Supercedes: 160.78-PW1 (913) Form 160.78-PW1 (615) WIRING DIAGRAMS CONTRACTOR ORDER NO. YORK CONTRACT NO. YORK ORDER NO. FIELD CONNECTIONS DIAGRAM FOR YMC 2 MODEL A CHILLER WITH M1 COMPRESSOR PURCHASER JOB NAME LOCATION ENGINEER REFERENCE DATE APPROVAL DATE CONSTRUCTION DATE JOB DATA: CHILLER MODEL NO. YMC 2 NO. OF UNITS MOTOR/VARIABLE SPEED DRIVE POWER: 460V, 60Hz; 380V, 60Hz; 415V, 50Hz or 400V, 50Hz Issue Date: June 18, 2015
IMPORTANT! READ BEFORE PROCEEDING! This equipment is a relatively complicated apparatus. During rigging, installation, operation, maintenance, or service, individuals may be exposed to certain components or conditions including, but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and both high and low voltage. Each of these items has the potential, if misused or handled improperly, to cause bodily injury or death. It is the obligation and responsibility of rigging, installation, and operating/service personnel to identify and recognize these inherent hazards, protect themselves, and proceed safely in completing their tasks. Failure to comply with any of these requirements could result in serious damage to the equipment and the property in GENERAL SAFETY GUIDELINES FORM 160.78-PW1 (615) which it is situated, as well as severe personal injury or death to themselves and people at the site. This document is intended for use by owner-authorized rigging, installation, and operating/service personnel. It is expected that these individuals possess independent training that will enable them to perform their assigned tasks properly and safely. It is essential that, prior to performing any task on this equipment, this individual shall have read and understood the on-product labels, this document and any referenced materials. This individual shall also be familiar with and comply with all applicable industry and governmental standards and regulations pertaining to the task in question. SAFETY SYMBOLS The following symbols are used in this document to alert the reader to areas of potential hazard: DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. CAUTION identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution. Usually an instruction will be given, together with a brief explanation. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. NOTE is used to highlight additional information which may be helpful to you. External wiring, unless specified as an optional connection in the manufacturer s product line, is NOT to be connected inside the equipments cabinet. Devices such as relays, switches, transducers and controls may NOT be installed inside the equipments panel. NO external wiring is allowed to be run through the panel. All wiring must be in accordance with YORK/ Johnson Controls published specifications and must be performed ONLY by qualified YORK/ Johnson Controls personnel. Johnson Controls will not be responsible for damages/problems resulting from improper connections to the controls or application of improper control signals. Failure to follow this will void the manufacturer s warranty and cause serious damage to property or injury to persons. 2
FORM 160.78-PW1 (615) CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls policy for continuous product improvement, the information contained in this document is subject to change without notice. Johnson Controls makes no commitment to update or provide current information automatically to the manual or product owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson Controls Service office or accessing the Johnson Controls QuickLIT website at http://cgproducts. johnsoncontrols.com. It is the responsibility of rigging, lifting, and operating/ service personnel to verify the applicability of these documents to the equipment. If there is any question regarding the applicability of these documents, rigging, lifting, and operating/service personnel should verify whether the equipment has been modified and if current literature is available from the owner of the equipment prior to performing any work on the chiller. CHANGE BARS Revisions made to this document are indicated with a line along the left or right hand column in the area the revision was made. These revisions are to technical information and any other changes in spelling, grammar or formatting are not included. TABLE OF CONTENTS FIGURE 1 VARIABLE SPEED DRIVE (490A)...8 FIGURE 2 VARIABLE SPEED DRIVE (744A)...9 FIGURE 3 FIELD CONNECTIONS...10 3
NOTES: 1. All field wiring shall be done in accordance with the NEC codes listed within this manual. NEC articles and paragraphs cited are for reference only and may not be current NEC code. 2. Variable Speed Drive (VSD) shall be grounded in accor dance with the 2008 N.E.C. (Paragraph 250-118) for equipment grounding. Flexible conduit is required for final connection to the VSD. A separate grounding conductor is required, it must be a copper conductor only and sized per the N.E.C. (Table 250-122). Per the 2008 N.E.C. (Paragraph 250-122(f)), where multiple (parallel) con duits are used each must contain a grounding conductor. See TABLE 1 for grounding lug wire range. 3. Wiring, electrical conduit, junction boxes, fused disconnect switches (FDS), or circuit breakers, starters (M), pushbutton stations (PB), manual-off-automatic switch (S), flow switch (FLS), and control relays furnished by others unless otherwise specified. 4. Items marked * furnished by Johnson Controls. 5. Items marked ** available from Johnson Controls at additional cost. 6. Control power supply 115V - 50/60 Hz, 2.0 KVA capacity for control center only, is supplied by (1)-2.0 KVA control power transformers (1T) mounted Inside the VSD, they are factory wired. 7. A removable cover plate with pilot knockouts is supplied for connection of power supply conduits. VSD power conduit connection removable cover plate (cut holes to suit) locations per FIGURE 1. Flexible conduit must be used for final connections to VSD. Multiple conduits shall contain an equal number of wires from each phase in each conduit to prevent overheating per the 2008 N.E.C. (Paragraph 300-20(a)). Use copper conductors only; DO NOT USE aluminum conductors. See TABLE 1 for factory furnished VSD terminal lug wire ranges and conduit connection provisions. 8. The following terminal lugs are factory furnished for field wiring supply connections. All lugs are rated AL9CU. 9. Condenser water pump motor starter (3M) holding coil to be furnished for 115V - 50/60 Hz. The power require ments for the water pump starter (3M) must be a max. of 1 Amp holding and 10 Amps inrush. If power requirements exceed this value, furnish coil for line voltage, and control relay with 115V coil (see Note 20). VARIABLE SPEED DRIVE (490A) FORM 160.78-PW1 (615) 10. Automatic control of 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 1 Amp holding and 8 Amps inrush. If power requirements exceed this value, furnish coil for line voltage, and control relay with 115V coil (see Note 20). The pumps operate during com pressor operation & during cycling shutdown. For manual chilled water pump control, connect a manual start/stop switch as shown in the Field Connections diagram for 115VAC coils only. Table 1 - CONDUIT DETAILS Input Voltage/ Frequency Chiller Motor Code M1 Max. No. of Conduits (2) 3 in. 11. Units shipped knocked down require field connection of harnesses to control center, power wiring between compressor motor and VSD. These harnesses and power wiring are furnished by Johnson Controls for field assembly and consist of proper lengths of flexible conduit with necessary con nectors, and contain the wires (shown in Note 12) prop erly terminated and marked. 12. Wire #14 AWG copper for one way distance of less than 175 feet. Wire #12 AWG copper for one way distance of more than 175 feet, but less than 300 feet. 13. Wiring diagram for YORK control center and Field Control Modifications Form 160.78-PW2. 15.The branch circuit overcurrent protection device for the YORK VSD must be a time delay type with a rating which is the standard fuse/circuit breaker size required to pro tect the field supply wiring conductors per the N.E.C. 16. The YORK Variable Speed Drive power supply wiring ampacity shall be calculated as follows. Model YMC 2 minimum circuit ampacity: Ampacity = 1.25 (Job FLA) Where 125% factor per 2008 N.E.C. (Para. 440-33). Table 3 - LUG DETAILS Option Circuit Breaker Disconnect 4 Input Voltage/ Frequency Line Side Lugs BBL Per Terminal Wire Range Grounding Lug Wire Range, Qty. 2 2/0-350 mcm #14-2/0, 2 bbl 2 2/0-350 mcm #14-2/0, 2 bbl
FORM 160.78-PW1 (615) VARIABLE SPEED DRIVE (490A) 17. The VSD is equipped with a U.L. Listed rotary disconnect switch or optional circuit breaker. In both cases, fast acting semiconductor fuses, downstream of the disconnecting device, to provide additional protection to the VSD. Ground fault is employed on both circuit breaker and disconnect switch models via the VSD logic control board using a hall effect current sensor one per phase. Ground fault protection is also provided as part of the circuit breaker protection. 18.The minimum value of line impedance shall be determined by the case in which the VSD is fed from a transformer whose kva rating is equal to 5 times rated power of the VSD. The transformer shall be specified to have 3% impedance. The supply voltage, at VSD input terminals, during start-up must be maintained above 391 volts for 440V/460V/480V 60 Hz units, above 323 volts for 380V/400V 50/60 Hz units, above 353 volts for 415V 50 Hz units. The following Table provides allowable supply voltage range during normal operation. Table 2 - VOLTAGE RANGES Input Voltage Voltage Range 380/400V 50/60 Hz 342-423 415V 50 Hz 374-456 440/460V 60 Hz 414-508 Maximum value of line impedance will be determined by the case in which the VSD is fed from a transformer whose kva rating is equal to the rated power of the VSD. The transformer will be specified to have 7% impedance. The VSD will comply with IEEE Std. 519-1992 section 10.3. 20. Each 115VAC field-connected inductive load, i.e. relay coil, motor starter coil, etc. will have a transient suppressor wired (by others) in parallel with its coil, physically located at the coil. Spare transient suppressors are factory sup plied in a bag attached to the keypad cable clamp in the OptiView Control Center. 21. All switches and circuit breakers used as switches will be located so they may be operated from a readily accessible place. They will be installed per 2008 N.E.C. (Para. 404.8).Switches and circuit breakers installed adjacent (close-coupled) to motors, appliances, or other equipment that they supply shall be permitted to be located higher than 6'-7" (2m) and to be accessible by portable means per 2008 N.E.C. (Para. 404.8 Exception No. 2). 19.Maximum line voltage imbalance (calculated as the difference between any of the three line voltages and the average of the three line voltages, and multiplied by 100%) will be 5%. Maximum line voltage total harmonic distortion (THD) will be 5% per phase (from n=2nd to n=50th harmonic) when line impedance is specified as follows: Minimum value of line impedance will be determined by the case in which the VSD is fed from a transformer whose kva rating is equal to 5 times the rated power of the VSD. The transformer will be specified to have 3% impedance. 5
NOTES: 1. All field wiring shall be done in accordance with the NEC codes listed within this manual. NEC articles and paragraphs cited are for reference only and may not be current NEC code. 2. Variable Speed Drive (VSD) shall be grounded in accor dance with the 2008 N.E.C. (Paragraph 250-118) for equipment grounding. Flexible conduit is required for final connection to the VSD. A separate grounding conductor is required, it must be a copper conductor only and sized per the N.E.C. (Table 250-122). Per the 2008 N.E.C. (Paragraph 250-122(f)), where multiple (parallel) con duits are used each must contain a grounding conductor. See TABLE 4 for grounding lug wire range. 3. Wiring, electrical conduit, junction boxes, fused disconnect switches (FDS), or circuit breakers, starters (M), pushbutton stations (PB), manual-off-automatic switch (S), flow switch (FLS), and control relays furnished by others unless otherwise specified. 4. Items marked * furnished by Johnson Controls. 5. Items marked ** available from Johnson Controls at additional cost. 6. Control power supply 115V - 50/60 Hz, 4.0 KVA capacity for control center only, is supplied by (2)-2.0 KVA control power transformers (1T)/(2T) mounted outside the VSD, they are factory wired. 7. A removable cover plate with pilot knockouts is supplied for connection of power supply conduits. VSD power conduit connection removable cover plate (cut holes to suit) locations per FIGURE 2. Flexible conduit must be used for final connections to VSD. Multiple conduits shall contain an equal number of wires from each phase in each conduit to prevent overheating per the 2008 N.E.C. (Paragraph 300-20(a)). Use copper conductors only; DO NOT USE aluminum conductors. See TABLE 4 for factory furnished VSD terminal lug wire ranges and conduit connection provisions. 8. The following terminal lugs are factory furnished for field wiring supply connections. All lugs are rated AL9CU. 9. Condenser water pump motor starter (3M) holding coil to be furnished for 115V - 50/60 Hz. The power require ments for the water pump starter (3M) must be a max. of 1 Amp holding and 10 Amps inrush. If power requirements exceed this value, furnish coil for line voltage, and control relay with 115V coil (see Note 20). VARIABLE SPEED DRIVE (744A) FORM 160.78-PW1 (615) 10. Automatic control of 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 1 Amp holding and 8 Amps inrush. If power requirements exceed this value, furnish coil for line voltage, and control relay with 115V coil (see Note 20). The pumps operate during com pressor operation & during cycling shutdown. For manual chilled water pump control, connect a manual start/stop switch as shown in the Field Connections diagram for 115VAC coils only. Table 5 - CONDUIT DETAILS Input Voltage/ Frequency Chiller Motor Code M1 Max. No. of Conduits (4) 3 in. 11. Units shipped knocked down require field connection of harnesses to control center, power wiring between compressor motor and VSD. These harnesses and power wiring are furnished by Johnson Controls for field assembly and consist of proper lengths of flexible conduit with necessary con nectors, and contain the wires (shown in Note 12) prop erly terminated and marked. 12. Wire #14 AWG copper for one way distance of less than 175 feet. Wire #12 AWG copper for one way distance of more than 175 feet, but less than 300 feet. 13. Wiring diagram for YORK control center and Field Control Modifications Form 160.78-PW2. 15.The branch circuit overcurrent protection device for the YORK VSD must be a time delay type with a rating which is the standard fuse/circuit breaker size required to pro tect the field supply wiring conductors per the N.E.C. 16. The YORK Variable Speed Drive power supply wiring ampacity shall be calculated as follows. Model YMC 2 minimum circuit ampacity: Ampacity = 1.25 (Job FLA) Where 125% factor per 2008 N.E.C. (Para. 440-33). 17. The VSD is equipped with a U.L. Listed rotary discon- Table 4 - LUG DETAILS Option Circuit Breaker Disconnect 6 Input Voltage/ Frequency Line Side Lugs BBL Per Terminal Wire Range Grounding Lug Wire Range, Qty. 4 4/0-500 mcm #4-500 mcm, 4 bbl 4 #2-600 mcm #4-500 mcm, 4 bbl
VARIABLE SPEED DRIVE (744A) FORM 160.78-PW1 (615) nect switch or optional circuit breaker. In both cases, fast acting semiconductor fuses, downstream of the disconnecting device, to provide additional protection to the VSD. Ground fault is employed on both circuit breaker and disconnect switch models via the VSD logic control board using a hall effect current sensor one per phase. Ground fault protection is also as part of the circuit breaker protection. 18.The minimum value of line impedance shall be determined by the case in which the VSD is fed from a transformer whose kva rating is equal to 5 times rated power of the VSD. The transformer shall be specified to have 3% impedance. The supply voltage, at VSD input terminals, during start-up must be maintained above 391 volts for 440V/460V/480V 60 Hz units, above 323 volts for 380V/400V 50/60 Hz units, above 353 volts for 415V 50 Hz units. The following Table provides allowable supply voltage range during normal operation. Table 6 - VOLTAGE RANGES Input Voltage Voltage Range 380/400V 50/60 Hz 342-423 415V 50 Hz 374-456 440/460V 60 Hz 414-508 19.Maximum line voltage imbalance (calculated as the difference between any of the three line voltages and the average of the three line voltages, and multiplied by 100%) will be 5%. Maximum line voltage total harmonic distortion (THD) will be 5% per phase (from n=2nd to n=50th harmonic) when line impedance is specified as follows: Minimum value of line impedance will be determined by the case in which the VSD is fed from a transformer whose kva rating is equal to 5 times the rated power of the VSD. The transformer will be specified to have 3% impedance. Maximum value of line impedance will be determined by the case in which the VSD is fed from a transformer whose kva rating is equal to the rated power of the VSD. The transformer will be specified to have 7% impedance. The VSD will comply with IEEE Std. 519-1992 section 10.3. 20. Each 115VAC field-connected inductive load, i.e. relay coil, motor starter coil, etc. will have a transient suppressor wired (by others) in parallel with its coil, physically located at the coil. Spare transient suppressors are factory sup plied in a bag attached to the keypad cable clamp in the OptiView Control Center. 21. All switches and circuit breakers used as switches will be located so they may be operated from a readily accessible place. They will be installed per 2008 N.E.C. (Para. 404.8).Switches and circuit breakers installed adjacent (close-coupled) to motors, appliances, or other equipment that they supply shall be permitted to be located higher than 6'-7" (2m) and to be accessible by portable means per 2008 N.E.C. (Para. 404.8 Exception No. 2). 7
Input Voltage/ Frequency * Per U.L. Listing of VSD RMS Symmetrical Amperes VARIABLE SPEED DRIVE (490A) Chiller Motor Code VSD Circuit Breaker Rating @ 480VAC, 60 Hz or 400VAC, 50 Hz Trip Withstand Semiconductor Fuse Rating (Amps) @ 660 VAC FORM 160.78-PW1 (615) Ground Fault Trip M1 450A 100,000* 550A 40A TOP VIEW 25-1/4" (638mm) 26-3/8" (670mm) 24-1/4" (616mm) 9" (229mm) INPUT 4-1/2" (112mm) 1-1/8" (28.5mm) APPROX. OVERALL OF DOOR 21-1/2" (546mm) 55-1/4" (1403mm) APPROX. OVERALL OF DOOR 31" (787mm) FRONT VIEW 38-1/8" (968mm) CIRCUIT BREAKER (OPTIONAL) 15-1/8" (384mm) 14-1/4" (363mm) SEE NOTE 21 DISCONNECT SWITCH Figure 1 - VARIABLE SPEED DRIVE (490A) 8 LD14634
Input Voltage/ Frequency * Per U.L. Listing of VSD RMS Symmetrical Amperes VARIABLE SPEED DRIVE (744A) Chiller Motor Code VSD Circuit Breaker Rating @ 480VAC, 60 Hz or 400VAC, 50 Hz Trip Withstand Semiconductor Fuse Rating (Amps) @ 660 VAC FORM 160.78-PW1 (615) Ground Fault Trip M1 800A 100,000* 800A 80A TOP VIEW 26-3/8" (670mm) 25-1/4" (638mm) 24-1/4" (616mm) 16-1/4" (412mm) INPUT 8" (203) 1-1/8" (28.5mm) APPROX. OVERALL OF DOOR 25" (635mm) 61-1/4" (1555mm) APPROX. OVERALL OF DOOR 33-1/2" (851mm) FRONT VIEW 51" (1295mm) CIRCUIT BREAKER (OPTIONAL) 18-3/8" (466mm) 14-1/8" (466mm) SEE NOTE 21 DISCONNECT SWITCH Figure 2 - VARIABLE SPEED DRIVE (744A) LD14634 9
FORM 160.78-PW1 (615) FIELD CONNECTIONS FIELD SUPPLIED FDS5 FDS3 5M SEE NOTE 21 3M OFF S AUTO MAN SEE NOTE 20 5T1 5T2 5T3 SUPR 5LL1 5LL2 5LL3 3LL1 3LL2 3LL3 3T1 3T2 3T3 SUPR NOTE 9 SEE NOTE 21 CHILLED WATER PUMP MOTOR WIRE # 14 AWG COPPER NOTES 11 & 18 CONDENSER WATER PUMP MOTOR WIRE # 14 AWG COPPER NOTE 11 TB4* 1 95 18211131 9113 12 120191 8 7 1 TB2* 44 45 55 56 26 27 42 43 40 41 150 151 1 1 2 2 OPTIVIEW CONTROL CENTER * GRD. SCREWS* Figure 3 - FIELD CONNECTIONS 10 LD14566
FORM 160.78-PW1 (615) FIELD CONNECTIONS (CONT'D) FIELD SUPPLIED POWER SUPPLY (NOTE 19) L1 L2 L3 VOLT PHASE 3 HERTZ FDS4 FDS2** NOTES 5 & 15 4LL1 4LL2 4LL3 4M 4T1 4T2 4T3 2LL1 2LL2 2LL3 COOLING TOWER FAN MOTOR NOTE 7, 16 COPPER CONDUCTORS ONLY DO NOT USE ALUMINUM CONDUCTORS. TB2* 152 153 154 155 156 157 164 36 35 TB6* 5 3 4 1516242553 1 11 1LL L 222 2 GRD L1 NOTES 2 & 8 L2 L3 NOTE 8 1 1 2 2 1T* 2M YORK VSD CHILLER MOTOR WIRE #14 AWG COPPER, NOTE 11 OPTIVIEW CONTROL CENTER * NOTES 4 & 6 T1 T2 T3 T2* T1* T3* FIGURE 3 FIELD CONNECTIONS (CONT'D) COMPRESSOR MOTOR* LD14567 11
P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA Copyright by Johnson Controls 2015 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 160.78-PW1 (615) Issue Date: June 18, 2015 Supercedes: 160.78-PW1 (913)