160 78-m1

CENTRIFUGAL LIQUID CHILLER
SERVICE INSTRUCTION
Supersedes: 160.78-M1 (1112)
Form 160.78-M1 (813)
YMC2 MODEL A
WITH OPTIVIEW CONTROL CENTER
LD14000
R-134a
Issue Date:
August 1, 2013
FORM 160.78-M1
ISSUE DATE: 8/1/2013
IMPORTANT!
READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus.
During installation, operation maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
materials under pressure, rotating components, and
both high and low voltage. Each of these items has the
potential, if misused or handled improperly, to cause
bodily injury or death. It is the obligation and responsibility of operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure
to comply with any of these requirements could result
in serious damage to the equipment and the property in
which it is situated, as well as severe personal injury or

death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that these
individuals possess independent training that will enable them to perform their assigned tasks properly and
safely. It is essential that, prior to performing any task
on this equipment, this individual shall have read and
understood this document and any referenced materials. This individual shall also be familiar with and
comply with all applicable governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Identifies a hazard which could lead to

damage to the machine, damage to other
equipment and/or environmental pollution if proper care is not taken or instructions and are not followed.
Indicates a potentially hazardous situation which will result in possible injuries

or damage to equipment if proper care is
not taken.
Highlights additional information useful

to the technician in completing the work
being performed properly.
External wiring, unless specified as an optional connection in the manufacturers product line, is
not to be connected inside the OptiView 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 manufacturers warranty and cause serious damage to property or personal injury.
Ensure power is removed from the input side of the VSD at all times when the chiller is under vacuum
(less than atmospheric pressure). The VSD maintains voltage to ground on the motor when the chiller
is off while voltage is available to the VSD. Insulating properties in the motor are reduced in vacuum
and may not insulate this voltage sufficiently.
JOHNSON CONTROLS
FORM 160.78-M1
YMC2 with high speed direct drive permanent magnet rotor hermetic motor
Motor auto-rotation electrical hazard
While the chiller is off, thermal energy provided to

the chiller shells through the plant systems can result
in auto rotation of the hermetic motor by refrigerant
vapor driven across the compressor impeller. This results in the permanent magnet motor rotor acting as
an electrical generator. The output at the motor terminals will vary directly with speed of rotation and may
provide a safety hazard to a service person if unaware.
The force to drive the rotation depends on maintenance
of differential pressure across the chiller shells by
cooled or warmed liquid flow through the tubes of one
shell and existence of refrigerant to vaporize and flow
across the impeller. Rotation is impeded when the motor leads are connected to the VSD output and is also
impeded when the leads are removed and electrically
connected together. Conditions that do not initiate rotation when the motor leads are connected could incite
rotation and electrical potential across phases if the
leads are disconnected.
The following are recommendations to safely service
the machine:
S
hut down the machine, extend the Variable
Geometry Diffuser and close discharge isolation
valve (if so equipped). Isolation prevents a path for
refrigerant movement. Isolation that is relied upon
should be locked in position to prevent inadvertent
restoration to a dangerous condition.
O
pen the VSD panel with proper electrical PPE
for the drive rating and measure voltage at the
motor connection points.
I f measured voltage is zero, install shorting/
grounding wires to short together and ground the
three motor phases. Wire should be a minimum of
AWG 0. NOTE: A shorting harness is also available as P/N 325-44935-000.
I f the voltage is not zero, this indicates that the
motor is auto rotating. The service technician must
take the necessary measures to stop refrigerant
and/or liquid flow through the machine such as
closing discharge or liquid line isolation, stopping
customer water pumps, etc. to cease generation of
electrical potential before shorting or grounding
motor leads.
I f the motor is to be disconnected from the output
of the VSD, a set of shorting/grounding wires
would need to be installed directly to the motor
structure.
When the machine is ready for return
to service or standby, remove shorting/
grounding wiring with care that autorotation remains prohibited so the free
motor wires are safe to handle.
Because of the use of shorting and
grounding devices during the process,
be very certain they have been removed
before applying line power to the VSD for
return to service.
R
emove and secure input power to the VSD and
wait 15 minutes for DC bus to dissipate.
JOHNSON CONTROLS
FORM 160.78-M1
CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls policy for continuous product improvement, the information contained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically to
the manual owner. Updated manuals, if applicable, can
be obtained by contacting the nearest Johnson Controls
Service office.
Operating/service personnel maintain responsibility for
the applicability of these documents to the equipment.
If there is any question regarding the applicability of
these documents, the technician should verify whether

the equipment has been modified and if current literature is available from the owner of the equipment prior
to performing any work on the chiller.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical information and any other changes in spelling, grammar
or formatting are not included.
ASSOCIATED LITERATURE
MANUAL DESCRIPTION
FORM NUMBER
YMC Installation
160.78-N1
YMC2 Unit Re-assembly
160.78-N2
YMC2 Field Connections
160.78-PW1
YMC Unit Wiring and Field Control Modifications
160.78-PW2
YMC Unit Renewal Parts
160.78-RP1
YMC2 OptiViewTM Renewal Parts
160.78-RP2
2
2
YMC2 Operations and Maintenance
160.78-O1
YMC2 OptiViewTM Operation
160.78-O2
YMC OptiView
160.78-M2
TM
Service
JOHNSON CONTROLS
FORM 160.78-M1
SYSTEM NOMENCLATURE
Y M C 2 - S 0756 A A
YORK
Mod Level
Magnetic Bearing
Refrigerant R-134a
Centrifugal Chiller
S = Single Stage
T = Two Stage
Capacity in KW
COMPRESSOR NOMENCLATURE
M1 B - 197 F A A
Gas Path Revision Level

Impeller Design Revision Level
Motor
Motor Design Level
Impeller Tip Diameter (mm)
Rotation
F = Forward
R = Reverse
VESSEL NOMENCLATURE
E A 25 14 271 B R 1 1 F C R
Inlet from Front View

R = Right
L = Left
Waterbox Type
C = Compact
M = Marine
Water Connection Type
F = Flanges
G = Grooved Standard
A = Victaulic AGS
Vessel
E = Evaporator
C = Condenser
Heat Exchanger Mod Level
Nominal Inside Diameter (Inches)
Nominal Length (Feet)
Marketing Tube Number
Tube Code
B = 3/4" Code 1
C = 3/4" Code 2
D = 3/4" Code 3
E = 3/4" Code 4
2 = 1" Code 1
3 = 1" Code 2
4 = 1" Code 3
5 = 1" Code 4
Vessel Refrigerant Pressure Code

R = Code 180
S = Code 235
T = Code 300
U = Code 350
V = Code 400
Number of Passes
Water Side Pressure Code
1 = 150 psi
3 = 300 psi
VARIABLE SPEED DRIVE NOMENCLATURE

HYP 744 X H 15 D - 40
Hyper
Amps
X = Factory Mount
R = Retrofit Model
H = YMC2 Chiller
40 = 380V 60Hz
50 = 400V 50Hz
46 = 460V 60Hz
68 = 415V 50Hz
D = Disconnect Switch
B = Circuit Breaker
Liquid DWP
15 = 150 psi
30 = 300 psi
JOHNSON CONTROLS
FORM 160.78-M1
THIS PAGE INTENTIONALLY LEFT BLANK
JOHNSON CONTROLS
FORM 160.78-M1
TABLE OF CONTENTS
SECTION 1 - GENERAL.......................................................................................................................................... 11
General Description......................................................................................................................................... 11
Chiller Refrigerant Service.............................................................................................................................. 12
Piping Joint Assembly..................................................................................................................................... 13
SECTION 2 - COMPRESSOR SERVICE.................................................................................................................15
Service Guidelines.......................................................................................................................................... 15
Cleaning and Checking Wearing Parts........................................................................................................... 15
Rigging the Compressor or Motor................................................................................................................... 16
Special Tools................................................................................................................................................... 17
Disassembly of the Driveline........................................................................................................................... 18
Reassembly of the Driveline............................................................................................................................ 21
Drive Motor Repair.......................................................................................................................................... 24
Installing and Removing the Compressor Impeller.......................................................................................... 26
Removing the Balance Piston Seal................................................................................................................. 30
Removing the Diffuser Plate............................................................................................................................ 30
Re-Assembly of the Balance Piston Seal........................................................................................................ 30
Removing the Nozzle Base Plate (VGD)......................................................................................................... 30
Nozzle Baseplate Disassembly (VGD)............................................................................................................ 31
Removing the Impeller Eye Seal..................................................................................................................... 31
Re-Assembly of the Eye Seal (Flat Style Springs Only).................................................................................. 32
Re-Assembly of Nozzle Base Plate (VGD)..................................................................................................... 32
VGD - Assembly and Adjustment of Axial Bearings........................................................................................ 33
VGD - Radial Bearing Tensioner Adjustment ................................................................................................. 34
Re-Installation Of Nozzle Base Plate.............................................................................................................. 34
Adjustment Of VGD Motor Linkage Gas Path Revision Level A................................................................... 34
Variable Geometry Diffuser Calibration........................................................................................................... 35
Adjustment Of VGD Motor Linkage Gas Path Revision Level B - See Figure 41......................................... 36
Removing the Pre-Rotation Vane Housing...................................................................................................... 37
Replacing Control Shaft Assembly.................................................................................................................. 41
SECTION 3 - VGD THEORY....................................................................................................................................43
SECTION 4 - DRIVELINE MAGNETIC BEARING SERVICE..................................................................................45
Description of Components............................................................................................................................. 45
Magnetic Bearing Controller Description......................................................................................................... 47
Troubleshooting the Magnetic Bearing System............................................................................................... 50
MBC Troubleshooting Guide and Motor Service (MegOhm Testing).............................................................. 54
Test Points....................................................................................................................................................... 64
JOHNSON CONTROLS
FORM 160.78-M1
LIST OF FIGURES
FIGURE 1 - Refrigerant Flow Thru Chiller10
FIGURE 2 - Unit Data Plate 11
FIGURE 3 - Refrigerant Charging12
FIGURE 4 - Adjustable End Fitting13
FIGURE 5 - Back Off Locknut14
FIGURE 6 - Screw Fitting Into Port14
FIGURE 7 - Torque Fitting14
FIGURE 8 - SAE Straight Thread O-Ring Port 14
FIGURE 9 - Rigging Guide16
FIGURE 10 - Use of Compressor Tools (-39, -40, -42, -44)17
FIGURE 11 - Motor Power Leads18
FIGURE 12 - Adapter Box Mounting18
FIGURE 13 - Winding Thermistor Wiring18
FIGURE 14 - Piping - Gas Path A19
FIGURE 15 - Piping - Gas Path B19
FIGURE 16 - Bearing Control Cables (Piping Varies Depending on Gas Path) 20
FIGURE 17 - Motor and Compressor21
FIGURE 18 - Motor Power Adapter Box22
FIGURE 19 - Motor Power Adapter Box22
FIGURE 20 - Mounting the Adapter Box22
FIGURE 21 - Re-routed Stator Cooling Supply Line23
FIGURE 22 - Magnetic Bearing Feedthough25
FIGURE 23 - Motor Cooling Expansion Valve26
FIGURE 24 - Impeller Assembly Details27
FIGURE 25 - Impeller Stud27
FIGURE 26 - Impeller Mounting27
FIGURE 27 - Impeller Mounting Nut27
FIGURE 28 - Hydraulic Pump28
FIGURE 29 - Check Impeller Runout28
FIGURE 30 - Hydraulic Stud Tensioner (Provided In Motor Tool Kit (464 52939 000)) 29
FIGURE 31 - Balance Piston Seal Retainer30
FIGURE 32 - Rotor Scroll30
FIGURE 33 - Tension Block31
FIGURE 34 - Nozzle BasePlate31
FIGURE 35 - Eye Seal Components31
FIGURE 36 - Eye Seal32
FIGURE 37 - Drive Ring Flush Verification32
FIGURE 38 - Drive Pin32
FIGURE 39 - Wedge Placement33
FIGURE 40 - VGD Extended / Retracted Positioning - Gas Path Revision Level A 36
FIGURE 41 - VGD - Gas Path Revision Level B37
FIGURE 42 - Removing PRV Support37
FIGURE 43 - Internal Parts - Pre-Rotation Vane Assembly - Gas Path A 37
FIGURE 44 - Pre-Rotation Vane Housing Assembly - Gas Path A38
FIGURE 45 - Pre-Rotation Vane Assembly - Gas Path B38
FIGURE 46 - Pre-Rotation Vane Assembly - Gas Path A39
FIGURE 47 - Control Shaft Assembly40
FIGURE 48 - Side View of Diffuser43
FIGURE 49 - Rear View of Diffuser44
FIGURE 50 - Driveline Diagram45
8
JOHNSON CONTROLS
FORM 160.78-M1
LIST OF FIGURES (CONTD)

FIGURE 51 - Bearing Diagram46
FIGURE 52 - Radial Bearing, Sensors and Axis Orientation46
FIGURE 53 - Axis Identification46
FIGURE 54 - Magnetic Bearing Controller Description 47
FIGURE 55 - Magnetic Bearing Control System Circuit Block Diagram 48
FIGURE 56 - Magnetic Bearing Control Cabinet49
FIGURE 59 - Measurements Screen51
FIGURE 57 - Serial Port Configuration51
FIGURE 58 - Application Mode51
FIGURE 60 - Magnetic Bearing Control Cabinet Amb-Link Serial Connectors 54
FIGURE 61 - Motor Winding Thermistors55
FIGURE 62 - Thermistors / Motor Lead Connections56
FIGURE 63 - R261 Resistor56
FIGURE 64 - WIR Converter (ELCART-0946)58
FIGURE 65 - DC/DC Converter (ELCART-0011)59
FIGURE 66 - AMB Control Board (ELCART-1001)59
FIGURE 67 - Oscillator Board (ELCART-0944)60
FIGURE 68 - WIR Board IGBT Verification61
FIGURE 69 - Diode Meter on WIR Board IGBT Connections61
FIGURE 70 - Axial Sensor63
FIGURE 71 - Radial Sensor63
FIGURE 72 - Control Board65
FIGURE 73 - Amplifier Board66
FIGURE 74 - Bearing Temperature Sensor67
FIGURE 75 - VGD Calibration Template68
LIST OF TABLES
TABLE 1 - Assembly Torque13
TABLE 2 - Driveline Weights (lbs.)16
TABLE 3 - Torque Values16
TABLE 4 - Compressor16
TABLE 5 - Variable Speed Drive Weights16
TABLE 6 - Compressor Tool Kit (364 50048 000)17
TABLE 7 - M1 Motor Tool Kit (464 52939 000) 17
TABLE 8 - Impeller Runout28
TABLE 9 - Shims34
TABLE 10 - Solution57
TABLE 11 - Thermistor Curve57
TABLE 12 - WIR Converter (ELCART-0946)58
TABLE 13 - DC/DC Converter (ELCART-0011)59
TABLE 14 - AMB Control Board (ELCART-1001)59
TABLE 15 - Oscillator Board (ELCART-0944)60
TABLE 16 - Resistance67
TABLE 17 - SI Metric Conversion69
JOHNSON CONTROLS
FORM 160.78-M1
LEGEND
High Pressure Vapor
High Pressure Liquid Refrigerant
ROTOR COOLING GAS VENT

(ONLY ON M1B-197FAA and
M1B-205FAA COMPRESSORS)
Low Pressure Liquid Refrigerant

Low Pressure Vapor
COMPRESSOR
PRE-ROTATION VANES
(ONLY ON M1B-197FAA
and M1B-205FAA
COMPRESSORS)
HOT GAS
BYPASS VALVE
DISCHARGE
CHECK VALVE
SUCTION
DISCHARGE
LIQUID LEVEL
VALVE
ISOLATION
VALVE
EVAPORATOR
CONDENSER
SUCTION
BAFFLE
SUB-COOLER
ISOLATION
VALVE
LIQUID COOLING
FOR MOTOR STATOR
LD00924a
Figure 1 - REFRIGERANT FLOW THRU CHILLER

10
JOHNSON CONTROLS
FORM 160.78-M1
SECTION 1 - GENERAL
GENERAL DESCRIPTION
The chiller is a dual shell vapor-compression machine
with a single stage centrifugal compressor directly connected to the rotor of a hermetic permanent magnet AC
variable frequency motor. The motor rotor is a permanent
magnet design. The motor housing is aluminum and is
removable from the compressor scroll housing at the diffuser plate joint. The compressor casing is fully accessible
with vertical circular joints and fabricated of close-grain
cast iron. The compressor castings are designed for 235
PSIG working pressure. The compressor contains prerotation vanes and variable geometry diffuser technology.
Compressors M1B-197FAA and M1B-205FAA, where the
Gas Path Revision level in the compressor model number
is designated A operate the pre-rotation vanes as part of
the capacity control logic. Other compressors, which have
Gas Path Revision level B, have the pre-rotation vanes
clamped full open internally and use the variable geometry
diffuser for throttling gas in capacity control. It is important to recognize the compressor Gas Path Revision level
to understand the compressor construction and motor cooling scheme. The motor stator is cooled with liquid or twophase refrigerant and the rotor and bearings cooled by refrigerant vapor. For chillers with Gas Path Revision A,
the two cooling circuits are independent. For chillers with
Gas Path Revision B, the liquid used for stator cooling is
expanded and the resultant gas continues for rotor and bearing cooling. A return drain path is piped to the evaporator
shell on those units for the excess liquid.
Figure 2 - UNIT DATA PLATE

JOHNSON CONTROLS
The lightweight, high strength, cast aluminum, fully

shrouded impeller is mounted directly to the motor rotor shaft, which is described in detail in the driveline
magnetic bearing service section of this manual.
Ensure power is removed from the input
side of the VSD at all times when the
chiller is under vacuum (less than atmospheric pressure). The VSD maintains
voltage to ground on the motor when the
chiller is off while voltage is available to
the VSD. Insulating properties in the motor are reduced in vacuum and may not
insulate this voltage sufficiently.
The evaporator is a hybrid falling film and flooded design. The refrigerant enters a spray header at the top
and is distributed over the axial length of tubes. Evaporated and overspray refrigerant exits the bottom of the
falling film section to the flooded section. Evaporated
refrigerant exits the flooded section around the outside
of the falling film shroud, through mist eliminating
baffles, and to the suction.
LD14813
11
FORM 160.78-M1
SECTION 1 - GENERAL
The condenser is conventional shell and tube with integral subcooler section in the bottom, from which liquid
refrigerant is passed to the evaporator though the liquid
line and variable orifice throttling device.
NOMENCLATURE
Each chiller is identified by nomenclature as shown below. The nomenclature is printed on a data plate which is
located on the side of the unit control panel (see Figure
2 on page 11). When contacting the factory, include
the complete chiller and compressor model and serial
numbers. Be sure these numbers are copied accurately.
CHILLER REFRIGERANT SERVICE

Trimming Charge in the Chiller
The following flow diagram outlines the proper way
to attain correct refrigerant charge and set proper level
control setpoint in the chiller. The level control setpoint is programmable from the OptiView panel refer to YMC2 OptiView Control Panel Service Manual
(Form 160.78-M2) for additional details.
Begin with 90% of

calculated charge
Operate Chiller
at any steady
conditions
NO
Set Condenser level

setpoint to a value
that maintaines liquid
above the top of the
sub-cooler by 1/2 to 1
Is Evaporator
Small Temperature
Difference
> Design
YES
NO
Operate Chiller
at Full Load
Design conditions
Is Discharge
Superheat
> 90% of Design
YES
Add Charge
in increment
2 to 3% of Design
Set Condenser level

setpoint 2 to 3%
higher
(80% is limit)
YES
NO
Measured
improvement in
Evap STD or
Chiller COP?
YES
Is Discharge
Superheat
< 90% of Design
NO
Done
LD15077
Figure 3 - REFRIGERANT CHARGING

12
JOHNSON CONTROLS
FORM 160.78-M1
SECTION 1 - GENERAL
Transferring Charge
Adjustable End Assembly
Although the chiller is an oil-free design, the components are not degraded by trace amount of polyolester
(POE) oil. However, excess oil introduced by pumpout
units can eventually effect the heat transfer. When using and oil-lubricated charge transfer unit, use only
POE oil and minimize oil loss or carryover as much a
practical.
Locknut
Back-up
Washer
O-ring
PIPING JOINT ASSEMBLY

Assembly of SAE Straight Thread O-ring Port
Fittings
The male and female ends of SAE straight thread Oring ports have UN/UNF straight threads. An elastomeric O-ring is fitted to the male end. During assembly,
the O-ring is firmly sandwiched between the angular
sealing surface of the female port and the shoulder of
the male end. Sealing is thus affected and maintained
by the O-ring compression which results from the
clamping force generated by tightening. The straight
threads do NOT offer sealing action; they provide the
resistance (holding power) for service pressure.
LD14838a
Figure 4 - ADJUSTABLE END FITTING
1. Inspect to ensure that both matching parts are free

of burrs, nicks, scratches or any foreign particles.
2. Install O-ring on port end ofLocknut
fitting, if it is NOT
pre-installed, take care NOT
to nick the O-ring.
Completely
Backed-off
3. Lubricate O-ring with a light coat of synthetic

Polyolester (POE) oil or POE grease.
Back-up
Washer
Contacts
Face
Table 1 - ASSEMBLY TORQUE

TUBE
SIZE
SAE STRAIGHT
SAE STRAIGHT
THREAD SIZE
THREAD
(O-RING PART NUMBER) TORQUE (ft-lbs.)
FACE SEAL TUBE-SIDE

THREAD SIZE
(O-RING PART NUMBER)
FACE SEAL
TUBE-SIDE
TORQUE (ft-lbs.)
18
1/4"
7/16-20
(028-12961-001)
25
9/16-18
(028-12961-011)
3/8"
9/16-18
(028-12961-003)
35
11/16-16
(028-12961-012)
1/2"
3/4-16
(028-12961-004)
60
13/16-16
(028-12961-013)
5/8"
7/8-14
(028-12961-005)
100
1-14
(028-12961-014)
60
3/4"
1 1/16-12
(028-12961-006)
135
1-3/16-12
(028-12961-015)
85
1"
1 5/16-12
(028-12961-008)
200
1-7/16-12
(028-12961-016)
110
1-1/4"
1 5/8-12
(028-12961-017)
250
1-11/16-12
(028-12961-022)
140
1-1/2"
1 7/8-12
(028-12961-020)
305
2-12-UN2A
(028-12961-019)
180
**
2 1/4-12
(028-12961-)
225
Torque30
Locknut
40
NOTE:
** = SAE SIGHTGLASS
JOHNSON CONTROLS
13
FORM 160.78-M1
SECTION 1 - GENERAL
Locknut
4. Back off locknut as far as possible.
Back-up Make sure
back-up washer is NOT looseWasher
and is pushed up as
O-ring
far as possible.
Locknut
Back-up
Washer
O-ring
Straight Non-Adjustable End Assembly

2. Install O-ring on port end of fitting, if it is NOT
pre-installed, use care NOT to nick the O-ring.
Locknut
Completely
Backed-off
4. Screw fitting into port until the hex flat contacts

the port face. Light wrenching may be necessary.
LD14838
Locknut
Figure 5 - BACK OFF LOCKNUT
Male O-ring
Locknut
Completely
Port End
Backed-off
Back-up
5. Screw fitting intoFemale
port until
the
back-up washer
Port
Washer
Back-up
Sealing
contacts the face of the port.Washer
Light
wrenching may
O-ring
SurfaceContacts
be necessary.
Face
Back-up
Washer
Contacts
Face
Female
O-ring
Port
O-RING PORT
Locknut
Completely
Backed-off
Torque
Locknut
5. Tighten to give torque for the specified size as

specified in Table 1.
Sealing is done
here with O-ring
Thread here
for Holding Power
(Resisting Pressure
Blowout)
THREAD O-RING PORT ASSEMBLY
LD14838
Figure 8 - SAE STRAIGHT THREAD O-RING PORT
Assembly of O-ring Face Seal Fittings

LD14838a
Figure 6 - SCREW FITTING INTO

PORT
Back-up
Washer
Torque
Contacts
6. To align the tube end of fitting
to accept incomLocknut
Face
ing tube or hose assembly, unscrew by required

amount, but NOT more than one full turn.
7. Using two wrenches, hold fitting in desired position and tighten locknut to the appropriate torque
value shown in Table 1.
8. Inspect to ensure that O-ring is NOT pinched and
the back-up washer seats flat on face of port.
The male end and female nut of face seal fittings have
UN/UNF straight threads. An elastomeric O-ring is fitted into the grooved male end. During assembly, the Oring is firmly sandwiched between the sealing surfaces.
Sealing is thus affected and maintained by the O-ring
compression which results from the clamping force
generated by tightening the nut. The straight threads do
NOT offer sealing action; they provide the resistance
(holding power) for service pressure.
O-ring Face Seal Assembly
2. Install O-ring in grooved face seal end of fitting,
if it is NOT pre-installed, use care NOT to nick
the O-ring.
Torque
Locknut

4. Thread the nut by hand, and tighten nut to the appropriate torque value shown in Table 1.
LD14838a
Figure 7 - TORQUE FITTING

14
JOHNSON CONTROLS
FORM 160.78-M1
SECTION 2 - COMPRESSOR SERVICE

The compressor is the heart of the chiller and every effort should be made to maintain and keep it operating
at peak efficiency. Being a precision-built machine, it
is important to check ensure cleanliness when the system is opened.
The compressor should not be disassembled for inspection purposes only. However, if the compressor fails to
function as outlined in the OPERATING MANUAL, it
may be necessary to do so. Individual parts are available for replacement as described in the following
compressor servicing section.
SERVICE GUIDELINES
The overhaul and replacement of parts of these compressors, like any other mechanical operation on machinery, is best accomplished by experienced service
personnel using tools and measuring instruments to accomplish accuracy in their work.
Protect Parts and Surfaces - Do not pile or throw

parts indiscriminately. Tape surfaces subject to scratching or nicking during repair operations. Plug off any
passages likely to accumulate dust or abrasives.
Clean Thoroughly - No compressor is completely
overhauled if it is not cleaned internally to new part
condition. Dirty parts can not be inspected or fitted and
will cause excessive wear when the compressor is in
operation.
CLEANING AND CHECKING WEARING
PARTS
Before reassembling the compressor, all parts should
be thoroughly checked for wear.
Worn parts should be replaced with new and each new
part should be thoroughly examined for shipping damage.
There are a number of good practices that should be

followed in disassembly and reassembly of the compressor; some of these are listed below.
While the driveline is open, carefully clean the interior,

using an approved safety solvent and a lint free cloth.
Do Not Mix Parts - Keep parts in some general order

when removing them from the compressor. It is suggested that parts be laid out to follow exploded views
as shown in the many illustrations outlining the disassembly and assembly of the various parts.
Before assembling parts, all friction surfaces should be

lightly coated with a molybdenum disulfide lubricant
such as Molykote or Molkolube and oil. Be sure to
use new, YORK POE refrigerant Oil.
Clean and check all cooling passageways and all tubing.
Molkolube is available from:

Dow Corning Corporation
Dept. A0021
P.O. Box 1767
Midland, Michigan
Do Not Mix Cap Screws and Washers - Cap screws

are suited to the location in which they are used. Too
long or too short a cap screw can result in leakage and/
or interference with some interior parts. Washers have
been selected for specific screws, etc. It is very important to use correct washers or lock washers. The Parts
List and Figures in this instruction show the correct
length and size of screws and washers. See the Renewal Parts Manual to order the correct part numbers.
Westinghouse Electric Corporation (Sales offices in all

major cities). When ordering Molkolube No. 85653, available from YORK Part No. 364-21508 in 2 oz.
cans.
Inspect as Compressor is Disassembled - If possible,

it is desirable to record shaft and impeller runouts before disassembly. Once driveline parts have been disassembled and cleaned, many valuable indications of
the compressor condition are lost. Materials found or
burned surfaces can often give an indication as to why
a part or parts have failed.
When reassembling parts, each part should be carefully

checked for signs of uneven wear, keeping in mind that
a nicely polished surface is not an indication of excessive wear. Sudden, excessive wear on any part of the
compressor is not normal but is usually caused by some
other condition which must be determined and corrected
to assure long periods of trouble-free operation.
JOHNSON CONTROLS
15
FORM 160.78-M1
Seals may be reused if their rubbing surfaces and

matching surfaces of their corresponding rotating parts
are nicely polished with no sign of uneven wear or
gouging.
The impeller should be checked around its outside circumference for evidence of rubbing. If this condition is
found, excess displacement is indicated, and the impeller may be worn sufficiently to require replacement.
All gaskets and O-rings should be replaced with new
when reassembling the driveline to assure that all surfaces have a tight seal after reassembly.
RIGGING THE COMPRESSOR OR MOTOR

When it becomes necessary to remove a compressor
or motor from a unit or base, proper rigging methods
must be used to avoid damage to the equipment and/
or injury to service personnel. Portable cranes must
be of adequate capacity and properly positioned and
blocked to prevent tipping or slipping while lifting the
compressor or motor. Be sure chains are of adequate
strength. Compressor weights are shown in Table 2.
Table 2 - DRIVELINE WEIGHTS (LBS.)

COMPRESSOR
CODE
COMPLETE
DRIVELINE
MOTOR/DIFFUSER
PLATE
SCROLL ASSEMBLY
W/ PRV AND
NOZZLE BASE
DISCHARGE
CHECK VALVE
M1B-197FAA
1950
600/200
1,073
70
M1B-205FAA
1970
600/205
1,085
70
M1B-197FAB
1920
600/200
1050
70
M1B-205FAB
1940
600/205
1065
70
NOTE Motor weights (lbs.) (Located on Motor Data Plate)
Table 3 - TORQUE VALUES

BOLT SIZE
INCHES
1/4
TORQUE
POUND FOOT
HEX HD
10
12PT OR
SOC HD
14
3/8
35
1/2
85
5/8
200**
3/4
300
VENT PRESENT ONLY FOR

M1B-197FAA AND M1B-205FAA
Unless otherwise specified, all screws must be tightened to the

following torque values with lightly oiled threads.
** Lubricated with oil and graphite on male and female threads and
under bolt heads. Moly-kote not acceptable.
Table 4 - COMPRESSOR
COMPRESSOR CODE
COMPRESSOR PART
NUMBER
M1B-197FAA
364 52443 000
M1B-205FAA
364 52470 000
M1B-197FAA
364-53065-000
M1B-205FAA
364-53066-000
Table 5 - VARIABLE SPEED DRIVE WEIGHTS

POUNDS
KILOGRAMS
HYP744VSD
2,075
941
HYP490VSD
1,100
500
16
PRV ACTUATOR ONLY PRESENT FOR

M1B-197FAA AND M1B-205FAA
LD14811
Figure 9 - RIGGING GUIDE

JOHNSON CONTROLS
FORM 160.78-M1
SPECIAL TOOLS
Special tools are available as an option and will be furnished when ordered. These tools are listed in Tables 5
and 6.
13
Table 6 - COMPRESSOR TOOL KIT (364 50048 000)

ITEM
DESCRIPTION
QUANTITY
PER KIT
PART
NUMBER
Eyebolt .3125-18
021 12420
Washer, Plain .3125
16
021 05166
Guide Pin .250-20
064 46499
11
Stud Special
064 14500
12
Hex Nut - .500-20
021 00483
13
Eyebolt - .875
021 07703
14
Washer, Plain - .875
021 05158
15
Eyebolt - .375-16
021 13498
16
Washer, Plain - .375
39
021 05167
14
16
15
11
12
7
6
8
15
16
Figure 10 - USE OF COMPRESSOR TOOLS (-39, -40, -42, -44)
LD11205a
Table 7 - M1 MOTOR TOOL KIT (464 52939 000)

ITEM
DESCRIPTION
QUANTITY PER KIT
PART NUMBER
Tensioner, Stud Impeller
064 52598 000
Hydraulic Tensioner Hand Pump
364 52526 000
Pump, Hand
029 25819 000
Adapter Gauge
023 25103 000
Elbow, Street 45degree
023 25154 000
Gauge, Pressure
029 25817 000
Hose, High Pressure
029 25818 000
Adapter, Pipe
023 25206 000
Tensioner
364 52930 000
Tensioner Cyclinder
064 52928 000
Tensioner Piston
064 52929 000
Seal, Piston T
028 16529 000
Seal, Rod T
028 16527 000
Screw, Set Hex Cone Pt .190
021 33163 000
Socket, Driver Nut Impeller
064 52596 000
Housing, tensioner Impeller
064 52597 000
Wrench, Hex 3-32 Lg
029 18461 000
JOHNSON CONTROLS
17
FORM 160.78-M1
DISASSEMBLY OF THE DRIVELINE

Removing the driveline from the chiller or
motor from the compressor scroll:
4. Disconnect the motor winding thermistor wiring

from the Variable Speed Drive.
1. Lock-out electrical power to the chiller Variable

Speed Drive
2. Disconnect Motor power leads and ground from
inside the Variable Speed Drive Cabinet.
WINDING
THERMISTOR
WIRING
MOTOR
POWER
LEADS
LD14893
Figure 13 - WINDING THERMISTOR WIRING
LD14891
Figure 11 - MOTOR POWER LEADS
3. Remove the six bolts that mount the Motor Power

Adapter Box to the back of the drive. The box will
be removed with the motor or driveline.
MOUNTING
BOLTS
5. Disconnect both motor bearing control cables at

the motor (come from Magnetic Bearing Control
Cabinet). These are released by pulling down on
the connector sleeve, then pulling the connector
free.
6. Disconnect the wiring from the OptiView panel to
the motor housing thermistor, located on the underside of the motor.
Gas Path A Compressors
Remove the stator cooling supply line from the
top of the motor to the isolation valve on the supply pipe from the liquid line. Plug motor opening.
Disconnect the stator cooling return line to the liquid line at the evaporator from the bottom of the
motor. Plug motor opening.
Disconnect the rotor cooling supply vapor line
from the evaporator at the bottom of the motor.
Plug motor opening.
Gas Path B Compressors
LD14892
Figure 12 - ADAPTER BOX MOUNTING
Remove the stator cooling supply line from the bottom of the motor to the isolation valve on the supply pipe from the liquid line. Plug motor opening.
Disconnect the bearing liquid drain line to the
evaporator from the bottom of the motor. Plug
motor opening.
Disconnect the rotor cooling return vapor line to
the evaporator at the bottom of the motor. Plug
motor opening.
18
JOHNSON CONTROLS
FORM 160.78-M1
STATOR COOLING
SUPPLY
AN EEV AND ISOLATION

VALVE COME ON
REPLACEMENT MOTORS
THE EEV IS NOT WIRED
AND THE VALVE MUST
BE CLOSED FOR GAS
PATH A - (SEE DETAIL B
FOR GAS PATH B)
STATOR COOLING
VAPOR RETURN
REPLACEMENT MOTORS
HAVE A PLUG FOR UNUSED
BEARING DRAIN. IT MUST
BE INSTALLED FOR THIS
CONFIGURATION. (SEE
DETAIL A)
ROTOR COOLING
VAPOR SUPPLY
STATOR COOLING
RETURN
COMPRESSOR
FLANGE
DETAIL A
BOTTOM OF MOTOR
LD15953
Figure 14 - PIPING - GAS PATH A

ISOLATION VALVE PLUG
(SEE DETAIL B)
ELECTONIC EXPANSION
VALVE (EEV)
TO OPTIVIEW
ROTOR COOLING
VAPOR RETURN
PIPE PLUG
REMAINS
INSTALLED
IN ALL
CASES
STATOR COOLING
LIQUID SUPPLY
BEARING CAVITY
LIQUID DRAIN
ISOLATION
VALVE
OPEN FOR
GAS PATH B
COMPRESSOR
FLANGE
ISOLATION
VALVE PLUG (IV)
TORQUE 10
FT-LBS
DETAIL B
TOP OF MOTOR
EEV
LD15954
Figure 15 - PIPING - GAS PATH B

JOHNSON CONTROLS
19
FORM 160.78-M1
MOTOR
ENDBELL
BEARING
CONTROL
CABLES
LD14894
Figure 16 - BEARING CONTROL CABLES (PIPING VARIES DEPENDING ON GAS PATH)
If only the motor will be removed with the

compressor scroll in place on the chiller:
1. Remove the rotor cooling vapor return U-bend
tube to the PRV cavity. Plug openings. Applies to
Gas Path A compressors only.
2. Install lifting eyes to the diffuser plate and rear of
the motor and rig to support the motor weight as
indicated in the Table 2 in this manual.
3. Remove two of the 12-point cap screws holding
the diffuser plate to the compressor scroll. These
are torqued to 121 ft-lb. Insert guide pins in place
of the two cap screws.
4. Loosen the remaining 12-point cap screws fastening the diffuser plate to the compressor scroll.
Quantity of 32 total.
20
5. Use three of the cap screws as jacking screws in

the tapped holes provided to separate the diffuser
plate from the compressor scroll.
6. Rig the motor with diffuser plate rearward until
the impeller clears the nozzle eye seal and remove
from the chiller.
7. If the motor power adapter box will be removed,
open the cover and disconnect the motor stator
thermistor wiring.
8. If necessary, the power adapter box can be removed from the motor.
9. If necessary, the motor power leads can be removed from the motor studs. Torque is 25 ft-lb.
JOHNSON CONTROLS
FORM 160.78-M1
ROTOR
COOLING
RETURN
GAS PATH A
ONLY
FOR
LIFTING
MOTOR AND
DIFFUSER
DIFFUSER
PLATE
CAP SCREW
LD14811a
Figure 17 - MOTOR AND COMPRESSOR
If the motor and compressor as a unit will be

removed from the chiller:
1. Remove the rotor cooling vapor return U-bend
tube to the PRV cavity. Plug openings. Applies to
Gas Path A compressors only.
2. Install lifting eyes to the front of the compressor scroll
section and rear of the motor and rig to support the
driveline weight as indicated in Table 2 in this manual.
3. Remove the flange bolts connecting the discharge
check valve to the discharge elbow.
4. Remove the two bolts securing the compressor
base to the evaporator shell bracket.
5. Remove the flange bolts connecting the compressor nozzle to the suction elbow.
6. Lift the driveline from the chiller.
7. If necessary the discharge check valve can be removed from the compressor by removing the nuts
on the discharge studs.
8. Refer to the previous section if the motor or motor
power adapter connection box will be removed.
JOHNSON CONTROLS
REASSEMBLY OF THE DRIVELINE

Assembling the motor to the compressor
scroll:
1. The motor should be mated with the compressor
scroll carefully so the impeller eye engages the
nozzle eye seal squarely.
2. The motor and diffuser plate assembly should be
joined to the scroll with a new O-ring lightly lubricated with POE oil.
3. Apply a light coating of oil and Molykote to the
impeller where it enters the eye seal ring.
4. Install guide pins in two of the tapped holes in the
face of the compressor scroll to guide the diffuser
plate and motor assembly into position.
5. Carefully slide the assemblies together with attention to impeller eye engagement and then install
the 12-point cap screws. Remove the guide pins
last and replace with the final two cap screws.
Quantity of 32. These are torqued to 121 ft-lb.
21
FORM 160.78-M1
ONLY EXISTS FOR

GAS PATH REV A
COMPRESSORS
MOTOR
POWER ADAPTER
BOX
NOTE: AN ACCORDIAN
STYLE BOX MAY BE USED
LD14895
Figure 18 - MOTOR POWER ADAPTER BOX
4. Install the motor power adapter box cover.
Assembling the driveline to the chiller:

1. The motor power leads should be connected to
the appropriate labeled lugs and torque to 25 ft-lb.
Tape the lugs with electrical tape.
2. The motor power adapter box should be installed
on the motor.
3. Connect the motor stator thermistor wiring to the
proper spade lugs.
5. Install the discharge check valve to the discharge

over the discharge studs and install nuts. Be sure
a new O-ring lightly lubricated with POE oil or
POE grease is in place.
6. Prepare a new suction gasket and install a new
O-ring to the check valve outlet using POE grease.
LD14897
Figure 19 - MOTOR POWER ADAPTER BOX

22
LD14896
Figure 20 - MOUNTING THE ADAPTER BOX

JOHNSON CONTROLS
FORM 160.78-M1
7. Install bolts for the suction, discharge, and support connections.
Motor Cooling Piping Depends on

Compressor Gas Path Revision Level
8. While routing the motor power leads into the

opening in the drive, rig the driveline into position to the suction elbow flange, discharge elbow
flange, and support bracket on the evaporator.
Gas Path A drivelines
9. Connect the six bolts that mount the motor power

adapter box to the back of the drive from inside
the drive panel.
10. Connect the motor power leads and ground inside the
variable speed drive cabinet. Torque to 18-20 ft-lbs.
11. Pack insulation into the motor power lead adapter
box opening from inside the drive.
12. Connect the motor winding thermistor wiring to
the variable speed drive.
13. Connect both motor bearing control cables (come
from Magnetic bearing control cabinet). Orient
properly and push onto terminals. Ensure the connector sleeve is pushed up securing to the detents.
14. Connect the wiring from the OptiView panel to
the motor housing thermistors.
1. Using new O-rings lightly lubricated with POE

oil, connect the rotor cooling vapor return U-bend
tube to the top of the motor and the compressor
PRV cavity.
oil, connect the stator cooling supply line at the
top of the motor orifice elbow to the isolation
valve on the supply pipe coming from the chiller
liquid line. NOTE: If the motor is a new replacement, the stator cooling supply line must be rerouted to avoid the motor cooling rib on the housing. Fabricate new tubing (steel 3/8 O.D. x 0.065
wall, 003-00969-000 bulk by foot) from the liquid
line pipe to the strainer inlet as shown. An O-ring
face sleeve (023-20760-000) will be required
brazed on at each end.
oil, connect the stator cooling return from the bottom of the motor to the chiller liquid line on the
evaporator side of the variable orifice valve.
LD15592
Figure 21 - RE-ROUTED STATOR COOLING SUPPLY LINE

JOHNSON CONTROLS
23

oil, connect the rotor cooling vapor supply line
from the evaporator to the bottom of the motor.
5. If the motor is a new replacement, open the isolation valve plug (marked IV) and turn the valve
fully clockwise for full SHUTOFF. Re-install the
access plug.
6. Ensure nothing is connected to the bearing cavity
liquid drain port and the plug is in place
Gas Path B drivelines
oil, connect the stator cooling supply line to the
bottom of the motor orifice elbow from the isolation valve on the supply pipe coming from the
chiller liquid line.
FORM 160.78-M1
DRIVE MOTOR REPAIR

(See Figure 22)
The motor power feedthrough plate
and the magnetic bearing control
feedthroughs and access plates are system
pressure boundaries. Refrigerant must be
removed from the motor side of the system
before removing these parts.
Motor Power Feedthrough Plate Replacement:
1. Remove the motor thermistor leads from the external spade terminals.
2. Remove the power leads and ground lead from the
external feedthrough studs by holding Nut 1 stationary and removing Nut 2. The torque specification at installation is 25 ft-lb.

oil, connect the bearing liquid drain line to the
bottom of the motor near the compressor from the
side of the evaporator.
3. Remove the bolts (Item 1) securing the motor

power feedthrough cover plate (Item 3) and hold
the plate near position. Wiring is attached from
the inside.
3. Using new O-rings lightly lubricated with POE oil,

connect the rotor cooling vapor return line from the
bottom of the motor to the evaporator top.
4. Remove the motor thermistor leads from the internal spade terminals.
4. If the motor is a new replacement, open the isolation valve plug (marked IV) and turn the valve
fully counter-clockwise for full OPEN. Re-install
the access plug.
5. Ensure nothing is connected to the two ports on
top of the motor and the plugs are in place.
Original motors for Gas Path A drivelines
were machined with only the necessary
cooling connection ports. Replacement
M1B motors are machined to suit Gas
Path A and Gas Path B drivelines. Plugs
must be removed for only the necessary
ports and those applicable to the opposite
style unit left in place. A socket head pipe
plug is installed in the compressor end of
the motor face and must remain in place
for any revision. Additionally, replacement motors come with an Electronic
Expansion Valve installed. This is left in
place and only connected electrically for
Gas Path Revision B. Replacement motors also have a valve installed internally
which is accessed through the plug shown
on top of the motor in the figure. The valve
must be fully closed for Gas Path A and
fully opened for Gas Path B.
24
5. With the plate away from the housing to provide

access to the power wire studs, remove the internal wiring from the feedthrough studs by holding
Nut 1 stationary and removing Nut 2. The torque
specification at installation is 15 ft-lb.
6. Remove the O-ring (Item 2) and replace with a
new O-ring. If necessary to hold the O-ring in
place, use a light film of Polyolester grease.
7. Position the new feedthrough cover plate near position.
8. With the plate away from the housing to provide
access to the power wire studs, install the internal wiring to the feedthrough studs. Ensure wires
are landed to the proper studs. Wires and studs are
marked with a pair of wires and stud as U, a pair
of wires and stud as V, and a pair of wires and stud
as W. Place the terminal lugs between Nut 1 and
Nut 2 and by holding Nut 1 stationary torque Nut
2 to 15 ft-lb.
9. Install the six motor thermistor leads and common
to the proper location internal spade terminal.
Wires and terminals are marked as U1, V1, W1,
U2, V2, W2, and Common.
10. Install the motor power feedthrough cover plate
(Item 3) and torque the retaining bolts to 35 ft-lb.
JOHNSON CONTROLS
FORM 160.78-M1
ENDBELL
O-RING
TORQUE
90 Ft-Lb
LD15094
Figure 22 - MAGNETIC BEARING FEEDTHOUGH
11. Install the external power wiring to the feedthrough

studs. Ensure wires are landed to the proper studs.
Place the terminal lugs between Nut 1 and Nut 2
and by holding Nut 1 stationary torque Nut 2 to
25 ft-lb.
12. Install the motor thermistor leads and common to
the proper location on the external spade terminals.
Magnetic Bearing Control Feedthrough
replacement:
Each of the two magnetic bearing control feedthroughs
can be replaced individually.
1. Disconnect the bearing control cable at the
feedthrough by pulling the sleeve down and then
pulling the connector from the feedthrough connection.
2. Remove the bolts (Item 1) securing the cover
plate at the respective feedthrough (Item 4) and
remove the plate.
3. Remove the feedthrough retention nut (Item 6).
NOTE: This nut is only torqued to 90 inch-lbs
(7.5 ft-lb).
JOHNSON CONTROLS
4. Remove the feedthrough from the housing.

5. Disconnect the ground wire for the feedthrough at
the screw inside the access port.
6. Disconnect the wiring from the feedthrough by
disconnecting each of the two plastic connectors
from the internal bearing pigtails.
7. Install a new O-ring from the parts center (Item 5)
for the feedthrough seal, which has been coated
with a film of Loctite 518 sealant. Do not use an
O-ring that shipped on the new feedthrough.
8. Install the new feedthrough connector into the
housing ensuring the flat on the feed through
matches the flat on the hole in the housing that it
inserts to.
9. Install the feedthrough retention nut and carefully
torque to 90 inch-lbs (7.5 ft-lb).
10. Connect the internal wiring for the feedthrough.
This includes the two plastic connectors from the
internal bearing pigtails and the ground wire to
the screw in the access port.
25
FORM 160.78-M1
11. Install a new O-ring (Item 6) for the access cover

plate. Use a light film of Polyolester grease.
ing. Torque the 4 cap screws securing its flange to

the motor housing to 22 Ft-lb.
12. Reinstall the access coverplate (Item 4) and torque

the retention bolts (Item 1) to 35 ft-lb.
2. Use a new sealing gasket between the motor actuator housing and the body. Screw the actuator
into place and torque to 45 Ft-lb with the nut on
the housing.
Motor Endbell Removal

The Endbell does NOT ship with a replacement motor. The Endbell must be
retained for re-installation if the motor
is replaced (see Figure 22).
3. Reconnect the electrical connector and fasten its

cover in place.
1. Remove the the Endbell bolts.
ACTUATOR
2. Remove the Endbell and O-ring.

Motor Endbell Installation
1. Install a new O-ring lightly coated with Polyolester Grease.
2. Install Endbell and torque bolts to 90 Ft-Lb.
If the motor requires replacement, as
required for bearing failure, return the
motor to Product Technical Support in the
same shipping container the replacement
motor shipped in from the parts center.
CAP SCREW
O-RINGS
GASKET
BODY
Motor Cooling Expansion Valve replacement

The valve assembly consists of a body installed in the
motor housing, sealed with two O-rings and held in
place with a bolted flange. See Figure 23 on page 26
1. Remove the power wiring connection to the motor cooling valve motor terminal. This connector
requires the detent be released and then the cover
removed from the connection.
2. The actuator can be removed by leaving the
flanged body in the motor housing and removing
the motor by rotating the nut counterclockwise.
3. The sealing gasket is between the motor actuator
housing and the body. Replace during reassembly.
4. If the body is required to be removed, remove the
4 cap screws securing its flange to the motor housing and lift out.
To replace the valve parts
1. Put new O-rings lightly lubricated with POE oil
on the valve body and install into the motor hous-
26
Figure 23 - MOTOR COOLING EXPANSION VALVE
INSTALLING AND REMOVING THE

COMPRESSOR IMPELLER
The M1 Motor Tool Kit (464 52939 000) is
required to perform the following procedures and is available through Baltimore
Parts.
Installing the Compressor Impeller Assembly

The Impeller and Balance Piston are delivered as an
assembly, with the Balance Piston installed and the
assembly balanced.
1. Install the Ball Bearing Thrust Ring and Axial Position Sensor Ring on the shaft (refer to Figure 24
on page 27).
JOHNSON CONTROLS
FORM 160.78-M1
2. Install the Impeller Assembly over the key onto

the shaft.
4. Thread the impeller nut (064-52453-000) onto the

stud threads to ensure it spins freely beyond the
point where it would engage the impeller. Correct
any thread issues that prevent free travel. Remove
the nut.
5. Apply Molykote in K oil to the outside diameter
of the impeller balance piston and install the impeller over the stud against the shaft end.
MOLYKOTE
LD15096
Figure 24 - IMPELLER ASSEMBLY DETAILS
3. Install the impeller stud (064-52452-000) into the

shaft, threading by hand until it bottoms out and
then back out approximately 1 turn. This should
leave the stud protruding 2.9 to 3 from the end
of the shaft. If the stud can not be turned to result
in 2.9 to 3 beyond the end of the shaft, check the
stud and the hole for thread damage.
LD14900
Figure 26 - IMPELLER MOUNTING
6. Thread the impeller nut (064-52453-000) onto the

stud threads fingertight against the impeller.
TURN
NUT
AGAINST
SEAT
Figure 27 - IMPELLER MOUNTING NUT
Figure 25 - IMPELLER STUD
JOHNSON CONTROLS
LD15065
LD14899
27
FORM 160.78-M1
7. Assemble the hydraulic stud tensioner assembly

onto the impeller stud end and against the impeller end according to Figure 30 on page 29.
RIM
RADIAL
8. Connect the Enerpac hydraulic hand pump to the

stud tensioner according to Figure 30 on page 29.
Ensure the tensioner cylinder is stamped
364-5293-000. This part number applies the
proper force at 2600psi.
EYE
RADIAL
Figure 29 - CHECK IMPELLER RUNOUT
LD15068
Removing the Compressor Impeller
Figure 28 - HYDRAULIC PUMP
LD15067
To remove the impeller, refer to the details for impeller installation. The stud and nut can be re-used during
installation. The nut must be removed by stretching
the stud and should not be removed with a standard
wrench and torque.
9. Apply 1600 psig to the device within +/- 100 psi

to stretch the stud.
1. Assemble the hydraulic stud tensioner onto the

impeller stud end and against the impeller end.
10. Using the rotation wrench (029-18461-000), rotate the nut driver until fingertight. With the stud
stretched at 1600 psi, the nut will need rotated
about 2/3 of a turn. The force necessary to turn the
nut is very light. Holding the impeller should be
sufficient to prevent the shaft from turning. If the
nut will not tighten easily to contact the impeller
face, investigate for problems with the hardware.
2. Connect the Enerpac hydraulic hand pump to the

stud tensioner.
3. Apply 1600 psig to the device within +/- 100 psi
to stretch the stud.
12. Remove the tensioner.
4. Using the rotation wrench (029-18461-000), rotate the nut driver counterclockwise 1 full turn to
back the nut from the impeller face with the stud
stretched at 1600 psi. The force necessary to turn
the nut is very light. Holding the impeller should
be sufficient to prevent the shaft from turning.
13. Check impeller runout. It should be within tolerances specified in Table 7.
5. Release pressure on the tensioner and then remove

the tensioner assembly.
Table 8 - IMPELLER RUNOUT
6. Remove the impeller by lifting and moving away

from the shaft.
11. Release pressure on the tensioner.
IMPELLER SIZE
RIM RADIAL
EYE RADIAL
197FA - 7.760
inch diameter
0.004 inch
0.004 inch
205FA - 8.052
inch diameter
0.004 inch
0.004 inch
28
7. Remove the impeller stud from the threaded hole

in the shaft end. The stud should turn easily.
JOHNSON CONTROLS
FORM 160.78-M1
LD15400
Figure 30 - HYDRAULIC STUD TENSIONER (PROVIDED IN MOTOR TOOL KIT (464 52939 000))
JOHNSON CONTROLS
29
FORM 160.78-M1
REMOVING THE BALANCE PISTON SEAL

The balance piston seal can be accessed with the impeller removed.
1. Remove the balance piston seal retainer by removing the (3) sockethead shoulder screws from
the diffuser plate.
SHOULDER
SCREWS
The diffuser plate cap screws are torqued to the aluminum motor housing at 90 ft-lb.
RE-ASSEMBLY OF THE BALANCE PISTON
SEAL
1. Clean the Diffuser Plate surfaces.
2. Pre-lube the mating surfaces on the seal ring, including the ID grooves, and install the diffuser
plate.
3. Install the Spring Washer.
4. Pre-lube inside corners of the retainer plate.
5. Install the Retainer Plate and secure with the shoulder screws using threadlocker and torque to 14 ft-lbs.
REMOVING THE NOZZLE BASE PLATE
(VGD)
LD15066
Figure 31 - BALANCE PISTON SEAL RETAINER
2. Remove the Balance Piston Seal Retainer, Spring

Washer and Impeller Eye Seal from the diffuser
plate.
1. Remove hand hole cover. Disconnect the VGD

Drive linkage at VGD Drive Ring.
2. Remove the cap screws that hold the nozzle base
plate to the rotor scroll housing.
Note that (2) of these holes are
spaced 180 apart and are tapped for
the eyebolts.
REMOVING THE DIFFUSER PLATE

The diffuser plate can be removed with the impeller
removed.
The diffuser plate has lifting eye holes in the rim at top
and off center for rigging.
3. Using eyebolts, lift the nozzle base plate from the

rotor scroll housing.
PRV PLATE
PRV DEVICE
NOZZLE BASEPLATE
Figure 32 - ROTOR SCROLL

30
EYE SEAL
NOZZLE BASEPLATE
CAP SCREWS
LD15955
JOHNSON CONTROLS
FORM 160.78-M1
NOZZLE BASEPLATE DISASSEMBLY (VGD)

1. Remove brass tipped set screw from tensioner pin
in tensioner block.
12. Remove the drive pins.

13. Remove the bushings from the nozzle base.
2. Remove tensioner bolt and conical washer set.
3. Remove tensioner pin from tensioner block.

4. Remove two cap screws from each axial bearing
block and remove blocks (3 or 4).
5. Remove nuts and washers and remove bearings
from bearing block.
6. Remove stop bolt from drive ring.
O-RING
GROOVE
NOZZLE
BASEPLATE
7. Rotate drive ring clockwise and remove from

bearings on drive pins.
8. Remove cap screws, radial bearings and spacers
(3 or 4).
LD11202
Figure 34 - NOZZLE BASEPLATE
9. Remove the shoulder bolt and tensioner block.

10. Remove nuts and remove bearings and washers
from drive pins (3 or 4).
SET SCREW
REMOVING THE IMPELLER EYE SEAL

1. Remove the (3) sockethead shoulder cap screws
that hold the eye seal retainer to the nozzle base
plate.
2. Remove the eye seal retainer and the eye seal ring
from nozzle base plate (see Figure 35 on page 31).
ROLL PIN
LD11392
CONICAL
WASHER SET
TENSION
BLOCK
O-RING
GROOVE
EYE
SEAL RING
NOTE: CONICAL WASHER SET ORIENTATION REQUIRED AS

ILLUSTRATED ABOVE.
SHOULDER
SCREWS
Figure 33 - TENSION BLOCK
11. Working from the nozzle base plate face, remove

cap screws (3 or 4 pair) in diffuser ring and remove ring.
JOHNSON CONTROLS
EYE SEAL
RETAINER
26301A
Figure 35 - EYE SEAL COMPONENTS
31
FORM 160.78-M1
RE-ASSEMBLY OF THE EYE SEAL

(FLAT STYLE SPRINGS ONLY)
1. Inspect all parts before re-assembly. See Cleaning
And Checking Wearing Parts, Section 2. Replace
with new parts as necessary.
IMPELLER
EYE SEAL
RETAINER
FLAT SPRING
WASHER
LD11394
IMPELLER
EYE SEAL
Figure 37 - DRIVE RING FLUSH VERIFICATION
4. Install drive pins in nozzle base plate, lubricate

with 50/50 mix of Molybdenum disulfide and
grease, use care not to get 50/50 mix into tapped
holes. Attach with two cap screws. Do NOT tighten (see Figure 38 on page 32).
LD15071
Figure 36 - EYE SEAL
Place flat spring washer into retainer and position eye

seal over spring retainer.
2. Take complete eye seal assembly and position on
nozzle base plate. Insert (3) sockethead shoulder
cap screws and tighten to 14 ft-lbs. Check that the
seal ring is free to float.
RE-ASSEMBLY OF NOZZLE BASE PLATE
(VGD)
1. Install two bushings in each drive pin hole. Inner
bushing should be driven to within 1/32 of diffuser ring groove on front of nozzle base plate.
Use caution not to protrude into groove area. Outer bushing should be driven flush with machined
surface.
2. To true up the bushings, insert a pin in the hole
and tap side to side in 4 directions with a rubber
mallet until slip fit is obtained. Do NOT install
pins at this time.
3. Flip nozzle base plate over and install the diffuser ring. Center holes in ring over drive pin
holes. Center holes in ring over drive pin holes.
Center ring in groove by shimming ID with .004
(.10mm) shims. Verify that ring sits flush or below
face of nozzle base plate (see Figure 37 on page
32).
LD11393
Figure 38 - DRIVE PIN
5. Flip nozzle base plate over and align drive pins

using alignment tool and dowel pins inserted
through holes in pin.
6. Remove cap screws one at a time, apply Loctite
243 and torque to 30 ft-lbs.
7. Remove shims and install fixture or block to hold
diffuser ring in retracted position.
8. Install cam followers, washers (located between
cam followers and pins) and nuts to drive pins,
apply Loctite 243 and torque nuts to 95 in-lbs.
9. Install one or two radial bearing tension blocks to
nozzle base plate using the screws and torque to
18 ft-lbs.
10. Install one or two tensioner pins into tensioner
blocks. Position pins so that the tapped holes are
aligned with the hole in the tensioner blocks
11. Make up one or two tensioner spring assemblies
from screws, washers, and conical washers, note
the orientation of conical washers (See Figure 33
on page 31).
32
JOHNSON CONTROLS
FORM 160.78-M1
12. Insert tensioner spring assemblies through holes

in nozzle base plate, into tensioner blocks and just
start to engage in the tapped holes in the tensioner
pins. Do NOT tighten at this time.
13. Assemble radial bearings and spacers to the nozzle base plate and tensioner using screws, apply
Loctite 243 and torque to 35 ft-lbs.
14. Lower drive ring over drive pin cam followers and
rotate counter clockwise into fully retracted position.
15. Install drive ring stop screw.
16. Tighten tensioner spring assemblies to a finger
tight condition. Do NOT tighten with tools. This
will provide just enough tension to keep drive ring
centered.
VGD - ASSEMBLY AND ADJUSTMENT OF
AXIAL BEARINGS
5. Snug the nuts on the axial bearing just enough to

seat the axial bearings against face of the support
block.
6. Rotate the drive ring counterclockwise until it stops.
7. Working through the hole in the drive ring, rotate
the axial bearings to move the drive ring to the
furthest most position away from the nozzle base
plate. Work one bearing at a time.
8. Using a dial indicator on the drive ring top face,
re-adjust the axial bearings to obtain a .001.002 axial backlash to the drive ring at all four
locations.
9. Apply Loctite 243 and torque the axial bearing retaining nuts to 95 in-lbs.
10. Verify the backlash at the axial bearings.
1. Assemble axial support blocks, bearings, washers,

and nuts do NOT tighten.
2. Use wedges to hold drive ring away from nozzle
and keep diffuser ring fully retracted.
3. Determine shim quantity:
A. Measure H (between nozzle and lower edge
of the inside groove at the drive pins of the
drive ring. Measure at each pin location).
B. Utilize wooden wedge between nozzle base
and the drive ring to force the drive ring up as
high as possible before measuring (See Figure 39 on page 33).
C. Measure L (the distance from hole in axial
bearing block to bottom of block, measure all
blocks).
D. Determine T for eack block.
T = (H + .125) - L
LD11406
E. Determine the number of .015 thick shims

to place under the axial bearing block.
4. Assemble the shims and axial support block/ bearing assemblies to the nozzle base plate. Align the
blocks such that the face of the block is parallel to
the inside diameter of the drive ring. Apply Loctite 243 and torque screws to 14 ft-lbs.
LD11395
Figure 39 - WEDGE PLACEMENT
JOHNSON CONTROLS
33
FORM 160.78-M1
Table 9 - SHIMS
T
SHIM QTY.
0-.010
.011-.025
.026-.040
.041-.055
VGD - RADIAL BEARING TENSIONER

ADJUSTMENT
Adjust radial bearing tensioner(s) by tightening screws
1-1/2 to 1-3/4 turns for two tensioner units and 3 turns
for single tensioner units.
1. Apply Loctite 243 and assemble set screw into
tensioner pin using care to not get sealer between
pin and block. Torque the set screw to 30 in. lbs.
2. Remove any fixtures or blocking. Operate mechanism, it should operate smoothly through the full
range of travel without any binding.
3. Lubricate all moving surfaces with 50/50 mix of
Molybdenum disulfide and grease.
RE-INSTALLATION OF NOZZLE BASE PLATE
1. Using Eyebolts, set the nozzle base plate into the
scroll housing.
2. Install the cap screws that hold the nozzle base
plate to the housing. Torque to 14 ft-lb.
ADJUSTMENT OF VGD MOTOR LINKAGE
GAS PATH REVISION LEVEL A
Procedure is specific to the
compressor gas path revision level
1. With the drive link disconnected from the external lever (motor lever installed and drive link connected to motor lever out-most hole), manually
operate the VGD control to the fully retracted position (the most clockwise position of the actuater
motor viewing the shaft end).
2. Loosen the the two set screws that hold the external lever to the feed through shaft. (torques to 120
ft.lbs.) This is just a clamped joint, there is no key
or spline.
4. Snug the lever screws enough to work the VGD

mechanism, but not loose enough to slip on the
shaft.
5. Slowly rotate the external lever clockwise (retracting the VGD mechanism) until it reaches the
internal hard limit.
6. Check the alignment of the holes between the
external lever and and the link. The center of the
hole should be to the right of the center of the external lever hole.
7. With the VGD mechanism against the internal
limit, loosen the external lever clamp bolts just
enough to allow rotation of the lever about the
shaft but not loosen enough to be overly free.
Do NOT make bolts too loose as the shaft
may want to rotate counter clockwise.
8. Continue holding the VGD mechanism against

the internal stop and rotate the external lever
clockwise (slipping on the shaft) to properly align
the holes in the link with the hole in the lever. this
assures that the VGD mechanism does not bind
against the internal limit when fully retracted.
Proper alignment is obtained when the
center of the hole in the lever is approx.
1/8 to the right (over traveling) of the
centerline of the hole in the link
9. Tighten the actuating arm clamping bolts, torque

to 120 ft-lbs.
10. Re-assemble the link to the lever.
11. Cycle the VGD mechanism through full travel.
The link should never get tight or bind and should
always be loose when shaken.
The OptiView VGD calibration needs
performed if the VGD arm or actuator
is replaced.
3. Rotate the external lever counter clockwise approx. 30 with respect to the feed through shaft.
34
JOHNSON CONTROLS
FORM 160.78-M1
VARIABLE GEOMETRY DIFFUSER

CALIBRATION
Gas Path Revision Level A - See Figure 39
The VGD calibration serves to capture the feedback potentiometer output voltage that corresponds to the start
and end of the active portion of the VGD internal mechanism travel. The compressor is marked at the assembly
plant with an index punch on the actuator arm and two
marks on the VGD shaft coverplate or two marks on the
arm and a pointer on the cover plate bolts. That signifies
the start and end of the active travel range. The front of
the arm is scribed continuous onto the end of the shaft
to indicate its alignment with the shaft when the punch
marks were made. The following procedure is to be performed if the VGD requires calibration.
1. At the keypad, login at SERVICE access level using login code 1 3 8 0.
2. Select VGD (Variable Geometry Diffuser) Screen
from the Compressor Screen and select VGD
CALIBRATE. This navigates to the VGD Calibration Screen that allows manual control of the
VGD and entry of calibration values.
3. Using open/close commands, position the VGD
so that the match mark on the VGD arm aligns
with the match marks on the VGD shaft cover
plate or pointer signifying the most retracted end
of the active travel of the internal mechanism.
This is the first mark encountered moving from
Open to Closed (counterclockwise from the free
end of the shaft).
4. With the match marks aligned, press the Set 100%
VGD key to accept the existing feedback voltage
as the beginning of the effective travel range.
5. Using manual open/close commands, position the
VGD so the match mark on the VGD arm aligns
with the match mark on the VGD shaft cover plate
or pointer signifying the most extended end of the
active travel of the internal mechanism. This is
the second (last) mark encountered moving from
Open to Closed.
JOHNSON CONTROLS
6. With the match marks aligned, press the Set 0%

VGD key to accept the existing feedback voltage
as the end of the effective travel range.
7. If any questions exist to the validity of the punch
marks, the following FIGURE demonstrates a
means to verify approximate positions.
8. Remove the shoulder bolt connecting the VGD
arm to the actuator link.
9. Pull the VGD arm fully clockwise (viewed as,
from front) until it stops.
10. Position the Template with the hole over the pin
on the end of the VGD shaft and the three lines
facing the VGD arm.
A VGD Calibration Template (Figure 70)
has been created to scale. Remove from
manual and affix to a more rigid paperstock or cardboard.
11. With the VGD arm against the clockwise stop,

secure the template to the structure to keep from
rotating with the line marked CLOCKWISE
STOP aligned with a fresh mark on the tip of the
VGD arm.
12. Rotate the VGD arm along the stationary template until the fresh mark previously made on
the tip aligns with the line marked START OF
ACTION. Index the VGD arm to the VGD shaft
cover plate at this position.
13. Rotate the VGD arm along the stationary template
until the fresh mark previously made on the tip
aligns with the line marked END OF ACTION.
Index the VGD arm to the shaft cover plate at this
position.
14. Restore the actuator link to the VGD arm.
15. Perform the VGD feedback calibration process
using the index marks defined from the process.
35
FORM 160.78-M1
EXTENDED
(CLOSED)
RETRACTED
(OPENED)
(SHOWN)
SHOULDER
BOLT
VGD
ARM
VGD
SHAFT
LD15100
Figure 40 - VGD EXTENDED / RETRACTED POSITIONING - GAS PATH REVISION LEVEL A
ADJUSTMENT OF VGD MOTOR LINKAGE GAS

PATH REVISION LEVEL B - See Figure 41
1. With the drive link disconnected from the external VGD lever and the motor lever installed and
drive link connected to the motor lever in Hole #1,
manually operate the VGD actuator to the fully
extended position (the most counter-clockwise
position viewing the actuator from the shaft end).
2. Loosen the two set screws that hold the external
lever to the feed through shaft (These are torqued
to 120 ft.lbs.). This is just a clamped joint, no key
or splines.
3. Position the lever on the shaft about 90 degrees
clockwise from vertical and snug the set screws
that hold the arm to the shaft enough that the lever
can slip but drags the shaft.
5. With the VGD shaft remaining at the stop, rotate

only the arm further counter-clockwise so the center of the hole in end of the arm is 1/8 inch overtravel beyond the center of the mating hole in the
connecting link in the counter-clockwise direction
when the connecting link is raised into position.
Tighten the two set screws to clamp the arm to the
VGD shaft in this position. Torque to 120 Ft.lbs.
6. Re-assemble the link to the lever.
7. Cycle the VGD mechanism through full travel.
The link should never get tight or bind and should
always be loose when shaken.
The OptiView VGD calibration needs
performed if the VGD arm or actuator
is replaced.
4. Rotate the external lever counter-clockwise,

bringing the VGD shaft counterclockwise until
the internal hard stop is contacted (drive ring stop
pin contacts the stop shoulder bolt).
36
JOHNSON CONTROLS
FORM 160.78-M1
ASSEMBLE
LINKAGE IN
HOLE 1
B. Lifting off the vane arm.
RETRACTED
(SHOWN
OPENED)
LINK
EXTENDED
TORQUE
80 IN LBS
ADJUST LEVER ON SHAFT SUCH

THAT LEVER CAN OVER TRAVEL
MOTOR LINKAGE BY APPROX 1/8
IN FULLY EXTENDED POSITION
C. Lifting off the two special washers and pulling the vane out toward the inside of the vane
housing (See Figure 44 on page 38).
VGD
ARM
VGD
SHAFT
GUIDE PIN
PRV SUPPORT PLATE
00593VIP
LD15956
Figure 41 - VGD - GAS PATH REVISION LEVEL B
REMOVING THE PRE-ROTATION VANE

HOUSING
Access to the PRV assembly can be made by removing
the suction piping and removing the cap screws that secure the PRV plate support to the rotor scroll. Insert the
proper guide pins and using the proper rigging methods, remove the PRV support plate from the compressor scroll to gain access the PRV assembly (see Figure
42 on page 37).
Figure 42 - REMOVING PRV SUPPORT
4. If any of the individual vanes were removed

or replaced, coat the vane shank with oil and
Molykote. Tighten the vane cap screws when
clamped in the closed position to the torque as
indicated in Table 3.
5. Re-assemble the pre-rotation vane assembly and
the nozzle base plate together in reverse order.
Torque all screws in accordance with Table 3.
1. Remove the 12 pt. hd. cap screw and fill piece to

disconnect the adjustable bearing rod from the
vane driving ring (see Figure 43 on page 37).
2. Remove 2 hex hd. cap screws at approximately
180 apart. Replace these screws with two guide
pins from the tool kit. Then remove the remaining screws from around the perimeter of the PRV
assembly. Carefully pull the PRV assembly about
halfway on the guide studs. Hook a lifting device
to the assembly. Pull it off the guide studs and
place on a bench to replace any parts.
3. The Pre-Rotation Vanes are actuated for Gas Path
A compressors by a rotating vane driving ring
through individual vane arms to each vane. Individual vanes may be removed by:
A. Unscrewing the cap screw which secures the
vane arm to the vane.
JOHNSON CONTROLS
PRE-ROTATION
VANE DRIVE RING
INTERNAL LEVER
26666a
Figure 43 - INTERNAL PARTS - PRE-ROTATION

VANE ASSEMBLY - GAS PATH A
37
FORM 160.78-M1
For Gas Path B Compressors, the PreRotation Vanes are individually fixed
full open and not connected to actuating
levers.
TORQUE
45 ft-lbs.
26667A
DETAIL A
Figure 44 - PRE-ROTATION VANE HOUSING ASSEMBLY - GAS PATH A
SCREW CAP
TORQUE 45 FT-LB
SPACER, PRV
HOUSING,
PRE-ROTATION
VANE
PRIMER
SEALER
VANE, PRE-ROTATION
SET VANES TO THE FULL OPEN (AXIAL) POSITION
PRIOR TO TORQUING THE CAP SCREW
LD15957
Figure 45 - PRE-ROTATION VANE ASSEMBLY - GAS PATH B
38
JOHNSON CONTROLS
FORM 160.78-M1
2
4
6
9
ITEM
DESCRIPTION
(7, 12)*
21501
11
QUANTITY
ITEM
Ring, Driving
Washer
DESCRIPTION
QUANTITY
10
Vane
Stud, Ball
Arm, Vane
Screw 12 pt.
Spacer, Arm
11
Nut, Self-Locking
Washer
12
Housing
Figure 46 - PRE-ROTATION VANE ASSEMBLY - GAS PATH A

JOHNSON CONTROLS
39
FORM 160.78-M1
EXTERNAL
LEVER
LINKAGE
VANE MOTOR
DETAIL A
LD11203
PRV
INTERNAL
LINKAGE
PRV
CONTROL SHAFT
COVER
PRV CONTROL
SHAFT
ADJUSTABLE
STOPS
BRACKET
SUPPORT
EXTERNAL PRV
LEVER
PRV PLUG
ASSEMBLY
O-RING
O-RING
INTERNAL
1 I.D. (95) 1-1/8 (94)
LEVER
(33)
LD11204
12 PT HD CAP SCREW
3/8 - 16 UNC X 1-1/2 LG (60)
SPECIAL WASHER (28)
ONE - 12 PT HD
1/2 - 20 UNF x 6 LG (57)
GASKET
(87)
CONTROL
SHAFT (21)
NOTE: CAN BE TAPERED

OR SQUARE DRIVE
COVER
PLATE (94)
NEOPRENE
SLEEVE
12 PT HD CAP SCREW
3/8 - 16 UNC x 1-1/2 LG (60)
EXTERNAL PRV
LEVER (34)
SPECIAL STUD
1/2 - 20 UNF x 9
LD11538
Figure 47 - CONTROL SHAFT ASSEMBLY

40
JOHNSON CONTROLS
FORM 160.78-M1
REPLACING CONTROL SHAFT ASSEMBLY

The external and internal levers are secured to the control
shaft by means of a single 12 pt. hd. cap screw threaded
into the internal lever (refer to Figure 46 on page 39).
Adjustable stops are provided in the internal lever arm.
These stops are NOT to be used to stop the vanes in the extreme positions of normal travel, but are supplied as protection should some external force be applied to the linkage.
The stops are set about 1/32 away from the rotor scroll
casting walls when the vanes are in their extreme position,
and will prevent overtravel from damaging the internal
vane mechanism. Loctite 243 is used on the threads when
the stops are initially positioned to prevent any change in
position. The compound should be used again if the stops
are ever removed.
12. Install the cover plate, but do not tighten the cap
screws at this time.
13. Tighten the nut on the outside end of the stud
against the end of the control shaft to pull the internal lever hard up on the taper of the shaft.
14. With the cover plate loosely installed, close the
vanes by turning the nut on the outside end of the
stud. Position the external lever on the control shaft
so that the indicator pin punch mark or split on the
lever aligns with the closed C mark on the housing. Snug pinch bolts for the split lever.
15. Remove the nut and stud (taper type only).
To replace control shafts, refer to Figure 47 on page

40 and proceed as follows:
16. Install the 6 cap screw and washer. Draw the cap
screw tight. Move the external lever to the open
and closed positions, to check the indicator
points on the cover plate. Readjust the external
lever position, if necessary.
1. Reduce the system pressure to slightly above atmospheric pressure.
17. Using a torque wrench, tighten the cap screw to a

torque of 85 ft-lbs.
2. Disconnect the linkage from the external lever

(refer to Figure 47 on page 40, Detail A).
18. Move the external lever to its midposition (vanes

half open) and tighten the cover plate cap screw to
a torque of 35 ft-lbs.
This is important and assures that the
sleeve will twist equally when the vanes
are moved to either the wide open or the
fully closed position.
3. Loosen and remove the 12 pt. hd. cap screw and

washer. For square drive design, the O-ring plug
must be removed from the end of the shaft to gain
access to the cap screw.
4. Remove external lever (loosen pinch bolts on split
lever).
5. Insert the special stud through the hole in the control shaft, and screw the stud into the internal lever. Be sure to put a nut on the outside end of the
special stud (refer to Figure 46 on page 39).
6. Using a hammer and block of hard wood, tap the
outside end of the stud to loosen the internal lever.
DO NOT REMOVE THE SPECIAL STUD.
7. Remove the cover plate cap screws.
8. Remove the external lever and the control shaft
cover from the scroll.
9. Replace the existing gasket with a new one.
10. Install the new O-rings in their respective grooves
in the new control shaft. Liberally coat the control
shaft (O-rings and neoprene sleeve) and the inside
of the cover plate with YORK Valve Stem Lubricant. Do not lubricate the tapered surfaces of the
shaft or gasket face.
19. Connect the linkage to the external lever.

20. Torque the lever pinch bolts to 121 ft-lbs. and install the O-ring plug into the end of the shaft.
When connecting the vane linkage to the electric motor, rotate the motor shaft to the closed position and
connect the vane linkage while holding the vanes in
the closed position. Operate the vane motor open and
closed several times to be sure the motor does not jam
at either end of its travel. Adjust as necessary by either lengthening or shortening the distance between
the motor linkage and the external lever to be sure the
vanes are wide open and tightly closed as the motor
rotates from one end of its travel to the other.
IT IS IMPORTANT that the arm length from motor centerline to force point, the arm length from control shaft centerline to force point and the length of connection arm be the
same as they were set at the factory. Also, the angular position of the motor shaft must be as it came from the factory.
11. Slide the new shaft with O-rings into position over
the special stud.
JOHNSON CONTROLS
41
FORM 160.78-M1
THIS PAGE INTENTIONALLY LEFT BLANK
42
JOHNSON CONTROLS
FORM 160.78-M1
SECTION 3 - VGD THEORY

VGD DIAGRAM
Actuating Arm
Nozzle Base Plate
Drive Ring
Cam Groove
Drive Pin
LD11522
ACTUATING ARM - Driven by an external actuating-motor this arm rotates the Drive Ring.
DRIVE RING - Circular rotating Drive Ring is driven by an external actuating motor.
CAM GROOVES - Drive-Pin Cam-Followers (hidden behind the Drive Pins) ride in this groove.
DRIVE PIN - Multiple drive pins are pushed and pulled by the Drive Pin Cam-Follower.
DIFFUSER RING - This circular ring is pushed in and out of the diffuser gap, by the drive pins,
continuously varying the diffuser width to match the changing flow. Cannot be seen from this view.
Figure 48 - SIDE VIEW OF DIFFUSER
JOHNSON CONTROLS
43
FORM 160.78-M1
SECTION 3 - VGD THEORY
Drive Pins
and
Drive Pin Cam
Followers
(3 or 4)
Connecting Link
Actuating Arm
Drive Ring
Nozzle Base Plate
Radial
Bearing
Drive Pins
and
Drive Pin Cam
Followers
Axial Bearing
Assembly
Drive Pins
and
Drive Pin Cam
Followers
LD11490
ACTUATING ARM - Driven by an external actuating-motor this arm rotates the Drive Ring.
DRIVE RING - Circular rotating Drive Ring is driven by an external actuating-motor.
DRIVE PIN CAM FOLLOWER - Follows precision cam-groove machined into the Drive Ring OD.
DRIVE PIN - Multiple Drive Pins are pushed and pulled by the Drive Pin Cam-Follower.
DIFFUSER RING - This circular ring is pushed in and out of the diffuser gap, by the Drive Pins,
continuously varying the diffuser width to match the changing flow. Cannot be seen from this view.
Figure 49 - REAR VIEW OF DIFFUSER
44
JOHNSON CONTROLS
FORM 160.78-M1
SECTION 4 - DRIVELINE MAGNETIC BEARING SERVICE

Axial Magnet The axial magnetic bearing applies attractive force to a step on the rotor shaft.
DESCRIPTION OF COMPONENTS
Magnetic Bearings Description
The compressor is driven by a hermetic permanentmagnet high speed motor with magnetic bearings. The
impeller is mounted directly to the common shaft of
the motor rotor, overhung outside of the impeller-end
bearing set. The motor is supported between an impeller end bearing set and an opposite-impeller end bearing set. Each one of the two bearing sets includes the
following components:
Four Radial Magnets The bearings radial
electromagnets are in pairs with magnets oriented directly across the axis of the shaft from each
other. Two pairs exist for each bearing oriented
in orthogonal axes. The axes are rotated 45 degrees from horizontal and vertical so that gravity
is countered by the shared attraction of the upper
magnet in both axes together.
Radial Position Sensors The bearing set includes a pair of radial position sensors in two orthogonal axes in line with the magnetic bearing
axes. These are inductive coil sensors.
Axial Position Sensor The bearing set includes
an axial inductive coil position sensor.
Touchdown Bearing A pair of angular contact
ball bearings exists with clearance from their inside diameter to the shaft to accept touchdown of
the rotating shaft on a magnetic bearing failure
and to support the shaft when idle.
TOUCHDOWN
BEARING
AXIAL
MAGNET
AXIAL
MAGNET
RADIAL
MAGNET
IMPELLER
ROTOR
STATOR
RADIAL
MAGNET
TOUCHDOWN
BEARING
Figure 50 - DRIVELINE DIAGRAM

JOHNSON CONTROLS
LD15078
45
FORM 160.78-M1
AXIAL
SENSOR
(This face NOT shown)
The Aixial magnets are called Z1 at the Impeller end

and Z2 on the end opposite the impeller.
RADIAL
SENSOR
The bearing position sensors, when powered and having signals processed electronically, produce an output
voltage proportional to their distance away from the
target. For radial sensors, the target is the shaft. For
axial sensors, the target is a magnetic steel ring pressed
on the shaft between two aluminum rings.
The radial sensors are located as an opposed pair across
the shaft in each axis. The axial sensors are an adjacent
annular pair at each target ring. Each locations sensor
pair output voltage is processed so it equals zero when
the shaft or target ring is centered between the sensors
and increases positively or negatively as the target is
moved in either direction.
RADIAL
BEARING
LD15079
BALL
BEARING
AXIAL
BEARING
Figure 51 - BEARING DIAGRAM
The Magnetic Bearing Controller (MBC) determines

the shaft position by comparing the position sensor
processor output DC signal to a reference voltage input. The current to the magnets in the bearings is then
modulated in proportion to move the shaft and maintain the position sensor signal equal to the reference.
The reference voltage for YMC2 is held as zero volts
DC for levitated operation, which centers the shaft between the sensors.
SENSORS
ELECTRO
MAGNETS
LD15080
Figure 52 - RADIAL BEARING, SENSORS AND

AXIS ORIENTATION
Y
Rotation Direction
W2
V2
Z2
V1
W1
X1
Impeller
End
X1
Z1
V4
W4
Y1
V3
Figure 53 - AXIS IDENTIFICATION

46
W3
Y1
LD15081
JOHNSON CONTROLS
FORM 160.78-M1
Power
Amplifiers
Signal
Conditioning
Reference
Signal
Error
+
PID
Electromagnets
V1
Postion
Sensors
+
-
ROTOR
V2
Sensor Signal
LD15080
Figure 54 - MAGNETIC BEARING CONTROLLER DESCRIPTION
MAGNETIC BEARING CONTROLLER

DESCRIPTION
The Magnetic Bearing Control Cabinet
receives 750VDC from the VSD. Live
750VDC exists inside this cabinet when
the VSD DC bus is energized.
The Magnetic Bearing Controller (MBC) is a separate cabinet that contains the hardware and software
to operate the compressor driveline magnetic bearings.
The MBC is powered directly from the chiller Variable
Speed Drive (VSD) cabinet with DC voltage from the
DC bus. The MBC is operable when greater than 350
volts is available from the VSD DC bus on power-up
and until less than 75 volts is present on power-down.
The MBC monitors shaft position and bearing temperatures. The MBC receives a signal indicating the motor rotational speed from the VSD. The VSD monitors
motor stator temperatures from winding thermistors
connected to the drive. When the MBC is operable it
communicates with the OptiView panel.
The MBC communicates with the OptiView panel using Modbus serial protocol over an RS-485 link. OptiView issues state change commands and fault status
requests to the MBC and the MBC issues operating
data, state status, and fault data to the OptiView as described in the YMC2 OptiView Service Manual (Form
160.78.M2).
The magnetic bearing controller has three dry contact
digital outputs that are fed to the OptiView to indicate
significant conditions about the MBC status.
ESD - Emergency Shutdown. The MBC opens
this contact when it has a shutdown fault condition standing. This contact remains closed during
warning level conditions.
Watchdog - The MBC opens this contact when
internal software has not communicated properly
to its internal control watchdog feature, indicating
a control malfunction. The MBC will remain in
the prevailing state of operation when the failure
occurred, either Rotation, Levitation or De-levitated.
Rotation Allowed - The MBC closes this contact
to indicate that the rotor is levitated properly off
the touchdown bearings and can be rotated.
JOHNSON CONTROLS
47
FORM 160.78-M1
The magnetic bearing controller has three states of operation:

De-levitated - The motor shaft is resting on the
physical touchdown bearings, no current is supplied to magnetize the magnetic bearings.
Levitation - The motor shaft is suspended by the
magnetic bearings. The controller is maintaining
shaft position by controlling bearing currents in
relation to feedback from displacement sensors.
Rotation - This is the same as levitation state but
enables a safety interlock to prevent de-levitating
the motor shaft unless the drive speed is below
a touchdown threshold (10 Hz). Also, this state
enables the automatic anti-vibration reduction
system (AVR) and automatic balancing system
(ABS) , which react to or filter the rotational speed
vibration response in specific running frequency
bands. The MBC automatically switches to Rotation state when it detects a speed signal from the
VSD that is greater than 10 Hz, regardless of the
OptiView command.
The Magnetic Bearing Controller has two features
related to the 1x rotation vibration. These are called
Automatic Vibration Reduction (AVR) and Automatic
Balancing System (ABS).
Some degree of imbalance is inevitable in any rotating machine. Imbalance presents itself as a vibration at
rotational speed. Standard bearings put force into the
shaft to keep it centered and into the housing to counter
the shaft force caused by imbalance. This units magnetic bearing system can manipulate its reaction to this
imbalance as required to smooth the operation. AVR
operates over the range of the bearing system natural
frequency and shifts the phase of its radial displacement reaction 90 degrees to control 1x rotation as it
passes through the minimum bearing stiffness point.
AVR becomes active when Rotation is commanded
on and the speed signal from the VSD indicates to the
MBC that speed is above 80 HZ. The AVR technology
is effective above 80 Hz and to the ABS frequency of
220 Hz. The ABS technology is effective above 220
Hz, and becomes active when Rotation is commanded
on and the speed signal from the VSD indicates to the
MBC that speed is above 220 HZ.
ABS allows the shaft to vibrate freely only at 1x rotation by filtering this frequency out of the driver signal
to the radial bearings. This prevents imbalance and runout forces from transmitting to the stationary driveline
hardware. It also reduces the bearing currents required
to stabilize the shaft and eliminates the cyclic force that
would exist to keep the shaft geometrically centered in
opposition to the natural orbit due to minor imbalance.
MAGNETIC BEARING CONTROLLER CABINET

POWER
SUPPLY
INTERFACE
WIDE
INPUT
RANGE
DC/DC
CONVERTER
CONTROLLER
CUSTOMER
INTERFACE
OSCILLATOR
AMPLIFIERS
MOTOR
LD15083
Figure 55 - MAGNETIC BEARING CONTROL SYSTEM CIRCUIT BLOCK DIAGRAM

48
JOHNSON CONTROLS
FORM 160.78-M1
The individual control boards are explained below:

1. The Power Supply Interface accepts the DC supply power feed from the VSD DC bus. In addition,
the Power Supply Interface board provides a connection point for OptiView serial communication to
transfer to the Customer Interface Board.
2. The Wide Input Range Board (WIR) has capability to accept a wide range of input voltages; thereby,
allowing the other MBC components to be common
to a variety of different applications. It powers up
when the input is greater than or equal to 450VDC
and remains powered until input is less than
120VDC. The Power Supply WIR decreases the bus
voltage received from the VSD to a level suitable to
drive the DC/DC Converter (120 to 140VDC). The
Power Supply WIR also supplies power to the MBC
circulation fans (24VDC).
3. The DC/DC Converter regulates the Power Supply
WIR output to the various DC voltages required by
the other circuit boards in the MBC. It outputs control board voltages 8VDC (6 to 9VDC range) and
POWER
SUPPLY
INTERFACE
15VDC (13.5 to 16.5VDC range) and 150VDC to

180VDC to the Bearing Amplifier Board.
4. The Control Board is the brain of the MBC. Its Oscillator sub-assembly provides bias to drive the position sensors, and then the Control Board processes
the sensors position signals through PID controllers to manage the electromagnets. In addition, the
logic functions on the Control Board include control
mode selection and alarm detection and management for all bearing sytem components.
5. The Amplifier Board supplies required current to
the bearing electromagnets to levitate and sustain
the rotor shaft. It responds to the signals received
from the Control Board.
6. The Customer Interface Board provides the communication between the MBC system and the chillers OptiView control panel. This includes serial
Modbus com and digital output. The RS485 transceiver resides on this board.
7. Oscillator board generates excitation current for the
bearing position sensors.
WIDE
INPUT RANGE
BOARD
AMPLIFIER
BOARD
CONTROL
BOARD
OSCILLATOR
BOARD
DC/DC
CONVERTER
CUSTOMER
INTERFACE
BOARD
LD15084
Figure 56 - MAGNETIC BEARING CONTROL CABINET

JOHNSON CONTROLS
49
FORM 160.78-M1
Motor Cooling
The motor stator is cooled with liquid refrigerant flowing in a double-pass helical path along the outside of
the stator, between the stator and the motor housing.
The refrigerant from the liquid line leaving the condenser is driven by condenser pressure through the stator cooling circuit and returns to the liquid line near
the evaporator downstream of the liquid line variable
orifice.
A restriction orifice 3.4 mm diameter exists in the liquid supply to the stator at the tubing elbow connection to the housing to control flow. It is protected by
an inline strainer with greater free area to control any
flushed inadvertent construction debris. A ball valve
and an angle isolation valve exist in this line as part
of chiller isolation to segregate charge in either shell
for maintenance and to isolate the strainer if it ever requires maintenance due to flow restriction and motor
overheating. The valves must be open for operation.
The motor rotor and bearings are cooled with refrigerant vapor flowing from the top of the evaporator,
through the bearings and rotor gap, and returning to
the compressor impeller eye between the eye and the
pre-rotation vanes. The gas is driven by differential
pressure between the evaporator and the impeller eye.
Bearing temperatures are monitored by the MBC and
stator thermistors monitored by the OptiView panel
through the VSD, as described above.
TROUBLESHOOTING THE MAGNETIC
BEARING SYSTEM
Manual Command
Normal chiller operation maintains power on the VSD
DC bus only when run is commanded and for 60 seconds after the driveline stops rotating upon issue of a
stop command. The MBC can be powered with the
chiller stopped in SERVICE access level using manual
features available at the OptiViews RAPTYR VSD
DETAILS SCREEN.
This screen allows service level access to issue manual command to the VSD. The selections are DISABLED, PRE-CHARGE, and PRE-REGULATION.
DISABLED disables the manual command to
the drive and resumes automatic operation.
PRE-CHARGE charges the DC bus from line
voltage.
50
PRE-REGULATION allows the DC bus to

come to full operational voltage, including boost.
PRE-CHARGE is sufficient to develop operational level DC voltage for the MBC.
The manual command is timer-limited to prevent leaving a standing energized command indefinitely when
the chiller is off. Also, the shaft can be commanded
to levitate with the chiller stopped and VSD DC bus
energized in SERVICE access level using manual
features available in the OptiViews MBC SCREEN.
This screen allows service level access to issue manual
command to the MBC. The selections are DE-LEVITATED and LEVITATION.
DE-LEVITATED disables the manual levitate
command to the MBC and resumes automatic operation.
LEVITATION causes the MBC to levitate and
suspend the rotor. This command should not be
maintained indefinitely due to bearing cooling issues without compressor operation. See the YMC2
OptiView Service Manual (Form 160.78.M2).
The MBC Event log should always be saved as the initial step of troubleshooting following a chiller trip related to the MBC. This log will contain data that could
be significant to determine the conditions and status at
the time of the trip. The log buffer is limited and could
be over-written if not captured soon after an event. The
AMB-link software described below will allow a save
of the MBC internal event log.
AMB-LINK Software
An RS232 serial link exists on the MBC Control Board
to interface with the manufacturers diagnostic software on a personal computer. YMC2 chillers ship with
a harness that connects the serial SubD 9 contact port
on the board to a port on the side of the cabinet for external access. The software is named AMB-LINK and
can extract operating data from logged MBC parameters at high resolution for advanced troubleshooting.
The software also allows viewing of MBC data including bearing currents at high frequency updates during
troubleshooting. Contact Product Technical Support
for assistance.
The AMB-LINK program can be downloaded from
the internal Johnson Controls service literature site, in
the section for Chiller Service Literature / Centrifugal
Chillers / YMC2 (Click on Link to proceed).
JOHNSON CONTROLS
FORM 160.78-M1
To run the program, connect a serial connector from

the port on the side of the MBC cabinet to the laptop
that contains the program files.
The MBC must be powered up for the program to recognize good communications and continue. This can
be done with the VSD manual DC bus command as explained previously when the chiller is stopped. When
the chiller is running, the MBC should be energized.
Run the file AMB-LINK.exe to start the program. The
following precursors must be setup.
Set the AMB-LINK Com port setting to a port
that matches the computer port number where the
cable is connected (use right click, my computer,
then properties-hardware-device manager-ports to
read the port number on a computer running Microsoft windows).
LD15097
Figure 57 - SERIAL PORT CONFIGURATION
Once the program is running in communication with

the MBC, the following screen displays and several
common tasks can be performed:
Ensure or Set computer COM to 19200 baud, 8

bits, zero parity, 1 stop.
When AMB-LINK boots, it defaults to a COM port
and if that is not the correct one for the connection,
it puts up a com error. Just acknowledge the error and
reset the Com port to the correct one that the computer
shows for the line.
Figure 58 - APPLICATION MODE
LD15098
Measurements Screen
The following screen is a view of the live data from
the MBC.
LD15099
Figure 59 - MEASUREMENTS SCREEN

JOHNSON CONTROLS
51
FORM 160.78-M1
Functional Mode Window contains

Yellow Box with the status of the control unit
Delevitated - The shaft is resting on backup bearing.
5. One operating time counter, which is a cumalative

counter of the time during which the controller
has been powered up, whatever the mode.
Levitated - The shaft is controlled by the controller.
Bar Graph
Acceleration - The shaft is levitated, rotating and

speeding up.
Displays the speed of the machine.

The programmed minimum speed setpoint (example represents 500 RPM).
Rotation - The shaft is levitated and rotating.

Normal - The shaft is levitated, rotating at speed
above nominal speed.
The programmed maximum continous operating

speed (example represents 15,000 RPM).
Deceleration - The shaft is levitated, rotating and

decreasing speed.
The overspeed setpoint (example represents

45,500 RPM).
3 Control Buttons
Alarms Reset - Reset Failure massages.
AMB ON - Levitate the shaft. Machine is ready
to rotate.
AMB OFF - Delevitate the shaft.
The commands AMB ON / AMB OFF are
only active if PC has been selected in
the Remote Command menu.
Current Speed
Measurements is shown in the following:
RPS = Rotations per Second (Hertz).
RPM = Rotation per Minute.
10 Bearing Coil Currents
CV1, CV3, CW1 and CW3 are the currents of the
four bearing coils associated with the radial bearing of the 1-3 end of the machine.
CZ1, CZ2 are the currents of the thrust (or axial)
bearing acting along the machine Z axis.
Date and Time

Displays the date and time of the controller internal
clock.
Warning Box
CV2, CV4, CW2 and CW4 are the currents of the

four bearing coils associated with the radial bearing of the 2-4 end of the machine.
These currents can displayed with either
1 or 3 decimal points.
Shows any failure, alarm and information messages.

Counter Zone with 5 Counters
1. One Hard Landing counter counting the number of times the shaft radial (and axial) position
has exceeded during rotation the programmed
landing setpoint, typically set at 80% of the ball
bearing clearance.
Positions Analog Information

Up to six position signals are monitored by the control
unit:
2. One counter recording the number of times a DSP

interrupt ocurred.
Four Radial signals associated with the radial axes

V13, W13, V24 and W24.
3. One start counter counting the number of times

the the rotation input has been activated or the
number of times the machine speed has exceeded
the minimum speed setpoint.
One Axial signal (associated to the Z axis) Shaft

axial position.
4. One Rotation Counter, which is a cumlative counter of the time during which the controller has
been in the rotation mode.
52
Shaft elongation (when available).

The position amplitude is the overall amplitude taking
into accounts both DC and AC position. The amplitude
is given as the zero to peak amplitude. The unit can be
either micron or mil (1 mil = 25.4 m = .001 inch).
JOHNSON CONTROLS
FORM 160.78-M1
Vibrations Zone
Software
Is associated with the ABS funtion and displays the

filtered synchronous component of the position signal
supported by a tracking filter synchronized with the
machine speed signal, which extracts the synchronous
(also referred to as Harmonic 1 or One Time vibration) component. Typically this vibration synchronous
signal represents the shaft unbalance and/or sensor
run-out.
Displays the current software version installed.
NOTE: One can see in the position, the vibration and

elongation bar graph is represented with yellow and
red lines.
Yellow: Indicates the programmed level 1 alarm
setpoint.
Red: Indicates the programmed level 2 alarm setpoint.
The vibration amplitude is given as the zero to peak
amplitude. The unit can be either micron or mil.
Vibration measurements are only available when the machine speed has exceeded one of the AVR or the ABS ON/
OFF setpoint (below this AVR and ABS
ON setpoint, the tracking fiilters are
disabled).
Temperature
The control unit can process up to 4 temperature
signals.
Two temperature signals related to the machine
mechanical hardware (typically bearing temperature or motor temperature, information on the location of the temperature probes can be labeled
with up to 5 charaters).
Two temperature signals related to the control
unit hardware (typically temperature probes are
located on the power amplifier module, information on the location of the temperature probes can
be labeled with up to 5 characters).
Temperatures can be displayed either in
Degree Celsius C or Degree Fahrenheit
F.
Boot Loader - Software

Monitoring - Software
DSP or Control algo - Software
Identifier - Is a specific function built-in the control
unit allowing recognizing what type of machine or
bearing hardware is connected to control the unit. This
function is only used when the same control unit can be
connected to different bearing hardware. When NOT
used the identifier is represented by 255 LSB.
Converter Selector
Allow at any time to change temperature and position.
Capture
This function allows (by clicking on the capture button) at any given time to download in a Microsoft Excel file the list of all the control unit operating parameters (speed, position, unbalance, currents, electronic
temperature, machine temperature, identifier and rotor
elongation). This function can actually be used as a
Data Logger.
Event Log Screen
This screen displays a buffer listing the type of event
for the most recent events with its time, date, alarm
level and MBC state. The save button will save the
Event Log to a file on the connected computer. The file
is acessible with Microsoft Excel.
ESD Snapshot Screen
This screen allows the data that was recorded before
and after recent level 2 and 3 events to be saved to a file
on the connected computer. The SAVE button initiates
the save of the Level 2 and 3 events shown in the table
on that screen. This file is accessible with Microsoft,
then formatted as comma delimited columns. This data
is most useful to successfully perform the diagnostics
of an MBC Fault.
SAVE ALL DATA
This function box on the main screen allows the ESD
Snapshot, the Event Log, and the Measurement Capture to all be saved at once. This function is useful to
collect data for troubleshooting any MBC fault.
JOHNSON CONTROLS
53
FORM 160.78-M1
BOARD
AMB-LINK
CONNECTOR
EXTERNAL
AMB-LINK
CONNECTOR
LD15085
Figure 60 - MAGNETIC BEARING CONTROL CABINET AMB-LINK SERIAL CONNECTORS
MBC TROUBLESHOOTING GUIDE AND

MOTOR SERVICE (MEGOHM TESTING)
Refer to YMC2 Wiring Diagram - MBC (Form 160.78PW3) for more information on procedures in this section.
Motor
The motor is wired as two parallel circuits in WYE
configuration. Phase to Ground can be checked with
Meg Ohm meter. Phase to Phase can only be checked
with a milliohm meter, because the phases are ganged
together internally in WYE configuration. Resistance
to ground should be at least 5 Meg Ohm at 500 volts if
they need to be checked.
Motor leads should be disconnected from the lugs in
the drive for testing. Adhere to cautions in the front of
this manual regarding auto rotation electrical hazard. If
initial readings at power wire ends are below criteria,
remove the external leads and test at the motor lugs to
disinguish lead versus motor issues.
Unit must be at positive pressure (no
vacuum) during the megging procedure.
54
Motor Winding Thermistor

This testing is be conducted when any one of the motor winding thermistor values is either minimum (low
32F) or maximum (high 303F). These extreme values will cause either a high or low motor winding temperature fault on the Motor Details Screen in Optiview.
Perform the following test to verify motor winding
thermistor integrity. There are 6 motor winding thermistors that are connected to the motor on spade connectors where the motor power leads penetrate the motor
housing. The testing described below will be conducted from within the VSD cabinet and this access to these
test locations requires that all electrical, lock out tag
out policies must be adhered to.
All of the below steps are to be conducted at the J4
wire harness, the J4 connector on the VSD Logic Board
031-02911-001 and at 4TB inside the VSD cabinet.
The J4 cable must removed for all of the below steps.
The thermistors are set up in pairs at the connector. The
J4 harness connector test location will check the integrity of the entire electrical path from the J4 connector
and harness, through 4TB and the wires from 4TB to
the motor housing temperature spade connector as well
as the internal wiring to the actual winding thermistors. Table 11 on Page 57 for equivalent resistance
to temperature values.
JOHNSON CONTROLS
FORM 160.78-M1
Once all 4 numbered steps are performed, use the Solution Table 10 on Page 57 for what needs to be done
to resolve issue.
Sockets 7 to 8 = Motor Temp # 4

Prior to proceeding, all wire terminations should be

verified for proper installation, location and tightness.
2. Should any of the previous locations yield an unacceptable value, perform a resistance check of
the thermistors at the 4TB terminal strip inside
the VSD. This will eliminate or confirm the integrity of the J4 wiring harness from 4TB to the VSD
Logic board J4 location. This check must be done
on the motor side of 4TB at the wires to the motor.
These wires are also set up in pairs and should be
measured on the pairs as outlined below.
1. Using a Digital multi meter conduct a resistance

test of the motor winding thermistors. The first
step is to check the thermistor resistance values
that feed back to the logic board. This is also to
check the wiring integrity back to the motor sensing locations. If any channel should indicate a
resistance value inconsistent with the expected
value, proceed to step 2. The J4 Harness sockets should equal some very high resistance value
equivalent to the values as shown on the Thermistor curve, Table 11 on Page 57 for the motor
ambient temperature and be consistent between
all 6 thermistors. An example would be that 50K
resistance = 76.3F and 40K = 85.5F.
Measurments should be taken on the 4TB wire

pairs
1 and 2 MTR = Motor Temp # 1
V2
W1
W2
V1C
WHT
THV
GRN
V2C
WHT
THY
ORG
W1C
WHT
THW
YEL
W2C
WHT
THZ
BRN
MOTOR HOUSING
4 MTR
5 MTR
6 MTR
7 MTR
8 MTR
9 MTR
10 MTR
11 MTR
12 MTR
BLK
WHT
19B
BLK
GRN
4
12
19D
BLK
YEL
19C
BLK
BLU
19C
BLK
4TB
THX
3 MTR
19A
19A
WHT
RED
19E
U2C
2 MTR
19B
RED
BLK
19F
V1
THU
1 MTR
J4
19E
4TB
U2
WHT
BRN
BLK
YEL
BLK
U1
U1C
BLU
BLK
WHT
BLK
RED
BLK
GRN
BLK
COM
19D
Measurments should be taken on the J4 wire

harness connector socket pairs
BLK
BRN
19F
VSD
LOGIC BOARD
031 02911 001
4TB
VSD
VSD
LD16807
Figure 61 - MOTOR WINDING THERMISTORS

JOHNSON CONTROLS
55
FORM 160.78-M1
U
THERMISTOR TABLE
Wire
Marking Terminal
THU
U1
THV
V1
THW
W1
THX
THY
THZ
Unmarked
U2
V2
W2
COM
W
U1
U2
V1
V2
W1
COM
W2
Attach thermistor motor leads

per thermistor table.
LD16808
Figure 62 - THERMISTORS / MOTOR LEAD CONNECTIONS
3. If the previous locations still yield unacceptable

values, there are 2 options. The first is to perform
a resistance check of the thermistors from the
motor penetration connecting spades. This will
eliminate or confirm the integrity of the wiring
harness between the motor and 4TB and identify
if the source is the thermistors and/or internal motor monitoring wiring. Each spade is numbered as
shown on Figure 62 on Page 56.
Measurments should be taken on the spade
connector wire pairs
Com and W1 = Motor Temp # 1
Com and V1 = Motor Temp # 2
Com and U1 = Motor Temp # 3
Com and W2 = Motor Temp # 4
Com and V2 = Motor Temp # 5
Com and U2 = Motor Temp # 6
4. On the VSD Logic board, the J4 Board connector Pins should be equal in value in the 25 KOhm
range or higher. Note that these values will climb
the longer the test leads are in contact. This check
is performed to validate the board level physical handling of the thermistor signals at the VSD
Logic board. This check is for proper resistance
values in the signal path where it lands on the
board.
56
Measurement points
Pins 1 to 2 =
Pins 3 to 4 =
Pins 5 to 6 =
Pins 7 to 8 =
Pins 9 to 10 =
Pins 11 to 12 =
Measure the R261 resistor on the back of the logic
board. It is next to the J4 connector but on the back of
the board. It should equal 11 Ohm.
J4 Pins on Back of Board
R261
LD16810
Figure 63 - R261 RESISTOR
5. After all of the above steps have been completed

please refer to the Table 10 on Page 57 to determine the solution.
JOHNSON CONTROLS
FORM 160.78-M1
Table 10 - SOLUTION
STEP 1
RESULT
STEP 2
RESULT
STEP 3
RESULT
STEP 4
RESULT
SOLUTION
Pass
Pass
Pass
Pass
The issue is with the VSD Logic board and it will need to be replaced.
Fail
Pass
Pass
Pass
Replace connector and sockets for wire harness from 4TB to VSD
Logic board J4 connection.
Pass
The issue is the wires from the motor penetration spades to 4TB. This
not a serviceable item. Remove the wires from 4TB and securely wire
nut them. Disable the appropriate motor temperture at the Motor Details Screen. This requires an Admin password. This can be serviced
at a later date.
The issue is the motor thermistor(s). This not a serviceable item.
Remove the wires from 4TB and securely wire nut them. Disable
the appropriate motor temperture at the Motor Details Screen. This
requires an Admin password.
Fail
Fail
Pass
Fail
Fail
Fail
Pass
Pass
Pass
Pass
Fail
The issue is with the VSD Logic board and it will need to be replaced.
Table 11 - THERMISTOR CURVE

R OHM
50000
49500
49000
48500
48000
47500
47000
46500
46000
45500
45000
44500
44000
43500
43000
42500
42000
41500
41000
40500
40000
39500
39000
38500
38000
37500
37000
36500
36000
35500
35000
34500
34000
33500
DEG C
24.60
24.83
25.06
25.29
25.52
25.76
26.00
26.25
26.49
26.74
27.00
27.25
27.51
27.78
28.04
28.31
28.59
28.86
29.15
29.43
29.72
30.01
30.31
30.61
30.92
31.23
31.55
31.87
32.19
32.52
32.86
33.20
33.55
33.90
JOHNSON CONTROLS
DEG F
76.28
76.69
77.10
77.52
77.94
78.37
78.80
79.24
79.69
80.14
80.59
81.06
81.52
82.00
82.48
82.96
83.46
83.96
84.46
84.97
85.50
86.02
86.56
87.10
87.65
88.21
88.78
89.36
89.95
90.54
91.15
91.76
92.39
93.03
R OHM
33500
33000
32500
32000
31500
31000
30500
30000
29500
29000
28500
28000
27500
27000
26500
26000
25500
25000
24500
24000
23500
23000
22500
22000
21500
21000
20500
20000
19500
19000
18500
18000
17500
DEG C
33.90
0.01
34.63
35.00
35.38
35.77
36.16
36.56
36.97
37.38
37.81
38.24
38.68
39.13
39.59
40.07
40.55
41.04
41.54
42.06
42.59
43.13
43.68
44.25
44.83
45.43
46.05
46.68
47.33
48.01
48.70
49.41
50.15
DEG F
93.03
32.02
94.33
95.00
95.68
96.38
97.09
97.81
98.54
99.29
100.05
100.83
101.63
102.44
103.27
104.12
104.98
105.87
106.78
107.70
108.65
109.63
110.63
111.65
112.70
113.78
114.89
116.03
117.20
118.41
119.66
120.94
122.27
R OHM
17000
16500
16000
15500
15000
14500
14000
13500
13000
12500
12000
11500
11000
10500
10000
9500
9000
8500
8000
7500
7000
6500
6000
5500
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
DEG C
50.91
51.70
52.51
53.36
54.23
55.15
56.09
57.08
58.11
59.19
60.32
61.50
62.75
64.06
65.44
66.91
68.47
70.13
71.92
73.83
75.90
78.14
80.60
83.31
86.32
89.70
93.55
98.01
103.28
109.70
117.84
128.82
145.32
176.69
DEG F
123.64
125.05
126.52
128.04
129.62
131.26
132.97
134.75
136.60
138.54
140.57
142.70
144.94
147.30
149.80
152.44
155.25
158.24
161.45
164.89
168.62
172.66
177.08
181.95
187.37
193.46
200.39
208.41
217.90
229.46
244.11
263.87
293.57
350.04
57
FORM 160.78-M1
MBC Powering up
This procedure applies to the E150/4 bearing controller
used on the M1B YMC chiller
Power the VSD DC Bus - Manual Pre-regulate from
Optiview VSD Details Screen when chiller is stopped
Check that the MBC is energized by checking LEDs in
the MBC cabinet - (Note that the MBC has live 750
Volt DC)
WIR board - Green
DC/DC converter board - Green
Control board - Yellow
If WIR LED is not lit, check for the DC Bus Voltage
value on the VSD Details screen and check for this bus
voltage at MBC power supply interface connection and
check proper polarity.
MBC Power Supply Interface Board Terminal J20
is +
MBC Power Supply Interface Board Terminal J31
is -
If necessary check MBC supply fuses in the VSD,

25FU and 26FU. If the fuses are electrically open, perform the WIR board IGBT verification section of this
manual, to verify if the WIR was damaged in the event
that opened the fuses.
If voltage is at good at J20 and J31, check red and black
cable connectors from MBC power supply interface
board to the WIR board for bus voltage.
Red from J18/1 and 2 to WIR X6.2 is +.
Black from J19/1,2,3 to WIR X6.3 is -.
If the WIR LED is lit and the DC/DC converter not,
check for 130 VDC from the WIR to the DC/DC converter board. If not present, check the cables to these
terminals:
DC/DC Converter board terminal X1.5/1 and 2
from WIR X6.1/1 and 2 is +
DC/DC Converter board terminal X1.5/3 and 4
from WIR X6.1/3 and 4 is If the Control Board LED is not lit, check cabling from
the DC/DC converter to control board.
Boards Diagrams
Table 12 - WIR CONVERTER (ELCART-0946)
LED
COLOR
MEANING WHEN LED COMES ON
V1
Green
Presence of 750 VDC voltage
V1
LD15801
Figure 64 - WIR CONVERTER (ELCART-0946)
58
JOHNSON CONTROLS
FORM 160.78-M1
Table 13 - DC/DC CONVERTER (ELCART-0011)

LED
COLOR
CR17
Green
CR17
LD15802
Figure 65 - DC/DC CONVERTER (ELCART-0011)
Table 14 - AMB CONTROL BOARD (ELCART-1001)

LED
COLOR
V1
Yellow
V2
Green
Normal operation (Levitation activated)
V3
Yellow
Normal operation (automatic balancing system activated)
V4
Red
Abnormal operation (alarm levels 2 or 3)
V4
V3
V2
V1
LD15803
Figure 66 - AMB CONTROL BOARD (ELCART-1001)

JOHNSON CONTROLS
59
FORM 160.78-M1
Table 15 - OSCILLATOR BOARD (ELCART-0944)

LED
COLOR
V1
Red
Oscillator failure / radial side
V2
Red
Oscillator failure / radial side
V3
Red
Oscillator failure / axial side
V4
Red
Oscillator failure / axial side
V1
V2
V3
V4
LD15804
Figure 67 - OSCILLATOR BOARD (ELCART-0944)
WIR Board IGBT Verification - to be performed in

the field when the fuses protecting the MBC DC supply
lines have opened (25FU and 26FU in the VSD cabinet):
Using a multimeter with the diode meter function, verify the integrity of the WIR Q2 IGBT.
This operation shall be done by verifying:
The Vbe voltage shall be measured at around
0.68V for a healthy WIR
The Vce voltage shall be measured as Overload
for a healthy WIR
If one these two measurements is not correct, the WIR
DC/DC converter shall be considered as damaged and
shall be replaced.
60
The diode meter shall be connected to the WIR DC/DC

converter as shown on the pictures below:
The MBC shall not be powered. Make
sure to let enough time after powering
down the MBC elapse before doing any
measurement on the board (some of the
capacitors can take several minutes to
discharge).
The board is varnished so one has to pierce through the
varnish with the meter probes to actually make contact
with the IGBT pins and be able to measure the Vbe
and Vce.
Proper polarity of the meter leads is important (Black
lead is negative, Red lead is positive)
JOHNSON CONTROLS
FORM 160.78-M1
AREA OF MEASUREMENT
Figure 68 - WIR BOARD IGBT VERIFICATION
LD15805
_
VBE = 0.68V
+
LD15807
_
VCE = OL
+
LD15806
LD15808
Figure 69 - DIODE METER ON WIR BOARD IGBT CONNECTIONS

JOHNSON CONTROLS
61
FORM 160.78-M1
Oscillator Fault
The position sensors are inductive coils driven by a 20
kHz, sine wave excitation from the oscillator board in
the MBC. The radial sensor excitation is 12 Vpk-pk and
the axial sensor excitation is 20 Vpk-pk The MBC control board oscillator circuit will overload and trip if the
connections to the position sensors are opened while
the device is powered. The sensor inductance is offset
by a control capacitor across the oscillator circuit. If the
inductive load of the sensors is removed, the excitation
current will be shorted through the capacitor. The connections to the position sensors should not be broken
when the MBC is powered. An inadvertent oscillator
trip requires verification that the position sensor wiring
is in tact. The device will reset when the overload condition is cleared by having the sensor coils connected.
Communication Issue
The VSD DC Bus must be powered so the MBC is
powered (Note that 750 volt is present).
Connect AMB Link
If it is not communicating with the MBC: Check
Serial port setting on computer and that the serial
cable has continuity.
If the cable is in-tact and the port settings good,
Reboot computer and try again.
Check Optiview MBC Screen for valid data and check
AMB link Measurement Screen, Functional Mode
field- Should read De-levitated when Optiview has the
chiller stopped and commanding De-levitated. If the
values on Optiview are showing XXX and/or Levitated
or Aceleration shown in AMB-Link then a problem
likely exists with the serial communication between the
MBC and Optiview.
Check the Optiview COM 6 transmit and receive
LEDs
Red CR3 = Transmit
Green CR2 = Receive
If transmit is flashing and not receive:
Check that MBC Controller Address is set
to 2. This is found looking at the Measurement
Screen data capture file or on the Remote Command tab in AMB-Link, password USER.
62
Then check the Optiveiw to MBC Modbus

communication cable continuity and polarity
end to end per 160.78-PW2.
The RS485 device of the MBC is located on
the Customer Interface Board.
If transmit is not flashing, check optiview microboard.
Digital Fault Signal Issues
ESD or Watchdog Faults
Check that Optiview MBC screen does not have MBC
Digital fault (ESD) LED lit when the MBC is powered
and has no standing fault. The MBC will have continuity through the ESD dry contacts when no fault is present.
If Optiview shows a fault, the 120VAC signal back to
Optiview I/O board TB3-70 is open. Ensure that AMB
link showed no standing Level 2 or Level 3 fault, which
would cause the MBC fault contact to break the circuit.
(Shown on AMB-Link Event Log as a Red-colored
Level 2 or Level 3 Alarm with State= ON.
If MBC AMB-Link shows a level 2 or level 3 alarm
with state = ON, check the fault message and refer to
YMC2 OptiViewTM Operation (Form 160.78-O2) for
alarm message and causes for it. Some may be simple
motor cable connections.
If no such faults show on AMB link and Optiview
shows fault LED lit, check 120VAC fault wiring from
Optiview I/O board to MBC. Check for 120 volts AC at
MBC Customer Interface Board X4.2/4 and that MBC
ESD and Watchdog contacts are closed (120 VAC at
X4.2/1). Then check for 120 VAC at Optiview I/O
board TB3-70. If 120VAC is at I/O board TB3-70, issue is with Optiview.
Rotation Allowed Contacts
Manually Levitate from Optiview MBC Screen and
check that the Rotation Allowed LED on the Optiview
MBC screen lights after the AMB-link shows Levitated in the Measurement Screen, Functional Mode field.
If not check 120VAC wiring from Optiview I/O board
to MBC. Check for 120 volts AC at MBC Customer Interface Board X4.2/6 and that MBC Rotation Allowed
contacts are closed (120 VAC at X4.2/5). They should
be closed. Then check for 120 VAC at Optiview I/O
board TB3-30. If 120VAC is at I/O board TB3-30, issue is with Optiview.
JOHNSON CONTROLS
FORM 160.78-M1
Magnet Coil or Sensor Failures Encountered

Upon Levitation
Manual Levitate from Optiview MBC Screen and
check MBC screen:
Position Sensors
Disconnect the position sensor circuit from the MBC
control board. Check sensor resistance according to
the tables below:
Positions V13, W13, V24, W24, Z12 when levitated and static should go to <10 um
E+
All bearing currents when levitated and static go

greater than 0.5 amp
If ALL of the bearing currents = 0 AND amplifier
board temperature = 0 (MBC Details Screen), suspect
the ribbon cable between the MBC control board and
the MBC amplifier board.
If ALL of the bearing currents = 0 and a valid amplifier

board temperature exists, suspect the amplifier board.
If individual positions are showing failure to respond,
measure bearing and position sensor resistances at
MBC end of X1 and X2 and work back toward motor
to find breaks in wiring. Refer to 160.78-PW3. Expected resistance values are found below:
When the VSD is powered, the MBC cabinet will have 750 VDC supplied to it. The
MBC should be powered down and power
isolated for resistance checks of bearing
coils or position sensor coils.
ESENSOR
DIRECTION
LEADS
VALUE
Axial
Between E+ and E-
34 Ohm + 10%
Axial
Between E- and L
17 Ohm + 10%
Figure 70 - AXIAL SENSOR
E+
Magnetic Bearing Coils

Disconnect the two applicable coil power wires from
the amplifier board at the terminal blocks on the amplifier board or disconnect the X1 or X2 cables which
connect the MBC to the Motor at the MBC end. Connect an ohmmeter to the two power wires to determine
resistance through the bearing coils. If an impedance
meter is available, the inductance can be checked also.
For a radial bearing
The resistance should be 1.7 Ohm + 10%.
The inductance (at 4 Amp) should be 43 mH.
LD15809
Lv
Lw
ELD15810
SENSOR
DIRECTION
LEADS
VALUE
Radial
Between E+ and E-
1.8 Ohm + 10%
Radial
Between E- and L
1.5 Ohm + 10%
Figure 71 - RADIAL SENSOR
For an axial bearing

The resistance should be 5.5 Ohm + 10%.
The inductance (at 4 Amp) should be 675 mH
Check insulation resistance using a 500 VDC Megohmeter from one bearing coil wire to ground. The resistance to ground should be higher than 100 M.
JOHNSON CONTROLS
63
FORM 160.78-M1
Check insulation resistance using a 500 VDC Megohmeter across conductors below. The resistance to
ground should be higher than 100 M.
Check between the machine casing and each sensor connection wire.
Check between the shielding of the sensor connection wires and each sensor connection wire.
Check between the machine casing and the shielding of the sensor connection wire.
Check Software identifications are correct on AMB
Link Measurement Screen and not displaying Monitoring software or Control Algorithm UNKNOWN,
- If so contact Product Technical Support.
MBC Control Board and Amplifier Board
Diagnostics
Please note that you will be doing this testing with the
MBC energized so please exercise great caution while
working in the MBC. There will be 750 VDC present!
The Magnetic Bearing Control Cabinet
receives 750VDC from the VSD. Live
750VDC exists inside this cabinet when
the VSD DC bus is energized.
Theory of Operation
The control board processes the bearing position feedback from the position sensors and adjusts the current
necessary to properly align/position the shaft at all
times when levitated. This command by the control
board is then communicated to the amplifier board as
a DC voltage (0 10 +/- VDC) value for each bearing
position. Because the bearings are arranged in an opposite fashion, the control board will only communicate a
control signal for one bearing on each axis. The opposite bearing is provided a reverse proportional current.
(V13 for example, are two of the bearings on the drive
end of the shaft and oppose one another at 180 degrees.
The control board will communicate the control signal
for bearing V3). This signal is used by the amplifier
board to provide the proper amount of electrical current split to both the V1 and V3bearings.
The amplifier board is a slave to the control board by
processing the control board input signal and converting those signals to power the bearings. The amplifier
board maintains the proper bearing current based on
64
the control signal voltage where 0 VDC signal voltage

(from control board) = 0 Amps to the bearing (from
amplifier board), 10 VDC signal voltage (from control
board) = 4 Amps to the bearing (from amplifier board).
Testing the Control and Amplifier Boards
This test is typically conducted to determine which
board likely has a problem when there is inconsistent,
none or maximum current (4A) present on one or more
locations while others do have the expected current.
You must first determine which bearing positions are
not indicating the expected current on the MBC screen.
The shaft must be in Levitate mode to perform this
test. To levitate the shaft, the DC Buss must be at 750
VDC. To power the DC Buss, go to: Home > VSD >
VSD Details > Manual DC Buss > Pre Regulate > 20
Minutes.
To levitate the shaft, go to: Home > Compressor >
MBC > Levitate > Enable.
Control Board
The control board is mounted on the standoffs on the
front of the amplifier board and can be tested in location. See Figure 56 on page 49 for location. Measure
the voltage of each of the test points referenced to the
board ground JP1OVA., If voltage is, 0 VDC with
no deviation, the problem is the control board and it
should be replaced. If there is an output voltage greater than 0, the control board is sending a signal to the
amplifier board so you will need to test the amplifier
board in the next step to make that the control board
signal voltage is commensurate with the current output
of the Amplifier board.
TEST POINTS
Control Board
Ground for the test points is labeled JP1/0VA. See Figure 72 on page 65 for locations.
The output signal test points are
CW3 (output signal for W13 bearings)
CW4 (output signal for W24 bearings)
CV3 (output signal for V13 bearings)
CV4 (output signal for V24 bearings)
CZ (output signal for Z13 bearings)
JOHNSON CONTROLS
FORM 160.78-M1
LD15803a
CZ2
CW4 CW3 CV4 CV3
JP1 OVA
Figure 72 - CONTROL BOARD
Amplifier Board
On the amplifier board 2 test points for each bearing
where you can check with a voltmeter what command
is received by the amplifier board and what the corresponding output current should be.. They are labeled
C ( Command signal ) and I (Current image),
These test points should be measured reference to the
common points labeled JP1 OVA, JP2 ova and
JP3 ova. The test points are arranged in sections on
the amplifier board so that the test points for each bearing are grouped together by the bearing title. Bearing
V1 test points are located in the top left corner of the
amplifier board for example.
The C values must agree with the control signal from
the control board. If it has already been established that
the control board output is correct, you must verify that
the amplifier board shows agreement via the C test
pins.
TEST POINTS
Amplifier Board
Ground for the test points is labeled JP1/ova, JP2 ova
and JP3 ova. See Figure 73 on page 66 for locations.
The output signal test points are
V1 C (control signal for V1 bearing)
V1 I (current output signal for V1 bearing)
W1 C (control signal for W1 bearing)
W1 I (current output signal for W1 bearing)
After verifying the C points, the I points must be

checked to show a commensurate output current corresponds to the scaling discussed above, where 0 VDC
signal voltage (from control board) = 0 Amps to the
bearing (from amplifier board), 10 VDC signal voltage
(from control board) = 4 Amps to the bearing (from
amplifier board).
The amplifier board output I test points will provide

voltage values where 1 VDC = .8A output to the bearing. To verify the amplifier output agrees with the control signal, every 2 VDC C should equal 1 VDC at
the corresponding I test points.
Z1 C (control signal for Z1 bearing)
JOHNSON CONTROLS

Z1 I (current output signal for Z1 bearing)
Z2 C (control signal for Z2 bearing)
Z2 I (current output signal for Z2 bearing)
65
FORM 160.78-M1
V1C
V1I
V3C
V3I
W1C
W1I
W3C
JP3 OVA
JP2 OVA
W3I
Z2C
Z1I
Z2I
Z1C
V2C
V2I
V4C
JP1 OVA
V4I
W4C
W2I
W2C
W4I
LD16847
Figure 73 - AMPLIFIER BOARD
Example Readings
Levitated
Delevitated
When levitated on a given axis, the voltage on the C

test point should be about 2 to 4 Volt DC, this equates
to a DC current of about 0.8 to 1.6 Amp.
When the shaft is not levitated on a given axis (for example W13), it is normal for the command to the bottom coil (for example W3 ) to be 0 or negative. But the
command to the upper coil (for example W1) should be
a positive voltage.
For the same scenario when levitated, the voltage on

the I test point should be about 1 to 2 Volt DC, this
equates to a DC current of about 0.8 to 1.6 Amp.
66
JOHNSON CONTROLS
FORM 160.78-M1
Speed Signal Fault

Check continuity and polarity from VSD per below:
VSD Logic 4TB 1MBC goes to MBC Power Supply Interface J5/3 and
VSD Logic 4TB 2MBC goes to MBC Power Supply Interface J5/5
Check 5 VDC voltage pulses on the signal from the
VSD when running
Bearing Temperature
Bearing temperature fault could be a problem with air
gap cooling or the thermocouple. To check the thermocouple:
Switch off the MBC power supply. Disconnect the
temperature sensor to be checked.
The temperature sensor diagram is as follows:
THXX
Check the resistances between two sensor probe connection conductors.

Table 16 - RESISTANCE
(C)
(F)
RESISTANCE
()
(%/K)
MIN.
TYP.
MAX.
-40
-40
0.84
340
359
379
-30
-22
0.83
370
391
411
-20
-4
0.82
403
424
446
-10
14
0.80
437
460
483
32
0.79
474
498
522
10
50
0.77
514
538
563
20
68
0.75
555
581
607
25
77
0.74
577
603
629
30
86
0.73
599
626
652
40
104
0.71
645
672
700
50
122
0.70
694
722
750
60
140
0.68
744
773
801
Check insulation:
Between the machine casing and each sensor con
nection wire.
Between
the shielding of the sensor connection

wires and each sensor connection wire.
PTXA PTXB
PT100 (2 conductors)
LD15811
Figure 74 - BEARING TEMPERATURE SENSOR
JOHNSON CONTROLS
Between the machine casing and the shielding of
the sensor connection wire.
The insulation values must be greater than 2 M at

500 VDC.
67
FORM 160.78-M1
Figure 75 - VGD CALIBRATION TEMPLATE
68
JOHNSON CONTROLS
FORM 160.78-M1
The following factors can be used to convert from

English to the most common SI Metric values.
Table 17 - 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)
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)
Pounds / Square Inch (psi)
6.895
Kilopascals (kPa)
Length
Pressure Drop
TEMPERATURE
To convert degrees Fahrenheit (F) to degrees Celsius
(C), subtract 32 and multiply by 5/9 or 0.5556.
Example: (45.0F - 32) x 0.5556 = 27.2C
To convert a temperature range (i.e., a range of 10F)
from Fahrenheit to Celsius, multiply by 5/9 or 0.5556.
Example: 10.0F range x 0.5556 = 5.6 C range
JOHNSON CONTROLS
69
P.O. Box 1592, York, Pennsylvania USA 17405-1592

Copyright by Johnson Controls 2013
Form 160.78-M1 (813)
Issue Date: August 1, 2013
Supersedes: 160.78-M1 (1112)
800-861-1001
www.johnsoncontrols.com
Subject to change without notice. Printed in USA

ALL RIGHTS RESERVED

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CENTRIFUGAL LIQUID CHILLER

Supersedes: 160.78-M1 (1112)

Form 160.78-M1 (813)

READ BEFORE PROCEEDING!

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

Identifies a hazard which could lead to

Indicates a potentially hazardous situation which will result in possible injuries

Highlights additional information useful

While the chiller is off, thermal energy provided to

CHANGEABILITY OF THIS DOCUMENT

these documents, the technician should verify whether

YMC2 Unit Re-assembly

YMC2 Field Connections

YMC Unit Wiring and Field Control Modifications

YMC Unit Renewal Parts

YMC2 OptiViewTM Renewal Parts

YMC2 Operations and Maintenance

YMC2 OptiViewTM Operation

Gas Path Revision Level

Inlet from Front View

Vessel Refrigerant Pressure Code

VARIABLE SPEED DRIVE NOMENCLATURE

THIS PAGE INTENTIONALLY LEFT BLANK

LIST OF FIGURES (CONTD)

ROTOR COOLING GAS VENT

Low Pressure Liquid Refrigerant

Figure 1 - REFRIGERANT FLOW THRU CHILLER

Figure 2 - UNIT DATA PLATE

The lightweight, high strength, cast aluminum, fully

CHILLER REFRIGERANT SERVICE

Begin with 90% of

Set Condenser level

Set Condenser level

Figure 3 - REFRIGERANT CHARGING

Adjustable End Assembly

PIPING JOINT ASSEMBLY

Figure 4 - ADJUSTABLE END FITTING

1. Inspect to ensure that both matching parts are free

3. Lubricate O-ring with a light coat of synthetic

Table 1 - ASSEMBLY TORQUE

FACE SEAL TUBE-SIDE

Straight Non-Adjustable End Assembly

4. Screw fitting into port until the hex flat contacts

5. Tighten to give torque for the specified size as

Figure 8 - SAE STRAIGHT THREAD O-RING PORT

Assembly of O-ring Face Seal Fittings

Figure 6 - SCREW FITTING INTO

ing tube or hose assembly, unscrew by required

3. Lubricate O-ring with a light coat of synthetic

Figure 7 - TORQUE FITTING

SECTION 2 - COMPRESSOR SERVICE

Protect Parts and Surfaces - Do not pile or throw

There are a number of good practices that should be

While the driveline is open, carefully clean the interior,

Do Not Mix Parts - Keep parts in some general order

Before assembling parts, all friction surfaces should be

Clean and check all cooling passageways and all tubing.

Molkolube is available from:

Do Not Mix Cap Screws and Washers - Cap screws

Westinghouse Electric Corporation (Sales offices in all

Inspect as Compressor is Disassembled - If possible,

When reassembling parts, each part should be carefully

SECTION 2 - COMPRESSOR SERVICE