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332

FORM 160.54-M1

ISSUE DATE: 10/25/2019

SECTION 35 - SYSTEM COMMISSIONING CHECKLIST

JCI COMPANY CONFIDENTIAL JOHNSON CONTROLS

OPERATIONS Screen (160.54-M1)

____ Select desired Control Source (Operating

Mode); Local, ISN Remote, Digital Remote

or Analog Remote

____ Refrigerant Level Control operation Enable/

Disable

____ Hot gas bypass Control (optional) Enable/

Disable

____ Variable Geometry Diffuser (Enable/Disable)

(Chillers equipped with Variable Geometry

Diffuser. Software version C.MLM.01.10.

xxx (and later) or C.OPT.01.10.302 (and

Later)

____ Edit regional phone number if necessary

(Flash memory card version C.MLM.01.05.

xxx and later)

____ Enter local phone number (Flash memory

card version C.MLM.01.05.xxx and later)

____ Enter Chiller Style/Compressor (Flash

memory card version C.MLM.01.07.xxx

and later)

____ Enter Flow Sensor type (Flash memory card

version C.MLM.01.08.xxx and later).

Main Page

TABLE 1 - Control Panel Applications4
Table of Contents5
Section 1 - Introduction15
Section 2 - System Architecture17
FIGURE 1 - Optiview Control Center - Electromechanical Starter Applications22
FIGURE 2 - Optiview Control Center - MOD a Solid State Starter Applications23
FIGURE 3 - Optiview Control Center - MOD B Solid State Starter Applications24
FIGURE 4 - Optiview Control Center - Medium Voltage Solid State Starter Applications25
FIGURE 5 - Optiview Control Center - Compressor Motor Variable Speed Drive (YORK Serial Communications Protocol)26
FIGURE 6 - Optiview Control Center - Compressor Motor Variable Speed Drive27
(Modbus Serial Communications Protocol)27
FIGURE 7 - Optiview Control Center - Compressor Motor Medium Voltage Variable Speed Drive28
FIGURE 8 - Operation Sequence Timing Diagram (Electromechanical and Solid State Starter Applications)29
FIGURE 9 - Operation Sequence Timing Diagram (Compressor Motor Variable Speed Drive Applications)30
Section 3 - Microboard 031-01730-00031
Boot-Up Step and Description33
TABLE 2 - Boot-Up LED Indicators33
TABLE 3 - Addresses and Associated Data34
Power Supply38
Service Replacement38
FIGURE 11 - Flash Memory Card40
FIGURE 12 - Microboard (031-01730-000) Power Supply Test Points41
Program Jumpers42
Program Switches44
FIGURE 13 - Microboard Lamp Dimmer Circuit45
FIGURE 14 - Microboard Serial Data Communications Ports46
FIGURE 15 - Configurable Analog and Remote Setpoint Inputs47
Section 4 - Microboard 031-02430-000 and 031-02430-00149
Description49
TABLE 4 - Diagnostic Display Codes50
TABLE 5 - Multiplexer Channels53
Configuration and Setup58
FIGURE 16 - BRAM Socket62
TABLE 6 - Summary of Differences62
TABLE 7 - Microboard62
Downloading a Program from Aprogram Card63
Program Jumpers64
Program Switches65
FIGURE 17 - Microboard 031-02430-000 and 031-02430-00166
FIGURE 18 - Program Card 031-02474-00167
FIGURE 19 - Microboard (031-02430-000 and 031-02430-001) DC Power Supply Test Points67
FIGURE 20 - Microboard Lamp Dimmer Circuit68
FIGURE 21 - Microboard Serial Data Communications Ports69
FIGURE 22 - Configurable Analog and Remote Setpoint Inputs70
FIGURE 23 - Configurable Analog and Remote Setpoint Inputs (Heat Pump Duty)71
FIGURE 24 - Low Voltage Digital Inputs72
Section 5 - Microboard 031-03630-00173
Chiller Operating Program74
TABLE 8 - Diagnostic Display Codes74
Program Jumpers77
Program Switches78
TABLE 9 - Multiplexer Channels79
Configuration and Setup84
Downloading a Program from Aprogram Card88
FIGURE 25 - Microboard 031-03630-00190
FIGURE 26 - Program Card 031-03601-00191
FIGURE 27 - Microboard (031-03630-001) DC Power Supply Test Points91
FIGURE 28 - Microboard Lamp Dimmer Circuit92
FIGURE 29 - Microboard Serial Data Communication Ports93
FIGURE 30 - Configurable Analog and Remote Setpoint Inputs94
FIGURE 31 - Configurable Analog and Remote Setpoint Inputs (Heat Pump Duty)95
FIGURE 32 - Low Voltage Digital Inputs96
Section 6 - I/O Board97
I/O Board97
Digital Inputs97
Digital Outputs97
Triacs98
Relay Timing98
FIGURE 33 - I/O Board101
FIGURE 34 - I/O Board Digital Inputs102
FIGURE 35 - I/O Board Typical Optocoupler Circuit103
FIGURE 36 - I/O Board Typical Field Connections103
FIGURE 37 - J1 I/O Board Digital Outputs104
Section 7 - Liquid Crystal Display107
Backlight Lamp Replacement109
FIGURE 38 - Display Mounting110
FIGURE 39 - Liquid Crystal Display Assembly - Sharp LQ10D367/368 (031-01774-000) Display111
FIGURE 40 - Liquid Crystal Display Assembly - Sharp LQ104V1DG61 (031-02886-000) Display111
FIGURE 41 - Liquid Crystal Display Assembly - LG Semicon LP104V2-W (031-02046-000)112
FIGURE 42 - Liquid Crystal Display Assembly - Sharp LQ104V1DG81 (031-01771-000)112
FIGURE 43 - Liquid Crystal Display Typical Control Signal Timing113
FIGURE 44 - Display (Sharp LQ10D367/368) Lamp Replacement113
FIGURE 45 - Display (Sharp LQ104V1DG61 (031-02886-000) and LG LP104V2-W (031-02046-000))114
Section 8 - Display Interface Board115
FIGURE 46 - Display Interface Board 031-01765-001 and 031-01765-002117
FIGURE 47 - Display Interface Board 031-02887-000118
Section 9 - Display Backlight Inverter Board119
FIGURE 48 - Display Backlight Inverter Board (Sharp LQ10D367/368 (031-01774-000) and LG Semicon LP104V2-W (031-02046-000))120
FIGURE 49 - Display Backlight Inverter Board - Sharp LQ104V1DG61 Display 031-02886-000121
Section 10 - Keypad123
FIGURE 50 - Keypad Interface124
FIGURE 51 - Keypad125
Section 11 - Power Supply127
FIGURE 52 - Power Supply127
FIGURE 53 - Power Supply - DC Power Distribution (Refer to Optiview Control Center Wiring Diagram for Wire Connections)128
Section 12 - Current Module (CM-2)129
TABLE 10 - MUX Address130
FIGURE 54 - CM-2 Current Module (Electromechanical Starter Application)131
FIGURE 55 - CM-2 Current Module (Electromechanical Starter Applications)131
FIGURE 56 - CM-2 Current Module - Interface, Current Transformers, and Variable Resistors132
Section 13 - Solid State Starters133
Solid State Starters133
Medium Voltage Solid State Starter133
FIGURE 57 - Style B Liquid Cooled Solid State Starter (LCSSS) - Interface (YORK Protocol)137
FIGURE 58 - Style B Liquid Cooled Solid State Starter (LCSSS) - Interface (YORK Protocol)137
FIGURE 59 - Style B Liquid Cooled Solid State Starter (LCSSS) - Interface (Modbus Protocol)138
FIGURE 60 - Solid State Starter Logic Board138
TABLE 11 - Microboard Multiplex Channels140
FIGURE 61 - Mod a Liquid Cooled Solid State Starter (LCSSS) - Interface141
Section 14 - Adaptive Capacity Control Board143
YORK Protocol Configuration143
Modbus Protocol Configuration150
FIGURE 62 - Compressor Motor Variable Speed Drive (VSD) Adaptive Capacity Control (ACC) Board152
FIGURE 63 - Serial Communications Interface - YORK Protocol153
FIGURE 64 - Serial Communications Interface - Modbus Protocol154
FIGURE 65 - Adaptive Capacity Control (ACC) Board155
Section 15 - Proximity Probe157
TABLE 12 - Proximity Probes159
FIGURE 66 - Proximity Probe Interface - Probe Part Number 025-30961-000160
FIGURE 67 - Proximity Probe Interface - Probe Part Number 025-35900-000 and 025-35900-001160
FIGURE 68 - Proximity Probe Interface - Probe Part Number 025-40496-000161
FIGURE 69 - Proximity Probe162
Section 16 - High Speed Thrust Bearing Limit Switch163
FIGURE 70 - High Speed Thrust Bearing Limit Switch - Interface163
FIGURE 71 - High Speed Thrust Bearing Limit Switch164
Section 17 - Refrigerant Level Control165
Automatic Operation165
Manual Operation167
Actuators167
FIGURE 72 - Refrigerant Liquid Level Sensor168
FIGURE 73 - Refrigerant Liquid Level Control - Interface169
Section 18 - Oil Pump Variable Speed Drive171
Automatic Operation171
Manual Operation172
Oil Heater Operation173
FIGURE 74 - Oil Pump Variable Speed Drive (VSD)173
FIGURE 75 - Oil Pump VSD / Oil Heater Control - Interface174
FIGURE 76 - Oil Pump VSD Speed Control Signal174
Section 19 - Communications175
FIGURE 77 - E-Link Gateway Interface Block Diagram175
Section 20 - Pressure Transducers177
FIGURE 78 - Pressure Transducers178
TABLE 13 - Pressure Transducer Applications179
Section 21 - Temperature Thermistors181
TABLE 14 - Leaving Chilled Liquid Temperature182
TABLE 16 - Return Chilled Liquid Temperature188
TABLE 18 - Return and Leaving Condensing Water192
TABLE 19 - Oil and Discharge Temperature195
TABLE 20 - Drop Leg Refrigerant Sensor200
TABLE 21 - Evaporator Refrigerant Sensor200
TABLE 22 - Leaving and Return Heating Condenser Water Temperature Sensor201
Section 22 - Remote Setpoints203
Remote Operating Modes203
Current Limit203
Leaving Chilled Liquid Temperature205
Leaving Condenser Liquid Temperature (Heat Pump Mode)207
Section 23 - Hot Gas Bypass211
Setpoints211
Operation212
Hot Gas Operation with Variable Geometry Diffuser (VGD)213
Manual Control213
I/O Board213
Pre-Rotation Vanes Potentiometer214
FIGURE 79 - Interface, Hot Gas Bypass (Analog I/O Board 371-02514-000)215
FIGURE 80 - Interface, Hot Gas Bypass (I/O Board 031-02895-000)216
Section 24 - Smart Freeze Protection217
Section 25 - Surge Protection219
Surge Detection219
Excess Surge Detection220
Surge Protection220
Hot Gas Bypass/Compressor Motor Variable Speed Drive (VSD) Applications221
Section 26 - Variable Geometry Diffuser223
Stall Detection223
Surge Detection223
Automatic Operation223
Stall Sensor Validation225
Extreme Stall Monitor225
Manual Operation226
Setpoints226
Pre-Rotation Vanes Position227
I/O Board227
Stall Transducer227
Stall Detector Board227
FIGURE 81 - Variable Geometry Diffuser Block Diagram228
FIGURE 82 - Variable Geometry Diffuser State Diagram229
Section 27 - Large Tonnage Chiller (Ltc) I/O Board 031-02895-000/001231
Digital Inputs231
FIGURE 83 - LTC I/O Board Basic Block Diagram232
FIGURE 84 - 120 VAC Digital Input232
Digital Outputs233
FIGURE 85 - +5 VDC Digital Input233
FIGURE 86 - Relay Outputs233
FIGURE 87 - Triac Outputs233
Analog Inputs234
FIGURE 88 - Open Collector234
FIGURE 89 - Analog Inputs234
Analog Outputs235
FIGURE 90 - Analog Outputs235
Auto Detection236
Diagnostic Screen236
FIGURE 91 - I/O Board (031-02895-XXX)236
Section 28 - Heat Recovery237
Inputs/Outputs237
Control237
FIGURE 92 - Heat Recovery Block Diagram238
FIGURE 93 - PID Controller Diagram239
FIGURE 94 - Heat Recovery Flow Diagram240
Remote Hot Water Setpoint241
Condenser Flow Switch Open Fault241
TABLE 23 - Control Source Setpoints241
Section 29 - Head Pressure Control243
Inputs/Outputs243
FIGURE 95 - Head Pressure Control Block Diagram243
Control244
FIGURE 96 - Head Pressure Control Flow Diagram244
Operation When Equipped with both Heat Recovery and Head Pressure Control245
Section 30 - Quick Start247
Quick Start Modes247
Setpoints247
Operation249
TABLE 24 - Compare a Normal Start, Quick Normal Start, and a Quick Restart250
Section 31 - Heat Pump Duty253
Inputs/Outputs253
Setpoints253
Control254
Hot Gas Bypass Control255
Heat Recovery and Head Pressure Control255
Quick Start255
Variable Speed Drive255
Condenser Temperature Range255
Condenser High Pressure Warning255
GPIC Objects255
FIGURE 97 - Heat Pump Duty Block Diagram256
Section 32 - Motor Monitoring257
FIGURE 98 - Motor Monitoring Board (031-02893-000/001)257
FIGURE 99 - Motor Monitoring Board Basic Block Diagram258
Motor Monitoring Board259
FIGURE 100 - Motor Monitoring Block Diagram260
Winding Temperatures262
FIGURE 101 - Winding Temperature - Thermistors262
Bearing Temperatures264
FIGURE 102 - Winding and Bearing Temperature - RTD264
Vibration265
FIGURE 103 - Bearing Vibration Sensor265
Cooling Coil Leak Detection267
FIGURE 104 - Motor Cooling Coil Leak Detector - Float Sensor267
FIGURE 105 - Motor Cooling Coil Leak Detector - Optical Sensor268
TABLE 25 - RTD Resistance/Temperature Chart269
TABLE 26 - Thermistor Resistance/Temperature Chart269
Section 33 - System Calibration, Service Setpoints, and Reset Procedures271
Electromechanical Starter Applications271
Solid State Starter Applications272
Compressor Motor Variable Speed Drive Applications276
Proximity Probe279
High Speed Thrust Bearing Limit Switch280
Refrigerant Level Control280
Oil Pump Variable Speed Drive282
Oil Return Min283
Standby Lubrication283
High Condenser Pressure Warning Threshold283
Brine Low Evaporator Pressure Cutout284
Leaving Chilled Liquid Temperature Control Sensitivity284
Drop Leg Refrigerant Temperature284
Smart Freeze Protection285
Evaporator Refrigerant Temperature285
Hot Gas Bypass Control285
Chiller Starts and Operating Hours Reset286
Service Phone Numbers286
Surge Protection287
Sales Order Data287
Custom User ID and Passwords288
Record Setpoint Changes289
Chiller Style/Compressor289
TABLE 27 - Flash Memory Card Version C.MLM.01.07.XXX and C.MLM.01.07A.XXX290
TABLE 28 - Flash Memory Card Version C.MLM.01.08.XXX291
TABLE 29 - Flash Memory Card Version C.MLM.01.08.105A and C.MLM.01.08.206A (and Later)291
TABLE 30 - Software Version C.MLM.01.10B.XXX (and Later) or C.OPT.01.10B.XXX (and Later)291
Flow Switch292
TABLE 31 - Software Version C.OPT.01.16.XXX (and Later)292
Microboard 031-02430-000-001 and 031-03630-001 Setup/Configuration293
Variable Geometry Diffuser293
High Condenser Pressure Fault While Shutdown - Reset Procedure295
Motor Lubrication Notification295
Quick Start298
Heat Pump Duty299
Motor Monitoring Software (Version C.opt.01.22.307 and Later)299
Motor Details Screen299
Motor Setpoints Screen301
Section 34 - Diagnostics and Troubleshooting305
Diagnostics Screen306
FIGURE 106 - Diagnostics Screen306
Serial/Sd Screen307
FIGURE 107 - Serial/Sd Screen307
Main Diagnostics Screen308
FIGURE 108 - Main Diagnostics308
Motor Monitoring Board Diagnostic Screen309
FIGURE 109 - Motor Monitoring Board Diagnostic Screen309
I/O Board (031-02895-000) Diagnostic Screen311
FIGURE 110 - I/O Board Diagnostic Screen311
Keypad Test313
FIGURE 111 - Keypad Test Screen313
Display Test Main Screen314
FIGURE 112 - Display Test Main Screen314
Bit Patterns Test Screen316
FIGURE 113 - Bit Patterns Test Screen316
Serial Inputs/Outputs Test Screen318
FIGURE 114 - Serial Inputs/Outputs Test Screen318
FIGURE 115 - Microboard - COM 5 Serial Data Port319
Digital Inputs/Outputs Test Screen320
FIGURE 116 - Digital Inputs/Outputs Test Screen320
Analog Inputs Test Screen323
FIGURE 117 - Analog Inputs Test Screen323
Section 35 - System Commissioning Checklist327
Section 36 - Software Enhancements333
SI0006 - Software Enhancements Effective May 2001333
SI0019 - Software Enhancements Effective March 2002335
SI0034 - Software Enhancements Effective August 2002337
SI0058 - Software Enhancements Effective February 2003340
SI0062 - Software Enhancements Effective March 2003342
SI0080 - Software Enhancements Effective January 2004343
SI0089 - Software Enhancements Effective May 2004345
SI0148 - Software Enhancements Effective June 2006349
SI0158 - Software Enhancements Effective October 2006350
SI0164 - Software Enhancements Effective April 2007351
SI0186 - Software Enhancements Effective October 2006354
SI0201 - Software Enhancements (Ver 19) Effective October 2008356
SI0210 - Software Enhancements (Ver 20) Effective June 2009361
SI0212 - Software Enhancements (Ver 21) Effective June 2009363
SI0224 - Software Enhancements (Ver 22) Effective April 2010368
SI0252 - Software Enhancements (Ver 23) Effective May 2011369
TABLE 32 - Loop Back Connections371
SI0265 - Software Enhancements (Ver 24) Effective May 2012372
SI0271 - Software Enhancements (Ver 25) Effective August 2013374
FIGURE 118 - Diagnostic Screen377
TABLE 33 - Data Logging378
FIGURE 119 - Head Pressure Control Screen381
FIGURE 120 - Power Fault Recovery Screen382
Si0300 - Software Enhancements (Ver 27) Effective June 2015384
TABLE 34 - si Metric Conversion389

York OPTIVIEW YK - Page 332

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