WIRING DIAGRAMS VARIABLE SPEED DRIVE

WIRING DIAGRAMS

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

REFERENCE DATE ________ APPROVAL DATE ________ CONSTRUCTION DATE _______

Supersedes: 160.76-PW7 (818) Form: 160.76-PW7 (619)

FIELD CONNECTIONS MODEL YK CHILLERS (STYLE H)

WITH LOW VOLTAGE VARIABLE SPEED DRIVE

Issue Date: June 28, 2019

JOB DATA:

CHILLER MODEL NO. YK ________________________________________________________

NO. OF UNITS _____________

MOTOR/VARIABLE SPEED DRIVE POWER: 380, 460, OR 575 VOLTS, 3-PHASE, 60 HZ OR 400 OR 415 VOLTS, 3-PHASE, 50HZ

JOHNSON CONTROLS2

FORM 160.76-PW7 ISSUE DATE: 06/28/2019

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

IMPORTANT!READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

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

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

SAFETY SYMBOLSThe following symbols are used in this document to alert the reader to specific situations:

Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken.

Indicates a potentially hazardous situa-tion which will result in possible injuries or damage to equipment if proper care is not taken.

Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollu-tion if proper care is not taken or instruc-tions and are not followed.

Highlights additional information useful to the technician in completing the work being performed properly.

External wiring, unless specified as an optional connection in the manufacturer’s product line, is not to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls and any external wiring must not be installed inside the micro panel. All wiring must be in accor-dance with Johnson Controls’ published specifications and must be performed only by a qualified electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of improper control signals. Failure to follow this warn-ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3


CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for con-tinuous product improvement, the information con-tained in this document is subject to change without notice. Johnson Controls makes no commitment to update or provide current information automatically to the manual or product owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson Controls Service office or accessing the John-son 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, rig-ging, 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 BARSRevisions made to this document are indicated with a line along the left or right hand column in the area the revision was made. These revisions are to technical information and any other changes in spelling, gram-mar or formatting are not included.

MANUAL DESCRIPTION FORM NUMBER

Wiring Diagrams - Field Control Modifications 160.76-PW4

Wiring Diagrams - Model YK (Style H, Q3-Q7) with OptiView™ Control Center and SSS with Modbus, LVVSD with Modbus

160.76-PW6

Operation - Variable Speed Drive - TM Model 160.00-O1

Operation - Variable Speed Drive - VSD and LVD Model 160.00-O4

Operation - Variable Speed Drive - HYP Model 160.00-O10

ASSOCIATED LITERATURE

JOHNSON CONTROLS4


NOTES1. All field wiring must be in accordance with the

current edition of the National Electrical Code (NEC), as well as all other applicable codes and specifications.

2.

Proper grounding is required:

• Variable Speed Drive (VSD) must be grounded in accordance with the 2017 NEC (Paragraph 250.118).

• Ground wires must be copper only and sized per the NEC. Refer to Table 250.122.

• A separate grounding conductor must be run in each conduit or for each 3-phase bundle within a cable tray. See Figure 1 on page 5.

• Each ground wire must be connected directly between the supply transformer’s secondary ground and the VSD ground lug.

• Flexible conduit is required for final connection to the VSD for vibration isolation.

• Conduit is not an acceptable grounding means.

• See Table 2 on page 6 for VSD ground lug sizing.

3. Johnson Controls does not furnish wiring, elec-trical 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, unless otherwise specified.

4. Items marked * are furnished by Johnson Con-trols.

5. Items marked ** are available from Johnson Con-trols at additional cost.

6. Control power supply 115 V - 50/60 Hz, 2.0/3.0 kVA capacity for control center only, is supplied by a control power transformer(s) (1T)/(2T) mounted inside the VSD. It is factory wired.

7. Flexible conduit must be used for final connec-tions to VSD.

Multiple conduits must contain an equal number of wires from each phase in each conduit to prevent overheating per the 2017 NEC (Paragraph 300.20(a)). Use copper conductors only; DO NOT USE aluminum conductors.

See Table 2 on page 6 and Note 8 for factory furnished VSD terminal lug wire ranges and con-duit connection provisions.

8. A removable cover plate with pilot knockouts is supplied for connection of power supply conduits.

9. The condenser water pump motor starter (3M) holding coil is furnished for 115 V - 50/60 Hz. The power requirements for the water pump starter (3M) must be a maximum of 1 A holding and 10 A inrush. If power requirements exceed this value, furnish coil for line voltage, and control relay with 115 V coil. The control panel contains a set of dry contacts TB-2-150/151, which close coincident with the start of System run.

10. Units shipped knocked down require field con-nection of harnesses to control center, power wir-ing between compressor motor and VSD, and oil pump starter to VSD. These harnesses and power wiring are furnished by Johnson Controls for field assembly. They consist of proper lengths of flex-ible conduit with necessary connectors, and con-tain the wires (shown in Note 13) properly termi-nated and marked.

11. Wire #14 AWG copper for one way distance of less than 175 ft (53.34 m). Wire #12 AWG cop-per for one way distance of more than 175 ft (53.34 m), but less than 300 ft (91.44 m).

12. Refer to the following wiring diagrams for addi-tional information:

FORM DESCRIPTION160.76-PW6 YORK control center160.76-PW4 Field wiring modifications160.00-O1

YORK Variable Speed Drive160.00-O4160.00-O10

JOHNSON CONTROLS 5


TABLE 1 - POWER SUPPLY CONDUITS

INPUT VOLTAGE/FREQUENCY

OUTPUT VOLTAGE/FREQUENCY

CHILLER MOTOR CODE

NUMBER OF CONDUITS - MAX T

575 V/600 V/60 Hz 575 V/600 V/60 Hz CF-CR EF-ER

(2) 2 1/2 in.440 V/460 V/480 V/60 Hz 440 V/460 V/480 V/60 Hz CF-CN

EF-EN380 V/60 Hz 380 V/60 Hz EF-EK415 V/50 Hz 415 V/50 Hz 5EC-5EI

380 V/400 V/50 Hz 380 V/400 V/50 Hz 5CC-5CI 5EC-5EI

575 V/600 V/60 Hz 575 V/600 V/60 Hz CS-CV ES-EV

(2) 3 in.440 V/460 V/480 V/60 Hz 440 V/460 V/480 V/60 Hz CP-CT

EP-ET380 V/60 Hz 380 V/60 Hz EL-EP415 V/50 Hz 415 V/50 Hz 5EJ-5EM

380 V/400 V/50 Hz 380 V/400 V/50 Hz 5CJ-5CM 5EJ-5EM

440 V/460 V/480 V/60 Hz 440 V/460 V/480 V/60 Hz CU-CZ,CA,CB,DA,DB EU-EZ, EA, EB, FA, FB

(4) 3 in.380 V/60 Hz 380 V/60 Hz ER-EV

CW-CZ, CA

415 V/50 Hz 415 V/50 Hz 5CP-5CX 5EN-5EX

380 V/400 V/50 Hz 380 V/400 V/50 Hz 5CN-5CX,5DA 5EN-5EX, 5FA

440 V/460 V/480 V/60 Hz 575 V/60 Hz FB-FD(4) 4 in.

380 V/400 V/415 V/50 Hz 575 V/60 Hz FA-FB

LD27401

Each conduit shall contain a copper conductor of each phase and a copper ground wire.

Wire tray shall contain bundles of copper wire with one conductor per phase and a copper ground wire in each bundle.

Ground

ABC

Conduit

ConduitTransformer

Terminal Block

VSDTerminal

Block

Neutral (if applicable)

Ground Ground

Phase A*

Phase B*

Phase C*

*See Note 7.

C GA B

C GA B

C GA B

C GA B

FIGURE 1 - GROUNDING VSD

JOHNSON CONTROLS6


The following terminal lugs are factory furnished for field wiring supply connections. All lugs are rated AL-9CU.

TABLE 2 - TERMINAL LUGS

INPUT VOLTAGE/

FREQUENCY

OUTPUT VOLTAGE/

FREQUENCY

CHILLER MOTOR CODE AND VSD

CIRCUIT BREAKER RATING

LINE SIDE LUGS BBL

PER TERMINAL

WIRE RANGE

GROUNDING LUG WIRE RANGE,

QUANTITY

575 V/600 V/60 Hz 575 V/600 V/60 HzCF-CR EF-ER 400A

2 2/0-350 kcmil#6 AWG to 250 kcmil, two bbl

440 V/460 V/480 V/ 60 Hz

440 V/460 V/480 V/ 60 Hz

CF-CN EF-EN 400A

380 V/60 Hz 380 V/60 HzEF-EK 400A

415 V/50 Hz 415 V/50 Hz5EC-5EI

400A

380 V/400 V/50 Hz 380 V/400 V/50 Hz5CC-5CI 5EC-5EI

400A

575 V/600 V/60 Hz 575 V/600 V/60 HzCS-CV ES-EV 600A

2 3/0-500 kcmil#6 AWG to 250 kcmil, two bbl

440 V/460 V/480 V/ 60 Hz

440 V/460 V/480 V/ 60 Hz

CP-CT EP-ET 600A

380 V/60 Hz 380 V/60 HzEL-EP 600A

415 V/50 Hz 415 V/50 Hz5EJ-5EM

600A

380 V/400 V/50 Hz 380 V/400 V/50 Hz5CJ-5CM 5EJ-5EM

600A

440 V/460 V/480 V/ 60 Hz

440 V/460 V/480 V/ 60 Hz

CU-CZ,CA,CB,DA,DB EU-EZ, EA, EB, FA, FB

1200A

4 3/0-500 kcmil#4 AWG to 500 kcmil, four bbl

380 V/60 Hz 380 V/60 HzER-EZ, EA CW-CZ, CA

1200A

415 V/50 Hz 415 V/50 Hz5CP-5CX 5EN-5EX

1200A

380 V/400 V/50 Hz 380 V/400 V/50 Hz5CN-5CX,5DA 5EN-5EX, 5FA

1200A440 V/460 V/480 V/

60 Hz575 V/60 Hz

FB-FD 1600A

4500-1000

kcmil250-500 kcmil,

four bbl380 V/400 V/415 V/ 50 Hz

575 V/60 HzFA-FB 1600A

JOHNSON CONTROLS 7


13. The following interconnecting wires are factory sup-plied when a YORK Variable Speed Drive is used:

• VSD to control center – L, 2, 16, 24, 53. A 4-conductor shielded cable, or fiber optic cable pair for communications.

• VSD to oil pump motor starter – 72, 73, 74.14. The 60 Hz oil pump motor for compressor is

2 HP. See Table 4 for full load amperes for oil pump drive panel (furnished by Johnson Controls with VSD factory wired). A combination of con-trol transformers provide power to the VSD and chiller control panel. The current requirements are listed in Table 4 (furnished by Johnson Controls and factory wired).

TABLE 3 - OIL PUMP AND CONTROL TRANSFORMERS

3-PHASE VOLTAGE HZ

OIL PUMP DRIVE

PANEL (A)

CONTROL POWER TRANSFORMERS

(A)

MOTOR CODES

575/600 60 2.9 5.2CF-CV, EF-EV

440/460/ 480

60 3.6 6.5CF-CT, EF-ET

380 60 4.3 7.5 EF-EP

380/400/ 415

50 4.3 7.55CC - 5CM, 5EC-5EM

440/460/ 480

60 3.6 8.7CU-DB, EU-FB

380 60 4.3 10ER-EZ, EA CW-CZ, CA

415 50 4.3 105CP-5CX, 5EN-5EX

380/400 50 4.3 105CN - 5DA, 5EN-5FA

440/460/ 480

60 3.6 10.8 FB-FD*

380/400/ 415

50 4.3 7.5 FA-FB*

15. The branch circuit overcurrent protection de-vice for the YORK VSD must be a time delay type with a rating that is the standard fuse/circuit breaker size required to protect the field supply wiring conductors per the NEC.

Motor overload protection is provided by the YORK VSD according to UL 508C. The YORK VSD does not have provisions to provide motor temperature sensing, thermal memory, or thermal retention protection for motor overload condi-tions as a standard offering. If thermal overload protection is required, an optional motor monitor-ing board and resistance thermometer devices or thermistors are available.

16. The YORK VSD power supply wiring ampacity shall be calculated as follows.

Model YK minimum circuit ampacity:

Ampacity = 1.25 (Job FLA)

Where 125% factor per 2014 NEC (Paragraph 440- 33).

17. The VSD is equipped with a U.L. listed ground fault sensing circuit breaker sized per Table 4. All of the VSD and LVD models of drives have an in-put inductor to reduce the rate of rise of the input current during a fault condition. No input fuses are required on the input of the power circuit on the VSD and LVD models. The ground fault sen-sor is factory set to trip instantaneously when a ground fault is detected.

18. Control circuit wiring for 3M condenser water pump motor starter is shown for cooling only ap-plication. The condenser water pump should be wired to terminals 2, 22, 150, and 151. Refer to 160.76-PW6 Wiring Diagram.

JOHNSON CONTROLS8


TABLE 4 - CIRCUIT BREAKER

INPUT VOLTAGE/ FREQUENCY

OUTPUT VOLTAGE/ FREQUENCY

CHILLER MOTOR CODE

VSD CIRCUIT BREAKER RATING

(AMPS) AT 600 VAC, 60 HZ OR 480 VAC, 60 HZ OR

400 VAC, 50 HZ TRIP

SEMICONDUCTOR FUSE RATING

(AMPS) AT 700 VAC WITHSTAND

GROUND FAULT TRIP

(AMPS)

TRIP WITHSTAND

575 V/600 V/60 Hz 575 V/600 V/60 HzCF-CR EF-ER

400 35,000*+

N/A 120

440 V/460 V/480 V/ 60 Hz

440 V/460 V/480 V/ 60 Hz

CF-CN EF-EN

400 65,000*+380 V/60 Hz 380 V/60 Hz EF-EK415 V/50 Hz 415 V/50 Hz 5EC-5EI

380 V/400 V/50 Hz 380 V/400 V/50 Hz5CC-5CI 5EC-5EI

575 V/600 V/60 Hz 575 V/600 V/60 HzCS-CV ES-EV

600 50,000*+

N/A 160

440 V/460 V/480 V/ 60 Hz

440 V/460 V/480 V/ 60 Hz

CP-CT EP-ET

600 100,000*+380 V/60 Hz 380 V/60 Hz EL-EP415 V/50 Hz 415 V/50 Hz 5EJ-5EM

380 V/400 V/50 Hz 380 V/400 V/50 Hz5CJ-5CM 5EJ-5EM

440 V/460 V/480 V/60 Hz

440 V/460 V/480 V/60 Hz

CU-CZ EU-EZ

1200 100,000*+ N/A 240380 V/60 Hz 380 V/60 Hz ER-EV

415 V/50 Hz 415 V/50 Hz5CP-5CT 5EN-5ET

380 V/400 V/50 Hz 380 V/400 V/50 Hz5CN-5CS 5EN-5ES

440 V/460 V/480 V/ 60 Hz

440 V/460 V/480 V/ 60 Hz

CA,CB,DA,DB EA,EB,FA,FB

1200 100,000*+ N/A 240380 V/60 Hz 380 V/60 Hz

CW-CZ, CA EW-EZ, FA

415 V/50 Hz 415 V/50 Hz5CU-5CX 5EU-5EX

380 V/400 V/50 Hz 380 V/400 V/50 Hz5CT-5CX, 5DA 5ET-5EX, 5FA

440 V/460 V/480 V/ 60 Hz

575 V/60 Hz FB-FD1600 100,000*+

1800 @650VAC

360380 V/400 V/415 V/

50 Hz575V/60 Hz FA-FB

NOTES: * Per UL listing of VSD † RMS Symmetrical Amperes

JOHNSON CONTROLS 9


19. The main power transformer should be adequately sized such that the transformer voltage drop does not exceed 10% during unit start-up. The supply voltage, at VSD input terminals, during start-up must be maintained above 489 V for 575 V/600 V, 391 V for 440 V/460 V/480 V, 323 V for 380 V 60 Hz units, and 323 V for 380 V/400 V, 353 V for 415 V 50 Hz units. The allowable supply volt-age range during normal operation is 540 VAC to 630 VAC, 3-phase 575 V/600 V, 60 Hz or 432 VAC to 504 VAC, 3-Phase 440 V/460 V/480 V 60 Hz or 343 VAC to 415 VAC, 3-Phase 380 V, 60 Hz or 342 VAC to 440 VAC, 3-Phase 380 V/415 V 50 Hz.

20. 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 115 V – 50/60 Hz. The power requirements for the water pump starter (5M) must be a maximum of 2 A holding and 10 A inrush. If power require-ments exceed this value, furnish coil for line volt-age, and control relay with 115 V coil (see Note 21).

The pumps operate during oil pump prerun, dur-ing compressor operation, and during cycling shutdown.

For manual chilled water pump control, connect a manual start/stop switch as shown in the Field Connections diagram on page 10 for 115 VAC coils only.

21. Each 115 VAC field-connected inductive load, for example, relay coil, motor starter coil, and so on, must 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.

22. The Condenser Flow Switch is optional. If not present, a jumper must be installed between TB4-11 and TB4-1.

23. A jumper is installed between terminals 21 and 24 for normal operation. To check motor rotation on initial start-up, the jumper may be removed as a momentary switch installed between termi-nals 21 and 24. Press the start key on the display screen on the control panel. After completion of the pre lube sequence jog the motor with the mo-mentary switch. When proper rotation is obtained, replace the momentary switch with a jumper. The momentary switch must have a minimum contact rating of 1 FLA, 10 LRA at 115 VAC.

JOHNSON CONTROLS10


FIGURE 2 - WIRING DIAGRAM – FIELD CONNECTIONS (VARIABLE SPEED DRIVE - ALL MODELS)

SUPR

SUPR

4T2

4T1

4T3

FD

S2*

*N

OT

ES

5 &

15

L1

L3

L2

PO

WE

R S

UP

PLY

(N

OT

E 1

9)

FD

S4

FD

S5

FD

S3

5MS

EE

NO

TE

21

SE

EN

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E20 C

HIL

LED

WA

TE

RP

UM

PM

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WG

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S 1

1 &

18

CH

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D W

AT

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FLO

W S

WIT

CH

**

NO

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5

FLS

WIR

E #

14

AW

GC

OP

PE

RN

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E 1

1

WIR

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14 A

WG

CO

PP

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NO

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11

OP

TIV

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CO

NT

RO

L C

EN

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R *

GR

D. S

CR

EW

S*

CO

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EN

SE

R W

AT

ER

PU

MP

MO

TO

RC

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LIN

G T

OW

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FAN

MO

TO

R

3MS

4M

SE

EN

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E21

NO

TE

9

AU

TO

MA

N

OFF

VO

LTP

HA

SE

3H

ER

TZ

5T1

5T2

5T3

3T1

3T2

3T3

5LL1

5LL2

5LL3

3LL1

3LL2

3LL3

4LL1

4LL2

4LL3

2LL1

2LL2

2LL3

TB

4*1

951

8211

131

91

1312

120

191

87

1

TB

2*44

4555

5626

2742

4340

4115

015

115

315

415

516

436

3515

615

715

2

TB

6*3

45

1516

25

531

11

1L

2

CO

ND

EN

SE

R W

AT

ER

FLO

W S

WIT

CH

N

OT

E 2

2

TB

4-1

TB

4-11

#14

AW

G(N

OT

E 1

1)N

OT

E 7

, 16

CO

PP

ER

CO

ND

UC

TO

RS

ON

LYD

O N

OT

US

E A

LUM

INU

MC

ON

DU

CT

OR

S.

GR

DL2

L1L3

NO

TE

S 2

& 8

NO

TE

S 4

& 6

1T*

T2*

T1*

T3*

CO

MP

RE

SS

OR

MO

TO

R*

2M YO

RK

VS

DN

OT

ES

4 &

13

WIR

E #

14 A

WG

CO

PP

ER

, NO

TE

11

NO

TE

8

T2

T1

T3

TB

5*22 25 23

22

2L

L21

24

See

Not

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2T*

LD16110b

NO

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side

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e ca

bine

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odel

s.

JOHNSON CONTROLS 11


The following factors can be used to convert from English to the most common SI Metric values.

TEMPERATURETo convert degrees Fahrenheit (°F) to degrees Celsius (°C), subtract 32° and multiply by 5/9 or 0.5556.

Example: (45.0°F - 32°) x 0.5556 = 7.22°C

To convert a temperature range (i.e., a range of 10°F) from Fahrenheit to Celsius, multiply by 5/9 or 0.5556.

Example: 10.0°F range x 0.5556 = 5.6°C range

TABLE 5 - SI METRIC CONVERSION

MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT

Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW)

Power Horsepower 0.7457 Kilowatts (kW)

Flow Rate Gallons / Minute (gpm) 0.0631 Liters / Second (l/s)

LengthFeet (ft) 0.3048 Meters (m)

Inches (in) 25.4 Millimeters (mm)

Weight Pounds (lb) 0.4538 Kilograms (kg)

Velocity Feet / Second (fps) 0.3048 Meters / Second (m/s)

Pressure DropFeet of Water (ft) 2.989 Kilopascals (kPa)

Pounds / Square Inch (psi) 6.895 Kilopascals (kPa)

5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 1-800-524-1330 Subject to change without notice. Printed in USACopyright © by Johnson Controls 2019 www.johnsoncontrols.com ALL RIGHTS RESERVEDForm 160.76-PW7 (619)Issue Date: June 28, 2019 Supersedes: 160.76-PW7 (818)

WIRING DIAGRAMS VARIABLE SPEED DRIVE

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