Supersedes: 160.

54-PW6 (419) Form 160.54-PW6 (519)

FIELD CONNECTIONS
MODEL YK CHILLERS
(STYLE F AND G)
WIRING DIAGRAM WITH VARIABLE SPEED DRIVE
CONTRACTOR ________________________ PURCHASER _____________________________________________
ORDER NO. ___________________________ JOB NAME _______________________________________________
JCI CONTRACT NO. ____________________ LOCATION _______________________________________________
JCI ORDER NO. ________________________ ENGINEER ______________________________________________

REFERENCE DATE _______ APPROVAL DATE________ CONSTRUCTION DATE ________

JOB DATA:

CHILLER MODEL NO. YK ____________________________________________________________

NO. OF UNITS _____________________________________________________________________

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

Issue Date:
May 31, 2019
FORM 160.54-PW6
ISSUE DATE: 05/31/2019

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 rigging, installation, operation, maintenance, death to themselves and people at the site.
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to: This document is intended for use by owner-authorized
heavy objects, refrigerants, materials under pressure, rigging, installation, and operating/service personnel. It
rotating components, and both high and low voltage. is expected that these individuals possess independent
Each of these items has the potential, if misused or training that will enable them to perform their assigned
handled improperly, to cause bodily injury or death. It tasks properly and safely. It is essential that, prior to
is the obligation and responsibility of rigging, instal- performing any task on this equipment, this individual
lation, and operating/service personnel to identify and shall have read and understood the on-product labels,
recognize these inherent hazards, protect themselves, this document and any referenced materials. This in-
and proceed safely in completing their tasks. Failure dividual shall also be familiar with and comply with
to comply with any of these requirements could result all applicable industry and 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 control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accor-
dance with Johnson Controls’ published specifications and must be performed only by a qualified
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

2 JOHNSON CONTROLS
 FORM 160.54-PW6
ISSUE DATE: 05/31/2019

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for con- regarding the applicability of these documents, rig-
tinuous product improvement, the information con- ging, lifting, and operating/service personnel should
tained in this document is subject to change without verify whether the equipment has been modified and
notice. Johnson Controls makes no commitment to if current literature is available from the owner of the
update or provide current information automatically equipment prior to performing any work on the chiller.
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest CHANGE BARS
Johnson Controls Service office or accessing the John-
son Controls QuickLIT website at http://cgproducts. Revisions made to this document are indicated with
johnsoncontrols.com. a line along the left or right hand column in the area
the revision was made. These revisions are to technical
It is the responsibility of rigging, lifting, and operating/ information and any other changes in spelling, gram-
service personnel to verify the applicability of these mar or formatting are not included.
documents to the equipment. If there is any question

ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
Wiring Diagram - YK Style G Chillers with OptiView Control Center Field Connections with Remote MVVSD 160.75-PW3
Wiring Diagram - YK Style G Chillers Field Control Modifications 160.75-PW4
Wiring Diagram - YK Style G Chillers OptiView Control Center with SSS, LVVSD with Modbus, and MVVSD 160.75-PW6
Wiring Diagram - YK Style G Chiller OptiView Control Center with LTC I/O Board with Unit Mounted
160.75-PW8
Low or Medium Voltage SSS, Unit Mounted LVVSD with Modbus or Remote Mounted MVVSD

JOHNSON CONTROLS 3
FORM 160.54-PW6
ISSUE DATE: 05/31/2019

NOTES
1. All field wiring must be in accordance with the conductors only. DO NOT USE aluminum con-
current edition of the National Electrical Code ductors. See Table 2 on page 6 and Note 8 for
(NEC) as well as all other applicable codes and factory furnished VSD terminal lug wire ranges
specifications. and conduit connection provisions.
2. Proper grounding is required: 8. A removable cover plate with pilot knockouts is
supplied for connection of power supply conduits.
See Table 1 on page 5.
9. The condenser water pump motor starter (3M)
•
The Variable Speed Drive (VSD) must be control voltage is provided by others. The starter
grounded in accordance with the 2017 NEC control voltage may be interlocked through con-
(Paragraph 250.118). trol panel dry contacts TB2-150/151, which close
• Ground wires must be copper only and sized per coincident with the start of System run. Contacts
the NEC. Refer to Table 250.122. are gold-plated silver cadmium oxide rated for 5A
maximum.
• A separate grounding conductor must be run in
each conduit or for each 3 phase bundle within a 10. Units that are shipped knocked down require field
cable tray. See Figure 1 on page 5. connection of harnesses to control center, power
• Each ground wire must be connected directly wiring between the compressor motor and VSD,
between the supply transformer’s secondary and oil pump starter to VSD. These harnesses and
ground and the VSD ground lug. power wiring are furnished by Johnson Controls
for field assembly and consist of proper lengths
• Flexible conduit is a requirement for final con- of flexible conduit with necessary connectors, and
nection to the VSD for vibration isolation. contain the wires (shown in Note 13) properly ter-
• Conduit is not an acceptable grounding means. minated and marked.
• See Table 2 on page 6 for VSD ground lug 11. If control voltage is 120 VAC, use #14 AWG cop-
sizing. per wire for one way distance less than 175 feet
and #12 AWG copper wire for one way distance
3. Johnson Controls does not furnish the wiring,
more than 175 feet, but less than 300 feet.
electrical conduit, junction boxes, fused discon-
nect switches (FDS), or circuit breakers, starters 12. Refer to the following wiring diagrams for addi-
(M), push-button stations (PB), manual-off-auto- tional information:
matic switch (S), flow switch (FLS), and control
FORM DESCRIPTION
relays, unless otherwise specified.
160.75-PW4 Field Wiring Modifications
4. Items marked * are furnished by Johnson Controls. 160.75-PW6
York Control Center
5. Items marked ** are available from Johnson Con- 160.75-PW8
trols at additional cost.
13. The following interconnecting wires are factory
6. Control power supply 115 V - 50/60 Hz, 2.0/3.0 supplied when a YORK Variable Speed Drive is
kVA capacity for control center only, is supplied used:
by a control power transformer (1T)/(2T) mount-
• VSD to control center – L, 2, 16, 24, 53.
ed inside the VSD. It is factory wired.
A 4-conductor shielded cable or fiber optic
7. Flexible conduit must be used for final connec- cable pair for communications.
tions to VSD. Multiple conduits must contain
• VSD to oil pump motor starter – 67, 68, 69
an equal number of wires from each phase in
GND.
each conduit to prevent overheating per the
2017 NEC (Paragraph 300.20(a)). Use copper

4 JOHNSON CONTROLS
 FORM 160.54-PW6
ISSUE DATE: 05/31/2019

Table 1 - POWER SUPPLY CONDUITS

INPUT OUTPUT CHILLER NUMBER OF
VOLTAGE/FREQUENCY VOLTAGE/FREQUENCY MOTOR CODE CONDUITS - MAX T
CF-CR
575 V/600 V/60 Hz 575 V/600 V/60 Hz
EF-ER
CF-CN
440 V/460 V/480 V/60 Hz 440 V/460 V/480 V/60 Hz
EF-EN
(2) 2-1/2 in.
380 V/60 Hz 380 V/60 Hz EF-EK
415 V/50 Hz 415 V/50 Hz 5EC-5EI
5CC-5CI
380 V/400 V/50 Hz 380 V/400 V/50 Hz
5EC-5EI
CS-CV
575 V/600 V/60 Hz 575 V/600 V/60 Hz
ES-EV
CP-CT
440 V/460 V/480 V/60 Hz 440 V/460 V/480 V/60 Hz
EP-ET
(2) 3 in.
380 V/60 Hz 380 V/60 Hz EL-EP
415 V/50 Hz 415 V/50 Hz 5EJ-5EM
5CJ-5CM
380 V/400 V/50 Hz 380 V/400 V/50 Hz
5EJ-5EM
CU-CZ,CA,CB,DA,DB
440 V/460 V/480 V/60 Hz 440 V/460 V/480 V/60 Hz
EU-EZ, EA, EB, FA, FB
ER-EV
380 V/60 Hz 380 V/60 Hz
CW-CZ, CA
(4) 3 in.
5CP-5CX
415 V/50 Hz 415 V/50 Hz
5EN-5EX
5CN-5CX,5DA
380 V/400 V/50 Hz 380 V/400 V/50 Hz
5EN-5EX, 5FA
440 V/460 V/480 V/60 Hz 575 V/60 Hz FB-FD
(4) 4 in.
380 V/400 V/415 V/50 Hz 575 V/60 Hz FA-FB

Phase A* A
Conduit
B
C
Transformer VSD Ground
Terminal Phase B* Terminal
Conduit
Each conduit shall contain a copper conductor
Block Block of each phase and a copper ground wire.
Phase C*
Neutral (if applicable)
C G C G C G C G
A B A B A B A B

Ground Ground
Wire tray shall contain bundles of copper wire with
*See Note 7. one conductor per phase and a copper ground
wire in each bundle.

LD27401

Figure 1 - GROUNDING VSD

JOHNSON CONTROLS 5
FORM 160.54-PW6
ISSUE DATE: 05/31/2019

The following terminal lugs are factory furnished for

field wiring supply connections. All lugs are rated AL-
9CU.

Table 2 - TERMINAL LUGS

CHILLER MOTOR LINE SIDE GROUNDING
INPUT OUTPUT
CODE AND VSD LUGS BBL WIRE LUG WIRE
VOLTAGE/ VOLTAGE/
CIRCUIT BREAKER PER RANGE RANGE,
FREQUENCY FREQUENCY
RATING TERMINAL QUANTITY
CF-CR
575 V/600 V/60 Hz 575 V/600 V/60 Hz EF-ER
400A
CF-CN
440 V/460 V/480 V/ 440 V/460 V/480 V/
EF-EN
60 Hz 60 Hz
400A
#6 AWG to 250
EF-EK 2 2/0-350 kcmil
380 V/60 Hz 380 V/60 Hz kcmil, two bbl
400A
5EC-5EI
415 V/50 Hz 415 V/50 Hz
400A
5CC-5CI
380 V/400 V/50 Hz 380 V/400 V/50 Hz 5EC-5EI
400A
CS-CV
575 V/600 V/60 Hz 575 V/600 V/60 Hz ES-EV
600A
CP-CT
440 V/460 V/480 V/ 440 V/460 V/480 V/
EP-ET
60 Hz 60 Hz
600A
#6 AWG to 250
EL-EP 2 3/0-500 kcmil
380 V/60 Hz 380 V/60 Hz kcmil, two bbl
600A
5EJ-5EM
415 V/50 Hz 415 V/50 Hz
600A
5CJ-5CM
380 V/400 V/50 Hz 380 V/400 V/50 Hz 5EJ-5EM
600A
CU-CZ,CA,CB,DA,DB
440 V/460 V/480 V/ 440 V/460 V/480 V/
EU-EZ, EA, EB, FA, FB
60 Hz 60 Hz
1200A
ER-EZ, EA
380 V/60 Hz 380 V/60 Hz CW-CZ, CA
1200A #4 AWG to 500
4 3/0-500 kcmil
5CP-5CX kcmil, four bbl
415 V/50 Hz 415 V/50 Hz 5EN-5EX
1200A
5CN-5CX,5DA
380 V/400 V/50 Hz 380 V/400 V/50 Hz 5EN-5EX, 5FA
1200A
440 V/460 V/480 V/ FB-FD
575 V/60 Hz
60 Hz 1600A 500-1000 250-500 kcmil,
4
380 V/400 V/415 V/ FA-FB kcmil four bbl
575 V/60 Hz
50 Hz 1600A

6 JOHNSON CONTROLS
 FORM 160.54-PW6
ISSUE DATE: 05/31/2019

Table 3 - CIRCUIT BREAKER

VSD CIRCUIT
BREAKER RATING
(AMPS) AT SEMICONDUCTOR GROUND
CHILLER
INPUT VOLTAGE/ OUTPUT VOLTAGE/ 600 VAC, 60 HZ OR FUSE RATING FAULT
MOTOR
FREQUENCY FREQUENCY 480 VAC, 60 HZ OR (AMPS) AT 700 VAC TRIP
CODE
400 VAC, 50 HZ TRIP WITHSTAND (AMPS)

TRIP WITHSTAND
CF-CR
575 V/600 V/60 Hz 575 V/600 V/60 Hz 400 35,000*+
EF-ER
440 V/460 V/480 V/ 440 V/460 V/480 V/ CF-CN
60 Hz 60 Hz EF-EN
N/A 120
380 V/60 Hz 380 V/60 Hz EF-EK
400 65,000*+
415 V/50 Hz 415 V/50 Hz 5EC-5EI
5CC-5CI
380 V/400 V/50 Hz 380 V/400 V/50 Hz
5EC-5EI
CS-CV
575 V/600 V/60 Hz 575 V/600 V/60 Hz 600 50,000*+
ES-EV
440 V/460 V/480 V/ 440 V/460 V/480 V/ CP-CT
60 Hz 60 Hz EP-ET
N/A 160
380 V/60 Hz 380 V/60 Hz EL-EP
600 100,000*+
415 V/50 Hz 415 V/50 Hz 5EJ-5EM
5CJ-5CM
380 V/400 V/50 Hz 380 V/400 V/50 Hz
5EJ-5EM
440 V/460 V/480 V/60 440 V/460 V/480 V/60 CU-CZ
Hz Hz EU-EZ
380 V/60 Hz 380 V/60 Hz ER-EV
5CP-5CT 1200 100,000*+ N/A 240
415 V/50 Hz 415 V/50 Hz
5EN-5ET
5CN-5CS
380 V/400 V/50 Hz 380 V/400 V/50 Hz
5EN-5ES
440 V/460 V/480 V/ 440 V/460 V/480 V/ CA,CB,DA,DB
60 Hz 60 Hz EA,EB,FA,FB
CW-CZ, CA
380 V/60 Hz 380 V/60 Hz
EW-EZ, FA
1200 100,000*+ N/A 240
5CU-5CX
415 V/50 Hz 415 V/50 Hz
5EU-5EX
5CT-5CX, 5DA
380 V/400 V/50 Hz 380 V/400 V/50 Hz
5ET-5EX, 5FA
440 V/460 V/480 V/
575 V/60 Hz FB-FD
60 Hz 1800
1600 100,000*+ 360
380 V/400 V/415 V/ @650VAC
575V/60 Hz FA-FB
50 Hz

NOTES: * Per UL listing of VSD

† RMS Symmetrical Amperes

JOHNSON CONTROLS 7
FORM 160.54-PW6
ISSUE DATE: 05/31/2019

14. 60 Hz oil pump motor for compressor is 2 HP. See • Model YK minimum circuit ampacity:
Table 4 for full load amperes for oil pump drive
Ampacity = 1.25 (Job FLA)
panel (furnished by Johnson Controls with VSD
factory wired). A combination of control trans- Where 125% factor per 2014 NEC (Para-
formers provide power to the VSD and the chiller graph 440-33).
control panel have the current requirement list in
Table 4. Control power transformers are furnished 17. The VSD is equipped with a UL listed ground fault
by Johnson Controls and are factory wired. sensing circuit breaker, sized as shown in Table 3
on page 7. All of the VSD model drives have
Table 4 - OIL PUMP AND CONTROL an input inductor to reduce the rate of rise of the
TRANSFORMERS input current during a fault condition. No input
OIL fuses are required on the input of the power circuit
3-PHASE PUMP CONTROL POWER
MOTOR of the drive. The ground fault sensor is factory set
VOLT- HZ DRIVE TRANSFORMERS
AGE PANEL (AMPS)
CODES to trip instantaneously when a ground fault is de-
(AMPS) tected.
CF-CV,
575/600 60 2.9 5.2
EF-EV
18. Control circuit wiring for 3M condenser water
440/460/ CF-CT,
pump motor starter is shown for cooling only ap-
480
60 3.6 6.5
EF-ET plication.
380 60 4.3 7.5 EF-EP 19. The main power transformer must be adequately
380/400/
50 4.3 7.5
5CC - 5CM, sized such that the transformer voltage drop does
415 5EC-5EM not exceed 10% during unit start-up. The supply
440/460/
60 3.6 8.7
CU-DB, voltage, at VSD input terminals, during start-up
480 EU-FB must be maintained above 489 volts for 575 V/600
ER-EZ, EA V, 391 volts for 440 V/460 V/480 V, 323 volts for
380 60 4.3 10
CW-CZ, CA
380V 60 Hz units and 323 volts for 380 V/400 V,
5CP-5CX, 353 volts for 415 V 50 Hz units. The allowable
415 50 4.3 10
5EN-5EX
supply voltage range during normal operation is
5CN - 5DA,
380/400 50 4.3 10 540 VAC to 630 VAC, 3-Phase 575 V/600 V, 60
5EN-5FA
Hz or 432 VAC to 504 VAC, 3-Phase 440 V/460
440/460/
60 3.6 10.8 FB-FD* V/480 V 60 Hz or 343 VAC to 415 VAC, 3-Phase
480
380 V, 60 Hz or 342 VAC to 440 VAC, 3-Phase
380/400/
50 4.3 7.5 FA-FB* 380 V/415 V 50 Hz.
415
20. The chilled water pump motor starter (5M) control
NOTE: *575/60 output motor voltage
voltage is provided by others. The starter control
voltage may be interlocked through control panel
15. The branch circuit overcurrent protection de-
dry contacts TB2-44/45, which close during oil
vice for the YORK VSD must be a time delay
pump prerun, compressor operation, and during
type with a rating that is the standard fuse/circuit
cycling shutdown. Contacts are gold-plated silver
breaker size required to protect the field supply
cadmium oxide rated for 5A maximum.
wiring conductors per the NEC.
21. Each 115 VAC field-connected inductive load, for
Motor overload protection is provided by the
example, relay coil, motor starter coil, and so on,
YORK VSD according to UL 508C. The YORK
must have a transient suppressor wired (by others)
VSD does not have provisions to provide motor
in parallel with its coil, that is physically located
temperature sensing, thermal memory, or thermal
at the coil. Spare transient suppressors are factory
retention protection for motor overload condi-
supplied in a bag that is attached to the keypad
tions as a standard offering. If thermal overload
cable clamp in the OptiView Control Center.
protection is desired, an optional motor monitor-
ing board and resistance thermometer devices or 22. The Condenser Flow Switch is optional. If it is
thermistors are available. not present, a jumper must be installed between
TB4-11 and TB4-1.
16. Calculate the YORK VSD power supply wiring
ampacity as follows:

8 JOHNSON CONTROLS
 FORM 160.54-PW6

POWER SUPPLY (NOTE 19)

L1 VOLT
L2 PHASE 3
L3 HERTZ

JOHNSON CONTROLS
FDS5 FDS3 FDS4 FDS2**
NOTES 5 & 15

2LL2

4LL2
2LL3

2LL1

4LL3

4LL1

3LL2
3LL3

3LL1

5LL3
5LL2
5LL1
5M 3M S 4M
SEE AUTO
NOTE

OFF
21 MAN

SUPR
SUPR
SEE
NOTE
NOTE 21
CONDENSER WATER 9
FLOW SWITCH

5T3
5T2
4T2

3T2

5T1
4T3

4T1

3T3

3T1
NOTE 22

TB4-1
TB4-11
CHILLED

Figure 2 - WIRING DIAGRAM – FIELD CONNECTIONS

WATER
#14 AWG PUMP NOTE 7, 16
COPPER MOTOR COPPER CONDUCTORS ONLY
(NOTE 11) CONDENSER WATER COOLING TOWER DO NOT USE ALUMINUM
WIRE # 14 AWG
PUMP MOTOR FAN MOTOR CONDUCTORS.
COPPER
NOTES 11 & 18
CHILLED WATER
FLOW SWITCH ** TB5 22
OPTIVIEW CONTROL CENTER * NOTE 8
NOTE 5 25
WIRE GRD L1 L2 L3
23
# 14 AWG TB4* TB2* TB6
COPPER 1 95 1 82 11 1 31 9 1 13 12 1 20 19 1 8 7 1 44 45 55 56 26 27 42 43 40 41 150 151 152 153 154 155 156 157 164 36 35 5 3 4 15 16 24 25 53 1 1 1 1 L L L 2 2 2 2 NOTES 2 & 8

FLS NOTE 11

2M
YORK VSD
1T*
NOTES 4 & 13
WIRE # 14 AWG
COPPER
NOTE 11
Contactor Control NOTES 4 & 6
Voltage Supplied
by Others 2T*
GRD. SCREWS* T1 T2 T3

T1* T2* T3*

Control transformers are
COMPRESSOR MOTOR*
mounted inside the VSD
cabinet on all models.

LD16111a

9
ISSUE DATE: 05/31/2019
FORM 160.54-PW6
5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 1-800-524-1330 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2019 www.johnsoncontrols.com ALL RIGHTS RESERVED
Form 160.54-PW6 (519)
Issue Date: May 31, 2019
Supersedes: 160.54-PW6 (419)