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YORK CHILLER 371 03788 336

YORK CHILLER 371 03788 336

    • YORK CHILLER 371 03788 336
    • YORK CHILLER 371 03788 336
    • YORK CHILLER 371 03788 336
  • YORK CHILLER 371 03788 336

    Product Details:

    Place of Origin: USA
    Brand Name: YORK/JCI
    Model Number: 371 03788 336
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    Detailed Product Description

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    VARIABLE SPEED DRIVE RENEWAL PARTS Supersedes: 160.00-RP4 (1012) Form 160.00-RP4 (813) 292 HP – 50 HZ, 400VAC (P/N 371-03700-XXX) 351 HP – 60 HZ, 460VAC (P/N 371-02767-XXX) 419 HP – 50 HZ, 400VAC (P/N 371-03789-XXX) 424 HP – 60 HZ, 575VAC (P/N 371-04881-XXX) 503 HP – 60 HZ, 460VAC (P/N 371-03789-XXX) 608 HP – 60 HZ, 575VAC (P/N 371-04563-XXX) 00616VIP Issue Date: August 30, 2013
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or During installation, operation maintenance or service, death to themselves and people at the site. individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, This document is intended for use by owner-authorized materials under pressure, rotating components, and operating/service personnel. It is expected that these both high and low voltage. Each of these items has the individuals possess independent training that will en- potential, if misused or handled improperly, to cause able them to perform their assigned tasks properly and bodily injury or death. It is the obligation and respon- safely. It is essential that, prior to performing any task on this equipment, this individual shall have read and sibility of operating/service personnel to identify and recognize these inherent hazards, protect themselves, understood this document and any referenced mate- rials. This individual shall also be familiar with and and proceed safely in completing their tasks. Failure to comply with any of these requirements could result comply with all applicable governmental standards and in serious damage to the equipment and the property in regulations pertaining to the task in question. SAFETY SYMBOLS The following symbols are used in this document to alert the reader to specific situations: Indicates a possible hazardous situation ,GHQWL¿HVDKD]DUGZKLFKFRXOGOHDGWR which will result in death or serious injury damage to the machine, damage to other if proper care is not taken. equipment and/or environmental pollu- tion if proper care is not taken or instruc- tions and are not followed. Indicates a potentially hazardous situa- Highlights additional information useful tion which will result in possible injuries to the technician in completing the work or damage to equipment if proper care is being performed properly. not taken. ([WHUQDOZLULQJXQOHVVVSHFL¿HGDVDQRSWLRQDOFRQQHFWLRQLQWKHPDQXIDFWXUHU¶VSURGXFWOLQHLVQRW to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls and any external wiring must not be installed inside the micro panel. All wiring must be in accor- GDQFHZLWK-RKQVRQ&RQWUROV¶SXEOLVKHGVSHFL¿FDWLRQVDQGPXVWEHSHUIRUPHGRQOEDTXDOL¿HG electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of improper control signals. Failure to follow this warn- LQJZLOOYRLGWKHPDQXIDFWXUHU¶VZDUUDQWDQGFDXVHVHULRXVGDPDJHWRSURSHUWRUSHUVRQDOLQMXU 2 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls’ policy for con- these documents, the technician should verify whether tinuous product improvement, the information con- the equipment has been modified and if current litera- tained in this document is subject to change without ture is available from the owner of the equipment prior notice. Johnson Controls makes no commitment to to performing any work on the chiller. update or provide current information automatically to the manual owner. Updated manuals, if applicable, can CHANGE BARS be obtained by contacting the nearest Johnson Controls Revisions made to this document are indicated with a Service office. line along the left or right hand column in the area the Operating/service personnel maintain responsibility for revision was made. These revisions are to technical in- the applicability of these documents to the equipment. formation and any other changes in spelling, grammar If there is any question regarding the applicability of or formatting are not included. Although many of these parts are similar to the parts used in previous Variable Speed Drive (VSD) designs, these parts are only compatible with drives of the following base part numbers (371-02767- XXX, 371-03700-XXX, 371-03787-XXX, 371-04881-XXX, and 371 04563-XXX). For example, if the VSD logic board 031-02077-000 were used in place of the 031-01433-000 logic board, as used on the previous VSD designs, major damage to other components will occur. JOHNSON CONTROLS 3
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 THIS PAGE INTENTIONALLY LEFT BLANK. 4 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LIST OF FIGURES FIGURE 1 - Left Side Of Cabinet (Detailed) 292/351/424 HP .................................................................................17 FIGURE 2 - Left Side Of Cabinet 292/351/424 HP .................................................................................................18 FIGURE 3 - Left Center Of Cabinet 292/351/424 HP ..............................................................................................19 FIGURE 4 - Right Side Of Cabinet 292/351/424 HP ...............................................................................................20 FIGURE 5 - Inside Right Door All Horse Powers.....................................................................................................21 FIGURE 6 - Back Of Cabinet 292/351/424 HP ........................................................................................................22 FIGURE 7 - Cooling System 292/351/424 HP .........................................................................................................23 FIGURE 8 - Cooling System 419/503/608 HP .........................................................................................................24 FIGURE 9 - Left Side Of Cabinet 419/503/608 HP .................................................................................................25 FIGURE 10 - Left Side Of Cabinet (Detailed) 419/503/608 HP ...............................................................................26 FIGURE 11 - Upper Right Side Of Cabinet 419/503/608 HP ..................................................................................27 FIGURE 12 - Opti Speed Power Unit Detail 419/503/608 HP .................................................................................28 FIGURE 13 - Opti Speed Harmonic Filter Power Unit Detail 419/503/608 HP ........................................................29 LIST OF TABLES TABLE 1 - VSD Parts List 292 HP and 351 HP ........................................................................................................7 TABLE 2 - VSD Parts List 424 HP 575 VAC .............................................................................................................9 TABLE 3 - VSD Parts List 419 HP and 503 HP ...................................................................................................... 11 TABLE 4 - VSD Parts List 608 HP 575 VAC ...........................................................................................................13 TABLE 5 - Miscellaneous........................................................................................................................................15 TABLE 6 - SI Metric Conversion .............................................................................................................................31 JOHNSON CONTROLS 5
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 NOTES The footnotes referenced within the tables appear 5. The drive logic and the filter logic replacement below. boards are not shipped with new software. The soft- ware must be removed from the old board and in- 1. On the 292, 351, 419, and 503 Hp drives built stalled in the new board. This also includes the U40 before 5/05, the bleeder resistors have a value of chip on the drive logic board, and the U26 chip on 2K ohms, and required the application of thermal the filter logic board. If there is concern that the old grease. These drives now use a 2.4 K ohm resistor, board had a power supply problem, then new soft- and require the application of a silicon pad. If one of ware may need to be ordered. the 2K ohm resistors were to fail, then both resistors will need to be replaced. The bleeder resistors for 6. Part number 031-02077-000 is no longer available. the harmonic filter will also use a thermal pad, but This part number is replaced with a kit that includes the resistor value does not change. new software and instructions. Installing the old software into the new board may cause a drive fail- 2. The harmonic filter main contactor changed styles ure. in 6/06. The old style was a contactor that used com- pression fittings. The old style is still available as a 7. Part number 031-01632-XXX is no longer avail- repair part, but new production will switch to a style able. This part number is replaced with a kit that of contactor that will accept ring tong lugs. This will includes new software and instructions. When in- improve the installation of a retrofit harmonic filter. stalling the new board 031-02932 board reuse the U42 chip from the old board. 3. The trap assembly on the 424 and 608 Hp drives has a different design than on the other drives. The 3 8. There were cases where the line voltage became resistors at the top of the trap assembly are mounted unstable and caused a single phase fault. Software on a silicon pad. The other drives still need to use was changed to extend the time required for a single thermal grease in the mounting process. phase fault to occur. 4. Snubber modules were added to all styles of drives covered by this parts book. The snubber module protects the input SCR from voltage transients that may occur on the incoming supply voltage. The snubber modules maybe applied on existing drives, but warranty would not apply. 6 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 1 - VSD PARTS LIST 292 HP AND 351 HP ITEM DESCRIPTION PART NUMBER FIGURE 1 AC Line Inductor 025-35176-000 2 2 Bus Isolator Board 031-01624-000 4 3 Bus Plate Kit 371-03710-001 4 62 Bus Snubber Capacitor 025-35972-000 4 4 Circuit Breaker (used before 6/06) 400 Amp 224-30987-000 2 4 Circuit Breaker (used after 6/06) 600 Amp 224-35428-000 2 * Circuit Breaker Operator Door Kit 024-35429-000 * 5 Control Transformer, 120 VAC 60 Hz, 3 KVA 025-31499-000 1 5 Control Transformer, 120 VAC 50 Hz, 3 KVA 025-32983-000 1 6 Coolant Manifold Plastic 371-02767-371 6 6 Coolant Manifold Copper without Harmonic Filter 023-20842-000 7 6 Coolant Manifold Copper with Harmonic Filter 023-20822-000 7 7 Coolant Pump 026-33890-000 6 8 Coolant Reservoir 3” PVC with Fill Plug 371-02767-361 6 * Door Latch 029-25614-000 * 9 2 Pole Fuse Holder (2 per unit) 025-35172-000 1 10 3 Pole Fuse Holder 025-35915-000 1 11 5 AMP Cartridge Fuse (YT Style Chillers 60 Hz) 025-27922-000 1 11 6 AMP Cartridge Fuse (YT Style Chillers 50 Hz) 025-27970-000 1 11 7 AMP Cartridge Fuse (YK Style Chillers 50/60 Hz) 025-25515-000 1 12 10 AMP Cartridge Fuse 025-27971-000 1 13 15 AMP Cartridge Fuse 025-25584-000 1 14 20 AMP Cartridge Fuse 025-28967-000 1 * 50/60 Hz Inverter (used on 50 Hz drive only) 371-02202-101 * 15 ,QSXW5HFWL¿HUV
    6&56&56&5 RQHHDFK.LW 371-03709-001 4 17 Internal Cabinet Fan 025-32557-000 3 18 Internal Cooling Coil 026-37566-000 3 19 Output Current Transformer 531-01672-001 3 20 Power Module Chill Plate Kit 371-05143-001 4 21 Relay, Control Fan / Pump 024-30441-000 4 22 SCR Trigger Board 60 Hz 031-02060-001 4 22 SCR Trigger Board 50 Hz 031-02060-002 4 * SCR Trigger Board Cable Between J7 on Trigger to J1 in Gate Driver Board 571-02767-251 * 23 Shell and Tube Heat Exchanger 026-37572-000 6 * Shell and Tube Heat Exchanger Head Gaskets (set of two) 371-03716-001 * 63 Silicon Pad (1 each) 1 028-15299-000 3, 4 66 Snubber Capacitor (.047uF, 1600 VAC ) 025-35188-000 3 65 Snubber Module as applied to the SCR/Diode module 4 331-02556-001 4 16 Snubber Resistor (10 ohm) 025-35953-000 3 24 Transformer, 24 VAC, Class 2 025-27911-000 4 * Temperature Sensor Supplied on chill plate with the SCR/Diode 571-01484-212 * modules (As Separate Item) 60 Voltage Transient Board 031-02453-000 3 61 Voltage Transient Board Fuses 025-38523-000 3 25 VSD DC Balancing Resistor 1 025-35157-000 4 * Items are NOT shown. 1-8 Important Changes refer to page 6. JOHNSON CONTROLS 7
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 1 - VSD PARTS LIST 292 HP AND 351 HP (CONT'D) ITEM DESCRIPTION PART NUMBER FIGURE VSD Logic Board (if board P/N is 031-02077-000, order this kit) 5, 6 26 331-02506-602 5 (USE ON PART # 371-02767-XXX, and 371-03700-XXX ONLY) VSD Logic Board (if board P/N is 031-02506-002, order this part) 5, 6 (USE ON 26 031-02506-002 5 PART # 371-02767-XXX, & 371-03700-XXX ONLY) 27 VSD Power Module Kit 371-03708-001 4 * VSD Power Unit Complete Kit (IGBT, Capacitors, Heatsink, etc.) 371-02769-401 * * Wiring (J8, J9, and J10 from drive logic board to IGBT module) 571-02767-291 * OPTIONAL HARMONIC FILTER PARTS LIST 292 HP AND 351 HP ITEM DESCRIPTION PART NUMBER FIGURE 2 Bus Isolator Board 031-01624-000 4 3 Bus Plate Kit 371-03710-001 4 62 Bus Snubber Capacitor 025-35972-000 4 * '&&7&DEOH
    FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-02768-271 * * '&&7&DEOH
    FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-02768-272 * 30 Direct Current Transducer, 200 AMP (DCCT) 025-32582-000 4 31 Filter DC Balancing Resistor 025-35955-000 4 32 Filter Inductor 025-35177-000 2 34 Filter Input Fuse 025-32581-000 2 5, 7 Filter Logic Board (if board P/N is 031-01632-031, order this kit) 35 331-02932-631 5 (USE ON PART # 371-02767-XXX, and 371-03700-XXX ONLY) Filter Logic Board (if board P/N is 031-02932-031, order this kit) 5, 7 35 031-02932-031 5 (USE ON PART # 371-02767-XXX, & 371-03700-XXX ONLY) 33 Filter Main Contactor with compression lugs 2 024-30984-000 1 33 Filter Main Contactor use with ring tong lugs 2 024-35434-000 1 36 Filter Power Module Kit 371-03707-001 4 * Filter Power Unit Complete Kit ( IGBT, Capacitors, Heatsink, etc.) 371-02768-401 * 37 Filter Pre-Charge Contactor 024-30985-000 1 38 Filter Pre-Charge Resistor 025-32502-000 1 39 Filter Trap Assembly 371-03711-001 3 64 Filter Trap Resistor Kit ( Trap Resistors only) 371-02768-355 3 40 Input Current Transformer 531-01672-001 1 41 Line Isolator Board 031-02022-000 4 20 Power Module Chill Plate Kit 071-02769-309 4 42 16 Conductor Ribbon Cable - VSD Logic to Filter Logic Jumper 031-01658-000 5 63 Silicon Pad (1 each)1 028-15299-000 4 HARMONIC FILTER UPGRADE KITS (TO RETROFIT FILTER TO A NON-FILTER UNIT) * Filter Upgrade (60 Hz) 351 Hp 371-03717-001 * Filter Upgrade (50 Hz) 292 Hp 371-03717-002 * Items are NOT shown. 1-8 Important Changes refer to page 6. 8 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 2 - VSD PARTS LIST 424 HP 575 VAC ITEM DESCRIPTION PART NUMBER FIGURE 1 AC Line Inductor 025-40388-000 2 2 Bus Isolator Board 031-01624-000 4 3 Bus Plate Kit 371-03710-001 4 62 Bus Snubber Capacitor 025-35972-000 4 4 Circuit Breaker 224-35428-000 2 * Circuit Breaker Operator Door Kit 024-35429-000 * 5 Control Transformer, 120 VAC 60 Hz, 3 KVA 025-40381-000 1 6 Coolant Manifold Copper without Harmonic Filter 023-20842-000 7 6 Coolant Manifold Copper with Harmonic Filter 023-20822-000 7 7 Coolant Pump 026-33890-000 6 8 Coolant Reservoir 3” PVC with Fill Plug 371-02767-361 6 * Door Latch 029-25614-000 * 9 2 Pole Fuse Holder (2) per unit 025-38196-000 1 10 3 Pole Fuse Holder 025-34185-000 1 11 4 AMP Cartridge Fuse (YT Style Chillers 60 Hz) 025-35911-000 1 11 5 AMP Cartridge Fuse (YK Style Chillers 60 Hz) 025-35901-000 1 12 10 AMP Cartridge Fuse 025-35905-000 1 13 12 AMP Cartridge Fuse 025-35906-000 1 14 20 AMP Cartridge Fuse 025-35908-000 1 15 ,QSXW5HFWL¿HUV
    6&56&56&5 RQHHDFK.LW 371-05156-001 4 17 Internal Cabinet Fan 025-32557-000 3 18 Internal Cooling Coil 026-37566-000 3 19 Output Current Transformer 531-01672-001 3 20 Power Module Chill Plate Kit 371-05143-001 4 21 Relay, Control Fan / Pump 024-30441-000 4 22 SCR Trigger Board 60 Hz 031-02060-003 4 * SCR Trigger Board Cable Between J7 on Trigger to J1 on Gate Driver Board 571-02767-251 * 23 Shell and Tube Heat Exchanger 026-37572-000 6 * Shell and Tube Heat Exchanger Head Gaskets (set of two) 371-03716-001 * 63 Silicon Pad (1 each) 028-15299-000 3, 4 66 Snubber Capacitor 025-39806-000 3 65 Snubber Module complete assembly for SCR/Diode module 371-05898-100 4 16 Snubber Resistor 025-35953-000 3 24 Transformer, 24 VAC, Class 2 025-27911-000 4 Temperature Sensor Supplied on chillplate * 571-01484-212 * with the SCR/Diode modules (As Separate Item) 60 Voltage Transient Board 031-02453-001 3 61 Voltage Transient Board Fuses 025-38523-000 3 25 VSD DC Balancing Resistor 025-40408-000 4 VSD Logic Board ( if board P/N is 031-02077-001, order this kit) 5, 6 26 331-02506-603 5 (USE ON PART # 371-04881-XXX ONLY) VSD Logic Board ( if board P/N is 031-02506-003, order this part) 5, 6 26 031-02506-003 5 (USE ON PART # 371-04881-XXX ONLY) 27 VSD Power Module Kit 371-05157-001 4 * VSD Power Unit Complete Kit ( IGBT, Capacitors, Heatsink, etc.) 371-02769-403 * * Wiring (J8, J9, and J10 from drive logic board to IGBT module) 571-02767-291 * * Items are NOT shown. 1-8 Important Changes refer to page 6. JOHNSON CONTROLS 9
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 2 - VSD PARTS LIST 424 HP 575 VAC (CONT'D) OPTIONAL HARMONIC FILTER PARTS LIST 424 HP 575 VAC ITEM DESCRIPTION PART NUMBER FIGURE 2 Bus Isolator Board 031-01624-000 4 3 Bus Plate Kit 371-03710-001 4 62 Bus Snubber Capacitor 025-40526-000 4 * '&&7&DEOH
    FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-02768-271 * * '&&7&DEOH
    FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-02768-272 * 30 Direct Current Current Transducer, 200 AMP (DCCT) 025-32582-000 4 31 Filter DC Balancing Resistor 025-40408-000 4 32 Filter Inductor 025-40374-000 2 34 Filter Input Fuse 025-40404-000 2 Filter Logic Board (if board P/N is 031-01632-101, order this kit) 5, 7 35 331 02932 101 5 (USE ON PART # 371-04881-XXX ONLY) Filter Logic Board (if board P/N is 031-02932-101, order this part) 5, 7 35 031-02932 101 5 (USE ON PART # 371-04881-XXX ONLY) 33 Filter Main Contactor use with ring tong lugs 024-35434-000 1 36 Filter Power Module Kit 371-05158-001 4 * Filter Power Unit Complete Kit ( IGBT, Capacitors, Heatsink, etc.) 371-02768-403 * 37 Filter Pre-Charge Contactor 024-30983-000 1 38 Filter Pre-Charge Resistor 025-40425-000 1 39 Filter Trap Assembly 3 371-04881-349 3 40 Input Current Transformer 531-01672-001 1 41 Line Isolator Board 031-02022-001 4 20 Power Module Chill Plate Kit 071-02769-309 4 42 16 Conductor Ribbon Cable - VSD Logic to Filter Logic Jumper 031-01658-000 5 63 Silicon Pad (1 each) 028-15299-000 3, 4 HARMONIC FILTER UPGRADE KITS (TO RETROFIT FILTER TO A NON-FILTER UNIT) * Filter Upgrade (60 Hz) 424 Hp (575VAC) 371-03717-003 * Items are NOT shown. 1-8 Important Changes refer to page 6. 10 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 3 - VSD PARTS LIST 419 HP AND 503 HP ITEM DESCRIPTION PART NUMBER FIGURE 1 AC Line Inductor 025-38134-000 9 2 Bus Isolator Board 031-01624-000 10 3 Bus Plate Kit 371-04163-001 12 62 Bus Snubber Capacitor 025-35972-000 12 4 Circuit Breaker 224-34025-000 9 * Circuit Breaker Lug Kit 025-34027-000 * 5 Control Transformer, 120 VAC 60 Hz, 3 KVA 025-31499-000 9 5 Control Transformer, 120 VAC 50 Hz, 3 KVA 025-32983-000 9 6 Coolant Manifold Copper with or without Harmonic Filter 023-21710-000 8 7 Coolant Pump 026-33890-000 8 8 Coolant Reservoir 3” PVC with Fill Plug 371-03789-361 8 * Door Latch 029-25614-000 * 9 2 Pole Fuse Holder (2) per unit 025-38196-000 1 10 3 Pole Fuse Holder 025-34185-000 1 11 5 AMP Cartridge Fuse (YT Style Chillers 60 Hz) 025-35901-000 1 11 6 AMP Cartridge Fuse (YT Style Chillers 50 Hz) 025-35902-000 1 11 7 AMP Cartridge Fuse (YK Style Chillers50/60 Hz) 025-35903-000 1 12 10 AMP Cartridge Fuse 025-35905-000 1 13 15 AMP Cartridge Fuse 025-35907-000 1 14 20 AMP Cartridge Fuse 025-35908-000 1 * 50/60 Hz Inverter (Used On 50 Hz Drive Only) 371-022202-101 * 15 ,QSXW5HFWL¿HUV
    6&56&56&5 RQHHDFK.LW 371-04162-001 12 17 Internal Cabinet Fan 025-32577-000 3 18 Internal Cooling Coil 026-37990-000 3 19 Output Current Transformer 025-21173-003 10 20 Power Module Chill Plate Kit 071-03787-309 12 21 Relay, Control Fan / Pump 024-30441-000 11 22 SCR Trigger Board 60 Hz 031-02060-001 11 22 SCR Trigger Board 50 Hz 031-02060-002 11 * SCR Trigger Board Cable Between J7 on Trigger to J1 on Gate Driver Board 571-03789-251 * 23 Shell and Tube Heat Exchanger 026-37572-000 8 * Shell and Tube Heat Exchanger Head Gaskets (set of two) 371-03716-001 * 63 Silicon Pad (1 each) 1 028-15299-000 11, 12 66 Snubber Capacitor 025-35188-000 11 65 Snubber Module as applied to the SCR/Diode module 4 331-02556-001 12 16 Snubber Resistor 025-35953-000 11 24 Transformer, 24 VAC, Class 2 025-27911-000 11 Temperature Sensor Supplied on chill plate * 571-01484-212 * with the SCR/Diode modules (As Separate Item) 25 VSD DC Balancing Resistor 1 025-35157-000 12 VSD Logic Board (if board P/N is 031-02077-000, order this kit) 5, 6 26 331-02506-602 5 (USE ON PART # 371-03789-XXX ONLY) VSD Logic Board (if board P/N is 031-02506-002, order this part) 5, 6 26 031-02506-002 5 (USE ON PART # 371-02767-XXX, & 371-03700-XXX ONLY) 27 VSD Power Module Kit 371-04164-001 12 60 Voltage Transient Board 031-02453-000 10 61 Voltage Transient Board Fuses 025-38523-000 10 * VSD Power Unit Complete Kit ( IGBT, Capacitors, Heatsink, etc.) 371-03787-401 * * Wiring (J8 from Drive Logic Board to IGBT Module Phase A) 571-03789-291 * * Wiring (J9 from Drive Logic Board to IGBT Module Phase B) 571-03789-293 * * Wiring (J10 from Drive Logic Board to IGBT Module Phase A) 571-03789-295 * JOHNSON CONTROLS 11
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 3 - VSD PARTS LIST 419 HP AND 503 HP (CONT'D) OPTIONAL HARMONIC FILTER PARTS LIST 419 HP AND 503 HP ITEM DESCRIPTION PART NUMBER FIGURE 2 Bus Isolator Board 031-01624-000 11 3 Bus Plate Kit 371-03710-001 13 62 Bus Snubber Capacitor 025-35972-000 13 * '&&7&DEOH
    FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-03788-271 10 * '&&7&DEOH
    FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-03788-272 10 30 Direct Current Current Transducer, 300 AMP (DCCT) 025-30994-000 10 31 Filter DC Balancing Resistor 025-35955-000 13 32 Filter Inductor 025-38135-000 10 34 Filter Input Fuse 025-30992-000 10 Filter Logic Board (if board P/N is 031-01632-042, order this kit) 5, 7 35 331-02932-642 5 (USE ON PART # 371-03789-XXX ONLY) Filter Logic Board (if board P/N is 031-02932-042, order this kit) 5, 7 35 031-02932-042 5 (USE ON PART # 371-02767-XXX, & 371-03700-XXX ONLY) 33 Filter Main Contactor with compression lugs 2 024-34028-000 9 33 Filter Main Contactor use with ring tong lugs 2 024-35433-000 9 36 Filter Power Module Kit 371-04165-001 13 * Filter Power Unit Complete Kit (IGBT, Capacitors, Heatsink, etc.) 371-03788-401 * 37 Filter Pre-Charge Contactor 024-30985-000 9 38 Filter Pre-Charge Resistor 025-38197-000 9 39 Filter Trap Assembly 371-03788-349 10 64 Filter Trap Resistor Kit (Trap Resistors only) 371-02768-355 10 40 Input Current Transformer 531-01660-001 9 41 Line Isolator Board 031-02022-000 11 20 Power Module Chill Plate 071-02769-309 13 63 Silicon Pad (1 each) 1 028-15299-000 13 42 16 Conductor Ribbon Cable - VSD Logic to Filter Logic Jumper 031-01658-000 5 HARMONIC FILTER UPGRADE KITS (TO RETROFIT FILTER TO A NON-FILTER UNIT) * Filter Upgrade (60 Hz) 503 Hp 371-04167-001 * Filter Upgrade (50 Hz) 419 Hp 371-04167-002 * Items are NOT shown. 1-8 Important Changes refer to page 6. 12 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 4 - VSD PARTS LIST 608 HP 575 VAC ITEM DESCRIPTION PART NUMBER FIGURE 1 AC Line Inductor 025-40384-000 9 2 Bus Isolator Board 031-01624-000 10 3 Bus Plate Kit 371-04163-001 12 62 Bus Snubber Capcitor 025-35972-000 12 4 Circuit Breaker 224-34025-000 9 5 Control Transformer, 120 VAC 60 Hz, 3 KVA 025-40381-000 9 6 Coolant Manifold Copper with or without Harmonic Filter 023-21710-000 8 7 Coolant Pump 026-33890-000 8 8 Coolant Reservoir 3” PVC with Fill Plug 371-03789-361 8 * Door Latch 029-25614-000 * 9 2 Pole Fuse Holder (2) per unit 025-38196-000 1 10 3 Pole Fuse Holder 025-34185-000 1 11 4 AMP Cartridge Fuse (YT Style Chillers 60 Hz) 025-35911-000 1 11 5 AMP Cartridge Fuse (YK Style Chillers 60 Hz) 025-35901-000 1 12 10 AMP Cartridge Fuse 025-35905-000 1 13 12 AMP Cartridge Fuse 025-35906-000 1 14 20 AMP Cartridge Fuse 025-35908-000 1 15 ,QSXW5HFWL¿HUV
    6&56&56&5 RQHHDFK.LW 371-05156-001 12 17 Internal Cabinet Fan 025-32577-000 3 18 Internal Cooling Coil 026-37990-000 3 19 Output Current Transformer 025-21173-003 10 20 Power Module Chill Plate Kit 071-03787-309 12 21 Relay, Control Fan / Pump 024-30441-000 11 22 SCR Trigger Board 60 Hz 031-02060-003 11 * SCR trigger board cable between J7 on trigger to J1 on gate driver board. 571-03789-251 * 23 Shell and Tube Heat Exchanger 026-37572-000 8 * Shell and Tube Heat Exchanger Head Gaskets (set of two) 371-03716-001 * 63 Silicon Pad (1 each) 028-15299-000 11, 12 66 Snubber Capacitor 025-39806-000 11 65 Snubber Module complete assembly for SCR/Diode module 371-05890-100 12 16 Snubber Resistor 025-35953-000 11 24 Transformer, 24 VAC, Class 2 025-27911-000 11 * Temperature Sensor Supplied on chill plate 571-01484-212 * with the SCR/Diode modules (As Separate Item) 60 Voltage Transient Board 031-02453-001 8 61 Voltage Transient Board Fuses 025-38523-000 8 25 VSD DC Balancing Resistor 025-40408-000 12 VSD Logic Board (if board P/N is 031-02077-001, order this kit) 5, 6 26 331 02506-603 5 (USE ON PART # 371-04563-XXX ONLY) VSD Logic Board (if board P/N is 031-02506-003, order this part) 5, 6 26 031-02506-003 5 (USE ON PART # 371-04563-XXX ONLY) 27 VSD Power Module Kit 371-05159-001 12 * VSD Power Unit Complete Kit ( IGBT, Capacitors, Heatsink, etc.) 371-03787-403 * * Wiring (J8 from Drive Logic Board to IGBT Module Phase A) 571-03789-291 * * Wiring (J9 from Drive Logic Board to IGBT Module Phase 3) 571-03789-293 * * Wiring (J10 from Drive Logic Board to IGBT Module Phase C) 571-03789-295 * JOHNSON CONTROLS 13
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 4 - VSD PARTS LIST 608 HP 575 VAC (CONT'D) OPTIONAL HARMONIC FILTER PARTS LIST 608 HP 575 VAC ITEM DESCRIPTION PART NUMBER FIGURE 2 Bus Isolator Board 031-01624-000 11 3 Bus Plate Kit 371-03710-001 13 62 Bus Snubber Capacitor 025-40526-000 13 * '&&7&DEOH
    FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-03788-271 10 * '&&7&DEOH
    FDEOHEHWZHHQWKH¿OWHUORJLFERDUGDQGWKH'&&7 571-02767-272 * 30 Direct Current Current Transducer, 300 AMP (DCCT) 025-30994-000 8 31 Filter DC Balancing Resistor 025-40408-000 13 32 Filter Inductor 025-40375-000 10 34 Filter Input Fuse 025-40405-000 10 Filter Logic Board (if board P/N is 031-01632-102, order this kit) 5, 7 35 331-02932-102 5 (USE ON PART # 371-04563-XXX ONLY) Filter Logic Board (if board P/N is 031-02932-102, order this part) 5, 7 35 031-02932-102 5 (USE ON PART # 371-04563-XXX ONLY) 33 Filter Main Contactor use with ring tong lugs 024-35433-000 9 36 Filter Power Module Kit 371-05160-001 13 * Filter Power Unit Complete Kit (IGBT, Capacitors, Heatsink, etc.) 371-03788-403 * 37 Filter Pre-Charge Contactor 024-30985-000 9 38 Filter Pre-Charge Resistor 025-40424-000 9 39 Filter Trap Assembly 3 371-04563-349 10 40 Input Current Transformer 531-01660-001 9 41 Line Isolator Board 031-02022-001 11 20 Power Module Chill Plate 071-02769-309 13 63 Silicon Pad (1 each) 028-15299-000 10, 13 42 16 Conductor Ribbon Cable - VSD Logic to Filter Logic Jumper 031-01658-000 5 HARMONIC FILTER UPGRADE KITS (TO RETROFIT FILTER TO A NON-FILTER UNIT) * Filter Upgrade (60 Hz) 608 Hp (575VAC) 371-04167-003 * Items are NOT shown. 1-8 Important Changes refer to page 6. 14 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 5 - MISCELLANEOUS ITEM DESCRIPTION PART NUMBER Not Shown Pre-Mixed Coolant (Inhibitor) 1 gallon container 013-02987-000 Not Shown 6QXEEHUIRU0RWRU7HUPLQDO%R[±5HPRWH5HWUR¿WV9$& 375-22732-000 Not Shown 6QXEEHUIRU0RWRU7HUPLQDO%R[±5HPRWH5HWUR¿WV9$& 375-22732-001 Not Shown 50/60 Hz Inverter for 50 Hz VSD Units 371-02202-101 Not Shown Vane Pot with Couplings 371-02012-001 Not Shown Bracket for Vane Pot Mtg. to Compressor 064-48851-000 Not Shown Ferrite Beads 025-32843-000 Not Shown Motor Adapter Plate (4” Deep) - 405S Frame Motors 025-28400-001 Motor Adapter Plate (4” Deep) - 404R, 405R, 444S, 445S, 447S,449S, Not Shown 025-28400-002 503S, 504S, 505S, 507S, 509S, 588S and 5011S Frame Motors Not Shown Motor Adapter Plate (4” Deep) - 445R, 447R Frame Motors 025-28400-003 Not Shown Motor Adapter Plate (5 ¾” Deep) - 405T Frame Motors 025-28400-004 Not Shown Motor Adapter Plate (7 ¾” Deep) - 405T, 445T, 447T Frame Motors 025-28400-005 MICRO-COMPUTER CONTROL CENTER PARTS FOR VSD APPLICATION (ONE LINE DISPLAY) Not Shown Adaptive Capacity Control Board 031-01579-000 Not Shown Membrane Keypad for Control Panel 024-26943-000 ACC Installation Kit – Mounting rails, ribbon cables, hardware. Not Shown 375-22734-000 Does not include ACC Board. (YT) ACC Installation Kit – Mounting rails, ribbon cables, hardware. Not Shown 375-22733-000 Does not include ACC Board. (YK) Not Shown Replacement Ribbon Cable – Micro Board to ACC (Quant. = 1) 031-01322-000 Not Shown Condenser Transducer for R-11, R-123 025-29148-009 OPTIVIEW CONTROL CENTER PARTS FOR VSD APPLICATION Not Shown Adaptive Capacity Control Board 031-01782-000 ACC Installation Kit – (YT) Not Shown 371-02725-001 includes mounting hardware, cables, and ACC Board. ACC Installation Kit – (YK) Not Shown 371-02724-001 includes mounting hardware, cables, and ACC Board. Not Shown Replacement Shielded Cable – Micro Board to ACC (Quant. = 1) 571-02264-411 HARNESSES Not Shown Vane Pot Wiring from Vane Pot to ACC Board 375-22735-402 Not Shown VSD Cabinet to Control Center Wiring Kit - 10 Feet 375-22736-000 Not Shown VSD Cabinet to Control Center Wiring Kit - 50 Feet 375-22737-000 PIPING 28 Clear PVC Tubing, 3/4” I.D. (Figures 6, 7, 8) 028-14491-000 29 Clear PVC Tubing, 1/2” I.D. (Figures 6, 7) 028-14439-000 62 Clear PVC Tubing, 1” I.D. (Figure 8) 028-13553-000 Not Shown Rubber Hose, Black, 150# DWP, 1 ½” ID 028-15001-000 Not Shown Rubber Hose, Red, 300# DWP, 1 ½” ID 028-15028-000 Not Shown Hose Clamp for 150# DWP, 1 ½” ID hose 021-30656-000 Not Shown Hose Clamp for 300# DWP, 1 ½” ID hose 023-40048-000 * Items are NOT shown. 1-8 Important Changes refer to page 6. JOHNSON CONTROLS 15
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 5 - MISCELLANEOUS (CONT'D) DRIVE SOFTWARE 292, 351, 419, AND 503 HP ITEM DESCRIPTION PART NUMBER FIGURE 51 U33 Battery Backed RAM for the VSD Logic Board and ACC board 031-01620-000 5 52 U34 VSD Logic Board EPROM (60Hz used on 031-02077 board) 031-01617-006 5 52 U34 VSD Logic Board EPROM (50Hz used on 031-02077 board) 031-01617-007 5 53 U40 VSD Logic Board Serial PROM used on 031-02077 board 031-01619-003 5 * U42 VSD Logic Board 485 communications driver 031-02074-000 * 54 U45 VSD Logic Board EPROM (60 Hz used on 031-02506 board only) 031-01618-001 5 54 U45 VSD Logic Board EPROM (50 Hz used on 031-02077 board) 031-01618-002 5 * U22 VSD Logic Board EPROM used on 031-02506 board Rev. F and 031-03420-001 * later U34 VSD Logic Board EPROM used on 031-02506 board (460v/60Hz, * 031-02547-002 * 400v/50Hz) * U34 VSD Logic Board EPROM used on 031-02506 board (400v/60Hz, 031-02547-005 * 415v/50Hz) * U45 VSD Logic Board EPROM used on 031-02506 board 031-02572-001 * * U6 SCR Trigger Board 8 331-02065-601 * 55 U26 Harmonic Filter Logic Board Serial PROM used on 031-01632 board 031-01680-003 5 56 U42 Harmonic Filter Logic Board EPROM (60Hz) 031-01633-006 5 56 U42 Harmonic Filter Logic Board EPROM (50Hz) 031-01633-007 5 57 U78 Harmonic Filter Logic Board Serial PROM used on 031-01632 board 031-02091-001 5 DRIVE SOFTWARE 424 AND 608 HP 51 U33 Battery Backed RAM for the VSD Logic Board and ACC board 031-01620-000 5 52 U34 VSD Logic Board EPROM (60Hz used on 031-02077 board) 031-01617-009 5 53 U40 VSD Logic Board Serial PROM used on 031-02077 board 031-01619-003 5 U42 VSD Logic Board 485 communications driver * 031-02074-000 * (Used on 031-02506-xxx board only) 54 U45 VSD Logic Board EPROM (60 Hz used on 031-02077 board) 031-01618-001 5 * U34 VSD Logic Board EPROM used on 031-02506 board (575v/60Hz) 031-02547-003 * * U22 VSD Logic Board EPROM used on 031-02506 board Rev. F and 031-03420-001 * later * U6 SCR Trigger Board 8 331-02065-601 * 55 U26 Harmonic Filter Logic Board Serial PROM used on 031-01632 board 031-01680-003 5 56 U42 Harmonic Filter Logic Board EPROM (60Hz) 031-01633-008 5 57 U78 Harmonic Filter Logic Board Serial PROM 031-02091-001 5 SOFTWARE FOR THE MICRO-COMPUTER CONTROL CENTER WITH VSD Not Shown U17 Micro Board EPROM (VSD 60 Hz) YT chiller 031-01676-003 Not Shown U17 Micro Board EPROM (VSD 50 Hz) YT chiller 031-01676-002 Not Shown U17 Micro Board EPROM (VSD 60 Hz) YK chiller 031-01675-003 Not Shown U17 Micro Board EPROM (VSD 50 Hz) YK chiller 031-01675-002 Not Shown U22 Adaptive Capacity Control Board EPROM 031-01674-002 Not Shown U21 Battery Backed RAM for the ACC Board 031-01620-000 * Items are NOT shown. 1-8 Important Changes refer to page 6. 16 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 TABLE 5 - MISCELLANEOUS (CONT'D) SOFTWARE FOR THE OPTIVIEW CONTROL CENTER WITH VSD ITEM DESCRIPTION PART NUMBER FIGURE Not Shown U46 Micro Board Flash Card (YK 50 / 60 Hz) (031-01730-XXX Board only) 031-01797-001 U46 Micro Board Flash Card (YK 50 / 60 Hz) (031-01730-XXX Board only) Not Shown 031-02073-001 (P Compressor only) Not Shown U46 Micro Board Flash Card (YT 50 / 60 Hz) (031-01730-XXX Board only) 031-02004-001 Not Shown Program Card (YK) (031-02430-XXX Board only) 031-02474-001 Not Shown Program Card (YT) (031-02430-XXX Board only) 031-02469-001 Not Shown U16 Adaptive Capacity Control Board EPROM 031-01674-002 Not Shown U15 Battery Backed RAM for the ACC Board 031-01620-000 * Items are NOT shown. 1-8 Important Changes refer to page 6. JOHNSON CONTROLS 17
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD07014 FIGURE 1 - LEFT SIDE OF CABINET (DETAILED) 292/351/424 HP 18 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD07015 FIGURE 2 - LEFT SIDE OF CABINET 292/351/424 HP JOHNSON CONTROLS 19
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09128a FIGURE 3 - LEFT CENTER OF CABINET 292/351/424 HP 20 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09127a FIGURE 4 - RIGHT SIDE OF CABINET 292/351/424 HP JOHNSON CONTROLS 21
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD07018 FIGURE 5 - INSIDE RIGHT DOOR ALL HORSE POWERS 22 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD07019 FIGURE 6 - BACK OF CABINET 292/351/424 HP JOHNSON CONTROLS 23
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09065 FIGURE 7 - COOLING SYSTEM 292/351/424 HP 24 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09066 FIGURE 8 - COOLING SYSTEM 419/503/608 HP JOHNSON CONTROLS 25
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09064 FIGURE 9 - LEFT SIDE OF CABINET 419/503/608 HP 26 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09063a FIGURE 10 - LEFT SIDE OF CABINET (DETAILED) 419/503/608 HP JOHNSON CONTROLS 27
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09062a FIGURE 11 - UPPER RIGHT SIDE OF CABINET 419/503/608 HP 28 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD12020 FIGURE 12 - OPTI SPEED POWER UNIT DETAIL 419/503/608 HP JOHNSON CONTROLS 29
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 LD09060 FIGURE 13 - OPTI SPEED HARMONIC FILTER POWER UNIT DETAIL 419/503/608 HP 30 JOHNSON CONTROLS
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    FORM 160.00-RP4 ISSUE DATE: 8/30/2013 The following factors can be used to convert from English to the most common SI Metric values. TABLE 6 - SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW) Power Horsepower 0.7457 Kilowatts (kW) Flow Rate Gallons / Minute (gpm) 0.0631 Liters / Second (l/s) Feet (ft) 0.3048 Meters (m) Length Inches (in) 25.4 Millimeters (mm) Weight Pounds (lbs) 0.4538 Kilograms (kg) Velocity Feet / Second (fps) 0.3048 Meters / Second (m/s) Feet of Water (ft) 2.989 Kilopascals (kPa) Pressure Drop Pounds / Square Inch (psi) 6.895 Kilopascals (kPa) TEMPERATURE To convert degrees Fahrenheit (°F) to degrees Celsius (°C), subtract 32° and multiply by 5/9 or 0.5556. Example: (45.0°F - 32°) x 0.5556 = 27.2°C To convert a temperature range (i.e., a range of 10°F) from Fahrenheit to Celsius, multiply by 5/9 or 0.5556. Example: 10.0°F range x 0.5556 = 5.6 °C range JOHNSON CONTROLS 31
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    P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2013 www.ENENG.com ALL RIGHTS RESERVED Form 160.00-RP4 (813) Issue Date: August 30, 2013 Supersedes: 160.00-RP4 (1012)

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