COMPOUND YK CENTRIFUGAL

LIQUID CHILLER

OPERATION AND MAINTENANCE Supersedes: 160.82-OM1 (611) Form 160.82-OM1 (813)

MODEL CYK CENTRIFUGAL CHILLER / HEAT PUMP SYSTEM

WITH QUANTUM™ LX CONTROLS

LD15345

R-134a

Issue Date:
August 30, 2013
 FORM 160.82-OM1
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 individual 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
sibility of operating/service personnel to identify and on this equipment, this individual shall have read and
recognize these inherent hazards, protect themselves, understood this document and any referenced mate-
and proceed safely in completing their tasks. Failure rials. This individual shall also be familiar with and
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 Identifies a hazard which could lead to

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.

External wiring, unless specified as an optional connection in the manufacturer’s product line, is
not to be connected inside the Quantum™ LX 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 accordance 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 warning will void the manufacturer’s warranty and cause serious damage to property or
personal injury.

2 JOHNSON CONTROLS
FORM 160.82-OM1
ISSUE DATE: 8/30/2013

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for contin- these documents, the technician should verify whether
uous product improvement, the information contained the equipment has been modified and if current litera-
in this document is subject to change without notice. ture is available from the owner of the equipment prior
Johnson Controls makes no commitment to update or to performing any work on the chiller.
provide current information automatically to the man-
ual owner. Updated manuals, if applicable, can be ob- CHANGE BARS
tained by contacting the nearest Johnson Controls Ser- Revisions made to this document are indicated with a
vice office or accessing the Johnson Controls QuickLIT line along the left or right hand column in the area the
website at http://cgproducts.johnsoncontrols.com. revision was made. These revisions are to technical in-
Operating/service personnel maintain responsibility for formation and any other changes in spelling, grammar
the applicability of these documents to the equipment. or formatting are not included.
If there is any question regarding the applicability of

ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
Renewal Parts 160.82-RP1
Startup Checklist 160.82-CL1
Wiring Diagrams 160.82-PW1

JOHNSON CONTROLS 3
 FORM 160.82-OM1
ISSUE DATE: 8/30/2013

NOMENCLATURE

CYK WH TB J4 J1 — DA DA G S
Special Features
Model
Design Level
Cooler Code
High Stage Motor Code
Condenser Code
Low Stage Motor Code
Low Stage Compressor Code
Power Supply
High Stage Compressor Code - for 60 Hz
5 for 50 Hz

4 JOHNSON CONTROLS
FORM 160.82-OM1
ISSUE DATE: 8/30/2013

TABLE OF CONTENTS

SECTION 1 - DESCRIPTION OF SYSTEM...............................................................................................................9

SECTION 2 - FUNDAMENTALS OF OPERATION.................................................................................................33

SECTION 3 - QUANTUM LX CONTROL PANEL....................................................................................................55

Home Screen.................................................................................................................................................. 63
System Screen................................................................................................................................................ 65
Evaporator Screen.......................................................................................................................................... 67
Condenser Screen.......................................................................................................................................... 69
Subcooler Screen.........................................................................................................................................71
Hot Gas Screen............................................................................................................................................73
Low Stage Compressor Screen...................................................................................................................... 75
LS Proximitor Calibration (Low And High Stages) Screen............................................................................77
PRV Calibration Screen................................................................................................................................79
Oil Sump (Unified Sump Pressure) Screen..................................................................................................81
Oil Sump (Ice Thermal Storage) Screen.......................................................................................................83
LS Variable Geometry Diffuser Screen.........................................................................................................87
High Stage Compressor Screen...................................................................................................................... 89
HS Proximitor Calibration Screen.................................................................................................................91
Liquid Cooled Solid State Starter (Optional).................................................................................................93
Capacity Controls Screen................................................................................................................................ 96
Manual Auto Station (Capacity Controls) Screen..........................................................................................98
PID Tuning Screen......................................................................................................................................100
Overrides Screen.....................................................................................................................................102
Anti-Surge Screen.......................................................................................................................................104
Setup Screen................................................................................................................................................. 106
Test Outputs Screen...................................................................................................................................108
Setpoints 1 Screen......................................................................................................................................109
Setpoints 2 Screen...................................................................................................................................... 110
Pressure Calibration Screen....................................................................................................................... 113
Temperature Calibration Screen................................................................................................................. 114
Miscellaneous Calibration Screen............................................................................................................... 115
Digital Input Configuration Screen.............................................................................................................. 117
Digital Output Configuration Screen........................................................................................................... 118
Auxiliary Analog Configuration Screen........................................................................................................ 119
Auxiliary Analog Calibration Screen, Page 1..............................................................................................121
Auxiliary Analog Calibration Screen, Page 2..............................................................................................122
Retransmitting Outputs Screen...................................................................................................................123
Economizer Screen....................................................................................................................................... 124
History Screen............................................................................................................................................... 126
Freeze Screen............................................................................................................................................127
Trending Screen............................................................................................................................................ 128
Trending Setup Screen...............................................................................................................................130
Custom Display Screen..............................................................................................................................131

SECTION 4 - SOFTWARE UPDATE PROCEDURE.............................................................................................133

SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING........................................................................137

SECTION 6 - TROUBLESHOOTING.....................................................................................................................181

JOHNSON CONTROLS 5
 FORM 160.82-OM1
ISSUE DATE: 8/30/2013

LIST OF FIGURES

FIGURE 1 - Main Controller Board and Peripherals�����������������������������������������������������������������������������������������������13

FIGURE 2 - Quantum™ LX Jumper Settings����������������������������������������������������������������������������������������������������������14
FIGURE 3 - Quantum™ LX 5 Motherboard Power Connector Pinout������������������������������������������������������������������� 14
FIGURE 4 - Quantum LX Interface Board���������������������������������������������������������������������������������������������������������������15
FIGURE 5 - Quantum LX Interconnections�������������������������������������������������������������������������������������������������������������16
FIGURE 6 - Power Supplies������������������������������������������������������������������������������������������������������������������������������������17
FIGURE 7 - Potentiometer Adjustment�������������������������������������������������������������������������������������������������������������������18
FIGURE 8 - Digital Input Modules���������������������������������������������������������������������������������������������������������������������������20
FIGURE 9 - DIO Connector Plug����������������������������������������������������������������������������������������������������������������������������21
FIGURE 10 - Digital Board #1���������������������������������������������������������������������������������������������������������������������������������23
FIGURE 11 - Digital Board #2���������������������������������������������������������������������������������������������������������������������������������24
FIGURE 12 - Potentiometer Adjustment�����������������������������������������������������������������������������������������������������������������26
FIGURE 13 - Analog Outputs����������������������������������������������������������������������������������������������������������������������������������28
FIGURE 14 - Motor Amps���������������������������������������������������������������������������������������������������������������������������������������29
FIGURE 15 - Enhanced Analog Board Diagram�����������������������������������������������������������������������������������������������������30
FIGURE 16 - Quantum™ LX Keypad����������������������������������������������������������������������������������������������������������������������33
FIGURE 17 - Quantum™ LX Basic Panel Layout���������������������������������������������������������������������������������������������������34
FIGURE 18 - General Operating Sequence������������������������������������������������������������������������������������������������������������35
FIGURE 19 - System Status�����������������������������������������������������������������������������������������������������������������������������������36
FIGURE 20 - Control Model������������������������������������������������������������������������������������������������������������������������������������40
FIGURE 21 - Valve Locations����������������������������������������������������������������������������������������������������������������������������������44
FIGURE 22 - System Anti-Surge�����������������������������������������������������������������������������������������������������������������������������46
FIGURE 23 - Parameters For Anti-Surge����������������������������������������������������������������������������������������������������������������46
FIGURE 24 - Stage Operations�������������������������������������������������������������������������������������������������������������������������������47
FIGURE 25 - Capacity Control Diagrams����������������������������������������������������������������������������������������������������������������51
FIGURE 26 - Quantum™ LX Graphic Display��������������������������������������������������������������������������������������������������������55
FIGURE 27 - Allowable Range��������������������������������������������������������������������������������������������������������������������������������57
FIGURE 28 - Manual Automatic Stations����������������������������������������������������������������������������������������������������������������59
FIGURE 29 - Control Center�����������������������������������������������������������������������������������������������������������������������������������61
FIGURE 30 - Home Screen�������������������������������������������������������������������������������������������������������������������������������������63
FIGURE 31 - System Screen����������������������������������������������������������������������������������������������������������������������������������65
FIGURE 32 - Evaporator Screen�����������������������������������������������������������������������������������������������������������������������������67
FIGURE 33 - Condenser Screen�����������������������������������������������������������������������������������������������������������������������������69
FIGURE 34 - Subcooler Screen������������������������������������������������������������������������������������������������������������������������������71
FIGURE 35 - Hot Gas Screen���������������������������������������������������������������������������������������������������������������������������������73
FIGURE 36 - Low Stage Compressor Screen���������������������������������������������������������������������������������������������������������75
FIGURE 37 - LS Proximitor Calibration (Low And High Stages) Screen����������������������������������������������������������������� 77
FIGURE 38 - PRV Calibration Screen���������������������������������������������������������������������������������������������������������������������79
FIGURE 39 - PRV Position Sensor�������������������������������������������������������������������������������������������������������������������������79
FIGURE 40 - Oil Sump (Unified Sump Pressure) Screen���������������������������������������������������������������������������������������81
FIGURE 41 - Oil Sump (Ice Thermal Storage) Screen��������������������������������������������������������������������������������������������83
FIGURE 42 - Low Stage Oil Return Eductor�����������������������������������������������������������������������������������������������������������84
FIGURE 43 - High Stage Oil Return Eductor����������������������������������������������������������������������������������������������������������85
FIGURE 44 - Oil Level Sensor��������������������������������������������������������������������������������������������������������������������������������86
FIGURE 45 - High Stage Oil Sump�������������������������������������������������������������������������������������������������������������������������86
FIGURE 46 - LS Variable Geometry Diffuser Screen����������������������������������������������������������������������������������������������87
FIGURE 47 - High Stage Compressor Screen��������������������������������������������������������������������������������������������������������89
FIGURE 48 - HS Proximity Calibration Screen�������������������������������������������������������������������������������������������������������91
FIGURE 49 - Liquid Cooled Solid State Starter (Optional)��������������������������������������������������������������������������������������93
FIGURE 50 - Chiller Mode��������������������������������������������������������������������������������������������������������������������������������������96
FIGURE 51 - Heat Pump Mode�������������������������������������������������������������������������������������������������������������������������������97
FIGURE 52 - Manual Auto Station (Capacity Controls) Screen������������������������������������������������������������������������������98
FIGURE 53 - PID Tuning Screen��������������������������������������������������������������������������������������������������������������������������100
FIGURE 54 - Overrides Screen�����������������������������������������������������������������������������������������������������������������������������102

6 JOHNSON CONTROLS
FORM 160.82-OM1
ISSUE DATE: 8/30/2013

LIST OF FIGURES (CONT'D)

FIGURE 55 - Temperature-Based Demand Limiter Function��������������������������������������������������������������������������������103

FIGURE 56 - Anti-Surge Screen���������������������������������������������������������������������������������������������������������������������������104
FIGURE 57 - Setup Screen�����������������������������������������������������������������������������������������������������������������������������������106
FIGURE 58 - Test Outputs Screen������������������������������������������������������������������������������������������������������������������������108
FIGURE 59 - Setpoints 1 Screen��������������������������������������������������������������������������������������������������������������������������109
FIGURE 60 - Setpoints 2 Screen�������������������������������������������������������������������������������������������������������������������������� 110
FIGURE 61 - HS PRV Offset Control Scale Function������������������������������������������������������������������������������������������� 111
FIGURE 62 - Pressure Calibration Screen������������������������������������������������������������������������������������������������������������ 113
FIGURE 63 - TemperaTure Calibration Screen����������������������������������������������������������������������������������������������������� 114
FIGURE 64 - Miscellaneous Calibration Screen��������������������������������������������������������������������������������������������������� 115
FIGURE 65 - Flow Instruments Wiring������������������������������������������������������������������������������������������������������������������ 116
FIGURE 66 - Digital Input Configuration Screen �������������������������������������������������������������������������������������������������� 117
FIGURE 67 - Digital Output Configuration Screen������������������������������������������������������������������������������������������������ 118
FIGURE 68 - Auxiliary Analog Configuration Screen�������������������������������������������������������������������������������������������� 119
FIGURE 69 - Auxiliary Analog Input Safeties Screen�������������������������������������������������������������������������������������������� 119
FIGURE 70 - Auxiliary Analog Calibration, Page 1������������������������������������������������������������������������������������������������121
FIGURE 71 - Auxiliary Analog Calibration, Page 2������������������������������������������������������������������������������������������������122
FIGURE 72 - Retransmitting Outputs Screen�������������������������������������������������������������������������������������������������������123
FIGURE 73 - Economizer Screen�������������������������������������������������������������������������������������������������������������������������124
FIGURE 74 - History Screen���������������������������������������������������������������������������������������������������������������������������������126
FIGURE 75 - Freeze Screen���������������������������������������������������������������������������������������������������������������������������������127
FIGURE 76 - Trending Screen������������������������������������������������������������������������������������������������������������������������������128
FIGURE 77 - Real Time Trending Screen�������������������������������������������������������������������������������������������������������������129
FIGURE 78 - Trending Setup Screen��������������������������������������������������������������������������������������������������������������������130
FIGURE 79 - Custom Display Screen�������������������������������������������������������������������������������������������������������������������131
FIGURE 80 - USB Flash Drive������������������������������������������������������������������������������������������������������������������������������135
FIGURE 81 - Ethernet Connection������������������������������������������������������������������������������������������������������������������������137
FIGURE 82 - Typical RJ-45 Connector�����������������������������������������������������������������������������������������������������������������138
FIGURE 83 - Crossover cable�������������������������������������������������������������������������������������������������������������������������������139
FIGURE 84 - Typical Switch����������������������������������������������������������������������������������������������������������������������������������139
FIGURE 85 - Ethernet Setup���������������������������������������������������������������������������������������������������������������������������������141
FIGURE 86 - Serial Port Locations�����������������������������������������������������������������������������������������������������������������������144
FIGURE 87 - Communications Setup�������������������������������������������������������������������������������������������������������������������145
FIGURE 88 - Communications Data Logging Screens�����������������������������������������������������������������������������������������148
FIGURE 89 - ModBus TCP Communications Log�������������������������������������������������������������������������������������������������149
FIGURE 90 - How the Data Packets are Created�������������������������������������������������������������������������������������������������149
FIGURE 91 - Data Station Pinout��������������������������������������������������������������������������������������������������������������������������150
FIGURE 92 - Virtual HMI���������������������������������������������������������������������������������������������������������������������������������������151
FIGURE 93 - BACnet IP Over Ethernet�����������������������������������������������������������������������������������������������������������������151
FIGURE 94 - BACnet MSTP Over RS-485�����������������������������������������������������������������������������������������������������������152
FIGURE 95 - RJ-45 Connector�����������������������������������������������������������������������������������������������������������������������������152
FIGURE 96 - MODBUS RTU or AB DF1 Over RS-485�����������������������������������������������������������������������������������������153
FIGURE 97 - Create Your Own�����������������������������������������������������������������������������������������������������������������������������153

JOHNSON CONTROLS 7
 FORM 160.82-OM1
ISSUE DATE: 8/30/2013

LIST OF TABLES

TABLE 1 - Communications Settings����������������������������������������������������������������������������������������������������������������������25

TABLE 2 - Dipswitch Settings���������������������������������������������������������������������������������������������������������������������������������25
TABLE 3 - Enhanced Analog Board Input Configuration Table�������������������������������������������������������������������������������27
TABLE 4 - Communications������������������������������������������������������������������������������������������������������������������������������������31
TABLE 5 - Current Transformer (CT)����������������������������������������������������������������������������������������������������������������������31
TABLE 6 - Dipswitch Settings (Used to set the board address)������������������������������������������������������������������������������31
TABLE 7 - Analog Board�����������������������������������������������������������������������������������������������������������������������������������������31
TABLE 8 - System Details���������������������������������������������������������������������������������������������������������������������������������������60
TABLE 9 - Full Load Amps��������������������������������������������������������������������������������������������������������������������������������������94
TABLE 10 - Start Current����������������������������������������������������������������������������������������������������������������������������������������94
TABLE 11 - Ethernet Component Recommendations�������������������������������������������������������������������������������������������140
TABLE 12 - Serial Communication Setup�������������������������������������������������������������������������������������������������������������146
TABLE 13 - Communications Board���������������������������������������������������������������������������������������������������������������������147
TABLE 14 - Quantum LX for CYK Protocol List����������������������������������������������������������������������������������������������������155
TABLE 15 - List Alarm Codes�������������������������������������������������������������������������������������������������������������������������������175
TABLE 16 - SI Metric Conversion�������������������������������������������������������������������������������������������������������������������������183

8 JOHNSON CONTROLS
FORM 160.82-OM1
ISSUE DATE: 8/30/2013

SECTION 1 - DESCRIPTION OF SYSTEM

1
The Quantum™ LX system is a fully integrated control SYSTEM ARCHITECTURE
system for Compound YK chillers. The versatility of
The Quantum™ LX control panel contains all of the
the CYK product allows it to be used as either a chiller
necessary control hardware and software within one
or a heat pump application as a standard option. The
self contained enclosure, and is mounted to the chiller
advanced CYK control system manages all aspects
package. The front of this control enclosure contains
of chiller operation, monitoring vital parameters and
a graphic display and keypad, to allow the operator to
making real-time adjustments as necessary to ensure
access various system information and to make neces-
safe and efficient operation of primary system compo-
sary adjustments to setpoints, calibrations and features.
nents.
Operator access to this system is through various
A full-color, animated graphic operator interface pro-
screens. A screen is the physical representation of data
vides the operator access to all real-time sensor data,
on the display. Each screen has a title area. The title is
and is equipped with both sensor history logging and
descriptive of the screen. The current date and time is
complete alarm/system trip history features. Manual
shown as well as the day of the week, Sunday (Sun.)
adjustments to operational parameters may be made by
through Saturday (Sat.) is displayed in the title area.
a qualified service technician. Among the monitored
The month of the year from January (Jan.) to Decem-
operating parameters are:
ber (Dec.) is displayed. The day of the month from 1 to
• Chilled liquid temperatures 31 and the year from 0001 to 9999 is displayed. Time is
displayed in military 24 hours format. The hours, min-
• Refrigerant pressures and temperatures utes and seconds.
• Cooling liquid temperatures
Some screens are for informational purposes only, and
• Compressor data cannot be modified. These screens typically show ana-
log values such as temperature and pressure, which are
• Pre-rotation vane positions strictly functions of an associated sensor, and as such,
• Evaporator data cannot be modified. Other screens show setpoint val-
ues which can be changed, in order modify the units
• Condenser data operating characteristics. For easier viewing, related
• Subcooler data information is separated into boxes. Sometimes selec-
tions are hidden when that the feature is unavailable.
• Oil pump pressures
Quantum™ LX control system consists of five major
• Motor Load
areas:
• General system data and data trending
• Quantum™ LX Controller – The Quantum™
The system setpoints are operator entered and include: LX runs a software program that communicates
with all of the digital and analog boards. This
• Local Chilled liquid temperature setpoint communication allows the Quantum™ LX to read
• Remote setpoint temperature the status of all the I/O boards, and display the
data on the interface screen. The Quantum™ LX
• Percent load limit acts on this data, and provides the necessary con-
• Clock trol information to the I/O boards to provide the
appropriate control of all input and output signals,
Additional modifications may be made to system PID based upon the configuration of installed features
tuning. All data and control features are accessible and options of the compressor package.
from the operator interface display. The system is also
accessible across an Ethernet LAN through a standard • Operator interaction is provided through the key-
web browser. pad, as well as informational status to the dis-
play. Interaction to the outside world is provided

JOHNSON CONTROLS 9
 FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

through industry-standard communications pro- history/trending), pressure and temperature val-

tocols. Additional information about the Quan- ues, digital I/O status, setpoints, etc. are viewed
tum™ LX can be found under the QUANTUM™ from this display. The Keypad is used by the oper-
LX CONTROLLER section in this manual. ator to enter data such as setpoint values, calibra-
tion data, etc, into the Quantum™ LX controller.
• Power Supply – Provides the necessary operat-
Additional information about the display can be
ing voltages for the proper operation of all con-
found under the DISPLAY section in this manual.
trol components. Additional information about
the power supply can be found under the POWER Quantum™ LX Controller Board
SUPPLY section in this manual.
Troubleshooting the Quantum™ LX Control
The DC power/communications harness in this Panel
panel is color-coded to make wire identification
easier. The color coding is as follows: This section contains information on troubleshooting
and making corrections to the boards and control cir-
• +5VDC - Red cuits of the Quantum™ LX.
• +12VDC - Yellow General Information
• +24VDC – Dark Blue The components within the control panel are sensi-
• Common/Ground - Black tive and can be damaged by static electricity or mis-
handling. Only qualified technicians should directly
• +RX/TX – White with Red handle these components.
• -RX/TX – White w/ Black stripe • DO NOT attempt to make corrections to the power
• Digital Input / Output Boards – Digital (on/off) supply without shutting off the power to the con-
signals are sent and received by these boards. The trol panel. Accidental shorts can irreparably dam-
output signals are used for energizing solenoids, age the processor boards or the display screen.
valves, contactors, relays, etc., and the input sig- • DO NOT handle the panel boards when the cables
nals are used to sense the condition of switches, are disconnected without first attaching a properly
relay contacts, auxiliary contacts, etc. This board grounded wrist ground strap to your body that will
runs an independent software program from the prevent static electrical discharge. Most problems
Quantum™ LX to control devices, and com- encountered with the microprocessor and control
municates the status of all devices back to the circuits will be the result of a wiring fault, a blown
Quantum™ LX. Additional information about the fuse, faulty I/O module or failure of a peripheral
Digital Boards can be found under the DIGITAL control such as a solenoid coil or a pressure trans-
BOARD section in this manual. ducer.
• Analog Input / Output Boards – Analog (vari- Faults in the computer, while possible, are unlike-
able) signals are sent and received by these ly. If a fault develops in the computer, the prob-
boards. The output signals are used for control- ability is that all functions will cease and the dis-
ling damper motors, modulated valves, etc., and play screen will go blank.
the input signals are used to read the values being
sent from pressure transducers, temperature sen- The control system of the compressor consists of
sors, etc. This board runs an independent software an AC (high voltage) side, which is 120 volts, and
program from the Quantum™ LX to control de- a DC (low voltage) side. The AC side actuates so-
vices, and communicates the status of all devices lenoids, relays, alarms, and other electromechani-
back to the Quantum™ LX. The analog board has cal functions. The DC side operates the computer
24 analog inputs and 8 analog outputs. and its various sensors.
When working within the panel, the AC
• Operator Interface – This section actually con-
high voltage side, which is nominal 120
sists of two major components; the display and the
VAC and CAN CAUSE INJURY OR
keypad. The display is used to show the operator,
DEATH.
via a graphical interface, the actual status of all
compressor values. Warnings and shutdowns (and

10 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

To troubleshoot the low-voltage side of the control cir- Replacing the Quantum™ LX Controller Board
cuits, it is necessary to have the following tools: Flash Card memory load is done prior to the board be-
1
1. Accurate digital multimeter (capable of reading to ing shipped. The customer needs to have their settings
DC/AC, mA to the hundreds place). manually recorded, or saved to a Flash Card, so that
the new board can be setup the same as the old one.
2. Small wire stripper. It is suggested that the operator first record all control
3. Small screwdriver (with insulated shaft). setpoints prior to board replacement. Factory Setup
settings will also be lost. The Setpoint Data sheets later
4. Small snip nose pliers. in this manual are useful for recording this informa-
5. Wrist Grounding strap. tion. A Maintenance Flashcard may also be purchased
that will allow these setpoints to be saved electroni-
6. Static free grounded work surface. cally, and may be downloaded at a later time (Refer to
Proper panel voltage refers to the AC the Renewal Parts Manual).
(high voltage) that has been supplied to
The procedure to replace the Quantum™ LX is out-
the panel, which could be either nominal
lined below:
120 VAC (Reference the Control Panel
Power Specifications). 1. Shut off control power.
2. Remove the old board from the machine and the
Some problems that are encountered involve trouble- new board from its packing and place both on an
shooting the digital inputs and outputs. The Digital anti-static surface.
I/O (Input/Output) boards have six Digital I/O (DIO)
board connectors labeled P1 through P6. The input and 3. Ensure that the jumpers on the new board are set
output modules are wired into a DIO connector plug. the same as those on the old board.
Position 3 provides power and position 4 is a neutral on 4. Install the flash card from the old board to the re-
the DIO connectors. placement board.
What To Do Before Calling for Service 5. Install the modified replacement board into the
Before calling for service, review the information on panel.
the following pages and try to discover and resolve 6. If program changes are necessary through the
the Quantum™ LX problem. The actual cause of most USB port download, then follow the directions in
problems is usually not with the Quantum™ LX itself, the Software Maintenance section of this manual
but with something external to the panel. However, on for the procedure to reload a program.
the rare occasion that the problem has been identified
as being the Quantum™ LX controller, use the fol- 7. Power the panel up, and set the date and time.
lowing section as a guideline for servicing the panel.
What Should Occur When Applying Power
A blank screen could be the result of many different
problems. Following is a list of possible reasons for no When powering up the Quantum™ LX, the following
display: sequence of events are indicative of a properly working
main processor board:
• No power
• There are LED’s on the main Quantum™ LX for
• Loose or Faulty Display Cable or Inverter Cable CYK controller board.
• Bad Display • PWR (Power) LED will turn on solid on the Key-
• Bad Backlight Inverter pad Interface Board. This should be an indication
that the board has received power.
• Bad Backlight Fluorescent Tube
• The ACT (Active) LED will blink on the Keypad
• Wrong Combination of Display, Cable, Inverter, Interface Board.
or Software
• The boot sequence will show the CMOS boot in-
• Faulty CPU Board formation briefly on the display.

JOHNSON CONTROLS 11
 FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

• Once the board begins to boot the operating sys- 5. Check for bad connections.
tem “TUX” penguin icons will appear briefly in
6. Check the display. If the CPU board is booting but
the top left corner.
you have no display, check the following:
• The HOME screen will appear on the display once
• Check the LCD backlight tube. Look very
the control application has started.
closely at the display to see if anything is
• The RX/TX lights of the Analog and Digital visible in the dark screen. Using a beam type
boards will also flash. source of good lighting, such as a flashlight,
look for any ghost type image. If it appears
After the Quantum™ LX has properly powered up, the
that there is something on the screen but
following sequence of events is indicative of proper
very dark, the problem maybe with the LCD
communication to the analog and digital boards:
backlight tube. On the LG Philips, NEC and
• The TX/RX LED’s near the white connector will Sharp displays this tube is field replaceable.
begin to blink. On the Samsung LCD display it is not avail-
able and the display will have to be replaced.
• The Analog and Digital I/O boards TX/RX lights There may be a sticker on the display mount-
should be blinking. ing plate. If there is, it will have a part num-
• Each I/O board should have the power LED (next ber that describes the type of display. If there
to the white connector) lighted and the active LED is no sticker, you must take the display apart
(next to the blue Dipswitch) should be blinking. to identify the display manufacturer.

What If The CYK “Home” Status Screen Is • Verify that both the display cable and the in-
Not Shown verter cable are firmly seated.

If the Operating Status screen is not shown, check the • These cables both originate from the same
following items: connector on the Quantum™ LX. It may be
necessary to remove the video cable from the
1. If no LED’s on the Keypad Interface board are lit, back of the LCD display and reseat it to be
then check AC and DC power with a Multimeter. sure it is connected properly.
2. Check if the lighting of the LED’s is occurring as • NOTE: This is a small connector and caution
described in the What Should Occur When Apply- should be observed so that it is not damaged
ing Powering section. If the powering up sequence due to excessive force.
continues to repeat without displaying the HOME
status screen, then there is a booting problem. Refer to the Display Assembly Component Replace-
ment Guide at the end of this section, and check that the
3. Check if an error message is displayed when boot- LCD, LCD cable, and software versions are matched
ing. Be sure to write down any error messages ex- correctly.
actly as they appear.
4. Check that the software is OK:
• Is the correct software installed?
• Did you just install new software?
• If you need to clear the numerical setpoint
and calibration areas of memory for any rea-
son, clear the memory as described in the
Software Maintenance section of this manual.
• NOTE: This information will be replaced by
factory default values, so any setpoint and
calibration data values that need to be cus-
tomized must be reentered.

12 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

CONTROLLER
POWER

ETHERNET INVERTER CABLE

BIOS BATTERY PORT

COM-4 RS-485
I/O SERIAL
PORT

COM-3
(OPTIONAL)
STARTER
COMMUNICATIONS
SERIAL PORT

TOUCHSCREEN
CABLE

COM-1

TOUCHSCREEN
INTERFACE BOARD
CABLE

COM 2 RS-232 SERIAL INTERFACE INTERFACE

USB
SLAVE COMMUNICATION BOARD POWER KEYBOARD BOARD
STATUS PORTS
PORT TO PROTOCOL POWER
LIGHTS
GATEWAY
LD15224

Figure 1 - MAIN CONTROLLER BOARD AND PERIPHERALS

JOHNSON CONTROLS 13
 FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

Set the Quantum™ LX 5 board jumpers as follows

DISPLAY TYPE
JUMPER
JLVD53
61 = before Jan. 2013
81 = after Jan. 2013

JUMPER
JLVD52

NORMAL
JUMPER
CN4 JUMPER
CMOS1

BLUE
POWER OK

JUMPER
CN3
TOUCHSCREEN

LD15321
Figure 2 - QUANTUM™ LX JUMPER SETTINGS

BATTERY FUNCTION AND REPLACEMENT Place your fingernail under the edge of the battery, and
gently lift up. The battery should release itself from the
The Quantum™ LX board utilizes a battery to main-
socket easily. Take a new battery and place it into the
tain correct date and time for the purpose of stamp-
holder in the same orientation as the old battery (the
ing warnings and shutdowns with the date and time
side with the writing must be facing out).
that they occurred. If the date and time are not being
maintained properly, this may indicate that the bat- Return the Control Power switch back to ON. Once
tery is not functioning, and should be replaced. The the Quantum™ LX has rebooted, the correct Date and
battery may be ordered through Baltimore Parts (P/N Time must be set.
333Q0001786) or may be purchased at most electronic
shops (manufacturers P/N CR-2032).
The battery is fully assessable, but is surrounded by
sensitive electronic components, so care should be tak-
en when changing.
To replace the battery, ensure that the Control Power
switch has been turned OFF.
Locate the Battery socket, as shown on the following
drawing:

LD15322
Figure 3 - QUANTUM™ LX 5 MOTHERBOARD
LD17439
POWER CONNECTOR PINOUT

14 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

COMM COMM
4 3

1
COMM
2

Baud Rate Jumpers

J15 Not Installed = 19200 (Default)
J15 Pins 1-2 Installed = 38400
J15 Pins 3-4 Installed = 56K
J15 Pins 1-2 and 3-4 Installed = 115K
COMM
1

Do Not
Remove J14
P1
Power Connector JP1

JP1 SYSTEM SETTINGS

Jumper JP1 Function Jumper Setting

1-2 Not Used Not Installed

3-4 Reformat E2Prom Installed

5-6 Erase Setpoints (at boot-up) Installed

DG81 Display Installed (default) Installed

7-8
DG61 Display Inst alled Not Inst alled

9 - 10 Disable Watchdog Installed

NOTE: Jumper 7-8 is normally the only jumper that would be installed (for a DG81 display only)

COMMS 1 & 2 JUMPER SETTINGS COMMS 1-4 PINOUTS AND JUMPER LOCATIONS
(Comms 3 and 4 have no jumpers) COMM-4 COMM-3
Comm 1 Comm 2 Function Jumper Setting (P17) (P16)
RS-485 RS-485
(RESERVED)
3
RS-422 (4-Wire) +TX/+RX
2 1 - 2 Closed
Default 1
GND -TX/-RX

J1 J7
3
RS-485 COMM-2
2 2 - 3 Closed
(2-Wire) 1
(P11)
RS-422 RS-485
GND GND
Pull Down +TX N/C
J2 J13 1 Pin Only
Default -TX
+RX
N/C
+TX/+RX
Pull Up -RX -TX/-RX
J3 J16 1 Pin Only
Default
RS-422
1 Pin Only
Default
J5 J17
RS-485 1 - 2 Closed
RS-422
1 Pin Only
Default RS-422 RS-485
J6 J18 GND GND
+TX N/C
RS-485 1 - 2 Closed -TX N/C
+RX +TX/+RX
-RX -TX/-RX
High Speed Target
J4 J22 1 - 2 Closed COMM-1
Default (P10)
NOTE: The triangle symbol ( ) denotes Pin 1 on connectors. LD17440

Figure 4 - QUANTUM LX INTERFACE BOARD

JOHNSON CONTROLS 15
 FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

QUANTUM™ LX INTERCONNECTIONS
The pictorial below depicts the Quantum™ LX moth-
erboard, and the necessary interconnects between it
and the Interface board. Each of the interconnecting
harnesses must be installed as shown for proper opera-
tion.

If the harness for either

COMM1 or COMM2 is
ever removed for either
repair, replacement or
troubleshooting, ensure
that the pinout matches
as shown here when
plugging the ends back
in. All other Intercon-
nection harness ends
share the same pinout at
both ends.
LD17441

Figure 5 - QUANTUM LX INTERCONNECTIONS

16 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

POWER SUPPLY (QUANTUM™ LX) It is possible for the screwdriver (and the
person making the adjustment) to come 1
Description into contact with potentially lethal voltag-
The power supply of the Quantum™ LX control panel es. Proper Personal Protective Equipment
consists of three independent supplies, and are locat- (PPE) measures need to be observed.
ed on the inside of the front door below the Interface
board. They supply the following DC voltages: All circuit boards within the Quantum™ LX control
• +5 VDC panel require accurately adjusted DC voltages in order
to function properly. Periodic measurement and adjust-
• +12 VDC ment of the DC power system is recommended for op-
timum system operation. Over time, it is possible for
• +24 VDC
temperature, humidity, vibration and component age,
All three supplies are adjustable and each has an indi- to degrade the accuracy of these voltages. When any
cator to show that they are powered. Refer to the fol- of the DC voltages begin to stray from their optimum
lowing page for the location for the adjustment. range, mysterious problems can begin to arise. Even
with a perfectly adjusted supply, it is possible for a po-
tential drop in voltage at each connection point. This
drop normally is in the millivolt range, but under some
conditions, the drop can be much greater (as high as
tenths of a volt). By the time the voltage reaches the
last board in the daisy chain, and all of these potential
voltage drops are considered, the combined drop can
be such that problems can be apparent. Some examples
LD17442 of problems could be:
Figure 6 - POWER SUPPLIES • Loss of or intermittent communications failures.
• A shutdown message stating Digital Board x Re-
POWER DISTRIBUTION set (where “x” is replaced by the number of the
DC power coming from the power supplies is wired Digital Board that failed).
directly to a series of terminal blocks. The terminals for • An shutdown message stating Digital Board x
these voltages are labeled as follows: Comm. Fail - Shutdown (where “x” is replaced by
• Common (1000) the number of the Digital Board that failed).

• +24 VDC (1004) • An shutdown message stating Analog Board x

Comm. Fail - Shutdown (where “x” is replaced by
• +5 VDC (1001) the number of the Analog Board that failed).
• +12 VDC (1002) • Numerous sensor fault shutdown messages.
Power is then distributed to the Quantum™ LX pro- • Quantum™ LX reboots for no apparent reason.
cessor board, Interface Board, and Digital/Analog I/O
boards from these terminals. • Improper readings of analog pressures and tem-
peratures.
MEASURING VOLTAGES • LED's on the Quantum™ LX are lit, but nothing
CAUTION! Measuring and adjusting the power supply appears on the display.
voltages require the control power switch to be ener-
To perform measurements and adjustments on the
gized. Extreme care must be observed when taking any
power supply voltages, use a reliable, calibrated Digi-
readings, as 120 or 230 VAC (depending on incoming
tal Volt Meter (DVM). The DVM should be accurate
system voltage) will be present next to the DC voltage
to 1/100 of a volt DC. With the control power switch
connector. Adjusting the supplies requires the use of a
turned ON, wait until the Operating Screen appears.
small Philips screwdriver inserted into the supply to
This is because the graphics required to create this
access an adjusting potentiometer.

JOHNSON CONTROLS 17
 FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

screen will draw more current than when the screen +5 VDC Adjustment
is showing the normal POST (DOS) style messages Locate the DC power terminal strip. Terminal 1001 is
during a boot up. If the screen never appears however the +5 VDC, and 1000 is common (COM). Place the
(possibly due to a voltage problem), you will need to negative lead on 1000, and the positive lead on 1001.
proceed regardless of what is or is not displayed. Verify that the DVM is displaying in the range of +5.10
In order to properly measure the DC power system, it to +5.20.
must be checked at the DC power terminal strip. If adjustment is required, locate the adjustment ac-
cess hole on the +5 VDC supply, as previously shown.
ADJUSTMENT
While watching the DVM, slowly rotate the screw-
Ensure that the meter is set to the proper range (DC, driver blade clockwise to increase the voltage or coun-
0-50 V or equivalent), as well as observing proper wire ter-clockwise to decrease until the voltage is correctly
polarity. The power supply drawing shown on the fol- adjusted.
lowing page applies to all three power supplies. The
adjustment access hole for each supply is located on +12 VDC Adjustment
the lower left of the front of the supplies. If an adjust- Locate the DC power terminal strip. Terminal 1002
ment is required, use a thin, Philips screwdriver, insert is the +12 VDC, and 1000 is common (COM). Place
the tip into the access hole for the appropriate voltage the negative lead on 1000, and the positive lead on
potentiometer (refer to the diagram on the following 1002. Verify that the DVM is displaying in the range of
page for adjustment location). +12.10 to +12.20.
Extreme care must be used when adjust-
If adjustment is required, locate the adjustment access
ing the potentiometer. Adjustment should
hole on the +12 VDC supply, as previously shown.
only be performed by qualified personnel.
While watching the DVM, slowly rotate the screw-
The use of a non-conductive device is
driver blade clockwise to increase the voltage or coun-
recommended.
ter-clockwise to decrease until the voltage is correctly
adjusted.

+24 VDC Adjustment

Locate the DC power terminal strip. Terminal 1004
is the +24 VDC, and 1000 is common (COM). Place
the negative lead on 1000, and the positive lead on
1004. Verify that the DVM is displaying in the range of
+24.20 to +25.50.
If adjustment is required, locate the adjustment access
hole on the +24 VDC supply, as previously shown.
While watching the DVM, slowly rotate the screw-
driver blade clockwise to increase the voltage or coun-
ter-clockwise to decrease until the voltage is correctly
adjusted.

POWER SUPPLY REPLACEMENT

If any of the power supplies are found to be bad, or not
capable of acceptable adjustment, the failing supply
LD17443
will need replacing. Refer to the Recommended Spare
Figure 7 - POTENTIOMETER ADJUSTMENT Parts list for the appropriate part number.

18 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

Digital Board requirements, as well as the communications capabili-

The information that follows in this section can help ties. Two different harnesses have been used and a dia- 1
locate problems that may occur with Digital Input and gram of each of these wiring harnesses can be found
Output circuit boards, and their interaction with the later in this manual (see the Power I/O Wiring Harness
Quantum™ LX controller. drawings). Depending on the type of panel, the follow-
ing harness will be used:
Digital Board Description
The wires that are inserted into the positions of one
The Digital Board is actually a small microprocessor row are internally daisy chained on each I/O board,
board and programmed to control discrete outputs, to continue the voltages and signals to the adjacent
or accept discrete inputs, from external electrical de- row. Therefore, any time that a connector is un-
vices. Each Digital Board has the capability of 24 in- plugged from the daisy chain, these voltages and sig-
dependent channels or I/O (Input/Output). These I/O nals cannot continue through the daisy chain to the
channels are dedicated as to their function, through the next board. Whenever a plug is not to be inserted
operating system (software), enabled options and ex- into a board, either for service or if not all boards are
ternal wiring. Each channel that is used by the software present, then a shunting plug (refer to Recommend-
will have a module plugged into it. A yellow module ed Spare Parts list) must be installed onto the open
indicates that it is used for Inputs. A black module is connector. The four wires that feed from the power
used for Outputs. A white module is for 24VDC inputs supply to the Quantum™ LX provide all of the neces-
channels. The standard Quantum™ LX for CYK will sary D.C. voltage that is required (+5 VDC, -12 VDC,
have two Digital Boards. +12 VDC, and Return or Common). The voltages are
passed through the connector on the Quantum™ LX,
Communications LED's and two new signals are generated by the Quantum™
The Quantum™ LX controller is in constant commu- LX to be passed on through the daisy chain to the I/O
nication with all Digital (and Analog) Boards. You will boards. These two signals are the RX (receive) and
notice on each Digital and Analog board, that there TX (transmit). These signals are the means by which
are a pair of LED's labeled as RX and TX. These let- the Quantum™ LX communicates to the I/O.
ters represent Receive (RX) and Transmit (TX). These
The Digital Boards only require the +5 VDC voltage
LED's should be flashing at a high rate during normal
and the Return (or common) for logic power. The com-
operation. This indicates that the Quantum™ LX, and
munications signals (RX and TX) are required by all
the Digital Board that you are looking at, are properly
boards.
communicating with each other.
Reference the JUMPER AND DIPSWITCH SET- Logic Voltage (Power) LED
TINGS section later in this manual. This section con- Located on the Digital Board is a Power LED. This
tains the dipswitch settings for addressing the Digital LED will be illuminated as long as the Control Power
I/O Boards. When these switches are properly set, the switch is ON, and the proper voltage is present at the
Quantum™ LX is able to serially communicate with Quantum™ LX power supply. The power supply gen-
each I/O board and provide control signals and data erates the +5 VDC voltage and passes it on through the
exchange. If these switches are not properly set, the Power-I/O harness. This LED does not indicate how-
result will be lost or failed communications, the wrong ever that the proper voltage is necessarily present at the
outputs being energized, or the wrong inputs being re- board, only that the voltage is enough to energize the
ceived. voltage sensing circuitry. If a voltage related problem
is suspected with regard to a Digital Board, the only
Connections to the Quantum™ LX way to actually determine this is to read the voltage on
As stated earlier, the Quantum™ LX for CYK control a Digital Voltage Meter (DVM). This may be accom-
system utilizes two Digital, and two Analog Boards. plished by locating the white power / communications
(A third Analog board is optional for motor tempera- connector on the board. Notice that the Digital Board
ture or vibration monitoring.) To connect all of these has one of these connectors on both ends of the board.
boards together so that the Quantum™ LX can con- The associated power/communications harness will
trol them, they must be interconnected with a wiring only be plugged into one of these connectors. Take the
harness that provides all of the necessary D.C. voltage red (positive) probe of the DVM and carefully insert

JOHNSON CONTROLS 19
 FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

the end into the “+5V” lead, and the black (negative) is present on the Oil Level Sensor input, the software
probe end into the “RET” (Return or Common) lead, as will determine that the Separator has sufficient oil level
shown in the previous section. for the oil heaters to be energized (if the temperature
of the oil is also sensed to be low. Temperature sensing
Set the DVM to read DC, and set the proper range. The will be discussed in the Analog Input section). There are
voltage reading must read a minimum of +5.0 VDC. The two possible varieties of Digital Input modules used on
Power-I/O harness will have an associated voltage drop at Frick standard control packages, however the CYK sys-
each board connection. As an example, if you are reading tem only uses 120 VAC modules. Both of these module
the voltage at the first I/O board in the daisy chain, and it styles for 240 VAC and 120 VAC are yellow in color. Be
reads 4.98 VDC, you can be assured that the voltage at the certain that you have the correct module for 120 VAC. A
subsequent connections for the remaining boards will be side profile of these modules is shown below:
lower yet. The voltage will need to be corrected for proper
operation of the system. The cause for a low voltage read-
ing could be: COM OUT VDC
5VDC LOGIC
90 140 VDC
AC INPUT
COM OUT VDC 180-280 VAC
5VDC LOGIC AC INPUT
5 4 3 2 1 5 4 3 2 1
• The Quantum™ LX power supply may need ad- - + + - - + + -

justment (see the section on power supplies).

120 VAC Input 240 VAC Input
• The Power-I/O communications harness has a LD15226

problem (a new harness may be needed).

Figure 8 - DIGITAL INPUT MODULES
• A problem may exist with one of the I/O boards
(Digital or Analog). These Input modules, can be identified as to their op-
• If the power LED is not lighted, check the cable erating voltage by looking at either the side, as shown
for proper connectivity. Note: Each board pro- above, or from the top. You will notice the module
vides the necessary connections to feed all sig- operating voltage printed on the top, and the voltage
nals to the following connectors. If the auxiliary range printed on the side.
Analog board is not installed, then a jumper plug Never plug a 120 Volt Input module into a 240 Volt
(see Renewal Parts List) must be installed to daisy system, and vice-versa. Never plug an Output module
chain the signals. into a position designated for an Input module. You will
The most common problem that is due to a low +5 notice that when a module is plugged into the Digital
VDC voltage to the Digital Boards is an alarm message board, there is a fuse located directly adjacent to the
that reads Digital Board Reset Shutdown. module. This fuse is of the pluggable variety, and must
be plugged into the IN position for an Input module.
Active LED
Digital Outputs
The Digital Boards have an Active LED indicator on
the board that blinks when the board’s software is A Digital Output is the portion of the hardware that
running. The activity LED indicators are labeled TX the Quantum™ LX is to control (energize). These de-
and RX. If the Active LED’s are not blinking, check vices include solenoids, relay coils, and heaters to be
to ensure that the EPROM is installed properly. The energized, based upon the logic within the Quantum™
EPROM is located in chip slot U8, next to the power LX software program. There is one variety of Digital
connector. Output modules used on standard compressor control
packages. This module is black in color. A side profile
Digital Inputs of this module is shown below: Although this Output
A Digital Input is the portion of the hardware that allows module is labeled as 280 VAC on the top, and on the
devices such as limit switches, relay contacts, and level side, it can be used on both 120 and 240 volt appli-
switches, to interface with the Quantum™ LX. The soft- cations. Never plug an Input module into a position
ware program within the Quantum™ LX is constantly designated for an Output module. You will notice that
looking at these Input channels, via communications, when a module is plugged into the Digital Board, there
and based upon whether a control voltage is present or is a fuse located directly adjacent to the module. This
not, will provide the necessary control for an associ- fuse is of the pluggable variety, and must be plugged
ated Output channel. For instance, if a control voltage into the OUT position for an Output module.

20 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

Checking The Digital Inputs and Outputs 8. If the fuse is faulty, check for external shorts on
Some problems that may be encountered involve trou- the corresponding circuit, the replace the fuse 1
bleshooting the digital inputs and outputs. The Digital with a new plug-type fuse (refer to Recommended
I/O (Input / Output) Boards have six Digital I/O (DIO) Spare Parts list).
board connectors labeled P1 through P6. The Input and Input and Output Module Testing and
Output modules are wired to a DIO connector plug. Replacement
Position 3 provides power and position 4 is a neutral on
the DIO connectors. Positions 1, 2, 5, and 6 are signal 1. Power off the panel.
connections, as shown below: 2. Open the panel door.
1 2 3 4 5 6 3. Replace the questionable module.
4. Power on the panel.
Position Position
1 Signal 2 Signal HOT
Position Position
NEUTRAL 3 Signal 4 Signal 5. If it is an Output module, check for proper panel
LD15227 voltage on the DIO connector plug. Check the
voltage between position 4 (neutral) and the as-
Figure 9 - DIO CONNECTOR PLUG
sociated position to the Output module.
6. If it is an Input module, check if the associated
The Digital I/O board’s I/O modules are configured by LED is on when power is applied to the module.
proper module selection, AC or DC, operating volt-
age, input or output, and moving the fuse to the in or Troubleshooting an Output
out position. The CYK I/O boards will be configured
1. Make sure the LED associated with the Output is
properly, refer to the Renewal Parts manual for details.
on when power is applied to the module.
An LED is associated with each module and displays
the state of each module. A lit LED represents an In- 2. If the LED is on when it should be, check for
put that is High, receiving a signal or an Output that proper panel voltage on the DIO connector plug.
is On. Each of the sixteen modules has a correspond- Check the voltage between the position 4 (neutral)
ing display value shown on the I/O diagnostics screen. and the associated position to the
If a properly configured Digital I/O is not responding
3. Output module.
correctly, first look at the Digital Board on the “Setup
Screen >> Digital I/O” and check if the module is on. 4. If the voltage is OK, check for proper panel volt-
If it is not on, check if the LED on the Digital Board is age between the associated position to the
also not lit. If the LED is not lit, then check the fuse. If
5. Output module on the DIO connector and the as-
the fuse is OK, then check the module.
sociated position on the terminal strip.
Fuse Testing and Replacement 6. If the voltage is OK, check the wiring external to
1. Power off the panel. the panel.

2. Open the panel door. 7. If voltage is not OK, check the fuse.

3. Remove the questionable fuse. 8. If the fuse is OK then check the module.

4. Place the questionable fuse into the fuse tester at 9. If the module is OK, check for proper panel volt-
the one end of each Digital I/O Board refer to the age on the DIO connector plug between position
Digital Board drawings at the end of this section 3 (Hot) and position 4 (neutral).
for exact fuse tester location). 10. If the LED is not on when it should be and there
5. Power on the panel. is no operating condition preventing it, contact the
Service Department.
6. Check the LED on the tester. If the LED is lit, the
fuse is OK.
7. Power off the panel.

JOHNSON CONTROLS 21
 FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

Troubleshooting an Input Replacing a Defective Digital Board

1. Make sure the LED associated with the Input is on The procedure to replace a Digital board is outlined
when power is applied to the module. below:
2. If the LED is on then the fuse and Input module 1. Shut off control power.
are good.
2. Remove the old board from the machine and the
3. If the LED is on and there is no input voltage, new board from its packing and place both on an
replace the Input module. anti-static surface.
4. If the LED is not on when power is applied, check 3. Check that all jumpers, dipswitches and compo-
the fuse. nents are properly setup on the new board as it
5. If the fuse is good, replace the Input module. was on the old board (refer to the Digital Settings
tables near the end of this section).
6. If you are receiving an Alarm or Shutdown from a
digital input in which the adjacent LED indicator 4. Install the modified replacement board in the panel.
light is on, check the Service Screen to see if that
channel is turning on and off. If so, replace the
input module.

22 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

DIGITAL BOARD #1
INSTALL FUSES AND MODULES AS SHOWN 1
Black = Output, Yellow=Input 120v, White=Input 24VDC

LD15299

Figure 10 - DIGITAL BOARD #1

JOHNSON CONTROLS 23
 FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

DIGITAL BOARD #2
INSTALL FUSES AND MODULES AS SHOWN
Black = Output, Yellow=Input 120v, White=Input 24VDC

LD15300

Figure 11 - DIGITAL BOARD #2

24 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

Analog Board Analog Board Description (32 Channel)

The Analog Board is actually a small microprocessor
1
Overview
board and is programmed to control analog outputs,
The Frick Quantum™ LX control panel is capable of
or accept analog inputs, from external electrical de-
reading external analog devices, such as temperature
vices. Each enhanced board has the capability of 24
probes and pressure sensors. It uses these input signals
independent input channels. With the Quantum™ LX
for the purpose of monitoring and control. As an ex-
CYK Control panel, these I/O channels are dedicated
ample, if an external temperature sensor began to read
through the software and external wiring, as to the
a higher than expected temperature in some area, the
function of each channel. The Quantum™ LX control-
controller would sense this change, and provide the
ler can utilize up to three separate analog boards (Ana-
necessary output control signal to remedy the situation.
log board #1, #2, and optionally #3), depending on the
Unlike a digital signal, which is typically either an on
selected options.
or off state, an analog signal can assume a wide variety
of states, such as a temperatures probe reading a wide The CYK application requires a specific
range of temperatures. The method used for receiving level of firmware in the Analog I/O board.
(and sending) these signals, is the analog board. The Only use the approved part number for
analog devices are wired directly to the board, and the Analog Board #2, which controls the
on-board software/hardware converts the electrical PWM output control of the VS Oil Pump
signals received from these devices into data, which Drives. Only replace an Analog Board #2
is then sent on to the Quantum™ LX control board via that has a Firmware Version 2.52 or high-
communications, and is monitored by the Operating er, refer to the Renewal Parts manual.
system.

DIGITAL BOARD SETTINGS

Table 1 - COMMUNICATIONS SETTINGS

The following table is to be used when configuring the Quantum™ LX for external communications.
in 120 ohm long communications line termination.
J5
out* No termination.
in RS-422/485 transmit pull-up for long communications lines.
J7
out* No pull-up.
in RS-422 transmit pull-up for long communications lines.
J8
out* No pull-up.
in RS-422/485 receive pull-down for long communications lines.
J9
out* No pull-down.
in RS-422 receive pull-down for long communications lines.
J10
out* No pull-down.
* standard setting

Table 2 - DIPSWITCH SETTINGS

The following table is to be used to set the digital board addresses. If there is only one board installed, it should be set as
board #1, if there are two boards they each need to be set according to the wiring diagrams.
SW1 SW2 SW3 SW4 SW5 SW6
Board #1 on on on on off on
Board #2 off on on on off on

JOHNSON CONTROLS 25
 FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

Communications LED's nector on the Quantum™ LX, and two new signals are
The Quantum™ LX controller is in constant communi- generated by the Quantum™ LX to be passed on through
cation with the Analog (and Digital) Board(s). You will the daisy chain to the I/O boards. These two signals are
notice on each Analog and Digital board, that there is a the RX (receive) and TX (transmit). These signals are
pair of LED's that are labeled as RX and TX. These let- the means by which the Quantum™ LX communicates
ters represent receive (RX) and Transmit (TX). These to the I/O. The Analog Board requires the +5 VDC for
LED's should be flashing at a high rate during normal logic, the -12 VDC for internal voltage reference, and
operation. This indicates that the Quantum™ LX, and +12 VDC for external sensors (plus or +) and the Return
the board that you are looking at, are properly commu- (common or -). The communications signals (RX and
nicating with each other. TX) are required by all boards.

Refer to the Analog I/O board setup later in this sec- Logic Voltage (Power) LEDs
tion. This section contains the dipswitch settings for Located on the enhanced Analog Board are two power
addressing the Analog I/O Boards. When these switch- LEDs. The first of these is D1 LED (+5VDC), and will
es are properly set, the Quantum™ LX is able to se- be illuminated as long as the Control Power switch is
rially communicate with each I/O board and provide ON, and the proper voltage is present at Analog Board
control signals and data exchange. If these switches are connector P3. The power supply generates the +5 VDC
not properly set, the result can be one of the following: voltage, and passes it on through the Power-I/O har-
ness. This LED does not indicate however that the
• Lost or failed communications (displayed in the
proper voltage is necessarily present at the board, only
Communications Status box on the Home screen)
that the voltage is enough to energize the voltage sens-
• The wrong analog input signals being received ing circuitry. If a voltage related problem is suspected
with regard to an Analog Board, the best way to actu-
• The wrong analog output signals being sent from
ally determine this is to read the voltage on a DVM
the board.
(Digital Volt Meter). This may be accomplished by lo-
Connections to the Quantum™ LX cating the white power / communications connector on
the board. Notice that the Analog Board has only one
A copy of the chiller elementary wiring schematic is
of these connectors. The associated power/communi-
shipped with the CYK in a document pocket in the
cations harness plugs in to it. Take the red (positive)
control panel (see the Chiller Elementary Schematic
probe of the DVM and carefully insert the end into the
drawing). This harness has a 6-pin connector at one
+5V lead, and the black (negative) probe end into the
end that plugs into the Quantum™ LX. Another con-
RET (Return or Common) lead, as shown below:
nector plugs into the power supply. The remaining four
connectors (16 pin) will plug into each of the Digital
and Analog Boards in the system (up to four total).
Upon close examination of this harness, you will notice
that each of the connectors for both the Quantum™ LX
and the four I/O boards, have two rows of connections.
The wires that are inserted into the positions of one row
are internally daisy chained on each I/O board, to con-
tinue the voltages and signals to the adjacent row. There-
fore, any time that a connector is unplugged from the
daisy chain, these voltages and signals cannot continue
through to the next board. Whenever a plug is not to be
inserted onto a board, either for servicing, or if not all
boards are present because of the options that are present,
then a shunting plug (refer to the Recommended Spare
Parts list) must be installed onto the open connector. The
four wires that feed from the power supply to the Quan-
tum™ LX provide all of the necessary D.C. voltage that LD17443

is required (+5 VDC, -12 VDC, +12 VDC, and Return Figure 12 - POTENTIOMETER ADJUSTMENT
or Common). The voltages are passed through the con-

26 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

Set the DVM to read DC, and set the proper range. The ed, check the cable for proper connectivity. Note:
voltage reading must read a minimum of +4.98 VDC. Each board provides the necessary connections to 1
The Power-I/O harness will have an associated voltage feed all signals to the following connectors as in a
drop at each board connection. As an example, if you “daisy-chain” network.
are reading the voltage at the first I/O board in the daisy
chain, and it reads 4.98 VDC, you can be assured that the Active LED
voltage at the subsequent connections for the remaining The Analog Boards have an Active LED indicator that
boards will be lower yet. The voltage will need to be blinks when the board’s software is running. If the Ac-
corrected for proper operation of the system. tive LED is not blinking, it could be an indication that the
internal program is not running. Try powering the Quan-
The cause for a low voltage reading could be:
tum™ LX controller off, then back on to see if the Active
• The Quantum™ LX power supply may need ad- light starts blinking. If not, a new board may be required.
justment (see the section on power supplies).
• The Power-I/O communications harness has a Analog Inputs
problem (a new harness may be needed). An Analog Input is the portion of the hardware that
• A problem may exist with one of the I/O boards allows devices such as temperature sensors and pres-
(Digital or Analog). If the power LED is not light- sure transducers to interface with the Quantum™ LX.

Table 3 - ENHANCED ANALOG BOARD INPUT CONFIGURATION TABLE

CT ACCELEROMETER RTD (MOTOR
POT
CHANNEL ICTD 0-5VDC 0-10VDC 0-20MA (MOTOR (VIBRATION PROTECTION
(POTENTIOMETER)
CURRENT) MONITORING) ONLY)
1 * * * * *
2 * * * * *
3 * * * * *
4 * * * * *
5 * * * * *
6 * * * * *
7 * * * * *
8 * * * * *
9 * * * * *
10 * * * * *
11 * * * * *
12 * * * * *
13 * * * * *
14 * * * * *
15 * * * * *
16 * * * *
17 * * * * * *
18 * * * * * *
19 * * * * * *
20 * * * * * *
21 * * * * * *
22 * * * * * *
23 * * * * * *
24 * * * * * *
NOTE: Enhanced Analog Board 2 can utilize channels 17 through 24 for PhD if Analog Board 1 is of the old style. Refer to the section on
Software Configuration for specific information on the procedure to set these channels.

JOHNSON CONTROLS 27
 FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

The software program within the Quantum™ LX is sensor calibration screen. These settings are all pre-
constantly looking at these Input channels, via com- programmed at the factory for the CYK Quantum™
munications, and based upon what the voltage or cur- LX control center. Improper setup of either the hard-
rent level of the channel is, will provide the necessary ware or software will result in improper operation or
control for an associated action. (Digital Inputs are dis- range. The most common fault associated with the im-
cussed in the Digital Input section). proper reading of the analog channels other than hard-
ware or software setup problems fall into one of the
Analog inputs arrive at the board on connectors P4 following categories:
through P10. Each of these connectors can receive two
channels (for a total of twenty-four). Each of the twen- • Sensor fault
ty-four analog input channels is board software config-
• Wiring problem
urable to select for the following type of input signals:
• Improper grounding of system.
Analog Outputs
An open wire, shorted wire, or faulty sensor will usu-
An Analog Output is the portion of the hardware that ally give a reading at either the minimum or maximum
the Quantum™ LX uses to provide control. With the end of the range scale. An erratic reading or a reading
Quantum™ LX, this output is dedicated for a 4-20 mA that seems to float up and down is usually indicative
signal that is outputted to an external device, and can- of a grounding problem. When a single transducer or
not be changed through the software configuration. cable is shorted to earth (or system) ground, this can
show up as a whole assortment of problem channels.
Troubleshooting the Analog Inputs and Outputs
The easiest way to find a short to earth problem is to
Some problems that are encountered involve trouble- disconnect all the sensor plugs and ohm out each plug
shooting the Analog inputs and outputs. The Analog screw terminal to earth for open (infinite) impedance.
Board has twelve Analog I/O board connectors labeled All sensors should read open to earth with the excep-
P4 through P10. The external Analog devices are wired tion of the CT motor current channel. One side of the
to a connector plug. Position 1 connects to the plus (+) CT is grounded in the Motor Terminal Box. (The third
of the external device for channel 1, position 2 connects pin on pressure sensors is ground.)
to the signal (SIG) of the external device for channel 1
and position 3 connects to ground (GND) of the ex- Replacing a Defective Analog Board
ternal device for channel 1. Position 4 connects to the The procedure to replace an Analog board is outlined
plus (+) of the external device for channel 2, position 5 below:
connects to the signal (SIG) of the external device for
channel 2 and position 6 connects to ground (GND) of 1. Shut off control power.
the external device for channel 2, as shown below:
2. Unplug all connectors from the board. Remove
Channel 2 Channel 2 the old board from the machine and remove the
+ Signal GND
new board from its packing and place both on an
anti-static surface.
Channel 1 Channel 1 3. Check that all jumpers and dipswitches are prop-
+ Signal GND
LD15229
erly setup on the new board as it was on the old
board.
Figure 13 - ANALOG OUTPUTS
4. Install the modified replacement board in the panel.

Each input channel is configurable through the op- 5. Plug all connectors back in.
erating software. There are twenty-four analog input 6. Turn on control power.
channels that can be selected for 4-20 mA, 0-5 VDC,
0-10 VDC, 0.5-4.5 VDC Ratiometric, ICTD, or RTD. 7. After replacing or installing an Analog Board and
Channel #16 will also take the 0-1 Amp motor CT as an powering on the control panel, select [Redetect
input. Besides properly setting the software configura- I/O Comms] from the Home >> Setup >> Serial
tion, each channel is setup through software calibra- Port Setup screen (from Service User level 2).
tion for the proper transducer type and range, and each This selection provides a method to detect all con-
transducer must be calibrated through the appropriate nected Analog and Digital boards. If a board has

28 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

been removed, a communication error shutdown or from an external source. When reading motor amps
will be issued until this key is selected. The History directly at the P8 terminal strip from a CT, the input 1
screen will show what was detected. The [Redetect signal cannot exceed 5 amps. TR1 and TR2 timers in
I/O Comms] key resets the memory of the proces- the control panel will provide a short around the motor
sor as to which boards it requires communications current detection circuitry to avoid any currents over
from. Therefore, it is important to check the His- 5 amps from reaching the detection circuitry during
tory screen to see which boards have been detected Locked Rotor Amp inrush. If you are using an exter-
relative to the I/O boards actually in the panel. nal direct current mA or voltage device, remove the
jumper at Link 2, and connect the wiring to connector
Current Transformer (Motor Amps) P7B. If you intend on utilizing the on-board current
Channel 16 of Enhanced Analog Board 1 is dedicated transformer, then install Link 2, and connect the wiring
to reading motor amps, either through the use of the on to Channel 16, as shown in the diagram below:
board current transformer when using a 0-1 amp CT,

LK2
Install this jumper when
using the on board Current
Transformer and connector
P8 to use CH. 16 (P8)
to read Motor Amps

Remove for CH. 16 external

Motor Amps signal and
connect to P7B directly

CH. 16
Current Transformer (CT)
connection - Standard direct
connection, 0 - 5 amp input
(Install LK2)

CH. 16
Motor Amps - Alternate
external signal connection,
0 - 20mA input
(Remove LK2)

LD15286

Figure 14 - MOTOR AMPS

JOHNSON CONTROLS 29
 FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

D5 - +24VDC Power LED CH. 8 Output

CH. 4 Output
CH. 7 Output
CH. 3 Output
CH. 6 Output
LK3 and LK4 CH. 2 Output
Install for Vibration
CH. 5 Output
Sensor Gain
(When needed) CH. 1 Output
CH. 24 Input
P1 - J-TAGG Port
CH. 22 Input
CH. 23 Input

SW1 - DIP Switch CH. 21 Input

(See Settings Chart) CH. 20 Input
CH. 18 Input
CH. 19 Input
CH. 17 Input

LK 2 - Install jumper for CH. 16 CT,

Remove for CH. 16 Motor Amps

CH. 16 - Current Transformer (CT) -

Standard (Install LK2)

CH. 16 Input - Motor Amps (Remove LK2)

Current Transformer (Install LK2)
CH. 14 Input

D9 - Active LED CH. 15 Input

D3 - Not Used CH. 13 Input
D2 - Not Used
D7 - COMM Rx LED
D8 - COMM Tx LE CH. 12 Input
CH. 10 Input
LK1 - Install for 120 ohm
terminator on RS-485 CH. 11 Input
Communications CH. 9 Input
CH. 8 Input
CH. 6 Input
CH. 7 Input
CH. 5 Input
CH. 4 Input
CH. 2 Input
CH. 3 Input
D1 - +5VDC Power
CH. 1 Input

+5 VDC
+12 VDC +Tx/+Rx
-12 VDC -Tx/-Rx
GND
LD15287

Figure 15 - ENHANCED ANALOG BOARD DIAGRAM

30 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

ENHANCED ANALOG BOARD SETTINGS

1
Table 4 - COMMUNICATIONS
The following table is to be used when configuring the Quantum™ LX for external communications.
In 120 ohm long communications line termination.
LK1
Out* No termination.
* default setting

Table 5 - CURRENT TRANSFORMER (CT)

ANALOG BOARD #1 ANALOG BOARD #2
In* Install for CT (Current Transformer). In* (Must be removed)
LK2 LK2
Out Remove to read Motor Amps on P8. Out Remove ( Not Used)
* default setting

Table 6 - DIPSWITCH SETTINGS (USED TO SET THE BOARD ADDRESS)

The following table is to be used to set the analog board addresses. If there is only one board installed, it should be set as
board #1, if there are two boards they each need to be set according to the wiring diagrams.
SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
Board #1 off off off off off off off off
Board #2 on off off off off off off off

Table 7 - ANALOG BOARD

DESCRIPTION ENHANCED ANALOG BOARD
Input Channels 24
Output Channels 8 (no driver chips required)
On Board CT (Current Transformer) Yes (transformer incorporated on board
On Board Vibration Circuit Yes (no external modules required)
Channel Configuration Software
Dimensions 4" x 11" (fits original board footprint)
Types of inputs:
4 - 20mA Yes
0 - 5 volt Yes
1 - 5 volt Yes
ICTD Yes
RTD (1000 platinum) Yes (currently for motor RTD inputs only)
Support Quantum™ LX Software Version Resides in Flash Memory
(Version 5.xx)
Service Dates June 2003 - Present

ANALOG ANALOG ANALOG ANALOG

REPLACEMENT PART NUMBERS
BOARD 1 BOARD 2 BOARD 1 BOARD 2
Baltimore Parts Replacement 640C0026G01 640C0026G02 640C0057G01 640C0057G02
Field Installation Kit N/A 640C0057G11 N/A 640C0057G12

JOHNSON CONTROLS 31
 FORM 160.82-OM1
SECTION 1 - DESCRIPTION OF SYSTEM
ISSUE DATE: 8/30/2013

THIS PAGE INTENTIONALLY LEFT BLANK

32 JOHNSON CONTROLS
FORM 160.82-OM1
ISSUE DATE: 8/30/2013

SECTION 2 - FUNDAMENTALS OF OPERATION

Quantum™ LX
2

7 8 9
4 5 6
1 2 3
. 0 +/-

LD15323

Figure 16 - QUANTUM™ LX KEYPAD

OPERATOR INTERFACE

Description 1. Shut off control power.

The Quantum™ LX Operator Interface actually con- 2. Remove the defective display.
sists of two components: A color 10-1/2” (diagonally
measured) graphic display, and a membrane touch key- 3. Install the new display.
pad, The display is used to view information coming
Keypad
from the Quantum™ LX controller, while the keypad
and touch display allows the user to enter information The Keypad consists of two areas, the Display window
into the controller. and the Keypad itself. The Display window is simply
a clear portion of the Keypad assembly which the Dis-
Display Assembly play is able to be viewed through. The Keypad area
consists of a series of 27 membrane switches. Depress-
The Display assembly consists of a 640 x 480 resolu-
ing each switch (key) should result in an audible tac-
tion, LCD screen (which includes a fluorescent back-
tile clicking sound. To ensure that each key is actually
light tube, a backlight inverter circuit board, a wiring
functioning, visually inspect the D8 LED located on
harness, and a touch sensitive layer. Refer to the Re-
the keypad interface board control board. This LED
newal Parts List manual for specific replacement part
will normally flash on and off at a rate of about once
numbers.
per second. Pressing a key on the keypad will interrupt
Before replacing a display unit, ensure this flash rate, and repeatedly depressing a key will
that the symptom is not actually being cause the LED to flash each time a key is pressed.
caused by a bad fluorescent tube, inverter
or harness. Keypad Replacement
1. Shut off control power.
2. Unplug the defective keypad from the Quantum™
Display Replacement LX.
3. The keypad is affixed to the controller door with
a double-sided tape film. Start by lifting the key-

JOHNSON CONTROLS 33
 FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

pad at one of the corners. Once the keypad starts 7. Carefully align the keypad on the door, ensuring
to break free from the underlying tape, continue that the display is centered within the window of
pulling. A carefully used putty knife can help to the keypad. Once you are satisfied with the posi-
separate the keypad from the adhesive. tion, firmly press the keypad into place.
4. Once the keypad has been entirely removed, you 8. Plug the keypad cable back into the Quantum™
will notice that much of the double-backed tape LX.
is remaining on the panel door. Carefully using a 9. Turn Control power back on.
window scraper style razor will remove most of
this tape. Be careful not to scratch the paint out- 10. Test the new keypad as described earlier.
side of the keypad footprint.
5. Take the new keypad, and feed the flat cable
through the slotted opening at the bottom of the
display area.
6. Remove the paper backing of the keypad to ex-
pose the double-backed tape underneath.

LD15289

Figure 17 - QUANTUM™ LX BASIC PANEL LAYOUT

34 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

CONDENSER

HIGH-STAGE PCV-116
HOT GAS

LOW-STAGE
LCV-114
INTERCOOLER

LCV-116
EVAPORATOR

LCV-117
LD15238

Figure 18 - GENERAL OPERATING SEQUENCE

Unit Not Operating • The Variable Geometry Diffuser(s) are set to the
1. Control power is available to the control panel. “StartCV” command position.

2. Compressor sump oil heaters are thermostatically • Oil Heaters are controlling the oil temperature to
controlled 53°F above saturation. maintain 53°F above saturation.
Only apply auxiliary control voltage to System Startup
the chiller when the oil sumps have been
1. All chiller safety logic must be satisfied prior to
filled with oil. Uncovered oil heater as-
starting, with the exception of the compressor oil
semblies will produce high temperatures
pressure. The oil pressure safeties are bypassed
and destroy chiller oil sump components.
initially, until the main oil pumps can establish
pressures. The flow safeties are bypassed until the
3. The capacity controls are disabled. water pumps can establish flows. 5 seconds be-
• The compressor pre-rotation vanes are closed. fore the Pre-lubrication cycle completes the flows
must be established, or the unit will trip on loss of
• The hot gas bypass is closed when the evapo- water flow.
rator pressure is below a freezing potential /
open above freezing The hardwired safety relay MUST be clear
of previous safety trips or power failures.
• The subcooler valve is closed above freezing The R1 hardwired safety relay must be
potential, open below freezing potential. physically reset. The R1 relay is hardwired
• The economizer valve is partially open. in series with the high-pressure cutout and
the emergency stop to shut down the main
• The economizer bypass valve is partially motors in the most extreme danger.
open.

JOHNSON CONTROLS 35
 FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

During the commissioning procedures, The chilled and condenser water flows
the Emergency Stop button should be must be established by the customer's
pressed in, and R1 relay should be re- pump control system or manually by the
moved to prevent any undesired and operator within 45 seconds after a start is
inadvertent operation of the main motor initiated in order to close the chilled and
starters. The Emergency Stop button is condenser water low flow cutout contacts
the “twist to reset” type. and continue with the start sequence.
The System Status indicator box in the 3. With the above “START INITIATED” signal,
upper left corner of the DISPLAY screen the chiller controls start the low stage VSD oil
will display the GREEN text “READY pump and their respective representations on the
TO START.” This display will change display indicate a running oil pump. The oil heater
at various times during the start-up and shuts down during oil pump operation. A Pre-lube
shutdown of the chiller. of 50 seconds will be started on the low stage
compressor. The VSD Oil Pumps will produce 45
See Graphic Displays for further details on the op-
psid (3.10 BarD) pressure for the first 15 seconds
erator interface.
of runtime. After 15 seconds, then they will main-
If the chiller has been recently started and shut tain the setpoint of 36 psid (2.48 BarD).
down, the motor must remain off for sufficient
4. If the pumps fail to start within 2 seconds after
time to cool down. See “Anti-recycle operation”
the PLC output is energized, an alarm signal will
at the further details.
be transmitted to the DISPLAY for indication and
2. The chiller start may be initiated at this time by recording.
pushing the START key . 5. Low Head Start
Local vs. Remote control of the start
is established by the condition of the If the lift requirements of the chiller are less than the
“LOCAL-REMOTE START” buttons on Immediate Two Stage threshold, sensed by enter-
the “Evaporator” Screen. A start mode ing Condenser Water Temperature minus Entering
change may only be made with the unit Chilled Water Temperature, the system will start in
stopped. single stage mode. The low stage motor contactor
will engage only after pre-lube is completed. When
When in LOCAL, the start sequence begins as the starter has completed and the transition to full
soon as the operator pushes the START key voltage operation, an auxiliary contact from the
on the front of the chiller control panel. starter run (full voltage) contractor is input to the
chiller control panel to operate the following:
When in REMOTE, the “DCS CHILLER RE-
MOTE START CONTACT” at (Across the net- a. The capacity control system will be put into
work interface) must momentarily close to en- a hold condition in order to establish a level
ergize and initiate the chiller start sequence. within the economizer vessel. The Econo-
Alternately, the chiller can be started by a remote mizer Level control valve LCV-116 will
run contact. The option for remote hardwired start start ramping closed to maintain a level in
must be configured on the Evaporator Screen. the economizer. The LCV-116 will maintain
This will be covered in this section. the economizer level until shutdown. This
refrigerant inventory management procedure
insures that vast quantities of refrigerant

LD15240

Figure 19 - SYSTEM STATUS

36 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

aren’t accumulated in the evaporator, which A. The capacity control system will be put into a hold
can cause liquid carryover. condition in order to establish a level within the
economizer vessel. The Economizer Level control
b. Once the economizer level has been estab-
valve LCV-116 will start ramping closed to main-
lished, the capacity controls enable. Com-
tain a level in the economizer. The LCV-116 will
pressor pre-rotation vanes and hot gas bypass
valve will now begin to ramp open / closed
maintain the economizer level until shutdown. This 2
refrigerant inventory management procedure insures
respectively at a predetermined rate. See “Ca-
that vast quantities of refrigerant aren’t accumulated
pacity Control Operation” for further details
in the evaporator, which can cause liquid carryover.
on the ramp-up of the controls.
B. Once the economizer level has been established,
After the interlock is established, the com-
the capacity controls enable. Compressor pre-ro-
pressor pre-rotation vanes are opened to
tation vanes and hot gas bypass valve will now be-
their minimum position necessary to prevent
gin to ramp open / closed respectively at a prede-
“surging” during the initial acceleration at
termined rate. See “Capacity Control Operation”
start-up.
for further details on the ramp-up of the controls.
c. After the low stage compressor interlock is After the motor starter interlock is established, the
closed and the minimum vane position is compressor pre-rotation vanes are opened to their min-
reached, the capacity controls try to maintain imum position necessary to prevent “surging” during
the chilled water out temperature. The system the initial acceleration at start-up.
status display will display “LOWSTAGE
RUN” with only the Low Stage compressor The capacity controls operate to control chiller capac-
running in Single compressor mode. ity in response to process water outlet temperature.
The hot gas will ramp closed first while maintaining a
d. If the system head exceeds a predetermined
minimum vane anti-surge position on the vanes. If pro-
Head pressure threshold, the high stage will
grammed for Load Matching, the High Stage vanes are
be prelubed and started. This mode is 2-stage
reacting to the motor current of the Low Stage com-
operating mode and will allow the chiller
pressor. The capacity controls are further described by
to operate over a wider range of head con-
flowchart in a later section. The system status display
ditions. The booster stage allows the chiller
will display “SYSTEM RUN” with both stages of
to produce a greater lift, than a single stage
compression running.
could possibly produce.
e. As the High Stage Compressor vanes open, If the Head on the chiller reduces to below a program-
the refrigerant path is re-directed from the mable threshold, the High Stage compressor will be
bypass check valve, into the High Stage dropped offline. Under this condition, the low stage
compressor. The check valve seals off the by- compressor will continue to run and attempt to make
pass path around the High Stage compressor, capacity with a reduced requirement for lift.
producing two stages of compression.
Ramp-Up of Capacity Controls
6. High Head Start The ramp-up feature is used to provide a gradual in-
If the lift requirements of the chiller are greater than crease in chiller capacity during start-up.
the Immediate Two Stage threshold, sensed by enter- Refer to the “Capacity Control Diagrams” in Figure 25
ing Condenser Water Temperature minus Entering on page 51 along with the following to best under-
Chilled Water Temperature, the system will start in stand the operation.
two stage mode. The low stage motor contactor will
engage only after pre-lube is completed. When the The DISPLAY will indicate when the “CHILLED WA-
starter has completed and the transition to full volt- TER OUT TEMPERATURE CONTROL” is in the
age operation, an auxiliary contact from the starter manual mode.
run (full voltage) contractor is input to the chiller
control panel to engage the High Stage starter, which This occurs when the unit is shut down, during ramp-
started its pre-lube process only seconds after the up and when the “DEMAND LIMITER” or the “EVAP
Low stage pre-lube process had started. LOW PRESS. OVERRIDE” control signal is being
used to control the capacity of the chiller.

JOHNSON CONTROLS 37
 FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

With the unit stopped, the “CHILLED WATER OUT When the ramp-up is completed (PRV signal at 100%)
TEMPERATURE CONTROL” is in manual, its and/or the “CHILLED WATER OUT TEMP. CON-
setpoint is equal to the chilled water out temperature TROL” is changed to automatic, its setpoint will return
and its output is equal to the PRV signal. (When in to whatever setpoint is stored in the PLC memory at
manual, the controller drives its output to the same as that time (if in “LOCAL SETPOINT” mode), or will
the tieback valve, which would be 0% with unit off.) change to the PROGRAMMED remote setpoint (if
in “REMOTE SETPOINT” mode). The setpoint will
When start is initiated, the PRV signal goes to the “PRV
change slowly at a rate determined by the “SETPOINT
START-UP SIGNAL” value. This value determines the
RAMP” rate value to the desired value.
position of the compressor pre-rotation vanes at the in-
stant the main motor starts. It is adjusted to keep the start- The above tracking and reset tieback controls disable
ing load on the motor low but also allow enough gas flow the “CHILLED WATER OUT TEMP. CONTROL”
through the compressor to prevent surging at start-up. during shutdown and ramp-up when other logic is in
control and provide for a smooth transition to automat-
After the compressor motor starts, the “START-UP SIG-
ic control as required.
NAL” value increases at a rate determined by the “PRV
Ramp Rate” setpoint until it reaches PROGRAMMED The “CAPACITY CONTROLS DIAGRAM” Screen
CAPACITY CONTROL FUNCTIONS, the “MIN PRV will indicate which signals are currently in control of
SIGNAL” value (minimum PRV signal allowed with the pre-rotation vanes and valves during start-up.
the compressor running), and then holds at this value.
System Shutdown
The “HGV RAMP CONTROL” output begins to de-
crease at this time to start closing the hot gas bypass 1. The chiller may be shutdown normally by momen-
valve. tarily closing the DCS REMOTE STOP CON-
TACT to energize Input across the network (refer
After the motor power drops below the “DEMAND to the protocol listing manual), or by depressing
LIMITER” setpoint, its output signal increases rapidly the local STOP key . Also, the chiller may be
to 100%. LSR-3 and LSR-4 will then select the lower stopped via a safety control, in which event the
output signal. Quantum™ LX displays and records the cause of
The hot gas valve will continue closing during the shutdown.
ramp-up period at a rate determined by the “HGV 2. Avoid shutting down the chiller while still un-
RAMP TIME” setpoint as long as the “HOT GAS der high head conditions. Backspin can be vio-
CONTROL” output remains below the HGV ramp lent and damaging to the compressor. Discharge
output signal. check valves are installed to prevent damage
During the ramp-up period, the “CHILLED WATER on unplanned stops of the chiller; however it is
OUT TEMP. CONTROL” setpoint will track the best practice to unload the chiller before shutting
chilled water out temperature and its output will be down. During a controlled stop unload procedure,
driven to equal the PRV signal. The vanes will con- the vanes are brought closed, the and Hot Gas
tinue to open at a rate determined by the “PRV RAMP Valve is opened to drop the head across the ves-
RATE” setpoint as long as the “CHILLED WATER sels. Process Chiller controlled stops are generally
OUT TEMP. CONTROL” remains in “MANUAL.” shorter than Comfort Cooling Controlled stops.
The following safeties are “Hardwired”
If during ramp-up the capacity increases sufficiently to to stop the chiller regardless of the condi-
lower the chilled water outlet temperature to less than 2° tion of the Output controlling the motor
above the desired setpoint, the “CHILLED WATER OUT starter:
TEMP. CONTROL” is changed to the automatic mode
and its output now changes in response to load changes. Emergency Stop (Pull to Stop Pushbut-
ton) Compressor Discharge High Pres-
If the chilled water temperature continues to fall, the sure Cutout
“CHILLED WATER OUT TEMP. CONTROL” out-
put will decrease causing the hot gas valve and PRV a. The compressor pre-rotation vanes are
to move to whatever positions are required to maintain closed to minimize back flow of gas through
the chilled water at setpoint and provide stable com- the compressor. The hot gas valve is opened
pressor operation.

38 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

(above freezing conditions) to equalize the 2. Hot Starts

condenser pressure with the evaporator. The
If the chiller has been running less than 20 min-
sideload valve is ramped closed. These ac-
utes, the cool down time will be the difference be-
tions are taken to reduce backspin of the
tween 45 minutes and the hot motor running time
compressor on shutdown.
since last start. For example, if chiller has run 5
b. The compressor motor start relays are de- minutes since last start, cool down time = 45-5 = 2
energized to open their contacts and de-ener- 40 minutes.
gize the motor starter control circuits.
If the chiller has been running 20 minutes or lon-
c. The subcooler level control valve is opened ger, the cool down time will be 2 minutes.
fully to drain the refrigerant out of the
subcooler. Excessive Starts
When the motor is started, a 24-hour counter is en-
d. The water flow, and low oil pressure safe-
abled. During the next 24-hour period, a total of 7 ad-
ty logic is inactivated to prevent nuisance
ditional starts are allowed. If 8 starts are attempted in
alarms.
any 24-hour period, the chiller start logic is locked out
e. The anti-recycle timer is activated at this for a minimum of 3 hours.
time. The anti-recycle (cool down) time de-
pends on the description under “Anti-recycle CAPACITY CONTROL OPERATION
operation” at the end of this section.
Chiller Applications
During this time, further restarts of the motor Much of the function of the Control System is dedicat-
are prevented. ed to chiller capacity control. Sensors register system
f. The compressor post-lube timing logic is en- conditions that are used to infer the total cooling load
abled and the VSD pumps will run for 3 min- and make necessary adjustments to the system compo-
utes to cool the oil system with the auxiliary nents.
water solenoid valve opened. There are two primary mechanisms by which cooling
3. The condenser water flow may be shut off after capacity is controlled: pre-rotation vanes, and the hot
the postlube cycle is complete. gas bypass valve. The primary directive of the Control
If the shutdown is caused by Low Refrig- System is first to maintain safe operating conditions,
erant Pressure, this could be an indication then to keep the system online, and finally to efficient-
of a major refrigerant leak. In this event, ly maintain setpoints.
the chilled water flow must be maintained The interaction of capacity control subsystems is com-
to prevent freeze-up and damage to the plex, and can be better understood by referring to the
tubes. capacity control diagram in the accompanying figures.

4. Five seconds after the oil pumps shut down, the The capacity control philosophy of the YORK CYK
compressor oil heaters are energized if the tem- chiller control system allows efficient, fully automated
perature of the oil requires it. control, without need for operator intervention. The
CYK control system is designed for industrial process
Anti-Recycle applications. This control system also monitors and
1. Cold Starts displays all safety aspects of the chiller and provides
alarms and a shutdown if safety limits are exceeded. If
If the motor has been shutdown for 8 hours, the operator intervention is required, manual controls are
cool down (anti-recycle) time will be 2 minutes provided on the Electronic Operator interface, for all
for the first and second cold start. electric actuators.
To start a third time, the chiller must be off for 30
The Capacity Controls algorithm automatically seeks
minutes.
out the most efficient operation of the CYK chiller. The
Any additional starts would be considered hot pre-rotation vanes are automated to obey the tempera-
starts. ture controller to maintain process water production.

JOHNSON CONTROLS 39
 FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

In cases of low load, the pre-rotation vanes automati- In cases of high load and high head (ice building duty),
cally throttle and are limited to a minimum anti-surge the Booster compressor is brought back online to per-
position, which is calculated from a head curve. To form the additional gas compression. The unit runs
provide light duty operation, the hot gas recycle valve in compound mode with the flash economizer in the
is seamlessly throttled open according to temperature cycle.
demands. This keeps the centrifugal compressor out of
surge and maintains process water production. Basic Control Model
The analog model in Figure 20 on page 40 is de-
In cases of high load, which exceeds the motor current
rived from the pneumatic control systems that predated
usage, the capacity controls algorithm automatically
modern digital controllers. In pneumatics the lines con-
unloads the system to maintain a restriction on power
necting the controllers and select relays contained air
consumption. In the same way, conditions of high dis-
at between 3 an 15 psi, representing the analog con-
charge pressure or low suction pressure override the
trol values. In digital implementations of this model
production of process water in the interests of keeping
the connection points are variables which represent
the chiller system online.
the loading and unloading values of the controllers in
In cases of light load and low head, the Booster com- terms of 0% to 100%. The controller generates an out-
pressor is dropped offline, the intercooler bypassed, put of 100% at a fully loaded state, and 0% at a fully
and the unit will be run with the Low-Stage compres- unloaded state. Controllers may be direct or reverse
sor like a single-stage YK chiller. acting depending on the relationship between the pro-
cess variable and setpoint.

CHILLED WATER HEATING WATER CONDENSER

TEMPERATURE TEMPERATURE PRESSURE
CONTROLLER CONTROLLER OVERRIDE
(DOES NOT UNLOAD CONTROLLER
LESS THAN ANTISURGE)

MOTOR CURRENT LIMIT

<
CONTROLLER
LESS THAN
(DOES NOT UNLOAD
SELECTOR
LESS THAN ANTI-SURGE)

ANTISURGE VANE >

RATIO CONTROLLER
POSITION FOR A GREATER
= 100-(100*LESS THAN
GIVEN LIFT THAN
SELECTOR)/ANTISURGE)
CONDTION SELECTOR

COMPRESSOR HOT GAS

PRE-ROTATION RECYCLE
VANES VALVE

Figure 20 - CONTROL MODEL

40 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

In this figure, the vanes do not unload past the Anti-Surge In practice for chillers this means the condenser tem-
map. As the Low Selector result value decreases past the perature is kept as low as economically possible, and
value of the Anti-Surge map, the hot gas valve begins to still maintaining a minimum lift requirement that pro-
open ratio metrically. At a fully unloaded command out duces the required differential pressure required for the
of the Low Selector, the hot gas will be fully open. sizing of the expansion valve. What we find in a chiller
Gain scheduling is important for this implementation
when running fully loaded at a low head the inlet guide 2
vanes can be very closed, and the chiller still main-
to separate the dynamic reaction that the pre-rotation tains a full load chilling output. As the lift requirements
vanes have on the system, from the reaction response increase as the condenser temperature raises, the inlet
of the hot gas valve on the system. The tuning param- guide vanes must open more to maintain a fully loaded
eters of the controllers are changed to accommodate condition. More work must be done to overcome the
the change in output device when the result of the ra- lift requirements.
tio controller becomes greater than zero. The control
theory is discussed in greater detail later in this section. In a WTWHP application the head alleviation found on
an ARI chiller profile is not present. At light loads the
Heat Pump Applications chiller can run at a lower head. When a WTWHP must
The CYK chiller also becomes a heat pump when the unload the lift requirements actually increase. In a
capacity controls system is switched mode to control hot chiller the difference between inlet and outlet cold wa-
leaving water out of the condenser vessel. Leaving con- ter temperature goes down, and the difference between
denser water is the process variable of the heat pump. hot water inlet and outlet temperatures goes down. But
The leaving chilled water controller becomes a low the temperature difference between the Hot and Cold
temperature override in this mode. However there are water sides goes up, increasing the lift requirements
considerations that must be made to create an effective on the compressor. At a satisfied or unloaded state, the
control system around the “Water to Water Heat Pump”. Hot Water leaving the WTWHP will be hot as possible,
In a typical chiller refrigerant cycle, it is assumed that and the Cold Water will be as cold as possibly allowed.
the evaporator conditions remain relatively constant,
A centrifugal compressor must move a minimum
and the condenser conditions are allowed to be adjusted
amount of refrigerant gas flow with relation to the lift
to maintain the most efficient operating conditions.
requirements to keep out of surge. As the lift require-
The Heat Pump is limited to produce heat on the avail- ments go up, as the load goes down, the minimum
able heat extracted from the chilled water loop. If there mass flow requirements of the compressor increase.
is insufficient load on the chilled water loop, then hot This presents a problem, in that the Centrifugal WT-
gas will generate as much heat as it can to make up the WHP cannot effectively unload as much as a chiller
lack of source heat from the chilled loop. More im- application. Experience tells us that this value is about
portantly the Heat Pump must have sufficient load on 40% of rated heating capacity.
the condenser (heating) side to carry away the heat of
Recall that a chiller can actually run with no load on
compression of the system. The Design working pres-
the evaporator, and that the temperature difference can
sure of the condenser vessel is the limiting factor of the
be nearly zero. However if our useful heat is measured
hot water production. On the condenser side of the heat
at the condenser side we quickly realize that due to the
pump, if the load is less than the heat of compression
heat of compression, and inherent inefficiencies of the
load plus the refrigeration effect, the system will not
refrigeration effect, the heating capacity must always
be able to stay online as the total heat generated in the
be non-zero. This minimum capacity of the heat pump
heat pump is not removed from the heating water loop
must always be satisfied, or the unit must be switched
and will accumulate causing a high pressure shutdown.
off.
Heat Pump mode and Chiller/Heat Recovery capac-
ity controls operation are mutually exclusive opera- Role of Hot Gas Bypass
tional modes. The Chiller mode produces cold water The natural solution on a centrifugal chiller applica-
at setpoint, and any hot water recovered simply a ben- tion is that when the surge line is approached with a
efit. The inverse is also true. Whichever limitation is decrease in load, the mass flow cannot be decreased
reached first becomes the limiting factor and the Heat without aerodynamic instability; therefore the hot gas
Pump will unload based on low water temperature or bypass is used to supplement mass flow. This supple-
high discharge pressure. mental mass flow creates a source of inefficiency in

JOHNSON CONTROLS 41
 FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

the refrigeration cycle and allows the chiller to run at Therefore, if the minimum heat energy produced by
lower evaporator loads than it could without hot gas. the heat pump is not removed into the heating load,
This isn’t particularly helpful in a WTWHP from a the discharge pressure will start to rise. Once the dis-
standpoint of unloading the hot water capacity. The charge pressure rises above the PC-113 discharge pres-
shift of importance is placed on the heating water side. sure override limit, the system will open the hot gas
In order to reduce capacity on the heating water side, valve in an attempt to alleviate the pressure. When this
the chiller must remain efficient as possible. Adding a occurs the “Death Spiral” of the heat pump has begun.
source of inefficiency, such as Hot Gas Bypass, creates If the process heating load does not begin to absorb the
more heat than without. This will actually increase the energy produced by the heat pump, then the centrifugal
energy being deposited in the heating water system. heat pump will shut down on high pressure safety.
Conversely, the Hot Gas Valve has an important role, If the heating load establishes equilibrium with the heat
in that when the heat source of the evaporator water pump while its hot gas valve is open, then the hot gas
side is insufficient, the WTWHP can simply become recycle effect will false load the heat pump keeping
inefficient by opening the hot gas valve to generate the temperature satisfied possibly at an elevated dis-
heat. There may be an economic breakpoint at which charge pressure. This is not a desirable condition, and
running the WTWHP with Hot Gas is less efficient therefore the excursion into such a situation should be
than using fossil fuels for heat. avoided by rejecting all the available energy provided
by the heat pump before a high pressure override oc-
The Importance of Heat Balance curs. This can be likened to orbiting the event horizon
It becomes apparent that having a heat sink outside to of a black hole. The discharge pressure must be made
WTWHP to use as much energy as possible is impor- to be less than the Discharge Override Setpoint, in or-
tant. A Heat Balance must be maintained at all times. der for the hot gas valve to close. To break away from
If the external system does not reject the energy from this condition, an increase in heating requirement must
the heating water side, the energy is returned to the en- be placed on the heat pump to shut the hot gas so that
tering condenser water of the WTWHP. This increases the false loading of the recycle gas can be eliminated
the temperature of the loop. As the chiller unloads, it and the “Death Spiral” avoided.
reaches that point at which the minimum mass flow
through the compressor is reached. If this trend were Major Capacity Control Devices
left to continue, the hot water loop would increase Compressor Pre-rotation Vanes
in temperature, until it reached the equivalent design
The compressor pre-rotation vanes (PRV's) are internal
working pressure of the condenser vessel. The WT-
guide vanes in the suction flow path to the impeller
WHP must be switched off before the high pressure
wheel. The PRV's are used to throttle the refrigerant
safety threshold is reached.
flow through the system as a means of controlling ca-
It becomes apparent that a WTWHP should never be pacity in response to the leaving chilled water tem-
oversized for an application. The Heat Pump is limited perature. If the leaving chilled water temperature falls
to produce heat on the available heat extracted from the below the setpoint, the PRV's are partially closed until
chilled water loop. If there is insufficient load on the the net cooling is reduced and the leaving chilled water
chilled water loop, then hot gas recycle will generate as returns to setpoint.
much heat as it can to make up the lack of source heat
In the event of high motor power, the capacity con-
from the chilled loop. More importantly the Heat Pump
trol signal is over-ridden and the compressor PRV's are
must have sufficient load on the condenser (heating)
closed to keep the motor power down. On start-up, the
side to carry away the heat of compression of the sys-
PRV's are closed to reduce the starting load torque of
tem. The Design working pressure of the condenser
the compressor.
vessel is the limiting factor of the hot water produc-
tion. On the condenser side of the heat pump, if the The compressor pre-rotation vanes are closed on shut-
load is less than the heat of compression load plus the down to reduce backflow of high-pressure gas from the
refrigeration effect, the system will not be able to stay condenser, which might otherwise cause the compres-
online as the total heat generated in the heat pump is sor to spin backwards at a high rate of speed.
not removed from the heating water loop and will ac-
cumulate causing a high pressure shutdown.

42 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

A shaded pole motor operates the mechanical pre-rota- The hot gas valve is a rotary ball type control valve
tion vane linkage, at the compressor. The shaded pole with an electric actuator. The control signal is a mod-
motor is operated by a contact closure to either open or ulating direct current signal, which is converted to a
close the vanes. A pre-rotation vane position potenti- position by an electric actuator. The valve will be fully
ometer senses the position of the vanes and reports it to closed at low signal and open at high signal. Refer to
the controller as a percentage open value. the Wiring Diagram to see the 4-20mA Control Signal 2
wiring. The Output Scaling screen allows factory se-
On Startup the low stage PRV’s are opened to mini- lection of the proper output signal.
mum vane. As the high stage compressor is started;
the vanes are locked to together so that the high stage Subcooler Liquid Level Valve LCV-114
tracks ahead of the low stage at a predetermined offset
The subcooler liquid level valve controls the refrig-
percentage.
erant liquid level in the subcooler located in the bot-
There is also an operational mode to balance motor tom of the condenser to maintain the proper amount of
current usage by controlling the high-stage vanes on subcooling and provide the most efficient operation at
the basis of motor current sharing. This algorithm al- all loads.
lows the compressors to share compression ratios,
This valve is opened after shutdown to allow a slow
while the low stage is controlled by the leaving process
change in pressure between evaporator and condenser.
Water Temperature Controller. Vane opening is limited
The pressure in the condenser forces the liquid out of
by pressure overrides and independently by motor cur-
the condenser into the economizer and the evapora-
rent overrides.
tor. Allowing low-pressure cold refrigerant from the
Hot Gas Bypass Valve evaporator to migrate into the condenser would create
a freezing hazard for the condenser water. It opens at
The hot gas bypass valve is used primarily at low loads start-up and then slowly closes until it reaches the posi-
to maintain a minimum suction gas flow required by tion dictated by the liquid level control PID instruction
the compressor for stability. When the compressor has in the Quantum LX logic.
reduced capacity to its minimum flow (via pre-rotation
vane throttling), further capacity reductions are ac- The liquid level valve is a rotary ball type control valve
complished by opening the hot gas bypass valve. This with an electric actuator. The control signal from the
maintains the flow to the compressor by bypassing the Quantum LX is modulated direct current, which is con-
discharge gas back to the compressor suction. verted to a position by an electric actuator. The valve
will be fully closed at low signal and open at high sig-
However, the hot gas flow replaces the useful evapora- nal.
tion in the cooler since the compressor flow is at mini-
mum. Thus, the net chilling capacity is reduced (albeit Economizer Liquid Level Valve LCV-116
not efficiently).
The Economizer liquid level valve controls the refrig-
The minimum suction flow or minimum compres- erant liquid level in the economizer to maintain a good
sor PRV position will vary. As the differential “head” liquid seal between the flash gas in the top of the econ-
pressure is lowered (due to colder condenser water) omizer and the liquid to the evaporator, this provides
the compressor is capable of stable operation at lower the most efficient operation at all loads.
loads. The programming in the chiller panel thus uses
The liquid level valve is a rotary ball type control
the differential “HEAD” pressure to establish when the
valve with an electric actuator. The control signal from
hot gas may be needed.
the Quantum LX is modulating direct current, which
• On a water chilling application, this valve goes is converted to a position by an electric actuator. The
open on shutdown. valve will be fully closed at low signal and open at high
signal.
• On a brine application this valve is closed at
shutdown to allow the pressures to drop slowly.
Allowing low-pressure cold refrigerant from the
evaporator to migrate into the condenser would
create a freezing hazard for the condenser water.

JOHNSON CONTROLS 43
 FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

Economizer Bypass Valve LCV-117 Interstage Gas Sideload Valve PCV-116

The Economizer Bypass Valve is normally closed. It is The interstage sideload valve controls refrigerant flash
used as a subcooler level control valve in system con- gas, from the economizer to the second stage compres-
ditions when flow thru the economizer is reduced. This sor impeller wheel when required to maintain a mini-
is manifested by the LCV-114 subcooler control valve mum pressure differential between the economizer and
controlling at 100% open and the subcooler level is ris- the evaporator.
ing. The LCV-117 and LCV-114 are essentially split
ranged, with the LCV-117 valve at the high end of the At normal conditions, the interstage valve will remain
controller. The Bypass control valve generally comes fully open during compressor operation and close on
into operation when there is high refrigerant volume shutdown to reduce compressor backspin.
flow, or in single stage operation. This valve remains closed for after start-up to allow
The liquid level valve is a rotary ball type control the subcooler level controller to establish a liquid level
valve with an electric actuator. The control signal from in the subcooler and then slowly opens when the High
the Quantum LX is modulating direct current, which Stage Compressor comes online.
is converted to a position by an electric actuator. The The interstage valve is a rotary butterfly type control
valve will be fully closed at low signal and open at high valve with an electric actuator. The control signal from
signal. the Quantum LX is a digital output through a double
pole relay. The valve will be fully closed at low signal
and open at high signal.

LCV-116
LCV-117

LCV-114
PVC-116

TCV-100B
HGV

LD15239

Figure 21 - VALVE LOCATIONS

44 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

Programmed Capacity Control Functions then pass this lower signal on to close the compressor
pre-rotation vanes, thus reducing the demand on the
Chilled Temperature Control
motor and returning the motor demand limit to below
Using the input signal from a temperature sensor in the the maximum threshold.
leaving chilled water line, this control provides an out-
The pressure override systems prevent a system opera-
put signal, which decreases as water temperature drops
tion condition from shutting down a chiller premature- 2
below set point to reduce the capacity of the chiller.
When override and anti-surge conditions are satis- ly. The pressure override loop controllers maintain the
fied, the temperature control subsystem may dominate. chiller operation just within the safe operational limits
Since temperature control is the highest function as- of the vessels, until system conditions return to design.
sociated with capacity control, its task must be con- The discharge pressure override produces an unloading
current and compliant with all other subsystems and effect on the chiller if the cooling water to the chiller
subsystem directives. It indirectly controls the hot gas goes above design. If the chiller were not unloaded
valve, and pre-rotation vanes in its attempt to maintain in this condition, the high-pressure cutout would shut
the chilled water temperature setpoint while keeping the chiller down, and no cooling would be done. The
the compressor out of surge. economizer pressure override operates the same way,
to protect the pressure limitations of the economizer
Heat Pump Temperature Control
vessel.
Using the input signal from a temperature sensor in the
leaving condenser water line, this control provides an The low evaporator pressure override is a key over-
output signal, which increases as water temperature ride in preventing the unit from either freezing or go-
drops below set point to increase the capacity of the ing down on low evaporator conditions. A system over-
chiller. When override and anti-surge conditions are shoot, or a low temperature transition in process water
satisfied, the temperature control subsystem may dom- can result in a low suction pressure condition. During
inate. Since temperature control is the highest function startup, the condensing pressure may initially be low.
associated with capacity control, its task must be con- This can cause the refrigerant to back up. If this occurs,
current and compliant with all other subsystems and the low level of evaporator liquid uncovers a portion of
subsystem directives. It indirectly controls the hot gas the tube bundle, thereby reducing the heat exchanger
valve, and pre-rotation vanes in its attempt to maintain performance, and lowering the evaporator pressure.
the condenser water temperature setpoint while keep- The low evaporator pressure override unloads the
ing the compressor out of surge. The Chilled Tempera- chiller rapidly, and often opens the hot gas valve to try
ture Control automatically acts as an override in Heat to maintain a suction pressure in the chiller. As the fault
Pump mode, by providing a control loop to keep the condition subsides, the override backs off and returns
water leaving the evaporator from becoming danger- the chiller to normal temperature controlled operation.
ously cold. The two temperature controls act thru LSR-
1 selector. Anti-surge
Compressor surge is an undesirable condition occur-
Dynamic Override Controls ring at low partial loading in which the system head
There are four operating parameters that are primar- pressure exceeds the dynamic pressure developed at
ily concerned with the safe operation of the system: the compressor discharge volute, causing localized
evaporator pressure, condenser pressure, economizer reverse fluid flow through the impeller accompanied
pressure, and motor load. If any of these parameters with loud noise and mechanical stresses. Opening the
were to exceed the limits defined by the setpoints, it hot gas bypass valve, and keeping the vanes at a cal-
could lead to a shutdown of the chiller by the safety culated position according to head mitigates surge.
setpoints. Maintaining chiller operation is the function Keeping the compressor out of surge is the function
of the Dynamic Override subsystem. of the anti-surge subsystem. The anti-surge system is
based on a straight-line approximation of the compres-
This power override control function uses the motor sor surge curve.
power input signals to limit capacity. When one of the
motor powers exceeds the setpoint, the control puts out
a decreasing signal. The LSR-2, LSR-3 and LSR-4 will

JOHNSON CONTROLS 45
 FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

SYSTEM ANTI-SURGE MAP

200
mass flow to the compressor by using the Hot Gas
Bypass valve. This allows the chiller to be unloaded
without danger of surge. Once the anti-surge system
PD1 150 has been set for the maximum head condition, and the
minimum head condition, the compressor is protected
from surge. The point represented by the intersection
H 100 of PD1 and MVP1 is the worst case operating condi-
E
A
tion of the compressor, with high head and low load.
x The other condition that defines the anti-surge line is at
D
PD2 50 low head and low load, represented by the intersection
of PD2 and MVP2. The shaded area of the left side of
the map is the surge area. The vanes cannot close more
0
than a given percentage for a given head condition, de-
0 25 50 75 100
fined by this line. As the capacity control system un-
MVP2 MVP1 loads the chiller, the Hot Gas Bypass valve is opened
% VANES
LD15231
proportionally to maintain stable operation and control
the process.
Figure 22 - SYSTEM ANTI-SURGE
There are two sets of parameters for anti-surge. One set
defines the map of the single stage compressor system,
The anti-surge line is biased to the right of the actual another set defines the 2-stage operating mode with
surge line. When the compressor needs to move left on both compressors running.
the map, and move less mass flow, the vanes can only
be reduced so far, before a lack of mass flow causes Anti-surge override acts at HSR-1 on the capacity con-
a surge condition. The anti-surge system supplements trols diagram.

LD15298

Figure 23 - PARAMETERS FOR ANTI-SURGE

46 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

Single Stage Operation

Two Stage Operation

LD15278

Figure 24 - STAGE OPERATIONS

JOHNSON CONTROLS 47
 FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

Anti-Surge Calculation • Repeat the procedure for low head operation.

The anti-surge tuning values are based on estimated • At the lowest condensing temperature, start reduc-
part load conditions and minimum vane signals re- ing the load on the chiller, by reducing the flow, or
quired at these conditions to prevent unstable opera- decreasing the inlet temperature. This will cause
tion (surging): the capacity control system to back the vanes in
an unload sequence.
Compressor Minimum PRV Signal
Differential Setpoint for • If the chiller surges before the Hot Gas valve be-
(Head) Pressure Stable Operation gins to open, then the anti-surge line must move
High Head 185 psid MVP1 = 35% Open
right on the map.
(PD1)
Low Head 120 psid MVP2 = 12% Open • If the chiller never surges down to minimum load,
(PD2)
then the anti-surge parameters are adequate for
protection, but may not be most efficient.
It is very important that this control be
adjusted to suit chiller operating condi- • During the unload sequence, record the operating
tions to achieve maximum efficiency of head as PD2.
operation.
• Increasing and decreasing the parameter MVP2
will move the anti-surge line right and left on the
map. Listen for a surge, and move the anti-surge
ANTI-SURGE TUNING line right several percent, to increase refrigerant
flow, by supplementing hot gas.
Repeat this procedure for both LS ANTI-SURGE
CALC and 2-STAGE SYSTEM ANTI-SURGE CALC, The plant condenser water control system will deter-
sets of parameters. mine the actual high and low head conditions depending
on the range of condenser water temperature allowed.
• With the chiller running in automatic, take the
condensing conditions to the highest inlet tem- If actual operating conditions are different than those
perature attainable in the system (without tripping shown above, you must enter the new values for the an-
on high discharge pressure). Increase tower inlet ti-surge parameter calculation to produce the required
temperature or reduce tower flow. output signals as shown in the following example:
• At the highest condensing temperature, start re- Compressor Minimum PRV
ducing the load on the chiller, by reducing the Differential Signal Setpoint
flow, or decreasing the inlet temperature. This (Head) Pressure for Stable Operation
High Head ?? psid / ?? bar MVP1 = ??% Open
will cause the capacity control system to back the (PD1)
vanes in an unload sequence. Low Head ?? psid / ?? bar MVP2 = ??% Open
(PD2)
• If the chiller surges before the Hot Gas valve be-
gins to open, then the anti-surge line must move
The “ANTI-SURGE MIN PRV POS” output (Y%) is
right on the map.
calculated based on the actual calculated differential
• If the chiller never surges down to minimum load, pressure (head) as follows:
then the anti-surge parameters are adequate for PD (Head) = (Compressor Discharge Pressure) – (Evaporator Pressure)
protection, but may not be most efficient.
Y% = (PD-PD2) x (MVP1-MVP2) / (PD1-PD2) + MVP2
• During the unload sequence, record the operating at High Head (92 psid), Y% = (92-40) x (38-12) / (92-40) + 12 = 38%
head as PD1.
at Medium Head (66 psid), Y% = (66-40) x (38-12) / (92-40) + 12 = 25%
• Increasing and decreasing the parameter MVP1
at Low Head (40 psid), Y% = (40-40) x (38-12) / (92-40) + 12 = 12%
will move the anti-surge line right and left on the
map. Listen for a surge, and move the anti-surge
line right several percent, to increase refrigerant
flow, by supplementing hot gas.

48 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

Hot Gas Control Tuning The tuning values are estimated only and may require
The “HOT GAS CONTROL” is automatically adjust- adjustment depending on actual chiller operating con-
ed to achieve full hot gas (100% output change) as a ditions. See “Graphic Display Description” for details
decreasing load causes the “CHILLED WATER OUT on entering new tuning values on the “CAPACITY
TEMP. CONTROL” output to drop below the “ANTI- CONTROLS TUNING” screen.
SURGE (MIN. PRV POSITION)” output to 0%.
Tuning Parameters
2
The “HOT GAS CONTROL” output is calculated The PID controller calculation (algorithm) involves
based on the “ANTI-SURGE (MIN PRV POSITION)” three separate parameters; the proportional, the inte-
output signal and the actual capacity control signal (in- gral and derivative values. The proportional value de-
put %) as follows: termines the reaction to the current error, the integral
value determines the reaction based on the sum of
Output % = 100 x LSR-3 % / HSR-2 %
recent errors, and the derivative value determines the
If the chiller was operating at the above low head con- reaction based on the rate at which the error has been
dition (HSR-2 =12%), the outputs would be as follows changing. The weighted sum of these three actions is
as the load decreases causing the capacity control sig- used to adjust the process via a control element such as
nal to drop to 0%. the position of a control valve or the power supply of a
heating element.
Capacity Control Signal at 12%
Output % = 100 x 12 / 12 = 100% (Valve Fully Closed) By tuning the three constants in the PID controller al-
Capacity Control Signal at 5%
gorithm, the controller can provide control action de-
signed for specific process requirements. The response
Output % = 100 x 5 / 12 = 41.7% (Valve Partially Open)
of the controller can be described in terms of the re-
Capacity Control Signal at 0% sponsiveness of the controller to an error, the degree
Output % = 100 x 0 / 12 = 0% (Valve Fully Open) to which the controller overshoots the setpoint and the
degree of system oscillation.
Load Matching Control
Some applications may require using only one or two
Load matching is the control system that controls the
modes to provide the appropriate system control. This
vane operation of the High Stage compressor. This pro-
is achieved by setting the gain of undesired control out-
grammed control function uses the Low Stage motor
puts to zero. A PID controller will be called a PI, PD, P
load as a Setpoint signal. The process variable is the High
or I controller in the absence of the respective control
Stage motor load. It uses proportional plus reset control
actions. PI controllers are particularly common, since
to provide an output signal which increases as the current
derivative action is very sensitive to measurement
goes above the setpoint to open the High Stage Vanes and
noise, and the absence of an integral value may pre-
maintain a balance of compression ratios. Conversely, this
vent the system from reaching its target value due to
option can be deactivated in favor of a fixed offset vane
the control action.
control, which is sometimes better with variable loads.
The load matching control can be trimmed with a bias to PID Controller Theory
attain an optimum interstage operating condition, for the
economization cycle of the economizer. This section describes the parallel or non-interacting
form of the PID controller.
Capacity Controls Tuning The PID control scheme is named after its three cor-
The PID controls are configured using the following recting terms, whose sum constitutes the Control Vari-
tuning parameters: able (CV). Hence:
SP = Setpoint CV(t) = P out + I out + D out
P = Proportional where
I = Integral Gain / Reset Time (Minutes/Repeat)
Pout, Iout, and Dout are the contributions to the out-
D = Derivative Gain / Rate (Minutes) put from the PID controller from each of the three
terms, as defined below.

JOHNSON CONTROLS 49
 FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

Proportional Term where

The proportional term (sometimes called gain) makes Iout: Integral term of output
a change to the output that is proportional to the current
error value. The proportional response can be adjusted Ki: Integral gain, a tuning parameter
by multiplying the error by a constant Kp, called the e: Error = SP − PV
proportional gain.
t: Time or instantaneous time (the present)
The proportional term is given by:
τ: a dummy integration variable
Pout = Kp e(t) The integral term (when added to the proportional
term) accelerates the movement of the process towards
where setpoint and eliminates the residual steady-state error
Pout: Proportional term of output that occurs with a proportional only controller. How-
ever, since the integral term is responding to accumu-
Kp: Proportional gain, a tuning parameter lated errors from the past, it can cause the present value
e: Error = SP − PV to overshoot the setpoint value (cross over the setpoint
and then create a deviation in the other direction).
t: Time or instantaneous time (the present)
Derivative Term
A high proportional gain results in a large change in the
output for a given change in the error. If the proportion- The rate of change of the process error is calculated
al gain is too high, the system can become unstable. In by determining the slope of the error over time (i.e.,
contrast, a small gain results in a small output response its first derivative with respect to time) and multiply-
to a large input error, and a less responsive (or sensi- ing this rate of change by the derivative gain Kd. The
tive) controller. If the proportional gain is too low, the magnitude of the contribution of the derivative term
control action may be too small when responding to (sometimes called rate) to the overall control action is
system disturbances. termed the derivative gain, Kd.

In the absence of disturbances, pure proportional con- The derivative term is given by:
trol will not settle at its target value, but will retain a
steady state error that is a function of the proportional d e(t)
Dout = Kd —
gain and the process gain. Despite the steady-state off- dt
set, both tuning theory and industrial practice indicate
that it is the proportional term that should contribute where
the bulk of the output change. Dout: Derivative term of output
Integral Term Kd: Derivative gain, a tuning parameter
The contribution from the integral term (sometimes e: Error = SP − PV
called reset) is proportional to both the magnitude of
the error and the duration of the error. Summing the in- t: Time or instantaneous time (the present)
stantaneous error over time (integrating the error) gives The derivative term slows the rate of change of the
the accumulated offset that should have been corrected controller output and this effect is most noticeable
previously. The accumulated error is then multiplied close to the controller setpoint. Hence, derivative con-
by the integral gain and added to the controller output. trol is used to reduce the magnitude of the overshoot
The magnitude of the contribution of the integral term produced by the integral component and improve the
to the overall control action is determined by the inte- combined controller-process stability. However, differ-
gral gain, Ki. entiation of a signal amplifies noise and thus this term
The integral term is given by: in the controller is highly sensitive to noise in the error
term, and can cause a process to become unstable if the
⌠t noise and the derivative gain are sufficiently large.
Iout = Ki e(τ) dτ
⌡0

50 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

LD15290

Figure 25 - CAPACITY CONTROL DIAGRAMS

JOHNSON CONTROLS 51
 FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

LD15291

FIGURE 23 - CAPACITY CONTROL DIAGRAMS (CONT'D)

52 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

LD15292

FIGURE 23 - CAPACITY CONTROL DIAGRAMS (CONT'D)

JOHNSON CONTROLS 53
 FORM 160.82-OM1
SECTION 2 - FUNDAMENTALS OF OPERATION
ISSUE DATE: 8/30/2013

THIS PAGE INTENTIONALLY LEFT BLANK

54 JOHNSON CONTROLS
FORM 160.82-OM1
ISSUE DATE: 8/30/2013

SECTION 3 - QUANTUM LX CONTROL PANEL

Quantum™ LX

7 8 9
4 5 6
1 2 3
. 0 +/-

LD15323

Figure 26 - QUANTUM™ LX GRAPHIC DISPLAY

The Quantum™ LX Control Center is a microproces- recall it for viewing at any time. During operation, the
sor based control system for R134a centrifugal chillers. user is continually advised of the operating conditions
It controls the leaving chilled liquid temperature via by various status and warning messages. In addition, it
Pre-rotation Vane controls and has the ability to limit may be configured to notify the user of certain condi-
motor current via control of the Pre-rotation Vanes. It is tions via alarms. A complete listing of shutdown, sta-
compatible with YORK Solid State Starter (optional), tus, and warning messages is detailed in the DISPLAY
Medium voltage solid state starters, and electrome- MESSAGES portion of this manual.
chanical starters.
There are certain screens, displayed values, program-
The panel comes configured with a full touchscreen mable setpoints and manual control shown in this
LCD Graphic Display mounted in the middle of a key- manual that are for Service Technician use only. They
pad interface. The graphic display allows the presenta- are only displayed when logged in at SERVICE access
tion of several operating parameters at once. In addi- level or higher. The setpoints and parameters displayed
tion, the operator may view a graphical representation on these screens are explained in detail in this section.
of the historical operation of the chiller as well as the These parameters affect chiller operation and should
present operation. For the novice user, the locations of never be modified by anyone other than a qualified
various chiller parameters are clearly and intuitively Service Technician. They are shown in this manual for
marked. Instructions for specific operations are pro- reference only.
vided on many of the screens.
Also included are detailed descriptions of chiller fea-
The graphic display also allows information to be rep- tures, such as the Refrigerant Level Control, Variable
resented in both English (temperatures in °F and pres- Speed Drive Oil Pump, Hot Gas Bypass, High Speed
sures in PSIG) and Metric (temperatures in °C and Thrust Bearing Proximity Probe, Remote Setpoints,
pressures in kPa or Bar) mode. The advantages are and Standby Lubrication.
most apparent, however, in the ability to display many
languages. The Control Center expands the capabilities of remote
control and communications. By providing a common
The Control Center continually monitors the system networking protocol through the Building Automation
operation and records the cause of any shutdowns. This System (BAS), YORK Chillers not only work well in-
information is recorded in memory and is preserved dividually, but also as a team. This new protocol al-
even through a power failure condition. The user may lows increased remote control of the chiller, as well

JOHNSON CONTROLS 55
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

as 24-hour performance monitoring via a remote site. LOAD VALUE - Not Used
In addition, compatibility is maintained with the pres-
ent network of BAS communications. The chiller also
maintains the standard digital remote capabilities as ALARM SILENCE - Immediately silences
a sounding alarm and turns off the alarm
well. Both of these remote control capabilities allow
annunciation device that is connected to
for the standard Energy Management System (EMS) this panel.
interface:
MANUAL - Not Used
1. Remote Start
2. Remote Stop 7 8 9 NUMERALS [0 - 9] - The numerical keys
are used to enter a value in a data field.
3. Remote Leaving Chilled Liquid Temperature Set- 4 5 6
point adjustment (0 to 10VDC, to 4 to 20mA). 1 2 3
0
4. Remote Condenser Water Setpoint adjustment
(0 to 10VDC, or 4 to 20mA). DECIMAL [.] - This key is used when
entering a decimal value in a data field.
5. Safety Shutdown Contacts
[+ /-] - When changing a value in a data
The chiller operating program resides in the Control field, this key toggles the value between
Center Microboard. The Quantum™ LX Control Cen- negative and positive.
ter could be equipped with either of the following BACKSPACE - Pressing this key will
boards: cause the current location of the cursor to
backup one position per key depression.
• Prior to 2011 the BCM motherboard 025-43703- When changing a value in a data field, this
000 was supplied. key will delete the selected character.
• Chillers shipped after January of 2011 use an UP ARROW - Provides upward navigation
Avantech motherboard 025-44606-001. Any re- within the MAIN MENU window.
placements in the field will use the upgrade kit TAB - When in the mode of changing
025-44606-000. setpoints, pressing this key will cause the
cursor to jump to the next data entry field.
Navigating The Control Panel LEFT ARROW - When in the mode of
Navigation through the various screens of the opera- changing setpoints, this key is used to go
tor interface panel is highly intuitive. The touchscreen to the previous data entry field. When the
allows the user to select from the available screen dis- MAIN MENU is shown, pressing this key
plays and make setpoint adjustments. will cancel the window.
DOWN ARROW - Provides downward
The following is a list of the labeled keys on the key- navigation within the MAIN MENU window.
pad and the actions that occur when they are pressed.
RIGHT ARROW - When in the mode of
KEY FUNCTION changing a data entry field, this key is
STOP - When the compressor is running used to go to the next character.
in Manual Mode, pressing this key imme- ENTER - When changing data in a data entry
diately stops the compressor by placing it field, this key will accept the change. This key
into Stop Mode. The compressor is stopped is also used to select items on Menu Windows.
regardless of any other conditions. SUBMIT - After changing a setpoint value,
START - When in Manual Mode, this key use this key to enter (submit) the change.
places the compressor unit into the Start
Mode for running. MENU - Calibrate Touch Screen
UNLOAD VALUE - Not Used

56 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

SCREEN SELECTION Programmable Features

Graphical, animated screens display data and pro- The setpoints define the operation and limits of the
vide a means for accessing various system compo- chiller. These setpoints can be changed by operators
nents. Screens indicate all aspects of operation and in the field. These setpoints are stored on the compact
sensor data pertaining to the particular component Flash card.
depicted. Setpoints are not lost after power is inter-
At the top of each main screen is displayed the sys- rupted. However, we suggest that a list of
tem status, present date and time, local or remote Setpoints be recorded and stored safely to
control source and system access level. Sub-screens facilitate reentry, in case there is a need
may also be available for some system components, to return to the original settings. 3
providing additional data access. Screens are select-
ed by selecting the touch cell with the screen name 1. The data entry fields are identified by a black
on it. box with a white interior. The data is shown in
black text. When on a screen that has adjustable
setpoints, tab to the setpoint box that you wish
Display Features to modify (or select it on a web browser). Once
Display features are those that are available for the data field has been selected, the background
viewing only, and include read-only parameters turns blue, and the text turns white.
such as temperatures and pressures. Display fea- 2. The current value of that setpoint is shown. Use
tures may be given as numerical values or graphics the keypad to enter the new value. Typing a new
in the form of bar graphs, red indicator lights, or value will completely erase the old value.
animated graphs.
3. Press the keypad ENTER key to input the new
data in the data entry field and to move to the next
Interactive Screen Features data entry field.
Various aspects of chiller operation may be adjusted 4. Once all entries/changes have been made, press-
by the operator within the appropriate screen. Touch ing the SUBMIT key will save the setpoint
keys allow the operator to select a key appropriate to changes to memory.
the adjustments required. Some interactive controls are 5. If the value is out of bounds, an error message box
depicted graphically while others, such as setpoints, displays the proper range of values. Press the OK
appear as entry fields in which the operator may enter touch key to acknowledge the error message. Re-
values directly. enter a correct value.

LD15326

Figure 27 - ALLOWABLE RANGE

JOHNSON CONTROLS 57
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

Programmable features are supplied as entry fields User Login

(Black Letters in a White Box) into which numeric val- In order to gain access to service authorized features,
ues may be entered. These include setpoints and PID it is necessary to log into the system. On the home
tuning parameters as well as setpoint values and anti- screen is the LOGIN key. Selecting this key brings
surge parameters. up a display depicting the control panel keypad. Enter
the user access level and then the password and press
the return key on the keypad. The System Status dis-
play at the top of the screen shows the current login
The chiller Control System has four ac-
access level.
cess levels: VIEW, OPERATOR, SER-
VICE and FACTORY. This instruction Pressing LOGOUT on the Home screen will log
is intended only as a service manual. As out the current user and return the access level to
such, screens depicted here are the system VIEW.
parameters available at the SERVICE and
FACTORY levels of access, which require Manual Automatic Stations
user login. Manual automatic stations allow analog control of
valves and vanes. The analog process control system
The system is provided with four levels of security is based on a 0 – 100% range. The automatic control
access. system drives the valve or vanes with a percentage of
User Access Level 0: VIEW drive signal. The operator interface allows an experi-
enced technician to take manual control of a device.
The View mode allows non-setpoint screens to be Pressing the button marked AUTO toggles the device
viewed, but no setpoints to be changed. The View into a manual control state. The button turns red and
mode may not take manual control of the capacity the word MANUAL appears. Pressing MANUAL will
devices. toggle the device into an automatic state.
User Access Level 1: OPERATOR While in manual control, the OPEN (INCREASE) or
Operator is the privileged user. The operator may CLOSE (DECREASE) buttons may be used to ma-
look at any status item, but may not access safety nipulate the valve or vane. The bar graph on the right
setpoint screens. The operator also may change shows the actual position of the valve or vane. The au-
the chilled water and demand limit setpoints. The tomatic bar graph shows where the automatic control
operator may use the Manual / Auto stations. The system wants the device to be.
Operator user’s password is 9675 To provide a bumpless transfer of manual back to auto-
User Access Level 2: SERVICE matic operation, devices such as the Low Stage PRV’s
must be above antisurge to return to automatic opera-
The service user is privileged to access any chiller tion. The Hot Gas Bypass valve shown in this example
screen. This user may also change setpoints. Ser- has an inhibit function. The Hot Gas Valve must be
vice level may adjust tuning parameters, and per- within 5 percent of its automatic value before it can be
form general configuration and setup functions returned to automatic operation.
User Access Level 3: FACTORY
Screen Indicators
This user is privileged above all other users. Fac-
On (enganged) and Off (disengaged) signals are rep-
tory level may adjust Scaling, Input / Output as-
resented by “LED” symbols. A red LED symbol is
signments, or Alarm and Shutdown settings.
ON , and a grey LED symbol is OFF .
System adjustments should be performed
only by a qualified service person. Read The Shutdown Trip indicator will remain in the alarm
all instructions carefully before making state until the RESET pushbutton is pressed after the
adjustments conditions have returned to normal.

58 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

MANUAL control
value displayed
here

AUTOMATIC con-
trol value displayed
here 0-100% open
of valve position

3
Pressing toggles
between AUTO
and MANUAL
mode

OPEN or CLOSE
valve by pressing
LD15283

Figure 28 - MANUAL AUTOMATIC STATIONS

Status Bar The SYSTEM DETAILS block at the bottom shows

The status bar will indicate the running condition of the alarm messages. Pressing SYSTEM RESET on the
unit. The leftmost top SYSTEM STATUS area describes Home screen will attempt to reset any alarms or trips.
the operational mode. The right portion of this block
states whether the capacity controls are configured for
CHILLER operation or HEAT PUMP operation.

EXAMPLE 1

LD15327

EXAMPLE 2

LD15328

JOHNSON CONTROLS 59
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

The main status indicator bar at the top of the screen

will display the SYSTEM STATUS with the following
messages:
Table 8 - SYSTEM DETAILS

SYSTEM STATUS MESSAGE

READY TO START Unit is ready to start in Local Mode

REMOTE START ENABLED Unit is ready to start in Remote Mode

START / LS PRELUBE = XXX sec Locally initiated start / Prelube cycle

REM START / LS PRELUBE = XXX sec Remote initiated start / Prelube cycle

SYSTEM RUNNING 2-STAGE System Running with two stages

SYSTEM COASTDOWN = XXX sec System stopping / Postlube cycle

SYSTEM TRIPPED System Tripped Offline

ANTIRECYCLE = XX:XX Anti-recycle Countdown

LOW STAGE RUNNING Unit running with One stage only

VANES CLOSING Control Stop initiated

REMOTE LOCKOUT Remote mode selected / not confirmed

HS START / PRELUBE = XX sec High Stage booster is starting

RUNNING / DYNAMIC OVERRIDE System Running but override in control

FAULT / ERROR Processor is not responding

Web Browser with your ability to change data setpoints, because the
The web browser interface can be viewed from any screen will refresh while you are entering the data. To
desktop or laptop computer, which has access to the solve this, simply increase the refresh time. The other
network that the compressor panel is attached to. To alternative is to toggle the Refresh Button. By pressing
change screens, setpoints, etc., you simply use a mouse [Stop Refresh], screen refreshing will terminate, and
and the keyboard to view and change data. All screens the time setpoint box will reappear. In this state, the
that are shown will have a several buttons on the right particular screen that you are viewing will never up-
hand side of the screen. Most screens will have four date the displayed values. Changing to another screen
buttons, and one setpoint box. The three buttons are: will show the most recent values on the new screen,
and then will not update again. So in the Stop Refresh
[Start Refresh] [Stop Refresh] – This button(s) appears state, screens will only be updated when new screens
immediately below the [Menu] button. This is actually are accessed. This feature should not be used when
a toggle button, as it changes function from Start Re- monitoring for data. Try to find an acceptable refresh
fresh to Stop Refresh each time it is clicked on. When time for the Start Refresh state.
the button shows as Start Refresh, a setpoint box will
appear below it, with a time value displayed. The time [Submit] – After having made changes to any informa-
value determines how often the display screen will re- tion, the [Submit] button must be pressed for the con-
fresh, or update its values. This time value is defaulted troller to accept the new changes. This button performs
to 5 seconds, which means that the display will update the same function as the physical [Submit] button on
all values shown every 5 seconds. Depending on the the panel keypad.
network connection speed, this updating may interfere

60 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

CONTROL CENTER

Quantum™ LX

7 8 9
4 5 6
1 2 3
. 0 +/-

LD15323

Figure 29 - CONTROL CENTER

INTERFACE CONVENTIONS OVERVIEW PROGRAMMABLE

The new graphical display on each control panel al- Values in this group are available for change by the
lows a wide variety of information to be presented to user. In order to program any setpoints on the system,
the user. Each screen description in this document will the user must first be logged in with the appropriate ac-
begin with a section entitled OVERVIEW which will cess level. Each of the programmable values requires
describe the graphical elements on the screen and give a specific access level which will be indicated beside
a short summary of the functions available. Each ele- the specified value. All of the programmable controls
ment on the screen will then be categorized into three in the system fall into one of the categories described
distinct groups: Display Only, Programmable, and below:
Navigation. Below is a short description of what types
of information are included in these groups. Change Setpoints
On screens containing setpoints programmable at the
The Programmable values and Navigation commands
OPERATOR access level, a key with this label will be
are also subject to access level restrictions as described
visible if the present access level is VIEW. This key
below. For each of these elements, an indication is
brings up the access level prompt described above. It
given to show the minimum access level required to
allows the user to login at a higher access level without
program the value or navigate to the subscreen.
returning to the HOME Screen. After login, the user
DISPLAY ONLY may then modify setpoints on that screen.

Values in this group are read-only parameters of infor-

mation about the chiller operation. This type of infor-
mation may be represented by a numerical value, a text
string, or an LED image.

JOHNSON CONTROLS 61
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

Setpoints Home Screen (page 63)

The Control Center uses the setpoint values to control System Screen (page 65)
the chiller and other devices connected to the chiller Evaporator Screen (page 67)
system. Setpoints can fall into several categories. They Condenser Screen (page 69)
could be numeric values (such as 45.0°F for the Leav- Subcooler Screen (page 71)
ing Chilled Liquid Temperature), or they could enable Hot Gas Screen (page 73)
or disable a feature or function.
Low Stage Compressor Screen (page 75)
Manual Controls LS Proximitor Calibration
Some keys are used to perform manual control func- (Low And High Stages) Screen (page 77)
tions. These may involve manual control of items such PRV Calibration Screen (page 79)
as the Pre-rotation Vanes, variable orifice or oil pump Oil Sump (Unified Sump Pressure)
speed. Other keys in this category are used to initiate/ Screen (page 81)
terminate processes such as calibrations or reports. Oil Sump (Ice Thermal Storage)
Screen (page 83)
LANGUAGES LS Variable Geometry Diffuser Screen
(page 87)
The Screens can be displayed in various languages. High Stage Compressor Screen (page 89)
Language selection is done on the USER Screen. The
HS Prox Calibration Screen (page 91)
desired language is selected from those available.
Not all languages are available. English is the default Liquid Cooled Solid State Starter Screen
language. If a language other than English is being (Optional) (page 93)
displayed, an English-only speaking person should Capacity Controls Screen (page 96)
navigate to the USER Screen using the preceding navi- Manual Auto Station (Capacity Control) Screen
gation chart and select English per the USER Screen (page 98)
instructions in this manual. PID Capacity Controls Tuning Screen
(page 100)
Overrides (Capacity Override
Tuning Parameters) (page 102)
Anti-Surge Screen (page 104)
Setup / Diagnostics Screen (page 106)
Test Outputs Screen (page 108)
Setpoints 1 Screen (page 109)
Setpoints 2 Screen (page 110)
Pressure Calibration Screen (page 113)
Temperature Calibration Screen (page 114)
Miscellaneous Calibration Screen (page 115)
Digital Input Configuration Screen (page 117)
Digital Output Configuration Screen (page 118)
Auxiliary Analog Configuration Screen (page 119)
Auxiliary Analog Calibration Screen (page 121)
Retransmitting Outputs Screen (page 123)
Economizer Screen (page 124)
History Screen (page 126)
Freeze Screen (page 127)
Trending Screen (page 128)
Trending Setup Screen (page 130)
Custom Display Screen (page 131)

62 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

HOME SCREEN

LD15240a

Figure 30 - HOME SCREEN

OVERVIEW LS Motor Load

When the chiller system is powered on, the above de- Percent of Low Stage rated motor load as transmitted
fault display appears. The primary values which must from the motor protection relay.
be monitored and controlled are shown on this screen.
System Head
The HOME Screen display depicts a visual representa-
tion of the chiller itself. The head or lift as calculated from the condenser pres-
sure minus the evaporator pressure.

DISPLAY Hot Gas

The percentage of Hot Gas Valve opening.
HS PRV Position
The High Stage PRV calibrated feedback from the PRV Liquid Temperatures
position potentiometer. The cooling water and chilled water are measured at
the waterboxes of the chiller using ICTD’s.
LS PRV Position
The Low Stage PRV calibrated feedback from the PRV Condenser Flow / Evaporator Flow
position potentiometer. The red LED symbol will be on if there is water flow
detected across the heat exchanger vessel.
HS Motor Load
Percent of High Stage rated motor load as transmitted
from the motor protection relay.

JOHNSON CONTROLS 63
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

INTERACTIVE NAVIGATION
Blue function keys with white letters are screen navi- System
gation buttons. Screen access is limited by the security Used to provide additional system information.
access level of the user.
Evaporator
Login
A detailed view of all evaporator parameters, including
Pressing this button will bring up a numeric entry box. the programmable Leaving Chilled Liquid Setpoints.
Press the number keys on the keypad to enter the ac-
cess code. Press the Enter key after the code has been Condenser
entered. A detailed view of all condenser parameters, including
control of the liquid level functions.
Logout
Pressing this button will log the user out of any ad- Low Stage Compressor
vance access code, back to the VIEW level of access. This screen displays data about the Low Stage Com-
pressor.
System Reset
This button will attempt to reset any alarms experi- High Stage Compressor
enced by the control system. Alarms stay active until This screen Displays data about the High Stage Com-
reset. pressor.

Capacity Controls
PROGRAMMABLE
Returns the display to view the Capacity Controls
Manual / Auto Screen.
Access Level Required: OPERATOR
Allows the operator to switch between automatic chill- Setup
er control and temporary manual control of the system This screen provides a single location to program the
devices. In manual control, the device operation and most common system setpoints. It is also the gateway
position can be set as desired for troubleshooting or to many of the general system setup parameters such
maintenance outside of the normal control routine. as I/O configuration, Communications Setup, Software
Maintenance, Trending, and diagnostics.
Economizer
Access Level Required: OPERATOR History
Returns the display to the Economizer Screen. This screen provides access to a Time stamped Record
of shutdown conditions.

64 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

SYSTEM SCREEN

LD15241

Figure 31 - SYSTEM SCREEN

OVERVIEW PROGRAMMABLE
The system screen of the CYK chiller is a process flow Manual / Auto
representation of the refrigerant circuit. It shows key Access Level Required: OPERATOR
pressures, temperatures, levels, and actuator positions Allows the operator to switch between automatic chill-
around the system at a glance. er control and temporary manual control of the system
devices. In manual control, the device operation and
DISPLAY position can be set as desired for troubleshooting or
maintenance outside of the normal control routine.
Hot Gas
Displays the percent open valve position of the Hot Economizer
Gas Valve. Access Level Required: OPERATOR
Returns the display to the Economizer Screen.
Oil Pressure
Displays the compressor oil pressure.
NAVIGATION
System Head Home
Displays the differential pressure across the system. Used to provide additional Home information.
HS Load Evaporator
Displays the motor percent amp load. A detailed view of all evaporator parameters, including
the programmable Leaving Chilled Liquid Setpoints.
LS Load
Displays the motor percent amp load.

JOHNSON CONTROLS 65
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

Condenser Setup
A detailed view of all condenser parameters, including This screen provides a single location to program the
control of the liquid level functions. most common system setpoints. It is also the gateway
to many of the general system setup parameters such
Low Stage Compressor as I/O configuration, Communications Setup, Software
This screen displays data about the Low Stage Com- Maintenance, Trending, and diagnostics.
pressor.
Return
High Stage Compressor Returns the display to the previous screen.
This screen Displays data about the High Stage Com-
pressor.

Capacity Controls
Returns the display to view the Capacity Controls
Screen.

66 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

EVAPORATOR SCREEN

LD15242

Figure 32 - EVAPORATOR SCREEN

OVERVIEW Evaporator Pressure

The Evaporator screen shows the parameters associ- Displays the present refrigerant pressure in the evapo-
ated with the cooler heat exchanger. Flow is indi- rator.
cated by the red LED symbol. Leaving and Entering
water temperatures are shown, along with evapora- PROGRAMMABLE
tor refrigerant temperature and pressure. The small
difference temperature is calculated from the dif- Local Chilled Water Setpoint = XX.X
ference between the leaving process liquid and the Access Level Required: OPERATOR
evaporator refrigerant temperature. A high small dif- Pressing this button will allow the user to change the
ference temperature could indicate fouled tubes or leaving chilled water setpoint. Water duty machines
improper charge. The remote chilled water setpoint are limited to a minimum of 36°F leaving to prevent
is also shown for reference. freezing. Brine duty machines are limited to the specif-
ic temperature of the brine concentration. Press Submit
The ACTIVE leaving chilled water setpoint is shown
to confirm the new setpoint.
for reference in the center of the screen.

INTERACTIVE
DISPLAY
Local Start / Remote Start
Leaving Chilled Liquid Temperature
Access Level Required: SERVICE
Displays the temperature of the liquid as it leaves the
This button toggles between a Locally initiated start
evaporator.
from the chiller control panel START button, and a re-
Leaving Chilled Temperature Setpoint mote start from an external source.
Displays the present setpoint to which the chiller is op-
erating, whether controlled locally or remotely.

JOHNSON CONTROLS 67
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

Local Setpoint / Remote Setpoint When the system is configured for remote starts, a mes-
Access Level Required: SERVICE sage will appear “Please Press LOCAL START button
This button toggles between the local setpoint as de- to enable Remote Starts”. Pressing the local start but-
fined by this screen, or a remotely defined setpoint ton on the panel after remote starts has been enabled
from another source. insures the safety of the operator, so that no remote
user can start the chiller without a local operator’s
Network Remote Start / Hardwired Remote knowledge. The message will then change to “Remote
Start Starts Permitted until Mode is changed to LOCAL or
Access Level Required: SERVICE chiller trips offline”.
This button toggles between the sources of the remote
During a start sequence the economizer level will es-
start signals. They can either come from the START
tablish before the chiller/heat pump loads, to keep from
command from across the network, or from Channel 8
slugging the low stage compressor. The message will
input on the second digital input module. The remote
appear “PRV RAMP HOLD – BUILDING ECONO-
status of the signal is shown above this button.
MIZER LEVEL”. This will stay illuminated until the
• The remote START word is: A-B N119:10 or level is established.
Modbus 00001 (write a 1 to start)
• The remote STOP word is: A-B N119:11 or Mod- NAVIGATION
bus 00002 (write a 1 to stop)
Home
When in Hardwired start mode, opening the Hardwired Used to provide additional Home information.
contact initiates a controlled stop.
Economizer
• Remember remote Start / Stop / System Reset
across the communications network must be set Returns the display to the Economizer Screen.
to Logic HIGH momentarily to initiate the com-
Capacity Controls
mand. The bit must be returned to Logic LOW
after the command has been received. Returns the display to view the Capacity Controls
Screen.
Network Remote Setpoint / Hardwired
Setpoint Return
Access Level Required: SERVICE Returns the display to the previous screen.
This button toggles between the source of the remote
setpoint. It can either be sourced from A-B N102:98 or
Modbus 47299 across the network, or from a remote
analog signal shown on the wiring diagram. Remember
that analog values are times 10.

68 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

CONDENSER SCREEN

LD15243

Figure 33 - CONDENSER SCREEN

OVERVIEW Condenser Pressure

The condenser screen shows the operational nature of Displays the refrigerant pressure in the condenser.
the condensing heat exchanger. The temperatures of the
water entering and leaving the condenser are shown. Condenser Flow Switch
The Condensing pressure and saturation temperature Indicates whether flow is present in the condenser.
are also shown on this screen. The temperature of the
subcooled liquid coming out of the drop leg of the con-
PROGRAMMABLE (HEAT PUMP ONLY)
denser is displayed here. The conditions of the High
Pressure Cutout will always be OK under normal op- Local Heating Water Setpoint = XX.X
eration. If the High Pressure Cutout switch ever shows Access Level Required: OPERATOR
TRIP, investigate the pressure of the condenser vessel Pressing this button will allow the user to change the
and evaluate the integrity of the switch. This switch is leaving condenser water setpoint. Press Submit to con-
installed per code with no intervening stop valve. firm the new setpoint.
During a start sequence the economizer level will es-
DISPLAY tablish before the chiller/heat pump loads, to keep from
slugging the low stage compressor. The message will
Return Condenser Water Temperature
appear “PRV RAMP HOLD – BUILDING ECONO-
Displays the water temperature as it enters the con- MIZER LEVEL”. This will stay illuminated until the
denser. level is established.
Leaving Condenser Water Temperature
Displays the water temperature as it leaves the con-
denser.

JOHNSON CONTROLS 69
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

NAVIGATION

Home
Used to provide additional Home information.

Subcooler
Returns the display to the Subcooler Screen.

Hot Gas
Returns the display to the Hot Gas Screen.

Economizer
Returns the display to the Economizer Screen.

Capacity Controls
Returns the display to view the Capacity Controls
Screen.

Return
Returns the display to the previous screen.

70 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

SUBCOOLER SCREEN

LD15265

Figure 34 - SUBCOOLER SCREEN

OVERVIEW Condenser Small Temperature Difference

The Subcooler provides a cycle efficiency to the chiller Displays the temperature expressed as a differential
by cooling the high pressure refrigerant before it passes between the water leaving and the water entering the
through the high pressure expansion valve. condenser.

Evaporator Refrigerant Level

DISPLAY (Graphical) Displays the evaporator refrigerant level in
percent.
Return Condenser Water Temperature
Displays the temperature of the condenser water re-
turning to the condenser. INTERACTIVE

Leaving Condenser Water Temperature Subcooler Valve Manual / Auto Station

Displays the temperature of the condenser water re- Allows the operator to manually adjust the subcooler
turning to the condenser. valve to the desired setting Pressing the Auto key al-
lows the operator to adjust the subcooler level valve
Condenser Refrigerant Temperature from 0 – 100% open using the Increase and Decrease
Displays the current temperature of the condenser re- keys on the bottom of the display. Pressing the AUTO
frigerant. button when in manual adjustment mode toggles back
to automatic control.
Subcooler Temperature
Displays the temperature of the refrigerant in the
subcooler.

JOHNSON CONTROLS 71
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

PROGRAMMABLE • FIFO SAMPLES – Because the refrigerant repre-

sents a large fluid mass, constant wave and ripple
LC-114 is the subcooler level control box. Parameters
motion pervades the fluid level measurements.
include:
The processor samples the refrigerant level once
(PV) Process Variable – Indicates the process variable every 10 milliseconds, then takes the average of
value. this number of readings.

(SP single) Subcooler Level Setpoint – Operator uses • MIN CV – The subcooler level control valve can-
this entry field to adjust the subcooler level setpoint not be allowed to close. The control variable sig-
when running a single stage. nal is limited to this percentage, to keep the valve
from completely closing and the unit from going
(SP twostage) Subcooler Level Setpoint – Operator uses down on low suction pressure.
this entry field to adjust the subcooler level setpoint
while running compounded in two-stage mode.
NAVIGATION
PID – Proportional variable (P), integral variable (I),
and derivative variable (D). Return
Returns the display to the previous screen.
• ZONE 1 – Is the steady state control loop gains.
• ZONE 2 – Is the transient and more aggressive Condenser
control loop gains. A detailed view of all condenser parameters, including
control of the liquid level functions.
• DB – Deadband that defines Zone 1 and Zone 2.
The DB value is the Percentage of the total range History
that Zone 1 tuning values are used. For example, This screen provides access to a Time stamped Record
entering 10% will define a 10% band around the of shutdown conditions.
setpoint where the steady state Zone 1 gains will
be used.
• SUBCOOLER RAMP RATE in %/sec – When
the chiller is powered on, the subcooler valve at-
tempts to fill the subcooler at the designated rate.

72 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

HOT GAS SCREEN

LD15246

Figure 35 - HOT GAS SCREEN

OVERVIEW Compressor Head

This screen displays a cutaway view of the Hot Gas Displays the pressure expressed as a differential be-
Bypass Valve. The setpoints relating to the Hot Gas tween the compressor suction and compressor dis-
Bypass Control are maintained on this screen. Related charge pressures.
Hot Gas control parameters are displayed for refer-
Hot Gas Valve Position
ence. The Hot Gas Valve can be manually controlled
from this screen. Through animation, the relative valve Displays the position of the valve in terms of percent-
position is displayed. age open.

Antisurge Calculation
DISPLAY Is the present minimum Low Stage vane position for
the current running conditions.
HS PRV Position
Displays the position of the pre-rotation vanes in per- LS PRV Position
cent. Displays the position of the pre-rotation vanes in per-
cent.
HS Discharge Temperature
Displays the compressor discharge temperature. LS Discharge Temperature
Displays the compressor discharge temperature.
Discharge Superheat
Displays the temperature expressed as a differential
between the discharge temperature and the condenser
saturation temperature.

JOHNSON CONTROLS 73
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

Leaving Condenser Liquid Temperature NAVIGATION

Displays the temperature of the condenser liquid as the
Home
liquid exits the condenser.
Used to provide additional Home information.
Leaving Chilled Liquid Temperature
Evaporator
Displays the temperature of the chilled liquid as the
liquid exits the evaporator. A detailed view of all evaporator parameters, including
the programmable Leaving Chilled Liquid Setpoints.

INTERACTIVE Condenser
A detailed view of all condenser parameters, including
Hot Gas Valve Manual Auto Station control of the liquid level functions.
Allows the operator to manually adjust the position of
the hot gas bypass valve. Economizer
Returns the display to the Economizer Screen.
Pressing the Auto key allows the operator to adjust the
hot gas valve position from 0 – 100% open using the Capacity Controls
Open and Close keys on the bottom of the display. Returns the display to view the Capacity Controls
Pressing the AUTO button while in manual adjustment Screen.
mode to toggle back to automatic control will only be
accepted if the manual setting is within 5% of the au- Return
tomatic setting. Returns the display to the previous screen.

74 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

LOW STAGE COMPRESSOR SCREEN

LD15244

Figure 36 - LOW STAGE COMPRESSOR SCREEN

OVERVIEW To compensate for these differences between transduc-

ers and assure differential pressure sensing accuracy,
Displays data about the Low Stage Compressor.
the offset pressure is subtracted algebraically from the
oil (differential) pressure value. The offset pressure
DISPLAY calculation will not be performed if either transducer
is out of range and the offset value will be 0 PSI in this
Oil Supply Pressure instance.
Displays the pressure differential between the high
side oil pressure transducer (HOP, located between oil Oil Sump Temperature
filter output and compressor bearing input) and the low Displays the temperature of the oil in the sump.
side oil pressure transducer (LOP, located between oil
sump and compressor housing). The displayed value Discharge Temperature
includes offset pressure derived from auto-zeroing Displays the temperature of the refrigerant (vapor) at
during the system prelube. The display field will show discharge of the compressor before the refrigerant en-
_ _._ when either of the transducers used to calculate ters the condenser.
oil pressure are out of range. The zero function occurs
when the RESET button is pressed, the oil pumps are Discharge Superheat
not running, and there are no system faults or alarms. Displays the discharge superheat. This value is calcu-
The offset pressure is the pressure difference between lated by subtracting the condenser saturation tempera-
the high oil pressure (HOP) transducer and the low oil ture (PE-113) from the compressor discharge tempera-
pressure (LOP) transducer outputs. During this time, ture (TE-112).
the transducers should be sensing the same pressure.
However, due to accuracy tolerances in transducer de- LS PRV Position
sign, differences may exist in these pressure readings. Displays the Compressors PRV open position percent-
age.

JOHNSON CONTROLS 75
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

LS Thrust Prox Diff NAVIGATION

Displays the distance between the high-speed thrust
Home
collar and the tip of the proximity probe. This measure-
ment takes into account the reference position estab- Used to provide additional Home information.
lished at the time of compressor manufacture.
LS Prox Calibration
Oil Pump Frequency Returns the display to view the LS Prox Calibration
Displays operating frequency at which Oil Pump is Screen.
commanded to run.
PRV Calibration
LS Motor Load Access Level Required: OPERATOR
Displays the motor current as a percentage of the Full Only available if the chiller is stopped, advances to the
Load Amps (FLA) value. PRV Calibration Screen.

System Head Oil Sump

Displays the chiller head pressure calculated as (con- Returns the display to view the Oil Sump Screen.
denser pressure – evaporator pressure).
LS VGD
Compressor Head Returns the display to view the LS VGD Screen.
Displays the Compressors head pressure calculated as
Capacity Controls
condenser pressure minus economizer pressure.
Returns the display to view the Capacity Controls
Screen.

Return
Returns the display to the previous screen.

76 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

LS PROXIMITOR CALIBRATION (LOW AND HIGH STAGES) SCREEN

LD15244

Figure 37 - LS PROXIMITOR CALIBRATION (LOW AND HIGH STAGES) SCREEN

OVERVIEW Any time the Quantum™ LX controller

application program is updated, the axial
At the factory, or when a compressor is replaced on a
proximitor reference values, recorded on
chiller, the proximity probes must be calibrated. Insure
the panel door from commissioning, must
that there is oil in the oil sumps during this procedure.
be entered into these screens.
Navigate to this screen, and press [START CAL] to
start the calibration procedure. The oil pump will pro-
If a compressor proximity shutdown is
duce rated pressure, and the proximity reading will be
generated, it will be necessary to contact
taken. This will be the reference point. Press [ENTER
the YORK factory Technical Support
REF] to ACCEPT the calibration data. Press [END
to reset the panel to insure there is not
CAL] to end the calibration procedure.
damage to the compressor thrust bearing.
If the difference between the actual read-
ing and this reference exceed the alarm
and trip values, and a proximitor TRIP DISPLAY
is produced, the compressor should be
evaluated for thrust bearing damage. High Speed Thrust Bearing Proximity Position
N/A

High Speed Thrust Bearing Proximity Reference

N/A

Oil Supply Pressure

Displays available oil pressure to the compressor.

JOHNSON CONTROLS 77
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

Proximitor Forward HS Prox Calibration

Warning and Shutdown limits. This screen Displays data about the HS Prox Calibra-
tion.
Proximitor Reverse
Warning and Shutdown limits. History
This screen provides access to a Time stamped Record
of shutdown conditions.
NAVIGATION

Home
Used to provide additional Home information.

Low Stage Compressor

This screen displays data about the Low Stage Com-
pressor.

78 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

PRV CALIBRATION SCREEN

LD15266

Figure 38 - PRV CALIBRATION SCREEN

OVERVIEW DISPLAY
If a PRV position potentiometer must be replaced in the PRV Raw Input
field, the position of the potentiometer relative to the Displays the vane position signal read directly off the
actual vane position is critical. potentiometer.
1. The PRV POT assembly, shown below, should
first be assembled to the compressor. Next navi- PRV Position
gate to the PRV Calibration screen on the panel. Displays the real-time position of the vanes.

2. Loosen the Allen Set Screw on the PRV POT cou- PRV Opening / Closing
pling connected to the COMPRESSOR side of the Displays the status of the vane actuator.
coupling. This will allow you to turn the coupling
and move the potentiometer position.
3. Adjust the PRV POT position until the PRV RAW
INPUT percentage reads between 10% and 20%.
4. After this reading is obtained, tighten the Allen
Set Screw on the coupling, and the proceed to the
calibration procedure as described below.

LD14879a

Figure 39 - PRV POSITION SENSOR

JOHNSON CONTROLS 79
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

Vane Motor Switch (LED) NAVIGATION

Illuminates when the Vane Motor Switch contacts are
Home
closed (provided by PRV Closed Limit Switch ZS-
100A). Used to provide additional Home information.

Zero Value Setpoint Low Stage Compressor

Access Level Required: OPERATOR This screen displays data about the Low Stage Com-
For manual calibration of the PRV; corresponds to pressor.
the raw PRV potentiometer input with the vanes fully
High Stage Compressor
closed.
This screen Displays data about the High Stage Com-
Span Value pressor.
Access Level Required: OPERATOR
History
For manual calibration of the PRV; corresponds to the
raw PRV potentiometer input with the vanes fully open. This screen provides access to a Time stamped Record
of shutdown conditions.

INTERACTIVE
[START CAL]
Selecting this button initiates a vane position calibra-
tion algorithm.
[END CAL]
Selecting this button accepts the automated vane cali-
bration or cancels the calibration procedure.
When START CALIBRATION is selected, a mes-
sage “Vane motor stroking please wait” appears.
Press [END CAL] to accept calibration.

80 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

OIL SUMP (UNIFIED SUMP PRESSURE) SCREEN

LD15281

Figure 40 - OIL SUMP (UNIFIED SUMP PRESSURE) SCREEN

OVERVIEW PROGRAMMABLE
This screen displays a close-up of the chiller oil sump HS Auto/LS Auto
and provides all the necessary setpoints for maintain- Access Level Required: SERVICE
ing the Variable Speed Oil Pump (VSOP). In addition, Manual automatic stations allow analog control of
this screen allows manual control of the frequency valves and vanes. The analog process control system
command sent to the VSOP. is based on a 0 – 100% range. The automatic control
system drives the valve or vanes with a percentage of
DISPLAY drive signal. The operator interface allows an experi-
enced technician to take manual control of a device.
HS Oil Pump Run Pressing the button marked AUTO toggles the device
Indicates the run status of the Oil Pump. into a manual control state. The button turns red and
the word MANUAL appears. Pressing MANUAL will
LS Oil Pump Run toggle the device into an automatic state. While in
Indicates the run status of the Oil Pump. manual control, the OPEN (INCREASE) or CLOSE
(DECREASE) buttons may be used to manipulate the
Oil Heater valve or vane. The bar graph on the right shows the
Indicates the operational status of the oil heater. actual position of the valve or vane. The automatic bar
graph shows where the automatic control system wants
LS Oil Return Solenoid the device to be.
N/A

JOHNSON CONTROLS 81
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

P NAVIGATION
This key allows the service technician to set the propor-
Home
tional gain of the primary and economizer oil pumps.
Used to provide additional Home information.
I
Low Stage Compressor
This key allows the allows the service technician to
set the integral gain of the primary and economizer oil This screen displays data about the Low Stage Com-
pumps. pressor.

D High Stage Compressor

This key allows the service technician to set the deriva- This screen Displays data about the High Stage Com-
tive gain of the primary and economizer oil pumps. pressor.

History
This screen provides access to a Time stamped Record
of shutdown conditions.

82 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

OIL SUMP (ICE THERMAL STORAGE) SCREEN

LD15267

Figure 41 - OIL SUMP (ICE THERMAL STORAGE) SCREEN

OVERVIEW Oil Return Solenoid

This screen displays a close-up of the chiller oil sump Indicates the status of the oil return solenoid.
and provides all the necessary setpoints for maintain-
Oil Heater
ing the Variable Speed Oil Pump (VSOP). In addition,
this screen allows manual control of the frequency Indicates the operational status of the oil heater.
command sent to the VSOP.
INTERACTIVE
DISPLAY Auto / Manual
Oil Sump Temperature Allows SERVICE MODE to manually adjust the oil
Displays the oil sump temperature. pump drive speed.
Selecting Auto causes two additional screen tabs
Oil Sump Pressure (Hop)/(Lop)
to appear. Increases the drive frequency and De-
Displays the pressure at the high and low pressure creases the drive frequency. Pressing the MANUAL
sides of the oil sump. while in manual control mode toggles back to auto-
matic control.
Oil Supply Pressure
Displays the oil supply differential pressure (pump – This Manual / Auto station is not available below Ser-
sump). vice Level access.

Oil Pump Frequency Lubrication Auto/Lubrication Lock On

Displays the variable-speed oil pump drive frequency. Toggles the oil pumps off/on in standby mode, producing
rated oil pressure with the drives in automatic. This can be
Oil Pump Run used for testing the oil lubrication circuit. This button can
Indicates the operational status of the oil pump. also be used when jogging the motors for direction.

JOHNSON CONTROLS 83
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

PROGRAMMABLE mulate in the evaporator refrigerant charge. This oil

can have a negative impact on heat transfer for modern
Access Level Required: SERVICE tube surfaces. It is necessary to have an oil return sys-
Oil Supply Pressure Controller tem in place to return the lost oil back to the compres-
sor oil reservoir.
Includes proportional gain (P), integral gain (I), and
differential gain (D) accessible by SERVICE level. Eductor Block Low Stage Oil Return
On Non-Unified Oil Sumps the oil transfer settings are The compound YK oil return system uses an educ-
available to the SERVICE level. tor block to return oil to the low stage compressor oil
reservoir. The eductor block uses high-pressure refrig-
Oil Sump levels are indicated in the center of the screen. erant gas through a venturi nozzle eductor as motive
If the oil levels associated with each level alarm shown force to pull oil rich refrigerant liquid from the evapo-
in the bottom center of the screen and alarm will be rator and into to the low stage oil reservoir. Over time,
logged in the alarm history. oil lost from both compressors would accumulate in
The purposed of the oil transfer system is to maintain the low stage compressor reservoir.
equal levels of oil in each sump. If the oil levels are The Oil Return Eductor draws oil from the evaporator
more than 15% different, then a transfer is initiated au- and returns it to the Low Stage Sump Pressure. Oil could
tomatically. If the oil in the high stage sump is higher also have been lost from the High Stage Oil Sump.
then the balance transfer solenoid is opened until the
levels are equal or the LS High oil level STOP setpoint High Stage Oil Return
is reached. If the oil in the Low Stage is higher then the
A means to return oil to the High Stage Oil Sump is
oil transfer pump is started until the levels are equal, or
provided by a small pump. The pump activates when
until the LS Low oil level setpoint is reached, or the HS
the High Stage Oil Sump is 15% below the Low Stage,
High oil level setpoint is reached.
with the provision that the Low stage must not be near
Oil Return System Operation empty alarm.
Centrifugal chillers will lose a small amount of oil into
the refrigeration system. Over time, this oil will accu-

OIL
LEVEL
SENSOR

SUMP AT
EVAPORATOR
PRESSURE
LD15293

Figure 42 - LOW STAGE OIL RETURN EDUCTOR

84 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

An oil level control system is provided to return oil to eductor block to return the oil to the high stage reser-
the higher-pressure high stage oil reservoir. This sys- voir. Refer to the oil flow diagrams.
tem consists of a small oil pump piped between the two
oil reservoirs and individual level transmitters on each CAUTION: Use only the approved York “K” type
reservoir. The control system monitors the level in polyolester oil with R-134a. Do not use mineral oils.
each reservoir, and turns the oil transfer pump on when
Condensate Management System
the level in the high stage drops approximately an inch
below that of the low stage. If the oil level in the low The Low Stage Primary CYK chiller with separate oil
stage oil reservoir drops 1 inch below the level in the sump pressures requires additional valves and controls
high stage, oil is bled from the supply line to the high to manage refrigerant condensate. When the Low Stage
stage compressor to the low stage reservoir. A solenoid Compressor runs alone, the High Stage Compressor is 3
valve controls this. Low and high oil level alarms are at discharge pressure. The tendency is that a large heat
programmed for each reservoir, when the levels extend sink body like the High Stage Compressor is a natural
beyond the sight ports. After servicing the compressor place for refrigerant to condense. Often times the plant
oil, each reservoir should be filled to the sight glass. room is cooler than the tower water and increases the
When adding oil during operation, the oil may be add- proclivity for refrigerant to gather in the High Stage
ed into the low stage reservoir. The transfer pump will Compressor.
move the oil to the high stage reservoir as needed.
This situation is mitigated by additional valves not
Compressor PRV/suction plenum oil drain: A small found on a CYK Heat Pump or Radiator cooled unit,
connection in the PRV area of each compressor drains since their oil sumps operate both at suction pressure.
a small amount of oil that may collect there. Each com- These additional valves isolate the High Stage Oil
pressor is vented to its respective oil reservoir. The low Sump from the rest of the system and prevent refriger-
stage compressor drains this oil through the main educ- ant condensate from the High Stage Compressor from
tor block. The high stage compressor has a separate oil migrating down to the sump.

SUMP AT
INTERMEDIATE
TO LOW
PRESSURE
STAGE
SUMP
TRANSFER PUMP
0.2 GPM
1750 RPM
LD15294a

Figure 43 - HIGH STAGE OIL RETURN EDUCTOR

JOHNSON CONTROLS 85
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

LOW STAGE OIL

OIL LEVEL SENSOR PUMP HOUSING

HIGH STAGE OIL PUMP HOUSING

LD15295
Figure 44 - OIL LEVEL SENSOR

When the CYK chiller runs in single-stage operation, When the chiller runs in two-stage operation, the valve
valve FCV-141A (Drain Block) stops refrigerant gather- FCV-141A (Drain Block) opens to allow oil to return to
ing in the gearbox cavity from going down the oil drain the sump. Valve FCV-141B (Scavenge) closes. Valve
line. Valve FCV-141B (Scavenge) allows this condensed FCV-141C (Pump Isolation Valve) opens to allow oil
liquid to be returned to the evaporator. Valve FCV-141C to circulate through the lube system.
(Pump Isolation Valve) closes and prevents oil from si-
phoning out of the sump and filling the gearbox with oil.

PUMP
ISOLATION
SCAVENGE VALVE

OIL LEVEL
SENSOR

DRAIN BLOCK

TO LOW
STAGE
SUMP AT SUMP
INTERMEDIATE
PRESSURE

LD15294a

Figure 45 - HIGH STAGE OIL SUMP

86 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

LS VARIABLE GEOMETRY DIFFUSER SCREEN

LD15256

Figure 46 - LS VARIABLE GEOMETRY DIFFUSER SCREEN

OVERVIEW The voltage setpoint (SP) provides the limitation of

stall noise from the compressor. The deadband setpoint
The Variable Geometry Diffuser (VGD), provides
(DB) will allow some area around the setpoint (SP)
acoustic attenuation of the compressor noise. The
where the VGD won’t move constantly.
VGD ring extends into the discharge to attenuate stall
noise by straightening the gas flow, and retracts when PROBING takes place when the stall voltage drops be-
attenuation is not required. low the setpoint (SP) minus the dead band (DB). The
A standard manual-auto station is provided to take WAIT period is a soak hold period in between PROBE
control of the VGD. The reaction ramp will be set to pulses when the VGD is being retracted/probing for
Manual when transferring to Automatic operation. noise. The PROBE time and rate, control how much
the VGD retracts when probing (opening/retracting)
The Variable Geometry Diffuser operates when the for noise. The Probing state will continue until the stall
chiller is running. It has three modes of operation, with voltage increases to within the setpoint (SP) – dead-
a manual override feature: band (DB) range, or until the VGD is fully retracted/
1. PROBE open.
2. WAIT The REACT mode occurs if at any time the PV noise
3. REACT voltage rises above the setpoint (SP) + deadband (DB).
The REACTING ramp rate (%/sec) Closes/Extends the
The VGD transducer located in the compressor dis-
VGD at the programmed rate until the noise voltage
charge volute, sends a variable frequency signal repre-
level (PV is within the setpoint (SP) +/- deadband (DB)
senting the acoustic noise component in the compres-
range.
sor, to the VGD Stall Detector board. The VGD Stall
Detector board detects the acoustic signal and provides
a 0 to 5 vdc signal (PV) to the microboard. This Stall
Detector Voltage is compared to the Stall Detector
Voltage setpoint (SP) to determine the operating state
of the VGD.

JOHNSON CONTROLS 87
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

VGD CALIBRATION MANUAL/AUTO OPERATION

The VGD must be calibrated before it is used. Dur- When in manual override the manual-automatic sta-
ing the calibration process, the feedback potentiometer tion takes control of the reaction ramp and overrides
is calibrated such that 100.0% open is when the VGD the VGD target position. The positioner then follows
actuator is fully retracted, and 0.0% open is when the the manual controlled value.
VGD actuator is fully extended. Pressing START CAL
while the machine is off starts extending (closes) the
VGD to its full limit (Zero value). “Calibration In Pro- DISPLAY ONLY
cess” is displayed on the VGD screen. When the poten- VGD Algorithm Mode
tiometer input stops moving the VGD retracts (opens)
Displays the state of operation for the VGD.
to it’s full limit (Span value). The Zero and Span are
retained in memory during the calibration process so VGD Motor Opening (LED)
that the VGD can be controlled linearly throughout its
Illuminates when the Compressor VGD is in the pro-
range of travel. When “Calibration In Process” is no
cess of opening (retracting).
longer displayed on the VGD screen, “Pressing END
CAL will end the calibration procedure and “load” the VGD Motor Closing (LED)
ZERO and SPAN values retained by memory during
Illuminates when the Compressor VGD is in the pro-
the calibration process, and are shown in the Zero and
cess of closing (extending).
Span fields on the VGD screen.
The potentiometer raw input is shown in the Pot Po- VGD Position
sition field on the display. The VGD Position shown Displays the Compressor VGD position.
on the display is the results of the calibration process.
Note that Pot Position (raw potentiometer value) and
PROGRAMMABLE
VGD position value will not be the same values. The
scaled position of the VGD is calculated as follows: Auto
VGDPosition = (Pot_Value - VGDZeroValue) / Access Level Required: OPERATOR
((VGDSpanValue - VGDZeroValue) / 100). Refer to Figure 26 on page 55 for operational de-
scription.
At the end of the calibration procedure, the VGD
should return to normal operation. If the potentiometer
should go out of range, an alarm indicating that the po- NAVIGATION
tentiometer is out of range is displayed.
Home
Used to provide additional Home information.
VGD OUTPUTS/POSITIONING
Setup
The VGD outputs shown on the display as OPEN and
This screen provides a single location to program the
CLOSE drive the VGD actuator until the VGD Posi-
most common system setpoints. It is also the gateway
tion achieves the target value displayed in the AUTO/
to many of the general system setup parameters such
MANUAL fields.
as I/O configuration, Communications Setup, Software
To insure uniform operation on startup, a pre-set Maintenance, Trending, and diagnostics.
startup setting (StartCV) is given to the VGD position
controller, and positions the VGD to this value on unit History
shutdown, ready for the next unit start-up. The startup This screen provides access to a Time stamped Record
point (StartCV) is determined during commissioning, of shutdown conditions.
but is typically within the 70 to 90% range.
The maximum and minimum travel of the VGD ring is
limited by the MaxCV and MinCV limit settings. The
values of these settings should be set at MaxCV = 100,
MinCV= 0.

88 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

HIGH STAGE COMPRESSOR SCREEN

LD15245

Figure 47 - HIGH STAGE COMPRESSOR SCREEN

OVERVIEW Compressor Head

Displays data about the High Stage Compressor. Displays the head pressure expressed as a differential
between the compressor suction and discharge.

DISPLAY HS Thrust Prox Diff

Displays the distance between the high-speed thrust
Oil Supply Pressure collar and the tip of the proximity probe. This mea-
Displays the oil supply pressure. surement takes into account the reference position es-
tablished at the time of compressor manufacture.
Oil Sump Temperature
Displays the oil sump temperature. Oil Pump Frequency
Displays the operating frequency of the variable-speed
Discharge Temperature oil pump drive.
Displays the temperature of the refrigerant gas at the
compressor outlet. HS Motor Load
Displays the position.
Discharge Superheat
Displays the temperature expressed as the differentia HS PRV Position
between the discharge temperature and the condenser Displays the position of the pre-rotation vanes in per-
saturation temperature. cent.

System Head Vane Motor Switch

Displays the chiller head pressure calculated as (con- Indicates the status of the vane motor switch.
denser pressure – evaporator pressure).

JOHNSON CONTROLS 89
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

Oil Return Solenoid NAVIGATION

Displays the status of the oil return solenoid to the Low
Home
Stage Compressor.
Used to provide additional Home information.

INTERACTIVE HS Prox Calibration

Returns the display to view the HS Prox Calibration
Pre-Rotation Vane Manual / Auto Station Screen.
Access Level Required: OPERATOR
Operator may manually adjust the position of the pre- PRV Calibration
rotation vanes. Access Level Required: OPERATOR
Only available if the chiller is stopped, advances to the
Pressing the Auto button allows the operator to adjust
PRV Calibration Screen.
the pre-rotation vane setting from.
0 – 100% open using the OPEN and CLOSE keys on Oil Sump
the bottom of the display. Returns the display to view the Oil Sump Screen.

Pressing the MANUAL button while in manual control HS VGD

mode toggles back to automatic control. Returns the display to view the HS VGD Screen.

Capacity Controls
Returns the display to view the Capacity Controls
Screen.

Return
Returns the display to the previous screen.

90 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

HS PROXIMITOR CALIBRATION SCREEN

LD15252

Figure 48 - HS PROXIMITY CALIBRATION SCREEN

OVERVIEW PROGRAMMABLE
This screen displays a cutaway view of the chiller com- Thrust Prox Reference
pressor, revealing the proximity probe sensor and pro- Access Level Required: SERVICE
vides the capability of calibrating the proximity probe This key allows the technician to define the primary
sensor. compressor proximitor probe offset reference postion.

Primary Prox Calibration

DISPLAY ONLY
Access Level Required: SERVICE
Thrust Prox Probe Position Start
Displays the distance between the high-speed thrust This button activates a primary compressor proximitor
collar and the proximitor probe that is used to measure probe calibration procedure to begin, which starts the
the position. A positive number is in the forward direc- compressor oil pump.
tion, a negative number is in the reverse direction.
Accept
Thrust Prox Differential This button allows the technician to accept the position
Displays the difference between the proximitor probe of the primary compressor proximitor probe.
position and the proximitor reference position. End
Compressor Oil Pressure This button cancels the request for a primary compres-
sor proximitor calibration procedure.
Displays the primary compressor oil pressure.
Reset Tripped Prox
Calibration Active (LED)
Access Level Required: FACTORY
Illuminates when the primary compressor is currently
This button allows the tecnician to reset a tripped pri-
performing a proximitor calibration.
mary compressor proximitor probe under the direction
from the Factory Technical Support Team.

JOHNSON CONTROLS 91
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

NAVIGATION

Home
Used to provide additional Home information.

Low Stage Compressor

This screen displays data about the Low Stage Com-
pressor.

HS Prox Calibration
This screen Displays data about the HS Prox Calibra-
tion.

History
This screen provides access to a Time stamped Record
of shutdown conditions.

92 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

LIQUID COOLED SOLID STATE STARTER (OPTIONAL)

LD15325

Figure 49 - LIQUID COOLED SOLID STATE STARTER (OPTIONAL)

OVERVIEW bus ASCII serial data communications link. The STOP

relay contacts on the Logic/Trigger Board assure a pos-
The YORK model LCSSS is an option for the CYK in
itive shutdown on all LCSSS initiated shutdowns.
low voltage applications. The LCSSS is factory mount-
ed and integrated onto the Quantum™ LX industrial When the temperature sensors detect a heatsink tem-
control center. The starter is configured at the factory. perature above 108°F, the circulation pump will run
The LCSSS data is viewable from this screen. Refer to until the temperature drops below this threshold. The
the LCSSS literature FORM 160.00-O2 for operation high heatsink temperature is handled as a temperature-
of this equipment. Please recall that the CYK does not based anti-recycle. When the temperature returns to
support cycling shutdowns. normal, the LCSSS will be reset automatically by the
Quantum™ LX, and the System Status “READY TO
The LCSSS contains a single Logic/Trigger printed
START” will be displayed.
circuit board. This board performs the following func-
tions:
DISPLAY ONLY
• Generates the SCR trigger pulses.
• Receives start/stop commands from the Quantum™ Motor Run (LED)
LX. Indicates when the CYK Control Center is command-
ing the motor to run.
• Transmits status and fault data to the Quantum™
LX. Motor Full Voltage Run Interlock (LED)
• Generates all LCSSS initiated Safety shutdowns. Indicates when the LCSSS has confirmed motor opera-
tion.
The Logic/Trigger Board is powered by +24VDC from
the Quantum™ LX industrial control center Power Starter OK (LED)
Supply. The Quantum™ LX Motherboard COM 3 Indicates when the LCSSS has confirmed a no fault
communicates with this board via a 19.2K baud Mod- condition.

JOHNSON CONTROLS 93
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

Motor Current % Full Load Amps Table 9 - FULL LOAD AMPS

Displays the motor current as a percentage of Job Full LCSSS MODEL PERMISSIBLE FLA
Load Amps setpoint. 7L-46, 58 and 50 35 to 260 Amps
14L‑17, 28, 46, 58 and 50 65 to 510 Amps
Input Power
26L‑17, 28, 46, 58 and 50 125 to 850 Amps
Displays the kilowatts measured by and transmitted
33L‑17, 28, 46 and 50 215 to 1050 Amps
from the starter.
Start Current ‑ The Logic/Trigger Board will limit in-
Voltage – Phase A, B, C rush motor current to this value during starting. The
Displays the 3-phase input line voltage as measured by programmed value is sent to the Logic/Trigger Board
and transmitted from the starter. over the serial communications link. This setpoint
should be programmed to (0.45 x motor Delta Locked
Current – Phase A, B, C Rotor Amps). Each model starter has a permissible
Displays the 3-phase motor current as measured by and range over which this setpoint can be programmed as
transmitted from the starter. follows:
Starter Model Table 10 - START CURRENT
Displays the starter model number as transmitted from PERMISSIBLE START
LCSSS MODEL
the starter. CURRENT RANGE
7L-46, 58 and 50 310 to 700 Amps
14L‑17, 28, 46, 58 and 50 620 to 1400 Amps
INTERACTIVE
26L‑17, 28, 46, 58 and 50 1150 to 2600 Amps
When the Logic Board detects an Overload condi- 33L‑17, 28, 46 and 50 1460 to 3300 Amps
tion, Relay K1 contacts open and the Overload LED
illuminates. A Motor Starter Fault is displayed in the Voltage Range
System Details. The contacts remain open and the LED Access Level Required: SERVICE
remains illuminated until manually reset at the Quan- Allows the user to select specific line voltage range for
tum™ LX. voltage checking. When not disabled, this line voltage
The Low Stage SSS is configured as Modbus node 1, range is used to determine a low line and high line volt-
and the High Stage SSS is configured as Modbus node age threshold for initiating a shutdown.
2. The Quantum™ LX Com 3 port is used as the Mod- To assure the chiller is not permitted to run for ex-
bus Master to communicate with the starters. tended periods with the supply line voltage outside of
acceptable limits, the Logic/Trigger Board compares
PROGRAMMABLE the actual 3-phase line voltage to the thresholds estab-
lished with the Supply Line Voltage Range setpoint.
Local Motor Current Limit Each supply voltage application has an allowable up-
Access Level Required: OPERATOR per and lower limit. If the supply voltage goes above
Allows the user to specify the maximum allowed mo- or below these limits continuously for 20 seconds, the
tor current (as percentage of FLA). When the motor logic trigger Board initiates a Cycling shutdown and
current reaches this value, the Capacity Controls will displays “LCSSS - HIGH SUPPLY LINE VOLT-
not be permitted to load further. If the motor rises AGE” or “LCSSS - LOW SUPPLY LINE VOLT-
above this value, the Capacity Controls will reduce the AGE” as appropriate.
current to this value.
Open SCR (Enabled/Disabled)
Full Load Amps Access Level Required: SERVICE
Access Level Required: SERVICE Allows the user to enable or disable the Solid State
Defines the maximum amps at which the motor can Starter Open SCR safety detection. This must never
operate. This value is viewable when logged in at Op- be disabled unless under advisement of the YORK
erator or View access level. Factory.

94 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

Open SCR (Enabled/Disabled)

Access Level Required: SERVICE
Allows the user to enable or disable the Solid State
Starter Open SCR safety detection. This must never
be disabled unless under advisement of the YORK
Factory.

kWH Reset
Access Level Required: SERVICE
Allows the user to reset the cumulative Kilowatt Hours.
3
NAVIGATION

Low Stage Compressor

This screen displays data about the Low Stage Com-
pressor.

History
This screen provides access to a Time stamped Record
of shutdown conditions.

JOHNSON CONTROLS 95
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

CAPACITY CONTROLS SCREEN

LD15257

Figure 50 - CHILLER MODE

CHILLER MODE OVERRIDES

The Capacity Controls Screen schematically illustrates Evaporator Pressure
the logical operations of chiller capacity control. Sen- Displays the current evaporator pressure.
sor readings are linked with setpoint values and com-
pared. PID loops, depicted in each box, pass signals Low Pressure Setpoint
through high or low-pass relay (HSR/LSR) junctions. Displays the system low evaporator pressure setpoint,
The relay makes a simple comparison of two signals at which the chiller will be unloaded if the evaporator
and passes the higher or lower of the two depending on pressure goes below this threshold.
whether the relay is high or low pass.
Condenser Pressure
HEAT PUMP MODE Displays the current condenser pressure.

The CYK machine has the ability to control itself as High Pressure Setpoint
a CHILLER or a HEAT PUMP. In Chiller mode, the Displays the system high condenser pressure setpoint,
Leaving Water temperature from the evaporator heat at which the chiller will be unloaded if the condenser
exchanger is the process signal. In Heat Pump mode, pressure goes above this threshold.
the Leaving Water temperature from the condenser
heat exchanger is the process signal. The CYK control Interstage Pressure
system will adjust the vanes and hot gas valve to at- Displays the current interstage pressure.
tempt to generate the desired process temperature.
Interstage High Pressure Setpoint
Displays the system high condenser pressure setpoint,
at which the chiller will be unloaded if the condenser
pressure goes above this threshold.

96 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

Motor Load NAVIGATION

Displays the current motor load in percentage.
Home
Load Limit Used to provide additional Home information.
Displays the motor load limit setpoint.
Evaporator
HGV Ramp A detailed view of all evaporator parameters, including
Displays the hot gas valve ramp rate in percent. the programmable Leaving Chilled Liquid Setpoints.

HGV Condenser
Displays the current hot gas valve position from opened A detailed view of all condenser parameters, including 3
to closed in percent. control of the liquid level functions.

PRV Actual Return

Displays the actual current position of the pre-rotation Returns the display to the previous screen.
vanes from opened to closed in percent.

PRV Target
Displays the control system intended position of the
pre-rotation vanes.
Refer to the table of contents for the explanation of the
operation of the Capacity Controls System.

LD15247
Figure 51 - HEAT PUMP MODE

JOHNSON CONTROLS 97
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

MANUAL AUTO STATION (CAPACITY CONTROLS) SCREEN

LD15280

Figure 52 - MANUAL AUTO STATION (CAPACITY CONTROLS) SCREEN

OVERVIEW DISPLAY ONLY

The capacity controls manual-auto station screen can Leaving Chilled Liquid Temperature
be used to take manual control of all three capacity Displays the temperature of the chilled liquid as it
controls devices. (Putting both sets of vanes in manual leaves the evaporator.
control brings up an option on synchronous open and
closed keys to synchronously open and close both sets Leaving Chilled Temperature Setpoint
of vanes) Displays the present setpoint to which the chiller is op-
LED symbol indicators are shown for observing pulses erating, whether controlled locally or remotely.
fed to each PRV shaded pole actuator motor. The ac-
tual PRV position feedback is listed at the TOP of each System Head
manual-auto station. Displays the system head differential pressure.

Anti-surge values for both sets of vanes are depicted as

a RED bar graph to the right of each station. PROGRAMMABLE

If the Low or High Stage vanes are put back into auto- HS Auto
matic control, above the calculated anti-surge value, the Access Level Required: OPERATOR
Capacity Controls algorithm will adjust to the manual Refer to Figure 26 on page 55 for operational use.
value and calculate from that point. If released below
anti-surge calculation, the station will go into an inhibit LS Auto
condition. The manual value must be increased above Access Level Required: OPERATOR
anti-surge to transition back to automatic operation. Refer to Figure 40 on page 81 for operational use.

98 JOHNSON CONTROLS
FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

Hot Gas Auto Anti-Surge

Access Level Required: OPERATOR This screen displays data about the Anti-Surge.
Refer to Figure 26 on page 55 for operational use.
Capacity Controls
Returns the display to view the Capacity Controls
NAVIGATION Screen.
Home
Setup
Used to provide additional Home information.
This screen provides a single location to program the
most common system setpoints. It is also the gateway
Evaporator
to many of the general system setup parameters such 3
A detailed view of all evaporator parameters, including
as I/O configuration, Communications Setup, Software
the programmable Leaving Chilled Liquid Setpoints.
Maintenance, Trending, and diagnostics.
Condenser
Return
A detailed view of all condenser parameters, including
Returns the display to the previous screen.
control of the liquid level functions.

JOHNSON CONTROLS 99
 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

PID TUNING SCREEN

LD15261

Figure 53 - PID TUNING SCREEN

OVERVIEW For the setpoint of TC-100 and TC-103, the “LOC

SP=” text changes to “REM SP=” when being con-
This screen would normally only be used on initial
trolled remotely. See Evaporator Screen in Chiller
start-up by a York Service Technician to fine tune the
Mode, or Condenser Screen for Heat Pump Mode, for
capacity controls. The effects of changes to the PID
details on changing the setpoint of these controls.
tuning are observed by changing back to Screen #10 :
CAPACITY CONTROLS. Changing Tuning Parameters
Contact a YORK Service Agent if adjust- To change tuning parameters touch the numeric entry
ments are required to the Capacity Con- area, and a cursor will appear where a new value can be
trols tuning. entered. Enter the new value and press the [SUBMIT]
button.
The tuning values shown are estimated only and may
The present status of the adjustable tuning param- require adjustment depending on actual chiller operat-
eters are shown for each PID controller and other pro- ing conditions.
grammed control functions. The PID controllers are
configured using ISA equations, with the following Ramp Values
values: The Ramp Rates are used on chiller startup. The PID
controls are put into manual, and ramped slowly to
SP = Set Point reach their setpoints without overshoot. The actual
P = Controller Gain running conditions of the water system will determine
whether faster or slower ramp rates are appropriate.
I = Integral Gain (Reset)
TC-100 has a setpoint ramp rate in Degrees Tempera-
D = Derivative Gain ture per Second for both Single Stage and Two Stage
operation respectively indicated by a 1 and 2.

100 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

The Hot Gas Valve has a startup ramp rate which can NAVIGATION
be defined here. The Hot Gas Valve starts at 100%
open and ramps closed at this ramp rate until the ramp Home
is complete, or a setpoint, or override is reached. Used to provide additional Home information.

JC-160B Overrides
The HS motor load limiter controller has two func- Returns the display to view the Capacity Override Tun-
tions, depending on the system configuration. ing Parameters.

• If the system is configured for load matching be- Capacity Controls

tween the stages, then the setpoint for this control- Returns the display to view the Capacity Controls 3
ler comes from the actual motor load of the Low Screen.
Stage. LS LOAD is displayed next to the setpoint.
Setup
The BIAS setpoint controls the balance of the
This screen provides a single location to program the
compressor load matching. A positive value
most common system setpoints. It is also the gateway
will load the high stage this much more than
to many of the general system setup parameters such
the low stage. A negative value will keep the
as I/O configuration, Communications Setup, Software
high stage unloaded this much less percent
Maintenance, Trending, and diagnostics.
than the low stage.
• If the system is configured for an offset High History
Stage compressor operation, then this demand This screen provides access to a Time stamped Record
limiter PID takes its setpoint from the HS Limit of shutdown conditions.
setpoint block below the SP= value. HS LIMIT is
displayed in this case.

JOHNSON CONTROLS 101

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

OVERRIDES SCREEN

LD15262

Figure 54 - OVERRIDES SCREEN

OVERVIEW Enter the higher of the two temperatures in the

Pulldown Temp box. This is the starting entering
The Override Tuning Screen allows the operator to
chilled temperature. Enter the lower of the demand
adjust capacity controls tuning parameters. The screen
limit percentages in the Pulldown Lim box. This is
depicts four control loops:
the demand limit allowed during the pulldown of the
(PC-111) Evaporator Pressure system. As the system reaches setpoint, the lower of
the two entering chilled temperatures in the Demand
(PC-113) Compressor Discharge Pressure Temp box will result in a higher allowable Demand
(PC-116) Interstage Pressure Limit in the Demand Lim box. The Demand Temp
should be greater than the actual entering chilled liquid
(JC-160A) LS Motor Load Limiter temperature setpoint, by several degrees.
Refer to PID tuning procedures to adjust these loops. XC-149
JC-160A The PRV Anti-stall controller will become active when
the VGD gap on the LS compressor is fully extended.
The Low Stage demand limiter PID has a pulldown This controller will open the PRV’s on the LS com-
function associated with it. The pulldown is not pressor to maintain the stall setpoint given on the LS
time-based like conventional pulldown timers. This VGD screen. Refer to the LS VGD controller screen.
pulldown is temperature-based over a sliding scale As the stall noise decreases, the PRV’s are allowed to
of demand limitation. As the chiller attains the de- return to normal as the XC-149 controller goes back to
sired setpoint, from a standby state, the demand limit a zero output.
is slowly allowed to increase. This prevents a sudden
change of demand limit and also keeps the system from
overload during and ice-building start up.

102 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

PROGRAMMABLE start both compressors as quickly as possible when it is

started. If the difference is below this value, the head
Single To 2-Stage will not be great, and only the low stage is needed to
Access Level Required: SERVICE start with.
This setpoint determines at what head pressure (con-
denser pressure – evaporator pressure) the High Stage
booster compressor should be brought online. During NAVIGATION
operation with the single Low Stage compressor the
Home
head may increase above the ability for one stage of
compression to handle (high duty head or brine duty). Used to provide additional Home information.
Therefore, the booster is brought online to increase the
Anti-Surge
3
lift.
This screen displays data about the Anti-Surge.
2-Stage To Single
Access Level Required: SERVICE
Capacity Controls
This setpoint determines at what head pressure the High Returns the display to view the Capacity Controls
Stage booster compressor is not needed to accomplish Screen.
the lift of the system. Running the High Stage com-
Setup
pressor unnecessarily is a waste of energy (low head
duty). Below this threshold a single stage of compres- This screen provides a single location to program the
sion is enough to produce the system lift; therefore, the most common system setpoints. It is also the gateway
booster is dropped offline until it is needed again. to many of the general system setup parameters such
as I/O configuration, Communications Setup, Software
Immediate Two-Stage Threshold Maintenance, Trending, and diagnostics.
Access Level Required: SERVICE
History
The difference between the entering condenser water
and entering chilled water predicts the head conditions This screen provides access to a Time stamped Record
when the CYK is started. If the difference in tempera- of shutdown conditions.
ture is above this programmable setpoint, the CYK will

Demand
Limit

% FLA

Pulldown
Limit

Demand Degrees Pulldown

Temperature Temperature Temperature
LD15234

Figure 55 - TEMPERATURE-BASED DEMAND LIMITER FUNCTION

JOHNSON CONTROLS 103

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

ANTI-SURGE SCREEN

LD15263

Figure 56 - ANTI-SURGE SCREEN

OVERVIEW There are entry fields for three separate surge curves.
Depicted on the Anti-surge tuning parameters screen is • The LS ANTI-SURGE CALC is a surge curve for
plot showing the surge area as a function of compres- single stage CYK operation.
sor head versus PRV position. The area to the left the
line, highlighted in red, are the conditions under which • The 2-STAGE SYSTEM ANTI-SURGE CALC is
surge can be expected to occur. a surge curve for 2-stage CYK operation.
• The HS ANTI-SURGE CALC is a surge curve for
ANTI-SURGE MAP just the high stage compressor alone. This can be
PD1 is the maximum system head pressure as defined used to keep the High Stage Vanes from adjusting
by the entry fields. below the percentage of the Low Stage vanes at
low loads.
PD2 is the minimum system head pressure as defined
by the entry fields. HS curve is not depicted in a graphic.

MVP1 is the minimum allowable vane position at the These MVP1 and MPV2 are typically zero
maximum system head pressure PD1. for most applications.
The Anti-surge parameters must be deter-
MVP2 is the minimum allowable vane position at the
mined experimentally during the commis-
minimum system head pressure PD2.
sioning procedure. Values shipped with
An “X” on the plot shows the current Low Stage Vane the unit are only default.
operating point.

Refer to Anti-Surge Tuning on Page 48 for details on

anti-surge control line operation and tuning.

104 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

NAVIGATION

Home
Used to provide additional Home information.

Evaporator
A detailed view of all evaporator parameters, including
the programmable Leaving Chilled Liquid Setpoints.

Condenser
A detailed view of all condenser parameters, including 3
control of the liquid level functions.

PID Tuning
Returns the display to view the Capacity Controls Tun-
ing Parameters.

Overrides
Returns the display to view the Capacity Override Tun-
ing Parameters.

Capacity Controls
Returns the display to view the Capacity Controls
Screen.

JOHNSON CONTROLS 105

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

SETUP SCREEN

LD15255

Figure 57 - SETUP SCREEN

OVERVIEW INTERACTIVE
Provides access to advanced functions and setup of the Reset Start Count
CYK. Access Level Required: FACTORY
Resets the start counter (restricted access).
DISPLAY
Reset Run Timer
PLC Clock Present Access Level Required: FACTORY
Shows present date and time. Resets the run timer (restricted access).

Last Start Date Reset Anti-Recycle

Shows the date and time of the last motor start. Access Level Required: FACTORY
Resets the anti-recycle (restricted access).
Runtime Last Start
Shows the days, hours and minutes of the last motor Chiller Mode / Heat Pump Mode
run interval. Access Level Required: OPERATOR
Toggles between Chilling Operation and Heat Pump
operation.

106 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

NAVIGATION Serial Port Setup

Returns the display to view the Serial Port Setup
Home
Screen.
Used to provide additional Home information.
Ethernet
Trending
Returns the display to view the Ethernet Screen.
Returns the display to view the Trending Screen.
History
Diagnostics
This screen provides access to a Time stamped Record
Returns the display to view the Diagnostics Screen. of shutdown conditions.
3
Test Outputs
Returns the display to view the Test Outputs Screen.

Setup
This screen provides a single location to program the
most common system setpoints. It is also the gateway
to many of the general system setup parameters such as
I/O configuration, Communications Setup, Software
Maintenance, Trending, and diagnostics.

JOHNSON CONTROLS 107

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

TEST OUTPUTS SCREEN

LD16096

Figure 58 - TEST OUTPUTS SCREEN

OVERVIEW NAVIGATION
The Test Output screen is used to test a solenoid or Home
digital valve. Pressing the key corresponding to the de- Used to provide additional Home information.
vice name, will cause it to turn ON momentarily for
testing purposes. Setup
This screen provides a single location to program the
INTERACTIVE
most common system setpoints. It is also the gateway
Each solenoid in the system, as well as the oil transfer to many of the general system setup parameters such
pump has a test button associated with it on this screen. as I/O configuration, Communications Setup, Software
Maintenance, Trending, and diagnostics.
Pressing the corresponding button will engage the out-
put for two seconds for test purposes. For slow valves
the output will be engaged for a longer time delay.

108 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

SETPOINTS 1 SCREEN

LD15260

Figure 59 - SETPOINTS 1 SCREEN

OVERVIEW NAVIGATION
This screen is only available under the highest access Home
level.
Used to provide additional Home information.
The Safety setpoints are the thresholds of safe opera-
tion for the York CYK chiller. Each CYK is designed Setpoints 2
with unique applications in mind, therefore each will Returns the display to view the Setpoints 2 Screen.
have unique safety setpoints.
Saturation Calc
Consult the York Factory before attempt-
Returns the display to view the Saturation Calc Screen.
ing to change any safety setpoints. These
thresholds protect the CYK chiller from
operations outside its design parameters.
Safe operation of the chiller, and war-
ranty claims, will be compromised by
unauthorized changes.

JOHNSON CONTROLS 109

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

SETPOINTS 2 SCREEN

LD15249

Figure 60 - SETPOINTS 2 SCREEN

OVERVIEW HS PRV Offset

The miscellaneous setpoints screen allows access to In the case of an ice building application with dispro-
programmable features that control the more high level portionate expectations of lift between the HS and LS
parameters of the CYK control system. Care is to be compressors, another control method is needed. This
taken when accessing these setpoints. can also be used in other modes for an alternative mode
of HS compressor operation.
HS PRV Offset vs Load Matching
The two percent values of LOW HEAD OFFSET and
Control
HIGH HEAD OFFSET, must be supplied to create a
There are two modes of operation for the HS compres- linear scale between the lift requirements defined by
sor capacity control. System Antisurge PD1 and PD2 in terms of differen-
tial pressure. So, at a relatively high lift across the en-
Load Matching
tire system, the HS compressor operates its PRV’s the
The HS compressor can be selected to run equal com- HIGH HEAD OFFSET in percent above the LS com-
pression ratio as the LS compressor, as in a radiator or pressor vane position. The offset is calculated from
heat pump application. This selection is convenient in here down to the LOW HEAD OFFSET position at
that both compressor will use approximately the same PD2 in differential pressure, over a calculated linear
percent work to accomplish the total head. If LOAD scale.
MATCHING operation is selected the HS compressor
vanes will be operated on a demand limiter PID with The Offset slope can be either Positive or Negative,
the setpoint being slaved to the LS compressor motor meaning that the HIGH HEAD OFFSET can be (and
current. In this way the compressors will track nicely often is) less than the LOW STAGE OFFSET.
together always sharing the lift.
During this mode of operation the HS compressor de-
This method is not ideal when the compressors are se- mand limit (current limit) controller is active and will
lected to operate more efficiently with disproportionate override the offset function if the demand on the HS
sharing of compression ratios. motor is too high.

110 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

This method of High Stage Compressor control should RAMPS AND START POSITIONS
be used in situations where the best efficiency is ob-
tained by an intermediate temperature that is not equal PRV Ramp
compression ratio sharing between stages. Ramp rate that the vanes will be limited to during a
chiller start.
Figure 61 on page 111 illustrates the HS PRV offset
function. Start Unload
LS vane position limitation during two stage transition
from single stage to two stage.
CONTROL STOP

Control Stop Chiller Temp Setpoint LS PRV Start 3

This is the setpoint that the TC-100 temperature con- Open the vanes this small percentage before engaging
trol will receive during a controlled stop procedure. the drive motor while in prelube.
The setpoint should be higher than the inlet chilled wa-
HS PRV Start
ter temperature to unload the chiller quickly.
Open the vanes this small percentage before engaging
Control Stop Heat Pump Temp Setpoint the drive motor while in prelube.
This is the setpoint that the TC-103 temperature con-
PRV Response Gain
trol will receive during a control stop procedure in
Heat Pump mode. The setpoint should be lower than The PRV’s have a positioner algorithm that pulses
the inlet condenser water temperature to insure a quick them open or closed based on their target signal from
machine unload sequence. the capacity controls. This gain is defaulted to 4800
for most compressors. Very small compressors have
CONTROL STOP MAX TIMEOUT smaller faster PRV actuator motors, which may require
This time governs the maximum time that a control the gain to be reduced to 4000.
stop cycle should be allowed to take. If the chiller
doesn’t unload fast enough, this is the maximum time
allowed of running after the STOP button is pressed.

PD1 from
System
Antisurge
Map

Chiller
Head

PD2 from
System
Antisurge
Map Low Head Offset % Vane Position High Head Offset
LD15235

Figure 61 - HS PRV OFFSET CONTROL SCALE FUNCTION

JOHNSON CONTROLS 111

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

SS1 Ramp Rate LCV-117 % Open On Start

Selector Switch 1 has a rate of change limiter associ- On chiller start, the LCV-117 valve is forced to preset
ated with it, which limits the rate of change of the anti- to this percentage.
surge calculated value to the number entered here. This
prevents large transient changes caused by tower con- LCV-116 % Open On Start
dition upsets from affecting stable chiller operation. On chiller start, the LCV-116 valve is forced to preset
to this percentage.
Minvane Low Limit
This value is the minimum calculated value allowed Inlet Valve Level Control Setpoint Bias
out of SS1. If SS1 were to go to zero, then the ratiomet- The PRV Ramp Release is held until the economizer
ric hot gas calculation would not work. Therefore this level setpoint plus this (negative) value is obtained in
value must be greater than zero. the economizer vessel.

HS Catchup Offset Economizer Level Loss Bias

This percentage value defines how far the HS vanes In two stage operation, if the level in the economizer
need to be above the LS vanes, before the LS vanes are goes below the setpoint minus this value, then restart
allowed to resume Temperature Control, when a two- the economizer level control ramp. Minimizes oscilla-
stage transition occurs. tions in regaining level control.

Miscellaneous Settings Economizer Gas Bleed Solenoid (On and Off)

Motor Undercurrent Trip (LS and HS) ON – In single stage operation, if the economizer level
goes below the setpoint minus this value, the gas bleed
If the motor current does not exceed this value during
solenoid PCV-117 control becomes active.
run, then the load feedback is malfunctioning and must
be investigated. OFF – In single stage operation, in order to turn off the
Economizer Gas Bleed Solenoid the level must make
Standby Lube Cycle Interval an upward transition of this many percent.
Hours of delay between shaft seal lubrication cycles.
A shaft seal lubrication cycle is a 3 minute lubrication
cycle. NAVIGATION

Home
PRV Ramp Release
Used to provide additional Home information.
This is the percentage of LS PRV position that the LS
compressor is held at to establish an economizer level
Setpoint 1
prior to initial start ramp up. This value is ignored after
Returns the display to view the Setpoint 1 Screen.
the economizer level setpoint is met.

LCV-114 Open On Start

On chiller start, the LCV-114 valve is forced to preset
to this percentage.

112 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

PRESSURE CALIBRATION SCREEN

LD15268

Figure 62 - PRESSURE CALIBRATION SCREEN

OVERVIEW PROGRAMMABLE
This screen is only available under the highest access Atmospheric Pressure
level. Access Level Required: SERVICE
Scaling values in the processor must Atmospheric pressure is defined for Absolute Pressure
agree with the marked scaling values reading references. (Typically 14.7PSI)
on each instrument. If the scaling is not
correct, the safe operation of the chiller
is jeopardized. Only change scaling under NAVIGATION
the direction of the factory. Setup
This screen provides a single location to program the
The pressure sensors can be configured for many types
most common system setpoints. It is also the gateway
of inputs. Standard configuration uses YK Ratiomet-
to many of the general system setup parameters such
ric pressure sensors. Signal type is 0.5 to 4.5 VDC.
as I/O configuration, Communications Setup, Software
Each channel should be calibrated for zero and span bit
Maintenance, Trending, and diagnostics.
counts for the highest accuracy.

DISPLAY
Displays and controls the instrument scaling of each
Pressure transducer on the chiller.

JOHNSON CONTROLS 113

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

TEMPERATURE CALIBRATION SCREEN

LD15269

Figure 63 - TEMPERATURE CALIBRATION SCREEN

OVERVIEW PROGRAMMABLE
The Temperature inputs are set for ICTD (Integrated Temperature Probes
Circuit Temperature Detector) by default. These are Access Level Required: SERVICE
calibrated to a known temperature by the offset col- Temperature probes can be calibrated in Service Mode
umn. The usable range of readings is adjustable. by entering the actual temperature into the first col-
umn, or calculating an offset and entering it into the
DISPLAY second column. Press the SUBMIT key on the keypad
to confirm changes.
Displays and controls the instrument scaling of each
temperature detector on the chiller.
NAVIGATION

Setup
This screen provides a single location to program the
most common system setpoints. It is also the gateway
to many of the general system setup parameters such
as I/O configuration, Communications Setup, Software
Maintenance, Trending, and diagnostics.

114 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

MISCELLANEOUS CALIBRATION SCREEN

LD15270

Figure 64 - MISCELLANEOUS CALIBRATION SCREEN

OVERVIEW NAVIGATION
The Miscellaneous Calibration page configures any Setup
inputs that are not pressures or temperatures on the This screen provides a single location to program the
standard system. The motor CT’s range should be en- most common system setpoints. It is also the gateway
tered with the CT ratio from the Sales Order. The FLA to many of the general system setup parameters such
should be entered with the full load amps of the motors as I/O configuration, Communications Setup, Software
from the Sales Order. Maintenance, Trending, and diagnostics.

JOHNSON CONTROLS 115

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

LD15270a

FIGURE 62 - SCALING – MISCELLANEOUS INPUTS SCREEN (CONT'D)

The technician must configure the engineering units of temperatures. The liquid type must also be selected for
the flowmeter in GPM both Low and High. The sensor the capacity calculation to work out correctly. The liq-
signal from the dropdown box (4-20mA is preferred). uid can be water/ethylene glycol/ or propylene glycol.
The IO Board analog board and the channel to which The concentration of the brine solution must also be
the instrument is attached. The technician must also de- entered in percent volume. If the liquid is water, then
termine the flowmeter device location, whether it is on the concentration of brine is 0%.
the IN/OUT or an AVERAGE of the water box nozzle

CHANNEL 11
Chilled Brine Flow
0-2000 gpm
Inlet, Ethylene Glycol,
30%

CHANNEL 12
Condenser Water
Flow
0-3000 gpm
Inlet, Water, 0%

LD16095

Figure 65 - FLOW INSTRUMENTS WIRING

116 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

DIGITAL INPUT CONFIGURATION SCREEN

LD15272

Figure 66 - DIGITAL INPUT CONFIGURATION SCREEN

OVERVIEW
The Digital Input Configuration Screen allows a user
with sufficient privilege to assign digital inputs to the
correct Board and Channel.
This should only be changed under direction of the fac-
tory.

JOHNSON CONTROLS 117

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

DIGITAL OUTPUT CONFIGURATION SCREEN

LD16102

Figure 67 - DIGITAL OUTPUT CONFIGURATION SCREEN

OVERVIEW
The Digital Output Configuration Screen allows a user
with sufficient privilege to assign digital outputs to the
correct Board and Channel.
This should only be changed under direction of the fac-
tory.

118 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

AUXILIARY ANALOG CONFIGURATION SCREEN

LD16103

Figure 68 - AUXILIARY ANALOG CONFIGURATION SCREEN

LD15279

Figure 69 - AUXILIARY ANALOG INPUT SAFETIES SCREEN

JOHNSON CONTROLS 119

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

OVERVIEW Low Shutdown Delay – This setpoint specifies the pe-

riod of time that the associated auxiliary analog input
The Auxiliary Analog Configuration screen is used to
must remain below the Low Shutdown Setpoint before
allow the user to set the operating safeties of Auxiliary
an Auxiliary Shutdown will be issued.
inputs.
High Warning Setpoint – This setpoint specifies the
Drop down menu boxes are provided for the following:
High Warning threshold. In the event that the associ-
Auxiliary Analogs 1 through 24:
ated auxiliary analog input exceeds this value for a
• Disabled – The auxiliary channel will not be period of time exceeding the High Warning Delay, an
monitored for warnings or shutdowns. Auxiliary High Warning will be issued.
• When Running – The auxiliary channel will be High Warning Delay – This setpoint specifies the pe-
monitored for warning and shutdown occurrences riod of time that the associated auxiliary analog input
only when the compressor is in the run state. must remain above the High Warning Setpoint before
an Auxiliary High Warning will be issued.
• Always – The auxiliary channel will be monitored
for warning and shutdown occurrences at all times High Shutdown Setpoint – This setpoint specifies the
(Running or not). High Shutdown alarm threshold. In the event that the
associated auxiliary analog input exceeds this value for
The following setpoints are provided for each Auxil-
a period of time exceeding the High Shutdown Delay,
iary Analog channel in Figure 69 on page 119.
an Auxiliary High Shutdown will be issued, and the
Low Warning Setpoint – This setpoint specifies the compressor will stop.
Low Warning alarm threshold. In the event that the as-
High Shutdown Delay – This setpoint specifies the
sociated auxiliary analog input falls below this value
period of time that the associated auxiliary analog in-
for a period of time exceeding the Low Warning Delay,
put must remain above the High Shutdown Setpoint
an Auxiliary Low Warning will be issued.
before an Auxiliary Shutdown will be issued.
Low Warning Delay – This setpoint specifies the pe- If you wish to bypass the warnings and
riod of time that the associated auxiliary analog input utilize only the shutdown feature, then
must remain below the Low Warning Setpoint before set all warning values outside of the shut-
an Auxiliary Low Warning will be issued. down values.
Low Shutdown Setpoint – This setpoint specifies the
Low Shutdown threshold. In the event that the associ-
ated auxiliary analog input falls below this value for a
period of time exceeding the Low Shutdown Delay, an
Auxiliary Low Shutdown will be issued, and the com-
pressor will stop.

120 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

AUXILIARY ANALOG CALIBRATION SCREEN, PAGE 1

LD15273

Figure 70 - AUXILIARY ANALOG CALIBRATION, PAGE 1

CALIBRATION - AUXILIARY ANALOGS A drop down menu box exists for each of the displayed
auxiliary readings.
This Auxiliary Analog Calibration Screen can be used
to custom name each of the Auxiliary Analog channels • Current Value – The actual value that is being
as well as performing calibration. sensed (taking into account the offset).
To change a name: • Offset – A value entered here will allow the user
to compensate for calibration issues with a sensor.
• Locally, at the Panel – Use the [TAB] button to
scroll down the screen to the text line that you • Range
wish to change. Press the [^] (up arrow) button.
• Low
This will cause the screen to be replaced with an
Alpha/Numeric key pad entry screen. • High

JOHNSON CONTROLS 121

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

AUXILIARY ANALOG CALIBRATION SCREEN, PAGE 2

LD15273a

Figure 71 - AUXILIARY ANALOG CALIBRATION, PAGE 2

This Auxiliary Analog Calibration Screen will show Sensor Signal

any custom named auxiliaries from Page 1 at the left
side of the screen. Use this screen to set the Sensor Sig- • None
nal, Sensor Type, and to change the units if set to Other. • 0-5V
The following informational areas are provided and • 1-5V
cannot be changed from this screen: • 4-20mA
• Auxiliary Analogs – These are the names given • Pot. (Potentiometer)
to the each of the Auxiliary Analog channels. • ICTD
They may be shown as the original default names,
or as names that have been customized (see Fig- • RTD
ure 71 on page 122). • CT
• IO Board – The data shown here describes on • 0-20mA
which Analog board the associated sensor is lo- • Vibration
cated.
• 0-10V
• IO Channel – The data shown here describes on
which Analog channel of the Device Source the Sensor Type
associated sensor is located. • None
A drop down menu box exists for each of the displayed • Pressure
auxiliary readings: • Temperature
• Other
Units if Type is Other - Up to 5 characters may be
entered here.

122 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

RETRANSMITTING OUTPUTS SCREEN

LD15248a

Figure 72 - RETRANSMITTING OUTPUTS SCREEN

OVERVIEW
This screen allows the service level user to retransmit
any analog input to an analog output channel. This is
useful for providing analog signals to a BAS system
or remote controller, which does not communicate to
the panel.

PROGRAMMABLE
Select the channel A through P and use the drop down
list to select the "Input Channel To Retransmit". Then
select a spare IO Board and IO channel to re-transmit
the data on.
This channel will likely need to be calibrated. Navigate
to the Analog Output Calibration and perform a cali-
bration on the newly assigned channel.

JOHNSON CONTROLS 123

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

ECONOMIZER SCREEN

LD15248

Figure 73 - ECONOMIZER SCREEN

OVERVIEW On startup, the economizer level control will override

The economizer screen depicts the operation of the loading the chiller until a sufficient level is attained.
economization vessel, which is mounted beside the The refrigerant management aspect of the economizer
main heat exchanger vessels. The economizer takes must be maintained during normal operation. This pre-
subcooled liquid into its side port from the subcooler vents slugging liquid into the suction of the compres-
level control valve LCV-114. This liquid is decelerated sor.
thru a spray-pipe and a vortex breaker. The deceler- In single Stage operation the PCV-116 sideload control
ated liquid is exposed to intermediate interstage pres- valve is closed. The PCV-116 sideload control valve
sure. Some small amount of the liquid flashes into a is used only during two-stage operation; its purpose is
gas, and travels thru the top port (thru an eliminator) to prevent backspin at shutdown. When the unit goes
and out into the interstage. The remaining liquid trav- into a controlled stop, the sideload is closed to prevent
els thru the bottom of the economizer, where its level pressure from forcing the low stage compressor to spin
is controlled by the outlet level control valve LCV-116. backwards. The PCV-116 also protects the interstage
This action provides a cycle efficiency improvement from slugging liquid, by closing, if a high economizer
by adding flash-gas to the suction of the booster com- level occurs.
pressor. The level control of the economizer provides
a liquid seal between the intermediate gas pressure and On startup the PCV-116 valve opening can be de-
the evaporator pressure on the other side of the LCV- layed by a timer. This timer is programmable from this
116 level control valve. A 40 to 50% level is typical screen. The time delay in seconds should allow the HS
for the economizer vessel level. The level setpoint is compressor vanes to obtain a reasonably open position
not critical, just that the liquid seal is maintained. The before the sideload gas valve is opened. This prevents
LCV-116 level control is available with two sets of tun- reverse flow of gas through the sideload line.
ing parameters, since running in single stage mode and
two-stage mode present different running characteris-
tics.

124 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

PCV-117 is called the BLEED SOLENOID; it is used NAVIGATION

exclusively in single stage operation. As the gas pres-
sure builds in the top of the economizer vessel, no Home
more liquid can enter the vessel. To maintain a level Used to provide additional Home information.
setpoint during single stage operation, the gas that has
expanded in the top of the economizer must be bled Evaporator
off. This valve will open when the LT-116 level sensor A detailed view of all evaporator parameters, including
is 15% less than setpoint. It will remain open until the the programmable Leaving Chilled Liquid Setpoints.
level signal raises by 1%, or until its timer times out
after 1 minute. It is normal to have this valve open and Capacity Controls
close occasionally during a single stage run. Returns the display to view the Capacity Controls 3
Screen.
Standard Manual-auto stations are provided to take
control of any individual valve. The PID controlling Return
the valve will adjust to the manual position upon Man- Returns the display to the previous screen.
ual to Automatic operation transfer.

PROGRAMMABLE

LCV-114 Auto
Access Level Required: OPERATOR
Refer to Figure 26 on page 55 for operational use.

LCV-116 Auto
Access Level Required: OPERATOR
Refer to Figure 26 on page 55 for operational use.

JOHNSON CONTROLS 125

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

HISTORY SCREEN

LD15253

Figure 74 - HISTORY SCREEN

OVERVIEW INTERACTIVE
The History Screen provides a comprehensive report Acknowledge
of all system alarms and trips. Given are the date and The acknowledge function key stamps the alarm with
time of the trip or alarm along with a description of the date and time that the alarm occurred. Use the arrow
each. When an alarm is acknowledged, the system keys to highlight and move between alarm messages.
stamps the alarm with the date and time that the par- Press the ENTER key when an alarm is highlighted to
ticular alarm was acknowledged. view the frozen data capture at the time that this alarm
occured. This display as described in the next section
is the “Freeze Screen”.

NAVIGATION

Return
Returns the display to the previous screen.

126 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

FREEZE SCREEN

LD15254

Figure 75 - FREEZE SCREEN

OVERVIEW NAVIGATION
Access a Freeze Screen by highlighting a warning or Home
trip event on the HISTORY screen by using the up and Used to provide additional Home information.
down arrow keys and select the particular event by
pressing the [ENTER] button. Setup
These screens provide lists of various chiller parame- This screen provides a single location to program the
ters which were recorded at the instant the chiller event most common system setpoints. It is also the gateway
that produced a trip. to many of the general system setup parameters such
as I/O configuration, Communications Setup, Software
Record desired data prior to updating the Maintenance, Trending, and diagnostics.
Quantum™ LX software.
History
This screen provides access to a Time stamped Record
of shutdown conditions.

JOHNSON CONTROLS 127

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

TRENDING SCREEN

LD15250

Figure 76 - TRENDING SCREEN

OVERVIEW NAVIGATION
The Trending Screen provides a setup utility to trend Home
and log data points. The Realtime Trend feature stores Used to provide additional Home information.
data internally to view on a time basis live on the Quan-
tum™ LX. The History Data Log stores the data points Setup
in a file that can be transferred off the Quantum™ LX This screen provides a single location to program the
and onto a computer where the data can be stored or most common system setpoints. It is also the gateway
analyzed further. to many of the general system setup parameters such
as I/O configuration, Communications Setup, Software
Maintenance, Trending, and diagnostics.

128 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

LD15250

Figure 77 - REAL TIME TRENDING SCREEN

OVERVIEW
A total of 900 Realtime events can be trended. Real-
time events are lost upon each power cycle. The events
that can be logged are set using the Trending Setup
screen, shown on the previous page.
History trending can save up to 2000 values for each
selected channel. History data is stored in Flash mem-
ory. Flash memory is non-volatile and all information
is retained even if the power to the panel is lost. The
interval at which the data is saved can be adjusted. The
events that can be logged are set using the Trending
Setup screen.

JOHNSON CONTROLS 129

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

TRENDING SETUP SCREEN

LD15251

Figure 78 - TRENDING SETUP SCREEN

OVERVIEW Trending Data Files can be downloaded to a USB flash

drive for analysis or storage. Insert a USB Flash drive
There are 8 “pens” that can chart data. Touching the
into any USB port on the Quantum™ LX Controller
pens channel 1 through 8 will allow the user to assign
Board, and then press “DOWNLOAD TRENDING
a data point to the “pen”. Select the desired data by
DATA FILES” on this screen. The files will be stored
scrolling up and down through the list with the touch-
in a Comma Separated Variable format for analysis in
screen or with the UP and DOWN arrow keys.
a spreadsheet software package.
Return to the Trending Screen to select REAL TIME
TRENDING to view the trend.
NAVIGATION
Graphical display of sensor values over the entire pe-
Return
riod of operation of the chiller. Use the tab key on
the keypad to select between Pens 1 – 8. When a pen Returns the display to the previous screen.
has been selected, use the UP and DOWN arrow keys
on the keypad to assign the desired sensor to that Pen.
Press ENTER to confirm the selection.

130 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

CUSTOM DISPLAY SCREEN

LD15251a

Figure 79 - CUSTOM DISPLAY SCREEN

OVERVIEW
The Custom Display page allows access from the View
level to set a list of custom analog display items which
would not normally be viewable all in one location.
Press the Enable User Defined Status # and then select
from the list and press SUBMIT.

JOHNSON CONTROLS 131

 FORM 160.82-OM1
SECTION 3 - QUANTUM LX CONTROL PANEL
ISSUE DATE: 8/30/2013

THIS PAGE INTENTIONALLY LEFT BLANK

132 JOHNSON CONTROLS

FORM 160.82-OM1
ISSUE DATE: 8/30/2013

SECTION 4 - SOFTWARE UPDATE PROCEDURE

Access to update the chiller SOFTWARE MAINTE- Receiving The Update Image Windows 7
NANCE screen is only available on the SETUP screen 1. Run the installing program for SELFIMAGE
when the unit is in a standby state. The standby state is Selfimage may then be run from the Windows
defined as when the system is NOT running, and the oil "START" button.
pumps are NOT running. The system can be tripped, or
ready to start, but not coasting down. 2. Assuming that an appropriate compact flash card
image is available.
Receiving The Update Image for Windows XP
3. When the program is started. The work window is
The update image can be transmitted by email or by made up of 4 main areas:
use of an FTP service.
1. The command line including "File Edit Help"
The update will consist of three files: NOTE: This area will need to be used to
select the "Start" function on a Windows 7 4
• burnit.bat
machine.
• cf.zip
2. The Input area.
• dd.exe
3. The Processing area.
1. Place these files in the root C:\ folder on your
4. The Output area.
Windows personal computer.
4. The input area should be set to "File" and then
2. Use Winzip or Windows to extract the cf.img file
using "Input Location" browse to and select the
from the cf.zip file. (To use Windows XP to ex-
proper Compact Flash card image file.
tract the cf.img file, right click on it and select EX-
TRACT ALL. Then Type C:\) 5. Processing will not need changed when writing a
file to a compact flash card. This area can be used
3. Insure that the cf.img file resides in the C:\ folder
if saving a raw or compressed image file from a
on the harddrive
compact flash card.
4. Remove any other removable flash media from
6. The Output section is critical. When a USB based
your computer. There must only be one remov-
compact flash reader is plugged in (Prior to start-
able USB “thumb” drive attached when creating
ing Selfimage) it will create a drive name. For ex-
the update “thumb” flash drive.
ample the USB devices icon (bottom right of win-
5. Insert your USB flash drive (thumb drive) into dows work screen) if left clicked on the "Safely
your personal computer’s USB port. Remove Hardware" will show the name applied
All data on the USB flash drive will be to the device. In my example case I have a multi
overwritten in this procedure, and it will reader that shows E, F, G and I. I know that E is
become unusable to WINDOWS com- the actual drive name given for the compact flash
puters. See subsequent section to restore in my reader.
Windows usability of this flash drive. Selfimage in the Output area when selecting Out-
put Location will present a list of drive specs.
6. Click on the burnit.bat file in Windows Explorer, Knowing that my actual Compact card is an E:
and a DOS command prompt will open, and the drive I can look down that list and find \Device\
contents of cf.img will be written to your USB Hardiskl (entire disk). Note that the Hardiskl is
flash drive (thumb drive). Be patient as this pro- the same for both entries. One line higher refers
cess can take some time. to HardiskO and that would be my main primary
drive. This would be a very bad selection to make
7. When the message appears in the DOS box that
since it would rewrite my system with the image
you may “Press Any Key to Continue”, do so and
file. Be very careful to select the correct drive
then remove the USB flash drive safely from the
name spec before going any further.
computer.

JOHNSON CONTROLS 133

 FORM 160.82-OM1
SECTION 4 - SOFTWARE UPDATE PROCEDURE
ISSUE DATE: 8/30/2013

\Device\Harddiskl\Partitionl (E:\). That's the 12. The control application will restart and return to
wrong selection since it is referring to the parti- the HOME screen.
tion only.
13. Check the software version number on the LOG-
7. Select the "Start" button. It will ask if you are re- IN screen to see that the system has been updated.
ally sure about the destination and you can cancel
or allow it to start programming. Reclaim USB Flash Drive From Linux Ext
Partition
Applying the Software update to the When a USB flash drive is used with the Quantum™
Quantum™ LX LX, it will be repartitioned to a Linux ext partition
1. Stop the chiller, and allow the postlube cycle to type, which is unreadable by Microsoft Windows. Fol-
complete. low the directions below to reclaim the drive to a FAT
or FAT32 partition table. This will purge all informa-
2. With power ON, insert the USB flash drive (thumb
tion from the flash drive. You will need to be an admin-
drive) device into any USB port.
istrator on your Windows PC.
3. Enter (at least) User Level 2 (Service) by Pressing
LOGIN from the HOME screen. 1. Insert the USB flash drive into a port on your
computer.
4. Returns the user to the HOME screen.
2. Open the Disk Management program by clicking
5. Navigate to the SETUP screen. START >> RUN… and typing the following com-
mand:
6. Navigate to Software Maintenance.
The touch panel will stop working in the 3. mmc %systemroot%\system32\diskmgmt.msc
software Maintenance Screen, use the 4. Press enter on your keyboard.
keypad.
5. A Disk Management window will appear.
6. There should be more than one disk shown. Select
the drive letter of the USB flash drive [for exam-
7. Press [1] to Save Setpoints. ple (E:)]. Highlight this drive letter.
a. Enter any identification number (0 - 99) DO NOT HIGHLIGHT (C:) or all data on your
representing the file number to store your computer will be destroyed
setpoints, in the popup box.
7. From the menu select ACTION >> ALL TASKS
b. After entering the number, press the TAB >> DELETE PARTITION
key and then press the ENTER key.
8. A popup will appear saying that the selected parti-
8. Press [2] to do a Full System Install. tion was not created by Windows and might con-
tain data recognized by other operating systems.
9. Press [3] to Restore Setpoints.
Do you want to delete this partition. Respond YES
a. Enter the setpoint identification number that
9. Re-highlight the removable disk in the bottom of
was entered in step 7.a)
the Disk Management window and notice that it is
10. At the conclusion of the Full System Install the “Unallocated”.
Quantum™ LX may ask if you want to do a Sys-
10. From the menu select ACTION >> ALL TASKS
tem Update.
>> NEW PARTITION.
a. Reply with YES
11. A popup wizard will appear, select NEXT, and
11. After the System Update remove the USB thumb then select NEXT again to confirm the PRIMARY
drive as instructed and cycle the control panel PARTITION, then select again to confirm the de-
power. fault size.

134 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 4 - SOFTWARE UPDATE PROCEDURE
ISSUE DATE: 8/30/2013

USB
FLASH
DRIVE 4

Plug a USB Flash Memory Drive into any one of these USB ports on the bottom of the Main Controller board.
LD15274

Figure 80 - USB FLASH DRIVE

12. Assign the drive letter (E:) [or other if desired] 17. Type a Volume Label, select FAT32 and use the
and select NEXT. default allocation size.
13. Format the partition with a FAT32 file system, de- 18. Confirm the popup box that appears telling you
fault allocation, and type a volume label (or leave that all data will be erased on the flash drive with
at default), then select NEXT. an OK.
14. Click Finish 19. Close the Disk Management program.
15. Re-highlight the removable disk in the bottom of Your USB flash drive is now ready to use with
the Disk Management window and notice that it is Windows again.
“FAT23 and Healthy”.
16. From the menu select ACTION >> ALL TASKS
>> FORMAT

JOHNSON CONTROLS 135

 FORM 160.82-OM1
SECTION 4 - SOFTWARE UPDATE PROCEDURE
ISSUE DATE: 8/30/2013

THIS PAGE INTENTIONALLY LEFT BLANK

136 JOHNSON CONTROLS

FORM 160.82-OM1
ISSUE DATE: 8/30/2013

SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING

ETHERNET AND NETWORKING The other point that completes the connection is usu-
ally provided by an Internet Service Provider (or ISP).
YORK Industrial Systems Controls uses Ethernet as the
The Internet Service Provider usually has a very large
primary method of connecting one or multiple Quan-
network router, or means of bring in many individual
tum™ LX panels to a common computer network. In
connections. The router then assigns a discrete and in-
the past, this interconnection would have been done by
dividual address to each connection (much like a street
serial protocol wiring, such as RS-232/422/485. But
address). This address is known as an Internet Protocol
with the capabilities of today’s technology, Ethernet is
address (IP). The IP address consists of a series of 4 to
the quickest and most efficient way of providing this
12 digits, and is normally transparent to the end user.
inter connectivity. Whereas the old serial communica-
tions methods (RS232, etc.) were slow by today’s stan- For those individuals familiar with using the internet,
dards (kilobits per second transmission speed), Ether- they are familiar that every time they activate their
net is available in two speeds: 10 Mbps and 100 Mbps. web browser (the software that allows your computer
For connection examples, refer to the sec- to connect), there is an address bar that appears near
tion of this manual entitled Q uantum™ the top of the screen. This address bar is where you
LX Local Ethernet Configurations and would enter the IP address of the computer or network
Quantum™ LX Ethernet Network Con- that you would like to communicate with. To make
figurations. this simpler, these numeric IP addresses are also cod- 5
ed to allow alpha-numeric names to be masked over
them, so that rather than having to enter an address of
Ethernet is a data and information sharing system. To
216.27.61.137, you can simply enter in www.jci.com,
put it simply, it is a method of connecting one comput-
as an example. Although the actual process is more de-
er to many others on a common network. This network
tailed and complicated than this basic explanation, the
can consist of both hardwired connections, and wire-
end result is that most of the work is being done invis-
less devices, hence the name ETHERNET. Any Win-
ibly. The following write up describes how to set up the
dows or Linux based computer is capable of access-
Quantum™ LX to do this behind the scenes work, so
ing this network. All that is needed is either a modem,
that it can communicate both at the Internet level, and
USB port, or an Ethernet port. These devices provide
at a local Ethernet level.
the necessary point of connection for one end (branch)
of the connection (a home computer for instance).

CONNECT TO
LAN 1 FOR
ETHERNET
COMMUNICATIONS

Bottom view of Quantum™ LX controller board LD15274a

Figure 81 - ETHERNET CONNECTION

JOHNSON CONTROLS 137

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

Cabling • Do label the ends of each cable, to facility trouble-

Each Quantum™ LX Ethernet connection must be in- shooting and identifying in the future.
dividually cabled (known as a homerun) direct from a • Do test each individual cable run with an ap-
switch or computer. Unlike RS422/485 communica- proved CAT5 E cable tester. A TONING alone test
tions which allowed for cable daisychaining, Ethernet is NOT acceptable.
connections do not allow this. This type of cabling is • Do use rubber grommets anywhere that the cable
designed to handle the 100- Mbps speed needed by Eth- enters through a hole in a metal panel.
ernet. Both ends of each cable must have an RJ-45 con-
nector attached. The RJ-45 connector looks similar to • ALWAYS obey local, national and fire building
the RJ-11 connector on the end of a telephone cord but is codes.
slightly larger (and not compatible). You can buy Cat 5 The following are things that should NOT be done
cables in predetermined lengths with the connectors al- when installing and using CAT 5 Ethernet cable:
ready attached (for short runs), or you can buy the cable
in rolls, cut it to length and install the RJ-45 connectors • Don’t install cable taut, cables must always have
to the ends (up to 100 meters per each cable run). Al- some “play” or slack in them.
though it is recommended to use shielded, twisted pair • Don’t over-tighten cable ties.
Cat 5 cable, if the cable is not properly constructed and
tested, it can actually be more detrimental to the network • Don’t splice a cable. If a break occurs, or the
than unshielded cable. As long as all of the cables that length is not long enough (under 300 feet), replace
are used have been properly constructed AND tested, ei- the entire run with an intact length.
ther shielded or unshielded are acceptable. This is most- • Don’t tie cables to electrical conduits.
ly due to the excellent (electrical) noise immunity that is
• Don’t strip more than one inch from the end of
inherent with Ethernet components.
each cable when installing end connectors.
Follow standard networking procedures
• Don’t sharply bend or kink the cable.
for the interconnections of all compo-
nents. For individual cable runs in excess • Don’t mix 568A and 568B wiring at the same in-
of 300 feet (~100 meters), a Switch/ Hub stallation. 568B is the most common wiring.
must be used for each additional run. • Don’t use excessive force when pulling cable.

RJ-45 Connectors
Cabling Do’s and Don’ts –
Ethernet network cables require the use of industry
It is recommended to follow these guidelines when in-
standard RJ-45 plugs as shown below, for the termina-
stalling and using CAT 5 Ethernet cable:
tion of all cables:
• Do run all cables in a star (homerun) configuration.
• Do keep all individual cable lengths under 300
feet. If greater distances are needed, use a switch/
hub every 300 feet.
• Do ensure that the twists of the wire pairs within
the cable are maintained from end to end.
• Do make gradual bends in the cable. Keep each
bend radius over one inch.
• Do keep all cables tie wrapped neatly. LD15276

• Do try to maintain parallel cable runs where pos-

sible. Figure 82 - TYPICAL RJ-45 CONNECTOR
• Do keep the cable as far away as possible from
EMI sources (motors, transformers, solenoids, When looking at this connector, pin 1 is at the left, and
lighting, etc.) pin 8 is at the right.

138 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

The Hub So, if you start with a four-port Switch but eventually
A Hub is a common connection point for devices in add more panels, you can buy another Switch and con-
a network. Hubs are commonly used to connect seg- nect it to the one you already have, increasing the po-
ments of a LAN (Local Area Network). They also con- tential number of panels on your network.
tain multiple ports. When a data packet arrives at one
port, it is copied to the other ports so that all segments
of the LAN can see all packets.

The Switch
Network Switches look nearly identical to hubs, but a
switch generally contains more intelligence than a hub.
Unlike hubs, network switches are capable of inspect-
ing the data packets as they are received, determining
the source and destination device of a packet, and for- LD15277

warding that packet appropriately. By delivering mes-

Figure 84 - TYPICAL SWITCH
sages only to the connected device that it was intended
for, network switches conserve network bandwidth and
offer generally better performance than hubs.
If you want to connect one computer to
The Switch takes the signal from each computer/Quan- one Quantum™ LX, you can avoid the 5
tum™ LX and sends it to all of the other computers/LX switch and use a crossover Cat 5 cable.
panels in your plant or office. Switches come in several With a crossover cable, you directly con-
sizes, noted by the number of ports available -- a four- nect one Ethernet device to the other
port Switch can connect four computers, an eight-port without a Switch. To connect more than
Switch can connect up to eight computers and so on. two you need a Switch.

Refer to the following pictorial to construct a crossover cable:

BOTH ENDS OF A CROSSOVER CABLE

LD15275

Figure 83 - CROSSOVER CABLE

JOHNSON CONTROLS 139

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

Cat-5 Ethernet Cable Color Codes Because of the large number of possible configura-
1 – White w/orange stripe 5 – White w/blue stripe tions in an Ethernet network, you most likely will not
have any type of automated installation software. This
2 – Orange w/white stripe 6 – Green w/white stripe means that you will need to manually configure all the
options. To configure these options for the Quantum™
3 – White w/green stripe 7 – White w/brown stripe LX, please refer to Ethernet Setup on the next page.
4 – Blue w/white stripe 8 – Brown w/white stripe

Table 11 - ETHERNET COMPONENT RECOMMENDATIONS

COMPONENT DESCRIPTION PART NUMBER MANUFACTURER

Shielded solid 4-pair* (1000 Ft) BOXCAT5E-DSSO Cablesforless.com
E-PLG-SOLID-SH VPI
Shielded solid 4- pair* CR45-100S Cables Direct
9504 CS
Cable Alpha Wire Co.
9504 F
Un-shielded solid 4-pair**
E-PLG-SOLID VPI
345U5-1000BLK Ram Electronics
Un-shielded solid 4-pair** (1000 Ft)
0-5EPCS-BK Computercablestore.com
HT-210C Cablesforless.com
P-15027 Stonewall Cable, Inc.
Crimp Tool RJ-45 Crimp Tool
S2307692 Computers4sure.com
10-RJ1145 Computercablestore.com

RJ-45 For Shielded 4-pair solid wire cable P-15007 Stonewall Cable, Inc.

Connectors 5-554169-3 Tyco Electronics

RJ-45 For Un-shielded 4-pair solid wire cable 1-5E45-010 Computercablestore.com
P-15029 Stonewall Cable, Inc.
TST-5150 Cablesforless.com
Ethernet Cable Tester - Continuity only
Cable Tester TS075A-R2 Black Box
Complete Cable I/O Qualification Tester N/A Fluke
5 RJ-45 port SFN-5TX Phoenix
Switches 7 RJ-45 Port and 1 ST Fiber Optic Port SFN-7TX/FX ST Phoenix
8 RJ-45 port SFN-8TX Phoenix
*STP = Shielded Twisted Pair
**UTP = Unshielded Twisted Pair

140 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

Ethernet Setup IP Address – (Internet Protocol) Four setpoint boxes

Once all of the cabling has been run and all connec- are provided here. Every device on an Internet or Eth-
tions have been made, it is now necessary to setup the ernet network must be assigned a unique identifying
Quantum™ LX software to recognize and handle the number, called an IP Address (this is similar in con-
Ethernet connection. cept to the Quantum™ LX panel ID number). The IP
address is how the network identifies each device that
The following section describes the suggested panel is attached. A typical IP address would look like this:
setup for connecting the Quantum™ LX panel to an 216.27.61.137
existing Ethernet connection:
Gateway Address – Four setpoint boxes are provided
IP DATA here. This is the IP address for the computer or device
onto which your local network is connected to. This
Address Type – The following drop-down menu is pro- gateway device is how all of the devices attached to
vided: your local network are routed to other gateways and
Fixed (Static) – A fixed address is usually assigned by networks. A router is a Gateway device that routes
the network (LAN) administrator, and is normally al- packets between different physical networks. A gate-
ways the same. way is a network point that acts as an entrance to an-
other network.
DHCP (Dynamic) – Dynamic Host Configuration Pro-
tocol permits autoassignment of temporary IP address-
es for new devices connecting to the network.
5

HOME --> SETUP --> ETHERNET

LD15258a

Figure 85 - ETHERNET SETUP

JOHNSON CONTROLS 141

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

Subnet Mask – A TCP/IP number used to determine group could be named Heat Pump 1, and the remaining
to which TCP/IP subnet a device belongs. Devices in four units could be standard chillers, and they could be
the same subnet can be communicated with locally named Chiller1. So name each unit by these functional
without going through a router (to the outside world). Work Group names. The Work Group name must be
When a TCP/IP device tries to communicate with fifteen characters or less in length, and can use numer-
another device the bits of the TCP/IP destination ad- als and upper and lower case letters. When using the
dress are "ANDed" with the subnet mask to determine network neighborhood feature of Windows® Explorer,
whether the address is a local address (broadcastable) by looking at your Network Neighborhood, you would
or must be reached through a router. A subnet mask see the name of the Work Group, and within that work
of 255.255.255.0 used by a computer with a TCP/IP group you would see the individual Host Names of
address of 10.10.10.1 would include the addresses each unit within that work group. After modifying a
10.10.10.0 through 10.10.10.255 in the local network, Work Group name, you will be required to cycle pow-
basically telling the computer to try a router if it's er. The network router could take up to fifteen minutes
transmitting to any other IP address. This is all part of to recognize the change.
the TCP/IP protocol.
Server String – This is a comment area that can be used
Web Server Port – This is the port, or channel, that in conjunction with the Host Name. For example, if the
a web server uses to communicate through. Just as a Host Name is Plant1, you could set the Server String to
computer sends data to a printer through a printer port, print something like EastPlant, or some other additional
a web server sends and receives data through the Web information about the unit. The Server String has no con-
Server Port. By default, the port number for a Web trol function; it is strictly an informational area.
server is 80.
E-Mail Data
Naming Data
The purpose of the E-Mail data feature is to allow the
Host Name – Enter a distinct name that you wish to controller to send a Warning or Shutdown message to
be able to identify this particular compressor by (for defined listing of recipients.
example; Unit1). The Host Name must be fifteen char-
acters or less in length, use no spaces and use only up- Email Notification On Warning Or Shutdown – For the
per and lower case letters. It is similar in concept to E-mail notification feature to work, it must be enabled
the function of the Panel ID, and basically allows the (it is disabled as a default). The following drop-down
network router to interpret the actual IP address of a menu is provided:
particular unit as this host name. When using a web
• Disabled
browser within the system network, this name can be
entered as the web location that you wish to visit (in- • Enabled
stead of having to type in the IP address). After modify-
ing a Host Name, you will be required to cycle power. Local Email Address – Use this setpoint box to enter
The network router could take up to fifteen minutes to a valid E-mail address that has been assigned to the
recognize the change. internet account.

The IP Address Type must be set to DHCP Alias Name For Local Email Address – Enter here a
(Dynamic) for this section to work. custom name to identify more clearly the local Email
address. When a message is sent to all recipients, this is
the name that will appear in the Email FROM column.
Subject – Enter a custom subject that you would like to
appear when a message failure is sent. When a message
Work Group – All of the Quantum™ LX units within is sent to all recipients, this is the wording that will ap-
a network may be grouped into different categories. pear in the Email SUBJECT column.
These categories could be unit locations, or perhaps
categorized by unit function. For instance, if you want- SMTP Server Name OR IP Address – SMTP stands for
ed to group the units by function, and had 10 units, and Simple Mail Transfer Protocol. SMTP servers handle
three of them were Evaporators (located on the roof), outgoing email, and accept email from other domains.
then Evap1 could be the name of a work group. An- When you set up an email client, you must specify an
other three units may be Heat Pump Units, this work outgoing server (sometimes called an SMTP server).

142 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

Often, this server is designated in the form of smtp.do- serial communications port available. It was initially
main.com. But this can vary, so be sure to check with developed for the emerging computer industry in the
your email service provider or LAN administrator to 1960’s. Originally, it was a method of sending data from
find out their outgoing server. a mini or main frame computer, to devices such as print-
ers, punch card readers, teletypes, magnetic tape units
SMTP Server Port Number – This value is in almost and modems. In those early days, the maximum speed at
all cases going to be 25. This should be set by the net- which RS-232 was capable of transmitting (about 9600
work or LAN administrator. Comma-Delimited List Of bits per second), was quite satisfactory, as most of the
Email Recipients - This is simply the list of the Email receiving devices were mechanical in nature (except for
addresses that you would like to have any messages modems), and barely able to keep up with these speeds.
sent to. Separate each email address with a comma.
RS-232 uses single ended TX (transmit data) and RX
SMTP Authentication for Email Data – Emails can be (receive data). This means a common ground wire is
sent when the Quantum sets an alarm. shared between TX and RX, so only 3 wires are needed
or a data only serial channel: TX, RX, and GND.
Protocols
The purpose of this section is to enable or disable the Disadvantages of single ended signaling is that it is
Modbus TCP and Ethernet/IP parameters. more susceptible to noise than differential signaling
(RS-422/485), effective cable distances are shorter
• Modbus TCP: (typically about 50 Ft. total, due to low noise immu-
• Disabled nity) and data rates are slower. Additionally, there is 5
• Enabled the limitation that only two devices can communicate
together (master and slave).
• Ethernet/IP:
• Disabled The Quantum™ controller has one RS-232 port avail-
• Enabled able. Com-3 attached to the RedLion Data Station pro-
vides the communication link to Building Automation
SERIAL COMMUNICATIONS System or DCS.

General Description RS-485 Description

Serial communications to and from the Quantum™ LX When serial communications started moving into the in-
uses RS-232 or RS-485 hardware protocol depending dustrial environment, it was quickly noted that because
on the specific Com port. of the high electrical noise potential from electric mo-
tors, valves, solenoids, fluorescent lighting, etc., that
The Com-4 serial communications port is configured
the noise immunity characteristics of RS-232 protocol
for RS-485 and is connected directly to the I/O boards.
was grossly lacking. Additionally, the distances between
Com-1 is located at the bottom left of the controller
the communicating equipment on the factory floor was
board.
much greater than that within the typical office environ-
The Com-1 port is not used. ment. For these reasons, RS-485 was developed.

The Com-2 port is the programmable Serial Slave RS-485 is a half duplex bus. This means that it can
Communication Port on the Serial Setup screen. It only send data, or receive data at any given time. It
is an RS-232 port and can be used to communicate to cannot do both at the same time. The Quantum™ LX
an external supervisory system or networking gateway uses a 2-wire system for RS-485 one positive transmit/
device. receive wire and one negative transmit/receive wire).
Up to 30 Quantum™ LX controllers may be simulta-
The Com-3 port is reserved for the optional Liquid neously connected up to a total distance of 2000 ft. us-
Cooled Solid State Starter Modbus Master Communi- ing a daisychain wiring scheme (to be explained later).
cation Port. One advantage to using RS-485 as opposed to RS-422
is that only a single twisted pair cable need to be run
RS-232 Description
to all devices (while RS-422 requires a double twisted
RS-232 is by far the most common (and oldest) serial pair cable), much greater noise immunity than RS-232.
communications hardware protocol, as almost all laptop RS-422/RS-485 signals cannot be connected directly
and desktop computers will have at least one RS-232 to an RS-232 device.

JOHNSON CONTROLS 143

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

ETHERNET
PORT

COM-4 RS-485
I/O SERIAL
PORT

COM-3
(OPTIONAL) LCSSS
COMMUNICATIONS
SERIAL PORT

COM 1

LD15224

USB COM 2 RS-232 SERIAL

PORTS SLAVE COMMUNICATION
PORT TO PROTOCAL
GATEWAY

Figure 86 - SERIAL PORT LOCATIONS

144 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

Serial Communications Setup Active – Valid communications are actively occurring.

After the serial communications wiring has been con- Failed – An invalid command was received by the port.
nected, and jumpers correctly set, the LX software This could be due to a bad checksum value, a wiring
needs to be setup to match that of the device(s) that it issue, or hardware problem at either the transmitting
is to communicate with. The following screen is where (host) or receiving (Quantum™ LX) end.
this information can be found:
Baud Rate – The baud rate defines the speed at which
The following setpoints are provided: external communications can occur. The higher the
Compressor ID – A number that is used by an external baud rate, the faster the communications. It is best to
communications application, to converse to individual start out using a lower baud rate, and increasing the
compressors. On interconnected systems, this number value only after verifying that communications errors
must be unique. Valid values are from 1 – 99. do not occur. If errors start to occur, drop the baud rate
back down. A pull down menu is provided to select
Status – Shows the current communications status of from the following:
the port. The possible messages are:
• 1200
Off – No communications are currently taking place. • 2400
A delay of 15 seconds or more of inac- • 4800
tive communications (time between • 9600
valid responses) will cause this message • 19200 5
to display. • 38400
• 57600
• 115200

HOME >> SETUP >> SERIAL COMMUNICATIONS

LD15259

Figure 87 - COMMUNICATIONS SETUP

JOHNSON CONTROLS 145

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

Data Bits – Determines the number of bits in a trans- set bits. Parity checking is the most basic form of er-
mitted data package. A pull down menu is provided to ror detection in communications. A pull down menu is
select from the following: provided to select from the following:
• 7 • None
• 8 • Even
• Odd
Stop Bits – A bit(s) which signals the end of a unit of
transmission on a serial line. A pull down menu is pro- Protocol – A protocol is the special set of rules that
vided to select from the following: each end of a communications connection use when
they communicate. A pull down menu is provided to
• 1 select from the following Quantum™ LX recognized
• 2 protocols:

Parity – In communications, parity checking refers to • None

the use of parity bits to check that data has been trans- • ModBus ASCII
mitted accurately. The parity bit is added to every data • ModBus RTU
unit (typically seven or eight data bits) that are trans- • AB DF1 Full Duplex
mitted. The parity bit for each unit is set so that all • AB DF1 Half Duplex
bytes have either an odd number or an even number of
Use the following form to record all settings:

Table 12 - SERIAL COMMUNICATION SETUP

COMPRESSOR ID ________ (0 - 255)
Com 1 Com 3
1200

2400

4800

9600
Baud Rate
19200

38400

57600

115200

7
Data Bits
8

1
Stop Bits
2

None
Parity Even

Odd

None

Modbus ASCII
Protocol Modbus RTU

AB DF1 Full Duplex

AB DF1 Half Duplex

146 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

Serial Communications Port Wiring

COM-2
The following pictorial shows the communications On the Communications Setup screen, verify that the
board, as well as the jumpers, LED’s and signal pinouts proper Panel ID, Baud rate, data bits, and protocol has
to allow the end user to communicate to Com-2 using been setup at the Quantum™ LX, and matches that of
RS-232 protocol. the initiating device.

Table 13 - COMMUNICATIONS BOARD

PIN SIGNAL DESCRIPTION
1 DCD Data Carry Detect

1 2 2 SIN Serial In or Receive Data

3 SOUT Serial Out or Transmit Data
4 DTR Data Terminal Ready
5 GND Ground
6 DSR Data Set Ready 5
9 10 7
8
RTS
CTS
Request To Send
Clear To Send
VCC_
9 Power Source
COM
LD15236

JOHNSON CONTROLS 147

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

Communications Data Logging Screens Simply select the button at the upper right side of the
DESCRIPTION: This screen allows the technician to screen that corresponds to the port that you wish to
view the status of all serial communications ports. view. The selected port name (in this case Comm4) will
appear in the upper left side of the screen. Each time a
The following user selectable buttons are provided: new command is sent or received, the screen will need
to be refreshed by selecting the [Show Comm X] but-
• [Show Comm1] ton (where X is replaced with the comm port number).
• [Show Comm2] The top line of data is the most recent activity. At the
left of each line, you should see whether the data is
• [Show Comm3] IN or OUT (Receive or Send), and the actual data (in
• [Show Comm4] Hexadecimal format). This information can be used to
compare against the data being sent and received at the
• [Modbus TCP] other end of the communications link, to verify proper
This screen allows the technician to view all of the se- operation. Refer to the section on Hyperterminal for
rial communications information that the Quantum™ some examples of how this screen may be used.
LX is receiving and transmitting, one port at a time.

HOME >> SETUP >> DIAGNOSTICS >> COMMUNICATION LOGS

LD15282

Figure 88 - COMMUNICATIONS DATA LOGGING SCREENS

148 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

LD15284

Figure 89 - MODBUS TCP COMMUNICATIONS LOG

This screen allows the technician to view the ModBus the actual data (in Hexadecimal format). This informa-
TCP data communications information that the Quan- tion can be used to compare against the data being sent
tum™ LX is receiving and transmitting. Each time a and received at the other end of the communications
new command is sent or received, the screen will need link, to verify proper operation.
to be refreshed by selecting the [Refresh] button, as
described earlier. The top line of data is the most recent At the bottom of this page is an example for a break-
activity. At the left of each line, you should see whether down of how the data packets are created, using the
the data is IN or OUT (Response or Command), and data that has been shown on the above screen

Byte count in data returned

Data in register 2000
Data in register 2001

Response 01 Out: 00 · 00 00 · 00 00 · 07 01 03 04 00 · 20 00 · 16

Command 00 In: 00 · 00 00 · 00 00 · 06 01 03 07 · D0 00 · 02

# of registers to read
Address of first register (2001)
Read holding register
Panel ID
# of bytes in command
Always 0 for Modbus TCP
Transaction Identifier

Figure 90 - HOW THE DATA PACKETS ARE CREATED

JOHNSON CONTROLS 149

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

NETWORK INTERFACE PROTOCOLS Please refer to Red Lion Controls publication 07036
DSPLE for configuring and interfacing to the RLC
The Quantum™ LX for CYK supports the following
Data Station Plus.
protocols internally:
http://www.redlion.net/Products/Groups/DataStation
• ModBus ASCII
Plus/DataStationPlus/Docs/07038.pdf
• ModBus RTU
Data Station Pinout
• AB DF1 Full Duplex
RLC Crimson 3.0 configuration software can be down-
• AB DF1 Half Duplex loaded here.
• Modbus TCP over Ethernet http://www.redlion.net/Support/Downloads/Soft-
• Ethernet Industrial Protocol with Allen-Bradley wareLibrary/Crimson3.html
data table structures See the CYK protocol list document in the chiller IOM.
Additional protocols and media are supported by the
RedLion Data Station Plus.

LD15297

Figure 91 - DATA STATION PINOUT

150 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

QUANTUM LX FOR CYK PROTOCOL LIST

Example Hookups
Connecting the Quantum LX Industrial Control Cen-
ter to an existing network can be done in many ways.
Here are a few examples.

LD16258

Figure 92 - VIRTUAL HMI

LD16259

Figure 93 - BACNET IP OVER ETHERNET

JOHNSON CONTROLS 151

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

LD16260

Figure 94 - BACNET MSTP OVER RS-485

Use an RJ-45 connector. Pinout references the JACK. DaisyChain A

A cut-off Ethernet patchcord connector makes a suit-
able cable.
RS485

TxA
TxB
COMM

RS485
TxEN
RxB
RxA
TxA
TxB

DaisyChain B
LD16261

Figure 95 - RJ-45 CONNECTOR

152 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

LD16262 5
Figure 96 - MODBUS RTU OR AB DF1 OVER RS-485

LD16263

Figure 97 - CREATE YOUR OWN

JOHNSON CONTROLS 153

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

HOW TO UPDATE REDLION DATA STATION

PLUS CONFIGURATION
Updating the configuration of a Red Lion Controls
Data Station Plus is straightforward. The following
tools are required:
Crimson 2.0 software available at link above.
A USB A to B cable to plug the laptop into the
Data Station.
First make sure your computer has the RedLion
USB driver installed. You only have to do this
once.

Instructions Here
• Obtain a ".cd2" or ".cd3" crimson configuration
file from the factory (or create your own)
• Open the ",cd2" or ".cd3" file by double clicking
on it which launches Crimson
• Click the LINK menu and select OPTIONS
• Select USB for the communications port
• Click OK
• Click the LINK menu and select UPDATE
The RLC Data Station Plus will be update with the new
configuration file.
Test to see if data is available by doubling clicking on
the COMMUNICATIONS icon in Crimson.
• Click on the PLUS sign next to the port you are
using (RS-232, RS-485, Ethernet).
• Click on the PLUS sign next to the driver you are
using (modbus, bacnet, profibus, etc).
• Right click on any of the data blocks, and select
VIEW to see the data.
• Confirm that the data on the chiller matches the
points in the data block per the protocol listing
provided in this document.

154 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

Table 14 - QUANTUM LX FOR CYK PROTOCOL LIST

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
bit x10 bit DIGITAL WRITE DATA
00001 N119:10 BO0001 0 Remote Start Initiate 1= start (clear to 0 after set)
00002 N119:11 BO0002 1 Remote Stop Initiate 1= stop (clear to 0 after set)
00003 N119:12 BO0003 2 Remote System Reset / Alarm Acknowledge 1= ack (clear to 0 after set)

x10 x10 Float SETPOINT WRITE DATA

47199 N101:98 AO0001 198 Remote Chilled Water Setpoint
47202 N102:01 AO0002 201 Remote Condenser Temperature Setpoint
47168 N101:67 AO0003 167 Demand Limit Setpoint Percentage
47169 N101:68 AO0004 168 Pulldown Demand Limit Setpoint Percentage
Communication Units [0= PSIA,°C]
44567 N45:66 AO0005 566 Set by BMS
[1=panel display units]
See panel login page for panel display
engineering units

5
bit x10 bit DIGITAL READ ONLY DATA Scaling per Protocol
10001 N10:0 BI0001 0 Chilled Water Low Flow Effector Switch
10002 N10:1 BI0002 1 Condenser Water Low Flow Effector Switch
10003 N10:2 BI0003 2 LS Motor Starter Full Voltage (Run) Aux Contact
10004 N10:3 BI0004 3 HS Motor Starter Full Voltage (Run) Aux Contact
10005 N10:4 BI0005 4 LS Motor Starter Safety Fault Lockout Relay
10006 N10:5 BI0006 5 HS Motor Starter Safety Fault Lockout Relay
10007 N10:6 BI0007 6 Condenser Refrig. High Pressure Cutout
10008 N10:7 BI0008 7 LS Compressor Oil Heater Thermostat
10009 N10:8 BI0009 8 HS Compressor Oil Heater Thermostat
10010 N10:9 BI0010 9 LS PRV Closed Limit Switch
10011 N10:10 BI0011 10 HS PRV Closed Limit Switch
10012 N10:11 BI0012 11 LS Thrust Switch Only on certain compressors
10013 N10:12 BI0013 12 HS Thrust Switch Only on certain compressors
LS Compressor VS Oil Pump Drive Faulted
10014 N10:13 BI0014 13
Contact
HS Compressor VS Oil Pump Drive Faulted
10015 N10:14 BI0015 14
Contact
10016 N10:15 BI0016 15 HS Oil Drain Block Valve Open Limit Switch Only on ice thermal storage
10017 N10:16 BI0017 16 HS Oil Drain Block Valve Close Limit Switch Only on ice thermal storage
10018 N10:17 BI0018 17 Chiller Remote Hardwired Start/Stop
10019 N10:18 BI0019 18 Emergency Stop
10020 N10:19 BI0020 19 R1 Relay
10021 N10:20 BI0021 20
10022 N10:21 BI0022 21
10023 N10:22 BI0023 22 Blank
10024 N10:23 BI0024 23
10025 N10:24 BI0025 24
10026 N10:25 BI0026 25 LS Liquid Line Solenoid Valve
10027 N10:26 BI0027 26 HS Liquid Line Solenoid Valve

JOHNSON CONTROLS 155

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
10028 N10:27 BI0028 27 LS Oil Return Solenoid Valve
10029 N10:28 BI0029 28 Interstage Sideload Valve
10030 N10:29 BI0030 29 LS Compressor Oil Heater Contactor
10031 N10:30 BI0031 30 HS Compressor Oil Heater Contactor
10032 N10:31 BI0032 31 LS Compressor Motor Start/Stop Control Relay
10033 N10:32 BI0033 32 HS Compressor Motor Start/Stop Control Relay
10034 N10:33 BI0034 33 LS Compressor Oil Pump Start/Stop Relay
10035 N10:34 BI0035 34 HS Compressor Oil Pump Start/Stop Relay
10036 N10:35 BI0036 35 Oil Transfer Pump Relay Only on ice thermal storage
10037 N10:36 BI0037 36 HS Oil Transfer Solenoid Only on ice thermal storage
10038 N10:37 BI0038 37 Condensate Management Relay Only on ice thermal storage
10039 N10:38 BI0039 38 Economizer Gas Bleed Solenoid
10040 N10:39 BI0040 39 Open Low Stage PRV
10041 N10:40 BI0041 40 Open High Stage PRV
10042 N10:41 BI0042 41 Close Low Stage PRV
10043 N10:42 BI0043 42 Close High Stage PRV
10044 N10:43 BI0044 43 Open Low Stage VGD
10045 N10:44 BI0045 44 Open High Stage VGD
10046 N10:45 BI0046 45 Close Low Stage VGD
10047 N10:46 BI0047 46 Close High Stage VGD
10048 N10:47 BI0048 47
10049 N10:48 BI0049 48
Blank
10050 N10:49 BI0050 49
10051 N10:50 BI0051 50
10052 N10:51 BI0052 51 Software System Reset R1 Safety Relay
10053 N10:52 BI0053 52 Chiller Running
10054 N10:53 BI0054 53 Chiller Common Alarm

x10 x10 Float ANALOG READ ONLY DATA Scaling per Protocol
42001 N20:0 AI0001 0 Low Stage Motor Current (Amps)
42002 N20:1 AI0002 1 High Stage Motor Current (Amps)
42003 N20:2 AI0003 2 Evaporator Refrig. Pressure
42004 N20:3 AI0004 3 Condenser Refrig. Pressure
42005 N20:4 AI0005 4 Economizer Refrig. Pressure
42006 N20:5 AI0006 5 Low Stage Compressor Low Oil Pressure
42007 N20:6 AI0007 6 High Stage Compressor Low Oil Pressure
42008 N20:7 AI0008 7 Low Stage Compressor High Oil Pressure
42009 N20:8 AI0009 8 High Stage Compressor High Oil Pressure
42010 N20:9 AI0010 9 LS Oil Reservoir Level Only on ice thermal storage
42011 N20:10 AI0011 10 HS Oil Reservoir Level Only on ice thermal storage
42012 N20:11 AI0012 11 Subcooler Refrig. Liquid Level
42013 N20:12 AI0013 12 Economizer Refrig. Liquid Level
42014 N20:13 AI0014 13 LS Comp HS Thrust Bearing Probe Gap Only on certain compressors

156 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
42015 N20:14 AI0015 14 HS Comp HS Thrust Bearing Probe Gap Only on certain compressors
42016 N20:15 AI0016 15 Low Stage PRV Position
42017 N20:16 AI0017 16 High Stage PRV Position
42018 N20:17 AI0018 17 Hardwired Remote Chilled Water Setpoint
42019 N20:18 AI0019 18 Chilled Water Out Temperature
42020 N20:19 AI0020 19 Chilled Water In Temperature
42021 N20:20 AI0021 20 Condenser Water Out Temperature
42022 N20:21 AI0022 21 Condenser Water In Temperature
42023 N20:22 AI0023 22 Evaporator Refrig. Liquid Temperature
42024 N20:23 AI0024 23 LS Comp Refrig. Discharge Temperature
42025 N20:24 AI0025 24 HS Comp Refrig. Discharge Temperature
42026 N20:25 AI0026 25 Subcooled Refrig. Liquid Temperature
42027 N20:26 AI0027 26 Low Stage Compressor Oil Temperature
42028 N20:27 AI0028 27 High Stage Compressor Oil Temperature 5
42029 N20:28 AI0029 28 Five Volt Supply
42030 N20:29 AI0030 29 Hardwired Remote Heating Water Setpoint only on heat pumps
42031 N20:30 AI0031 30 Blank
42032 N20:31 AI0032 31 User defined analog input #1
42033 N20:32 AI0033 32 User defined analog input #2
42034 N20:33 AI0034 33 User defined analog input #3
42035 N20:34 AI0035 34 User defined analog input #4
42036 N20:35 AI0036 35 User defined analog input #5
42037 N20:36 AI0037 36 User defined analog input #6
42038 N20:37 AI0038 37 User defined analog input #7
42039 N20:38 AI0039 38 User defined analog input #8
42040 N20:39 AI0040 39 User defined analog input #9
42041 N20:40 AI0041 40 User defined analog input #10
42042 N20:41 AI0042 41 User defined analog input #11
42043 N20:42 AI0043 42 User defined analog input #12
42044 N20:43 AI0044 43 User defined analog input #13
42045 N20:44 AI0045 44 User defined analog input #14
42046 N20:45 AI0046 45 User defined analog input #15
42047 N20:46 AI0047 46 User defined analog input #16
42048 N20:47 AI0048 47 User defined analog input #17
42049 N20:48 AI0049 48 User defined analog input #18
42050 N20:49 AI0050 49 User defined analog input #19
42051 N20:50 AI0051 50 User defined analog input #20
42052 N20:51 AI0052 51
42053 N20:52 AI0053 52
42054 N20:53 AI0054 53 Blank
42055 N20:54 AI0055 54
42056 N20:55 AI0056 55

JOHNSON CONTROLS 157

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
42057 N20:56 AI0057 56
42058 N20:57 AI0058 57 Blank
42059 N20:58 AI0059 58
42060 N20:59 AI0060 59 Analog output #1
42061 N20:60 AI0061 60 Analog output #2
42062 N20:61 AI0062 61 Analog output #3
42063 N20:62 AI0063 62 Analog output #4
42064 N20:63 AI0064 63 Analog output #5
42065 N20:64 AI0065 64 Analog output #6
42066 N20:65 AI0066 65 Analog output #7
42067 N20:66 AI0067 66 Analog output #8
LS VGD Pressure Sensor / Intermediate Pres-
42068 N20:67 AI0068 67
sure
42069 N20:68 AI0069 68 LS VGD Stall Noise Level Only on certain compressors
42070 N20:69 AI0070 69 LS VGD Position Only on certain compressors
42071 N20:70 AI0071 70 HS VGD Pressure Sensor Only on certain compressors
42072 N20:71 AI0072 71 HS VGD Stall Noise Level Only on certain compressors
42073 N20:72 AI0073 72 HS VGD Position Only on certain compressors
Option when flow meter is
42074 N20:73 AI0074 73 Chilled Water / Brine Flow (GPM)
installed
Option when flow meter is
42075 N20:74 AI0075 74 Condenser Water Flow (GPM)
installed
42076 N20:75 AI0076 75
42077 N20:76 AI0077 76
Blank
42078 N20:77 AI0078 77
42079 N20:78 AI0079 78
42080 N20:79 AI0080 79 Hot Gas Bypass Valve
42081 N20:80 AI0081 80 Subcooler Variable Orifice Valve
42082 N20:81 AI0082 81 Economizer Variable Orifice Valve
42083 N20:82 AI0083 82 Economizer Bypass Variable Orifice Valve
42084 N20:83 AI0084 83 LS Comp VS Oil Pump Drive Control
42085 N20:84 AI0085 84 HS Comp VS Oil Pump Drive Control
42086 N20:85 AI0086 85 Analog output #9
42087 N20:86 AI0087 86 Analog output #10
42088 N20:87 AI0088 87 Analog output #11
42089 N20:88 AI0089 88 Analog output #12
42090 N20:89 AI0090 89 Analog output #13
42091 N20:90 AI0091 90 Analog output #14
42092 N20:91 AI0092 91 Analog output #15
42093 N20:92 AI0093 92 Analog output #16

158 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
x10 x10 Float CALCULATED VALUE READ ONLY DATA Scaling per Protocol
43001 N30:0 AI0100 0 System Head (Cond Pres - Evap Pres)
43002 N30:1 AI0101 1 Evaporator Small Diff Temp
43003 N30:2 AI0102 2 Condenser Small Diff Temp
43004 N30:3 AI0103 3 HS VS Frequency
43005 N30:4 AI0104 4 LS VS Frequency
43006 N30:5 AI0105 5 Auto HS VS Oil Pump Drive
43007 N30:6 AI0106 6 Manual HS VS Oil Pump Drive
43008 N30:7 AI0107 7 Auto LS VS Oil Pump Drive
43009 N30:8 AI0108 8 Manual LS VS Oil Pump Drive
43010 N30:9 AI0109 9 Auto LS Pre-Rotation Vanes
43011 N30:10 AI0110 10 Manual LS Pre-Rotation Vanes
43012 N30:11 AI0111 11 Auto HS Pre-Rotation Vanes
43013 N30:12 AI0112 12 Manual HS Pre-Rotation Vanes 5
43014 N30:13 AI0113 13 Auto Subcooler Level Valve
43015 N30:14 AI0114 14 Manual Subcooler Level Valve
43016 N30:15 AI0115 15 Auto Economizer Bypass Valve
43017 N30:16 AI0116 16 Manual Economizer Bypass Valve
43018 N30:17 AI0117 17 Event Log Flag
43019 N30:18 AI0118 18 Current Runtime
43020 N30:19 AI0119 19 Auto Hot Gas Valve
43021 N30:20 AI0120 20 Manual Hot Gas Valve
43022 N30:21 AI0121 21 Condenser Saturated Liquid Temperature
43023 N30:22 AI0122 22 Analog Board 1 Communications Fail
43024 N30:23 AI0123 23 Analog Board 2 Communications Fail
43025 N30:24 AI0124 24 Digital Board 1 Communications Fail
43026 N30:25 AI0125 25 Digital Board 2 Communications Fail
43027 N30:26 AI0126 26 Analog Board 3 Communications Fail
43028 N30:27 AI0127 27 Digital Board 1 Reset
43029 N30:28 AI0128 28 Digital Board 2 Reset
43030 N30:29 AI0129 29 Evaporator Saturated Liquid Temperature
43031 N30:30 AI0130 30 Subcooler Level Process Variable
43032 N30:31 AI0131 31 Economizer Level Process Variable
43033 N30:32 AI0132 32 Used In Displaying Alarms
43034 N30:33 AI0133 33 Interstage Saturated Temperature
43035 N30:34 AI0134 34 Liquid Seal Diff
43036 N30:35 AI0135 35 Auto Economizer Outlet Valve
43037 N30:36 AI0136 36 Manual Economizer Outlet Valve
43038 N30:37 AI0137 37 Chilled Water Out Temp PID Output
43039 N30:38 AI0138 38 Heat Pump Control PID Output
43040 N30:39 AI0139 39 HS Motor Load PID Output

JOHNSON CONTROLS 159

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
43041 N30:40 AI0140 40
43042 N30:41 AI0141 41
43043 N30:42 AI0142 42
43044 N30:43 AI0143 43
43045 N30:44 AI0144 44
Blank
43046 N30:45 AI0145 45
43047 N30:46 AI0146 46
43048 N30:47 AI0147 47
43049 N30:48 AI0148 48
43050 N30:49 AI0149 49
43051 N30:50 AI0150 50 Auto LS VGD
43052 N30:51 AI0151 51 Manual LS VGD
43053 N30:52 AI0152 52 Auto HS VGD
43054 N30:53 AI0153 53 Manual HS VGD
43055 N30:54 AI0154 54 Immediate Two Stage
43056 N30:55 AI0155 55 Chilled Water Out Temp PID Setpoint
43057 N30:56 AI0156 56 Vane Anti-Surge Calc
43058 N30:57 AI0157 57 HS Anti-Surge Calc
43059 N30:58 AI0158 58 LS Anti-Surge Calc
43060 N30:59 AI0159 59 Antirecycle Hours Til Next Start
43061 N30:60 AI0160 60 Antirecycle Minutes Til Next Start
43062 N30:61 AI0161 61 LS Discharge Superheat Temperature
43063 N30:62 AI0162 62 HS Discharge Superheat Temperature
43064 N30:63 AI0163 63 Heat Pump Temperature PID Setpoint
43065 N30:64 AI0164 64 Shutdown Text Index For Email Notification
43066 N30:65 AI0165 65 HS Oil Supply Pressure
43067 N30:66 AI0166 66 LS Oil Supply Pressure
43068 N30:67 AI0167 67 HS Compressor Head
43069 N30:68 AI0168 68 LS Compressor Head
43070 N30:69 AI0169 69 Blank
43071 N30:70 AI0170 70 Most Recent
43072 N30:71 AI0171 71
43073 N30:72 AI0172 72
43074 N30:73 AI0173 73
43075 N30:74 AI0174 74 List Of Current Safeties (0=ok, if non-zero refer
Refer to alarm Table for
43076 N30:75 AI0175 75 to offset in alarm table)
offset
43077 N30:76 AI0176 76
43078 N30:77 AI0177 77
43079 N30:78 AI0178 78
43080 N30:79 AI0179 79
43081 N30:80 AI0180 80
not used
43082 N30:81 AI0181 81
43083 N30:82 AI0182 82 Process Stopped Flag

160 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
43084 N30:83 AI0183 83 HS Oil Pump Frequency
43085 N30:84 AI0184 84 LS Oil Pump Frequency
43086 N30:85 AI0185 85 HS Oil Pressure PID Output
43087 N30:86 AI0186 86 LS Oil Pressure PID Output
43088 N30:87 AI0187 87 Evaporator Low Press Override PID Output
43089 N30:88 AI0188 88 Condenser High Press Override PID Output
43090 N30:89 AI0189 89 Low Stage Motor Limit PID Output
43091 N30:90 AI0190 90 Interstage Override PID Output
43092 N30:91 AI0191 91 PRV Antistall PID Output
43093 N30:92 AI0192 92 Low Stage PRV Position Converted
43094 N30:93 AI0193 93 High Stage PRV Position Converted
43095 N30:94 AI0194 94 Analog Output Test Value
43096 N30:95 AI0195 95 Averaged Low Stage Motor Load
43097 N30:96 AI0196 96 Averaged High Stage Motor Load 5
43098 N30:97 AI0197 97 HS Thrust Prox Diff
43099 N30:98 AI0198 98 LS Thrust Prox Diff
43100 N30:99 AI0199 99 SS2
43101 N30:100 AI0200 100 LSR1
43102 N30:101 AI0201 101 Hot Gas Ramp
43103 N30:102 AI0202 102 HSR4
Option when flow meter is
43104 N30:103 AI0203 103 Evaporator Tonnage in units of TR
installed
43105 N30:104 AI0204 104 Runtime Since Last Start Days
43106 N30:105 AI0205 105 Runtime Since Last Start Hours
43107 N30:106 AI0206 106 Runtime Since Last Start Minutes
43108 N30:107 AI0207 107 HS PRV With Offset
43109 N30:108 AI0208 108 Safety Index Of Oldest Uncleared Shutdown
43110 N30:109 AI0209 109 LS VGD Scaled Position
43111 N30:110 AI0210 110 HS VGD Scaled Position
43112 N30:111 AI0211 111 LSR3
43113 N30:112 AI0212 112 LSR2
43114 N30:113 AI0213 113 LSR4
43115 N30:114 AI0214 114 SS1
43116 N30:115 AI0215 115 HSR2
43117 N30:116 AI0216 116 HSR1
43118 N30:117 AI0217 117
Blank
43119 N30:118 AI0218 118
43120 N30:119 AI0219 119 Range Converter Result
43121 N30:120 AI0220 120 HSR3
43122 N30:121 AI0221 121 LS Motor Load Percent
43123 N30:122 AI0222 122 HS Motor Load Percent
LCSSS / MVSSS Starter
43124 N30:123 AI0223 123 LS Motor Kilowatts
Comms Only

JOHNSON CONTROLS 161

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
Option when flow meter is
43125 N30:124 AI0224 124 Condenser Heat Rejection in units of MBH
installed
43126 N30:125 AI0225 125 LS LCSSS Phase A Voltage
43127 N30:126 AI0226 126 LS LCSSS Phase B Voltage
43128 N30:127 AI0227 127 LS LCSSS Phase C Voltage
43129 N30:128 AI0228 128 LS LCSSS Phase A Current
43130 N30:129 AI0229 129 LS LCSSS Phase B Current LCSSS / MVSSS Starter
43131 N30:130 AI0230 130 LS LCSSS Phase C Current Comms Only
43132 N30:131 AI0231 131 LS LCSSS Phase A Temperature
43133 N30:132 AI0232 132 LS LCSSS Phase B Temperature
43134 N30:133 AI0233 133 LS LCSSS Phase C Temperature
43135 N30:134 AI0234 134 HS LCSSS INPUT POWER KW
43136 N30:135 AI0235 135 Blank
43137 N30:136 AI0236 136 HS LCSSS Phase A Voltage
43138 N30:137 AI0237 137 HS LCSSS Phase B Voltage
43139 N30:138 AI0238 138 HS LCSSS Phase C Voltage
43140 N30:139 AI0239 139 HS LCSSS Phase A Current
LCSSS / MVSSS Starter
43141 N30:140 AI0240 140 HS LCSSS Phase B Current
Comms Only
43142 N30:141 AI0241 141 HS LCSSS Phase C Current
43143 N30:142 AI0242 142 HS LCSSS Phase A Temperature
43144 N30:143 AI0243 143 HS LCSSS Phase B Temperature
43145 N30:144 AI0244 144 HS LCSSS Phase C Temperature

x10 x10 Float MODE VALUE READ ONLY DATA

0=View, 1=Operator,
44001 N40:0 AI0300 0 Copy of Setpoint 0 (User Level) 2=Service,
3=Factory; 4=Prog.
44002 N40:1 AI0301 1 Control Mode 0=Chiller, 1=Heat Pump
0=Not in Prelube, 1=In
44003 N40:2 AI0302 2 LS Prelube
Prelube
0=Not in Postlube, 1=In
44004 N40:3 AI0303 3 LS Postlube
Postlube
0=No Shutdowns, 1=Shut-
44005 N40:4 AI0304 4 Shutdown
down
44006 N40:5 AI0305 5 Warning 0=No Warning, 1=Warning
0=Single-Stage, 1=Two-
44007 N40:6 AI0306 6 Stage Mode
Stage
44008 N40:7 AI0307 7 Chiller Mode 0=Auto, 1=Manual
44009 N40:8 AI0308 8 Blank
44010 N40:9 AI0309 9 LCV-114 Mode 0=Auto, 1=Manual
44011 N40:10 AI0310 10 LCV-117 Mode 0=Auto, 1=Manual
44012 N40:11 AI0311 11 LS Pre-Rotation Vanes Mode 0=Auto, 1=Manual
44013 N40:12 AI0312 12 HS Pre-Rotation Vanes Mode 0=Auto, 1=Manual
44014 N40:13 AI0313 13 HS VS Oil Pump Drive Mode 0=Auto, 1=Manual
44015 N40:14 AI0314 14 LS VS Oil Pump Drive Mode 0=Auto, 1=Manual
44016 N40:15 AI0315 15 Hot Gas Valve Mode 0=Auto, 1=Manual

162 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
44017 N40:16 AI0316 16 LCV-116 Mode 0=Auto, 1=Manual
44018 N40:17 AI0317 17 Oil Sump Mode 0=Ice, 1=Heatpump
44019 N40:18 AI0318 18 LS VGD Mode 0=Auto, 1=Manual
44020 N40:19 AI0319 19 HS VGD Mode 0=Auto, 1=Manual
0=Ready To Start, 1=Re-
mote Start Enabled, 2=Start
/ LS Prelube, 3=Rem Start
/ LS Prelube, 4=System
Running 2-Stage, 5=Sys-
tem Coastdown, 6=System
44021 N40:20 AI0320 20 System Status
Tripped, 7=Antirecycle,
8=Low Stage Running,
9=Vanes Closing, 10=Re-
mote Lockout, 11=HS Start
/ Prelube, 12=Running /
Dynamic Override
44022 N40:21 AI0321 21 Start Mode 0=Local, 1=Remote 5
44023 N40:22 AI0322 22 Setpoint Mode (Control Source) 0=Local, 1=Remote
44024 N40:23 AI0323 23 Oil Sump Lubrication 0=Auto, 1=Lock On
44025 N40:24 AI0324 24 Modbus and AB protocols
0= ok
44026 N40:25 AI0325 25 Blank
10 decimal = alarm timing
44027 N40:26 AI0326 26 20 decimal = state of alarm
44028 N40:27 AI0327 27 LS VGD Algorithm Mode 0=Wait, 1=Probe, 2=React
44029 N40:28 AI0328 28 HS VGD Algorithm Mode 0=Wait, 1=Probe, 2=React
44030 N40:29 AI0329 29 LS VGD Calibration In Progress 0=No, 1=Yes
44031 N40:30 AI0330 30 HS VGD Calibration In Progress 0=No, 1=Yes
0=Not in Prelube, 1=In
44032 N40:31 AI0331 31 HS Prelube
Prelube
0 = Not in Postlube,
44033 N40:32 AI0332 32 HS Postlube
1 = In Postlube
44034 N40:33 AI0333 33 System Is Coasting Down 0 = No, 1 = Yes
44035 N40:34 AI0334 34 Anti-recycle Active 0 = No, 1 = Yes
44036 N40:35 AI0335 35 PRV Calibration In Progress 0 = No, 1 = Yes

0 = ok,
ALARM TABLE (OFFSET) ALARM WARNING / 1 decimal = alarm timing,
X10 X10 FLOAT
SHUTDOWN READ ONLY DATA 2 decimal = state of alarm,
Scaling Per Protocol
45001 N50:0 AI0500 0 Modbus and AB protocols,
0 = ok,
45002 N50:1 AI0501 1 Blank
10 decimal = alarm timing
45003 N50:2 AI0502 2 20 decimal = state of alarm
45004 N50:3 AI0503 3 Warning: Vane Motor Switches Not Closed
45005 N50:4 AI0504 4 Warning: High Discharge Temperature
45006 N50:5 AI0505 5 Warning: High Discharge Pressure
45007 N50:6 AI0506 6 Warning: High Stage Proximity Forward
45008 N50:7 AI0507 7 Warning: High Stage Proximity Reverse
45009 N50:8 AI0508 8 Warning: High Stage High Oil Pressure

JOHNSON CONTROLS 163

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
45010 N50:9 AI0509 9 Warning: High Stage High Oil Temperature
45011 N50:10 AI0510 10 Warning: High Stage Interlock W/O Run
45012 N50:11 AI0511 11 Warning: Low Discharge Temp On High Stage
45013 N50:12 AI0512 12 Warning: High Stage Low Oil Pressure
45014 N50:13 AI0513 13 Warning: High Stage Low Oil Temperature
45015 N50:14 AI0514 14 Warning: Low Stage Interlock W/O Run
45016 N50:15 AI0515 15 Warning: High Hs Oil Reservoir Level
45017 N50:16 AI0516 16 Warning: Low Hs Oil Reservoir Level
45018 N50:17 AI0517 17 Warning: High Economizer Refrig. Press
45019 N50:18 AI0518 18 Warning: High Interstage Pressure
45020 N50:19 AI0519 19 Warning: Invalid Antisurge Parameters Entered
45021 N50:20 AI0520 20
45022 N50:21 AI0521 21 Warning: Low Evaporator Pressure
45023 N50:22 AI0522 22
45024 N50:23 AI0523 23 Warning: Low Leaving Chilled Water Temp
45025 N50:24 AI0524 24 Warning: Low Stage Proximitor Forward
45026 N50:25 AI0525 25 Warning: Low Stage Proximitor Reverse
45027 N50:26 AI0526 26 Warning: Low Stage High Oil Pressure
45028 N50:27 AI0527 27 Warning: Low Stage High Oil Temperature
45029 N50:28 AI0528 28 Warning: Low Stage Interlock W/O Run
45030 N50:29 AI0529 29 Warning: Low Stage Low Oil Pressure
45031 N50:30 AI0530 30 Warning: Low Stage Low Oil Temperature
45032 N50:31 AI0531 31 Warning: Low Stage Motor Current W/O Run
45033 N50:32 AI0532 32 Warning: Low Stage High Reservoir Level
45034 N50:33 AI0533 33 Warning: Low Stage Low Reservoir Level
45035 N50:34 AI0534 34 Warning: Remote Start Denied / Check Mode
45036 N50:35 AI0535 35 Warning: Check Battery
45037 N50:36 AI0536 36 Warning: High Stage Motor Current W/O Run
45038 N50:37 AI0537 37 Warning: High Economizer Vessel Level
45039 N50:38 AI0538 38 Warning: Sideload Forced Closed, High Level
45040 N50:39 AI0539 39 Warning: High Sideload Differential
45041 N50:40 AI0540 40 Warning: Hs Oil Drain Not Open
45042 N50:41 AI0541 41 Warning: Hs Oil Drain Not Closed
45043 N50:42 AI0542 42 Warning: Hs Thrust Probe Cal Active
45044 N50:43 AI0543 43 Warning: Ls Thrust Probe Cal Active

164 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
45045 N50:44 AI0544 44
45046 N50:45 AI0545 45
45047 N50:46 AI0546 46
45048 N50:47 AI0547 47
45049 N50:48 AI0548 48
45050 N50:49 AI0549 49
45051 N50:50 AI0550 50
45052 N50:51 AI0551 51
45053 N50:52 AI0552 52
45054 N50:53 AI0553 53 Blank
45055 N50:54 AI0554 54
45056 N50:55 AI0555 55
45057 N50:56 AI0556 56
45058 N50:57 AI0557 57 5
45059 N50:58 AI0558 58
45060 N50:59 AI0559 59
45061 N50:60 AI0560 60
45062 N50:61 AI0561 61
45063 N50:62 AI0562 62
45064 N50:63 AI0563 63 Auxiliary Input 1 Shutdown
45065 N50:64 AI0564 64 Auxiliary Input 1 Warning
45066 N50:65 AI0565 65 Auxiliary Input 2 Shutdown
45067 N50:66 AI0566 66 Auxiliary Input 2 Warning
45068 N50:67 AI0567 67 Auxiliary Input 3 Shutdown
45069 N50:68 AI0568 68 Auxiliary Input 3 Warning
45070 N50:69 AI0569 69 Auxiliary Input 4 Shutdown
45071 N50:70 AI0570 70 Auxiliary Input 4 Warning
45072 N50:71 AI0571 71 Auxiliary Input 5 Shutdown
45073 N50:72 AI0572 72 Auxiliary Input 5 Warning
45074 N50:73 AI0573 73 Auxiliary Input 6 Shutdown
45075 N50:74 AI0574 74 Auxiliary Input 6 Warning
45076 N50:75 AI0575 75 Auxiliary Input 7 Shutdown
45077 N50:76 AI0576 76 Auxiliary Input 7 Warning
45078 N50:77 AI0577 77 Auxiliary Input 8 Shutdown
45079 N50:78 AI0578 78 Auxiliary Input 8 Warning
45080 N50:79 AI0579 79 Auxiliary Input 9 Shutdown
45081 N50:80 AI0580 80 Auxiliary Input 9 Warning
45082 N50:81 AI0581 81 Auxiliary Input 10 Shutdown
45083 N50:82 AI0582 82 Auxiliary Input 10 Warning
45084 N50:83 AI0583 83 High Auxiliary Analog 1 Shutdown
45085 N50:84 AI0584 84 High Auxiliary Analog 1 Warning
45086 N50:85 AI0585 85 Low Auxiliary Analog 1 Shutdown

JOHNSON CONTROLS 165

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
45087 N50:86 AI0586 86 Low Auxiliary Analog 1 Warning
45088 N50:87 AI0587 87 High Auxiliary Analog 2 Shutdown
45089 N50:88 AI0588 88 High Auxiliary Analog 2 Warning
45090 N50:89 AI0589 89 Low Auxiliary Analog 2 Shutdown
45091 N50:90 AI0590 90 Low Auxiliary Analog 2 Warning
45092 N50:91 AI0591 91 High Auxiliary Analog 3 Shutdown
45093 N50:92 AI0592 92 High Auxiliary Analog 3 Warning
45094 N50:93 AI0593 93 Low Auxiliary Analog 3 Shutdown
45095 N50:94 AI0594 94 Low Auxiliary Analog 3 Warning
45096 N50:95 AI0595 95 High Auxiliary Analog 4 Shutdown
45097 N50:96 AI0596 96 High Auxiliary Analog 4 Warning
45098 N50:97 AI0597 97 Low Auxiliary Analog 4 Shutdown
45099 N50:98 AI0598 98 Low Auxiliary Analog 4 Warning
45100 N50:99 AI0599 99 High Auxiliary Analog 5 Shutdown
45101 N50:100 AI0600 100 High Auxiliary Analog 5 Warning
45102 N50:101 AI0601 101 Low Auxiliary Analog 5 Shutdown
45103 N50:102 AI0602 102 Low Auxiliary Analog 5 Warning
45104 N50:103 AI0603 103 High Auxiliary Analog 6 Shutdown
45105 N50:104 AI0604 104 High Auxiliary Analog 6 Warning
45106 N50:105 AI0605 105 Low Auxiliary Analog 6 Shutdown
45107 N50:106 AI0606 106 Low Auxiliary Analog 6 Warning
45108 N50:107 AI0607 107 High Auxiliary Analog 7 Shutdown
45109 N50:108 AI0608 108 High Auxiliary Analog 7 Warning
45110 N50:109 AI0609 109 Low Auxiliary Analog 7 Shutdown
45111 N50:110 AI0610 110 Low Auxiliary Analog 7 Warning
45112 N50:111 AI0611 111 High Auxiliary Analog 8 Shutdown
45113 N50:112 AI0612 112 High Auxiliary Analog 8 Warning
45114 N50:113 AI0613 113 Low Auxiliary Analog 8 Shutdown
45115 N50:114 AI0614 114 Low Auxiliary Analog 8 Warning
45116 N50:115 AI0615 115 High Auxiliary Analog 9 Shutdown
45117 N50:116 AI0616 116 High Auxiliary Analog 9 Warning
45118 N50:117 AI0617 117 Low Auxiliary Analog 9 Shutdown
45119 N50:118 AI0618 118 Low Auxiliary Analog 9 Warning
45120 N50:119 AI0619 119 High Auxiliary Analog 10 Shutdown
45121 N50:120 AI0620 120 High Auxiliary Analog 10 Warning
45122 N50:121 AI0621 121 Low Auxiliary Analog 10 Shutdown
45123 N50:122 AI0622 122 Low Auxiliary Analog 10 Warning

166 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
45124 N50:123 AI0623 123
45125 N50:124 AI0624 124
45126 N50:125 AI0625 125
45127 N50:126 AI0626 126
Blank
45128 N50:127 AI0627 127
45129 N50:128 AI0628 128
45130 N50:129 AI0629 129
45131 N50:130 AI0630 130
45132 N50:131 AI0631 131 Auxiliary Input 11 Shutdown
45133 N50:132 AI0632 132 Auxiliary Input 11 Warning
45134 N50:133 AI0633 133 Auxiliary Input 12 Shutdown
45135 N50:134 AI0634 134 Auxiliary Input 12 Warning
45136 N50:135 AI0635 135 Auxiliary Input 13 Shutdown
45137 N50:136 AI0636 136 Auxiliary Input 13 Warning 5
45138 N50:137 AI0637 137 Auxiliary Input 14 Shutdown
45139 N50:138 AI0638 138 Auxiliary Input 14 Warning
45140 N50:139 AI0639 139 Auxiliary Input 15 Shutdown
45141 N50:140 AI0640 140 Auxiliary Input 15 Warning
45142 N50:141 AI0641 141 Auxiliary Input 16 Shutdown
45143 N50:142 AI0642 142 Auxiliary Input 16 Warning
45144 N50:143 AI0643 143 Auxiliary Input 17 Shutdown
45145 N50:144 AI0644 144 Auxiliary Input 17 Warning
45146 N50:145 AI0645 145 Auxiliary Input 18 Shutdown
45147 N50:146 AI0646 146 Auxiliary Input 18 Warning
45148 N50:147 AI0647 147 Auxiliary Input 19 Shutdown
45149 N50:148 AI0648 148 Auxiliary Input 19 Warning
45150 N50:149 AI0649 149 Auxiliary Input 20 Shutdown
45151 N50:150 AI0650 150 Auxiliary Input 20 Warning
45152 N50:151 AI0651 151 High Auxiliary Analog 11 Shutdown
45153 N50:152 AI0652 152 High Auxiliary Analog 11 Warning
45154 N50:153 AI0653 153 Low Auxiliary Analog 11 Shutdown
45155 N50:154 AI0654 154 Low Auxiliary Analog 11 Warning
45156 N50:155 AI0655 155 High Auxiliary Analog 12 Shutdown
45157 N50:156 AI0656 156 High Auxiliary Analog 12 Warning
45158 N50:157 AI0657 157 Low Auxiliary Analog 12 Shutdown
45159 N50:158 AI0658 158 Low Auxiliary Analog 12 Warning
45160 N50:159 AI0659 159 High Auxiliary Analog 13 Shutdown
45161 N50:160 AI0660 160 High Auxiliary Analog 13 Warning
45162 N50:161 AI0661 161 Low Auxiliary Analog 13 Shutdown
45163 N50:162 AI0662 162 Low Auxiliary Analog 13 Warning
45164 N50:163 AI0663 163 High Auxiliary Analog 14 Shutdown
45165 N50:164 AI0664 164 High Auxiliary Analog 14 Warning

JOHNSON CONTROLS 167

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
45166 N50:165 AI0665 165 Low Auxiliary Analog 14 Shutdown
45167 N50:166 AI0666 166 Low Auxiliary Analog 14 Warning
45168 N50:167 AI0667 167 High Auxiliary Analog 15 Shutdown
45169 N50:168 AI0668 168 High Auxiliary Analog 15 Warning
45170 N50:169 AI0669 169 Low Auxiliary Analog 15 Shutdown
45171 N50:170 AI0670 170 Low Auxiliary Analog 15 Warning
45172 N50:171 AI0671 171 High Auxiliary Analog 16 Shutdown
45173 N50:172 AI0672 172 High Auxiliary Analog 16 Warning
45174 N50:173 AI0673 173 Low Auxiliary Analog 16 Shutdown
45175 N50:174 AI0674 174 Low Auxiliary Analog 16 Warning
45176 N50:175 AI0675 175 High Auxiliary Analog 17 Shutdown
45177 N50:176 AI0676 176 High Auxiliary Analog 17 Warning
45178 N50:177 AI0677 177 Low Auxiliary Analog 17 Shutdown
45179 N50:178 AI0678 178 Low Auxiliary Analog 17 Warning
45180 N50:179 AI0679 179 High Auxiliary Analog 18 Shutdown
45181 N50:180 AI0680 180 High Auxiliary Analog 18 Warning
45182 N50:181 AI0681 181 Low Auxiliary Analog 18 Shutdown
45183 N50:182 AI0682 182 Low Auxiliary Analog 18 Warning
45184 N50:183 AI0683 183 High Auxiliary Analog 19 Shutdown
45185 N50:184 AI0684 184 High Auxiliary Analog 19 Warning
45186 N50:185 AI0685 185 Low Auxiliary Analog 19 Shutdown
45187 N50:186 AI0686 186 Low Auxiliary Analog 19 Warning
45188 N50:187 AI0687 187 High Auxiliary Analog 20 Shutdown
45189 N50:188 AI0688 188 High Auxiliary Analog 20 Warning
45190 N50:189 AI0689 189 Low Auxiliary Analog 20 Shutdown
45191 N50:190 AI0690 190 Low Auxiliary Analog 20 Warning
45192 N50:191 AI0691 191 Analog Board 1 Communications Shutdown
45193 N50:192 AI0692 192 Analog Board 2 Communications Shutdown
45194 N50:193 AI0693 193 Digital Board 1 Communications Shutdown
45195 N50:194 AI0694 194 Digital Board 2 Communications Shutdown
45196 N50:195 AI0695 195 Analog Board 3 Communications Shutdown
45197 N50:196 AI0696 196 Digital Board 1 Reset
45198 N50:197 AI0697 197 Digital Board 2 Reset
45199 N50:198 AI0698 198
45200 N50:199 AI0699 199 Blank
45201 N50:200 AI0700 200
45202 N50:201 AI0701 201 Trip: +5 Volt Supply Has Failed
45203 N50:202 AI0702 202 Trip: Bypass Didn’t Close
45204 N50:203 AI0703 203 Trip: Bypass Didn't Open
45205 N50:204 AI0704 204 Trip: Low Chilled Flow Switch
45206 N50:205 AI0705 205 Trip: Low Condenser Flow Switch
45207 N50:206 AI0706 206 Blank

168 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
45208 N50:207 AI0707 207 Trip: Emergency Stop Pulled
45209 N50:208 AI0708 208 Blank
45210 N50:209 AI0709 209 Trip: High Discharge Temperature
45211 N50:210 AI0710 210 Trip: High Discharge Pressure
45212 N50:211 AI0711 211 Trip: High Pressure Cutout
45213 N50:212 AI0712 212 Trip: High Stage Proximitor Forward
45214 N50:213 AI0713 213 Trip: High Stage Proximitor Reverse
45215 N50:214 AI0714 214 Trip: High Stage High Oil Pressure
45216 N50:215 AI0715 215 Trip: High Stage High Oil Temperature
45217 N50:216 AI0716 216 Trip: High Stage Low Oil Pressure
45218 N50:217 AI0717 217 Trip: High Stage Low Oil Temperature
45219 N50:218 AI0718 218 Trip: High Stage Motor Must Be Uncoupled
45220 N50:219 AI0719 219 Trip: High Stage Motor Interlock Lost
45221 N50:220 AI0720 220 Trip: High Stage Oil Pump Didn't Start 5
45222 N50:221 AI0721 221 Trip: High Stage Prox Is Uncalibrated
45223 N50:222 AI0722 222 Trip: High Economizer Refrig. Press
45224 N50:223 AI0723 223 Trip: High Interstage Pressure
45225 N50:224 AI0724 224 Trip: Hs Compressor Thrust Bearing Switch Fail
45226 N50:225 AI0725 225 Blank
45227 N50:226 AI0726 226 Trip: Ls Compressor Thrust Bearing Switch Fail
45228 N50:227 AI0727 227 Trip: Low Evaporator Pressure
45229 N50:228 AI0728 228 Blank
45230 N50:229 AI0729 229 Trip: Low Leaving Water Temperature
45231 N50:230 AI0730 230 Trip: Low Stage Proximity Forward
45232 N50:231 AI0731 231 Trip: Low Stage Proximity Reverse
45233 N50:232 AI0732 232 Trip: Low Stage High Oil Pressure
45234 N50:233 AI0733 233 Trip: Low Stage High Oil Temperature
45235 N50:234 AI0734 234 Trip: Low Stage Low Oil Pressure
45236 N50:235 AI0735 235 Trip: Low Stage Low Oil Temperature
45237 N50:236 AI0736 236 Trip: Low Stage Motor Must Be Uncoupled
45238 N50:237 AI0737 237 Trip: Low Stage Motor Interlock Lost
45239 N50:238 AI0738 238 Trip: Low Stage Oil Pump Didn’t Start
45240 N50:239 AI0739 239 Trip: Low Stage Prox Is Uncalibrated
45241 N50:240 AI0740 240 Trip: Power Failure Detected
45242 N50:241 AI0741 241 Trip: Major Fault
45243 N50:242 AI0742 242 Trip: High Stage Main Motor Starter Fault
45244 N50:243 AI0743 243 Trip: Low Stage Main Motor Starter Fault
45245 N50:244 AI0744 244 Trip: Excess Motor Starts In 24 Hour Period
45246 N50:245 AI0745 245 Trip: R1 Safety Relay Not Set
45247 N50:246 AI0746 246 Trip: Rack 0 Communication Failure
45248 N50:247 AI0747 247 Trip: Rack 1 Communication Failure
Trip: A Thrust Proximitor Is Tripped (Call Factory
45249 N50:248 AI0748 248
Service)

JOHNSON CONTROLS 169

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
45250 N50:249 AI0749 249 Trip: Low Stage Oil Pump Did Not Make Setpoint
Trip: High Stage Oil Pump Did Not Make
45251 N51:0 AI0750 250
Setpoint
45252 N51:1 AI0751 251
45253 N51:2 AI0752 252
45254 N51:3 AI0753 253
45255 N51:4 AI0754 254
45256 N51:5 AI0755 255
45257 N51:6 AI0756 256
45258 N51:7 AI0757 257
45259 N51:8 AI0758 258
45260 N51:9 AI0759 259
45261 N51:10 AI0760 260
45262 N51:11 AI0761 261
45263 N51:12 AI0762 262
45264 N51:13 AI0763 263
45265 N51:14 AI0764 264
45266 N51:15 AI0765 265
45267 N51:16 AI0766 266
45268 N51:17 AI0767 267
45269 N51:18 AI0768 268
45270 N51:19 AI0769 269
45271 N51:20 AI0770 270
Blank
45272 N51:21 AI0771 271
45273 N51:22 AI0772 272
45274 N51:23 AI0773 273
45275 N51:24 AI0774 274
45276 N51:25 AI0775 275
45277 N51:26 AI0776 276
45278 N51:27 AI0777 277
45279 N51:28 AI0778 278
45280 N51:29 AI0779 279
45281 N51:30 AI0780 280
45282 N51:31 AI0781 281
45283 N51:32 AI0782 282
45284 N51:33 AI0783 283
45285 N51:34 AI0784 284
45286 N51:35 AI0785 285
45287 N51:36 AI0786 286
45288 N51:37 AI0787 287
45289 N51:38 AI0788 288
45290 N51:39 AI0789 289
45291 N51:40 AI0790 290

170 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
45292 N51:41 AI0791 291
45293 N51:42 AI0792 292
45294 N51:43 AI0793 293
45295 N51:44 AI0794 294
45296 N51:45 AI0795 295
45297 N51:46 AI0796 296
45298 N51:47 AI0797 297
45299 N51:48 AI0798 298
45300 N51:49 AI0799 299
45301 N51:50 AI0800 300
45302 N51:51 AI0801 301
45303 N51:52 AI0802 302
45304 N51:53 AI0803 303
45305 N51:54 AI0804 304 5
45306 N51:55 AI0805 305
45307 N51:56 AI0806 306
45308 N51:57 AI0807 307
45309 N51:58 AI0808 308
45310 N51:59 AI0809 309
45311 N51:60 AI0810 310
45312 N51:61 AI0811 311
45313 N51:62 AI0812 312 Blank
45314 N51:63 AI0813 313
45315 N51:64 AI0814 314
45316 N51:65 AI0815 315
45317 N51:66 AI0816 316
45318 N51:67 AI0817 317
45319 N51:68 AI0818 318
45320 N51:69 AI0819 319
45321 N51:70 AI0820 320
45322 N51:71 AI0821 321
45323 N51:72 AI0822 322
45324 N51:73 AI0823 323
45325 N51:74 AI0824 324
45326 N51:75 AI0825 325
45327 N51:76 AI0826 326
45328 N51:77 AI0827 327
45329 N51:78 AI0828 328
45330 N51:79 AI0829 329
45331 N51:80 AI0830 330
45332 N51:81 AI0831 331
45333 N51:82 AI0832 332
45334 N51:83 AI0833 333

JOHNSON CONTROLS 171

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
45335 N51:84 AI0834 334
45336 N51:85 AI0835 335 Process Stopped - Check Event Log for Details
45337 N51:86 AI0836 336 LS SSS: Spare 1
45338 N51:87 AI0837 337 LS SSS: Invalid Starter Model
45339 N51:88 AI0838 338 LS SSS: Phase Loss
45340 N51:89 AI0839 339 LS SSS: Phase Locked Loop Alarm
45341 N51:90 AI0840 340 LS SSS: Power Fault
45342 N51:91 AI0841 341 LS SSS: Run Signal Alarm
45343 N51:92 AI0842 342 LS SSS: Current Imbalance
45344 N51:93 AI0843 343 LS SSS: Current Overload
45345 N51:94 AI0844 344 LS SSS: High Instantaneous Current
45346 N51:95 AI0845 345 LS SSS: High Line Voltage
45347 N51:96 AI0846 346 LS SSS: Low Line Voltage
45348 N51:97 AI0847 347 LS SSS: Open Scr
45349 N51:98 AI0848 348 LS SSS: Phase A Shorted Scr
45350 N51:99 AI0849 349 LS SSS: Phase B Shorted Scr
45351 N51:100 AI0850 350 LS SSS: Phase C Shorted Scr
45352 N51:101 AI0851 351 LS SSS: Phase A Inhibit High Temp
45353 N51:102 AI0852 352 LS SSS: Phase B Inhibit High Temp
45354 N51:103 AI0853 353 LS SSS: Phase C Inhibit High Temp
45355 N51:104 AI0854 354 LS SSS: Phase A High Temp
45356 N51:105 AI0855 355 LS SSS: Phase B High Temp
45357 N51:106 AI0856 356 LS SSS: Phase C High Temp
45358 N51:107 AI0857 357 LS SSS: Phase A Open Thermocouple
45359 N51:108 AI0858 358 LS SSS: Phase B Open Thermocouple
45360 N51:109 AI0859 359 LS SSS: Phase C Open Thermocouple
45361 N51:110 AI0860 360 LS SSS: Serial Receive Err
45362 N51:111 AI0861 361 LS SSS: Spare 26
45363 N51:112 AI0862 362 LS SSS: Spare 27
45364 N51:113 AI0863 363 LS SSS: Power Supply Fault
45365 N51:114 AI0864 364 LS SSS: Phase Rotation Fault
45366 N51:115 AI0865 365 LS SSS: Spare 30
45367 N51:116 AI0866 366 LS SSS: Spare 31
45368 N51:117 AI0867 367 LS SSS: Spare 32
45369 N51:118 AI0868 368 HS SSS: Spare 1
45370 N51:119 AI0869 369 HS SSS: Invalid Starter Model
45371 N51:120 AI0870 370 HS SSS: Phase Loss
45372 N51:121 AI0871 371 HS SSS: Phase Locked Loop Alarm
45373 N51:122 AI0872 372 HS SSS: Power Fault
45374 N51:123 AI0873 373 HS SSS: Run Signal Alarm
45375 N51:124 AI0874 374 HS SSS: Current Imbalance
45376 N51:125 AI0875 375 HS SSS: Current Overload

172 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
45377 N51:126 AI0876 376 HS SSS: High Instantaneous Current
45378 N51:127 AI0877 377 HS SSS: High Line Voltage
45379 N51:128 AI0878 378 HS SSS: Low Line Voltage
45380 N51:129 AI0879 379 HS SSS: Open SCR
45381 N51:130 AI0880 380 HS SSS: Phase A Shorted SCR
45382 N51:131 AI0881 381 HS SSS: Phase B Shorted SCR
45383 N51:132 AI0882 382 HS SSS: Phase C Shorted SCR
45384 N51:133 AI0883 383 HS SSS: Phase A Inhibit High Temp
45385 N51:134 AI0884 384 HS SSS: Phase B Inhibit High Temp
45386 N51:135 AI0885 385 HS SSS: Phase C Inhibit High Temp
45387 N51:136 AI0886 386 HS SSS: Phase A High Temp
45388 N51:137 AI0887 387 HS SSS: Phase B High Temp
45389 N51:138 AI0888 388 HS SSS: Phase C High Temp
45390 N51:139 AI0889 389 HS SSS: Phase A Open Thermocouple 5
45391 N51:140 AI0890 390 HS SSS: Phase B Open Thermocouple
45392 N51:141 AI0891 391 HS SSS: Phase C Open Thermocouple
45393 N51:142 AI0892 392 HS SSS: Serial Receive ERR
45394 N51:143 AI0893 393 HS SSS: Spare 26
45395 N51:144 AI0894 394 HS SSS: Spare 27
45396 N51:145 AI0895 395 HS SSS: Power Supply Fault
45397 N51:146 AI0896 396 HS SSS: Phase Rotation Fault
45398 N51:147 AI0897 397 HS SSS: Spare 30
45399 N51:148 AI0898 398 HS SSS: Spare 31
45400 N51:149 AI0899 399 HS SSS: Spare 32
45401 N51:150 AI0900 400
45402 N51:151 AI0901 401
45403 N51:152 AI0902 402 Blank
45404 N51:153 AI0903 403
45405 N51:154 AI0904 404
45406 N51:155 AI0905 405
45407 N51:156 AI0906 406
45408 N51:157 AI0907 407
45409 N51:158 AI0908 408 Blank
45410 N51:159 AI0909 409
45411 N51:160 AI0910 410
45412 N51:161 AI0911 411
45413 N51:162 AI0912 412 Low Auxiliary Analog Input #1 Sensor Warning
45414 N51:163 AI0913 413 High Auxiliary Analog Input #1 Sensor Warning
45415 N51:164 AI0914 414 Low Auxiliary Analog Input #2 Sensor Warning
45416 N51:165 AI0915 415 High Auxiliary Analog Input #2 Sensor Warning
45417 N51:166 AI0916 416 Low Auxiliary Analog Input #3 Sensor Warning
45418 N51:167 AI0917 417 High Auxiliary Analog Input #3 Sensor Warning

JOHNSON CONTROLS 173

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 14 - QUANTUM LX FOR CYK PROTOCOL LIST (CONT'D)

S/W REVISION 1.13
ALLEN-
MODBUS BACNET OFFSET DESCRIPTION REMARK
BRADLEY
45419 N51:168 AI0918 418 Low Auxiliary Analog Input #4 Sensor Warning
45420 N51:169 AI0919 419 High Auxiliary Analog Input #4 Sensor Warning
45421 N51:170 AI0920 420 Low Auxiliary Analog Input #5 Sensor Warning
45422 N51:171 AI0921 421 High Auxiliary Analog Input #5 Sensor Warning
45423 N51:172 AI0922 422 Low Auxiliary Analog Input #6 Sensor Warning
45424 N51:173 AI0923 423 High Auxiliary Analog Input #6 Sensor Warning
45425 N51:174 AI0924 424 Low Auxiliary Analog Input #7 Sensor Warning
45426 N51:175 AI0925 425 High Auxiliary Analog Input #7 Sensor Warning
45427 N51:176 AI0926 426 Low Auxiliary Analog Input #8 Sensor Warning
45428 N51:177 AI0927 427 High Auxiliary Analog Input #8 Sensor Warning
45429 N51:178 AI0928 428 Low Auxiliary Analog Input #9 Sensor Warning
45430 N51:179 AI0929 429 High Auxiliary Analog Input #9 Sensor Warning
45431 N51:180 AI0930 430 Low Auxiliary Analog Input #10 Sensor Warning
45432 N51:181 AI0931 431 High Auxiliary Analog Input #10 Sensor Warning
45433 N51:182 AI0932 432 Low Auxiliary Analog Input #11 Sensor Warning
45434 N51:183 AI0933 433 High Auxiliary Analog Input #11 Sensor Warning
45435 N51:184 AI0934 434 Low Auxiliary Analog Input #12 Sensor Warning
45436 N51:185 AI0935 435 High Auxiliary Analog Input #12 Sensor Warning
45437 N51:186 AI0936 436 Low Auxiliary Analog Input #13 Sensor Warning
45438 N51:187 AI0937 437 High Auxiliary Analog Input #13 Sensor Warning
45439 N51:188 AI0938 438 Low Auxiliary Analog Input #14 Sensor Warning
45440 N51:189 AI0939 439 High Auxiliary Analog Input #14 Sensor Warning
45441 N51:190 AI0940 440 Low Auxiliary Analog Input #15 Sensor Warning
45442 N51:191 AI0941 441 High Auxiliary Analog Input #15 Sensor Warning
45443 N51:192 AI0942 442 Low Auxiliary Analog Input #16 Sensor Warning
45444 N51:193 AI0943 443 High Auxiliary Analog Input #16 Sensor Warning
45445 N51:194 AI0944 444 Low Auxiliary Analog Input #17 Sensor Warning
45446 N51:195 AI0945 445 High Auxiliary Analog Input #17 Sensor Warning
45447 N51:196 AI0946 446 Low Auxiliary Analog Input #18 Sensor Warning
45448 N51:197 AI0947 447 High Auxiliary Analog Input #18 Sensor Warning
45449 N51:198 AI0948 448 Low Auxiliary Analog Input #19 Sensor Warning
45450 N51:199 AI0949 449 High Auxiliary Analog Input #19 Sensor Warning
45451 N51:200 AI0950 450 Low Auxiliary Analog Input #20 Sensor Warning
45452 N51:201 AI0951 451 High Auxiliary Analog Input #20 Sensor Warning

X10 X10 FLOAT SYSTEM PARAMETERS

47173 N101:72 AI1000 172 Single To 2-Stage Setpoint (differential pressure) Compare to system head
47174 N101:73 AI1001 173 2-Stage To Single Setpoint (differential pressure) Compare to system head
Immediate 2-Stage Threshold (differential tem- Compare to
47175 N101:74 AI1002 174
perature) (ECdWT-EChWT)

174 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

Table 15 - LIST ALARM CODES

CYK QUANTUMLX PRESENT ALARM CODES CYK QUANTUMLX PRESENT ALARM CODES
CODE CODE
AS DEFINED BY REGISTERS 43071 - 43080 AS DEFINED BY REGISTERS 43071 - 43080
0 System Ok 440
10 450
Blank
20 460
30 Warning: Vane Motor Switches Not Closed 470
40 Warning: High Discharge Temperature 480
50 Warning: High Discharge Pressure 490
60 Warning: High Stage Proximity Forward 500
70 Warning: High Stage Proximity Reverse 510
80 Warning: High Stage High Oil Pressure 520
90 Warning: High Stage High Oil Temperature 530 Blank
100 Warning: High Stage Interlock W/O Run 540
110 Warning: Low Discharge Temp On High Stage 550
120 Warning: High Stage Low Oil Pressure 560
130 Warning: High Stage Low Oil Temperature 570
140 Warning: Low Stage Interlock W/O Run 580 5
150 Warning: High Hs Oil Reservoir Level 590
160 Warning: Low Hs Oil Reservoir Level 600
170 Warning: High Economizer Refrig. Press 610
180 Warning: High Interstage Pressure 620
190 Warning: Invalid Antisurge Parameters Entered 630 Auxiliary Input 1 Shutdown
200 Blank 640 Auxiliary Input 1 Warning
210 Warning: Low Evaporator Pressure 650 Auxiliary Input 2 Shutdown
220 Blank 660 Auxiliary Input 2 Warning
230 Warning: Low Leaving Chilled Water Temp 670 Auxiliary Input 3 Shutdown
240 Warning: Low Stage Proximitor Forward 680 Auxiliary Input 3 Warning
250 Warning: Low Stage Proximitor Reverse 690 Auxiliary Input 4 Shutdown
260 Warning: Low Stage High Oil Pressure 700 Auxiliary Input 4 Warning
270 Warning: Low Stage High Oil Temperature 710 Auxiliary Input 5 Shutdown
280 Warning: Low Stage Interlock W/O Run 720 Auxiliary Input 5 Warning
290 Warning: Low Stage Low Oil Pressure 730 Auxiliary Input 6 Shutdown
300 Warning: Low Stage Low Oil Temperature 740 Auxiliary Input 6 Warning
310 Warning: Low Stage Motor Current W/O Run 750 Auxiliary Input 7 Shutdown
320 Warning: Low Stage High Reservoir Level 760 Auxiliary Input 7 Warning
330 Warning: Low Stage Low Reservoir Level 770 Auxiliary Input 8 Shutdown
340 Warning: Remote Start Denied / Check Mode 780 Auxiliary Input 8 Warning
350 Warning: Check Battery 790 Auxiliary Input 9 Shutdown
360 Warning: High Stage Motor Current W/O Run 800 Auxiliary Input 9 Warning
370 Warning: High Economizer Vessel Level 810 Auxiliary Input 10 Shutdown
380 Warning: Sideload Forced Closed, High Level 820 Auxiliary Input 10 Warning
390 Warning: High Sideload Differential 830 High Auxiliary Analog 1 Shutdown
400 Warning: Hs Oil Drain Not Open 840 High Auxiliary Analog 1 Warning
410 Warning: Hs Oil Drain Not Closed 850 Low Auxiliary Analog 1 Shutdown
420 Warning: Hs Thrust Probe Cal Active 860 Low Auxiliary Analog 1 Warning
430 Warning: Ls Thrust Probe Cal Active 870 High Auxiliary Analog 2 Shutdown

JOHNSON CONTROLS 175

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 15 - LIST ALARM CODES (CONT'D)

CYK QUANTUMLX PRESENT ALARM CODES CYK QUANTUMLX PRESENT ALARM CODES
CODE CODE
AS DEFINED BY REGISTERS 43071 - 43080 AS DEFINED BY REGISTERS 43071 - 43080
880 High Auxiliary Analog 2 Warning 1310 Auxiliary Input 11 Shutdown
890 Low Auxiliary Analog 2 Shutdown 1320 Auxiliary Input 11 Warning
900 Low Auxiliary Analog 2 Warning 1330 Auxiliary Input 12 Shutdown
910 High Auxiliary Analog 3 Shutdown 1340 Auxiliary Input 12 Warning
920 High Auxiliary Analog 3 Warning 1350 Auxiliary Input 13 Shutdown
930 Low Auxiliary Analog 3 Shutdown 1360 Auxiliary Input 13 Warning
940 Low Auxiliary Analog 3 Warning 1370 Auxiliary Input 14 Shutdown
950 High Auxiliary Analog 4 Shutdown 1380 Auxiliary Input 14 Warning
960 High Auxiliary Analog 4 Warning 1390 Auxiliary Input 15 Shutdown
970 Low Auxiliary Analog 4 Shutdown 1400 Auxiliary Input 15 Warning
980 Low Auxiliary Analog 4 Warning 1410 Auxiliary Input 16 Shutdown
990 High Auxiliary Analog 5 Shutdown 1420 Auxiliary Input 16 Warning
1000 High Auxiliary Analog 5 Warning 1430 Auxiliary Input 17 Shutdown
1010 Low Auxiliary Analog 5 Shutdown 1440 Auxiliary Input 17 Warning
1020 Low Auxiliary Analog 5 Warning 1450 Auxiliary Input 18 Shutdown
1030 High Auxiliary Analog 6 Shutdown 1460 Auxiliary Input 18 Warning
1040 High Auxiliary Analog 6 Warning 1470 Auxiliary Input 19 Shutdown
1050 Low Auxiliary Analog 6 Shutdown 1480 Auxiliary Input 19 Warning
1060 Low Auxiliary Analog 6 Warning 1490 Auxiliary Input 20 Shutdown
1070 High Auxiliary Analog 7 Shutdown 1500 Auxiliary Input 20 Warning
1080 High Auxiliary Analog 7 Warning 1510 High Auxiliary Analog 11 Shutdown
1090 Low Auxiliary Analog 7 Shutdown 1520 High Auxiliary Analog 11 Warning
1100 Low Auxiliary Analog 7 Warning 1530 Low Auxiliary Analog 11 Shutdown
1110 High Auxiliary Analog 8 Shutdown 1540 Low Auxiliary Analog 11 Warning
1120 High Auxiliary Analog 8 Warning 1550 High Auxiliary Analog 12 Shutdown
1130 Low Auxiliary Analog 8 Shutdown 1560 High Auxiliary Analog 12 Warning
1140 Low Auxiliary Analog 8 Warning 1570 Low Auxiliary Analog 12 Shutdown
1150 High Auxiliary Analog 9 Shutdown 1580 Low Auxiliary Analog 12 Warning
1160 High Auxiliary Analog 9 Warning 1590 High Auxiliary Analog 13 Shutdown
1170 Low Auxiliary Analog 9 Shutdown 1600 High Auxiliary Analog 13 Warning
1180 Low Auxiliary Analog 9 Warning 1610 Low Auxiliary Analog 13 Shutdown
1190 High Auxiliary Analog 10 Shutdown 1620 Low Auxiliary Analog 13 Warning
1200 High Auxiliary Analog 10 Warning 1630 High Auxiliary Analog 14 Shutdown
1210 Low Auxiliary Analog 10 Shutdown 1640 High Auxiliary Analog 14 Warning
1220 Low Auxiliary Analog 10 Warning 1650 Low Auxiliary Analog 14 Shutdown
1230 1660 Low Auxiliary Analog 14 Warning
1240 1670 High Auxiliary Analog 15 Shutdown
1250 1680 High Auxiliary Analog 15 Warning
1260 1690 Low Auxiliary Analog 15 Shutdown
Blank
1270 1700 Low Auxiliary Analog 15 Warning
1280 1710 High Auxiliary Analog 16 Shutdown
1290 1720 High Auxiliary Analog 16 Warning
1300 1730 Low Auxiliary Analog 16 Shutdown

176 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 15 - LIST ALARM CODES (CONT'D)

CYK QUANTUMLX PRESENT ALARM CODES CYK QUANTUMLX PRESENT ALARM CODES
CODE CODE
AS DEFINED BY REGISTERS 43071 - 43080 AS DEFINED BY REGISTERS 43071 - 43080
1740 Low Auxiliary Analog 16 Warning 2170 Trip: High Stage Low Oil Temperature
1750 High Auxiliary Analog 17 Shutdown 2180 Trip: High Stage Motor Must Be Uncoupled
1760 High Auxiliary Analog 17 Warning 2190 Trip: High Stage Motor Interlock Lost
1770 Low Auxiliary Analog 17 Shutdown 2200 Trip: High Stage Oil Pump Didn't Start
1780 Low Auxiliary Analog 17 Warning 2210 Trip: High Stage Prox Is Uncalibrated
1790 High Auxiliary Analog 18 Shutdown 2220 Trip: High Economizer Refrig. Press
1800 High Auxiliary Analog 18 Warning 2230 Trip: High Interstage Pressure
1810 Low Auxiliary Analog 18 Shutdown 2240 Trip: Hs Compressor Thrust Bearing Switch Fail
1820 Low Auxiliary Analog 18 Warning 2250 Blank
1830 High Auxiliary Analog 19 Shutdown 2260 Trip: Ls Compressor Thrust Bearing Switch Fail
1840 High Auxiliary Analog 19 Warning 2270 Trip: Low Evaporator Pressure
1850 Low Auxiliary Analog 19 Shutdown 2280 Blank
1860 Low Auxiliary Analog 19 Warning 2290 Trip: Low Leaving Water Temperature
1870 High Auxiliary Analog 20 Shutdown 2300 Trip: Low Stage Proximity Forward
1880 High Auxiliary Analog 20 Warning 2310 Trip: Low Stage Proximity Reverse 5
1890 Low Auxiliary Analog 20 Shutdown 2320 Trip: Low Stage High Oil Pressure
1900 Low Auxiliary Analog 20 Warning 2330 Trip: Low Stage High Oil Temperature
1910 Analog Board 1 Communications Shutdown 2340 Trip: Low Stage Low Oil Pressure
1920 Analog Board 2 Communications Shutdown 2350 Trip: Low Stage Low Oil Temperature
1930 Digital Board 1 Communications Shutdown 2360 Trip: Low Stage Motor Must Be Uncoupled
1940 Digital Board 2 Communications Shutdown 2370 Trip: Low Stage Motor Interlock Lost
1950 Analog Board 3 Communications Shutdown 2380 Trip: Low Stage Oil Pump Didn’t Start
1960 Digital Board 1 Reset 2390 Trip: Low Stage Prox Is Uncalibrated
1970 Digital Board 2 Reset 2400 Trip: Power Failure Detected
1980 2410 Trip: Major Fault
1990 Blank 2420 Trip: High Stage Main Motor Starter Fault
2000 2430 Trip: Low Stage Main Motor Starter Fault
2010 Trip: +5 Volt Supply Has Failed 2440 Trip: Excess Motor Starts In 24 Hour Period
2020 Trip: Bypass Didn’t Close 2450 Trip: R1 Safety Relay Not Set
2030 Trip: Bypass Didn't Open 2460 Trip: Rack 0 Communication Failure
2040 Trip: Low Chilled Flow Switch 2470 Trip: Rack 1 Communication Failure
2050 Trip: Low Condenser Flow Switch Trip: A Thrust Proximitor Is Tripped (Call Factory
2480
2060 Blank Service)
2070 Trip: Emergency Stop Pulled 2490 Trip: Low Stage Oil Pump Did Not Make Setpoint
2080 Blank Trip: High Stage Oil Pump Did Not Make
2500
Setpoint
2090 Trip: High Discharge Temperature
2510 Trip: Low Stage High Motor Current
2100 Trip: High Discharge Pressure
2520 Trip: High Stage High Motor Current
2110 Trip: High Pressure Cutout
2530 Trip: SSS Communications Failure
2120 Trip: High Stage Proximitor Forward
2540 Trip: LS Oil Pressure Sensors Will Not Zero
2130 Trip: High Stage Proximitor Reverse
2550 Trip: HS Oil Pressure Sensors Will Not Zero
2140 Trip: High Stage High Oil Pressure
2560 Trip: Excessive Surge
2150 Trip: High Stage High Oil Temperature
2160 Trip: High Stage Low Oil Pressure

JOHNSON CONTROLS 177

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 15 - LIST ALARM CODES (CONT'D)

CYK QUANTUMLX PRESENT ALARM CODES CYK QUANTUMLX PRESENT ALARM CODES
CODE CODE
AS DEFINED BY REGISTERS 43071 - 43080 AS DEFINED BY REGISTERS 43071 - 43080
2570 2990
2580 3000
2590 3010
2600 3020
2610 3030
2620 3040
2630 3050
2640 3060
2650 3070
2660 3080
2670 3090
2680 3100
2690 3110
2700 3120
2710 3130
2720 3140
2730 3150
2740 3160
Blank
2750 3170
2760 3180
2770 3190
Blank
2780 3200
2790 3210
2800 3220
2810 3230
2820 3240
2830 3250
2840 3260
2850 3270
2860 3280
2870 3290
2880 3300
2890 3310
2900 3320
2910 3330
2920 3340
2930 3350 Process Stopped - Check Event Log For Details
2940 3360 LS SSS: Spare 1
2950 3370 LS SSS: Invalid Starter Model
2960 3380 LS SSS: Phase Loss
2970 3390 LS SSS: Phase Locked Loop Alarm
2980 3400 LS SSS: Power Fault
3410 LS SSS: Run Signal Alarm

178 JOHNSON CONTROLS

FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 15 - LIST ALARM CODES (CONT'D)

CYK QUANTUMLX PRESENT ALARM CODES CYK QUANTUMLX PRESENT ALARM CODES
CODE CODE
AS DEFINED BY REGISTERS 43071 - 43080 AS DEFINED BY REGISTERS 43071 - 43080
3420 LS SSS: Current Imbalance 3850 HS SSS: Phase C Inhibit High Temp
3430 LS SSS: Current Overload 3860 HS SSS: Phase A High Temp
3440 LS SSS: High Instantaneous Current 3870 HS SSS: Phase B High Temp
3450 LS SSS: High Line Voltage 3880 HS SSS: Phase C High Temp
3460 LS SSS: Low Line Voltage 3890 HS SSS: Phase A Open Thermocouple
3470 LS SSS: Open Scr 3900 HS SSS: Phase B Open Thermocouple
3480 LS SSS: Phase A Shorted Scr 3910 HS SSS: Phase C Open Thermocouple
3490 LS SSS: Phase B Shorted Scr 3920 HS SSS: Serial Receive Err
3500 LS SSS: Phase C Shorted Scr 3930 HS SSS: Spare 26
3510 LS SSS: Phase A Inhibit High Temp 3940 HS SSS: Spare 27
3520 LS SSS: Phase B Inhibit High Temp 3950 HS SSS: Power Supply Fault
3530 LS SSS: Phase C Inhibit High Temp 3960 HS SSS: Phase Rotation Fault
3540 LS SSS: Phase A High Temp 3970 HS SSS: Spare 30
3550 LS SSS: Phase B High Temp 3980 HS SSS: Spare 31
3560 LS SSS: Phase C High Temp 3990 HS SSS: Spare 32 5
3570 LS SSS: Phase A Open Thermocouple 4000
3580 LS SSS: Phase B Open Thermocouple 4010
3590 LS SSS: Phase C Open Thermocouple 4020
3600 LS SSS: Serial Receive Err 4030
3610 LS SSS: Spare 26 4040
3620 LS SSS: Spare 27 4050
Blank
3630 LS SSS: Power Supply Fault 4060
3640 LS SSS: Phase Rotation Fault 4070
3650 LS SSS: Spare 30 4080
3660 LS SSS: Spare 31 4090
3670 LS SSS: Spare 32 4100
3680 HS SSS: Spare 1 4110
3690 HS SSS: Invalid Starter Model 4120 Low Auxiliary Analog Input #1 Sensor Warning
3700 HS SSS: Phase Loss 4130 High Auxiliary Analog Input #1 Sensor Warning
3710 HS SSS: Phase Locked Loop Alarm 4140 Low Auxiliary Analog Input #2 Sensor Warning
3720 HS SSS: Power Fault 4150 High Auxiliary Analog Input #2 Sensor Warning
3730 HS SSS: Run Signal Alarm 4160 Low Auxiliary Analog Input #3 Sensor Warning
3740 HS SSS: Current Imbalance 4170 High Auxiliary Analog Input #3 Sensor Warning
3750 HS SSS: Current Overload 4180 Low Auxiliary Analog Input #4 Sensor Warning
3760 HS SSS: High Instantaneous Current 4190 High Auxiliary Analog Input #4 Sensor Warning
3770 HS SSS: High Line Voltage 4200 Low Auxiliary Analog Input #5 Sensor Warning
3780 HS SSS: Low Line Voltage 4210 High Auxiliary Analog Input #5 Sensor Warning
3790 HS SSS: Open Scr 4220 Low Auxiliary Analog Input #6 Sensor Warning
3800 HS SSS: Phase A Shorted Scr 4230 High Auxiliary Analog Input #6 Sensor Warning
3810 HS SSS: Phase B Shorted Scr 4240 Low Auxiliary Analog Input #7 Sensor Warning
3820 HS SSS: Phase C Shorted Scr 4250 High Auxiliary Analog Input #7 Sensor Warning
3830 HS SSS: Phase A Inhibit High Temp 4260 Low Auxiliary Analog Input #8 Sensor Warning
3840 HS SSS: Phase B Inhibit High Temp 4270 High Auxiliary Analog Input #8 Sensor Warning

JOHNSON CONTROLS 179

 FORM 160.82-OM1
SECTION 5 - SYSTEM COMMUNICATION AND NETWORKING
ISSUE DATE: 8/30/2013

TABLE 15 - LIST ALARM CODES (CONT'D)

CYK QUANTUMLX PRESENT ALARM CODES
CODE
AS DEFINED BY REGISTERS 43071 - 43080
4280 Low Auxiliary Analog Input #9 Sensor Warning
4290 High Auxiliary Analog Input #9 Sensor Warning
4300 Low Auxiliary Analog Input #10 Sensor Warning
4310 High Auxiliary Analog Input #10 Sensor Warning
4320 Low Auxiliary Analog Input #11 Sensor Warning
4330 High Auxiliary Analog Input #11 Sensor Warning
4340 Low Auxiliary Analog Input #12 Sensor Warning
4350 High Auxiliary Analog Input #12 Sensor Warning
4360 Low Auxiliary Analog Input #13 Sensor Warning
4370 High Auxiliary Analog Input #13 Sensor Warning
4380 Low Auxiliary Analog Input #14 Sensor Warning
4390 High Auxiliary Analog Input #14 Sensor Warning
4400 Low Auxiliary Analog Input #15 Sensor Warning
4410 High Auxiliary Analog Input #15 Sensor Warning
4420 Low Auxiliary Analog Input #16 Sensor Warning
4430 High Auxiliary Analog Input #16 Sensor Warning
4440 Low Auxiliary Analog Input #17 Sensor Warning
4450 High Auxiliary Analog Input #17 Sensor Warning
4460 Low Auxiliary Analog Input #18 Sensor Warning
4470 High Auxiliary Analog Input #18 Sensor Warning
4480 Low Auxiliary Analog Input #19 Sensor Warning
4490 High Auxiliary Analog Input #19 Sensor Warning
4500 Low Auxiliary Analog Input #20 Sensor Warning
4510 High Auxiliary Analog Input #20 Sensor Warning

180 JOHNSON CONTROLS

FORM 160.82-OM1
ISSUE DATE: 8/30/2013

SECTION 6 - TROUBLESHOOTING

When there is a problem that makes no sense due to • Check that you are using the Frick recom-
unexplainable things happening, check the following: mended communications cable.
1. Is the panel powered by an isolating power source 11. If this is an older plant, has the plant wiring been
such as a control transformer in the starter panel? brought up to code?
2. Is the panel powered from a lighting or utility 12. Do you have power wiring mixed with control,
panel? sensor or communications wiring?
3. It is important to know if the unit ever worked 13. Check that the starter panel is grounded to the
properly. plant transformer. There are usually four wires: 3
for the 3 phases and 1 for plant ground.
4. If the unit used to work properly, try to determine
when the problem first showed up. 14. Check that the motor is grounded to the starter
panel. There are usually four wires: 3 for the phas-
5. It is important to know if the problem occurs ran- es and 1 for ground.
domly, frequently, or all the time.
15. Ensure that one side of the motor current trans-
6. Check what the temperature is in the engine room former is grounded in the motor starter panel. The
and at the panel. Is it very hot or very cold? Make wire to the control panel terminal #2 is usually the
sure that the motor is not blowing exhaust air on only one grounded.
the control panel.
16. Check that the temperature transducers are prop-
7. If it just started to act up, then check if there was erly grounded. The temperature probes usually
recently a severe lightning storm, fire, flood, or a have two short wires coming out of the sensor, 6
plant accident. If any of the following conditions and are tied to a shielded cable at the thermal well
are possible, then check for it: head. The shield is insulated at the temperature
Has any water, refrigerant, or oil leaked into the probe and grounded at the panel end.
panel or conduit? 17. Check if one of the temperature probes has a signal
8. If it just started to act up, then check if anything wire shorted to machine ground. To do this, first
was recently changed in the system (i.e. software pull the orange plug from the micro board and then
or hardware.) use a DVM and check each white wire to machine
ground and each black wire to machine ground.
9. If it just started to act up, then check if any service
was recently done to the chiller or its electrical 18. Check that all inductive loads (i.e. coils, sole-
system? noids, or relays, etc.) connected to the I/O out-
put modules have surge suppressors across them,
10. If there is communication wiring connecting the preferably at the devices. Most of the larger fac-
panel to another panel or device, then check the tory installed inductive loads should have surge
following: suppressors as well.
• If the Quantum™ LX is unexplainably shut- 19. If the chiller control settings unexplainably change
ting down, try disconnecting the communi- modes, it may be a noise problem affecting the
cations cable to see if the problem goes away. keypad’s input circuit. Check if it works OK with
• Check if the communications cable shields the keypad cable disconnected. If it works OK,
are tied to machine ground at only one lo- then check the grounding as described above. If
cation. For a PLC or Opto22 based system, the grounding is OK then replace the keypad.
the shield should normally be tied only at the 20. Make sure that you have a continuous ground
PLC or Opto22 panel. For dual sequencing back to the power source. The ground connection
machines, the shield should only be tied to must be copper. A conduit ground will not work.
ground in one panel, typically the “Lead” Do not drive a ground stake at the chiller since
machine. extraneous currents will be attracted to the chiller.

JOHNSON CONTROLS 181

 FORM 160.82-OM1
SECTION 6 - TROUBLESHOOTING
ISSUE DATE: 8/30/2013

21. Make sure that there is no AC wiring lying next to

the printed circuit board.
22. Unexplainable chiller auxiliary failures are usual-
ly indicative of noise due to wiring problems (i.e.
incorrect earth grounds, mixed power and control
wiring, unsuppressed coils, etc)
23. If the chiller is unexplainably shutting down,
check if the machine shares control transformer
power with something else. Make sure each chill-
er has its own isolation transformer in the motor
control center off the three-phase bus with the sec-
ondary properly grounded.

182 JOHNSON CONTROLS

FORM 160.82-OM1
ISSUE DATE: 8/30/2013

The following factors can be used to convert from

English to the most common SI Metric values.

Table 16 - 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 183

P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2011 www.johnsoncontrols.com ALL RIGHTS RESERVED
Form 160.82-OM1 (813)
Issue Date: August 30, 2013
Supersedes: 160.82-OM1 (611)