56 3.7646
189.46 87.48 3.5010 204.28 95.72 3.7695
189.71 87.62 3.5059 204.57 95.88 3.7744
189.96 87.76 3.5107 204.86 96.04 3.7793
190.21 87.90 3.5156 205.16 96.21 3.7842
190.46 88.04 3.5205 205.46 96.37 3.7891
190.71 88.18 3.5254 205.76 96.54 3.7939
190.96 88.32 3.5303 206.05 96.70 3.7988
191.22 88.46 3.5352 206.35 96.87 3.8037
191.47 88.60 3.5400 206.65 97.04 3.8086
191.73 88.75 3.5449 206.96 97.21 3.8135
191.98 88.88 3.5498 207.26 97.37 3.8184
192.23 89.02 3.5547 207.57 97.55 3.8232
192.49 89.17 3.5596 207.87 97.71 3.8281
192.75 89.31 3.5645 208.17 97.88 3.8330
193.01 89.46 3.5693 208.48 98.05 3.8379
193.27 89.60 3.5742 208.79 98.22 3.8428
193.53 89.75 3.5791 209.10 98.40 3.8477
193.79 89.89 3.5840 209.42 98.57 3.8525
194.05 90.03 3.5889 209.73 98.75 3.8574
194.31 90.18 3.5938 210.04 98.92 3.8623
194.57 90.32 3.5986 210.35 99.09 3.8672
194.84 90.47 3.6035 210.67 99.27 3.8721
195.10 90.62 3.6084 210.99 99.45 3.8770
195.37 90.77 3.6133 211.31 99.62 3.8818
195.63 90.91 3.6182 211.62 99.80 3.8867
195.90 91.06 3.6230 211.94 99.97 3.8916
196.16 91.21 3.6279 212.27 100.16 3.8965
196.43 91.36 3.6328 212.59 100.34 3.9014
196.70 91.51 3.6377 212.92 100.52 3.9063
196.97 91.66 3.6426 213.24 100.70 3.9111
197.24 91.81 3.6475 213.57 100.88 3.9160
197.51 91.96 3.6523 213.90 101.06 3.9209
197.78 92.11 3.6572 214.23 101.25 3.9258
198.06 92.26 3.6621 214.56 101.43 3.9307
198.33 92.41 3.6670 214.89 101.61 3.9355
198.61 92.57 3.6719 215.23 101.80 3.9404
198.88 92.72 3.6768 215.56 101.99 3.9453
199.15 92.87 3.6816 215.90 102.17 3.9502
199.43 93.02 3.6865 216.24 102.36 3.9551
199.71 93.18 3.6914 216.58 102.55 3.9600
199.99 93.34 3.6963 216.92 102.74 3.9648
200.27 93.49 3.7012 217.26 102.93 3.9697
200.55 93.65 3.7061 217.60 103.12 3.9746
200.83 93.80 3.7109 217.95 103.31 3.9795
201.11 93.96 3.7158 218.30 103.51 3.9844
201.39 94.11 3.7207 218.65 103.70 3.9893
201.68 94.27 3.7256 219.00 103.90 3.9941
201.97 94.44 3.7305 219.35 104.09 3.9990
202.25 94.59 3.7354 219.70 104.29 4.0039
202.54 94.75 3.7402 220.06 104.49 4.0088
202.82 94.91 3.7451
203.11 95.07 3.7500

110 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

FIG. 47 – EVAPORATOR REFRIGERANT SENSOR

Temp (°F) Temp (°C) Vin

0.04 -17.76 1.135 15
2.79 -16.23 1.214
5.44 -14.76 1.292
8.02 -13.32 1.370
10.53 -11.93 1.448
12.98 -10.57 1.526
15.39 -9.23 1.604
17.75 -7.92 1.683
20.08 -6.62 1.761
22.38 -5.34 1.839
24.66 -4.08 1.917
26.92 -2.82 1.995
29.17 -1.57 2.073
31.41 -0.33 2.151
33.66 0.92 2.230
35.90 2.17 2.308
38.15 3.42 2.386
40.41 4.67 2.464
42.69 5.94 2.542
44.99 7.72 2.620
47.31 8.51 2.698
49.67 9.82 2.777
52.06 11.15 2.855
54.49 12.50 2.933
56.96 13.87 3.011
59.50 15.28 3.089
62.10 16.72 3.167
64.77 18.21 3.245
67.51 19.73 3.324
70.35 21.31 3.402
73.29 22.94 3.480
76.36 24.65 3.558
79.55 26.42 3.636
82.89 28.27 3.714
86.41 30.23 3.792
90.12 32.29 3.871
94.07 34.49 3.949
98.31 36.84 4.027
102.87 39.38 4.105
107.81 42.12 4.183
113.26 45.15 4.261
119.30 48.50 4.339
126.10 52.28 4.418

JOHNSON CONTROLS 111

 Remote Setpoints
FORM 160.80-M1 (307)

SECTION 16
REMOTE SETPOINTS
(SEE FIGS. 10, 11 & 12)

There are three different Remote operating Modes that CURRENT LIMIT
can be selected at the Keypad: Analog Remote mode,
Digital Remote Mode or ISN Remote Mode. REMOTE CURRENT LIMIT SETPOINT with
0-10VDC, 2-10VDC, 0-20mA, 4-20mA or Pulse
The Control Center can receive a remote Current Limit Width Modulation Signal – The Remote Current Limit
and/or a Remote Leaving Chilled Liquid Temperature setpoint can be reset over the range of 100% to 30% Full
Setpoint via the following: Load Amps (FLA) by supplying (by others) a 0-10VDC,
2-10VDC, 0-20mA, 4-20mA or 1 to 11 second Pulse
Analog Remote Mode Width Modulated (PWM) signal to the Control Center.
• 0-10VDC Analog Input The Control Center must be configured appropriately to
accept the desired signal type as follows:
• 2-10VDC Analog Input
• 0-20mA Analog Input • The appropriate Remote Mode must be selected:
• 4-20mA Analog Input ANALOG Remote Mode must be selected when
using a voltage or current signal input. DIGITAL
Digital Remote Mode Remote Mode must be selected when using a
PWM input.
• Pulse Width Modulation (PWM) Input
• If ANALOG Remote Mode is selected, the RE-
ISN Remote Mode MOTE ANALOG INPUT RANGE setpoint must
• RS-232 Serial Port via MicroGateway be set to “0-10VDC” or “2-10VDC” as detailed
below, regardless of whether the signal is a voltage
or current input signal type.
The Analog inputs are connected to the Microboard J22
as shown in Fig. 10 and described below. Microboard • Microboard Program Jumper JP23 must be posi-
Program Jumpers JP23 and JP24 must be positioned tioned appropriately per the input signal type as
appropriately to receive either a 0-10VDC, 2-10VDC, 0- detailed below. It is recommended that a qualified
20mA or a 4-20mA signal. Refer to Table 1 “Microboard Service Technician position this jumper.
Program Jumpers” and for required configurations.
IMPORTANT! - The signal type used
The PWM inputs are in the form of a 1 to 11 second for Remote Current Limit setpoint re-
Relay contact closure that applies 115VAC to the I/O set and the signal type used for Remote
Board TB4-19 (Leaving Chilled Liquid Temp) and TB4- Leaving Chilled Liquid Temperature
20 (Remote Current Limit) for 1 to 11 seconds. Refer to setpoint reset must be the same. For
Fig. 14. The source of 115VAC is I/O Board TB4-1. The example, if a 0-10VDC signal is be-
PWM input must be received at a frequency of at least ing used for Remote Leaving Chilled
once every 30 minutes. If not received within this time
Liq uid Tem per a ture Reset, then a
interval, the Program assumes the remote device is de-
fective and defaults the Current Limit Setpoint to 100%
0-10VDC sig nal must be used for
and the Leaving Chilled Liquid Temperature Setpoint to Remote Current Limit Reset.
the locally programmed Local BASE value.
0-10VDC
The Microboard COM 4B RS-232 Serial Port (J2) As shown in Fig. 10, connect input to Microboard J22-1
receives the Setpoints in serial data form from the Mi- (signal) and J22-5 (Gnd). The setpoint varies linearly
croGateway located inside the Control Center enclosure. from 100% to 30% FLA as the input varies from 0
The MicroGateway receives Setpoints from remote to 10VDC. This input will only be accepted when
external devices and transfers them to the Microboard. ANALOG Remote Mode is selected, the REMOTE
ANALOG INPUT RANGE setpoint is set for “0-10

112 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

Volts and Microboard Program Jumper JP23 has been 4-20mA

removed. Calculate the Setpoint for various inputs as As shown in Fig. 11, connect input to Microboard J22-2
follows: (signal) and J22-5 (Gnd). The Setpoint varies linearly
Setpoint (%) = 100 – (VDC x 7) from 100% to 30% FLA as the input varies from 4mA to
20mA. This input will only be accepted when ANALOG
For example, if the input is 5VDC, the setpoint would remote mode is selected, the REMOTE ANALOG
be set to 65% as follows: INPUT RANGE setpoint is set for “2-10 Volts” and
Setpoint(%) = 100 - (5 x 7) Microboard Program Jumper JP23 has been placed on
pins 1 and 2. Calculate the Setpoint for various inputs
= 100 - 35 as follows:
16
= 65% Setpoint (%) = 100 – [(mA-4) x 4.375)]
2-10VDC For example, if the input is 8mA, the setpoint would be
As shown in Fig. 10, connect input to Microboard J22-1 set to 83% as follows:
(signal) and J22-5 (Gnd). The setpoint varies linearly
from 100% to 30% FLA as the input varies from 2 Setpoint (%) = 100 - [(8-4) x 4.375]
to 10VDC. This input will only be accepted when
ANALOG Remote Mode is selected, the REMOTE = 100 - (4 x 4.375)
ANALOG INPUT RANGE setpoint is set for “2-10 = 100 - 17.5
Volts” and Microboard Program Jumper JP23 has been
removed. Calculate the Setpoint for various inputs as = 82.5
follows:
= 83%
Setpoint (%) = 100 – [(VDC - 2) x 8.75]
PWM
For example, if the input is 5VDC, the setpoint would The Pulse Width Modulation input is in the form of a 1
be set to 74% as follows: to 11 second relay contact closure that applies 115VAC
Setpoint (%) = 100 - [(5 - 2) x 8.75] to the I/O Board TB4-20 for 1 to 11 seconds. As shown
= 100 - [3 x 8.75] in Fig. 14, connect dry closure relay contacts between
I/O Board TB4-20 (signal) and TB4-1 (115VAC). The
= 100 - 26.25
setpoint varies linearly from 100% to 30% as the relay
= 74% contact closure time changes from 1 to 11 seconds. The
0-20mA relay contacts should close for 1 to 11 seconds at least
As shown in Fig. 11, connect input to Microboard J22-2 once every 30 minutes to maintain the setpoint to the
(signal) and J22-5 (Gnd). The Setpoint varies linearly desired value. If a 1 to 11 second closure is not received
from 100% to 30% FLA as the input varies from 0mA to within 30 minutes of the last closure, the setpoint is de-
20mA. This input will only be accepted when ANALOG faulted to 100%. A closure is only accepted at rates not
remote mode is selected, the REMOTE ANALOG to exceed once every 70 seconds. This input will only
INPUT RANGE setpoint is set for “0-10 Volts” and be accepted in DIGITAL remote mode. Calculate the
Microboard Program Jumper JP23 has been placed on Setpoint for various inputs as follows:
pins 1 and 2. Calculate the Setpoint for various inputs
as follows: Setpoint (%) = 100 – [(pulse width in seconds - 1) x 7]
Setpoint (%) = 100 – (mA x 3.5) For example, if the relay contacts close for 3 seconds,
For example, if the input is 8mA, the setpoint would be the setpoint would be set to 86% as follows:
set to 72% as follows: Setpoint (%) = 100 - [(3-1) x 7]
Setpoint (%) = 100 - (8 x 3.5) = 100 - (2 x 7)
= 100 - 28 = 100 - 14
= 72% = 86%
= 74%

JOHNSON CONTROLS 113

 Remote Setpoints
FORM 160.80-M1 (307)

RS-232 as detailed below. It is recommended a qualified

As shown in Fig. 9, a setpoint can be received in serial Service Technician position this jumper.
data form at Microboard J2 from the GPIC.
IMPORTANT! - The signal type used
LEAVING CHILLED LIQUID TEMPERATURE for Remote Leaving Chilled Liquid
Temperature setpoint reset and the
REMOTE LEAVING CHILLED LIQUID TEM- signal type used for Remote Current
PERATURE SETPOINT with 0-10VDC, 2-10VDC, Limit setpoint reset must be the same.
0-20mA, 4-20mA or Pulse Width Modulation Signal For example, if a 0-10VDC signal is
– Remote Leaving Chilled Liquid Temperature setpoint
being used for Remote Current Limit
reset can be accomplished by supplying (by others) a
0-10VDC, 2-10VDC, 0-20mA, 4-20mA or 1 to 11
setpoint reset, then a 0-10VDC signal
second Pulse Width Modulated (PWM) signal to the must be used for Leaving Chilled Liq-
Control Center. The LEAVING CHILLED LIQUID uid Temperature reset.
TEMPERATURE setpoint is programmable over the
range of 38°F to 70°F (water applications); 36°F to 0-10VDC - As shown in Fig. 10, connect input to
70°F (water applications with Smart Freeze protection Microboard J22-3 (signal) and J22-5 (Gnd). A 0VDC
enabled); or 20°F to 70°F (brine applications). The Re- signal produces a 0°F offset. A 10VDC signal produces
mote input signal changes the setpoint by creating an the maximum offset (10, 20, 30 or 40°F above the Lo-
offset above the locally programmed Leaving Chilled cal Setpoint value). The setpoint is changed linearly
Liquid Temperature Base setpoint value. The setpoint between these extremes as the input varies linearly over
can be remotely changed over the range of 10, 20, 30 the range of 0VDC to 10VDC. This input will only be
or 40°F (as per the locally programmed REMOTE accepted when ANALOG Remote mode is selected, the
RESET TEMPERATURE RANGE setpoint) above REMOTE ANALOG INPUT RANGE setpoint is set
the Local Leaving Chilled Liquid Temperature Setpoint. for “0-10VDC” and Microboard Program Jumper JP24
For example, if the Local setpoint is 40°F and the RE- has been removed. Calculate the Setpoint for various
MOTE RESET TEMPERATURE RANGE setpoint inputs as follows:
is programmed for 10°F, the Leaving Chilled Liquid
Temperature setpoint can be remotely reset over the Offset (°F) = (VDC) (Remote Reset Temp Range)
range of 40°F to 50°F. The setpoint received through 10
the COM 4B RS-232 serial port is not an offset that
is applied to the locally programmed BASE value as Setpoint (°F) = Locally programmed BASE
described above. Rather, it is an actual Setpoint value. value
The locally programmed value is not used as a BASE + Offset
in this application.
For example, if the input is 5VDC and the Remote Reset
The Control Center must be configured appropriately to Temp Range setpoint is programmed for 10°F and the
accept the desired signal type as follows: Local Leaving Chilled Liquid Temperature setpoint is
programmed for 40°F, the setpoint would be set to 45°F
as follows:
• The appropriate Remote Mode must be selected:
ANALOG Remote Mode must be selected when Offset (°F) = 5 x 10
using a voltage or current signal input. DIGITAL 10
Remote Mode must be selected when using a PWM = 50
input. 10
• If ANALOG Remote Mode is selected, the RE-
= 5°F
MOTE ANALOG INPUT RANGE setpoint must
Setpoint = 40 + 5
be set to “0-10VDC” or “2-10VDC” as detailed
= 45°F
below, regardless of whether the signal is a voltage
or current signal type. 2-10VDC
• Microboard Program Jumper JP24 must be po- As shown in Fig. 12, connect input to Microboard J22-3
sitioned appropriately per the input signal type (signal) and J2-5 (Gnd). A 2VDC signal produces a 0°F
offset. A 10VDC signal produces the maximum allowed

114 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

offset (10, 20, 30 or 40°F above the Local Setpoint For example, if the input is 8mA, the Remote Reset
value). The setpoint is changed linearly between these Temp Range Setpoint is programmed for 10°F and the
extremes as the input varies over the range of 2VDC Local Leaving Chilled Liquid Temperature setpoint is
to 10VDC. This input will only be accepted when programmed for 40°F, the setpoint would be set to 44°F
ANALOG remote mode is selected, the REMOTE as follows:
ANALOG INPUT RANGE setpoint is set for “2-
10VDC” and the Microboard Program Jumper JP24 Offset (°F) = (8)(10)
has been removed. Calculate the setpoint for various 20
inputs as follows:
= 80
20 16
Offset (°F) = (VDC – 2) (Remote Reset Temp Range)
8 = 4°F

Setpoint (°F) = Local Setpoint + Offset Setpoint (°F) = 40 + 4

= 44°F
For example, if the input is 5VDC and the Remote Re-
set Temp Range setpoint is programmed for 10°F and
the Local Leaving Chilled Liquid Temperature setpoint 4-20mA - As shown in Fig. 10, connect input to
is programmed for 40°F, the setpoint would be set to Microboard J22-4 (signal) and J22-5 (GND). Program
43.8°F. Jumper JP24 must be placed on pins 1 and 2. A 4mA sig-
nal produces a 0°F Offset. A 20mA signal produces the
Offset (°F) = (5 – 2)(10) maximum allowed Offset (10 or 20°F above the Local
8 Setpoint). The setpoint is changed linearly between these
extremes as the input varies over the range of 4-20mA.
= (3)(10)
This input will only be accepted when ANALOG
8
Remote mode is selected, the REMOTE ANALOG
= 30 INPUT RANGE setpoint is set for “2-10VDC” and
8 Microboard Program Jumper JP24 has been placed on
pins 1 and 2. Calculate the Setpoint for various inputs
= 3.8°F
as follows:
Setpoint (°F) = 40 + 3.8
= 43.8°F Offset (ºF) = (mA-4) (Remote Reset Temp Range)
16
0-20mA
Setpoint (ºF) = Local Setpoint + Offset
As shown in Fig. 12, connect input to Microboard J22-4
(signal) and J22-5 (Gnd). A 0mA signal produces a 0°F For example, if the input is 8mA, and the Remote Reset
offset. A 20mA signal produces the maximum allowed Temp Range setpoint is programmed for 10°F and the
offset (10, 20, 30 or 40°F above the Local setpoint Local Leaving Chilled Liquid Temperature setpoint
value). The setpoint is changed linearly between these is programmed for 40°F, the setpoint would be set to
extremes as the input varies over the range of 0-20mA. 42.5°F as follows:
This input will only be accepted when ANALOG remote
mode is selected, the REMOTE ANALOG INPUT Offset (°F) = (8 – 4)(10)
RANGE setpoint is set for “0-10VDC” and Microboard 16
Program Jumper J24 has been placed on pins 1 and 2.
Calculate the setpoint for various inputs as follows: = (4)(10)
16
Offset (°F) = (mA) (Remote Reset Temp Range) = 40
20 16

Setpoint (°F) = Local Setpoint + Offset = 2.5°F

Setpoint (°F) = 40 + 2.5

= 42.5
JOHNSON CONTROLS 115
 Remote Setpoints
FORM 160.80-M1 (307)

PWM For example, if the relay contacts close for 5 seconds and
The Pulse Width Modulation input is in the form of a 1 to the Remote Reset Temp Range setpoint is programmed
11 second relay contact closure that applies 115VAC to to 10°F and the Local Leaving Chilled Liquid Tempera-
the I/O Board TB4-19 for 1 to 11 seconds. As shown in ture setpoint is programmed for 40°F, the setpoint would
Fig. 14, connect dry closure relay contacts between I/O be set to 44°F as follows:
Board TB4-19 (input) and TB4-1 (115VAC). A contact
closure time (pulse width) of 1 second produces a 0°F
offset. An 11 second closure produces the maximum Offset (°F) = (5 – 1)(10)
allowed offset (10 , 20, 30 or 40°F above the Local 10
Setpoint value). The relay contacts should close for 1 to
= (4)(10)
11 seconds at least once every 30 minutes to maintain
10
the setpoint to the desired value. If a 1 to 11 second
closure is not received within 30 minutes of the last = 40
closure, the setpoint is defaulted to the Local setpoint 10
value. A closure is only accepted at rates not to exceed
= 4°F
once every 70 seconds. This input will only be accepted
in DIGITAL Remote mode. Calculate the setpoint for
Setpoint (°F) = 40 + 4
various pulse widths as follows:
= 44°F
Offset (°F) =

(pulse width in seconds – 1)(Remote Reset Temp Range) RS-232 - As shown in Fig. 9, a Setpoint can be received
10 in serial data form at the Microboard COM 4B serial
port (J2) from the MicroGateway.
Setpoint (F°) = Local Setpoint + Offset

116 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

SECTION 17
HOT GAS BYPASS

The optional Hot Gas Bypass diverts hot gas directly it is turned off when the Return Chilled Liquid Tem-
from the Oil Separator to the Evaporator, bypassing the perature increases to > x°F (programmed as the OFF
Condenser. Solenoid Valve 3 SOL, located in the bypass Setpoint) above the Leaving Chilled Liquid Temperature
line, is driven by the I/O Board TB1-61 to control the by- Setpoint.
pass. Under Program control, it is turned on (energized)
to open the bypass line and turned off (de-energized) to The ON Setpoint is programmed over the range of 1.0 to
close the bypass line. 10.0°F (default 1.0). The OFF setpoint is programmed
over the range of 2.0 to 15.0°F (default 2.0). These
When the chiller is shutdown, the Hot Gas Bypass is turned Setpoints are programmed by a Service Technician
17
off coincident with removing the start signal from the motor using instructions in the “System Calibration, Service
starter. It remains off while the chiller is shut down. Setpoints and Reset Procedures” section of this book.
If the chiller is equipped with the Hot Gas Bypass op-
Each time the chiller is started, the solenoid valve is tion, operation must be enabled on the OPERATIONS
turned off for the first 3 minutes of operation. After Screen.
that, the solenoid valve is controlled per the differ-
ential between the Return Chilled Liquid Temperature The HOT GAS BYPASS Screen, accessed from the
and the Leaving Chilled Liquid Temperature Setpoint, COMPRESSOR Screen, displays a pictorial of the
as compared to the Hot Gas Bypass ON Setpoint and bypass line and solenoid valve location on the chiller.
OFF Setpoint as follows: It is turned on when the The Hot Gas ON and OFF Setpoints are programmed
Return Chilled Liquid Temperature decreases to < x°F on this screen and system parameters pertinent to Hot
(programmed as the ON Setpoint) above the Leaving Gas Bypass operation are displayed. An LED illuminates
Chilled Liquid Temperature Setpoint. Once turned on, when the Hot Gas Solenoid is ON.

FIG. 48 – FUTURE

JOHNSON CONTROLS 117

 Smart Freeze Protection
FORM 160.80-M1 (307)

SECTION 18
SMART FREEZE PROTECTION

The Smart Freeze feature prevents nuisance chiller SMART FREEZE protection is activated only when
shutdowns due to brief periods of chilled liquid flow the feature is enabled AND the Leaving Chilled Liquid
fluctuations or other brief operating conditions that Temperature Setpoint is < 38°F. Once activated, the
would normally cause Low Evaporator Pressure Safety total number of seconds that the evaporator refrigerant
shutdowns. With this feature enabled and activated, the temperature is below the freeze threshold is counted.
chiller is permitted to ride through these temporary con- The freeze threshold is 32.8°F (refrigerant temp. sensor
ditions. Also, this feature allows the Leaving Chilled RT7) or 34.0°F (evaporator saturation temp.). The count
Liquid temperature Setpoint to be set as low as 36.0°F. is incremented once for every second the evaporator
Smart Freeze protection can be enabled or disabled at refrigerant temperature is below the freeze threshold and
the Keypad, by a Service Technician, using a procedure decremented once for every second it is above the freeze
detailed in the “System Calibration, Service Setpoints threshold (but it is never decremented below zero). Thus
and Reset Procedures” section of this book. It cannot if the evaporator refrigerant temperature goes below
be used in Brine cooling mode. the freeze threshold for 30 seconds, then goes above
it for 10 seconds, then goes below the threshold for
The basis of this feature is that the chilled liquid contains 5 seconds, the total number of seconds the evaporator
an amount of heat, which cannot be eliminated imme- refrigerant temperature was below the freeze threshold
diately. Therefore, it requires a certain amount of time was 25 seconds. If Smart Freeze is no longer activated
for the liquid to change to a solid. During this period due to the Leaving Chilled Liquid Temperature Setpoint
of time, those parameters that determine when solidif- being raised to > 38°F, the total number of seconds being
ication will occur, are evaluated and the appropriate Low tracked is set to zero.
Evaporator Temperature shutdown threshold is applied.
This threshold could be lower, but not higher than the The number of seconds it will take the chilled liquid to
normal Safety threshold. freeze is based on how far the evaporator refrigerant
temperature is below the freeze threshold as follows:
Smart Freeze protection uses the Evaporator Refrig-
erant Temperature as one of the variables to determine Number of seconds to freezing =
when freezing is imminent. If the chiller is equipped with
the Evaporator Refrigerant Temperature Sensor (RT7), (4053.7)
and the sensor is enabled using the “System Calibration, (freeze threshold - evaporator refrigerant temperature)
Service Setpoints and Reset Procedures” section of this
book, this value is used as the refrigerant temperature. Thus , if the Evaporator Saturation Temperature is be-
Otherwise, the Evaporator Saturation Temperature (as ing used as the evaporator refrigerant temperature, and
derived from the output of the Evaporator Pressure that temperature is 26°F, it would take 8 minute and 26
Transducer. The pressure is converted to a temperature seconds for the chilled liquid to freeze.
via the appropriate refrigerant “pressure/temperature
lookup table”) is used as the refrigerant temperature. When the total number of seconds the evaporator
refrigerant temperature is below the freeze threshold
When Smart Freeze protection is Enabled, the Leaving exceeds the “Number of seconds to freezing”, a safety
Chilled Liquid Temperature Setpoint can be set as low shutdown is performed and “EVAPORATOR- LOW
as 36.0°F. If set to < 38.0°F, the LEAVING CHILLED PRESSURE - SMART FREEZE” is displayed on the
LIQUID – LOW TEMPERATURE cycling shutdown System Details line of the display.
threshold becomes a minimum of 34.0°F.
Even though Smart Freeze protection is enabled and
Unless Smart Freeze protection is activated, the fixed activated, the Slide Valve Load inhibit still occurs at the
Low Evaporator Pressure Safety thresholds (R22 – 54.3 same thresholds as with normal operation; inhibit at 56.2
PSIG, 29.6°F) (R134a – 25.0 PSIG, 28.7°F) are used. PSIG (R22) and 27.0 (R134a). As in normal operation,
loading will be allowed when the pressure increases to
57.5 PSIG (R22) and 28.0 PSIG (R134a).

118 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

The following is a summary of the operation with Smart low the Leaving Chilled Liquid Temperature
Freeze enabled and disabled: Setpoint, as programmed, or a minimum of
36.0°F.
SMART FREEZE DISABLED: 2. The Low Evaporator Pressure Safety shut-
• Minimum Leaving Chilled Liquid Setpoint: down threshold is the same as Smart Freeze
38.0°F Disabled above.
• Low Chilled Liquid Temp cycling shutdown • If the Leaving Chilled Liquid Temperature Setpoint
threshold: 1° to 34.0°F below the Leaving Chilled is <38.0°F:
Liquid temp Setpoint, as programmed, or a min-
imum of 36.0°F. 1. The Low Leaving Chilled Liquid Temperature
Cycling shutdown threshold: 1 to 3.0°F be-
• Low Evaporator Pressure safety shutdown thresh- low the Leaving Chilled Liquid Temperature
old: R22 - 54.3 PSIG (29.6°F); R134a – 25.0 PSIG Setpoint, as programmed, or a minimum of
(28.7°F) 34.0°F.
• PRV Load Inhibit: R22 – 56.2 PSIG; R134a – 27.0
18
2. Low Evaporator Pressure shutdown thresh-
PSIG old: Determined by how far the evaporator
Load Inhibit disable: R22 – 57.5 PSIG; R134a refrigerant temperature is below the freeze
– 28.0 PSIG threshold of 32.8°F (refrigerant sensor RT7)
or 34.0°F (Evaporator Saturation temp.), and
SMART FREEZE ENABLED: the total number of seconds it remains there.
• Minimum Leaving Chilled Liquid Setpoint: 36.0° Refer to previous explanation.
F • Slide Valve Load Inhibit: same as Smart Freeze
• If the Leaving Chilled Liquid Temperature Setpoint Disabled above.
is >38.0°F: • Load Inhibit Disable: same as Smart Freeze Dis-
1. The Low Leaving Chilled Liquid Temperature able above.
Cycling shutdown threshold: 1 to 34.0°F be-

JOHNSON CONTROLS 119

 Standby Chiller Freeze Protection FORM 160.80-M1 (307)

SECTION 19
STANDBY CHILLER FREEZE PROTECTION

In multiple chiller applications, it may be possible for Service Setpoints and Reset Procedures” section of this
the chilled liquid from an operating chiller (water or book. The condenser pump operation is independent of
brine) to flow through the evaporator of a standby chiller. this time delay.
This presents a possible freeze threat to the condenser
of the standby chiller. To minimize this freeze poten- At chiller shutdown, the condenser pump continues
tial, the Control Center of the standby chiller cycles the to run until the Condenser Saturation Temperature
condenser pump (via I/O Board TB2-151) based upon increases to > 35.0°F. During shutdown, anytime this
the Condenser Saturation Temperature of the standby temperature decreases to < 30.0°F, the pump is turned
chiller, while the chiller is shutdown. If the temperature on until the temperature increases to > 35.0°F. After
continues to decrease after the pump has been turned the chiller has been shutdown for at least the amount of
on, a Warning message is displayed and the Warning/ time programmed as the Freeze Warning Time Delay,
Anticipatory alarm contacts (I/O Board TB2-55/56) are if the temperature continues to decrease to < 28.0°F,
closed to annunciate the condition. If Standby Chiller “Warning – Freeze Threat From Operating Chiller” is
Freeze Protection feature is desired, it must be Enabled. displayed on the System Details line of the Display and
Otherwise, it must be Disabled. A Service Technician the Warning/Alarm contacts close. The Warning mes-
must Enable or Disable this feature using the “System sage and Warning/Alarm contacts automatically clear
Calibration, Service Setpoints and Reset Procedures” when the temperature increases to > 28.0°F.
section of this book.
The condenser water flow switch (I/O Board TB4-11)
is bypassed for 60 seconds after the condenser pump
The Warning and Alarm will occur only after the by- is turned on. If the flow switch is not closed within 60
pass time programmed as the Freeze Warning Time seconds after pump turn on or if it opens continuously
Delay Setpoint (30 to 60 minutes; default 30 minutes) for 2 seconds after the 60 second bypass, “Warning
has elapsed. This Setpoint is programmed by a Service – Freeze Threat, Condenser Flow Switch open” is
Technician using instructions in the “System Calibration, displayed on the System Details line of the Display.

120 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

SECTION 20
OIL RECOVERY FEATURE
20
An Oil Recovery feature is included in Flash Memory 1. If the discharge superheat is [>15.0 ºF (R22) (10.0ºF
Card version C.MLM.03.03.xxx (and later). Extended for R134a) and <25.0 ºF (R22)(13.0ºF for R134a)]
operation at low load, entering condenser water tempera- or the Slide Valve position is < 40%, the superheat
tures that are below design, oil cooler supply problems and superheat rate of change are evaluated every
or oil solenoid valve problems can allow oil to migrate 5 seconds and the following action is taken at the
from the oil separator to the evaporator refrigerant end of each 5-second period. While this operation
charge. This reduces the quantity of oil in the separator is in effect, “Warning – Oil Recovery limit” is dis-
and can result in “Oil Separator – Low Level” safety played on the System Details line of the display. If
shutdowns. Excess oil mixed with the refrigerant in the the change in discharge superheat:
evaporator will cause severe foaming when the chiller • Remains the same or increases, apply 0.5 second
is started. This foaming carries liquid refrigerant into load pulse
the compressor, lowering the compressor discharge
• Decreases by 0.1 to 0.9ºF, hold the slide valve
temperature. As the compressor discharge temperature
approaches the condenser saturation temperature (low • Decreases >1ºF, apply 0.5 second unload
discharge superheat), the refrigerant gas has a greater pulse.
affinity to absorb more oil. When the discharge superheat 2. If the discharge superheat is <15.0ºF(R22) (10.0ºF
is reduced, oil cannot be separated from the refrigerant for R134a) but >10ºF(R22) (5.0ºF for R134a), hold
gas in the oil separator. the slide valve.
3. If the discharge superheat is <10.0ºF(R22) (5.0ºF
The Oil Recovery feature is used to automatically re- for R134a):
cover the oil that has accumulated in the evaporator • Inhibit loading
refrigerant. It accomplishes this by applying load, unload
or hold outputs to the slide valve in 5-second intervals • If condition exists for > 10 seconds, invoke “Ex-
according to the rate of change of the discharge superheat cess Charge Override’ routine as follows: apply
in each interval. This operation is detailed below. The 0.5 second unload pulses every 3 seconds (dur-
feature can be Enabled or Disabled. The Default is Dis- ing which “Warning – Low Discharge Superheat
abled. Pertinent information for this feature is displayed Limit” is displayed) until Superheat >15.0ºF
on the Oil Separator Screen. The change in superheat (whereupon “Warning-Low Discharge Super-
that occurs in each 5-second interval is displayed as heat Detected” replaces the message “Warning
“Change in Discharge Superheat = xx.x ºF”. Increases – Low Discharge Superheat Limit”).
are displayed as xx.x. Decreases are displayed as –xx.x. 4. When both the superheat increases to > 25.0 ºF
The Oil recovery feature is Enabled and Disabled on (R22)(13.0ºF for R134a) and the slide valve po-
this screen. The access level is OPERATOR or higher. sition is > 40%, “Warning – Oil Recovery Limit”
This allows an Operator at the chiller facility, under the is cleared, Oil Recovery operation terminates and
direction of a qualified service technician from a remote normal operation resumes.
location, to enable the feature and restart a chiller that
has shutdown on an Oil Level safety shutdown. This If the Oil recovery feature is Enabled, the restart criteria
feature should only be is used as a tool to recover oil following an “Oil Separator – Low Level” safety shut-
and should only be enabled following an oil loss safety down is different than if the feature is Disabled. With the
shutdown. It should be disabled after the oil has been feature Disabled, the Separator Oil Level Switch (SOLS)
recovered. Since it inhibits Slide Valve loading, chiller must be closed before a restart is allowed. This require-
capacity will be affected while this routine is in effect. ment is the same as in all previous software versions.
Therefore, it should be disabled after the oil has been However, to eliminate the need to manually bypass the
recovered. SOLS in order to restart a chiller that has already suf-
fered oil loss, the SOLS does not have to be closed to
After a 3-minute bypass at start, during which the Sepa- start the chiller when the feature is Enabled.
rator Oil Level Switch (SOLS) status is bypassed, the
Oil Recovery operation is performed as follows:

JOHNSON CONTROLS 121

 System Calibration
FORM 160.80-M1 (307)

SECTION 21
SYSTEM CALIBRATION, SERVICE SETPOINTS AND RESET PROCEDURES

The chiller is supplied from the YORK Factory with all Some Safety shutdowns will not permit the chiller to
factory mounted components fully calibrated. The fol- start until a special reset procedure is performed. These
lowing procedures are used to verify these calibrations or reset procedures require SERVICE access level and
calibrate a component after it has been field replaced. should not be performed by anyone other than a Ser-
vice Technician. Each of these procedures is described
Programmable Service Setpoints are used by the Pro- below.
gram to control critical chiller operation. Also, some of
these Setpoints can be used to enable or disable certain ELECTRO-MECHANICAL STARTER
features. Although they have been entered at the YORK APPLICATIONS
Factory, they can be changed by a field Service Tech-
nician that has logged in at SERVICE access level. If If the Compressor Motor is driven by an Electro-Me-
the BRAM battery backed memory device (U52) is field chanical Starter, the Control Center is equipped with
replaced, all of the programmed setpoints will be lost. a CM-2 Current Module along with supporting com-
They will have to be reentered into the new BRAM. Each ponents Diode Bridge (DB) and Calibration Resistors
of these Setpoints is described below. Programming pro- (RES), as described in a previous chapter of this book.
cedures and Control Center Keypad operation required The following procedures can be used to verify the
in the procedures below are detailed in YORK Operation calibration and perform the calibration if Necessary. In
Manual 160.80-O1. In general, the following procedure addition to the calibration, Switch S1 and Potentiometer
is used to enter Setpoints in this section: R16 have to be set appropriately on the CM-2 Module. If
the CM-2 and/or RES are field replaced, field calibration
1. Unless noted otherwise in procedures below, log is necessary.
in at SERVICE access level using Access Code
1380. CM-2 Settings:
1. Place Switch S1 in the appropriate position per the
2. Select the appropriate Display Screen.
Starter type:
3. Press the desired Setpoint key. UP: Y-Delta or Autotransformer Starter
A dialog box appears, giving the minimum and Down: All others
maximum allowed values, Default value and pres-
2. Calculate LRA/FLA ratio by dividing the Motor
ent value. The dialog box can be canceled at any
Lock Rotor Amps by the chiller Full Load Amps
time by pressing the CANCEL (X) key.
(LRA/FLA = ratio) and then adjust Potentiometer
4. If the dialog box begins with the word “Enter”, use R16 to the ratio value.
the numeric keys to enter the desired value. Leading
zeroes are not necessary. Press the • key to place Calibration Verification:
a decimal point at the appropriate place. Pressing 1. At the Keypad, log in at SERVICE access level
the ▲ key displays the Default value. Pressing using access code 1 3 8 0 .
the ▼ key clears the entry. The ◄ key is a back-
space key and causes the entry point to move back 2. Select MOTOR Screen and set Current Limit and
one space. If the dialog box begins with “Select” Pulldown Demand Limit Setpoints to 100% FLA.
or “Enable”, use the ◄ and ► keys to select the 3. Run chiller. Read compressor motor current in
desired value. The ◄ key decreases the value. The Phase A, B, and C using a clamp-on Ammeter.
► key increases the value. Apply ammeter to highest Phase.
5. Press the ENTER ( ) key. If the value is within 4. Select COMPRESSOR Screen.
range, it is accepted and the dialog box disappears. 5. Manually operate the Pre-rotation Vanes by press-
The chiller will begin to operate based on the new ing the OPEN and CLOSE Keypad keys as required
value. If out of range, the value is not accepted and to achieve a motor current equivalent to 100% FLA
a message describing why it is not acceptable is as indicated by the clamp-on Ammeter. The motor
displayed momentarily. current value on the Display should indicate 100%
FLA.

122 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

6. Manually operate the Pre-rotation Vanes by press- SOLID STATE STARTER APPLICATIONS
ing the OPEN and CLOSE keys as required to
achieve a motor current equivalent to 105% FLA The chiller could be equipped with either of two dif- 21
as indicated by the clamp-on Ammeter. The 105% ferent YORK Solid State Starters. New production
LED on the CM-2 Module should illuminate. chillers after October 1999 are equipped with the
Mod “B” serial data interface Liquid Cooled Solid
If the calibration verification does not perform as State Starter (LCSSS). Earlier vintage chillers, such as
above, the following Calibration procedure will have those encountered in retrofit applications are equipped
to be performed: with the Style “A” multiplexed data interface LCSSS.
Microboard Program Jumper JP39 must be positioned to
Calibration: invoke the appropriate Microboard/Program operation
1. At the Keypad, log in at SERVICE access level for the starter applied (Refer to Table 1). A description
using access code 1 3 8 0 . of these starters is contained in the Solid State Starter
section of this book. The procedures for both starters
2. Select MOTOR Screen and set Current Limit and
are listed below.
Pulldown Demand Limit Setpoints to 100% FLA.
3. Select COMPRESSOR Screen. MOD “B” SERIAL DATA INTERFACE LIQUID
4. Run chiller and read compressor motor current in COOLED SOLID STATE STARTER
Phase A, B and C using a clamp-on Ammeter. Ap-
ply Ammeter to highest Phase. Complete details of the operation of this starter are con-
5. Manually operate the Slide Valve by pressing the tained in YORK Service Manual 160.00-O2.
LOAD and UNLOAD Keypad keys as required to
1. At the Keypad, log in at SERVICE access level
achieve a motor current equivalent to 100% FLA
using access code 1 3 8 0 .
as indicated by the clamp-on Ammeter. The volt-
age across Variable Resistors (RES) should be 0.90 2. Select MOTOR Screen.
to 1.05VDC. Measure this voltage by connecting 3. Enter the following Setpoints using procedures
a Voltmeter at CM-2 Board J1-2 (+) to J1-1(-). If below:
necessary, adjust RES to achieve this value. Figure
36 contains formulas to calculate the resistance of Full Load Amps:
RES required to achieve this voltage. Adjust both This is the Full Load Amps (FLA) of the chiller as listed
resistors equally such that the combined resistance on the Sales Order Screen. The Microboard uses the pro-
equals the calculated value. grammed value to perform Current Limit functions and
6. Manually operate the Slide Valve by pressing the display compressor motor current in terms of % FLA.
LOAD, UNLOAD and HOLD Keypad keys, as
required, to achieve a motor current equivalent to 1. Press FULL LOAD AMPS key.
105% FLA as indicated by the clamp-on Ammeter. 2. Use numeric keypad keys to enter correct value.
Loosen locking nut on Potentiometer R8 on CM-2 3. Press ENTER ( ) key.
and adjust until the CM-2 Module 105% LED il-
luminates. Counterclockwise increases signal level;
Start Current:
Clockwise decreases signal level. Tighten locking
nut.
The Logic/Trigger Board will limit compressor motor
7. Manually operate the Slide Valve by pressing the
current to this value during starting. The correct value
LOAD and UNLOAD Keypad keys, as required,
is (0.45 x Delta Locked Rotor amps), as listed on the
to achieve a motor current equivalent to 100% FLA
SALES ORDER Screen.
as indicated by the clamp-on Ammeter. Loose lock-
ing nut on Potentiometer R34 on CM-2 and adjust
1. Press STARTING CURRENT key.
until the motor current value on the Display indi-
cates 100% FLA. Clockwise increases the signal 2. Use numeric keypad keys to enter correct value.
level; Counterclockwise decreases the signal level. 3. Press ENTER ( ) key.
Tighten locking nut.

JOHNSON CONTROLS 123

 System Calibration
FORM 160.80-M1 (307)

Voltage Range: perform the calibration if necessary. If the Logic Board

This is the compressor motor AC Power line appli- is field replaced, field calibration is necessary using
cation. Selections are: 200-208, 220-240, 380, 400, the procedure below. Logic Board Program Jumper J5
415, 440-480, 550-600 and Disabled. The Microboard (300V/600V) must be placed in the appropriate position
uses the programmed value to determine the overvoltage per the Compressor Motor AC Power Supply.
and undervoltage shutdown thresholds for “LCSSS -
HIGH SUPPLY LINE VOLTAGE” and “LCSSS - LOW Logic Board Program Jumper:
SUPPLY LINE VOLTAGE” cycling shutdowns as de- Place Jumper J5 (300V/600V) in appropriate position
scribed in Operator Manual 160.80-O1. If DISABLED per the Compressor Motor AC Power Line application
is selected, the thresholds will be ignored and these as follows:
shutdowns will not occur. This check should not be 600V - Place over pins 1 & 2 for 380/400/415, 440/460/
arbitrarily disabled. 480 or 550/575/600VAC applications.
1. Press VOLTAGE RANGE key. 300V - Place over pins 2 & 3 for 200/208 or 220/230/
2. Use the ◄ and ► keys to scroll to desired value. 240VAC applications.
3. Press ENTER ( ) key.
Setpoints:
Open SCR Enable/Disable 1. At the Keypad, log in at SERVICE access level
This allows the Open SCR safety check, performed by the using access code 1 3 8 0 .
Logic/Trigger board, to be disabled. This must NEVER be
2. Select MOTOR Screen.
disabled unless advised by the YORK factory.
3. Enter the following Setpoints using procedures
1. Press OPEN SCR key.
below:
2. Use the ◄ and ► keys to scroll to desired value.
3. Press ENTER ( ) key. Full Load Amps :
This is the Full Load Amps (FLA) of the chiller as listed
Shorted SCR Enable/Disable: on the Sales Order Screen. The Microboard uses the pro-
(Flash Memory Card version C.MLM.03.01 or later) grammed value to perform Current Limit functions and
This allows the shorted SCR safety check, performed display compressor motor current in terms of % FLA.
by the Logic/Trigger Board, to be disabled. This must
1. Press FULL LOAD AMPS key.
NEVER be disabled unless advised by the YORK
factory! 2. Use numeric keypad keys to enter correct value.
1. Press SHORTED SCR key. 3. Press ENTER ( ) key.
2. Use the ◄ and ► keys to select Enable or Dis- Voltage Range:
able. This is the AC Power line voltage applied to the Com-
3. Press ENTER ( ) key. pressor Motor. Selections are: 200-208, 220-240, 380,
400, 415, 440-480, 550-600 and Supply Voltage Range
Kilowatt Hours (KWH) Disabled. The Microboard uses the programmed se-
This allows the KWH to be set to a desired starting value lection to determine the overvoltage and undervoltage
in the event the BRAM has to be field replaced. This thresholds for Starter High Supply Line Voltage and
must never be arbitrarily performed. Starter Low Supply Line Voltage cycling shutdowns
1. Press KWH RESET key. as described in Operator Manual 160.80-O1. If Supply
2. Use the ◄ and ► keys to scroll to desired value. Voltage Range Disabled is selected, the thresholds will
3. Press ENTER ( ) key. be ignored and these shutdowns will not occur. This
check should not be arbitrarily disabled.
MOD “A” MULTIPLEXED DATA INTERFACE 1. Press VOLTAGE RANGE key.
LIQUID COOLED SOLID STATE STARTER 2. Use the ◄ and ► keys to scroll to desired value.
3. Press ENTER ( ) key.
If the chiller is equipped with this model starter, the
Starter Logic Board is located in the Control Center.
Operation of this board and overall starter operation are
detailed in YORK Form 160.46-OM3.1. The following
procedures can be used to verify the calibration and

124 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

Current Unbalance Check Enable/Disable: If the calibration verification does not perform as above,
While the chiller is running, if the compressor Motor one or both of the following Calibration procedures will
current in phase A, B and C becomes unbalanced, a have to be performed: 21
Safety shutdown is performed. Refer to Operator Manual Calibration:
160.80-O1 for complete description of this check. This
Setpoint allows the check to be enabled or disabled. If At the Keypad, log in at SERVICE access level using
enabled, the check is performed; if disabled, the check access code 1 3 8 0 .
is not performed. 1. Start Current -
1. Press CURRENT UNBALANCE key. a. Select COMPRESSOR Screen.
2. Use the ◄ and ► keys to select Enable or Dis- b. Loosen locking nut on Solid State Starter Logic
able. Board Potentiometer R38.
3. Press ENTER ( ) key. c. Start chiller and monitor Compressor Motor
starting current in Phase A, B and C on the
Calibration Verification: COMPRESSOR Screen.
At the Keypad, log in at SERVICE access level using d. While chiller is starting, adjust START CUR-
access code 1 3 8 0 . RENT potentiometer (R38) on Solid State
1. Compressor Motor current display accuracy - Starter Logic Board to achieve the proper
a. Run chiller. start ing cur rent of (0.45 x Delta Locked
rotor Amps) on the highest phase. Turning
b. Select COMPRESSOR Screen. R38 Clockwise increases current; Counter-
c. Use the Slide Valve HOLD keypad key to sta- clockwise decreases current. Multiple starts
bilize the Compressor Motor current. could be required to achieve the correct cal-
d. Measure phase A, B and C Compressor Motor ibration. Tighten locking nut.
current with a clamp-on ammeter. Compare the 2. Overload -
Ammeter values with displayed motor current a. Select COMPRESSOR Screen.
values. If displayed values are not within +5%
of Ammeter values, refer to Solid State Starter b. Run Chiller and monitor Compressor Motor
Service Manual 160.46-OM3.1 to troubleshoot current on the COMPRESSOR Screen.
Starter. c. Manually operate the Slide Valve by pressing
2. Start Current - Proper starting current is (45% x the LOAD UNLOAD and HOLD keypad keys,
Delta locked Rotor amps). as required, until the highest phase indicates
a current equivalent to 105% FLA. Adjust
a. Select COMPRESSOR Screen. OVERLOAD potentiometer (R44) on Solid
b. Start chiller and monitor Compressor Motor State Starter Logic Board until the 105% FLA
starting current in phase A, B and C on the LED illuminates. Clockwise increases signal
Compressor Screen. level; Counterclockwise decreases signal level.
Highest phase should be equivalent to (45% x Tighten locking nut.
Delta Locked rotor amps).
SLIDE VALVE POSITION
3. Overload -
Potentiometer Calibration:
a. Select COMPRESSOR Screen.
b. Run chiller and monitor Compressor Motor To assure accuracy in the Slide Valve position display,
current on the COMPRESSOR Screen. a calibration procedure must be performed for the Slide
c. Manually operate the Slide Valve by pressing Valve position potentiometer. The Slide Valve position
the LOAD, UNLOAD and HOLD keys, as will be displayed as “XXX” until this procedure is per-
required, until the highest phase indicates a formed. The procedure can be performed whether the
current equivalent to 105% FLA. chiller is running or not. If performed while running,
the Slide Valve is automatically driven to the full closed
The Display should indicate 105% and the
and full open positions as described below. However,
105% LED on the Solid State Starter Logic
if the procedure is performed while the chiller is not
Board should illuminate when the 105% FLA
running, oil will have to be manually pumped into the
value is reached.

JOHNSON CONTROLS 125

 System Calibration
FORM 160.80-M1 (307)

Slide Valve assembly, since there will be no oil pressure HIGH CONDENSER PRESSURE WARNING
to move the Slide valve. THRESHOLD

In the following, the Slide Valve potentiometer feed- The condenser pressure at which a High Pressure warn-
back voltage is measured at the Microboard J8-1 to ing message is displayed and the Pre-rotation Vanes are
Microboard TP1 (Gnd). inhibited from further opening, is programmable over
the range of 44.9 to 251.3 PSIG. The Default value is
1. Remove Slide Valve potentiometer cover plate. 251.3 PSIG. The Warning message will clear and the
PRV inhibit is removed when the pressure decreases to 5
2. With chiller running, go to SLIDE VALVE CALI- PSIG below the programmed value. Proceed as follows
BRATION Screen from COMPRESSOR Screen. to enter this value:
3. Press Start Calibration key. Slide Valve will be
driven to the fully closed position. Monitor Slide 1. At the Keypad, log in at SERVICE access level
Valve potentiometer rotation. When potentiometer using access code 1 3 8 0 .
stops rotating, valve is fully closed. 2. Select CONDENSER Screen.
4. When valve is fully closed, press Set 0% Position 3. On the Condenser Screen, press HIGH PRESSURE
key. The potentiometer feedback voltage is stored in WARNING THRESHOLD key.
memory as the 0% position. If potentiometer feed-
4. Using numeric keypad keys, enter desired value.
back voltage is not within 0.04 to 0.12VDC range,
“Slide Valve Calibration Failed” is displayed. 5. Press ENTER ( ) key.

5. The Slide Valve will be driven to the fully open po- BRINE LOW EVAPORATOR PRESSURE CUTOUT
sition. Monitor Slide Valve potentiometer rotation.
When potentiometer stops rotating, valve is fully On Brine cooling applications, the Low Evaporator Pres-
open. sure safety shutdown threshold is programmable over the
6. When valve is fully open, press Set 100% Position range of 25.0 to 54.3 PSIG (Default 54.3 PSIG) for R22
key. If the feedback voltage at this position is Refrigerant and 6.0 to 25.0 PSIG (Default 25.0 PSIG)
0.122VDC greater than the feedback voltage at the for R134a Refrigerant. The actual percentage of Brine
0% position, “Slide Valve Calibration Successful” solution determines this threshold. It is calculated at the
is displayed. Otherwise, “Slide Valve Calibration YORK Factory and programmed at the time of manufac-
Unsuccessful” is displayed. ture. If the BRAM memory device on the Microboard is
replaced, the threshold will have to be programmed in
7. If calibration is successful, the calibration is com-
the field. The threshold is logged on an adhesive label
plete. Otherwise, correct the problem and repeat
attached to the inside of the Control Center door. Proceed
the calibration procedure.
as follows to enter this value:
8. Install Slide Valve potentiometer cover plate. 1. At the Keypad, log in at SERVICE access level
using access code 1 3 8 0 .
The calibration procedure can be termi-
2. Select EVAPORATOR Screen.
nated at any time during the procedure
by pressing the CANCEL CALIB key. If 3. On the EVAPORATOR Screen, press the BRINE
LOW EVAPORATOR CUTOUT key.
the Slide Valve was previously calibrated
successfully, it will revert to using the 4. Using numeric keypad keys, enter desired value.
previous calibration values. If they were 5. Press ENTER ( ) key.
not previously calibrated successfully, the
message “WARNING SLIDE VALVE
UNCALIBRATED” is issued.

126 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

SMART FREEZE PROTECTION 15 to 110 PSIG (R134a) as follows. The default value
is 25 PSIG for either refrigerant application.
This feature is described in the “Smart Freeze Pro- 1. At the Keypad, log in at SERVICE access level 21
tection” section of this book. When turned on, it allows using Password 1 3 8 0.
the Leaving Chilled Liquid Temperature Setpoint to be
2. From the CONDENSER Screen, select VARIABLE
as low as 36°F for water cooling applications. Along
ORIFICE Screen.
with this feature is a correspondingly lower Low Water
Temperature Cycling Shutdown threshold and Low 3. On the VARIABLE ORIFICE Screen, press DELTA
Evaporator Pressure Safety Shutdown threshold. The P setpoint key.
Smart Freeze Protection feature can be turned ON or 4. Using numeric keypad keys, enter desired value.
OFF using the following procedure: 5. Press ENTER ( ) key.
1. Shutdown the chiller and wait for completion of
SHUTDOWN. HOT GAS BYPASS CONTROL
2. At the Keypad, log in at SERVICE access level
using access code 1 3 8 0 . A complete description of the optional Hot Gas Bypass
control and the Setpoints that affect the operation is in
3. Select EVAPORATOR Screen. the “Hot Gas Bypass” section of this book. If the chiller
4. Press SMART FREEZE key. is equipped with this option, Hot Gas operation must be
5. Use the ◄ and ► keys to select ON or OFF. enabled and the setpoints programmed using the pro-
6. Press ENTER ( ) key. cedure below. Otherwise, it must be disabled.

EVAPORATOR REFRIGERANT TEMPERATURE Enable/Disable:

If the chiller is equipped with the optional Hot Gas By-
If the chiller is equipped with an Evaporator Refrigerant pass control, operation must be enabled. Otherwise, it
Temperature sensor, the feature must be Enabled with must be disabled. Use the following procedure:
the procedure below. If not equipped with this sensor, 1. Shut down chiller and place COMPRESSOR Start/
it must be Disabled. If enabled, this temperature is dis- Stop Switch in the Stop-Reset (O) position.
played on the EVAPORATOR Screen, and is also used
2. At the keypad, log in at SERVICE access level
in the Smart Freeze protection Low Evaporator Pressure
using Password 1 3 8 0.
Safety Shutdown threshold calculation, as explained in
the “Smart Freeze Protection” section of this book. 3. Select SETPOINTS Screen. From SETPOINTS
Screen, select SETUP Screen. From SETUP
Use the following procedure to Enable or Disable this Screen, select OPERATIONS Screen.
feature:
4. Use the ◄ and ► keys to select Enable or Dis-
1. At the Keypad, log in at SERVICE access level able.
using access code 1 3 8 0 .
5. Press ENTER ( ) key.
2. Select EVAPORATOR Screen.
3. Press REFRIGERANT key. Setpoints:
4. Use the ◄ and ► keys to select Enabled or Dis- The following are the setpoints and range of program-
abled. mable values. The Default value is shown in parenthesis.
5. Press ENTER ( ) key. Enter the value that will provide the desired operation.
Use procedure below.
VARIABLE ORIFICE CONTROL a. On Setpoint – 1.0 to 10.0°F (1.0)
b. Off Setpoint – 2.0 to 15°F (2.0)
This feature and associated setpoint is described in the 1. At the keypad, log in at SERVICE access level,
“Variable Orifice Control” section of this book. The vari- using Password 1 3 8 0.
able orifice is controlled by the DELTA P setpoint. It is
programmed over the range of 25 to 150 PSIG (R22);

JOHNSON CONTROLS 127

 System Calibration
FORM 160.80-M1 (307)

2. From COMPRESSOR Screen, select HOT GAS MAXIMUM LOAD LIMIT

BYPASS Screen.
After the chiller has been running for >3 minutes, this
3. On the HOT GAS BYPASS Screen, press the appro-
feature limits the compressor motor current to the pro-
priate key to select the setpoint to be programmed.
grammed “Maximum Load FLA” setpoint value (60% to
Using the numeric keypad keys, enter the desired
100%, default 100%) whenever the Leaving Chilled Liq-
value.
uid temperature is > the programmed “Maximum Load
4. Press ENTER ( ) key. Temperature” setpoint value (50°F to 70°F, default 70).
Whenever the slide valve loading is being inhibited by
TRANSDUCER AUTO ZERO this feature, “Maximum Load – Load Limit” is displayed
ENABLE/DISABLE on the System Details Line of the Display. Normally,
this feature is not required and should be disabled by
A complete description of Pressure Transducer Auto setting both setpoints to the default values. However,
Zeroing is in the “Pressure Transducers” section of when using certain compressor/chiller combinations
this book. Normally, Auto Zeroing should be enabled. under special operating conditions, separator overload
However, certain local conditions, as described in the could occur resulting in oil loss under high load condi-
Pressure Transducers section of this book, can require tions. Consult YORK factory for requirement. Program
the Auto Zeroing be disabled. Use the following pro- setpoints as follows:
cedure. 1. At the Keypad, log in at SERVICE access level
using password 1 3 8 0.
1. At the Keypad, log in at SERVICE access level 2. Select COMPRESSOR Screen.
using password 1 3 8 0. 3. Press MAXIMUM LOAD TEMPERATURE key.
2. Select OIL SUMP Screen. Using numeric keypad keys, enter desired value.
3. Press AUTO ZERO key. Press ENTER ( ) key.
4. Use the ◄ and ► keys to select ENABLE or DIS- 4. Press MAXIMUM LOAD FLA key. Using numeric
ABLE. keypad keys, enter desired value. Press ENTER
5. Press ENTER ( ) key. ( ) key.

SEAL OIL PRESSURE TRANSDUCER MINIMUM LOAD CONTROL SOURCE

ENABLE/DISABLE
The Minimum Load Control feature prevents the Slide
All new production chillers are equipped with Seal Oil Valve from unloading to a position that will not allow
Pressure Transducers. On these chillers, the Seal Oil sufficient oil transfer to the Oil Separator while the
Pressure Transducer operation must be Enabled. Earlier chiller is running. If the Slide valve is permitted to un-
vintage chillers, such as those encountered in Control load too far, there will not be enough oil transfer to the
Center retrofits, are not equipped with this transducer. If Oil Separator and a “Oil Separator – Low Level” Safety
the chiller is not equipped with this transducer, the Seal shutdown will result. There are two selectable methods
Oil Pressure Transducer operation must be disabled. Use of setting the minimum allowed Slide Valve position:
the following procedure. 1. Slide Valve – This method limits the minimum Slide
1. At the Keypad, log in at SERVICE access level Valve position to 15% (based on the position feed-
using password 1 3 8 0. back potentiometer) after the chiller has been run-
2. Select OIL SUMP Screen. ning for 3 minutes. When the Slide Valve unloads
3. Press SEAL PRESSURE key. to 15%, no more unload pulses will be applied. If it
decreases to < 15%, a 1 second load pulse is applied
4. Use the ◄ and ► keys to select ENABLE or every 3 seconds until the Slide Valve position is >
DISABLE. 15%.
5. Press ENTER ( ) key. 2. Motor FLA – This method limits the Slide Valve
minimum position to one that will maintain the
compressor motor current above the programmed
Minimum Load FLA (15% to 70% FLA) Setpoint
after the chiller has been running for 3 minutes.

128 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

When the Slide Valve unloads to the point where Freeze Warning Time Delay:
the motor current decreases to the Minimum Load If the standby chiller freeze protection is enabled us-
FLA Setpoint, no more unload pulses will be applied. ing procedure above, a Freeze Warning Delay Time of 21
If it unloads to the point where the motor current is < 30 to 60 minutes (default 30) must be programmed as
Minimum Load FLA Setpoint, a 1 second load pulse follows:
is applied every 3 seconds until the motor current is 1. At the Keypad, log in at SERVICE access level
> the Minimum Load FLA Setpoint. using Password 1 3 8 0.
2. Select CONDENSER Screen.
Regardless of which method is selected, “Minimum
Load – Load Limit” is displayed on the System Details 3. Press FREEZE TIME key.
line of the Display while the slide valve position is 4. Using numeric keypad keys, enter desired value.
being limited. 5. Press ENTER ( ) key.

Select the method that performs best in the application. LEAVING CHILLED LIQUID TEMPERATURE
The operating point at which low separator oil level will CONTROL SENSITIVITY
occur can be found by manually unloading the Slide
Valve while observing system conditions. This setpoint adjusts the Slide Valve unloading response
to changes in Leaving Chilled Liquid Temperature. Nor-
1. At the Keypad, log in at SERVICE access level mally, it is desired to have equal loading and unloading
using password 1 3 8 0. response. However, in applications where the load is
quickly removed from the chiller, faster unloading might
2. Select COMPRESSOR Screen.
be required. There are two selections as follows:
3. Press MINIMUM LOAD CONTROL SOURCE
key. NORMAL – Provides standard Slide Valve control. A
4. Use the ◄ and ► keys to select either Motor FLA Load or Unload pulse is applied, as required. This selec-
or Slide Valve. If Slide Valve is selected, proceed tion will provide proper operation in most applications.
to step 7.
5. Press MINIMUM LOAD FLA key. 2X – Provides fast unload Slide Valve operation. Opera-
6. Using numeric keypad keys, enter desired value. tion is same as NORMAL, except all Unload pulses are
twice as long as they would be in NORMAL operation.
7. Press ENTER ( ) key.
This provides for faster unloading.
STANDBY CHILLER FREEZE PROTECTION
1. At the Keypad, log in at SERVICE access level
A complete description of this feature is contained in using Password 1 3 8 0.
the “Standby Chiller Freeze Protection” section of this
2. Select EVAPORATOR Screen.
book. If this feature is desired, it must be Enabled using
the procedure below. Otherwise, it must be Disabled. 3. Press SENSITIVITY key.
If the feature is Enabled, the Freeze Warning Delay 4. Use the ◄ and ► keys to select NORMAL or
Time Setpoint must be programmed per the procedure 2X.
below.
5. Press ENTER ( ) key.
Enable/Disable:
ICE STORAGE MODE
1. At the Keypad, log in at SERVICE access level
using Password 1 3 8 0. A complete description of this feature is contained in the
2. Select CONDENSER Screen. York Manual 160.80.O1. This feature can only be used
3. Press FREEZE WARNING key. in Brine mode (Microboard Program Jumper JP35 out).
4. Use the ◄ and ► keys to select Enable or Dis- If this feature is desired, it must be turned ON. Otherwise
able. it must be turned OFF. Use procedure following.
5. Press ENTER ( ) key.

JOHNSON CONTROLS 129

 System Calibration
FORM 160.80-M1 (307)

Turn On/Turn Off: Field 3 – Local service phone number label. Default
If the Ice Storage feature is desired, it must be turned value is blank.
ON. Otherwise, it must be turned OFF. Field 4 – Local service phone number. Default value is
1. At the Keypad, log in at SERVICE access level blank.
using Password 1 3 8 0.
Use the following procedure to change any of the
2. Select EVAPORATOR Screen. fields:
3. Press ICE STORAGE key. 1. At the Keypad, log in at SERVICE access level
4. Use the ◄ and ► keys, select ON or OFF. using access code 1 3 8 0.
2. Select OPERATIONS Screen.
5. Press ENTER ( ) key.
3. Press EDIT PHONE NUMBERS Key.
MANUAL SLIDE VALVE CONTROL 4. Use the ◄ and ► keys to move green selection
box to the desired field to be changed.
The Slide Valve can be manually controlled from the 5. Press the ENTER ( ) key.
Keypad as follows:
6. In the Dialog box that appears, a red box appears
1. At the keypad, log in at SERVICE access level over the first changeable value. Use the ◄ and
using Password 1 3 8 0. ► keys to position the red box over the number/
character to be changed or entered. Use the ◄ and
2. Select COMPRESSOR Screen.
► keys to scroll sequentially through numbers,
3. Pressing the following keys applies the following alphabet characters and punctuation marks to
signals to the Slide Valve Actuator: select the desired value. When the desired value
LOAD – Applies a continuous load signal. displayed, use the ◄ and ► keys to move the red
box to the next value to be changed. The numeric
UNLOAD – Applies a continuous unload signal. keypad keys can also be used to enter numbers.
HOLD – Applies neither a load nor unload sig- Continue this process until all desired values have
nal. been entered.
7. After all desired values have been entered in pre-
AUTO – Places the Slide Valve under Program vious step, press ENTER ( ) key.
control (automatic operation).
CHILLER STARTS AND OPERATING HOURS RE-
SERVICE PHONE NUMBERS SET
(Flash Memory card version C.MLM.03.02.xxx and
later) The Number of Starts and the Operating Hours can be
reset to zero or preset to a desired number. However,
Two service phone numbers (Regional and Local), with this should never be arbitrarily performed. Use the fol-
labels, can be displayed on the OPERATIONS Screen. lowing procedure:
The Default value for the Regional number is the “North
American Toll Free Number” (1-800-861-1001). How- 1. At the keypad, log in at ADMIN access level. This
ever, the label and number can be changed to any desired password changes daily. Contact your local YORK
value. The Default value for the Local label and number Service Office.
is blank. The Service Technician enters the Local phone 2. Select OPERATIONS screen.
number and label. 3. Press NUMBER of STARTS or OPERATING
HOURS key as appropriate.
The entry format consists of 4 fields (rows), vertically 4. Using numeric keypad keys, enter desired number.
from the top. Up to 40 characters/numbers can be entered
5. Press ENTER key ( ) key.
for each field.

Field 1 – Regional phone number label. Default value is SALES ORDER DATA
“York Intl North American Toll Free Num-
ber” All of the Sales Order Data, except the “Chiller Com-
missioning Date” is entered at the YORK Factory at
Field 2 – Regional phone number. Default value is 1-
the time of chiller manufacture. The Service Technician
800-861-1001.
must enter the Chiller Commissioning Date and modify

130 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

the Job Name or Job Location if necessary at the comple- 4. Press CHANGE key. The first changeable area in the
tion of commissioning. Normally, the remainder of the selected category will be outlined in a green selection
Sales Order Data should never be modified. However, box. The procedure can be terminated anytime after 21
if there is a change to the chiller design, in the field, this by pressing the CANCEL (X) key.
this data can be modified. If the BRAM battery-backed 5. Use the ◄ and ► keys to move the green selection
memory device (U52) fails and requires field replace- box to the desired value to be changed, within the
ment, all of the data will be lost and will have to be category selected.
manually programmed.
6. Press ENTER ( ) key.
There are three different Passwords used, depending
7. Enter the appropriate data. Use the numeric key-
on the circumstances, to change the Sales Order Data
pad keys to enter numbers. Use the • key to enter
as follows:
a decimal point. Use the ◄ and ► keys to scroll
• Chiller Commissioning - Service Technician must sequentially up and down through the alphabet to
use password 1 3 8 0 to enter the Commissioning enter letters or a comma (,), slash (/) or minus sign
Date and modify Job Name and Job Location if (-). Each time the ► key is pressed, the next higher
necessary. sequential alphabet letter is displayed. Each time the
• Modifying Sales Order Data - Service Technician ▼ key is pressed, the next lower alphabet letter is
must use the ADMIN password. This password displayed. The comma, slash and minus sign can be
changes daily. Contact your local YORK Service selected after scrolling through the entire alphabet.
Office. During the entry process, the ◄ key can be used to
• BRAM Replacement - If the BRAM (U52) is backspace and the ► key can be used to forward
field replaced, the Service Technician must use space.
password 0 2 2 8 to enter all Sales Order Data into 8. Press ENTER ( ) key.
a new blank BRAM. When logged in at this level, 9. Use the ◄ and ► keys to select another value to be
the ACCESS LEVEL shown will be TEST OP. changed within the same category or press CAN-
This password only works with a blank BRAM. CEL (X) key to exit and allow selection of another
When using this password to enter data category.
into a new blank BRAM, the FINISH 10. EXTREMELY IMPORTANT! If the procedure
PANEL SETUP procedure (listed at above was performed using password 0 2 2 8 to
the end of the entry procedure below) enter data into a new blank BRAM, the following
must be performed after all data has procedure must be performed after all the desired
been entered. Failure to perform this data is entered. If the following procedure is per-
procedure will result in unreliable formed prior to entering all of the data, the ability to
Control Center operation! If this pro- enter more data will be terminated. Failure to perform
this procedure after all data has been entered will result
cedure is performed prior to entering
in unreliable Control Center Operation!
all data, the ability to enter more data
will be terminated. a. On SALES ORDER screen, press FINISH
PANEL SETUP key.
Use the following procedure to enter data: b. Use the ◄ and ► keys to select YES.
1. At the keypad, log in using the appropriate pass- c. Press ENTER ( ) key.
word as described above.
CUSTOM USER ID AND PASSWORDS
2. From the SETPOINTS Screen, select SETUP
SCREEN. From the SETUP Screen, select SALES When logging in, the user is requested to enter a User
ORDER Screen. ID, followed by a Password. The universal and Default
3. If logged in at SERVICE Access level, press SET User ID is zero (0). The universal Password to log in
ORDER INFO key to enter Commissioning date, Job at OPERATOR access level is 9 6 7 5 . The universal
Name or Location and proceed to step 4. If logged Password to log in at SERVICE access level is 1 3 8 0 .
in at ADMIN or TEST OP level, Press SELECT No log in is required for VIEW access level. However,
key to select the data category (ORDER, DESIGN, if desired, the service technician can establish up to four
NAMEPLATE, SYSTEM) to be entered. custom User IDs and Passwords that can be used by

JOHNSON CONTROLS 131

 System Calibration
FORM 160.80-M1 (307)

Operations personnel to log in at VIEW, OPERATOR, to view the details of a particular Setpoint change, select
or SERVICE level. the Setpoint change number with the LOG ENTRY key
and then press the VIEW DETAILS key. This moves to
Up to four Custom Users can be established with the Security Log Details Screen.
User ID’s from 1 to 9999. Each user can be assigned
a Password of 0 to 9999 and an access level of VIEW, The Security Log Details Screen displays the following
OPERATOR or SERVICE. Setpoint change details. The Setpoint is selected from
the list on the Security Log Screen as explained in the
Use the following procedure to establish Custom previous paragraph.
Users: • Setpoint Category
1. At the Keypad, log in at SERVICE access level • Setpoint
using 1 3 8 0. • Date and time of change
2. From the SETPOINTS Screen, select SETUP • Access Level and User ID used to make the
Screen. From SETUP Screen, select USER change
Screen. • Old Value
3. Press CHANGE USER ATTRIBUTES key. The • New Value
first changeable area is outlined in a green selection The following Setpoint changes are not logged:
box. • Clock Mode
4. Use the ◄ , ► , ▲ or ▼ keys to move the green • Custom Screen slot numbers
selection box to the desired value to be changed. • Advanced Diagnostics communication port tests
5. Press the ENTER ( ) key. • Advanced Diagnostics secondary multiplexer
6. Using numeric Keypad keys, enter desired pa- freeze
rameter as follows: • Soft shutdown initiated by operator
User ID – 1 to 9999 (numbers cannot be duplicated • System language
for more than one user) • Display units
Password – 0 to 9999 • Any Print report
Access Level – 0 = View, 1 = Operator, • Cancel any print report
2 = Service
• Schedule clear
7. Press ENTER ( ) key. • Schedule repeat exception days
8. After all values have been entered, press CANCEL • Schedule start and stop times
key (X) to exit.
• Log in/log out
• User attributes for ID, Password and Level
RECORD SETPOINT CHANGES
(Flash memory Card version C.MLM.03.03.xxx and • Trend start/stop
later) • Trend slot numbers, minimums and maximums
• Trend trigger data
This feature provides a record of the last 75 Setpoint • Trend print mode
changes. The date and time the Setpoint was changed,
• Trend view mode
the new Setpoint value and the Access Level and User
ID used to make the change are stored. The Security View the Setpoint changes as follows:
Log Screen and the Security Log Details Screen display 1. At the Keypad, login at SERVICE Access Level
levels of this information. using access code 1 3 8 0.
On the Security Log Screen, accessible from the History 2. From the HISTORY Screen, select SECURITY
Screen, the Setpoint, Setpoint Category and new Setpoint LOG Screen to view the complete list of setpoint
value are listed and numbered in reverse order in which changes.
they were changed. The most recent is listed as number
1; the next most recent as number 2, etc. A PRINT key To view the details of a particular setpoint change,
allows printing this entire list. Since 15 changes can be select it with the LOG ENTRY key, then press VIEW
displayed at one time, multiple pages could be necessary DETAILS key. This causes a jump to the SECURITY
to display all the changes. PAGE-UP and PAGE-DOWN LOG DETAILS Screen where the setpoint change details
keys are provided to view the entire list. If it is desired are displayed.

132 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

MICROBOARD 031-02430-000 SETUP/ While the chiller is stopped, if the condenser pressure ex-
CONFIGURATION ceeds 245.0 PSIG, a safety fault occurs and “Condenser
– High Pressure - Stopped” is displayed.
The following functions are programmed as Setpoints
21
on the 031-02430-00 microboard. Refer to SECTION The chiller can be started after the condenser pressure
3A for explanation of each setpoint. decreases to less than 245.0, and a special reset procedure
is performed as follows:
• Chilled Liquid Pump Operation
• Motor Drive Type 1. Place the COMPRESSOR switch in the Stop-
• Anti-recycle reset position.
• Power Failure Restart
2. At the keypad, login at Service access level using
Program the above setpoints as follows: code 1 3 8 0.
3. Select COMPRESSOR screen.
1. At the Keypad, login at SERVICE access level using
4. Press the FAULT ACKNOWLEDGE key on the
access code 1 3 8 0. (“Power Failure Restart” only
COMPRESSOR Screen. A dialog box appears
requires OPERATOR access level 9 6 7 5). (“Mo-
displaying “Enter Password to Clear Fault”.
tor Drive Type” requires chiller to be stopped with
Compressor Switch in the Stop-Reset position). 5. Enter 1 3 9 7 and press the ENTER key ( ).
2. Select SETUP Screen from SETPOINTS Screen.
This anticipatory fault is only performed while the chiller
3. Press CHANGE SETTINGS key. is stopped. If a “Condenser – High Pressure” fault is
detected while the chiller is in Pre-lube, System Run or
4. A green box will appear around the first changeable
Coastdown, the fault is handled in the normal way and
setpoint. Use ▲▼ keys to place the box around the
does not require the special reset procedure.
setpoint to be changed.
5. Press key. A dialog box will appear with the
range of settings.
6. Use ◄► keys to scroll to desired setting.
7. Press key.

High Condenser Pressure Fault While Shutdown –

reset procedure (Software version C.MLM.03.xx.xxx
(and later) or C.OPT.03.xx.xxx (and later))

High temperature condenser water flowing through

the condenser while the chiller is shutdown can cause
a condenser high pressure condition in the condenser
resulting in loss of refrigerant. This anticipatory safety
fault annunciates condenser high pressure conditions
when the chiller is not running as follows:

JOHNSON CONTROLS 133

 Diagnostics & Troubleshooting FORM 160.80-M1 (307)

SECTION 22
DIAGNOSTICS & TROUBLESHOOTING

The problems that could be encountered in the Control b. Place Compressor Start/Stop switch in the
Center are in the following categories: Stop-Reset position (O).
• Keypad c. Ensure the Compressor motor current is
• Display 0% FLA.
• Serial Input/Output (I/O) d. Log in at SERVICE access level using access
code 1 3 8 0.
• Digital Input/Output (I/O)
e. Move Microboard Program Switch SW1-4 to
• Analog Inputs
the ON position. A Watchdog reset will occur
and the Boot-up process will commence. At
There is a Diagnostic and associated Troubleshooting
the completion of the Boot-up process, the
procedure for each category. They are described on the
Diagnostics Main Screen will appear. (Note:
following pages. Each Diagnostic is accessed from the
If SWI-4 is moved to the ON position before
Diagnostics Main Screen, which is entered using the
step 4 above is performed, the “LOG IN” key
procedure below. If there is a Control Center problem,
will be displayed and Logging in at SERVICE
determine the category of the problem. Then perform
access level must be performed before the Main
the applicable Diagnostic. If the Diagnostic reveals a
Screen is displayed.
malfunction, perform the Troubleshooting procedure to
locate the defective component. 2. Not shown. Available when logged in at SER-
VICE access level, whether the chiller is running
There are several documents that must be referred to or not. Accessed from the SETUP screen via the
while performing the Diagnostics and Troubleshooting SETPOINTS screen. There are two screens avail-
procedures. Each procedure references the Section and able that allow the Analog Inputs voltage levels and
figures of this book that describe the operation of the com- Digital I/O states to be monitored. These screens
ponent being tested. Also, the applicable Control Center are preceded by a general screen that provides the
wiring diagram must be used as follows: 160.80-PW1 installed software versions.
(Electro-Mechanical Starter) or 160.80-PW2 (Mod “B”
Solid State Starter).
SOFTWARE VERSION
There are two versions of the Diagnostics screens avail- Controls - FLASH Memory Card on Microboard
able as follows: BIOS - BIOS EPROM on Microboard
1. Shown in figures 50 through 57. These screens are
Kernel - Software that is part of FLASH Memory
used during the Diagnostics and Troubleshooting
Card
process. They allow output states to be changed.
Access the Diagnostics Main Screen as follows: GUI - Software that is part of FLASH Memory Card
a. The chiller must be stopped. SIO - Software that is part of FLASH Memory Card
GPIC - EPROM in MicroGateway

134 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

22

This page intentionally left blank.

JOHNSON CONTROLS 135

 Diagnostics & Troubleshooting FORM 160.80-M1 (307)

MAIN DIAGNOSTICS SCREEN

FIG. 49 – MAIN DIAGNOSTICS SCREEN 00211VIP

Each of the Diagnostics is accessed from this screen. Main screen

Press the appropriate key to select the desired diag- - Keypad test
nostic. After each diagnostic is performed, return to - Display test
this MAIN Screen, from which the next diagnostic can - Bit patterns test
be selected. - All red
- All green
Some of the diagnostics have sub-screens that are - All blue
accessed from the selected diagnostic screen. The - All white
sub-screens are shown indented: - All black
- Serial 1/0 test
- Digital 1/0 test
- Analog Inputs

The ADVANCED SECURITY key is used during the

manufacturing process and has no field service use.

136 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

KEYPAD TEST

22

00212VIP
FIG. 50 – KEYPAD TEST SCREEN

This diagnostic is used to verify Keypad operation and b. Identify row/column coordinate of the key to
the Microboard’s ability to respond to a pressed key. be tested. Refer to Figure 31.
Refer to description of Keypad operation in Section 8 c. In the Keypad connector, locate the pins of the
of this book. row/column coordinate of the key of the key to
be tested.
PROCEDURE d. Insert the leads of an Ohmmeter into the pins
1. Press each keypad key. As the key is pressed, an identified in step “c” above.
illuminated LED is displayed corresponding to the e. Press the key to be tested. If the contact resis-
key location on the keypad. tance is >100 Ohms, the Keypad is defective.
2. Press the DIAGNOSTICS key to return to the f. Release the key. If the contact resistance is < 1
MAIN DIAGNOSTICS Screen. Meg Ohm, the Keypad is defective.
2. Ribbon Cable
TROUBLESHOOTING
Using an Ohmmeter, perform a continuity test on
If an LED is not displayed when a key is pressed, the all conductors in the ribbon cable. An open circuit
Keypad, Keypad ribbon cable or Microboard could be would indicate the ribbon Cable is defective.
defective. Use the following procedure to locate the 3. Microboard
defective component.
There are no checks or measurements to be made
on the Microboard. If the Keypad and Ribbon Cable
1. Keypad check OK per the above procedures, the Microboard
a. Disconnect the ribbon cable from the Keypad. is most likely the cause of the problem.

JOHNSON CONTROLS 137

 Diagnostics & Troubleshooting FORM 160.80-M1 (307)

DISPLAY TEST

FIG. 51 – DISPLAY TEST MAIN SCREEN 00213VIP

Each of the Display Diagnostics is accessed from this to create a completely red screen. Any red pixels
screen. After each diagnostic is performed, return to this that do not turn on will appear as black dots on the
screen, from which the next diagnostic can be selected. display. If any black dots appear, first ascertain it
Refer to description of Display operation in Sections 5 is not caused by dirt that is lodged between the
through 7 of this book. display surface and the protective plastic cover. It
is normal for a small number of randomly spaced
PROCEDURE
pixels to not illuminate. It is not necessary to re-
1. Press the appropriate keypad key to perform the place the display if a small number of black dots
desired test from the list below. appear. They will not be visible on the normal
2. Press the CANCEL (X) or ENTER (9) key to screens displayed outside of this diagnostic mode.
ter mi nate test and return to DISPLAY TEST However, large black areas would be indicative of
MAIN SCREEN, from which another test can be a defective display.
selected. • All Green - This test verifies the operation of all of
3. When all the desired tests have been performed, the green pixels. All of the green pixels are turned
press the DIAGNOSTICS key to return to the on to create a completely green screen. Refer to
MAIN DIAGNOSTICS SCREEN. description of “All Red” test above.
• Bit Patterns - This test is used to detect jitter • All Blue - This test verifies the operation of all of
and alignment defects. It verifies proper opera- the blue pixels. All of the blue pixels are turned
tion and compatibility of the Microboard Display on to create a completely blue screen. Refer to
Controller with the display. Four vertical bars of description of “All Red” test above.
green, dark blue, light blue and yellow, outlined • All White - This test verifies the display’s ability
by a red border are displayed. If the vertical bars to turn on all pixels to display a completely white
are not stable or straight, or the red border is not screen. Any pixel that does not turn on will appear
completely visible, then either the Microboard as a black dot. Refer to description of “All Red”
Program Jumpers are not configured correctly for test above.
the installed display or the Microboard Display • All Black - This test verifies the display’s ability
controller is defective. Refer to Figure 53. to turn off all pixels to display a completely black
• All Red - This test verifies the operation of all of screen. Any pixel that does not turn off will ap-
the red pixels. All of the red pixels are turned on pear as a red, green, blue or white dot. Refer to
description “All Red” test above.
138 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

BIT PATTERNS TEST SCREEN

22

00214VIP
FIG. 52 – BIT PATTERNS TEST SCREEN

TROUBLESHOOTING 3. Microboard:
a. With the “All Red” test selected, the voltage at
If any of the above tests do not perform correctly as de- Microboard J5-6 through J5-11 (Red drivers bits
scribed above, perform the applicable procedure below: 0-5), as measured to Gnd, should be > 3.0VDC.
Test Failed: If not, the Microboard is defective.
Bit Patterns - If the vertical bars are not straight or b. With the “All Green” test selected, the volt-
if the red border is not completely visible, either the age at Microboard J5-13 through J5-18 (Green
Microboard Program Jumpers are not configured cor- drivers bits 0-5), as measured to Gnd, should be
rectly or for the installed Display or the Microboard is >3.0VDC. If not, the Microboard is defective.
defective. c. With the “All Blue” test selected, the voltage
at Microboard J5-20 through J5-25 (Blue driv-
All Red, All Green, All Blue, All White or All ers bits 0-5), as measured to Grid, should be
Black: >3.0VDC. If not, the Microboard is defective.
If these tests do not produce appropriate solid color d. With the “All White” test selected, the volt-
screens, the Display Ribbon Cable, Display Interface age at Microboard J5-6 through J5-11, J5-13
Board, Microboard or Display could be defective. To through J5-18 and J5-20 through J5-25 should be
locate the defective component perform tests in the >3.0VDC. If not, the Microboard is defective.
following order: e. With “All Black” selected, the volt age at
Microboard J5-6 through J5-11, J5-13 through J5-
1. Display Ribbon Cable: 18 and J5-20 through J5-25 should be <1.0VDC.
Using an Ohmmeter, perform a continuity test on If not, the Microboard is defective.
all conductors in the ribbon cable. An open circuit 4. Display:
would indicate the ribbon cable is defective.
If the Display Ribbon Cable, Display Interface
2. Display Interface Board: Board and Microboard check OK per the above
Using an Ohmmeter, perform a continuity test on all procedures, the Display is most likely the cause of
conductors of the Interface Board. An open circuit the problem.
would indicate the Interface Board is defective.

JOHNSON CONTROLS 139

 Diagnostics & Troubleshooting FORM 160.80-M1 (307)

SERIAL INPUTS / OUTPUTS TESTS

FIG. 53 – SERIAL INPUTS / OUTPUTS TEST SCREEN 00215VIP

This diagnostic is used to verify correct operation of the From To

Serial Data Ports. There is a test for each of the five Serial COM 2 J13-5 (TX) J13-3 (RX)
Data Ports. Each RS-232 port (COM 1, 2 and 4b) is tested J13-7 (DTR) J13-1(DCD) & J13-2 (DSR)
by transmitting serial test data from outputs to inputs of J13-4 (RTS) J13-6 (CTS) & J13-8 (RI)
each port. Both the transmit and receive functions as well
as the control lines are tested. The RS-485 ports (COM 3 RS-485 From To
and 4a) are tested by transmitting serial test data from one (COM J12-3 (+) J11-3 (+)
RS-485 port to another. The TX/RX opto-coupled port 3 & 4a) J12-2 (-) J11-2 (-)
(COM 5) is tested by transmitting serial test data from the
TX output to the RX input. If the received data matches Microboard Program Jumper JP27 must be installed
the transmitted data, PASS is displayed, indicating the in position 1 & 2.
serial port is OK. Otherwise, FAIL is displayed, indicating
the serial port is defective. Prior to performing each test, From To
the Service Technician must install a wire loop-back con- COM 4b J2-7 (GTX) J2-6 (GRX)
nection as described below. Refer to Section 3 and Figure
9 of this book for description of the Serial data Ports. Microboard Program Jumper JP27 must be installed
in position 2 & 3.
PROCEDURE
1. Using small gauge wire, fabricate loop-back con- From To
nections and install as follows for each port to be
COM 5 J15-1 (TX) J15-4
tested. Failure to install the loop-back connection
or configure the Microboard Program jumper as J15-2 (RX) J15-5
noted will result in a FAIL outcome for the test. J15-3 (Common) J15-6

From To Make individual wire connections or use YORK loop-

COM 1 J2-4 (TX) J2-3 (RX) around diagnostic connector 025-33778-000 as depicted
J2-5 (DTR) J2-2 (DSR) in Figure 55. This connector is available from the YORK
Parts Distribution Center.

140 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

2. After connecting appropriate loop-back connec- read at DSR (J13-2) & DCD (J13-1). RTS
tions above, press the appropriate key to initiate (J13-4) is set to a Logic High and read at CTS
the desired test. An LED will illuminate indicating (J13-6) & R1 (J13-8). If any test fails, COM 2
the test is in progress. If it is desired to terminate tests are terminated.
the test, press the CANCEL TEST key. Test data is
sent from an output to an input as described below. RS-485 (COM 3 & 4a) – Test data is sent from
At the completion of each test, if the data received COM 3 RS-485 port to COM 4a RS-485 Port at
matches the data sent, the Serial Port operates 19200 Baud. Test data is then sent from COM
properly and PASS is displayed. Otherwise, FAIL 4a to COM 3 at the same rate. If either test fails,
is displayed, indicating the Serial Port is defective. RS-485 tests are terminated.
A FAIL result would be indicative of a defective COM 4b – Test data is sent from GTX (J2-7) to
Microboard. The following is a description of each GRX (J2-6) at 19200 Baud.
test.
COM 1 – Two tests are performed. Test data is COM 5 – Test data is sent from TX (J15-1)
sent from TX (J2-4) to RX (J2-3) at 9600 Baud to J15-4 at 1200 Baud. This output turns the
and DTR (J2-5) is set to a Logic High level and Microboard’s loop-around test Transistor on and
read at DSR (J2-2). If any test fails, COM 1 tests off, applying 0/+5VDC pulses from J15-5 to RX
are terminated. (J15-2) input.
COM 2 – Three tests are performed. Test data 3. After all desired tests have been performed, press 22
is sent from TX (J13-5) to RX (J13-3) at 19200 the DIAGNOSTICS key to return to the MAIN
Baud. DTR (J13-7) is set to a Logic High and DIAGNOSTICS Screen.

TRANSMIT
J15
TX
1 1
RX
2 2
COMMON
3 3
IN
4 4
RECEIVE OUT
5 5
6 6
+5VDC

LOOP-AROUND DIAGNOSTIC CONNECTOR

YORK PIN 025-33778-000
INSTALL TO PERFORM DIAGNOSTIC
+5VDC

LOOP-AROUND TEST

LD04250

FIG. 54 – MICROBOARD - COM 5 SERIAL DATA PORT

JOHNSON CONTROLS 141

 Diagnostics & Troubleshooting FORM 160.80-M1 (307)

DIGITAL INPUTS / OUTPUTS TESTS

FIG. 55 – DIGITAL INPUTS / OUTPUTS TEST SCREEN 00216VIP

This diagnostic is used to analyze the digital inputs and nected to these terminals. Tables 1 and 2 list the
outputs of the Microboard. Refer to description of I/O functions of the Program Jumpers and Switches.
Board in Section 4 of this book. 2. With 115VAC applied to a particular I/O Board
Digital Input, the applicable LED should be il-
The state of each Microboard Digital Input, Program luminated. If the LED is not illuminated, perform
Jumper and Program DIP Switch, as interpreted by the appropriate Troubleshooting procedure below.
Microboard, is depicted by an LED. If the Microboard
3. With 0VAC applied to a particular I/O Board Digital
interprets its input as being at a Logic Low (<1.0VDC)
Input, the applicable LED should be extinguished.
level, the LED is illuminated. If interpreted as being
If the LED is not extinguished, perform appropriate
at a Logic High (>4.0VDC) level, the LED is extin-
Troubleshooting procedure below.
guished.
4. If a Program Jumper is present, the applicable
The state of the Microboard’s intended drive signals LED should be extinguished. If the LED is not
to each of the Relays on the I/O Board is depicted by extinguished, the Microboard is defective.
an LED. If the intended output is a Logic Low level 5. If a Program Jumper is not present, the applicable
(<1.0VDC), the LED is illuminated. If the intended LED should be illuminated. If the LED is not il-
output is a Logic High level (>10.0VDC), the LED is luminated, the Microboard is defective.
extinguished. Logic Low outputs energize the Relays. 6. If a Program Switch (DIP) is in the ON position, the
Logic High outputs de-energize the Relays. The state of applicable LED should be illuminated. If the LED
any output can be manually set to either the ENABLED is not illuminated, the Microboard is defective.
(Logic Low) or DISABLED (Logic High) state. 7. If the Program Switch (DIP) is in the OFF position,
the applicable LED should be extinguished. If the
PROCEDURE LED is not extinguished, the Microboard is de-
fective.
Digital Inputs: 8. When all desired tests have been performed, press
1. The Digital Inputs are listed on this screen ac- DIAGNOSTICS key to return to MAIN DIAG-
cording to a.) Terminal number on the I/O Board NOSTICS Screen.
and b.) Microboard Program Jumpers and Program
DIP Switches. Figure 12 shows the devices con-

142 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

Digital Outputs: Inputs Procedure above to determine if the problem has

been resolved.
1. IMPORTANT! - The following steps cannot be 1. Remove 1/0 Board ribbon cable. Using an Ohm-
performed until the Motor Controller connection meter, perform a continuity check on I/O Board
between TB6-1 and TB6-53 has been removed. ribbon cable J1-21 to J19-21, J1-22 to J19-22 and
This connection could be a jumper or it could be applicable output pin of function that failed in Pro-
a connection from external devices in the starter. cedure above. If an open circuit is detected, replace
The Program will prevent manual control of Digital ribbon cable. Otherwise, install ribbon cable and
Output devices until this connection is removed. proceed to next step.
2. The Digital Outputs are listed on this Screen ac- 2. Measure the +5VDC supply voltage to the 1/0
cording to Relay and Triac number (KI, Q3, etc.). Board on 1/0 Board between J1-21 and J1-22.
Figure 15 shows the external devices that are con- If >4.5VDC, proceed to next step. If < 4.5VDC,
nected to these Relays and Triacs and the functions disconnect ribbon cable at I/O Board J1 and repeat
of each one. the measurement at J1. If <4.5VDC, replace the
3. Press SELECT key. An arrow will appear adjacent Microboard. Re-install the ribbon cable.
to Relay KO. 3. With 115VAC (± 10%) applied to the I/O Board
4. Select a relay or triac for manual control by using digital input that failed in Procedure above, the ap-
the ▲ and ▼ keys to place the arrow adjacent to plicable I/O Board output at J1 should be at a Logic 22
the desired device. low level (<1.0VDC). If it is >1.0VDC, replace the
I/O Board. If the output is at a Logic Low level, the
5. Press the ENABLE OUTPUT key to enable the
applicable LED should be illuminated. If the LED
selected output. The LED adjacent to the selected
is not illuminated, replace the Microboard.
output should illuminate. If it does not, perform
KEYPAD Diagnostics test. If a relay is selected, 4. With 0VAC applied to the I/O Board digital input
it should energize, closing its contacts. If a triac that failed in Procedure above, the applicable I/O
is selected, it will turn on, energizing the device it Board output at J1 should be at a Logic High level
is connected to. If the relay does not energize or (>4.OVDC). If it is <4.OVDC, replace the 1/0
triac does not turn on, perform appropriate trouble- Board. If the output is at a Logic High level, the
shooting procedure below. applicable LED should be extinguished. If it is not
6. Press the DISABLE OUTPUT key to disable the extinguished, replace the Microboard.
selected output. The LED adjacent to the selected Digital Outputs Troubleshooting:
output should extinguish. If it does not, perform
KEYPAD diagnostic test. If a relay is selected, it If any of the Digital outputs tests fail to perform as de-
should de-energize, opening its contacts. If a triac scribed above, perform the following steps in sequence.
is selected, it will turn off, de-energizing the device Refer to Figure 15 and applicable wiring diagram ref-
it is connected to. If relay does not de-energize or erenced at the beginning of Section 21. If a defective
triac does not turn off, perform appropriate trou- component is found during any of the steps, replace the
bleshooting procedure below. component as instructed and repeat the Procedure above
7. When all desired tests have been performed, press to determine if the problem has been resolved.
DIAGNOSTICS key to return to the MAIN DIAG- 1. Remove I/O Board ribbon cable. Using an Ohm-
NOSTICS Screen. meter, perform a continuity test on the cable J1-25 to
8. Install Motor Controller connection from TB6-I to J19-25, J1-26 to J19-26 and applicable output pin of
TB6-53 removed in step 1. function that failed in Procedure above. If an open
circuit is detected, replace ribbon cable. Otherwise,
Digital Inputs Troubleshooting: install ribbon cable and proceed to next step.
2. Measure the +12VDC supply voltage to the I/O
If any of the Digital Inputs tests fail to perform as de- Board on I/O Board between J1-26 (+12VDC) and
scribed above, perform the following steps in sequence. J1-25 (Gnd). If >11.0VDC, proceed to next step. If
Refer to Figure 12 and applicable wiring diagram ref- <11.0VDC, disconnects ribbon cable at I/O Board
erenced at the beginning of Section 21. If a defective J1 and repeat measurement at JI. If <11.0VDC, re-
component is found during any of the following steps, place the Microboard. Reinstall the ribbon cable.
replace the component as instructed and repeat the digital

JOHNSON CONTROLS 143

 Diagnostics & Troubleshooting FORM 160.80-M1 (307)

3. Using the Digital Outputs Procedure above, se- it is <10.0VDC, remove the ribbon cable from
lect the output that failed the digital Output test J1 of the I/O Board. On the I/O Board, measure
above. the resistance from J1-26 to the appropriate pin
4. Press ENABLE OUTPUT key. The LED adjacent to of J1 on the I/O Board for the selected relay. If
the selected output will illuminate. The appropriate the resistance is >100 Ohms, replace the I/O
Microboard output pin at J19 for the selected output Board. If the resistance is <100 Ohms, replace
should be at a Logic Low level (<1.0VDC). If it is the Microboard.
>1.0VDC, replace the Microboard. With the output b. If a Triac is selected as the output, the ap-
at a Logic Low, the following should occur: propriate Microboard output pin at J19 for
a. If a Relay is selected as the output, the contacts the selected output should be at a Logic High
of the relay should be closed. If they are not (>10.0VDC) level. If it is <10.0VDC, replace
closed, replace the I/O Board. the Microboard. With the output at a Logic High
level, the Triac should be turned off. If the Triac
b. If a Triac is selected as the output, the Triac
has not turned off, replace the I/O Board. See
should be turned on. If the Triac has not turned
note 1 below for Triac testing.
on, replace the I/O Board. See note 1 below for
Triac testing. Notes:
5. Press DISABLE OUTPUT key. The LED adjacent 1. The load (actuator) must be connected across the
to the selected output will extinguish. Triac to determine the on/off state of the Triac.
a. If a Relay is selected as the output, the ap- The on/off state of the Triac can be determined by
propriate Microboard output pin at J19 for measuring across the device (for example, TB1-3
the selected output should be at a Logic High to TB1-59 or TB1-58 to TB1-59) with an AC Volt-
(>10.0VDC) level. With the output at a Logic meter. If the Triac is turned on, the voltage will be
High level, the relay contacts should be open. <10VAC. If the Triac is turned off, the voltage will
If they are not open, replace the I/O Board. If be >100VAC (Slide Valve actuator).

144 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

ANALOG INPUTS TEST

22

FIG. 56 – ANALOG INPUTS TEST SCREEN 00217VIP

This diagnostic is used to analyze the Analog Inputs to 5 - Not Used.

the Microboard. The voltage level of each Analog in- 6 - Discharge Temperature
put, as interpreted by the Microboard, is displayed. The
7 - Oil Temperature
“Counts” listed for each parameter is the Analog-to-Dig-
ital (A/D) converter value and is for manufacturing and 8 - Evaporator Refrigerant Temperature
engineering use only. 9 - Condenser Pressure
10 - Evaporator Pressure
If the chiller is shutting down on an Analog Safety or
11 - Filter Oil Pressure
is prevented from starting because of an Analog input,
there is probably an Analog Input problem. This Screen 12 - Oil Pressure
can be used in the investigation of this problem. 13 - Not Used.
14 - Seal Oil Pressure
Important! This test does not apply to the Leaving 15 - Mod “A” Solid State Starter/CM-2 MUX output
Chilled Liquid Temperature analog input or a 0-10VDC Channel 0
Remote Setpoint input at channels 27 and 28.
16 - Mod “A” Solid State Starter/CM-2 MUX output
The following is a list of the Analog inputs displayed. Channel 1
Refer to the appropriate Section of this book for an 17 - Mod “A” Solid State Starter/CM-2 MUX output
explanation of each: Pressure Transducers - Section 14, Channel 2
Thermistors - Section 15, Solid State Starter - Section 11 18 - Mod “A” Solid State Starter/CM-2 MUX output
(Mod “A”) and Current Module (CM-2) - Section 10. Channel 3
Channel 19 - Mod “A” Solid State Starter/CM-2 MUX output
0 - +2.5VDC Analog supply voltage reference. Channel 4
Microboard TP6. 20 - Mod “A” Solid State Starter/CM-2 MUX output
1 - Not Used. Channel 5
2 - Return Chilled Liquid Temperature 21 - Mod “A” Solid State Starter/CM-2 MUX output
3 - Leaving Condenser Liquid Temperature Channel 6
4 - Return Condenser Liquid Temperature 22 - Mod “A” Solid State Starter/CM-2 MUX output
Channel 7

JOHNSON CONTROLS 145

 Diagnostics & Troubleshooting FORM 160.80-M1 (307)

23 -
Not Used. to J10-5 (Gnd). When completed, press CANCEL
24 -
Slide Valve Potentiometer FREEZE key.
25 -
Not Used. • Channels 27,28:
26 -
Not Used. IMPORTANT! This procedure only applies to
4-20mA inputs. It does not apply to 0-10VDC in-
27 -
Remote Leaving Chilled Liquid Temperature
puts. Using a Voltmeter, measure the Remote Cur-
Setpoint (0-20mA or 4-20mA)
rent Limit setpoint input at J22-2 (signal) or Remote
28 - Remote Current Limit Setpoint (0-20mA or
Leaving Chilled Liquid Temperature setpoint input
4-20mA)
at J22-4 (signal) to J22-5 (Gnd).
29 - Not Used
4. Compare the measured value in the previous step
30 - Not Used with the value displayed on the Analog Inputs
Screen for that value.
Procedure:
5. If the measured value is not within +15% of the dis-
played value, replace the Microboard. Otherwise,
1. From the chart above, select the analog input that
proceed to the troubleshooting procedure below to
is malfunctioning. All inputs except channel 0, 15
find the cause of the problem.
through 22, 27 and 28 are sensors that connect di-
rectly to the Microboard via shielded cable. Chan- 6. When all desired tests have been performed, press
nel 0 is a reference voltage for the Analog circuits DIAGNOSTICS key to return the MAIN DIAG-
on the Microboard. Channels 15 through 22 are NOSTICS Screen.
multiplexed outputs from the Mod “A” Solid State
Starter (Solid Sate Starter applications) or CM-2 Troubleshooting :
Current Module (Electro-Mechanical Starter appli-
cations). Channels 27 and 28 are Remote Setpoint • All Channels except 0, 1, 15-22, 27, 28:
inputs used in Analog Remote mode.
1. Disconnect both ends of the cable of the Analog
2. Refer to Wiring Diagrams listed in front of this input that is malfunctioning. Using an Ohmmeter,
Section to identify the device that performs this perform a continuity test on all conductors in the
function and the jack and pin connection to the cable. An open circuit would indicate the cable is
Microboard. defective.
3. • Channel 0:
2. Using a Voltmeter, measure the +12VDC supply
Using a Voltmeter, measure the voltage between voltage input at the Microboard J1-3 (+12VDC) to
Microboard TP6 (+2.5VDC) and TP1 (Gnd). J1-2 (Gnd). If voltage is < 11.5VDC, check wiring
Compare this measured value to the displayed to Power Supply. If wiring is OK, the Power supply
value. If the value is not within +10%, replace the is most likely defective.
Microboard.
3. Using a Voltmeter, measure the supply voltage
• All channels except 0, 1, 15-22: (+5VDC, +1 2VDC or +24VDC) to the sensor. If
Using a Voltmeter, measure the analog input to the voltage is not within +10% of specified voltage,
Microboard. Make the measurement between the disconnect J7, J8 and J9 from the Microboard.
device output and Ground connection to the device. This disconnects all analog devices from the
For example, measure the output of the Evaporator Microboard. If the voltage increases to the cor-
Transducer at Microboard J8-18 (signal) to J8-9 rect level, a Thermistor or Transducer is shorted.
(Gnd). Locate the shorted device and replace. If, after
• Channels 15-22: disconnecting the connectors the supply voltage
is still not within 10% of the specified value, the
Select the desired channel by pressing the SELECT
voltage supply source (Microboard or Power Sup-
CHANNEL key and using the ▲ and ▼ keys to
ply) is most likely defective.
place the arrow head next to the desired channel.
Then, freeze the address of that channel to the 4. Verify sensor accuracy using appropriate test de-
Mod “A” Solid State Starter or CM-2 Mux. Then vice. Replace sensor if necessary.
measure MUX output at Microboard J10-6 (signal)

146 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

• Channels 15 - 22: Board or input devices to these boards is most likely

the cause of the problem. If address is not correct, the
1. Disconnect both ends of ribbon cable connected
Microboard is most likely the cause of the problem.
to Microboard J10. Using an Ohmmeter, perform
a continuity test on all conductors in the cable. An 5. Press CANCEL FREEZE key.
open circuit would indicate the cable is defective.
2. Using a Voltmeter, measure the +12VDC supply • Channels 27, 28:
voltage input at the Microboard J1-3 (+12VDC) to
J1-2 (Gnd). If voltage is <11.5VDC, check wiring 1. Refer to Table 1 “Microboard Program Jumpers”
to Power Supply. If wiring is OK, the Power Supply and verify Program Jumpers JP23 and JP24 are
is most likely defective. configured correctly for the type of input (0-10VDC
or 4-20mA).
3. Using a Voltmeter, measure the +5VDC supply
voltage to the Solid State Starter Logic Board or 2. Disconnect both ends of the cable of the remote
CM-2 Board. Make measurement at Microboard input that is malfunctioning. Using an Ohmmeter,
J10-4(+5VDC) to J10-5 (Gnd). If voltage is perform a continuity check on all conductors in the
<4.5VDC, replace the Microboard. cable. An open circuit would indicate the cable is
4. Using a Voltmeter, verify the correct address is defective.
being sent from the Microboard to the Mod “A” 3. If steps are OK, problem most likely is in the remote
Solid State Starter Logic Board or CM-2 Board. device that supplies the remote signal. 22
Freeze address as described above. If the address is
correct, the Solid State Starter Logic Board or CM-2

JOHNSON CONTROLS 147

 System Commissioning Checklist
FORM 160.80-M1 (307)

SECTION 23
SYSTEM COMMISSIONING CHECKLIST
Use the following checklist during commissioning to assure VARIABLE ORIFICE CONTROL
all Setpoints have been programmed to the desired value and ____ Enter the Delta P Setpoint.
all calibrations have been performed. The programming of
some of the Setpoints require a SERVICE access level. To 4. COMPRESSOR Screen: (160.80-M1)
assure access to all Setpoints, log in at SERVICE access ____ Maximum Load
level before beginning. The Setpoints are grouped under
____ Maximum Load Temperature
the Display Screen in which they appear. The indented
screens are subscreens of the numbered screens and are ____ Maximum Load FLA
accessed from the numbered screens. An explanation of ____ Select Minimum Load Control Source (Slide
each setpoint or Calibration Procedure below is contained Valve or Motor FLA).
in the reference document listed in parenthesis adjacent to ____ If Motor FLA selected, enter Minimum
each item. If any of the Setpoints have to be changed, use Load FLA
the standard programming procedures in Operation Manual
HOT GAS BYPASS Screen: (160.80-M1)
Form 160.80-O1. Thresholds, values and calibrations of
If chiller is equipped with optional Hot Gas Bypass,
items marked with an asterisk “*” have been determined
enable operation on the OPERATIONS screen and
and entered/set at the YORK Factory at the time of man-
enter the following setpoints:
ufacture.
____ On Setpoint
1. PROGRAM JUMPERS/SWITCHES: ____ Off Setpoint
(160.80-M1)
SLIDE VALVE CALIBRATE Screen:
____ Verify Microboard Program Jumpers and
____ Perform Slide Valve calibration
Program Switches are configured appropriately. If
equipped with Microboard 031-01730-000, refer to 5. OIL SUMP (SEPARATOR) Screen:
Section 3 Tables 1 and 2. If equipped with Microboard (160.80-M1)
031-02430-000, refer to Section 3A Table 3 and 4.
____ Auto Zero Enable/Disable
2. EVAPORATOR Screen: (160.80-O1) ____ Seal Pressure Enable/Disable
Enter the following Setpoints: ____ Oil Recovery Enable or Disable (Flash
____ Leaving Chilled Liquid Temp (except ISN Memory Card version C.MLM.03.03.xxx and
Remote mode) later). Should only be enabled if oil recovery is
____ Remote Leaving Chilled Liquid Temp Set- required.
point Range (except ISN Remote mode) 6. MOTOR Screen: (160.80-O1)
____ Low Chilled Liquid Temp cycling shutdown ____ Local Motor Current Limit
temperature
____ Pulldown Demand Limit
____ Low Chilled Liquid Temp cycling shutdown
____ Pulldown Demand Time
Restart temperature
____ Leaving Chilled Liquid Temp Control Solid State Starter applications: (160.80-M1)
Sensitivity (160.80-M1) Mod “B” Solid State Starter:
____ Brine Low Evaporator Pressure Cutout thresh- Verify the following Setpoints have been
old* (160.80-M1) programmed:
____ Ice Storage Mode On/Off (160.80-O1) ____ Full Load Amps*
____ Smart Freeze Protection On/Off (160.80- ____ Start Current*
M1) ____ Supply Voltage Range*
____ Refrigerant Temp sensor Enable/Disable ____ Enable Open SCR Detection
(160.80-M1)
____ Enable Shorted SCR Detection (Flash Memory
3. CONDENSER Screen: (160.80-M1) Card version C.MLM.03.01 or later)
____ Enter the High Pressure Limit/Warning ____ KWH Reset
threshold Setpoint Mod “A” Solid State Starter:
____ Freeze Warning (standby chiller freeze pro- Verify the following Setpoints have been
tection) - Enable/Disable (160.80-M1) programmed:
____ Freeze Warning Time Delay (160.80-M1)
148 JOHNSON CONTROLS
 FORM 160.80-M1 (307)

____ Full Load Amps* ____ Power Failure Restart

____ Supply Voltage Range*
SCHEDULE Screen:
____ Current Unbalance Check - Enable/
____ Enable or Disable Daily start/stop schedule
Disable*
as required.
____ Enter chiller START/STOP schedule if
Logic Board:
required.
____ Verify location of 300V/600V Jumper*
USER Screen:
____ Verify Start Current calibration*
____ Select desired Display language
____ Verify 105% FLA calibration*
____ Select desired Display units; ENGLISH or
METRIC
Electro-Mechanical Starter applications:
____ If desired, establish custom USER IDs and
(160.80-M1)
PASSWORDS (160.80-M1)
Current Module: COMMS Screen:
____ Verify Switch S1 (Y-delta/57% or all others) If Modem and or Printer is connected to the Microboard
setting* Serial data ports, enter the following parameters as required
____ Verify Pot R16 (LRA/FLA ratio) setting* for each device connected:
____ Verify slide bar resistor “RES” setting* ____ Baud rate
____ Verify 105% FLA calibration* ____ Number of data bits
____ Verify 100% FLA display* ____ Number of stop bits
____ Parity
7. SETPOINTS Screen: (160.80-O1)
Enter appropriate number for Modem, Printer or ISN
The setpoints listed on the SETPOINTS Screen have al- Remote application:
ready been programmed above on Previous Screens. The ____ Chiller ID (identification)
values shown reflect the previously programmed values. 23
However, the setpoints listed here can be changed on this
PRINTER Screen:
screen if desired. This screen is used primarily as a central
location from which most setpoints can be programmed. If Printer is connected to Microboard serial ports, enter
If it is not desired to change any of the listed setpoints, the following:
proceed to the SETUP Screen below. ____ Automatic print logging Enable/disable
SETUP Screen: ____ Automatic printer logging start time
____ Enable Clock ____ Automatic print logging interval
____ Enter CLOCK Time and Date ____ Printer type
____ Select 12 or 24 hour display mode ____Report type; STATUS, SETPOINTS, SCHED-
ULE or SALES ORDER
Microboard 031-01730-000:
____ The state of Program Jumpers/Switches that SALES ORDER Screen:
affect chiller operation are displayed. These were
____ Enter system commissioning date
configured in step 1 above. Confirm they are cor-
rect. (160.80-M1 Section 3) OPERATIONS Screen:
Microboard 031-02430-000: ____ Select desired Control Source (operating
mode); LOCAL, ISN Remote, DIGITAL Remote
____ The state of Program Switches SW1-1 (Re-
or ANALOG Remote
frigerant Selection) and SW1-2 (Liquid Type) is
displayed. These were configured in step 1 above. ____ Hot Gas Bypass Control (optional) Enable/
Confirm they are correct. (160.80-M1) Disable
____ Edit regional phone number if necessary
Enter the following Setpoints: (160.80-M1)
(Flash memory Card version C.MLM.03.02.xxx
____ Chilled Liquid Pump Operation and later)
____ Motor Drive Type ____ Enter Local phone number (Flash memory
____ Anti-Recycle Card version C.MLM.03.02.xxx and later)
JOHNSON CONTROLS 149
 Service Information Letters / Bulletins
FORM 160.80-M1 (307)

SECTION 24
SERVICE INFORMATION LETTERS / BULLETINS

SI0007 - SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2001

GENERAL
Beginning May 2001, an enhanced Flash Memory Card will be supplied with new production Nema 1-4 and CE
chillers. New features are outlined below and are also included in YORK Operation Manual 160.80-O1 and Service
Manual 160.80-M1.
Flash Memory Card versions and part numbers are applied as follows:
• Nema 1-4 Chillers C.MLM.03.02A.101 (031-02005-001)
• CE Chillers C.MLM.03.02A.201 (031-02005-002)
The enhanced flash cards are also available from the Baltimore Parts Distribution Center for retrofit to existing
chillers.

TREND SCREEN – TRIGGERED CHART

A “TRIGGERED” chart can now be created. This is in addition to the ONE SCREEN and CONTINUOUS chart
types that can be created in previous Flash Memory Card versions. With the TRIGGERED chart type, data collection
can be set to START or STOP based upon the status of up to two Operator selected conditions (TRIGGERS) and a
selected TRIGGER DELAY. If START is selected, data collection will not begin until all triggers have been satisfied
and any selected TRIGGER DELAY has elapsed. Data collection will stop at the completion of one screen of data.
If STOP is selected, data collection will begin when manually initiated, and will stop when all triggers have been
satisfied and any selected TRIGGER DELAY has elapsed.

This feature is a valuable troubleshooting tool for Service technicians. It allows an event that occurs during unat-
tended hours to be captured for viewing at a later time. The trigger event results in a screen of frozen trend data that
will remain on the screen until manually cleared.

DISPLAY OF SERVICE PHONE NUMBERS

Two service phone numbers (Regional and Local), with labels, can be displayed on the OPERATIONS Screen. The
Default value for the Regional number is the North American Toll Free number. However, the label and number can
be changed to any desired value. The Local label and number can also be entered.

“EVAPORATOR-TRANSDUCER OR TEMPERATURE SENSOR” SAFETY SHUTDOWN

In Previous Flash Memory Card versions, the conditions for this safety shutdown were checked after the first 10
minutes of chiller run. Under certain operating conditions this would result in unnecessary shutdowns. In this ver-
sion, in addition to the previous criteria, the shutdown conditions are not checked unless Smart Freeze is enabled
and the Evaporator Refrigerant Temperature RT7 (if enabled) or Evaporator Saturation Temperature (derived from
the evaporator pressure transducer) is < 32º F.

150 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

SI0024 - SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2002

GENERAL
Beginning March 2002, an enhanced Flash Memory Card will be supplied in new production YS Nema 1-4 and CE
chillers. The new features are outlined below.

The Flash Memory Card versions and part numbers are as follows:
• Nema 1-4 Chillers ............................C.MLM.03.03.100 (031-02005-001)
• CE Chillers .........................C.MLM.03.03.200 (031-02005-002)

These versions are also available from the Baltimore Parts Distribution Center for retrofit to existing chill-
ers.

RECORD SETPOINT CHANGES

This feature provides a record of the last 75 Setpoint changes. The date and time the Setpoint was changed, the new
Setpoint value and the Access Level and User ID used to make the change are stored in the BRAM. The Security
Log Screen and the Security Log Details Screen display levels of this information. Both screens are available in
Service Access level or higher.

On the Security Log Screen, accessible from the History Screen, the Setpoint, Setpoint Category and new Setpoint
value are listed and numbered in reverse order in which they were changed. The most recent is listed as number 1;
the next most recent as number 2, etc. A PRINT key allows printing this entire list. Since 15 changes can be displayed
at one time, multiple pages could be necessary to display all the changes. PAGE-UP and PAGE-DOWN keys are
provided to view the entire list. If it is desired to view the details of a particular Setpoint change, select the Setpoint
change number with the LOG ENTRY key and then press the VIEW DETAILS key. This moves to the Security Log
details Screen.

The Security Log Details Screen, accessible from the Security Log Screen, displays the following Setpoint change
details. The Setpoint is selected from the list on the Security Log Screen as explained in the previous paragraph. A
PRINT key is provided to print this information.
• Setpoint Category
• Setpoint
• Date and time of change
• Access Level and User ID used to make the change
• Old Value
• New Value 24

JOHNSON CONTROLS 151

 Service Information Letters / Bulletins
FORM 160.80-M1 (307)

SI0091 - SOFTWARE ENHANCEMENTS EFFECTIVE MAY 2004

General
Beginning May 2004, enhanced software will be supplied in all new production YS chillers. It is backward compat-
ible to all previous YS chillers. The enhancements are outlined below.

The versions and part numbers for 031-01730-000 Microboards are:

• NEMA 1-4 chillers C.MLM.03.04.104 (p/n 031-02005-001)
• CE chillers C.MLM.03.04.204 (p/n 031-02005-002)

The version and part number for 031-02430-000 Microboards is:

• NEMA 1-4 & CE Chillers C.OPT.03.04.301 (p/n 031-02488-001)

High Condenser Pressure Fault While Shutdown

High temperature condenser water flowing through the condenser while the chiller is shutdown can cause a condenser
high pressure condition resulting in loss of refrigerant. Therefore, an anticipatory safety fault has been created to
annunciate condenser high pressure conditions when the chiller is not running as follows:

While the chiller is stopped, if the condenser pressure exceeds 245.0 PSIG, a safety fault occurs and “Condenser
– High Pressure - Stopped” is displayed.

The chiller can be started after the condenser pressure decreases to less than 245.0 PSIG and a special reset procedure
is performed as follows:
1. Place the COMPRESSOR switch in the Stop-reset position.
2. At the keypad, login at Service access level using code 1 3 8 0.
3. Select COMPRESSOR screen.
4. Press the FAULT ACKNOWLEDGE key on the COMPRESSOR Screen. A dialog box appears displaying “Enter
Password to Clear Fault”.
5. Enter 1 3 9 7 and press the ENTER key (√).

This anticipatory fault is only performed while the chiller is stopped. If a “Condenser – High Pressure” fault is de-
tected while the chiller is in Start Sequence Initiated, System Run or Coastdown, the fault is handled in the normal
way and does not require the special reset procedure.

Style B Solid State Starter Faults

The following changes apply to faults detected by the Style B Liquid Cooled Solid State Starter (LCSSS):

Open SCR (Silicon Controlled Rectifier) Fault

When the Solid State Starter initiates a shutdown, the fault data transferred to the Optiview Control Center is a func-
tion of the eprom (U16) in the starter Logic/Trigger Board.

152 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

SI0091 - SOFTWARE ENHANCEMENTS EFFECTIVE MARCH 2004 (CONT'D)

Previously, in starters equipped with eprom version C.SSS.01.00 through C.SSS.01.02, when an Open SCR fault
occurred, the fault data returned from the starter did not identify the phase in which the fault occurred. Therefore, the
message displayed by the Optiview Control Center was “LCSSS – OPEN SCR”. New version C.SSS.01.03 eprom
now supplied in the starter Logic/Trigger Board, returns fault data that identifies the phase in which the Open SCR
condition is detected.

This Flash Memory Card version interprets this fault data and displays a message that identifies the defective phase.
Therefore, when this Flash Memory Card version is used with a starter Logic/Trigger Board equipped with version
C.SSS.01.03 (and later) eprom, “LCSSS – Phase X Open SCR” (X replaced by A, B or C as appropriate) is displayed
when the fault occurs.

Start Inhibit Faults

The following Start Inhibit Faults are no longer logged on the History Screen. They will continue to be displayed
on the System Details line of the display and transferred to the MicroGateway.

“LCSSS – Phase X Heatsink Temperature – Stopped” (X replaced by A, B or C as appropriate)

Diagnostics Screen
The communications error counters now count up to 65535 (was 255).

Invalid System Details Messages

In previous Flash Memory Card versions, there have certain operating conditions that could cause messages on the
System Details line of the display to become “stuck”. The most prevalent one was “Motor – High Current Limit”.
This has been corrected in this version.

Microgateway Induced Reboots

With previous Flash Memory Card versions, Microgateway communications could cause the Microboard to randomly
reboot. This has been corrected in this version.

History Data Storage

The data capture has been modified to assure that all data is that which is valid at the instant of the event.

Microgateway Interface
This version uses Yorktalk 3 version 6.0. This version transfers Start Inhibit and Modified Run codes into the correct
Microgateway slots. In previous versions, these were transferred into cycling and safety shutdown slots. This caused
the third-party device to interpret these events as safety or cycling events.
24
The ISN number conversion routine has been modified to correctly interpret Leaving Chilled Liquid Temperature
Setpoint resets from the Microgateway in metric mode. Setpoints of 1.6 to 1.9 ºC were not interpreted correctly.

JOHNSON CONTROLS 153

 FORM 160.80-M1 (307)

NOTES:

154 JOHNSON CONTROLS

 FORM 160.80-M1 (307)

NOTES:

JOHNSON CONTROLS 155

P.O. Box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2007 www.york.com ALL RIGHTS RESERVED
Form 160.80-M1 (307)
Supersedes: 160.80-M1 (604)