Supersedes: 160.75-PW1 (311) Form: 160.75-PW1...

WIRING DIAGRAMS

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

REFERENCE DATE ________ APPROVAL DATE ________ CONSTRUCTION DATE _______

Supersedes: 160.75-PW1 (311) Form: 160.75-PW1 (1012)

FIelD CoNNeCtIoNS FoR YK ChIlleR (StYle G) optIVIeW CoNtRol CeNteR WIth ReMote loW oR MeDIuM VoltAGe eMS oR

uNIt MouNteD loW oR MeDIuM VoltAGe SSS

Issue Date: October 16, 2012

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 160.75-PW1 ISSUE DATE: 10/16/2012

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


NoteS

1. All field wiring shall be in accordance with the current edition of the National Electrical Code (N.E.C.) as well as all other applicable codes and specifications.

2. Compressor motor frame shall be grounded in accordance with N.E.C. (Table 250-95) for equipment grounding, using copper conductor only. Motor terminal box is furnished with one 3/8” hex head cap screw and lock washer (ground lug is not furnished) for grounding. Ground the control center with ground screw furnished, using copper conductor only.

3. Wiring, electrical conduit, junction boxes, fused disconnect switches (FDS), or circuit breakers, starters (M), push-button stations (PB), manual-off-automatic switch (S), flow switch (FLS), con-trol relays, and control power transformer (CPT) furnished by others unless otherwise specified.

4. Items marked * furnished by Johnson Controls.

5. Items marked ** available from Johnson Controls at additional cost.

6. Motor starter must be furnished in accordance with Form 160.45-PA5.1.

7. Control Center power supply 115V-50/60Hz, 20 ampere capacity for control center only should be supplied by a control power transformer (CPT) wired as shown. CPT should be incorporated in the chiller starter (2M) – see Note 6.

8. The following terminal lugs are factory furnished for field wiring connections when factory in-stalled disconnect switch or circuit breaker is not supplied. All lugs are rated AL9CU.

INput VoltAGeStARteR MoDel No. W/o

DISCoNNeCt / CIRCuIt BReAKeR optIoN

lINe SIDe luGS GRouNDING luG, WIRe RANGe, QuANtItY

Al9Cu QuAN. peR teRMINAl WIRe RANGe

380 SSS 7LK-40B

1 #4-600 kcmil #14-1/0, one bbl. 440-480 SSS 7LK-46B550-600 SSS 7LK-58B380-400 SSS 7LK-50B200-208 SSS 14LK-17B

2 #2-600 kcmil #14-1/0, two bbl.

220-240 SSS 14LK-28B380 SSS 14LK-40B

440-480 SSS 14LK-46B550-600 SSS 14LK-58B380-400 SSS 14LK-50B200-208 SSS 26LK-17B

3 #2-600 kcmil #4-600 kcmil, two bbl. or 1/0 - 250 kcmil, four bbl.

220-240 SSS 26LK-28B380 SSS 26LK-40B

440-480 SSS 26LK-46B550-600 SSS 26LK-58B380-400 SSS 26LK-50B200-208 SSS 33LK-17B

4 #2-600 kcmil #4-600 kcmil, two bbl. or 1/0 - 250 kcmil, four bbl.

220-240 SSS 33LK-28B380 SSS 33LK-40B

440-480 SSS 33LK-46B380-400 SSS 33LK-50B

JOHNSON CONTROLS4


The following terminal lugs are factory furnished for field wiring connections when a factory installed dis-connect switch or circuit breaker with ground fault pro-tection is supplied:

INput VoltAGe

StARteR MoDel No. & AVAIlABle DISCoNNeCt

SWItCh/ CIRCuIt BReAKeR AMp RAtING

lINe SIDe luGSluG

RAtING

GRouNDING luG, WIRe RANGe,

QuANtItY Al9Cu QuAN. peRteRMINAl

WIRe RANGe

380 SSS 7LK-40B 250A

1 #6-350 kcmil AL7CU #14-1/0, one bbl. 440-480 SSS 7LK-46B 250A550-600 SSS 7LK-58B 250A380-400 SSS 7LK-50B 250A380-400 SSS 7LKCE-50B 250A CB

380 SSS 7LK-40B 400A

2 3/0-250 kcmil AL7CU #14-1/0, one bbl. 440-480 SSS 7LK-46B 400A550-600 SSS 7LK-58B 400A380-400 SSS 7LK-50B 400A200-208 SSS 14LK-17B 400A

2 3/0-250 kcmil AL7CU #14-1/0, two bbl.

220-240 SSS 14LK-28B 400A380 SSS 14LK-40B 400A

440-480 SSS 14LK-46B 400A550-600 SSS 14LK-58B 400A380-400 SSS 14LK-50B 400A380-400 SSS 7LKCE-50B 400A CB200-208 SSS 14LK-17B 600A

2 250-500

kcmil AL9CU #14-1/0, two bbl.

220-240 SSS 14LK-28B 600A380 SSS 14LK-40B 600A

440-480 SSS 14LK-46B 600A550-600 SSS 14LK-58B 600A380-400 SSS 14LK-50B 600A380-400 SSS 14LKCE-50B 600A CB200-208 SSS 26LK-17B 960A CB

4 4/0-500 kcmil AL9CU #4-600 kcmil two bbl. or 1/0-250 kcmil, four bbl.

220-240 SSS 26LK-28B 960A CB380 SSS 26LK-40B 960A CB

440-480 SSS 26LK-46B 960A CB550-600 SSS 26LK-58B 960A CB380-400 SSS 26LK-50B 960A CB380-400 SSS 26LKCE-50B 960A CB200-208 SSS 26LK-17B 1200A DS


220-240 SSS 26LK-28B 1200A DS380 SSS 26LK-40B 1200A DS

440-480 SSS 26LK-46B 1200A DS 550-600 SSS 26LK-58B 1200A DS380-400 SSS 26LK-50B 1200A DS200-208 SSS 33LK-17B 1200A CB


220-240 SSS 33LK-28B 1200A CB380 SSS 33LK-40B 1200A CB

440-480 SSS 33LK-46B 1200A CB380-400 SSS 33LK-50B 1200A CB380-400 SSS 33LKCE-50B 1200A CB

JOHNSON CONTROLS 5


9. Motor power conduit connection location, mo-tor full load amperes (FLA) and type starting per Product Drawing Form 160.54-PA1. Multiple conduits should contain an equal number of wires from each phase in each conduit to prevent over-heating. Use copper conductors only; do not use aluminum conductors. Flexible final connections should be used to provide vibration isolation.

10. Wiring diagram for YORK® Graphic Control Center Form 160.54-PW1. Field wiring modifica-tions per form 160.54-PW7.

11. Condenser water pump motor starter (3M) hold-ing coil to be furnished for 115V-50/60Hz. The power requirements for the total of the condenser water pump starter (3M) and the chiller starter (2M) condenser must be a max. of 2 Amps hold-ing and 10 Amps inrush. If power requirements exceed this value, furnish coil for line voltage, and control relay with 115V coil. See note 27.

12. Units shipped knocked down require field con-nection of harness to control panel. These har-nesses are furnished by Johnson Controls for field assembly and consist of proper lengths of flexible conduit with necessary connectors, and contain the wires properly terminated and marked.

13. Motor leads shown for star delta starter (200 to 600 volts). For 3 lead starting arrangements, see diagram on motor data plate. Only three lead type of starting used above 600 volts. Connect full volt-age (run) interlock of compressor-motor starter to terminals 3 - 4.

14. Wire #14AWG copper for one way distance of less than 175 feet. Wire #12AWG copper for one way distance of more than 175 feet but less than 300 feet.

15. Units installed in Canada must have a field sup-plied CSA approved 30 Amp disconnect switch and 20 Amp dual element fuse mounted external to control center for 115 volt control supply.

16. Oil pump motor auxiliary power supply (FDS1) – See Product Drawing Form 160.54-PW1 for specified voltage and fusing. For 200 through 600 VAC compressor motor, the oil pump motor voltage is the same as compressor motor voltage and is wired (by others) as shown; three phase oil pump power supply can also be fed thru ei-ther a 3-pole, 30 Amp fuse block or a 3-pole cir-

cuit breaker from the compressor motor starter as shown in Form 160.45-PA5.1, Figure 3.5(a). For high voltage compressor motors (2300 through 4160VAC), the oil pump motor voltage shall be selected by the customer at one of the available voltages (200 through 600VAC) shown in Form 160.54-PW1 and wired to a separate supply (not shown on wiring diagram).

17. Control circuit wiring for 3M condenser water pump motor starter is shown for cooling only ap-plication.

18. Wiring shown from 200 to 600 volt starter (2M) is required only for optional safety devices in starter which will stop compressor (terminals 1 and 53 ) and for optional safety devices in the starter which will cycle the compressor and/or optional OFF-AUTO switch (terminals 1 and 13 ). When op-tional safety devices are installed, remove jumper between 1 and 53 . When optional cycling devices are installed, remove jumper between 1 and 13 .

For 2300 to 4160 volt U.L. to C.S.A. approved units only, compressor-motor starter (2M) over-loads (normally closed) must be connected (by others) between terminals 1 and 53 . Remove the factory supplied jumper between 1 and 53 when installing overloads or other safety devices. For 200 to 600 volt units, a jumper is provided between terminals 1 and 53 . See Control Center Wiring Diagram, Form 160.54-PW1 and Motor Starter, Form 160.45-PA5.1.

19. Medium voltage (2300 to 4160 volts) compressor-motor starters of NEMA Class E-2 (when used) have high interrupting capacity current limiting fuses plus an integral non-load disconnect func-tion and thus do not require the use of FDS2.

20. Low voltage motors (up to and including 600 volts) are furnished with six leads. High voltage (2300 to 4160 volts) motors have three leads up to 900 HP. 1000 HP and above motors that are dual 2300/4000V 60 Hz have 6 leads, jumpered to give 3 lead type starting. Motor leads are furnished with a crimp type connector having a clearance hole for a 3/8” bolt. Motor terminal lugs are not furnished.

JOHNSON CONTROLS6


21. Starter to motor power wiring ampacity shall be calculated as follows:

a. Six lead type of starting (star-delta) – mini-mum circuit ampacity per conductor (one of six):

Ampacity = .721 x compressor-motor amps

b. Three lead type of starting (across-the-line, auto-transformer, primary reactor or prima-ry resistor) - minimum circuit ampacity per conductor (one of three):

Ampacity = 1.25 x compressor motor amps

Where 125% factor is per N.E.C. (para. 440-33); .721 is 125% factor x 57.7% voltage (only star-delta starter); Compressor motor amps (See Note 8) are FLA.

22. The fused disconnect switch (FDS2), for the compressor motor starter, minimum ampere rat-ing shall be determined as follows for 200 to 600 volts:

Amp rating = 1.15 (compressor motor amps + oil pump motor amps + control power transformer amps)

23. The condenser is provided with a thermal type flow sensor. If an optional mechanical type flow switch is used instead, it is connected between TB4-11 and TB4-1

24. 60 and 50 Hz oil pump motors are 2HP for all compressor codes. The full load amperes for oil pump motor and 2.0 KVA control power trans-former to be used with notes 21, 23 and 25 are:

3-phASe VoltAGe hZ

oIl puMp MotoR (AMpS)

2 hp

CoNtRol poWeR (Cpt)

tRANSFoRMeR (AMpS)

208 220/230/240

60 60

6.0 5.7/5.5/5.3

10.0 9.1

380 416

60 60

4.0 3.7

5.3 4.8

440/460/480 550/575/600

60 60

3.5/3.3/3.2 2.8/2.7/2.6

4.6 3.6

2300 4000/4160

60 60

— —

0.9 0.5

220 346

50 50

5.7 3.7

9.1 5.8

380/400/415 440

50 50

4.0/3.9/3.7 3.5

5.3 4.5

25. Starter line-side power wiring ampacity shall be calculated as follows: minimum circuit ampacity:

Ampacity = 1.25 (compressor motor amps) + oil pump motor amps + control power transformer amps.

Where 125% factor is per N.E.C. (para. 440-33); compressor-motor amps (see Note 8) are FLA; when the oil pump motor power (200 thru 600 volts only) supply is fed thru the starter (2M), per Note 15 (not shown on diagram), amps are per Note 22 – If another power supply (FDS1) is used or compressor motor voltage is 2300 to 4160 volts, enter zero; the control power transformer is furnished with the compressor-motor starter (2M), control power transformer amps are per Note 22.

26. Power factor correction capacitors, when uti-lized, must be sized to meet the N.E.C. and veri-fied through the local Johnson Controls. Improp-erly installed or sized capacitors may result in equipment malfunction of damage.

27. The branch circuit over-current protection device(s) for the 200 thru 600 volt starter (2M) must be a time delay with a minimum rating equal to the next standard fuse/breaker rating above the following amps:

Amps = 1.5 (compressor motor amps) + oil pump motor amps + control power transformer amps.

Where 150% factor is per U.L. Standard 465 (7th Edition); compressor-motor amps (see Note 8) are FLA; when the oil pump motor power supply is fed thru the starter 2M, per Note 15 (not shown on diagram), amps are per Note 22, if another pow-er supply (FDS1) is used, enter zero; the control power transformer is furnished with the compres-sor-motor/starter (2M), control power transformer amps are per Note 22.

Fusing and fuse size must be coordinated with starter manufacturer.

The use of circuit breakers with open transition starter is NOT recommended; this combination could result in nuisance tripout on starting.

Starter overload relay trip time is shown in para. 3.10 on Product Drawing Form 160.45-PA5.1.

JOHNSON CONTROLS 7


28. The short-circuit withstand capacity, as described in UL 508, in symetrical RMS current is listed in the following table for each of the field wiring kits:

MoDel optIoN KIt

KA RAtING(SYMetRICAl A,

RMS)480V MAX.

600A MAX.

SSS 7L

Lug 18 18250A Disconnect Switch 18 18400A Disconnect Switch 18 18

250A Circuit Breaker 65 22400A Circuit Breaker 65 22

SSS 14L

Lug 30 30400A Disconnect Switch 30 22600A Disconnect Switch 30 30

400A Circuit Breaker 65 22600A Circuit Breaker 65 35

SSS 26LLug 42 42

1200A Disconnect Switch 42 42960A Circuit Breaker 65 50

SSS 33LLug 42 42

1200A Circuit Breaker 65 50

29. Automatic control on the chilled water pump by the Control Center is shown. Chilled water pump motor starter (5M) holding coil to be furnished for 115V – 50/60 Hz. The power requirements for the water pump starter (5M) must be a maximum of 2 Amps holding and 10 Amps inrush. If power requirements exceed this value, furnish coil for line voltage, and control relay with 115V coil.

For manual chilled water pump control, connect a manual start/stop switch as shown for the Hot Water Pump Motor in the Field Connections dia-gram.

30. Each 115VAC field-connected inductive load, i.e. relay coil, motor starter coil, etc. shall have a transient suppressor wired (by others) in parallel with its coil, physically located at the coil. Spare transient suppressors are factory supplied in a bag attached to the keypad cable clamp in the Control Center.

31. Three phase oil pump motor must be properly phased. L1, L2 and L3 corresponding to phase se-quence A, B and C.

32. The OptiView Control Center has a single output for condenser pump control. When using this con-trol output for heat recovery an additional control means is needed to select operation of tower wa-ter condenser pump or heating water condenser pump. The diagram depicts use of a 3 position se-lector switch which may be added near the chiller for such purposes. Alternatively, a BAS control scheme may be used to control operation of the two condenser water pumps.

33. For heat recovery applications, the heating con-denser is provided with a thermal type flow sen-sor. If an optional mechanical type flow switch is used instead, it is connected between terminal [1] on TB6 (lower right area of the panel) and termi-nal [1] of TB20 on the LTC I/O board in the upper right side of the control cabinet.

JOHNSON CONTROLS8


FIGuRe 1 - FIELD CONNECTIONS STANDARD COOLING APPLICATIONSLD12970a

WIRE # 14 AWG. COPPER

NOTE 14 AND 17

CHILLERCONTROL

CENTER FIELD WIRING TERMINAL

BLOCKS (TB4, TB2 AND TB6)

SEE NOTE 4

30

29

3011

23

#14 AWG.(NOTE 14)

WIRE # 14 AWG.COPPERNOTE 14

WIRE # 14 AWG.COPPERNOTE 14

FIelD CoNNeCtIoNS StANDARD CoolING ApplICAtIoNS

JOHNSON CONTROLS 9


WIRE#14 AWG.COPPERNOTE 14

NOTES 4 & 16

NOTE 18

WIRE#14 AWG.COPPERNOTE 14

CHILLERNOTES 13 & 20

NOTES 9 & 21

CPTNOTES7 & 14

2M ** NOTES 5, 6, 16 & 26

NOTES 25 & 26

NOTES 19, 22, & 27

NOTE 26NOTE 16

LD12971a

FIGuRe 1 - FIELD CONNECTIONS STANDARD COOLING APPLICATIONS (CONT'D)

FIelD CoNNeCtIoNS StANDARD CoolING ApplICAtIoNS (CoNt'D)

JOHNSON CONTROLS10


FIelD CoNNeCtIoNS heAt ReCoVeRY SuppleMeNt

WIRE # 14 AWG. COPPER

NOTE 14 AND 17

HEATING WATER PUMP

MOTOR

SELECTOR SWITCH OR CONTROL BOX

NOTE 32

HEATING CONDENSER

WATERFLOW

SWITCHNOTE 33

TB20

LTCI/O

BOARD

TO CHILLED WATER PUMP

CHILLERCONTROL

CENTER FIELD WIRING

TERMINAL BLOCKS

(TB20, TB2 AND TB6)

FDS6

6LL1

6LL2

6LL3

6T1

6T2

6T3

CONDENSER TOWER WATER PUMP MOTOR

OPTIVIEW CONTROL CENTER

HEATING PUMP

BOTH PUMP

TOWER PUMP

COOLING TOWER FAN MOTOR

1

SEE NOTE

30

SEE NOTE

11

FIGuRe 2 - FIELD CONNECTIONS HEAT RECOVERY SUPPLEMENT

Note: When a YK is ordered with a double bundle heat recovery option, an extra pump is needed for the hot water circuit.

LD15217a

JOHNSON CONTROLS 11


NoteS

P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USACopyright © by Johnson Controls 2012 www.johnsoncontrols.com ALL RIGHTS RESERVEDForm 160.75-PW1 (1012)Issue Date: October 16, 2012 Supersedes: 160.75-PW1 (311)

Supersedes: 160.75-PW1 (311) Form: 160.75-PW1...

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