Supersedes: 160.80-PW1 (1199) Form: 160.80-PW1 (114

WIRING DIAGRAMS

CONTRACTOR _________________________ PURCHASER _____________________________________________ ORDER NO. ____________________________ JOB NAME ________________________________________________ JCI CONTRACT NO. _____________________ LOCATION ________________________________________________ JCI ORDER NO. _________________________ ENGINEER _______________________________________________

REFERENCE DATE ________ APPROVAL DATE ________ CONSTRUCTION DATE _______

Supersedes: 160.80-PW1 (1199) Form: 160.80-PW1 (114)

ROTARY SCREW CHILLER MICROCOMPUTER CONTROL CENTER

WITH ELECTRO-MECHANICAL STARTER (STYLE E)

Issue Date: January 31, 2014

JOB DATA:

CHILLER MODEL NO. YK ________________________________________________________

NO. OF UNITS _____________

COMPRESSOR MOTOR ______________ VOLTS, 3-PHASE, _____________ HZ

OIL PUMP MOTOR _____________ VOLTS, 3-PHASE, _____________ HZ, _____________ FLA

JOHNSON CONTROLS2

FORM 160.80-PW1 ISSUE DATE: 1/31/2014

This equipment is a relatively complicated apparatus. During installation, operation maintenance or service, individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, materials under pressure, rotating components, and both high and low voltage. Each of these items has the potential, if misused or handled improperly, to cause bodily injury or death. It is the obligation and respon-sibility of operating/service personnel to identify and recognize these inherent hazards, protect themselves, and proceed safely in completing their tasks. Failure to comply with any of these requirements could result in serious damage to the equipment and the property in

IMPORTANT!READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

which it is situated, as well as severe personal injury or death to themselves and people at the site.

This document is intended for use by owner-authorized operating/service personnel. It is expected that these individuals possess independent training that will en-able them to perform their assigned tasks properly and safely. It is essential that, prior to performing any task on this equipment, this individual shall have read and understood this document and any referenced mate-rials. This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question.

SAFETY SYMBOLSThe following symbols are used in this document to alert the reader to specific situations:

Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken.

Indicates a potentially hazardous situa-tion which will result in possible injuries or damage to equipment if proper care is not taken.

Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollu-tion if proper care is not taken or instruc-tions and are not followed.

Highlights additional information useful to the technician in completing the work being performed properly.

External wiring, unless specified as an optional connection in the manufacturer’s product line, is not to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls and any external wiring must not be installed inside the micro panel. All wiring must be in accor-dance with Johnson Controls’ published specifications and must be performed only by a qualified electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of improper control signals. Failure to follow this warn-ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3


1. This wiring diagram describes the standard elec-tronic control scheme for use with an electrome-chanical starter. For details of standard modifica-tions. Refer to product form 160.80-PW1.

2. Field wiring to be in accordance with the national electrical code as well as all other applicable codes and specifications. See product from 160.80-PW3 for field wiring connections.

Field wiring contacts may have voltage present when power is removed. Field wiring contacts could be connected to external power sources.

3. Numbers along the left side of a diagram are line identification numbers. The numbers along the right side indicate the line number location of re-lay contacts. An underlined contact location sig-nifies a normally closed contact.

4. Main control panel class 1 field wiring terminal connection points are indicated by numbers with-in a rectangle. i.e. 15 . Main control panel factory wiring terminal connection points are indicated by numbers within a triangle. i.e. 5 . Component terminal markings are indicated by numbers with-in a circle. i.e. CI . Numbers adjacent to circuit lines are the circuit identification numbers.

5. To Cycle unit on and off automatically with con-tacts other than those shown. Install a cycling de-vice between terminals 1 & 13 (line 38) (See Note 9 ) If a cycling device is installed. Jumper must be removed between terminals 1 & 13 .

6. Compressor motor starter with starter interlock contacts (rated 0.2 AMPS @120 volts A.C.) Must be per for 160.47-FA12. Control panel shall be grounded.

7. Units installed in Canada must have a field sup-plied CSA approved 30 amp disconnect switch and a 15 AMP dual element fuse mounted exter-nal to control panel for 115 volt control supply.

8. To Stop unit and not permit it to start again. install a stop device between terminals 1 & 8 (line 33) (See Note 9). A remote start-stop switch maybe connected to terminals 1, 7 & 8 (Lines 32 & 33) (See Note 9). Remote start-stop switch (line 32) is operative only in the "Remote" operating mode.

9. Device contact rating is 5 AMPS resistance at 120 volts A.C. or 240 volts A.C.

10. Low Oil Pressure (LOP) safety shutdown occurs when oil pressure - Evaporator pressure differen-tial is less than 15 PSI following a 3 minute by-pass at compressor start.

11. Contact rating is 5 AMPS resistive at 120 volts A.C. or 240 Volts A.C.

12. A Jumper is installed between terminals 24 & 25 for normal operation. To Check motor rotation on initial start-up. The jumper may be removed and a momentary switch installed between terminals 24 & 25. Depress the start switch on the control panel. After completion of the prelube sequence, job the motor with the momentary switch. When proper rotation is obtained, replace the momen-tary switch with the jumper. The momentary switch must have a minimum contact rating of 1 FLA, IO LRA at 115 volts AC.

Caution: A temporary momentary switch or jump-er is the only connection permitted between ter-minals 24 & 25. Connection of any other devices to either terminal 24 or 25 May cause inadvertent compressor startup.

13. Motor overload (CM) is set to trip at 105% FLA. During momentary power interruption (Power Fault), Contact opens for 1 second.

14. For high and low voltage units, the factory sup-plied jumper between 1 & 53 must be removed when electromechanical stater overloads and /or safety devices are used. For high voltage (2300-4160) UL and CUL approved units only. Electro-mechanical compressor motor starter overloads (Normally Closed) must be connected between 1 & 53.

15. Contact rating is 5 AMPS resistive @ 250 volts A.C. & 30 volts D.C. 2 AMP inductive (.4 PF) @ @ 250 volts A.C.& 30 volts D.C.

16. Each 115VAC field-connected inductive load: i.e., relay coil, motor starter coil, etc. shall have a transient suppressor wired in parallel with its coil, physically located at the coil spare transient sup-pressors and control circuit fuses are supplied in a bag attached to keypad cable clamp in left side of control panel.

NOTES

JOHNSON CONTROLS4


LEGEND

a SOL Slide Valve-Unloadb SOL Slide Valve-LoadIHTR 500 Watt Oil Heater3M Condenser Pump Motor Starter

IRCompressor Motor / IHTR Heater Control Relay *K18 - Located on I/O BD.)

ISOL Oil Line Solenoid (125-400TR Chiller Only)

2SOLRefrigerant Level Solenoid (When Supplied)

ISS DPDT 3 Position Rocker Switch

CMSolid State Overload/Power Fault Contacts (Part of CM-2 Board)

FDTS Faulty Discharge Temperature SensorFLA Full Load Amps (Compressor Motor)FU Fuse

HDTRefrid. High Discharge Temperature (Provided by RT2)

HOPHigh Oil Pressure (Provided Two Transduc-ers)

HOT High Oil Temperature (Provided By RT3)HP High Pressure Cutout

LEPLow Evaporator Pressure (Provided By Evap. Press Transducer)

LOT Low Oil Temperature (Provided by RT3)LOP Low Oil Pressure

LWT Low Water Temperature (Provided by RT1)MOV Metal Oxide VaristorOL Motor Starter Overloads

RT1-RT9 Resistance Temperature Sensing ElementRES Resistor

SOLS Separator Oil Level SwitchSUPR Transient Suppressor

TB1, TB3, TB5

Terminal Block, Factory Wiring -

TB2, TB4 Terminal Block, Field Connection -

TB6Terminal Block, Field (Bottom), Factory (Top)Field WiringFactory WiringCircuit Board Or Enclosure BoundaryJack (J1, J2,...)Plug (P1, P2,...)Wire Entrance Hole In Control PanelOption (When Supplied) By Johnson ControlsMechanical LinkageShielded CableMetal Oxide Varistor

K13, K14, K17

Relays Mounted on I/O Board - See Opera-tor's Manual

JOHNSON CONTROLS 5


LIST OF FIGURESFIGURE 1 - Control Supply 115 VAC 50/60HZ .........................................................................................................7FIGURE 2 - Microboard 031-02430.........................................................................................................................10FIGURE 3 - Connection Boards ..............................................................................................................................12FIGURE 4 - Component Connection Details ...........................................................................................................14FIGURE 5 - Control Display ....................................................................................................................................15FIGURE 6 - Timing Diagram....................................................................................................................................16

LIST OF TABLESTABLE 1 - Pressure- Temperature Chart ................................................................................................................17

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THIS PAGE INTENTIONALLY LEFT BLANK.

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FIGURE 1 - CONTROL SUPPLY 115 VAC 50/60HZ

ELEMENTARY DIAGRAM

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FIGURE 1 - CONTROL SUPPLY 115 VAC 50/60HZ (CONT'D)

ELEMENTARY DIAGRAM (CONT'D)

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FIGURE 1 - CONTROL SUPPLY 115 VAC 50/60HZ (CONT'D)


JOHNSON CONTROLS10



FIGURE 2 - MICROBOARD 031-02430

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FIGURE 2 - MICROBOARD 031-02430 (CONT'D)

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CONNECTION DIAGRAM

FIGURE 3 - CONNECTION BOARDS

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CONNECTION DIAGRAM (CONT'D)

FIGURE 3 - CONNECTION BOARDS (CONT'D)

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FIGURE 4 - COMPONENT CONNECTION DETAILS

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FIGURE 5 - CONTROL DISPLAY

JOHNSON CONTROLS16


TIMING DIAGRAM

FIGURE 6 - TIMING DIAGRAM

JOHNSON CONTROLS 17


TABLE 1 - PRESSURE- TEMPERATURE CHART

APPLICATIONDEVICE UNITS

OPERATING POINTCHILLED WATER BRINE ON RISE ON FALL

a a HOT DEG.F / DEG.C 212/100 211/99.4

a a HOT DEG.F / DEG.C 170/76.7 169/76.1

a a HOT Warning DEG.F / DEG.C 165/73.9 160/71.1

a a LOP See Note 10

a a HP PSIG / kPaCut-Out

270/1862

Programmable Per Operator's Maunal From 160.80-O1*

Cut -In 210/1448

a LEP (R-22) PSIG / kPaCut-In

54.4/375

Allow Slide Valve

Loading 57.5/396

Inhibit Slide Valve

Loading 56.2/387

Cut-Out 54.3/374

a LEP (R-134 a) PSIG / kPaCut-In

25.1/173

Allow Slide Valve

Loading 28.0/193

Inhibit Slide Valve

Loading 27.0/186

Cut-Out 25.0/172

a a HOP PSIG / kPa 300/2068 299/2062

a a FDTS DEG.F / DEG.C 30.0/-1.10 29.9/1.20

a LWT DEG.F / DEG.C Programmable Per Operator's Manual Form 160.80-O1a LWT DEG.F / DEG.C

a a Clogged Oil Filter PSIG / kPa 25.0/172 24.9/172

a aDirty Oil Filter

WarningPSIG / kPa 20.0/138 19.9/137

* - Function porvided by condenser transducer

P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USACopyright © by Johnson Controls 2014 www.johnsoncontrols.com ALL RIGHTS RESERVEDForm 160.80-PW1 (114)Issue Date: January 31, 2014 Supersedes: 160.80-PW1 (1199)

Documents

Supersedes: 160.80-PW1 (1199) Form: 160.80-PW1 (114