Categories | YORK VSD&SSS |
---|---|
Brand Name: | YORK/JCI |
Model Number: | 371 03788 336 |
Place of Origin: | United States |
----------------------- Page 1-----------------------
VARIABLE SPEED DRIVE RENEWAL PARTS Supersedes: 160.00-RP4 (1012)
Form 160.00-RP4 (813) 292 HP – 50 HZ, 400VAC (P/N 371-03700-XXX)
351 HP – 60 HZ, 460VAC (P/N 371-02767-XXX) 419 HP – 50 HZ, 400VAC
(P/N 371-03789-XXX) 424 HP – 60 HZ, 575VAC (P/N 371-04881-XXX) 503
HP – 60 HZ, 460VAC (P/N 371-03789-XXX) 608 HP – 60 HZ, 575VAC (P/N
371-04563-XXX) 00616VIP Issue Date: August 30, 2013
----------------------- Page 2-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 IMPORTANT! READ BEFORE
PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a
relatively complicated apparatus. which it is situated, as well as
severe personal injury or During installation, operation
maintenance or service, death to themselves and people at the site.
individuals may be exposed to certain components or conditions
including, but not limited to: refrigerants, This document is
intended for use by owner-authorized materials under pressure,
rotating components, and operating/service personnel. It is
expected that these both high and low voltage. Each of these items
has the individuals possess independent training that will en-
potential, if misused or handled improperly, to cause able them to
perform their assigned tasks properly and bodily injury or death.
It is the obligation and respon- safely. It is essential that,
prior to performing any task on this equipment, this individual
shall have read and sibility of operating/service personnel to
identify and recognize these inherent hazards, protect themselves,
understood this document and any referenced mate- rials. This
individual shall also be familiar with and and proceed safely in
completing their tasks. Failure to comply with any of these
requirements could result comply with all applicable governmental
standards and in serious damage to the equipment and the property
in 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
,GHQWL¿HVDKD]DUGZKLFKFRXOGOHDGWR which will result in death or
serious injury damage to the machine, damage to other if proper
care is not taken. equipment and/or environmental pollu- tion if
proper care is not taken or instruc- tions and are not followed.
Indicates a potentially hazardous situa- Highlights additional
information useful tion which will result in possible injuries to
the technician in completing the work or damage to equipment if
proper care is being performed properly. not taken.
([WHUQDOZLULQJXQOHVVVSHFL¿HGDVDQRSWLRQDOFRQQHFWLRQLQWKHPDQXIDFWXUHU¶VSURGXFWOLQHLVQRW
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-
GDQFHZLWK-RKQVRQ&RQWUROV¶SXEOLVKHGVSHFL¿FDWLRQVDQGPXVWEHSHUIRUPHGRQOEDTXDOL¿HG
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-
LQJZLOOYRLGWKHPDQXIDFWXUHU¶VZDUUDQWDQGFDXVHVHULRXVGDPDJHWRSURSHUWRUSHUVRQDOLQMXU
2 JOHNSON CONTROLS
----------------------- Page 3-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 CHANGEABILITY OF THIS
DOCUMENT In complying with Johnson Controls’ policy for con- these
documents, the technician should verify whether tinuous product
improvement, the information con- the equipment has been modified
and if current litera- tained in this document is subject to change
without ture is available from the owner of the equipment prior
notice. Johnson Controls makes no commitment to to performing any
work on the chiller. update or provide current information
automatically to the manual owner. Updated manuals, if applicable,
can CHANGE BARS be obtained by contacting the nearest Johnson
Controls Revisions made to this document are indicated with a
Service office. line along the left or right hand column in the
area the Operating/service personnel maintain responsibility for
revision was made. These revisions are to technical in- the
applicability of these documents to the equipment. formation and
any other changes in spelling, grammar If there is any question
regarding the applicability of or formatting are not included.
Although many of these parts are similar to the parts used in
previous Variable Speed Drive (VSD) designs, these parts are only
compatible with drives of the following base part numbers
(371-02767- XXX, 371-03700-XXX, 371-03787-XXX, 371-04881-XXX, and
371 04563-XXX). For example, if the VSD logic board 031-02077-000
were used in place of the 031-01433-000 logic board, as used on the
previous VSD designs, major damage to other components will occur.
JOHNSON CONTROLS 3
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FORM 160.00-RP4 ISSUE DATE: 8/30/2013 THIS PAGE INTENTIONALLY LEFT
BLANK. 4 JOHNSON CONTROLS
----------------------- Page 5-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LIST OF FIGURES FIGURE 1 -
Left Side Of Cabinet (Detailed) 292/351/424 HP
.................................................................................17
FIGURE 2 - Left Side Of Cabinet 292/351/424 HP
.................................................................................................18
FIGURE 3 - Left Center Of Cabinet 292/351/424 HP
..............................................................................................19
FIGURE 4 - Right Side Of Cabinet 292/351/424 HP
...............................................................................................20
FIGURE 5 - Inside Right Door All Horse
Powers.....................................................................................................21
FIGURE 6 - Back Of Cabinet 292/351/424 HP
........................................................................................................22
FIGURE 7 - Cooling System 292/351/424 HP
.........................................................................................................23
FIGURE 8 - Cooling System 419/503/608 HP
.........................................................................................................24
FIGURE 9 - Left Side Of Cabinet 419/503/608 HP
.................................................................................................25
FIGURE 10 - Left Side Of Cabinet (Detailed) 419/503/608 HP
...............................................................................26
FIGURE 11 - Upper Right Side Of Cabinet 419/503/608 HP
..................................................................................27
FIGURE 12 - Opti Speed Power Unit Detail 419/503/608 HP
.................................................................................28
FIGURE 13 - Opti Speed Harmonic Filter Power Unit Detail
419/503/608 HP
........................................................29 LIST OF
TABLES TABLE 1 - VSD Parts List 292 HP and 351 HP
........................................................................................................7
TABLE 2 - VSD Parts List 424 HP 575 VAC
.............................................................................................................9
TABLE 3 - VSD Parts List 419 HP and 503 HP
......................................................................................................
11 TABLE 4 - VSD Parts List 608 HP 575 VAC
...........................................................................................................13
TABLE 5 -
Miscellaneous........................................................................................................................................15
TABLE 6 - SI Metric Conversion
.............................................................................................................................31
JOHNSON CONTROLS 5
----------------------- Page 6-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 NOTES The footnotes
referenced within the tables appear 5. The drive logic and the
filter logic replacement below. boards are not shipped with new
software. The soft- ware must be removed from the old board and in-
1. On the 292, 351, 419, and 503 Hp drives built stalled in the new
board. This also includes the U40 before 5/05, the bleeder
resistors have a value of chip on the drive logic board, and the
U26 chip on 2K ohms, and required the application of thermal the
filter logic board. If there is concern that the old grease. These
drives now use a 2.4 K ohm resistor, board had a power supply
problem, then new soft- and require the application of a silicon
pad. If one of ware may need to be ordered. the 2K ohm resistors
were to fail, then both resistors will need to be replaced. The
bleeder resistors for 6. Part number 031-02077-000 is no longer
available. the harmonic filter will also use a thermal pad, but
This part number is replaced with a kit that includes the resistor
value does not change. new software and instructions. Installing
the old software into the new board may cause a drive fail- 2. The
harmonic filter main contactor changed styles ure. in 6/06. The old
style was a contactor that used com- pression fittings. The old
style is still available as a 7. Part number 031-01632-XXX is no
longer avail- repair part, but new production will switch to a
style able. This part number is replaced with a kit that of
contactor that will accept ring tong lugs. This will includes new
software and instructions. When in- improve the installation of a
retrofit harmonic filter. stalling the new board 031-02932 board
reuse the U42 chip from the old board. 3. The trap assembly on the
424 and 608 Hp drives has a different design than on the other
drives. The 3 8. There were cases where the line voltage became
resistors at the top of the trap assembly are mounted unstable and
caused a single phase fault. Software on a silicon pad. The other
drives still need to use was changed to extend the time required
for a single thermal grease in the mounting process. phase fault to
occur. 4. Snubber modules were added to all styles of drives
covered by this parts book. The snubber module protects the input
SCR from voltage transients that may occur on the incoming supply
voltage. The snubber modules maybe applied on existing drives, but
warranty would not apply. 6 JOHNSON CONTROLS
----------------------- Page 7-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 1 - VSD PARTS LIST 292
HP AND 351 HP ITEM DESCRIPTION PART NUMBER FIGURE 1 AC Line
Inductor 025-35176-000 2 2 Bus Isolator Board 031-01624-000 4 3 Bus
Plate Kit 371-03710-001 4 62 Bus Snubber Capacitor 025-35972-000 4
4 Circuit Breaker (used before 6/06) 400 Amp 224-30987-000 2 4
Circuit Breaker (used after 6/06) 600 Amp 224-35428-000 2 * Circuit
Breaker Operator Door Kit 024-35429-000 * 5 Control Transformer,
120 VAC 60 Hz, 3 KVA 025-31499-000 1 5 Control Transformer, 120 VAC
50 Hz, 3 KVA 025-32983-000 1 6 Coolant Manifold Plastic
371-02767-371 6 6 Coolant Manifold Copper without Harmonic Filter
023-20842-000 7 6 Coolant Manifold Copper with Harmonic Filter
023-20822-000 7 7 Coolant Pump 026-33890-000 6 8 Coolant Reservoir
3” PVC with Fill Plug 371-02767-361 6 * Door Latch 029-25614-000 *
9 2 Pole Fuse Holder (2 per unit) 025-35172-000 1 10 3 Pole Fuse
Holder 025-35915-000 1 11 5 AMP Cartridge Fuse (YT Style Chillers
60 Hz) 025-27922-000 1 11 6 AMP Cartridge Fuse (YT Style Chillers
50 Hz) 025-27970-000 1 11 7 AMP Cartridge Fuse (YK Style Chillers
50/60 Hz) 025-25515-000 1 12 10 AMP Cartridge Fuse 025-27971-000 1
13 15 AMP Cartridge Fuse 025-25584-000 1 14 20 AMP Cartridge Fuse
025-28967-000 1 * 50/60 Hz Inverter (used on 50 Hz drive only)
371-02202-101 * 15 ,QSXW5HFWL¿HUV
6&56&56&5RQHHDFK.LW 371-03709-001 4 17 Internal Cabinet
Fan 025-32557-000 3 18 Internal Cooling Coil 026-37566-000 3 19
Output Current Transformer 531-01672-001 3 20 Power Module Chill
Plate Kit 371-05143-001 4 21 Relay, Control Fan / Pump
024-30441-000 4 22 SCR Trigger Board 60 Hz 031-02060-001 4 22 SCR
Trigger Board 50 Hz 031-02060-002 4 * SCR Trigger Board Cable
Between J7 on Trigger to J1 in Gate Driver Board 571-02767-251 * 23
Shell and Tube Heat Exchanger 026-37572-000 6 * Shell and Tube Heat
Exchanger Head Gaskets (set of two) 371-03716-001 * 63 Silicon Pad
(1 each) 1 028-15299-000 3, 4 66 Snubber Capacitor (.047uF, 1600
VAC ) 025-35188-000 3 65 Snubber Module as applied to the SCR/Diode
module 4 331-02556-001 4 16 Snubber Resistor (10 ohm) 025-35953-000
3 24 Transformer, 24 VAC, Class 2 025-27911-000 4 * Temperature
Sensor Supplied on chill plate with the SCR/Diode 571-01484-212 *
modules (As Separate Item) 60 Voltage Transient Board 031-02453-000
3 61 Voltage Transient Board Fuses 025-38523-000 3 25 VSD DC
Balancing Resistor 1 025-35157-000 4 * Items are NOT shown. 1-8
Important Changes refer to page 6. JOHNSON CONTROLS 7
----------------------- Page 8-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 1 - VSD PARTS LIST 292
HP AND 351 HP (CONT'D) ITEM DESCRIPTION PART NUMBER FIGURE VSD
Logic Board (if board P/N is 031-02077-000, order this kit) 5, 6 26
331-02506-602 5 (USE ON PART # 371-02767-XXX, and 371-03700-XXX
ONLY) VSD Logic Board (if board P/N is 031-02506-002, order this
part) 5, 6 (USE ON 26 031-02506-002 5 PART # 371-02767-XXX, &
371-03700-XXX ONLY) 27 VSD Power Module Kit 371-03708-001 4 * VSD
Power Unit Complete Kit (IGBT, Capacitors, Heatsink, etc.)
371-02769-401 * * Wiring (J8, J9, and J10 from drive logic board to
IGBT module) 571-02767-291 * OPTIONAL HARMONIC FILTER PARTS LIST
292 HP AND 351 HP ITEM DESCRIPTION PART NUMBER FIGURE 2 Bus
Isolator Board 031-01624-000 4 3 Bus Plate Kit 371-03710-001 4 62
Bus Snubber Capacitor 025-35972-000 4 * '&&7&DEOH
FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-02768-271 * *
'&&7&DEOH
FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-02768-272 * 30
Direct Current Transducer, 200 AMP (DCCT) 025-32582-000 4 31 Filter
DC Balancing Resistor 025-35955-000 4 32 Filter Inductor
025-35177-000 2 34 Filter Input Fuse 025-32581-000 2 5, 7 Filter
Logic Board (if board P/N is 031-01632-031, order this kit) 35
331-02932-631 5 (USE ON PART # 371-02767-XXX, and 371-03700-XXX
ONLY) Filter Logic Board (if board P/N is 031-02932-031, order this
kit) 5, 7 35 031-02932-031 5 (USE ON PART # 371-02767-XXX, &
371-03700-XXX ONLY) 33 Filter Main Contactor with compression lugs
2 024-30984-000 1 33 Filter Main Contactor use with ring tong lugs
2 024-35434-000 1 36 Filter Power Module Kit 371-03707-001 4 *
Filter Power Unit Complete Kit ( IGBT, Capacitors, Heatsink, etc.)
371-02768-401 * 37 Filter Pre-Charge Contactor 024-30985-000 1 38
Filter Pre-Charge Resistor 025-32502-000 1 39 Filter Trap Assembly
371-03711-001 3 64 Filter Trap Resistor Kit ( Trap Resistors only)
371-02768-355 3 40 Input Current Transformer 531-01672-001 1 41
Line Isolator Board 031-02022-000 4 20 Power Module Chill Plate Kit
071-02769-309 4 42 16 Conductor Ribbon Cable - VSD Logic to Filter
Logic Jumper 031-01658-000 5 63 Silicon Pad (1 each)1 028-15299-000
4 HARMONIC FILTER UPGRADE KITS (TO RETROFIT FILTER TO A NON-FILTER
UNIT) * Filter Upgrade (60 Hz) 351 Hp 371-03717-001 * Filter
Upgrade (50 Hz) 292 Hp 371-03717-002 * Items are NOT shown. 1-8
Important Changes refer to page 6. 8 JOHNSON CONTROLS
----------------------- Page 9-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 2 - VSD PARTS LIST 424
HP 575 VAC ITEM DESCRIPTION PART NUMBER FIGURE 1 AC Line Inductor
025-40388-000 2 2 Bus Isolator Board 031-01624-000 4 3 Bus Plate
Kit 371-03710-001 4 62 Bus Snubber Capacitor 025-35972-000 4 4
Circuit Breaker 224-35428-000 2 * Circuit Breaker Operator Door Kit
024-35429-000 * 5 Control Transformer, 120 VAC 60 Hz, 3 KVA
025-40381-000 1 6 Coolant Manifold Copper without Harmonic Filter
023-20842-000 7 6 Coolant Manifold Copper with Harmonic Filter
023-20822-000 7 7 Coolant Pump 026-33890-000 6 8 Coolant Reservoir
3” PVC with Fill Plug 371-02767-361 6 * Door Latch 029-25614-000 *
9 2 Pole Fuse Holder (2) per unit 025-38196-000 1 10 3 Pole Fuse
Holder 025-34185-000 1 11 4 AMP Cartridge Fuse (YT Style Chillers
60 Hz) 025-35911-000 1 11 5 AMP Cartridge Fuse (YK Style Chillers
60 Hz) 025-35901-000 1 12 10 AMP Cartridge Fuse 025-35905-000 1 13
12 AMP Cartridge Fuse 025-35906-000 1 14 20 AMP Cartridge Fuse
025-35908-000 1 15 ,QSXW5HFWL¿HUV
6&56&56&5RQHHDFK.LW 371-05156-001 4 17 Internal Cabinet
Fan 025-32557-000 3 18 Internal Cooling Coil 026-37566-000 3 19
Output Current Transformer 531-01672-001 3 20 Power Module Chill
Plate Kit 371-05143-001 4 21 Relay, Control Fan / Pump
024-30441-000 4 22 SCR Trigger Board 60 Hz 031-02060-003 4 * SCR
Trigger Board Cable Between J7 on Trigger to J1 on Gate Driver
Board 571-02767-251 * 23 Shell and Tube Heat Exchanger
026-37572-000 6 * Shell and Tube Heat Exchanger Head Gaskets (set
of two) 371-03716-001 * 63 Silicon Pad (1 each) 028-15299-000 3, 4
66 Snubber Capacitor 025-39806-000 3 65 Snubber Module complete
assembly for SCR/Diode module 371-05898-100 4 16 Snubber Resistor
025-35953-000 3 24 Transformer, 24 VAC, Class 2 025-27911-000 4
Temperature Sensor Supplied on chillplate * 571-01484-212 * with
the SCR/Diode modules (As Separate Item) 60 Voltage Transient Board
031-02453-001 3 61 Voltage Transient Board Fuses 025-38523-000 3 25
VSD DC Balancing Resistor 025-40408-000 4 VSD Logic Board ( if
board P/N is 031-02077-001, order this kit) 5, 6 26 331-02506-603 5
(USE ON PART # 371-04881-XXX ONLY) VSD Logic Board ( if board P/N
is 031-02506-003, order this part) 5, 6 26 031-02506-003 5 (USE ON
PART # 371-04881-XXX ONLY) 27 VSD Power Module Kit 371-05157-001 4
* VSD Power Unit Complete Kit ( IGBT, Capacitors, Heatsink, etc.)
371-02769-403 * * Wiring (J8, J9, and J10 from drive logic board to
IGBT module) 571-02767-291 * * Items are NOT shown. 1-8 Important
Changes refer to page 6. JOHNSON CONTROLS 9
----------------------- Page 10-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 2 - VSD PARTS LIST 424
HP 575 VAC (CONT'D) OPTIONAL HARMONIC FILTER PARTS LIST 424 HP 575
VAC ITEM DESCRIPTION PART NUMBER FIGURE 2 Bus Isolator Board
031-01624-000 4 3 Bus Plate Kit 371-03710-001 4 62 Bus Snubber
Capacitor 025-40526-000 4 * '&&7&DEOH
FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-02768-271 * *
'&&7&DEOH
FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-02768-272 * 30
Direct Current Current Transducer, 200 AMP (DCCT) 025-32582-000 4
31 Filter DC Balancing Resistor 025-40408-000 4 32 Filter Inductor
025-40374-000 2 34 Filter Input Fuse 025-40404-000 2 Filter Logic
Board (if board P/N is 031-01632-101, order this kit) 5, 7 35 331
02932 101 5 (USE ON PART # 371-04881-XXX ONLY) Filter Logic Board
(if board P/N is 031-02932-101, order this part) 5, 7 35 031-02932
101 5 (USE ON PART # 371-04881-XXX ONLY) 33 Filter Main Contactor
use with ring tong lugs 024-35434-000 1 36 Filter Power Module Kit
371-05158-001 4 * Filter Power Unit Complete Kit ( IGBT,
Capacitors, Heatsink, etc.) 371-02768-403 * 37 Filter Pre-Charge
Contactor 024-30983-000 1 38 Filter Pre-Charge Resistor
025-40425-000 1 39 Filter Trap Assembly 3 371-04881-349 3 40 Input
Current Transformer 531-01672-001 1 41 Line Isolator Board
031-02022-001 4 20 Power Module Chill Plate Kit 071-02769-309 4 42
16 Conductor Ribbon Cable - VSD Logic to Filter Logic Jumper
031-01658-000 5 63 Silicon Pad (1 each) 028-15299-000 3, 4 HARMONIC
FILTER UPGRADE KITS (TO RETROFIT FILTER TO A NON-FILTER UNIT) *
Filter Upgrade (60 Hz) 424 Hp (575VAC) 371-03717-003 * Items are
NOT shown. 1-8 Important Changes refer to page 6. 10 JOHNSON
CONTROLS
----------------------- Page 11-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 3 - VSD PARTS LIST 419
HP AND 503 HP ITEM DESCRIPTION PART NUMBER FIGURE 1 AC Line
Inductor 025-38134-000 9 2 Bus Isolator Board 031-01624-000 10 3
Bus Plate Kit 371-04163-001 12 62 Bus Snubber Capacitor
025-35972-000 12 4 Circuit Breaker 224-34025-000 9 * Circuit
Breaker Lug Kit 025-34027-000 * 5 Control Transformer, 120 VAC 60
Hz, 3 KVA 025-31499-000 9 5 Control Transformer, 120 VAC 50 Hz, 3
KVA 025-32983-000 9 6 Coolant Manifold Copper with or without
Harmonic Filter 023-21710-000 8 7 Coolant Pump 026-33890-000 8 8
Coolant Reservoir 3” PVC with Fill Plug 371-03789-361 8 * Door
Latch 029-25614-000 * 9 2 Pole Fuse Holder (2) per unit
025-38196-000 1 10 3 Pole Fuse Holder 025-34185-000 1 11 5 AMP
Cartridge Fuse (YT Style Chillers 60 Hz) 025-35901-000 1 11 6 AMP
Cartridge Fuse (YT Style Chillers 50 Hz) 025-35902-000 1 11 7 AMP
Cartridge Fuse (YK Style Chillers50/60 Hz) 025-35903-000 1 12 10
AMP Cartridge Fuse 025-35905-000 1 13 15 AMP Cartridge Fuse
025-35907-000 1 14 20 AMP Cartridge Fuse 025-35908-000 1 * 50/60 Hz
Inverter (Used On 50 Hz Drive Only) 371-022202-101 * 15
,QSXW5HFWL¿HUV
6&56&56&5RQHHDFK.LW 371-04162-001 12 17 Internal
Cabinet Fan 025-32577-000 3 18 Internal Cooling Coil 026-37990-000
3 19 Output Current Transformer 025-21173-003 10 20 Power Module
Chill Plate Kit 071-03787-309 12 21 Relay, Control Fan / Pump
024-30441-000 11 22 SCR Trigger Board 60 Hz 031-02060-001 11 22 SCR
Trigger Board 50 Hz 031-02060-002 11 * SCR Trigger Board Cable
Between J7 on Trigger to J1 on Gate Driver Board 571-03789-251 * 23
Shell and Tube Heat Exchanger 026-37572-000 8 * Shell and Tube Heat
Exchanger Head Gaskets (set of two) 371-03716-001 * 63 Silicon Pad
(1 each) 1 028-15299-000 11, 12 66 Snubber Capacitor 025-35188-000
11 65 Snubber Module as applied to the SCR/Diode module 4
331-02556-001 12 16 Snubber Resistor 025-35953-000 11 24
Transformer, 24 VAC, Class 2 025-27911-000 11 Temperature Sensor
Supplied on chill plate * 571-01484-212 * with the SCR/Diode
modules (As Separate Item) 25 VSD DC Balancing Resistor 1
025-35157-000 12 VSD Logic Board (if board P/N is 031-02077-000,
order this kit) 5, 6 26 331-02506-602 5 (USE ON PART #
371-03789-XXX ONLY) VSD Logic Board (if board P/N is 031-02506-002,
order this part) 5, 6 26 031-02506-002 5 (USE ON PART #
371-02767-XXX, & 371-03700-XXX ONLY) 27 VSD Power Module Kit
371-04164-001 12 60 Voltage Transient Board 031-02453-000 10 61
Voltage Transient Board Fuses 025-38523-000 10 * VSD Power Unit
Complete Kit ( IGBT, Capacitors, Heatsink, etc.) 371-03787-401 * *
Wiring (J8 from Drive Logic Board to IGBT Module Phase A)
571-03789-291 * * Wiring (J9 from Drive Logic Board to IGBT Module
Phase B) 571-03789-293 * * Wiring (J10 from Drive Logic Board to
IGBT Module Phase A) 571-03789-295 * JOHNSON CONTROLS 11
----------------------- Page 12-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 3 - VSD PARTS LIST 419
HP AND 503 HP (CONT'D) OPTIONAL HARMONIC FILTER PARTS LIST 419 HP
AND 503 HP ITEM DESCRIPTION PART NUMBER FIGURE 2 Bus Isolator Board
031-01624-000 11 3 Bus Plate Kit 371-03710-001 13 62 Bus Snubber
Capacitor 025-35972-000 13 * '&&7&DEOH
FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-03788-271 10 *
'&&7&DEOH
FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-03788-272 10
30 Direct Current Current Transducer, 300 AMP (DCCT) 025-30994-000
10 31 Filter DC Balancing Resistor 025-35955-000 13 32 Filter
Inductor 025-38135-000 10 34 Filter Input Fuse 025-30992-000 10
Filter Logic Board (if board P/N is 031-01632-042, order this kit)
5, 7 35 331-02932-642 5 (USE ON PART # 371-03789-XXX ONLY) Filter
Logic Board (if board P/N is 031-02932-042, order this kit) 5, 7 35
031-02932-042 5 (USE ON PART # 371-02767-XXX, & 371-03700-XXX
ONLY) 33 Filter Main Contactor with compression lugs 2
024-34028-000 9 33 Filter Main Contactor use with ring tong lugs 2
024-35433-000 9 36 Filter Power Module Kit 371-04165-001 13 *
Filter Power Unit Complete Kit (IGBT, Capacitors, Heatsink, etc.)
371-03788-401 * 37 Filter Pre-Charge Contactor 024-30985-000 9 38
Filter Pre-Charge Resistor 025-38197-000 9 39 Filter Trap Assembly
371-03788-349 10 64 Filter Trap Resistor Kit (Trap Resistors only)
371-02768-355 10 40 Input Current Transformer 531-01660-001 9 41
Line Isolator Board 031-02022-000 11 20 Power Module Chill Plate
071-02769-309 13 63 Silicon Pad (1 each) 1 028-15299-000 13 42 16
Conductor Ribbon Cable - VSD Logic to Filter Logic Jumper
031-01658-000 5 HARMONIC FILTER UPGRADE KITS (TO RETROFIT FILTER TO
A NON-FILTER UNIT) * Filter Upgrade (60 Hz) 503 Hp 371-04167-001 *
Filter Upgrade (50 Hz) 419 Hp 371-04167-002 * Items are NOT shown.
1-8 Important Changes refer to page 6. 12 JOHNSON CONTROLS
----------------------- Page 13-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 4 - VSD PARTS LIST 608
HP 575 VAC ITEM DESCRIPTION PART NUMBER FIGURE 1 AC Line Inductor
025-40384-000 9 2 Bus Isolator Board 031-01624-000 10 3 Bus Plate
Kit 371-04163-001 12 62 Bus Snubber Capcitor 025-35972-000 12 4
Circuit Breaker 224-34025-000 9 5 Control Transformer, 120 VAC 60
Hz, 3 KVA 025-40381-000 9 6 Coolant Manifold Copper with or without
Harmonic Filter 023-21710-000 8 7 Coolant Pump 026-33890-000 8 8
Coolant Reservoir 3” PVC with Fill Plug 371-03789-361 8 * Door
Latch 029-25614-000 * 9 2 Pole Fuse Holder (2) per unit
025-38196-000 1 10 3 Pole Fuse Holder 025-34185-000 1 11 4 AMP
Cartridge Fuse (YT Style Chillers 60 Hz) 025-35911-000 1 11 5 AMP
Cartridge Fuse (YK Style Chillers 60 Hz) 025-35901-000 1 12 10 AMP
Cartridge Fuse 025-35905-000 1 13 12 AMP Cartridge Fuse
025-35906-000 1 14 20 AMP Cartridge Fuse 025-35908-000 1 15
,QSXW5HFWL¿HUV
6&56&56&5RQHHDFK.LW 371-05156-001 12 17 Internal
Cabinet Fan 025-32577-000 3 18 Internal Cooling Coil 026-37990-000
3 19 Output Current Transformer 025-21173-003 10 20 Power Module
Chill Plate Kit 071-03787-309 12 21 Relay, Control Fan / Pump
024-30441-000 11 22 SCR Trigger Board 60 Hz 031-02060-003 11 * SCR
trigger board cable between J7 on trigger to J1 on gate driver
board. 571-03789-251 * 23 Shell and Tube Heat Exchanger
026-37572-000 8 * Shell and Tube Heat Exchanger Head Gaskets (set
of two) 371-03716-001 * 63 Silicon Pad (1 each) 028-15299-000 11,
12 66 Snubber Capacitor 025-39806-000 11 65 Snubber Module complete
assembly for SCR/Diode module 371-05890-100 12 16 Snubber Resistor
025-35953-000 11 24 Transformer, 24 VAC, Class 2 025-27911-000 11 *
Temperature Sensor Supplied on chill plate 571-01484-212 * with the
SCR/Diode modules (As Separate Item) 60 Voltage Transient Board
031-02453-001 8 61 Voltage Transient Board Fuses 025-38523-000 8 25
VSD DC Balancing Resistor 025-40408-000 12 VSD Logic Board (if
board P/N is 031-02077-001, order this kit) 5, 6 26 331 02506-603 5
(USE ON PART # 371-04563-XXX ONLY) VSD Logic Board (if board P/N is
031-02506-003, order this part) 5, 6 26 031-02506-003 5 (USE ON
PART # 371-04563-XXX ONLY) 27 VSD Power Module Kit 371-05159-001 12
* VSD Power Unit Complete Kit ( IGBT, Capacitors, Heatsink, etc.)
371-03787-403 * * Wiring (J8 from Drive Logic Board to IGBT Module
Phase A) 571-03789-291 * * Wiring (J9 from Drive Logic Board to
IGBT Module Phase 3) 571-03789-293 * * Wiring (J10 from Drive Logic
Board to IGBT Module Phase C) 571-03789-295 * JOHNSON CONTROLS 13
----------------------- Page 14-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 4 - VSD PARTS LIST 608
HP 575 VAC (CONT'D) OPTIONAL HARMONIC FILTER PARTS LIST 608 HP 575
VAC ITEM DESCRIPTION PART NUMBER FIGURE 2 Bus Isolator Board
031-01624-000 11 3 Bus Plate Kit 371-03710-001 13 62 Bus Snubber
Capacitor 025-40526-000 13 * '&&7&DEOH
FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-03788-271 10 *
'&&7&DEOH
FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-02767-272 * 30
Direct Current Current Transducer, 300 AMP (DCCT) 025-30994-000 8
31 Filter DC Balancing Resistor 025-40408-000 13 32 Filter Inductor
025-40375-000 10 34 Filter Input Fuse 025-40405-000 10 Filter Logic
Board (if board P/N is 031-01632-102, order this kit) 5, 7 35
331-02932-102 5 (USE ON PART # 371-04563-XXX ONLY) Filter Logic
Board (if board P/N is 031-02932-102, order this part) 5, 7 35
031-02932-102 5 (USE ON PART # 371-04563-XXX ONLY) 33 Filter Main
Contactor use with ring tong lugs 024-35433-000 9 36 Filter Power
Module Kit 371-05160-001 13 * Filter Power Unit Complete Kit (IGBT,
Capacitors, Heatsink, etc.) 371-03788-403 * 37 Filter Pre-Charge
Contactor 024-30985-000 9 38 Filter Pre-Charge Resistor
025-40424-000 9 39 Filter Trap Assembly 3 371-04563-349 10 40 Input
Current Transformer 531-01660-001 9 41 Line Isolator Board
031-02022-001 11 20 Power Module Chill Plate 071-02769-309 13 63
Silicon Pad (1 each) 028-15299-000 10, 13 42 16 Conductor Ribbon
Cable - VSD Logic to Filter Logic Jumper 031-01658-000 5 HARMONIC
FILTER UPGRADE KITS (TO RETROFIT FILTER TO A NON-FILTER UNIT) *
Filter Upgrade (60 Hz) 608 Hp (575VAC) 371-04167-003 * Items are
NOT shown. 1-8 Important Changes refer to page 6. 14 JOHNSON
CONTROLS
----------------------- Page 15-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 5 - MISCELLANEOUS ITEM
DESCRIPTION PART NUMBER Not Shown Pre-Mixed Coolant (Inhibitor) 1
gallon container 013-02987-000 Not Shown
6QXEEHUIRU0RWRU7HUPLQDO%R[±5HPRWH5HWUR¿WV9$& 375-22732-000 Not
Shown 6QXEEHUIRU0RWRU7HUPLQDO%R[±5HPRWH5HWUR¿WV9$&
375-22732-001 Not Shown 50/60 Hz Inverter for 50 Hz VSD Units
371-02202-101 Not Shown Vane Pot with Couplings 371-02012-001 Not
Shown Bracket for Vane Pot Mtg. to Compressor 064-48851-000 Not
Shown Ferrite Beads 025-32843-000 Not Shown Motor Adapter Plate (4”
Deep) - 405S Frame Motors 025-28400-001 Motor Adapter Plate (4”
Deep) - 404R, 405R, 444S, 445S, 447S,449S, Not Shown 025-28400-002
503S, 504S, 505S, 507S, 509S, 588S and 5011S Frame Motors Not Shown
Motor Adapter Plate (4” Deep) - 445R, 447R Frame Motors
025-28400-003 Not Shown Motor Adapter Plate (5 ¾” Deep) - 405T
Frame Motors 025-28400-004 Not Shown Motor Adapter Plate (7 ¾”
Deep) - 405T, 445T, 447T Frame Motors 025-28400-005 MICRO-COMPUTER
CONTROL CENTER PARTS FOR VSD APPLICATION (ONE LINE DISPLAY) Not
Shown Adaptive Capacity Control Board 031-01579-000 Not Shown
Membrane Keypad for Control Panel 024-26943-000 ACC Installation
Kit – Mounting rails, ribbon cables, hardware. Not Shown
375-22734-000 Does not include ACC Board. (YT) ACC Installation Kit
– Mounting rails, ribbon cables, hardware. Not Shown 375-22733-000
Does not include ACC Board. (YK) Not Shown Replacement Ribbon Cable
– Micro Board to ACC (Quant. = 1) 031-01322-000 Not Shown Condenser
Transducer for R-11, R-123 025-29148-009 OPTIVIEW CONTROL CENTER
PARTS FOR VSD APPLICATION Not Shown Adaptive Capacity Control Board
031-01782-000 ACC Installation Kit – (YT) Not Shown 371-02725-001
includes mounting hardware, cables, and ACC Board. ACC Installation
Kit – (YK) Not Shown 371-02724-001 includes mounting hardware,
cables, and ACC Board. Not Shown Replacement Shielded Cable – Micro
Board to ACC (Quant. = 1) 571-02264-411 HARNESSES Not Shown Vane
Pot Wiring from Vane Pot to ACC Board 375-22735-402 Not Shown VSD
Cabinet to Control Center Wiring Kit - 10 Feet 375-22736-000 Not
Shown VSD Cabinet to Control Center Wiring Kit - 50 Feet
375-22737-000 PIPING 28 Clear PVC Tubing, 3/4” I.D. (Figures 6, 7,
8) 028-14491-000 29 Clear PVC Tubing, 1/2” I.D. (Figures 6, 7)
028-14439-000 62 Clear PVC Tubing, 1” I.D. (Figure 8) 028-13553-000
Not Shown Rubber Hose, Black, 150# DWP, 1 ½” ID 028-15001-000 Not
Shown Rubber Hose, Red, 300# DWP, 1 ½” ID 028-15028-000 Not Shown
Hose Clamp for 150# DWP, 1 ½” ID hose 021-30656-000 Not Shown Hose
Clamp for 300# DWP, 1 ½” ID hose 023-40048-000 * Items are NOT
shown. 1-8 Important Changes refer to page 6. JOHNSON CONTROLS 15
----------------------- Page 16-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 5 - MISCELLANEOUS
(CONT'D) DRIVE SOFTWARE 292, 351, 419, AND 503 HP ITEM DESCRIPTION
PART NUMBER FIGURE 51 U33 Battery Backed RAM for the VSD Logic
Board and ACC board 031-01620-000 5 52 U34 VSD Logic Board EPROM
(60Hz used on 031-02077 board) 031-01617-006 5 52 U34 VSD Logic
Board EPROM (50Hz used on 031-02077 board) 031-01617-007 5 53 U40
VSD Logic Board Serial PROM used on 031-02077 board 031-01619-003 5
* U42 VSD Logic Board 485 communications driver 031-02074-000 * 54
U45 VSD Logic Board EPROM (60 Hz used on 031-02506 board only)
031-01618-001 5 54 U45 VSD Logic Board EPROM (50 Hz used on
031-02077 board) 031-01618-002 5 * U22 VSD Logic Board EPROM used
on 031-02506 board Rev. F and 031-03420-001 * later U34 VSD Logic
Board EPROM used on 031-02506 board (460v/60Hz, * 031-02547-002 *
400v/50Hz) * U34 VSD Logic Board EPROM used on 031-02506 board
(400v/60Hz, 031-02547-005 * 415v/50Hz) * U45 VSD Logic Board EPROM
used on 031-02506 board 031-02572-001 * * U6 SCR Trigger Board 8
331-02065-601 * 55 U26 Harmonic Filter Logic Board Serial PROM used
on 031-01632 board 031-01680-003 5 56 U42 Harmonic Filter Logic
Board EPROM (60Hz) 031-01633-006 5 56 U42 Harmonic Filter Logic
Board EPROM (50Hz) 031-01633-007 5 57 U78 Harmonic Filter Logic
Board Serial PROM used on 031-01632 board 031-02091-001 5 DRIVE
SOFTWARE 424 AND 608 HP 51 U33 Battery Backed RAM for the VSD Logic
Board and ACC board 031-01620-000 5 52 U34 VSD Logic Board EPROM
(60Hz used on 031-02077 board) 031-01617-009 5 53 U40 VSD Logic
Board Serial PROM used on 031-02077 board 031-01619-003 5 U42 VSD
Logic Board 485 communications driver * 031-02074-000 * (Used on
031-02506-xxx board only) 54 U45 VSD Logic Board EPROM (60 Hz used
on 031-02077 board) 031-01618-001 5 * U34 VSD Logic Board EPROM
used on 031-02506 board (575v/60Hz) 031-02547-003 * * U22 VSD Logic
Board EPROM used on 031-02506 board Rev. F and 031-03420-001 *
later * U6 SCR Trigger Board 8 331-02065-601 * 55 U26 Harmonic
Filter Logic Board Serial PROM used on 031-01632 board
031-01680-003 5 56 U42 Harmonic Filter Logic Board EPROM (60Hz)
031-01633-008 5 57 U78 Harmonic Filter Logic Board Serial PROM
031-02091-001 5 SOFTWARE FOR THE MICRO-COMPUTER CONTROL CENTER WITH
VSD Not Shown U17 Micro Board EPROM (VSD 60 Hz) YT chiller
031-01676-003 Not Shown U17 Micro Board EPROM (VSD 50 Hz) YT
chiller 031-01676-002 Not Shown U17 Micro Board EPROM (VSD 60 Hz)
YK chiller 031-01675-003 Not Shown U17 Micro Board EPROM (VSD 50
Hz) YK chiller 031-01675-002 Not Shown U22 Adaptive Capacity
Control Board EPROM 031-01674-002 Not Shown U21 Battery Backed RAM
for the ACC Board 031-01620-000 * Items are NOT shown. 1-8
Important Changes refer to page 6. 16 JOHNSON CONTROLS
----------------------- Page 17-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 5 - MISCELLANEOUS
(CONT'D) SOFTWARE FOR THE OPTIVIEW CONTROL CENTER WITH VSD ITEM
DESCRIPTION PART NUMBER FIGURE Not Shown U46 Micro Board Flash Card
(YK 50 / 60 Hz) (031-01730-XXX Board only) 031-01797-001 U46 Micro
Board Flash Card (YK 50 / 60 Hz) (031-01730-XXX Board only) Not
Shown 031-02073-001 (P Compressor only) Not Shown U46 Micro Board
Flash Card (YT 50 / 60 Hz) (031-01730-XXX Board only) 031-02004-001
Not Shown Program Card (YK) (031-02430-XXX Board only)
031-02474-001 Not Shown Program Card (YT) (031-02430-XXX Board
only) 031-02469-001 Not Shown U16 Adaptive Capacity Control Board
EPROM 031-01674-002 Not Shown U15 Battery Backed RAM for the ACC
Board 031-01620-000 * Items are NOT shown. 1-8 Important Changes
refer to page 6. JOHNSON CONTROLS 17
----------------------- Page 18-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD07014 FIGURE 1 - LEFT SIDE
OF CABINET (DETAILED) 292/351/424 HP 18 JOHNSON CONTROLS
----------------------- Page 19-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD07015 FIGURE 2 - LEFT SIDE
OF CABINET 292/351/424 HP JOHNSON CONTROLS 19
----------------------- Page 20-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09128a FIGURE 3 - LEFT
CENTER OF CABINET 292/351/424 HP 20 JOHNSON CONTROLS
----------------------- Page 21-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09127a FIGURE 4 - RIGHT
SIDE OF CABINET 292/351/424 HP JOHNSON CONTROLS 21
----------------------- Page 22-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD07018 FIGURE 5 - INSIDE
RIGHT DOOR ALL HORSE POWERS 22 JOHNSON CONTROLS
----------------------- Page 23-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD07019 FIGURE 6 - BACK OF
CABINET 292/351/424 HP JOHNSON CONTROLS 23
----------------------- Page 24-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09065 FIGURE 7 - COOLING
SYSTEM 292/351/424 HP 24 JOHNSON CONTROLS
----------------------- Page 25-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09066 FIGURE 8 - COOLING
SYSTEM 419/503/608 HP JOHNSON CONTROLS 25
----------------------- Page 26-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09064 FIGURE 9 - LEFT SIDE
OF CABINET 419/503/608 HP 26 JOHNSON CONTROLS
----------------------- Page 27-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09063a FIGURE 10 - LEFT
SIDE OF CABINET (DETAILED) 419/503/608 HP JOHNSON CONTROLS 27
----------------------- Page 28-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09062a FIGURE 11 - UPPER
RIGHT SIDE OF CABINET 419/503/608 HP 28 JOHNSON CONTROLS
----------------------- Page 29-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD12020 FIGURE 12 - OPTI
SPEED POWER UNIT DETAIL 419/503/608 HP JOHNSON CONTROLS 29
----------------------- Page 30-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09060 FIGURE 13 - OPTI
SPEED HARMONIC FILTER POWER UNIT DETAIL 419/503/608 HP 30 JOHNSON
CONTROLS
----------------------- Page 31-----------------------
FORM 160.00-RP4 ISSUE DATE: 8/30/2013 The following factors can be
used to convert from English to the most common SI Metric values.
TABLE 6 - 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) Feet (ft)
0.3048 Meters (m) Length Inches (in) 25.4 Millimeters (mm) Weight
Pounds (lbs) 0.4538 Kilograms (kg) Velocity Feet / Second (fps)
0.3048 Meters / Second (m/s) Feet of Water (ft) 2.989 Kilopascals
(kPa) Pressure Drop Pounds / Square Inch (psi) 6.895 Kilopascals
(kPa) TEMPERATURE To 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 = 27.2°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 JOHNSON
CONTROLS 31
----------------------- Page 32-----------------------
P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2013 www.ENENG.com ALL RIGHTS RESERVED Form 160.00-RP4 (813) Issue Date: August 30, 2013 Supersedes: 160.00-RP4 (1012)
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