;5 MILLENNIUM

ROTARY SCREW LIQUID CHILLERS

035L02377-GB0 TM

MILLENNIUM CONTROL CENTER OPERATION

STYLE C REFRIGERANTS : R22, R134a

Effective from 01/98

YORK INTERNATIONAL

GB

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TABLE OF CONTENTS
Section 1. Introduction & Physical Description 1.1 1.2 1.3 General System Architecture System Components 3 4 4 Page Section 7. Mode Keys & Compressor Switch 7.1 7.2 7.3 Program Mode Operating Modes Compressor Switch 18 18 19 Page

2. Basic Operation 2.1 2.2 2.3 Startup Normal Running and Cycling Shutdown 9 9 10

8. Programming the Control Center 8.1 8.2 8.3 8.4 General Chilled Liquid Temperature Setpoints Current Limit Setpoint Pull-down Demand Setpoint Internal Clock Setting Daily Operating Schedule Holiday Day Schedule Remote Reset Temperature Range Data Logging Setup 20 20 21 21 21 21 22 22 22

3. Display Keys 8.5 3.1 3.2 General Display Key Messages 11 8.6 11 8.7 4. Entry Keys 4.1 4.2 General Key Functions 13 13 9. Status Key and Status Displays 5. Setpoints Keys 5.1 5.2 General Setpoints Key Messages 14 14 9.1 9.2 9.3 9.4 6. Service Keys 9.5 6.1 6.2 6.3 6.4 6.5 General Slide Valve Keys Warning Reset Key Display Data Key History Print Key 16 16 17 17 17 10. Micro Board Program Jumpers 28 Startup/Rundown Status Messages 27 General System Run Status Messages System Run Warning Messages Shutdown Status Messages 23 23 24 25 8.8 8.9

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1. INTRODUCTION & PHYSICAL DESCRIPTION

1.1 GENERAL The York Millennium Control Center is a microprocessor based control system for the YS range of screw compressor liquid chillers. The primary function of the control system is to adjust compressor slide valve position to controls the leaving chilled liquid temperature. The control system can also use slide valve control to limit drive motor current if required. User interface is via a colour coded keypad and a 40 character alphanumeric display allowing access to operating and programmed data. Information can be displayed in Metric or Imperial units. For clarity this manual uses Metric units only. Conversion tables are provided at the back of this manual. The following information can be accessed via the display : Chilled liquid temperatures leaving and return Condenser liquid temperatures leaving and return (customer option; field installed) Refrigerant pressures evaporator and condenser Saturation temperatures - evaporator and condenser Compressor discharge temperature Oil temperature Oil pressure Input to compressor Input to oil filter 3

Oil filter differential Differential oil (oil pressure evap pressure) 3-phase motor current & 3-phase power line voltage (with solid state starter only) Fault history data Motor current in % of full load amps Slide valve position in % of maximum travel Operating hours and compressor starts counter The system setpoints are operator entered via the keypad. These setpoints can also be displayed on the 40 character display. The system setpoints are: Leaving chilled liquid temperature % Current limit Chiller full load amps (with solid state starter only) Pull-down demand limit Clock (day, time, calendar date) Daily schedule (7 day time-clock programming) with provision for special holiday schedule Remote leaving chilled water temperature reset range Data logger auto interval and start time The cause of all system shutdowns (safety or cycling) is preserved (until the system is reset or restarts) in the on board memory for subsequent viewing on the keypad display. The operator is continually advised of system operating conditions by various background and warning

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messages. The keypad contains special service keys for use by the service technician when performing system troubleshooting. External interface is available for control of the chiller via a York ISN system. In addition, customer connections are provided for remote control of the following control system functions:

signals are converted to 0/+5VDC logic level signals for use by the Micro Board. The output of the Digital Input Board is interfaced directly to the Micro Board. The Relay Output Board interfaces the Micro Board outputs with the rest of the system. The logic level outputs of the Micro Board energize or de-energize DC relays on the relay output board. The contacts of these relays energize or de-energize the system 115VAC solenoids and relays. The remote status customer contacts are also located on this board. The Power Supply Board supplies DC power to all circuit boards. AC power arrives at the power supply board via a 115VAC to 24VAC step-down transformer. The Compressor Motor Starter |nterface circuits are mounted on an auxiliary internal panel in front of the Micro Board and allow the Center to monitor and control motor current as well as to monitor any starter faults. Two systems are available for connection: a Starter Logic Board for connection to the YORK Solid State Starter or a CM-2 Starter Module for connection to a Remote Electro-Mechanical Starter. The Starter Logic Board performs compressor motor overload and power fault protection in addition to solid state starter control functions. The logic board also provides 3 phase power line voltage and compressor motor current values to the Micro Board for low line voltage and current imbalance protection and front panel display. The CM-2 module performs compressor motor overload and power fault protection. The module also provides motor current values to the Micro Board, which can be displayed as percentage of full load current.

_ Remote Start _ Remote Stop _ Remote LCWT Setpoint _ _ _ _

(Pulse Width Modulated signal) Remote Current Limit Setpoint (Pulse Width Modulated signal) A Remote Mode Ready to Start Status Contacts Safety Shutdown Status Contacts Cycling Shutdown Status Contacts

In addition to the standard remote control features, an optional card file with plug-in interface cards is available. These cards allow remote chilled liquid temperature setpoint offset and/or remote current limit setpoint interface using 4-20mA, 0-10 VDC, or contact closure signals rather than pulse width modulated signals. A main switch is provided to locally start or stop the chiller and to reset the control system after a manual reset shutdown by the safety controls.

1.2 SYSTEM ARCHITECTURE The Micro Board contains the microprocessor and supporting digital logic and analog circuits. All system operating decisions are made on this board; such as when to open or close the slide valve, when to operate the oil line solenoid, when to shutdown on safety shutdowns, etc. All inputs and outputs connected to the Micro Board operate on +5VDC. The 115VAC input and output signals are connected to the Micro Board via the Digital Input Board and the Relay Output Board respectively System pressures and temperatures are sensed by transducers and thermistors respectively. The transducer and thermistor inputs are connected directly to the Micro Board and are multiplexed to allow sharing of a single analog to digital converter. The input values are compared to stored safety threshold values and, if exceeded, the Micro Board initiates a chiller shutdown. The Digital Input Board accepts 115VAC inputs from system relays and external devices such as chilled water pump interlocks, local/remote cycling devices, EMS, separator oil level switch, etc. These 0/115VAC input 4

1.3 SYSTEM COMPONENTS MICRO BOARD The Micro Board contains the microprocessor, external RAM for scratchpad memory, and an external EPROM storing the operating program. Operator entered system setpoints are stored in RAM in the Real Time Clock (RTC) chip where it is battery backed up. The RTC also stores and updates the time-of-day, day-of-week, and calendar date. System analog parameters (Pressures, Temperatures, and Motor Current) are input to the multiplexer (MUX) circuit then transmitted serially to the analog to digital converter where they are converted to digital signals. The Micro Board compares these values to stored safety thresholds and initiates a chiller shutdown if thresholds

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Micro Board

Card File & EMS/BAS Interface Cards (Optional)

Relay Output Board

Power Supply Board

Digital Input Board

Transformer

Fuses

Customer Connection Terminal Blocks PANEL LAYOUT

are exceeded. These parameters can be viewed on the display if requested by the operator, transmitted via the RS-232 serial port to printer, or transmitted via RS-485 serial port to a YORK energy management system. The Micro Board also uses these parameters for leaving chilled water temperature control, current limit control and high/low pressure limit control via slide valve movement. An undervoltage detection circuit monitors the + 5VDC unregulated input from the power supply and compares this to a reference voltage. If the input voltage drops below the reference voltage threshold, the Micro Board initiates a chiller shutdown. The Micro Board will prevent a chiller restar t until the operator moves the COMPRESSOR switch to the STOP-RESET position and then to the START position. A watchdog circuit ensures that the complete program is executed every program cycle, preventing the program from looping in a subroutine and ignoring critical chiller 5

parameters. During each program cycle (approx. 100ms) a pulse is sent to the watchdog circuit starting a 2-second timer. If the watchdog circuit does not receive another pulse before the 2 seconds have elapsed a reset pulse is sent to the Micro Board. The Micro Board will then shut down the chiller, reinitialize the program and automatically restart the chiller. The Real Time Clock (RTC) chip stores and updates the time-of-day, day-of-week and calendar date. Any time the chiller shuts down on a safety or cycling shutdown, the Day and Time of shutdown is displayed along with the cause of shutdown. This Time information is also used to determine correct chiller start and stop times when the user programmable scheduler is used to automatically start and stop the chiller. The RTC chip contains a non-replaceable battery which powers the RTC RAM in the event of an AC power failure. All of the keypad programmable setpoints are stored in the RTC RAM. The life of this battery is 5-10 years. During each program cycle, the condition of the battery

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is monitored and if a low battery condition is detected a warning is displayed that the chip must be replaced. POWER SUPPLY BOARD The power supply board provides the necessary operating voltages for all the circuit boards in the Microcomputer Control Center. Two switching regulators supply +12VDC and +10VDC to the Relay Output Board and Micro Board respectively. The 10VDC output is further regulated to + 5VDC for use by the vacuum fluorescent display. A voltage regulator supplies + 24VDC to the optional card file for use by the remote LCWT setpoint card and remote current limit setpoint card.

The power supply board also contains a Display Reset Circuit which outputs a reset signal to the Vacuum Fluorescent Display during low voltage conditions, preventing Latch-up conditions. This causes the display to go blank whenever the +5VDC regulated power supply output to the display drops below +4.7VDC. A step-down transformer (external to the power supply board) provides 24VAC to a bridge rectifier, the unregulated output (approx. 30VDC) of which is supplied to the Solid State Starter logic board or CM-2 module. These boards have their own on-board power supplies which supply the required voltages for these boards.

RS-485 Connection

RS-232 Connection

Real Time Clock (RTC) Chip EPROM

MICRO BOARD LAYOUT

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(Display)

KEYPAD AND DISPLAY LAYOUT

DIGITAL INPUT BOARD The Digital Input Board converts 115VAC signals to +5VDC logic level signals for use by the Micro Board. When a digital input device closes, the 115VAC input is applied to a full wave rectifier. This unfiltered DC signal is then applied to an opto-coupler which switches on to allow + 5VDC to be dropped across the output resistor. A customer connection terminal strip on the Digital Input Board is used interfacing external signals (remote stop/start, remote cycling devices, etc.). The terminals are grouped together (according to function) with a 115VAC power source (terminal 1). The power source supplies voltage for externally located relay contacts, such as the flow switch which, when its contacts close, apply 115VAC to the revelent input terminal causing the Digital Input Board output to transition from OVDC to + 5VDC. The output will remain at + 5VDC as long as the flow switch is closed. For each terminal group, a 115VAC input signal causes a + 5VDC output level on the corresponding board output. A OVAC input causes a OVDC output. All outputs interface to the micro board via ribbon cable.

mounted relays each have one side of their relay coil connected to +12VDC regulated power supply. The other side of each coil is connected to the Micro Board which drives the appropriate connection to ground potential when it wants to energize a selected relay. A +12VDC level causes the output relay to de-energize. The normally open relay contacts are interfaced, via internal and customer terminal blocks to various external relays and solenoids. The internal connections are used for controlling the system start relay, system stop relay, some system safeties, system solenoids and the slide valve. The water temperature control circuits that control the slide valve are located on the Micro Board. These circuits control two triacs located on the relay output board; one to load the slide valve and one to unload the slide valve. The triacs are then interfaced to the load and unload slide valve solenoids. The external customer connections are used for field interface of system status contact closures, and chilled water pump contacts.

KEYPAD & DISPLAY RELAY OUTPUT BOARD The Relay Output Board allows the Micro Board to be interfaced to 115VAC output signals. The ten board7 The Control Center front panel layout consists of a 40 character display, a number of groups of keys and a rotary compressor switch as follows :

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Display - The 40 character, vacuum fluorescent, dot matrix display is used to view all messages, parameters, set points, and data. Status Key - This key is used to access background status, warning and fault messages about the chiller. Display Keys - These keys provide a direct read out of each monitored parameter on the alphanumeric display. Entry Keys - These keys are used to enter the values for the operator programmed setpoints. Setpoints Keys - These keys are used to view each setpoint, in any MODE, or to select the individual setpoints that are programmed by the operator in Program MODE. Service Keys - These keys are provided for use in some service operations and for trouble shooting by qualified service personnel. Access Code / Program / Mode Keys - These keys allow access to program the Control Center Setpoints and the control system operating modes. Compressor Switch - This 3-position rotary switch is used to start (except in remote mode), stop and reset the system.

SOLID STATE STARTER LOGIC BOARD If the Microcomputer Control Center is to be used with a solid state starter, a Solid State Starter Logic Board is fitted, mounted on a hinged panel inside the Control Center. This module provides compressor motor current Overload and Power Fault protection as well as 3-phase current and voltage information to the Micro Board. CM-2 CURRENT MODULE If the Microcomputer Control Center is to be used with an electromechanical starter, a CM-2 current module is fitted, mounted on a hinged panel inside the Control Center. This module provides compressor motor current Overload and Power Fault protection. The 100% FLA motor current signal is calibrated on this board and multiplexed to the Micro Board for use in current limit control and display purposes. Three CTs mounted in the motor terminal box provide 3 phase motor current signals to a diode bridge mounted on the hinged panel adjacent to the CM-2 module. The bridge rectifies the signal and applies it to two parallel variable resistors, also mounted on the hinged panel. The resistors are adjusted to provide a 1VDC signal to the CM-2 module when the compressor motor is at 100% FLA. On the CM-2 module, this signal is applied to a power fault detector circuit.

CM-2 Current Module

Diode Bridge Solid State Starter Logic Board STARTER INTERFACE PANELS 8

Variable Resistors

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2. BASIC OPERATION
2.1 STARTUP The chiller is permitted to start only if there are no Safety or Cycling shutdown conditions in effect and the slide valve position is less than 10 % open (30% if hot gas bypass is fitted - program jumper JP4 removed). When these conditions are met the following message is displayed on the 40 character display at the keypad:
SYSTEM READY TO START

2.2 NORMAL RUNNING AND CYCLING After the chiller has been running for 3 minutes, and providing all operating parameters are within programmed limits the following message is displayed:
SYSTEM RUN - LEAVING TEMP. CONTROL

As required, a 1 second load or unload signal is applied at 10 second intervals to maintain the leaving chilled water temperature to the programmed setpoint. Each chiller is fitted with a solenoid valve in parallel with the main fixed refrigerant flow control orifice. This solenoid valve is used to create a variable orifice which is opened and closed while the chiller is running in order of the following priorities : a) If discharge superheat falls below 8.3C (R22), 5.5C (R134a) the solenoid valve is closed until the superheat rises to more than 11.1C (R22), 8.3C (R134a). b) If evaporator pressure falls below a preprogrammed limit the solenoid valve opens until the pressure rises by approximately 80kPa. c) If the differential between condenser pressure and evaporator pressure falls below a preprogrammed setpoint, the solenoid valve is opened until the differential rises to more than 690kPa above setpoint. If the chiller is fitted with hot-gas bypass unloading, after the chiller has been running 3 minutes, the hot gas valve is opened and closed based on the difference between the entering chilled liquid temperature and the leaving chilled liquid temperature setpoint. The differential at which it is opened and closed is determined by preprogrammed setpoints within the range of 0.5C to 5.5C opening and 1.1C to 8.3C closing. The chiller can operate in three cooling modes: water cooling, glycol (brine) cooling and ice storage. These modes operate as follows :

When the compressor switch is moved to the Start position, a 30 second start sequence is initiated and the following is displayed :
SYSTEM START SEQUENCE INITIATED

The oil line solenoid valve (S0-S3 chillers only) is energized (opened) for 15 seconds then closed. Also for the first 15 second period, a pressure transducer auto-zeroing sequence is performed. The output of the oil pressure transducer is compared to the output of the evaporator transducer. In an equalised system these transducers are sensing the same pressure and should give the same reading. The Control Center identifies any difference between the measurements and adds or subtracts this, as required, from the differential value while the system is running. This same auto-zeroing is performed between the oil pressure transducer and the filter oil pressure transducer. After 25 seconds monitoring of the chilled liquid flow switch flow switch begins. At the completion of the 30 second start sequence, the oil line solenoid valve (S0-S3 chillers only) is energized, the start signal is sent to the motor starter, and the following message is displayed :
SYSTEM RUN

At this time, to ensure development of oil pressure, a continuous load signal is applied to the slide valve until it achieves a position of 25%. For the first 3 minutes of running this slide valve position is maintained by applying a load signal if the valve position drops to 22% until a the 25% position is again reached. Only Current Limit function, Low and High Pressure Limit functions and manual slide valve operation in Service Mode can cause the slide valve to drop below 22% during the first 3 minutes of chiller operation. After 3 minutes a programmable pull-down demand function is available to allow the maximum motor current to be limited for a specific period from compressor startup. When programmed, this limit takes priority over the Current Limit Setpoint, allowing different settings to apply to pull-down and to normal running. 9

Water Cooling Mode In this mode the leaving chilled liquid temperature setpoint can be programmed within the range 3.3C to 21.1C. If the leaving chilled liquid temperature falls more than 2.2C below the setpoint, a cycling shutdown is initiated and the following message is displayed:
DAY-TIME - LOW WATER TEMPERATURE - AUTOSTART

The chiller automatically restarts when the temperature rises to a programmable value between 0C and 5.5C above the setpoint. If the setpoint is increased with the chiller running, the shutdown threshold becomes 3.3C for 10 minutes. This prevents shut down when the setpoint is increased.

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Glycol Cooling Mode Operation in glycol cooling mode is similar to that in water cooling mode except that the leaving chilled liquid temperature setpoint is programmable in the range -6.7C to 21.1C. If the setpoint is increased with the chiller running in glycol mode, the shutdown threshold remains at its previous programmed value for the next 10 minutes. Ice Storage Mode Ice storage mode is an operating mode within the glycol cooling mode which allows the chiller to make ice at the fastest possible rate by inhibiting unload outputs to the slide valve. This causes the chiller to load until it shuts down on low leaving temperature at 2.2C below the setpoint. No unload outputs are applied to the slide valve unless the motor current exceeds the programmed current limit setpoint threshold. In ice storage mode, ice storage operation is automatically selected when the leaving chilled liquid temperature setpoint of 0C or lower is programmed. Normal glycol cooling operation will resume when a setpoint of more than 0C is programmed. The chiller can be switched between the two modes locally, or remotely by use of the leaving chilled liquid temperature setpoint offset function.

The temperature offset above setpoint at which the chiller will automatically restar t can be independently programmed between 0C and 5.5C for both glycol and ice storage modes. 2.3 SHUTDOWN If the chiller shuts down on a cycling shutdown, it will automatically restart when the condition that caused the shutdown no longer exists. Safety shutdowns require the operator to perform a manual reset at the keypad before restart is allowed. The event that caused the shutdown is either displayed automatically or can be viewed when the STATUS key is pressed. Any time the chiller shuts down, for any reason, it cannot be restarted for 2 minutes. During this period the following message is displayed:
2.0 MIN LOCKOUT DELAY

The chiller can be shutdown manually at any time by turning the compressor switch to the STOP position.

OVERALL START-UP AND SHUTDOWN SEQUENCE 10

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3. DISPLAY KEYS

3.1 GENERAL The Display keys give direct access to commonly required data about the operation of the chiller. This is particularly useful during commissioning, monitoring of the operation of the chiller, and for trouble shooting. The Display keys are operated as follows : Press and release the appropriate key the message will be displayed for 2 seconds. Press and hold the appropriate key the message will be displayed and updated every 0.5 seconds until the key is released. Press and release appropriate key, then press and release the Display Hold key in the Entry Keys section of the keypad the message will be displayed and updated every 2 seconds until the Display Hold key is again pressed and released, or 10 minutes have elapsed, whichever comes first. An indicator light in the corner of the Display Hold key shows when the function is operating.

of the example displays Xs are used to represent the numeric value being displayed. If Xs actually appear on the display it means the measured or calculated value is outside the display limits for that parameter.

Chilled Liquid Temps Key When the Chilled Liquid Temps key is pressed leaving and returning chilled liquid temperatures are displayed as follows :
CHILLED LEAVING = XX.X 0 C, RETURN = XX.X 0 C

Display limits are: Leaving : Return :

minimum -17.8C maximum 27.3C minimum -17.7C maximum 33.9C

Refrigerant Pressures Key When the Refrigerant Pressures key is pressed evaporator and condenser refrigerant pressure are displayed as follows :
EVAP = 428 KPA, COND = 1455 KPA

3.2 DISPLAY KEY MESSAGES Below, examples are given of the messages displayed when each of the nine Display Keys are pressed. In each 11

Display limits are: Evaporator : minimum maximum Condenser : minimum maximum

340 kPa 888 kPa 407 kPa 2172 kPa

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Oil / Filter Pressures Key When the Oil / Filter Pressures key is pressed overall oil differential pressure and oil filter differential pressure are displayed as follows :
DIFF OIL = XXX KPA; DIFF FLTR = XXX KPA

Overall oil differential pressure is taken as the oil pressure at the input to the compressor less the evaporator pressure. Differential filter pressure is taken as the oil pressure at the inlet to the oil filter less the oil pressure at the inlet to the compressor. Display limits are: Both Values :

Print Key If an optional printer is connected, this key is used to initiate a print of operating data. If the compressor switch is in the RUN position and the compressor is running, the time, date and system operating and setpoint data will be printed for the instant the Print key is pressed. If the compressor is not running the time, date and data will be for the last time the compressor was running. If the compressor switch is in the STOP position, printout is inhibited. When the Print key is pressed the following message is displayed :
PRINT ENABLE

minimum 407 kPa maximum 2172 kPa

If a printer is not connected, further presses of the key will make no change to the message. % Motor Amps / % Slide Valve Key When the %Motor Amps / % Slide Valve key is pressed Motor Current as a percentage of full load current and Slide Valve Position as a percentage of fully loaded are displayed as follows:
MOTOR CURRENT = XXX %FLA; SLIDE VALVE = % XXX

Options Key This key is not used.

SSS Motor Current / Volts Key For chillers fitted with a York Solid State Starter, this key can be pressed to display 3-phase compressor motor current and 3-phase solid state starter input line voltage. The information is presented as two separate messages which are displayed alternately when the key is pressed continuously. Alternatively, if the Display Hold Key is used, the messages will be swapped each time the SSS Motor Current / Volts Key is pressed. The messages are as follows :
A AMPS = XXXX; B AMPS = XXXX; C AMPS = XXXX V A-B = XXXX; V B-C = XXXX; V C-A = XXXX

The motor current displayed is the highest of the three line currents.

Operating Hours / Starts Counter Key When the Operating Hours / Start Counter key is pressed total operating hours and total number of compressor starts is displayed as follows:
ACCUMULATED RUN TIME = XXXX HOURS; START COUNTER = XXXX

If the chiller is not fitted with a York Solid State Starter, the following message is displayed when this key is pressed :
SOLID STATE STARTER NOT INSTALLED

Display limits are: Both Values : maximum 65535 (counter resets when maximum is reached)

Condenser Liquid Temps Key If the optional condenser water temperature sensors are fitted, when the Condenser Liquid Temps key is pressed leaving and returning condenser water temperatures are displayed as follows :
COND LEAVING = XX.X 0 C, RETURN = XX.X 0C

If the condenser water temperature sensors are not fitted, or both values are out of range, the display will go blank when this key is pressed. Display limits are: Both Values :

minimum -13.1C maximum 45.8C 12

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4. ENTRY KEYS

4.1

GENERAL

The Entry keys allow the user to change numerical values programmed in as chiller setpoints, cutouts, clock, etc.

4.2

KEY FUNCTIONS

Numeric Keys The Numerical keypad provides number keys plus an asterisk key to designate holidays when programming Daily Schedule holiday days. AM / PM Key The AM / PM key allows the user to change AM / PM while programming the time and date. This key is also used when setting the stop start timers for the Daily Schedule / Holiday feature. Enter Key The Enter key must be pushed after any change is made to setpoints, cutouts, or system clock. Pressing this key tells the micro to accept new values into memory. If this is not done, the new values entered will be lost and the original values will be returned. The Enter key is also used to scroll through available data when using the Program, Operating Data, History, or Set Schedule/Holiday keys. 13

Cancel Key The Cancel key is used during programming for correcting errors or returning to preprogrammed default values. Generally when the Cancel key is pressed, the cursor returns to the first programmable character in the display message, allowing the operator to begin reprogramming. Any values already keyed in will be erased and the original or default values will appear. In other instances the display will remain the same and the only reaction will be the cursor returning to the first character. Display Hold Key The Display Hold key can be used to maintain individual messages on the display. The display will be updated every 2 seconds until the Display Hold key is again pressed and released or 10 minutes have elapsed, whichever comes first. An indicator light in the corner of the Display Hold key shows when the function is operating. Advance Day / Scroll The Advance Day key is used to select the correct day of the week when programming the Time, Date, and Daily Schedule and also to scroll through available options when programming the chiller operating modes.

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5. SETPOINTS KEYS

5.1 GENERAL The Setpoints keys are used to access the operating setup of the chiller. The keys can be used by themselves to view the current setting for each item, or they can be used in conjunction with the Entry keys and the Access Code / Program keys to change the programmed settings. This allows access for changing the chiller setup to be limited to authorised personnel only. This section describes the use of the Setpoints keys to view the programmed settings. See Sections 4, 7 and 8 for use of Entry keys, Access Code / Program keys and Setpoints keys to change the settings. The Setpoints keys are operated as follows : Press and release the appropriate key the message will be displayed for 2 seconds. Press and hold the appropriate key the message will be displayed and updated every 0.5 seconds until the key is released. Press and release appropriate key, then press and release the Display Hold key in the Entry Keys section of the keypad the message will be displayed and updated every 2 seconds until the Display Hold key is again pressed and released or 10 minutes have 14

elapsed, whichever comes first. An indicator light in the corner of the Display Hold key shows when the function is operating.

5.2 SETPOINTS KEY MESSAGES Below, examples are given of the messages displayed when each of the eight Setpoints keys are pressed. In each of the example displays Xs are used to represent the numeric value being displayed. If Xs actually appear on the display it means the measured or calculated value is outside the display limits for that parameter.

Chilled Liquid Temps Key When the Chilled Liquid Temps key is pressed the current operating value of the leaving chilled liquid temperature setpoint, is displayed. Also displayed is the differential above the setpoint at which the chiller will restart after a cycling shutdown on low leaving temperature. In water or glycol cooling modes the displayed message is as follows :
LEAVING SETP = XX.X 0C RESTART = +XX 0 C

In ice storage mode the displayed message is as follows:

ICE LEAVING SETP = -XX.X 0C RESTART = +XX 0C

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In Local operating mode the display shows the locally programmed setpoint. In Remote operating mode the display shows the setpoint set by the BAS/EMS system attached to the chiller.

If the Daily Schedule key is pressed and released then the Display Hold key is pressed and released the displays will scroll continuously until the Display Hold is pressed again or 10 minutes has elapsed, whichever is sooner.

% Current Limit Key When the %Current Limit key is pressed the programmed value for maximum allowable running current is displayed as a percentage of full load current, and the value of the motor full load current in Amps as follows :
CURRENT LIMIT = XXX %FLA; MTR CUR = 000 FLA

Holiday Key When the Holiday key is pressed the days of the week programmed to use the Holiday start and stop times, rather than the standard start and stop times, are displayed as follows :
S_ M* T* W_ T_ F_ S_ HOLIDAY NOTED BY *

If a York Solid State Starter is not fitted, only the current limit value is given as follows:
CURRENT LIMIT = XXX %FLA

Holiday days indicated apply to the current week only and are cancelled at the end of the week.

Pull Down Demand Key When the Pull Down Demand key is pressed three values are displayed: the programmed time in minutes from startup that the pull down limit is applied for; the programmed maximum allowable running current as a percentage of full load current during this time; and the remaining time before the limit is removed. The values are displayed as follows :
SETPOINT = XXX MIN @ XX %FLA XXX MIN LEFT

Remote Reset Temp Range Key When the Remote Reset Temp Range key is pressed the programmed maximum allowable value for remote offset of the chilled liquid leaving temperature setpoint is displayed as follows :
REMOTE RESET TEMP RANGE = XX 0 C

Clock Key When the Clock key is pressed the current day-of-theweek, time-of-day and calendar date (Month-Day-Year) are displayed as follows :
TUESDAY 10 : 35 AM 8 / 22 / 98

Data Logger Key When the Data Logger key is pressed, the target printer designation, data logging start time, data logging interval, and remaining time until next data log are displayed as follows :
WTO - STRT = 5 : 00 AM INT = 3.0 HRS. 1.5 HRS. LFT

If the clock is not programmed the display reads :

SUNDAY 12 : 00 AM 1 / 1/ 90

Daily Schedule Key When the Daily Schedule key is pressed, and held, the programmed daily start and stop times for the chiller and the programmed holiday day start and stop times are displayed in sequence as follows :
SUN MON TUE WED THU FRI SAT HOL START = 08 : 30 AM START = 05 : 00 AM START = 05 : 00 AM START = 05 : 00 AM START = 05 : 00 AM START = 05 : 00 AM START = 05 : 00 AM START = 11 : 00 AM STOP = 04 : 30 PM STOP = 07 : 00 PM STOP = 07 : 00 PM STOP = 07 : 00 PM STOP = 07 : 00 PM STOP = 04 : 30 PM STOP = 04 : 30 PM STOP = 03 : 00 PM

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6. SERVICE KEYS

6.1 GENERAL The Service keys are provided to assist in routine maintenance or when troubleshooting the system. The Slide Valve keys and Warning Reset key can only be used in Service Operating Mode (see Section 8). The Display Data and History Print keys can be used in all operating modes.

Unload Key Press and release this key to unload the compressor slide valve. The following messages are displayed if the chiller is running or not running, respectively :
SYSTEM RUN - SLIDE VALVE UNLOADING SYSTEM READY TO START - SLIDE VALVE UNLOADING

The compressor slide valve will continue to unload until the Load, Hold or Auto key is pressed and released.

6.2 SLIDE VALVE KEYS Load Key Press and release this key to load the compressor slide valve. The following messages are displayed if the chiller is running or not running, respectively :
SYSTEM RUN - SLIDE VALVE LOADING SYSTEM READY TO START - SLIDE VALVE LOADING

Hold Key Press and release this key to hold the compressor slide valve at its current position. The following messages are displayed if the chiller is running or not running, respectively :
SYSTEM RUN - SLIDE VALVE HOLDING SYSTEM READY TO START - SLIDE VALVE HOLDING

The compressor slide valve will continue to load until the Unload, Hold or Auto key is pressed and released.

The compressor slide valve will continue to hold until the Load, Unload or Auto key is pressed and released.

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6.

Auto Key Press and release this key to put the compressor slide valve under leaving chilled water temperature control except when overridden by motor current limit controls. The following message is displayed when chiller is running and the slide valve is stationary:
SYSTEM RUN - AUTO SLIDE VALVE

6.5 HISTORY PRINT KEY History data for up to four cycling or safety shutdowns is stored in memory. If an optional printer is connected, the History Print key is used to initiate a print of this data. When the key is pressed the following message is displayed :
HISTORY PRINT ENABLE

While the slide valve is loading or unloading the following messages are displayed respectively :
SYSTEM RUN - SLIDE VALVE LOADING SYSTEM RUN - SLIDE VALVE UNLOADING

If there have been no cycling or safety shutdowns the following message is displayed :
INVALID HISTORY DATA WILL NOT BE PRINTED

The Control Center operates in Auto slide valve control in all modes other than Service Mode.

If there have been from one to four shutdowns, history data for all the shutdowns will be printed. If there have been more than four shutdowns, only data for the most recent four will be printed.

6.3 WARNING RESET KEY The Warning Reset key is pressed and released to reset any warning or status messages, unless the condition still exists. To reset a cycling or warning message, place the Control Center in service mode and press Warning Reset key. To reset any safety shutdown message, press Warning Reset key in service mode with the compressor switch in the Stop/Reset position.

6.4 DISPLAY DATA KEY The Display Data key is used to display certain system operating parameters that are relevant to troubleshooting the chiller system. Press and hold the display data key to sequentially scroll displays of the evaporator and condenser refrigerant saturation temperatures, the discharge gas and oil temperatures, and the compressor inlet and filter inlet oil pressures as follows :
SAT TEMPS EVAP = XX.X 0C, COND = XX.X 0 C DISCHARGE TEMP = XX.X 0 C, OIL TEMP = XX.X 0C OIL = XXXX KPA: FILTER = XXX KPA

Each message will appear for 2 seconds. To hold each of the messages, press and release the Display Data key, then press and release the Display Hold key. the first message will be displayed and updated every 2 seconds. When the Display Data key is again pressed and released the second message is then displayed and updated every 2 seconds. This can then be repeated to view the third message and then the first message again and so on. When the Display Hold key is pressed and released display data messages are removed from the display.

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7. MODE KEYS & COMPRESSOR SWITCH

7.1 PROGRAM MODE Program mode allows the operator to program the Setpoints parameters, and change operating modes. To enter Program Mode proceed as follows : Press the Access Code key to display the following message:
ENTER VALID ACCESS CODE __ __ __ __

Access is now granted to adjust the operating setpoints using the Setpoints keys, or to change the Chiller operating mode using the Mode key. Access to the Program key can be terminated by again pressing the Access Code key. The following message will be displayed:
ACCESS TO PROGRAM MODE DISABLED

In the Entry keys section, press the digit keys 9 6 7 5 then press the Enter key. As each digit is pressed, the characters Y O R K are displayed (if other digits are used, the characters Y O R K are still displayed). If incorrect digits are entered the following message appears for a few seconds:
INVALID ACCESS CODE

If access is not terminated manually, it is automatically disabled after 10 minutes have elapsed, after which the operator must again enter the valid access code.

7.2 OPERATING MODES The Chiller can be operated in three different operating modes as follows: Local Local is the normal operating mode. The compressor can be started and stopped from the Control Center where the Display and Setpoints parameters can also be displayed. Remote In this mode, the Control Center will accept control signals from a remote device (i.e., Energy Management System) or cycling inputs. The control signal inputs are :

The display then returns to the code entry message and further attempts can be made. If the correct digits are entered the following message is displayed:
ACCESS TO PROGRAM KEY AUTHORIZED

Now press the Program key to display the following message :

PROGRAM MODE, SELECT SETPOINT

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7.

Remote Start Remote Stop Remote LCWT Setpoint Remove Current Limit Setpoint

operating mode - see Section 8.2. To start the chiller locally, turn the Compressor Switch to the Start position then release it. The switch will spring-return to Run position and the compressor start sequence will be initiated. Run Position During normal operation the Compressor Switch should be in the Run position. This will allow the compressor to run whenever the automatic controls require, or to restart automatically after a cycling shutdown. Stop/Reset Position The chiller can be stopped locally, regardless of operating mode, by turning the Compressor Switch to the Stop/Reset position. Once in this position, the chiller can only be started, locally or remotely, by locally turning the switch back to the Run position. In this way the switch operates as the chiller emergency stop device and cannot be overridden remotely. Following a safety shutdown (and identification and rectification of the problem) the operator is required to reset the Control Center prior to restarting the system. This is achieved by turning the Compressor Switch from Run to the Stop/Reset position, then back to the Run position.

Service Mode Service mode enables the Slide Valve control keys and the Warning Reset key in the Service keys Section of the keypad - see Section 7.

Viewing the Operating Mode To determine which operating mode the Control Center is presently in, press the Mode key. One of the following messages will appear to indicate the current operating mode :
LOCAL OPERATING MODE IN EFFECT REMOTE OPERATING MODE IN EFFECT SERVICE OPERATING MODE IN EFFECT

Changing the Operating Mode To change the operating mode enter Program Mode as described in Section 8.1. Instead of selecting a setpoint to change, press the Mode key to display the mode currently selected. One of the following messages will be displayed:
LOCAL MODE SELECTED REMOTE MODE SELECTED SERVICE MODE SELECTED

To change the selected mode press the Advance Day key in the Entry keys section of the keypad to scroll through the available modes. When the desired mode is shown, press the Enter key. The display will then revert to the Program Mode message. Program Mode may then be terminated manually by pressing the Access Code key.

7.3 COMPRESSOR SWITCH The Compressor Switch is used to locally control the run status of the compressor, and to reset the Control Center after a safety shutdown. This switch functions as the local chiller emergency stop device. Start Position The chiller must receive a start signal to begin operation after a manual stop signal or a safety shutdown. This can be achieved locally only if the chiller is in Local 19

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8. PROGRAMMING THE MILLENNIUM CONTROL CENTER

8.1 GENERAL The Control Center setpoints can be entered or changed at any time. This can be done even if the chiller is running, although in some cases the change may not take effect immediately due to internal timers. Before entering or changing the system setpoints, it is necessary to select Program Mode so that the following message is displayed (see Section 7.1) :
PROGRAM MODE, SELECT SETPOINT

Use the Entry keys to program the required chilled liquid leaving temperature setpoint then press the Enter key. The programmable range for the setpoint is: Water Cooling applications 3.3C to 21.1C Glycol Cooling applications -6.7C to 21.1C (Ice Storage applications -6.7C to 0C) The default setting for chilled leaving liquid temperature setpoint is 7.2C. The Control Center will only accept setpoint values below 3.3C (for Glycol or Ice Storage applications) when program jumper JP3 on the microprocessor board has been removed. Restart Offset Press the Advance Day/Scroll key to display the following message:
LWT RESTART OFFSET = X.X 0 C

When entering a setpoint, all digits must be entered. Use leading zero(s) and/or a zero after the decimal place if these digits are not required. The Enter key must be pressed after any new or changed value has been keyed in. The new value is only accepted by the Control Center when the Enter key is pressed. Advancing to the next message or leaving Program Mode without pressing the Enter key will cause the new value to be ignored and the old value to remain as the setpoint. If at any time an entered value falls outside the programmable range, the following message will be displayed for 2 seconds:
OUT OF RANGE - TRY AGAIN !

The restart offset is the number of degrees above the setpoint at which the chiller will automatically restart after a cycling shutdown on low leaving temperature. Use the Entry keys to program the required restart offset then press the Enter key. The programmable range for the offset is 0C to 5.5C. The default value is 0C. For Water Cooling applications, programming of the leaving temperature setpoint and offset is now complete and Program Mode can be terminated or another setpoint selected. If Glycol or Ice Storage application is selected (program jumper JP3 removed) press the Advance Day/Scroll key again to display the following message:
ICE STORAGE MODE ? 0 ( YES=1; NO=0 )

followed by the above Program Mode message. If a mistake is made while entering a value, or the default setting is required, press the Cancel key and then the Enter key. The display will revert to the default value for that setpoint and the cursor will return to the first changeable digit.

8.2 CHILLED LIQUID TEMPERATURE SETPOINTS To program the chilled liquid leaving temperature setpoint and restart offset select Program Mode then press the Chilled Liquid Temps key. Leaving Temperature Setpoint When the key is pressed, the following message will be displayed:
LEAVING SETPOINT = XX.X 0 C (BASE)

Using the Entry keys, enter 0 for standard Glycol Cooling or enter 1 for Glycol Cooling with Ice Storage function (below 0C), then press the Enter key. In Ice Storage mode the restart offset can be set independently for operation in Ice Storage (below 0C) and standard Glycol Cooling (above 0C). To set the Ice Storage mode offset press the Advance Day/Scroll key again to display the following message:
ICE STORAGE LWT RESTART OFFSET = X.X 0C

(BASE) advises that this value is the base setpoint for the chiller. A remote leaving chilled liquid temperature setpoint offset signal from a BAS/EMS will offset upwards from this value. 20

Use the Entry keys to program the required restart offset then press the Enter key. The programmable range for the offset is 0C to 5.5C. The default value is 0C.

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Programming of the leaving temperature setpoint and offset is now complete and Program Mode can be terminated or another setpoint selected. 8.3 CURRENT LIMIT SETPOINT To program the current limit setpoint select Program Mode then press the % Current Limit key. One of the following message will be displayed: Solid State Starter fitted:
CURRENT LIMIT = XXX %FLA; MTR CUR = _ _ _ FLA

down Demand Limit value then the Minimum Allowable %FLA has priority.
8.5 INTERNAL CLOCK SETTING To program the Control Center internal clock and 7 day calendar, check that the microprocessor board program jumper J57 is in the CLKON position, then select Program Mode and press the Clock key to display the following message:
TODAY IS SUN 12 : 00 AM 1 / 1 / 90

Electromechanical Starter fitted:

CURRENT LIMIT = XXX %FLA

Use the Entry keys to program the required current limit value as a percentage of full load current, then press the Enter key. The programmable range for this setpoint is 40% to 100% FLA. The default value is 100%. The MTR CUR = ___FLA message on Solid State Starter applications displays the full load current value in amps for the compressor drive motor. This value is factory set and is not user programmable. Programming of the current limit setpoint is now complete and Program Mode can be terminated or another setpoint selected.

To set the correct date and time proceed as follows: 1. Press the Advance Day/Scroll key until the correct day of the week appears. 2. Use the Entry keys to program the time of day. 3. Press the AM/PM key to change AM to PM or vice versa. 4. Use the Entry keys to program the date in the order Month-Day-Year (if the month or day are a single digit a leading zero should be used, eg. 01/02/98). 5. Press the Enter key. Programming of the internal clock is now complete and Program Mode can be terminated or another setpoint selected. 8.6 DAILY OPERATING SCHEDULE To program the chiller daily operating schedule select Program Mode then press the Daily Schedule key to display the following message:
DAY START = XX : XX AM STOP = XX : XX AM

Note : a preprogrammed limit, the Minimum Allowable %FLA, determines the lowest allowable motor current permitted after the chiller has been running for 3 minutes. The chiller will not be allowed to unload below this limit. If the limit value is greater than the programmed Current Limit value then the Minimum Allowable %FLA has priority.
8.4 PULL-DOWN DEMAND SETPOINT To program the pull-down demand setpoint select Program Mode then press the Pull Down Limit key to display the following message:
SETPOINT = XXX MIN @ XXX %FLA XXX MIN LEFT

Us the Entry keys to program the required duration of the limit in minutes and the current limit value as a percentage of full load current, then press the Enter key. The programmable range for this setpoint is 1 to 255 minutes time duration and 100% to 40% FLA current limit. The default values are 00 minutes at 100 %FLA.

Note : a preprogrammed limit, the Minimum Allowable %FLA, determines the lowest allowable motor current permitted after the chiller has been running for 3 minutes. The chiller will not be allowed to unload below this limit. If the limit value is greater than the programmed Pull21

Programming an individual day To program the schedule for an individual day in the weekly schedule, or the holiday day schedule, proceed as follows: 1. Press the Advance Day/Scroll key until the required day of the week or HOL (holiday) appears. 2. To cancel the programmed schedule, press the Cancel key then go to step 6, otherwise continue at step 3. 3. Use the Entry keys to program the required start time. 4. Press the AM/PM key to change AM to PM or vice versa. If the required setting is already displayed, go straight to the next step - the cursor will automatically move to the stop time. 5. Use the Entry keys to program the required stop time. 6. Press the Enter key. Programming of the schedule is now complete and Program Mode can be terminated or another setpoint selected. Programming a full week To program the schedule for an entire week with a regular schedule for weekdays proceed as follows:

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1. Press the Advance Day/Scroll key until SUN (Sunday) appears. 2. Program the start and stop times for Sunday using steps 2 - 5 in Programming an individual day above (do not press the Enter key). 3. Press the Advance Day/Scroll key. 4. Program the start and stop times for Monday using steps 2 - 5 in Programming an individual day above (do not press the Enter key). 5. Press the Advance Day/Scroll key. The following message will now be displayed:
REPEAT MON. SCHEDULE MON-FRI ? YES = 1; NO = 2

8.8 REMOTE RESET TEMPERATURE RANGE The remote reset temperature range decides the maximum number of degrees by which the leaving chilled liquid temperature setpoint can be offset upwards by a remote reset signal. To program this limit, select Program Mode then press the Remote Reset Temperature Range key to display the following message:
REMOTE RESET RANGE ( 5.6 OR 11.1 ) = XX.X 0 C

6a.To program the same start and stop time for Monday to Friday, press 1, then press the Advance Day/ Scroll key to jump straight to Saturday. 6b.To program different start stop times for Monday to Friday, press 2, then press the Advance Day/Scroll key to advance to Tuesday. 7. Program the schedule for the remaining week days and the holiday day schedule. 8. Press the Enter key to store the schedule. Programming of the schedule is now complete and Program Mode can be terminated or another setpoint selected.

If either of the above ranges are desired, program the appropriate number using the Entry keys, then press the Enter key. Only use the number options given, remembering to use a leading zero for 5.6 0C (05.6). If neither of these ranges are required, press the Advance Day/Scroll key to display the following message:
REMOTE RESET RANGE ( 16.6 OR 22.2 ) = XX.X 0 C

Program the required number from the options given using the Entry keys then press the Enter key.

8.9 DATA LOGGING SETUP An automatic data logging function is available to produce regular printouts of operating data on an attached printer (available as an option). To program the data logging setup select Program Mode then press the Data Logger key to display the following message:
PRT START = 12 : 00 PM ; __.0 HRS ; PRT = WTO

Note : if only a start time is entered for a particular day, the compressor will not automatically stop until a scheduled stop time is encountered on a subsequent day.
The daily schedule can be overridden at any time using the Compressor switch. 8.7 HOLIDAY DAY SCHEDULE One or more days of the week can be designated to operate on the programmed Holiday day schedule (Section 8.6) as a one off event. After the designated day has past, the start / stop times will revert to the standard schedule. To designate days to operate on the Holiday day schedule select Program Mode then press the Holiday key to display the following message:
S_ M_ T_ W_ T_ F_ S_ HOLIDAY NOTED BY *

To program the logging setup proceed as follows : 1. If PRT does not equal WTO then press the Advance Day/Scroll key to scroll through the printer options until WTO appears. 2. Use the Entry keys and AM/PM key to program the required start time for the data logging. 3. Use the Entry keys to program the logging interval between 0.1 and 25.5 hours. 4. Press the Enter key to store the logging setup. Programming of the logging setup is now complete and Program Mode can be terminated or another setpoint selected.

Press the Advance Day/Scroll key to move the cursor to the day to be designated. Press the Asterisk (*) key to enter an asterisk beside the required day. Repeat this procedure for further days as necessary. On completion, press the Enter key to store the schedule. Program Mode can now be terminated or another setpoint selected. To remove the Holiday day designation asterisk from a specific day, repeat the procedure as above but press the Cancel key instead of the Asterisk key. Remember to finish by pressing the Enter key to store the schedule.

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9. STATUS KEY & STATUS MESSAGES

9.1 GENERAL The Millennium Control Center constantly monitors a wide range of functions and parameters while the chiller is in operation. The Control Center then uses numerous algorithms to keep the operating parameters within acceptable limits while maintaining the correct leaving chilled liquid temperature. Various types of status messages are displayed at the keypad display to inform the operator of the current operating status of the chiller. The messages are automatically displayed unless the operator is requesting other information via the keypad. Status messages fall into three general categories as follows: Status Messages - Chiller Running While the chiller is running System Run messages advise which condition is currently controlling the chiller load status as follows:
SYSTEM RUN -

If the shutdown was caused by a safety limit then the chiller must be reset at the Compressor Switch then given a new start signal before it can resume operation. If the chiller has been reset but a local or remote start signal has not yet been received, the following message is displayed:
SYSTEM READY TO START - PRESS STATUS

The reason for the shutdown or any warning messages can be displayed by pressing the Status key. These can be cleared from the display by entering Service Mode and pressing the Warning Reset key. They will be automatically cleared by initiating a compressor start. Status Messages - Startup & Shutdown Sequences During the short periods immediately before and after startup and shutdown, status messages are displayed giving information regarding the sequence. Backup Battery Condition Message In the event of a power failure, a battery in the real time clock chip (RTC - U16 on micro board) provides backup power to the memory to ensure programmed setpoints are retained. The following message indicates that the battery is defective and that the chip should be replaced:
REPLACE RTC, U16 - REPROGRAM SETPOINTS

MESSAGE

Background Warning messages advise of potential problems with the chiller. When a warning status exists the operator will be advised to press the Status key by the following message:
SYSTEM RUN - PRESS STATUS

The warning message will then be displayed:

WARNING :

MESSAGE

If there had been a power failure while this message is displayed, the setpoints will have been lost and must be reprogrammed. 9.2 SYSTEM RUN STATUS MESSAGES Leaving Chilled Liquid Temperature Control
SYSTEM RUN - LEAVING TEMP. CONTROL

If the Status key is pressed without being instructed to by the Press Status prompt, the following message is displayed:
NO MALFUNCTION DETECTED

Status Messages - Chiller Not Running When the chiller is idle and all conditions for commencement of operation are met the following message is displayed:
SYSTEM READY TO START

This message is displayed when the chiller is operating normally and the compressor slide valve is being controlled to maintain the correct leaving chilled liquid temperature. Low Load Limit Control
SYSTEM RUN - MINIMUM LOAD CONTROL

When the chiller has been running and then has shutdown again, System Shutdown messages advise the time and reason for the shutdown and also if the chiller will automatically restart when conditions allow:
DAY TIME - REASON FOR SHUTDOWN (AUTOSTART)

In general shutdowns are caused by cycling conditions such as low chilled liquid leaving temperature or daily start/stop schedule and restart will be automatic.

This message is displayed if after more than 3 minutes of operation the motor current drops to less than a minimum allowable limit. This limit is preprogrammed between 15% and 70% FLA, depending on application, and is used to avoid the possibility of separator oil loss due to excessively low load. While this message is displayed, a 1 second load signal is applied to the slide valve every 3 seconds until the motor current is greater than or equal to the programmed setpoint plus 2%. 23

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High Load Limit Control

SYSTEM RUN - LOAD LIMIT IN EFFECT

which is calculated as follows: Minimum Slide Valve Position (%) = (Cond. press - Evap. Press - 227) / 56.2 At this position the slide valve is inhibited from unloading. Below this position the slide valve load solenoid will be driven by 0.1 second pulses at 0.5 second intervals until the minimum slide valve position is reached. Service Mode Slide Valve Control
SYSTEM RUN - AUTO SLIDE VALVE SYSTEM RUN - SLIDE VALVE LOADING SYSTEM RUN - SLIDE VALVE HOLDING SYSTEM RUN - SLIDE VALVE UNLOADING

On some compressor / heat exchanger combinations, operating at extreme conditions, it is possible to overload the oil separator at high leaving chilled liquid temperatures. To prevent this some chillers are preprogrammed with a motor current limit between 60% and 100% FLA, depending on application, which is in effect until the leaving chilled liquid temperature is less than a second preprogrammed limit between 100C and 21.10C. High Motor Current Limit Control
SYSTEM RUN - CURRENT LIMIT IN EFFECT

This message is displayed when the chiller is running, and the motor current is equal-to or greater-than the operator programmed current limit value. When the motor current reaches 100% of this value, the slide valve is not permitted to load further. If the current continues to rise to 104% of this value, the slide valve will be unloaded just far enough to reduce the current to less than 104% of the operator programmed current limit. High Condenser Pressure Limit Control
SYSTEM RUN - HIGH PRESSURE LIMIT IN EFFECT

These messages are displayed when the chiller is operating in Service Mode and the slide valve position is being controlled by leaving chilled liquid temperature (Auto) or is being manually controlled - see Section 6.2. Low Superheat Limit Control
SYSTEM RUN - EXCESS CHARGE OVERRIDE

This message is displayed when the chiller is running and the condenser pressure rises to 1733kPa. The slide valve is inhibited from further loading to prevent system shutdown on high condenser pressure at 1862kPa. When the condenser pressure falls to 1724kPa the slide valve will again be permitted to load. Low Evaporator Pressure Limit Control
SYSTEM RUN - LOW PRESSURE LIMIT IN EFFECT

This message is displayed if after more than 3 minutes of operation the discharge gas superheat is less than or equal to 5.6C (R22); 2.8C (R134a). When this occurs the slide valve is inhibited from loading. If the condition exists continuously for more than 10 seconds, the slide valve unload solenoid will be driven with 0.5 second pulses at 3 second intervals until the discharge gas superheat is equal to or greater than 8.3C whereupon the following message is displayed:
SYSTEM RUN - PRESS STATUS

This message is displayed when the chiller is running and the evaporator pressure falls to 388kPa (R22); 186kPa (R134a). The slide valve is prevented from further loading to prevent shutdown on low- evaporator pressure at 374kPa (R22); 172kPa (R134a). When evaporator pressure rises to 397kPa (R22); 193kPa (R134a), the slide valve will again be permitted to load.

Pressing the status key produces the following message:

WARNING : EXCESS REFRIGERANT CHARGE

This message automatically clears when the condition clears. 9.3 SYSTEM RUN WARNING MESSAGES Certain fault conditions may occur while the chiller is running which cannot be corrected by adjusting the slide valve control, but do not require a safety shutdown of the chiller. In these cases a warning message is issued to advise the operator of the condition. The following message is displayed instructing the operator to press the Status key :
SYSTEM RUN - PRESS STATUS

Note: this limit control is not used when Micro Board program jumper JP3 is removed for low temperature glycol applications.
High Refrigerant Differential Pressure Limit Control
SYSTEM RUN - MIN. SLIDE VALVE OVERRIDE

This message is displayed if after more than 60 seconds of operation the condenser pressure exceeds the evaporator pressure by 227kPa or more, and the slide valve is at or below the minimum slide valve position 24

On pressing the key one of the following warnings will be displayed:

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WARNING : EXCESS REFRIGERANT CHARGE

MON 10 : 00 AM - FLOW SWITCH - AUTOSTART

See System Run - Low Superheat Limit Control (above).

WARNING : DIRTY OIL FILTER

This warning is displayed if the oil filter differential pressure exceeds 138kPa continuously for more than 5 seconds. This message automatically clears when the condition clears.
WARNING : HIGH OIL TEMPERATURE

The chiller is shut down because a chilled liquid flow switch has opened for more than 2 seconds. The flow switch is checked at 25 seconds into the compressor start sequence, and continuously thereafter.
MON 10 : 00 AM - SYSTEM CYCLING - AUTOSTART

A remote command (computer relay contact or manual switch) connected to the Remote/Local cycling input of the digital input board has shut down the chiller.
MON 10 : 00 AM - MULTI UNIT CYCLING - AUTOSTART

This warning is displayed when the oil temperature rises to 73.9C. This message automatically clears when the condition clears.
WARNING : COND TRANSDUCER ERROR

A Lead/Lag sequence control device connected to the Multi Unit cycling input of the digital input board has shut down the chiller.
MON 10 : 00 AM - LOW LINE VOLTAGE

This warning is displayed if the condenser pressure transducer indicates a pressure equal to or greater than 2138kPa continuously for more than 10 minutes. This message can be reset in service mode using the Warning Reset key.

(Solid State Starter Application Only) The chiller is shut down because the voltage in any phase of the line voltage has decreased to the undervoltage shut down threshold continuously for more than 20 seconds or at any time during the compressor start sequence.
MON 10 : 00 AM - HIGH LINE VOLTAGE

9.4 SHUTDOWN STATUS MESSAGES When the chiller is not running due to a cycling, safety or operator initiated shutdown the Control Center display will show the following message :
SYSTEM SHUTDOWN - PRESS STATUS

(Solid State Starter Applications Only) The chiller is shut down because the voltage in any phase of the line voltage has increased to the overvoltage shut down threshold continuously for more than 20 seconds or at any time during the compressor start sequence.

When the Status key is pressed a system shutdown message giving the time and reason for the last shutdown will be displayed for 2 seconds before returning to the Press Status message. The display can be held indefinitely by pressing display hold key while the shutdown message is showing. The time and day of the shutdown can have any value, but for the following example messages these will be taken as 10:00 am on Monday morning.

Note: The voltage setting for the chiller can be viewed by pressing the SSS Motor Current / Volts key in the Display Keys section of the Keypad while the Control Center is in Program Mode (see Section 7.1). The following message appears when the key is pressed:
SUPPLY VOLTAGE RANGE XXX

Shutdown and restart voltage levels for each voltage range are as follows:
LOW/HIGH LINE VOLTAGE TRIP/RESET VALUES COMPRESSOR LOW LINE VOLTAGE HIGH LINE VOLTAGE MOTOR OPERATING POINT OPERATING POINT VOLTAGE RANGE
380 (400) 415 SUPPLY VOLTAGE RANGE DISABLED
SHUTDOWN (ON FALL) RESTART (ON RISE) SHUTDOWN (ON RISE) RESTART (ON FALL)

Cycling Shutdown Messages Cycling shutdowns allow the chiller to automatically restart as soon as the reason for the shutdown clears:
MON 10 : 00 AM - LOW WATER TEMP - AUTOSTART

The chiller is shutdown on because the leaving chilled liquid temperature has dropped to 2.20C below the setpoint.
MON 10 : 00 AM - INTERNAL CLOCK - AUTOSTART

305 335 NONE

331 362 0

415 454 NONE

402 440 0

The operator programmed daily schedule has shut down the chiller. The chiller will automatically restart when the daily start schedule initiates a start. The schedule can be overridden by turning the Compressor Switch to the start position.

MON 10 : 00 AM - POWER FAULT - AUTOSTART

The chiller is shut down because the solid state starter, or electromechanical current module (CM-2) indicated a Power Fault. This is initiated if the motor controller contacts (CM-1) open and reclose in less than 3 seconds. 25

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MON 10 : 00 AM - AC UNDERVOLTAGE - AUTOSTART

MON 10 : 00 AM - LOW EVAP PRESSURE

The chiller is shut down because the chiller was operating in normal Leaving Temperature Control but the motor current was continuously less than 10%FLA for 25 seconds. This indicates that either an AC undervoltage condition has caused the start relay (1R) to de-energize, or a component has failed causing a loss of the start signal from the Control Center.
MON 10 : 00 AM - PROGRAM INITIATED RESET

The chiller is shut down because the evaporator pressure has dropped to 374kPa (R22); 172kPa (R134a). Restart is allowed when the pressure increases to 375kPa (R22); 173kPa (R134a) and the chiller is reset.
MON 10 : 00 AM - LOW EVAP PRESSURE - BRINE

The chiller is shut down because micro board did not receive a hardware-generated interrupt on schedule. This can be caused a hardware failure or electrical noise on micro board. The message indicates that the watchdog timer-circuit has reset the microprocessor and the software program has been initialized from the beginning.
MON 10 : 00 AM - MOTOR CONTROLLER - EXT. RESET

The chiller is shut down because the low evaporator pressure safety switch contacts have opened. On glycol (brine) applications a this separate low pressure switch is located external to the Control Center and has cutout settings appropriate to the application. Restart is allowed when the pressure rises above the switch reset setting and both the safety switch and the chiller are reset.
MON 10 : 00 AM - HIGH PRESSURE

The chiller is shut down because the solid state starter, or electromechanical current module (CM-2) indicated a fault. Restart occurs automatically for the following fault conditions: 1. Solid State Starter - power fault, 110F start inhibit, phase rotation/loss, out of lock. 2. Electromechanical Starter current module - power fault (see POWER FAULT - AUTOSTART). For other fault conditions the external device which caused the shutdown must be reset.
MON 10 : 00 AM - SLIDE VALVE ABOVE 10%

The chiller is shut down because condenser pressure has risen to 1862kPa and the high pressure safety control contacts (located on the condenser) have opened. Restart is allowed when pressure has dropped below the switch reset setting (1448kPa) and both the safety switch and the chiller are reset.
MON 10 : 00 AM - HIGH DISCHARGE TEMP

The chiller is shut down because the discharge temperature has reached 100C Restart is allowed when the temperature has fallen below 99.4C and the chiller is reset.
MON 10 : 00 AM - HIGH OIL TEMP

The chiller is shutdown and this message is displayed if one of the following occurs: 1. A chiller start was initiated but the slide valve position was greater than 10%. 2. The chiller was shut down by any stop signal but the slide valve did not return to a position of less than 10% within the 2 minute lockout period.

The chiller is shut down because the oil temperature has reached 76.7C Restart is allowed when the temperature has fallen below 76.1C and the chiller is reset.
MON 10 : 00 AM - LOW OIL PRESSURE

Note : if the micro board jumper JP4 is not connected (hot gas bypass fitted), this shutdown and message occurs at a slide valve position of 30%
REMOTE STOP

The chiller is shut down because the differential oil pressure (oil pressure at inlet to compressor - evaporator pressure) was less than 138 kPa when the chiller had been running for more than 3 minutes. Restart is allowed when the chiller is reset.
MON 10 : 00 AM - LOW SEPARATOR OIL LEVEL

The chiller is shut down because it is operating in Remote Mode and a remote device (typically an Energy Management System or Building Automation System) has commanded the chiller to shut down. Restart occurs on application of a separate start signal from the remote device.

The chiller is shut down because the separator oil level switch has opened continuously for more than 30 seconds, indicating a low oil level in the separator. Restart is allowed when the chiller is reset.
MON 10 : 00 AM - CLOGGED OIL FILTER

Safety Shutdown Messages Safety shutdowns require the operator to manually reset the chiller at the Compressor Switch after rectification of the fault - see Section 7.3.

The chiller is shut down because the oil filter differential pressure exceeded 172kPa continuously for more than 5 seconds. Restart is allowed when the chiller is reset.
MON 10 : 00 AM - OIL PRESSURE TRANSDUCER

The chiller is shut down because the transducer sensing oil pressure at the inlet to the compressor indicated 2069kPa or more. Restart will be allowed when the pressure has fallen below 2062kPa and the chiller is 26

035L02377-GB0 reset.
MON 10 : 00 AM - FAULTY OIL OR CONDENSER XDCR

9.

9.5

STARTUP/RUNDOWN STATUS MESSAGES

The chiller is shut down because the transducer sensing oil pressure at the inlet to the compressor indicated more than 138kPa above condenser pressure condenser pressure transducer reading for more than 10 minutes continuously. Restart is allowed when the chiller is reset.
MON 10 : 00 AM - EVAP TRANS OR PROBE ERROR

The following status messages are displayed for short periods immediately before or after chiller run periods:
START SEQUENCE INITIATED

The chiller is shut down because the evaporation saturation temperature (calculated from the evaporator pressure transducer reading) is more than 13.9C below or more than 1.4C above the leaving chilled liquid temperature for more than 10 minutes continuously. Restart is allowed when the chiller is reset.

Indicates the Control Center has received a local or remote start signal and has initiated the chiller start sequence. Message is displayed for 30 seconds while pressure transducers are auto-zeroed.
2.0 MINUTE LOCKOUT DELAY

Note : on low temperature glycol applications (micro board jumper JP3 out) this check is not performed at evaporator pressures below 341kPa. If hot gas bypass is also fitted (micro board jumpers JP3 and JP4 out) this check is not performed at all.
MON 10 : 00 AM - FAULTY DISCHARGE TEMP SENSOR

This message is displayed any time the chiller shuts down. It indicates that a 2 minute restart delay is in effect. While the delay is in effect, the message will indicate the time remaining in 0.1 minute steps. This delay allows system pressures to equalize so that the pressure transducers can be auto-zeroed during the start sequence. If the shutdown was caused by a safety limit then the chiller must be reset at the Compressor Switch then given a new start signal before it can resume operation. If the chiller has been reset but a local or remote start signal has not been received yet, the following message is displayed:
2.0 MINUTE LOCKOUT DELAY - PRESS STATUS

The chiller is shut down because the discharge temperature sensor reading is lower than -1.2C or is disconnected. Restart is allowed when the sensor reading is above -1.1C and chiller is reset.
MON 10 : 00 AM - AUX SAFETY SHUTDOWN

The reason for the shutdown or any warning messages can be displayed by pressing the Status key.
ANTI-RECYCLE, XX MIN LEFT

The system is shut down because an external auxiliary safety shutdown device, connected to digital input board, has initiated a system shutdown. This input is a general purpose input that can be used to indicate a user-defined safety shutdown. Restart is allowed when the external device and the chiller are reset.
MON 10 : 00 AM - STARTER MALFUNCTION DETECTED

The chiller may not restart more frequently than every 30 minutes. This message is displayed if the chiller is shut down at less than 30 minutes from startup and shows the time remaining on the anti-recycle timer. In normal operation, the chiller cannot be restarted until the timer reaches zero.

The chiller is shut down because the Control Center has detected a motor-current value greater than 15% FLA for more than 10 seconds while the compressor start signal is not energized. Restart is allowed when the chiller is reset.
MON 10 : 00 AM - MTR PHASE CURRENT UNBALANCE

(Solid State Starter Applications Only) The chiller is shut down because one of the motor line currents was more than 30% different from the average line current for more than 45 seconds (the current balance is only checked when the motor has been running for more than 45 seconds and the motor current is 80% FLA or greater). Restart is allowed when the chiller is reset.
MON 10 : 00 AM - POWER FAILURE

The chiller is shut down because there has been a power interruption or failure. Restart is allowed when power is restored and the chiller is reset. 27

10.

035L02377-GB0

10. MICRO BOARD JUMPERS

J57 J52

JP3 JP4 JP3 Link In Place : Chiller programmed for water cooling operating range.. Link Cut : Chiller programmed for low temperature glycol cooling range. Link In Place : Chillers with S1 to S5 compressors and without Hot Gas Bypass fitted. Link Cut : All chillers with S0 compressors, and chillers with S1 to S5 compressors and Hot Gas Bypass fitted J52 Jumper Fitted : System pressures and temperatures display in Imperial units (0F psig). Jumper Removed : System pressures and temperatures display in Metric units ( 0C, kPa ). Jumper in CLK ON position : Internal clock and 7 day calendar is operational (To start clock, place jumper in this position with power on to the Control Center) Jumper in CLK OFF position : Internal clock disabled to save increase life of memory backup batter y (backup operates in both jumper positions).

JP4

J57

28

035L02377-GB0 Temperature Conversion Chart Actual Temperatures

F 0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120 124 128 132 136 140 144 148 152 156 160 164 168 172 176 180 184 188 192 196 200 204 208 212 216 220 224 228 232 236 240 244 = C -17.8 -15.6 -13.3 -11.1 -8.9 -6.7 -4.4 -2.2 0.0 2.2 4.4 6.7 8.9 11.1 13.3 15.6 17.8 20.0 22.2 24.4 26.7 28.9 31.1 33.3 35.6 37.8 40.0 42.2 44.4 46.7 48.9 51.1 53.3 55.6 57.8 60.0 62.2 64.4 66.7 68.9 71.1 73.3 75.6 77.8 80.0 82.2 84.4 86.7 88.9 91.1 93.3 95.6 97.8 100.0 102.2 104.4 106.7 108.9 111.1 113.3 115.6 117.8 C -18 -16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 = F -0.4 3.2 6.8 10.4 14.0 17.6 21.2 24.8 28.4 32.0 35.6 39.2 42.8 46.4 50.0 53.6 57.2 60.8 64.4 68.0 71.6 75.2 78.8 82.4 86.0 89.6 93.2 96.8 100.4 104.0 107.6 111.2 114.8 118.4 122.0 125.6 129.2 132.8 136.4 140.0 143.6 147.2 150.8 154.4 158.0 161.6 165.2 168.8 172.4 176.0 179.6 183.2 186.8 190.4 194.0 197.6 201.2 204.8 208.4 212.0 215.6 219.2

Temperature Conversion Chart Differential Temperatures

F 0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 = C 0.0 2.2 4.4 6.7 8.9 11.1 13.3 15.6 17.8 20.0 22.2 24.4 26.7 28.9 31.1 33.3 C 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 = F 0.0 3.6 7.2 10.8 14.4 18.0 21.6 25.2 28.8 32.4 36.0 39.6 43.2 46.8 50.4 54.0

Pressure Conversion Chart Gauge or Differential

psi 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 = kPa 69 138 207 276 345 414 483 552 621 690 759 828 897 966 1034 1103 1172 1241 1310 1379 1448 1517 1586 1655 1724 1793 1862 1931 2000 2069 2138 2207 2276 2345 2414 2483 2552 2621 2690 2759 kPa 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 1700 1750 1800 1850 1900 1950 2000 2050 = psi 14.5 21.8 29.0 36.3 43.5 50.8 58.0 65.3 72.5 79.8 87.0 94.3 101.5 108.8 116.0 123.3 130.5 137.8 145.0 152.3 159.5 166.8 174.0 181.3 188.5 195.8 203.0 210.3 217.5 224.8 232.0 239.3 246.5 253.8 261.0 268.3 275.5 282.8 290.0 297.3

Europe
YORK INTERNATIONAL
32
Part No. 035L02377-GB0 (01/98)
Subject to change without notice. ALL RIGHTS RESERVED