yd mod a-c with optiview control center remote motor

JOB DATA:

CHILLER MODEL NO. YD __________________ CHILLER MODEL NO. YD __________________

NO. OF UNITS ___________________________ NO. OF UNITS ___________________________

TYPE OF STARTING ______________________ TYPE OF STARTING ______________________

Included by Johnson Controls for Field Installation (by others) are: YES NO PER UNIT

Condenser Water Temperature Sensor Kit, Part No. 375-01738-000 _____

Condenser Water Flow Switch _____

___________________________________________________ _____

___________________________________________________ _____

WIRING DIAGRAM

CONTRACTOR _______________________ PURCHASER ____________________________________________ORDER NO. __________________________ JOB NAME ______________________________________________JCI CONTRACT NO. ___________________ LOCATION ______________________________________________JCI ORDER NO. _______________________ ENGINEER _____________________________________________

REFERENCE DATE ______ APPROVAL DATE _______ CONSTRUCTION DATE _______

Supersedes: 160.69-PW4 (815) Form 160.69-PW4 (116)

YD (MOD A-C) WITH OPTIVIEW™ CONTROL CENTER

REMOTE MOTOR STARTER SPECIFICATIONS

Issue Date: January 29, 2016

JOHNSON CONTROLS2

FORM 160.69-PW4 ISSUE DATE: 1/29/2016

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

IMPORTANT!READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

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

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

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for con-tinuous product improvement, the information con-tained in this document is subject to change without notice. Johnson Controls makes no commitment to update or provide current information automatically to the manual owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson Controls Service office.

Operating/service personnel maintain responsibility for the applicability of these documents to the equipment. If there is any question regarding the applicability of

these documents, the technician should verify whether the equipment has been modified and if current litera-ture is available from the owner of the equipment prior to performing any work on the chiller.

CHANGE BARSRevisions made to this document are indicated with a line along the left or right hand column in the area the revision was made. These revisions are to technical in-formation and any other changes in spelling, grammar or formatting are not included.

External wiring, unless specified as an optional connection in the manufacturer’s product line, is not to be connected inside the OptiView cabinet. Devices such as relays, switches, transducers and controls and any external wiring must not be in-stalled inside the micro panel. All wiring must be in accordance with Johnson Con-trols’ 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 warning will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3


LIST OF FIGURES

FIGURE 1 - Typical Across-The-Line Starter 200 thru 600 VAC ...............................................................................8

FIGURE 2 - Typical Across-The-Line Starter 2300 thru 6900 VAC ...........................................................................9

FIGURE 3 - Single Phase Ammeter Circuit .............................................................................................................10

FIGURE 4 - 3-Phase Ammeter Circuit .....................................................................................................................10

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THIS PAGE INTENTIONALLY LEFT BLANK.

JOHNSON CONTROLS 5


JOB DATA TO BE FILLED IN BY JOHNSON CONTROLS REPRESENTATIVE

Motor starters for use with YORK Centrifugal Liquid Chilling Units must be furnished in accordance with the requirements of Johnson Controls Engineering Standard R-1137 (6/27/02) to ensure proper functioning of unit and its associated controls.

The Starter(S) To Be Furnished By ________________________________________________________________________

A. Quantity: _________________________________ B. Manufacturer: _______________________________________

C. Size and/or Model Number of Starter: ___________________________________________________________________

D. Starter type: Across-the-line

Primary Reactor ____ % tap Primary Resistor ____ % tap 200 – 600V: 80%, 65% or 57.7% Auto-Transformer, closed transition _____ % tap Wye-Delta, open transition WYE-Delta, closed transition other

E. Type Enclosure – Nema: __________________ (Nema-1 unless otherwise specified)

F. Type Mounting: Floor Wall

G. YORK Unit Model No. YD: __________________

H. Power Supply _____ volts – 3-phase – _____ hertz

I. Control power transformer required: Yes (to meet needs of starter control circuits)

J. Motor Full Load Amperes (FLA): _______________ (each) Motor Locked Rotor Amperes (lRA): _______________ full voltage Maximum Inrush Amperes: _______________ reduced voltage

K. Motor Service Factor (if greater than 1.05) __________

L. Type Control Center: Microcomputer

M. Power Factor Correction Capacitors (when required)(each compressor) full load PF:________ uncorrected, ________ corrected, or ________ KVAR required at ______ volts

N. Main contactors will drop out within 4 cycles of removal of 115 volt “RUN” signal. (This note to appear on starter wiring diagram.)

O. Ammeter Required: yes _______________ ( single-phase, three-phase), no

P. Code Approval Required U.L. yes no CU.L. yes no (Note: A U.L. or CU.L. Listed starter must be supplied with a U.L. or CU.L. listed chiller)

Q. Manual Reset Overland Relays: Required (high voltage only) for U.L. or CU.L. approval. optional solid state motor protection relay type:

R. Three-phase Oil Pump Power Supply (when required on 200-600V starters only) Fuse Block (30 AMP) ______ or Circuit Breaker __________ Oil Pump FLA ____________

S. Required approval, accessories and modifications: (detail) include customer specifications, as required. __________________________________________________________________________________________________ __________________________________________________________________________________________________

T. The pair of motor starters required per yd configured as: Stand alone individual starters Pair of starters in common cabinet with incoming bus or cable

U. Incoming line top entry bottom entry

}

JOHNSON CONTROLS6


This standard, defining the requirements of materials to be furnished or services to be performed, is not sub-ject to interpretation.

1. SCOPE1.1 This standard covers the special purchasing re-

quirements of remote E-M motor starters for use with Model YD YORK Centrifugal Liquid Chill-ing Units as follows:

a. YORK Single Stage Refrigerant R-134a Mod-els YD with open motors per ESG drawings 024-27800-000, 024-27801-000, 024-26514-000, 024-34014-000, 024-34020-000, and 024-34021-000.

1.2 YD chillers utilize two compressor motors. Start-ers shall be furnished in pairs in a common line up. See options on 6.1.

2. RELATED STANDARDSa. ANSI/IEEE Standard C57.13, Requirements for

Instrument Transformers.

b. National Electrical Code (NEC), ANSI/NFPA-70.

c. Underwriters Laboratories Standard UL 508A.

d. Canadian Standards Association (CSA) Std. C22.2 No. 14-91

e. NEMA Standards, Industrial Controls and Sys-tems, Pub. No. ICS

f. NEMA Standards, Motors and Generators, Pub. No. MG1

g. ESG Drawings 024-26514-000, 024-27800-000, 024-27801-000 or 024-27802-000 Mo-tors, 024-34014-000, 024-34020-000, and 024-34021-000.

3. REQUIREMENTS3.1 Starters supplied under this standard must comply

with the requirements of the NEC, ANSI/IEEE C57.13, and any additional codes or standards referenced on the Purchase Order.

3.2 On points of difference with the above referenced standards and codes, the requirements of this stan-dard shall prevail. The starter circuit must be ap-proved by ESG Engineering.

3.3 Type of Starter - The basic type of starter (across-the-line, auto-transformer, wye-delta, etc.) cov-ered by this standard shall be as specified on the Purchase Order.

a. For auto-transformer, primary resistor and pri-mary reactor starters, the design output voltage during starting shall not be less than 57.7% of the unit nameplate voltage for 200-600V and 65% of unit nameplate voltage for 2300-6900V.

b. Medium voltage starters shall be NEMA Class E2 which include an integral disconnect means, high interrupting capacity current-limiting fus-es and either an air break, drawout contactor or a slide-out vacuum contactor as standard, al-though not shown on Figure 2 on page 9.

3.4 Enclosure - Enclosure for the starter must be NEMA Type 1, General Purpose, unless other-wise specified on the Purchase Order.

3.5 Control Ciruit Wiring - Control circuit wiring and terminal blocks shall be as shown in Figure 1 on page 8 for 200 to 600 VAC motor starters and shall be as shown in Figure 2 on page 9 for 2300 to 6900 VAC motor starters.

3.6 Power Terminal Marking - Starter line and load terminals must be identified by suitable markers.

3.7 Nameplate Marking - Nameplate shall be marked as follows:

“Volts, phase, Hertz, FLA, LRA, for refrigeration and air conditioning duty only per ESG Standard R-1137”, also UL or cUL Listed under File No. ________________” or “CSA Certified under File No. __________________”.

3.8 Starter Control Circuit -

a. Start-stop signal - The starter control circuit is actuated by a 115V ± 10%, single phase, 50 or 60 Hertz “Run” signal (1 amp full load, 10 amp inrush maximum) applied across terminals “24” and “2” and “77” and “2” from the YORK Control Center. If either the starter control volt-age or current exceeds this rating, a separate ad-ditional control relay of proper rating shall be furnished within the starter. The “Stop” func-tion is accomplished by terminating the “Run” signal.

JOHNSON CONTROLS 7


b. All ungrounded conductors of the starter con-trol circuit shall be protected by an overcurrent device rated not more than 300% of the current rating of the conductors or control relay con-tacts.

c. The control circuit must be designed to open the main contactors within four (4) cycles (66.7 milliseconds) after removal of the 115V “Run” signal (including the dropout time of any con-trol relay added per Section 3.8(a)).

3.9 Solid State Motor Overload protection is provided in the York Control Center.

3.10 For 2300 to 5000 VAC motor starters, additional Manual Reset Overload Relays (OL’s) are re-quired.

a. Three (3) Overloads (OL's) shall be supplied for each starter.

b. OL's shall be manual reset, ambient compen-sated, adjustable type, either thermal or mag-netic or a YORK approved solid state device such as the Cutler-Hammer MP-3000.

c. OL’s may sense either line or phase current.

d. OL’s may sense motor current directly (with-in the current and voltage limitations of the OL coils), or they may be fed through two or three current transformers (CT’s). Refer to Paragraph 3.10(h).

e. The OL’s shall be factory set by the starter manufacturer for ultimate trip point corre-sponding to:

For Model YD units with open motors per ESG drawings 024-26514-000, 024-27800-000, 024-27801-000, 024-27802-000, 024-34014-000, 024-34020-000, and 024-34021, 105% of motor full load current (FLA).

f. If OL’s sense the motor phase current of del-ta-connected motors, the ultimate trip point shall correspond to the values as shown in Paragraph 3.10(e) divided by 1.73.

For units with power factor correction capaci-tors on the load side of the OL relays, the OL ultimate trip point must be decreased as fol-lows:

OL ultimate trip setting = OL setting without PF X PF before correction with PF correction correction PF after correction

g. OLs shall be adjusted for locked rotor trip time (seconds) as shown in Table 1 on page 9. OLs shall be temperature compensated to operate within the specified locked rotor trip time limits over an ambient temperature range of 40°F to 110°F (4.4°C to 43.3°C).

h. When used, current transformers must com-ply with ANSI/IEEE Requirements for In-strument Transformers, C57.13. The turns ratio shall appear in a readily visible location.

1. Current transformers feeding overloads must be sized to meet the accuracy and burden requirements of the overload re-lays.

2. The same current transformers may be used to feed overload relays and a three-phase ammeter circuit provided the ac-curacy and burden requirements of both functions are satisfied. See Paragraph 3.11.

JOHNSON CONTROLS8


FIGURE 1 - TYPICAL ACROSS-THE-LINE STARTER 200 THRU 600 VAC

Notes:

1 Connect the contacts of any voltage sensitive device(s) in circuits 13-1 and 95-1 rather than circuits 53-15 and 54-15. Any safety device(s) in the starter that may drop out due to loss of power must reset automatically when power is restored.

2 Each 115V inductive load: i.e., motor starter coil, relay coil, etc., shall have a transient suppressor wired in parallel with its coil, physically located at the coil. Transient suppressor shall be a series RC device, 0.1μf, 100 ohms, 250 VAC, UL approved - Rifa P/N PMR210ME6100M100 or Electrocube P/N RG-1782-6 or equal.

3 The jumper between terminals 53 and 15 and 54 and 15 in the chiller control panel must be removed when electromechanical starter overloads and/or safety devices are used.

LD08635

JOHNSON CONTROLS 9


3.11 Current Transformers Supplying Current Signal to Optional Ammeter - The turns ratio shall appear in a readily visible location. Cur-rent transformer shall be sized to provide 2.4 to 4 amperes at motor full load current and have an accuracy class of 0.6 and burden rating of B-0.1 with continuous thermal current rating factor of 1.0 at 30°C. See Paragraph 3.15.

3.12 Sequencing of Steps - Sequencing of multiple step starters shall be a function of time. The starter manufacturer shall furnish timer(s) with an adjustable range of sixty (60) seconds, factory set by the starter manufacturer for a 40 second final step for 200 – 600 VAC starter applications and 30 second final step for 2300 to 6900 VAC motor starter applications and with intermediate steps in proportion.

TABLE 1 - STARTER SETTINGS

Type of Starting

Percent Voltage

Percent LRA Overload Relay Trip Time (Sec.)Line Load

Across the Line 100 100 100 8-10Wye Start-Delta Run**

100+ 33 33 45-56

Auto-Transformer80 64 80 18-2265 42.3 65 33-41

Primary Resistor Primary Reactor

80 80 80 18-22

65 65 65 33-41

+ For Wye Start, line voltage is 100%, motor phase voltage is 57.7%.

** Wye-Delta available only for 200-600 volts.

Notes: 1 Connect the contacts of any voltage sensitive safety device(s) in circuits 13-1 and 95-1 rather than circuits 53-15 and 54-15.

Any safety device(s) in the starter that may drop out due to loss of power must reset automatically when power is restored.2 Switchgear with automatically operated circuit breaker(s) may be used in lieu of contactors on medium voltage units (above

600V). Switchgear must be furnished with AC capacitive trip or other approved fail safe trip device.3 Each 115V inductive load: i.e., motor starter coil, relay coil, etc., shall have a transient suppressor wired in parallel with its coil,

physically located at the coil. Transient suppressor shall be a series RC device, 0.1μf, 100 ohms, 250 VAC, UL approved - Rifa P/N PMR210ME6100M100 or Electrocube P/N RG-1782-6 or equal.

FIGURE 2 - TYPICAL ACROSS-THE-LINE STARTER 2300 THRU 6900 VAC

LD08636

JOHNSON CONTROLS10


3.13 Run Interlock - All starters must be furnished with a normally open interlock which closes when full voltage is applied to the motor. The run interlock contacts shall be pilot duty type, 125 VA at 115 volts. The interlock (terminals 3-4) must be suitable for reliable switching of 12 to 30 VA at 24 volts AC.

3.14 Control Power Transformer - A control power transformer and separate disconnect shall be supplied to meet the control power requirements of each starter. Unless specified otherwise the control circuit shall be 115 volt AC nominal. The transformer and control circuitry must op-erate satisfactorily over the operating and dip/startup voltage range as specified in paragraph 3.19.

3.15 Ammeters - When specified by the Purchase Order, an ammeter shall be furnished to measure motor line current for each motor. The ammeter shall have a 5 ampere movement and a direct reading scale which indicates actual motor cur-rent. Two (2) different arrangements are recom-mended as follows:

a. Single-phase ammeter circuit - The ammeter is installed in series with the current trans-former and a shorting switch is connected across the ammeter as shown in Figure 3 on page 10.

b. Three-phase ammeter circuit - Where indica-tion of all three phase currents is specified on the Purchase Order, a 4-position selector switch shall be provided with a common am-meter. This is wired in conjunction with two CT’s as shown in Figure 4 on page 10.

c. If both an ammeter and power factor correc-tion capacitors are specified, the ammeter shall be located in the circuit to indicate mo-tor current.

LD02363

FIGURE 3 - SINGLE PHASE AMMETER CIRCUIT FIGURE 4 - 3-PHASE AMMETER CIRCUIT

LD06893

JOHNSON CONTROLS 11


3.16 Space Requirements for Stress Cones - The following minimum distance between point of entry of conduits and line and load connections shall be provided when the use of stress cones for field wiring is indicated.

VOLTAGE MINIMUM DISTANCE 2-5 KV 14 inches

5.1-15 KV 19 inches

3.17 Power Factor Correction Capacitors - When PF correction capacitors are specified on the Pur-chase Order they shall be connected to the load side of each starter in all cases except for open-transition auto-transformer or Wye-Delta start-ing where they shall be connected to the line side per NEMA Std. MG-1, Part 20. See Paragraphs 3.10(f) and 3.15(c) for other considerations.

3.18 Three Phase Oil Pump Power Supply - op-tional one per chiller (or pair of starters) when specified.

3.18.1 200 - 600V Only - When specified on the Purchase Order, a protected branch cir-cuit (one per pair of starters), as shown in Figure 1 on page 8, shall be provid-ed to supply three-phase power to the oil pump motor controller mounted on the YORK YD chiller. The circuit shall com-ply with the following:

a. It shall be fed through either a 3-pole, 30 amp fuse block and disconnect.

b. Cartridge-type fuse holders, rated 30 am-peres and of the proper voltage rating, shall be provided. For maximum dual element fuse size and oil pump motor FLA, see Table 2 on page 11.

3.18.2 Above 600 Volts - When specified on the order a control power transformer with transformer disconnect and both primary and secondary transformer fusing shall be specified, as shown in Figure 2 on page 9, in compliance with the following requirements:

a. Capacity of the control transformer shall be 10.0 Net KVA.

b. Primary shall be connected to transformer terminals through fuses in the line conduc-tors that are sized for no more than 250% of the primary current.

c. Secondary voltage output shall be as speci-fied by the Purchase Order. Secondary car-tridge-type fuse holders rated 30 amperes and of the proper voltage rating shall be pro-vided. For maximum dual element fuse size and Variable Speed Oil Pump Panel FLA, see Table 2 on page 11. The secondary fuses shall be wired to control terminals “L1, L2 and L3”.

d. Transformer load regulation must be such that the output voltage remains within the range as shown in Table 3 on page 11.

TABLE 2 - FUSE SIZE

Hz Namplate Voltage TOT Amp Max Fuse

Size60 200 24.4 3060 230 23.5 3060 460 11.8 1560 575 9.4 1260 380 13.9 1560 416 12.2 1550 346 15.4 2050 380 13.9 1550 415 13.9 15

3.19 Voltage Limits - Low voltage starters must oper-ate properly within the voltage limits listed be-low:

TABLE 3 - VOLTAGE LIMITS

Hz Rated-Voltage

Distribution Voltage

Dip Voltage

(60 sec. Min.)

Continuous Operation

Min Vtg Max Vtg60 200V 200-208V 170V 180V 220V60 230V 220-240V 196V 208V 254V60 460V 440-480V 391V 414V 508V60 575V 550-600V 489V 520V 635V60 380V 380V 323V 342V 402V60 416V 416V 354V 375V 457V50 346V 346V 294V 311V 381V50 380V 380/400V 323V 342V 423V50 415V 415V 353V 374V 440V

3.20 A no load disconnect means shall be provided on medium voltage units, which will isolate each motor starter. Refer to Figure 2 on page 9. An optional main disconnect switch may be pro-vided.

JOHNSON CONTROLS12


4. CERTIFICATION4.1 The starter manufacturer must provide three (3)

sets (or more as specified on the Purchase Order) of certified drawings, identified with job name and ESG Sales Order Number and showing dimen-sions and wiring diagram, as follows:

a. Two (2) sets (or more as specified) to source of Purchase Order.

b. One (1) set, for record purposes only, to Service Department 36BE, Engineered Systems Group, Johnson Controls, York, PA 17405-1592.

5. PACKAGING AND MARKING5.1 The container used in shipment of the starter must

be identified with the ESG Purchase Order, Job Name and ESG Sales Order Number, and any special markings specified.

6. PURCHASING6.1 ESG Purchase Order is to specify:

a. Quantity

b. Manufacturer

c. Size and/or Model Number of starter

d. Type:

Across-The-Line

Wye-Delta (open or closed transition)

Auto-transformer

Primary reactor

Primary resistor

e. Type Enclosure - NEMA

f. Mounting (Floor or Wall)

g. YORK Unit Model Number .

h. Optional Three Phase Control Power (one per YD chiller):

1. Fused branch circuit with disconnect for Variable Speed Oil Pump Panel (when re-quired on 200-600 volt only). Fuse block (30 amp)_____; VSOP Panel FLA_____, fuse current rating _____.

2. 10 KVA (minimum) 3-phase control power transformer with primary disconnect and both primary and secondary fusing (primary voltages above 600 VAC). Secondary volt-age supply _____ volts, frequency _____ Hz, VSOP Panel FLA _____, fuse current rating _____ and secondary voltage rating ____.

i. Power Supply, Volts, Phase, Hertz ____________

j. Rating Data: FLA, LRA, max. inrush amps(per motor)

k. Motor Service Factor (if greater than 1.05)

l. Power Factor Correction Capacitors (when re-quired) Full Load PF: ______________

Uncorrected ______________ Corrected or

KVAR @ ______________ Volts

m. Required Accessories and Modifications (detail) (include customer specifications, as required)

n. Code Approval Required: UL or CUL

o. Manual Reset Overload Relays-required (high voltage only)or optional microprocessor motor protection relay.

p. Job Name, and ESG Sales Order Number

q. ESG Part Number, when applicable for ship-ment into ASO plants

r. ESG Standard R-1137

s. Main contactors will drop out within 4 cycles of removal of 115 volt “Run” signal”. This note to appear on the starter wiring diagram.

t. Incoming power shall be bussed to:

A single point wiring connection.

Individual feeds for each compressor.

Example: Contract Special

One (1) Model ABC, 65% Tap Auto-Transformer, Closed Transition Starter, NEMA 1 enclosure, floor mounted, for use with York Model YD XHXDJ2-DAA, Open Chiller at 4000 volts -3-60 with 130 FLA, 715 LRA and 302 amps maximum inrush, per ESG Standard R-1137, door mounted ammeter and three (3) phase ammeter selector switch, 3-phase 460 volt pow-er supply with 30 amp fuse block for panel rated 11.8 FLA and secondary fuses rated 15 amperes, customer XYZ, York Sales Order Number 00-000000.

JOHNSON CONTROLS 13


NOTES

P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USACopyright © by Johnson Controls 2016 ALL RIGHTS RESERVEDForm 160.69-PW4 (116)Issue Date: January 29, 2016 Superseded: 160.69-PW4 (815)

800-861-1001www.johnsoncontrols.com

yd mod a-c with optiview control center remote motor

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