Johnson Controls York 366-70488 Instruction Manual

LD12524a

FOR OT/HT MODEL CHILLERS STYLE “B” AND ”C”

CONTROL CENTERS 366-70488, 366-70487 AND 366-73582

LOW PRESSURE CUTOUT CONTROL

P/N 025-45742-000

INSTALLATION AND MAINTENANCE Supersedes: 160.43-NM4 (1206) Form 160.43-NM4 (1112)

035-21593-000

Issue Date:

November 12, 2012

JOHNSON CONTROLS

FORM 160.43-NM4

ISSUE DATE: 11/12/2012

This equipment is a relatively complicated apparatus.

During installation, operation maintenance or service,

individuals may be exposed to certain components or

conditions including, but not limited to: refrigerants,

materials under pressure, rotating components, and

both high and low voltage. Each of these items has the

potential, if misused or handled improperly, to cause

bodily injury or death. It is the obligation and respon-

sibility of operating/service personnel to identify and

recognize these inherent hazards, protect themselves,

and proceed safely in completing their tasks. Failure

to comply with any of these requirements could result

in serious damage to the equipment and the property in

IMPORTANT!

READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

which it is situated, as well as severe personal injury or

death to themselves and people at the site.

This document is intended for use by owner-authorized

operating/service personnel. It is expected that these

individuals possess independent training that will en-

able them to perform their assigned tasks properly and

safely. It is essential that, prior to performing any task

on this equipment, this individual shall have read and

understood this document and any referenced mate-

rials. This individual shall also be familiar with and

comply with all applicable governmental standards and

regulations pertaining to the task in question.

SAFETY SYMBOLS

The 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.

Identies 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 specied 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 specications and must be performed only by a qualied

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

FORM 160.43-NM4

ISSUE DATE: 11/12/2012

MANUAL DESCRIPTION FORM NUMBER

Operation and Maintenance Manuals – OT/HT Style “B” and “C” TURBOPAK Chillers

Electronic Control Center – Part No. 366-70488 160.43-NM1.1

Electronic Control Center – Part No. 366-73582 160.43-NM1.3

Wiring Diagrams – OT/HT Style “B” and “C” TURBOPAK Chillers

Electronic Control Center – Part No. 366-70488 160.43-W1.1

Electronic Control Center – Part No. 366-70488 160.43-W1.2

Electronic Control Center – Part No. 366-70487 160.43-W2.1

Electronic Control Center – Part No. 366-70487 160.43-W2.2

Electronic Control Center – Part No. 366-73582 160.43-W1.3

Renewal Parts – OT/HT Style “B” and “C” TURBOPAK Chillers

Electronic and Pneumatic Control Centers 160.43-RP1.5

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for con-

tinuous product improvement, the information con-

tained in this document is subject to change without

notice. Johnson Controls makes no commitment to

update or provide current information automatically to

the manual owner. Updated manuals, if applicable, can

be obtained by contacting the nearest Johnson Controls

Service office.

Operating/service personnel maintain responsibility for

the applicability of these documents to the equipment.

If there is any question regarding the applicability of

these documents, the technician should verify whether

the equipment has been modified and if current litera-

ture is available from the owner of the equipment prior

to performing any work on the chiller.

CHANGE 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 in-

formation and any other changes in spelling, grammar

or formatting are not included.

ASSOCIATED LITERATURE

JOHNSON CONTROLS

FORM 160.43-NM4

ISSUE DATE: 11/12/2012

THIS PAGE INTENTIONALLY LEFT BLANK.

JOHNSON CONTROLS 5

FORM 160.43-NM4

ISSUE DATE: 11/12/2012

TABLE OF CONTENTS

SECTION 1 - GENERAL...........................................................................................................................................7

Application........................................................................................................................................................7

Operation..........................................................................................................................................................7

SECTION 2 - INSTALLATION ..................................................................................................................................9

Tools Needed ...................................................................................................................................................9

Secure Chiller From Operation.........................................................................................................................9

Remove Pre-Existing LPCO Control ................................................................................................................9

Mounting 025 45742 LPCO Control .................................................................................................................9

Pressure Connection Piping...........................................................................................................................10

Wiring ............................................................................................................................................................. 11

SECTION 3 - TESTING AND ADJUSTMENTS ......................................................................................................13

Tools Needed .................................................................................................................................................13

Secure Chiller From Operation.......................................................................................................................13

Connect LPCO Pressure Connection To A Calibrated Vacuum Source .........................................................13

Cutout Setpoint Testing And Calibration.........................................................................................................14

Switch Deadband Testing And Calibration......................................................................................................14

Reconnect LPCO Evaporator Pressure Connection And Wiring.................................................................... 15

Return Chiller To Service................................................................................................................................15

SECTION 4 - PRODUCT SPECIFICATIONS.......................................................................................................... 17

JOHNSON CONTROLS

FORM 160.43-NM4

ISSUE DATE: 11/12/2012

THIS PAGE INTENTIONALLY LEFT BLANK.

JOHNSON CONTROLS 7

FORM 160.43-NM4

ISSUE DATE: 11/12/2012

SECTION 1 - GENERAL

APPLICATION

Low Pressure Cutout (LPCO) controls 025 45742 set

point and deadband settings are factory set for R-11 or

R-123 duty application as:

P/N DESCRIPTION

025 45742 002 CONTROL VACUUM SWITCH R-11 LPCO

Use with R-11 refrigerant

025 45742 003 CONTROL VACUUM SWITCH R-123 LPCO

Use with R-123 refrigerant

LPCO controls 025 45742 are available as retrofit

kits, inclusive of installation hardware, for converting

from the obsolete 225 15443 002 LPCO control used

in Model OT/HT Style “B” and “C” chillers having

Electronic Control Centers 366 70488, 366 70487, 366

73582, as:

P/N DESCRIPTION

325 45742 602 KIT, CONTROL LPCO R-11

VACUUM SWITCH Use with

R-11 refrigerant

325 45742 603 KIT, CONTROL LPCO R-123

VACUUM SWITCH Use with

R-123 refrigerant

OPERATION

The Low Pressure cutout (LPCO) controls 025 45742

are actuated by evaporator pressure. The LPCO control

operates to stop the chiller compressor operation on the

decrease of the evaporator pressure equivalent to a re-

frigerant temperature of 28° F and permits re-starting,

(via the start button) when the evaporator pressure in-

creases equivalent to a refrigerant temperature greater

than 40° F.

LPCO controls 025 45742 set point and deadband set-

tings are factory set for R-11 or R-123 duty applica-

tion. The cutout set point and deadband settings are

field adjustable as described in section III Testing and

Adjustments.

LPCO controls 025 45742 are vacuum switches which

are negative gauge pressure controls that operate at a

predetermined constant pressure below atmospheric.

This means that the absolute pressure of the cutout set-

ting will vary with local atmospheric pressure changes.

LPCO controls 025 45742 require cutout setpoint and

Before installing, the installation and

maintenance instructions provided with

unit must be read and understood.

Before installing, verify the control part

no. matches the refrigerant duty applica-

tion.

For all applications, a factory set safety

control should be tested before use.

To avoid damaging control, proof pressure

and maximum temperature limits stated in

literature and on nameplates must never

be exceeded, even by surges in the system.

Operation of the unit up to maximum

pressure or temperature is acceptable on

a limited basis (e.g., start-up, testing) but

continuous operation must be restricted to

the designated adjustable range. Excessive

cycling at maximum pressure or tempera-

ture limits could reduce sensor life.

Vacuum switches are negative gauge

pressure controls that operate at a pre-

determined constant pressure below at-

mospheric. This means that the absolute

pressure of the cutout setting will vary

with local atmospheric pressure changes.

Vacuum switches require settings verica-

tion at installation and require recalibra-

tion if installed elevation is 300 feet or

more above or below sea level.

Preventative maintenance and periodic

testing is necessary for critical applica-

tions where damage could endanger

property or personnel.

These products do not have any eld re-

placeable parts.

JOHNSON CONTROLS

FORM 160.43-NM4

ISSUE DATE: 11/12/2012

SECTION 1 - GENERAL

deadband settings verification at installation and re-

quire recalibration if installed elevation is 300 feet or

more above or below sea level. Refer to Section 3 Test-

ing and Adjustments.

LPCO controls 025 45742 are activated when the

bellows sensor responds to a pressure change. This

response actuates a single-pole double-throw snap-

action switch, converting the pressure signal into an

electrical signal.

At atmospheric pressure the switch contacts are made

between the Common and Normally Open terminals

and open between the Common and Normally Closed

terminals. As the pressure falls below the control CUT-

OUT setpoint the switch transfers to be made between

the Common and Normally Closed terminals and open

between the Common and Normally Open terminals.

As the pressure rises above the control CUTIN (CU-

TIN equals cutout plus deadband settings) the switch

transfers to be made between the Common and Nor-

mally Open terminals and open between the Common

and Normally Closed terminals. Refer to Figure 1.

FIGURE 1 - SWITCH CONTACTS

CUTOUT ON PRESSURE FALL

CUTIN ON PRESURE RISE

LD12521

JOHNSON CONTROLS 9

FORM 160.43-NM4

ISSUE DATE: 11/12/2012

SECTION 2 - INSTALLATION

TOOLS NEEDED

• Power Drill and a #25 or 9/64 in. drill bit

• Adjustable wrenches; 6 in. and 8 in.

• Open-end wrenches; 3/4 in., 5/8 in. and 9/16 in.

• Screwdrivers; Flat Blade and Phillips

SECURE CHILLER FROM OPERATION

1. Shut off power source feed to the chiller Electron-

ic Control Center (ECC).

2. Lock-Out, Tag-Out the chiller.

3. Pull ECC fuses 1FU, 2FU and 3FU to ensure the

LPCO control wiring is deenergized.

4. Close the evaporator service valve having gauge

piping going to the “Cooler” (evaporator) panel

gauge and LPCO control.

REMOVE PRE-EXISTING LPCO CONTROL

1. Disconnect LPCO control pressure (¼ in. are

nut) connection from the pressure tap behind the

“Cooler” (evaporator) panel gauge.

2. Using a voltage meter, reverify the ECC supply

power and to the LPCO control wiring is deener-

gized.

3. Disconnect the three wires (47, 48 and 49) from

the LPCO control and secure out of the way.

4. Remove the two mounting screws and the LPCO

control from the ECC.

MOUNTING 025 45742 LPCO CONTROL

Install unit where shock, vibration and

ambient temperature uctuations will not

damage unit or affect operation. Orient

unit so that moisture does not enter the

enclosure via the electrical connection.

When appropriate, this entry point should

be sealed to prevent moisture entry.

Do not mount unit in ambient temperature

exceeding Specied limits.

LPCO controls 025 45742 are mounted and operated in

a vertical position with the switch up and pressure con-

nection down. The controls are surface mounted using

two mounting ears, with holes for #10 screws, on either

side of the control bracket plate.

1. Remove enclosure cover rst by removing one

captive screw located on the front of the cover.

2. When replacing a former 225 15443 002 LPCO

control:

a. Select a vertical surface mounting location

on the back wall of the ECC for the replace-

ment LPCO control 025 45742 in the same

general area of the former control. Ensure

that the mounting location allows connection

to the preexisting wiring to the control switch

terminals and for the new capillary tubing to

the “Cooler” (evaporator) panel gauge pres-

sure tap.

b. To reach the LPCO control 025 45742 switch

terminals, the preexisting wires (47, 48 and

49) may need to be relocated through the

cabinet middle conduit fitting containing the

high pressure control wires.

c. Using the LPCO control 025 45742 bracket

plate as a guide, locate and mark the two

mounting holes locations on the ECC back

wall. Ensure that the mounting holes loca-

tions will not interfere with anything within

or outside of the ECC panel.

d. Using a power drill and a #25 or 9/64 in. drill

bit, drill out the two mounting holes.

e. Mount the replacement LPCO control 025

45742 to the back wall of the ECC using

two #10 self tapping screws (YORK p/n 021

14727 000) provided in kit.

3. When replacing a former 025 45742 LPCO con-

trol

a. Mount the replacement LPCO control 025

45742 to the back wall of the ECC where

the former control was located and using

two #10 self tapping screws (YORK p/n 021

14727 000) provided in kit.

JOHNSON CONTROLS

FORM 160.43-NM4

ISSUE DATE: 11/12/2012

SECTION 2 - INSTALLATION

PRESSURE CONNECTION PIPING

Never use the enclosure for leverage to

hand tighten the pressure connection. Al-

ways use a wrench to tighten the pressure

connection to the piping. To avoid damage

to control, always hold the wrench on the

wrench ats or hex portion of the pres-

sure connection when tightening piping

connections.

1. Installing kit supplied 1/4 Ext. Flare X 1/4 Ext.

Pipe half union tting (YORK p/n 023 00927

000) in 025 45742 LPCO control pressure 1/4 in.

NPTI connection. Refer to Figure 2.

a. Ensure 1/4 in. pipe thread mating surfaces

are clean and free of debris or defect.

b. Use pipe thread sealant YORK p/n 013

03089 000 (Grade 554, Red, 10 ml, for re-

frigerant pipe up to 1/2” dia.) applied to 1/4

in. external pipe threads only. Do not apply

to the first 2 threads of fitting.

c. Apply tightening torque to the fitting only

while holding back on hex portion of the

LPCO control pressure connection. Secure

fitting to pressure connection tight enough to

ensure a leak free seal.

2. Installing kit supplied Capillary Tube (48 in.)

YORK p/n 026 45010 000

a. Ensure 1/4 in. flare mating surfaces are clean

and free of debris or defect.

b. Connect the 1/4 in. flare nut on 90 deg. end

of capillary tube to the 1/4 in. external flare

half union fitting at the LPCO control pres-

sure connection. Apply tightening torque to

the flare nut only while holding back on fit-

ting. Secure flare nut to fitting tight enough

to ensure a leak free seal.

c. Route the capillary tubing across to the right

hand wall of the ECC and up the right hand

wall to the area of the “Cooler” (evaporator)

panel gauge. Coil any excess capillary tubing

near the evaporator pressure tap connection.

FIGURE 2 - PRESSURE CONTROL LEFT SIDE VIEW

LD12524

3. Connect the 1/4 in. are nut on straight end of

capillarytubetothe1/4in.externalareevapora-

tor pressure tap connection, behind the “Cooler”

(evaporator) panel gauge. Apply tightening torque

tothearenutonlywhileholdingbackontting.

Securearenuttottingtightenoughtoensurea

leak free seal.

4. Use kit supplied wire tie-wraps (YORK p/n

025 09607 000) to secure LPCO capillary tubing

as needed.

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