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P545 Series Electronic Lube Oil Control Product/Technical Bulletin

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Product/Technical Bulletin
                                                                                      Issue Date September 2018

                     P545 Series Electronic Lube Oil Control

The P545 Series Electronic Lube Oil Control is
designed for use on refrigeration compressors
equipped with an oil pump that accepts a single-point
differential pressure switch. The P400 switch
continuously monitors net lube oil pressure and the
P545 control locks out the compressor if lube oil
pressure falls below the manufacturer’s recommended
net pressure for longer than the recommended lube oil
time delay. Front-mount Light-Emitting Diodes (LEDs)
indicate the status of the lubrication system, and a
user-selectable, minimum-off time delay can be set to
minimize compressor short cycling.
A Johnson Controls/PENN® R310AD Current Sensing
Switch, sold separately, may be used to disable the
P545 control lockout circuit during abnormal
compressor shutdowns.                                      Figure 1: P545 Electronic Lube Oil Control with
                                                          P400 Single-Point Oil Pressure Differential Switch

                                             Features and Benefits
       Single-Pole Double-Throw (SPDT)           Allows liquid line solenoid to be closed if the
           Relay Contacts for Liquid Line         P545 control shuts off the compressor due to low oil
           Solenoid and Alarm Applications        pressure (minimizes refrigerant migration); provides
                                                  alarm indication, including circuits that use neon lights.

       Relay Contact Output for                  Provides reliable, long-lasting operation
           Compressor

       Built-in Test Circuit                     Verifies proper control operation quickly, without
                                                  additional tools or equipment

       Improved Noise Immunity                   Exceeds immunity requirements of UL 991 for transient
                                                  overvoltage: IEC 61000-4-3 for radiated Radio
                                                  Frequency (RF) and IEC 61000-4-6 for RF-induced
                                                  conducted disturbances

       Selection of Anti-short Cycle Time        Allows choice of anti-short cycle strategy for a wide
           Delay                                  range of equipment requirements; possible elimination
                                                  of external short-cycle timer

       User-Friendly Display Panel               Displays the status of the compressor lubrication system
                                                  continuously

       Backwards Compatibility                   Allows easy replacement of existing electronic lube oil
                                                  controls

© 2018 Johnson Controls                                                                                             1
  Code No. LIT-12011012                                                                         www.penncontrols.com
  Part No. 24-7664-2616, Rev. D
Operation
Figure 2 shows an operational flowchart for the P545 control.

                      Power to the refrigeration control                    Note:
                       system is interrupted and the                        Compressor Contacts: M1 to M2
                       anti-short cycling timer starts.
                                                                            Alarm Contacts: CMA to NOA

                Operating control energizes the P545 control,
                 and if time other than zero is selected, the               Liquid Line Solenoid Contacts: CMA to NCA
                 anti-short cycle timer continues to time out.

                               Has anti-short              No
                                 cycle delay                                 Yellow LED On
                               time elapsed?

                                        Yes                     .

                       Compressor contacts close;
                       LLS contacts remain closed                                         No                                    Yes
                                                                                                 Do you want
                        and alarm remains open;
                                                            Push Reset button.                    short cycle
                            green LED On;
                                                                                                 to continue?
                            yellow LED On.

                            Low lube oil pressure
                             time delay initiated.

                                 Is the net          No             Green and yellow LEDs On;
                              lube oil pressure                       time delay counts up.
                                 sufficient?

                                        Yes                                 Has lube
                         Timer                                            delay timeout         No
                      counts down;                                         limit been
                         yellow                                             reached?
                        LED Off.
                                                                                 Yes

                                                                      Alarm contacts close;
                                                                    compressor contacts and
                                                               liquid line solenoid contacts open;
                                                            red LED On, yellow and green LEDs Off.

                                                                             Correct
                        Red LED Off;                                   lubrication problem

                                                                                                                1201102_2.cdr
                        alarms clear.                                     and press the
                                                                          Reset button.

                                              Figure 2: P545 Control Flowchart

2   P545 Series Electronic Lube Oil Control Product/Technical Bulletin
IMPORTANT: The P545 Series Electronic Lube Oil             R310AD Current Sensing Switch for False Oil
Control is intended to provide an input to equipment       Failure Lockouts
under normal operating conditions. Where failure or        False oil pressure failure lockouts can occur when the
malfunction of the electronic lube oil control could       P545 control remains powered despite a loss of power
lead to personal injury or property damage to the          to the compressor motor (for example, when an
controlled equipment or other property, additional         internal motor overload switch trips).
precautions must be designed into the control              An R310AD switch disables the oil-failure delay timer
system. Incorporate and maintain other devices,            when there is no power to the compressor, thus
such as supervisory or alarm systems or safety or          avoiding false lockouts.
limit controls, intended to warn of or protect against
failure or malfunction of the electronic lube oil          Install the R310AD switch after the main contactor on
control.                                                   one of the compressor power leads, and wire to
                                                           terminals W1 and W2 on the P545 control. In addition,
IMPORTANT: Le P545 Series Electronic Lube Oil              remove resistor R39 by cutting the leads to the circuit
Control est destiné à transmettre des données              board. See Figure 13.
entrantes à un équipement dans des conditions
normales de fonctionnement. Lorsqu'une défaillance
                                                            IMPORTANT: The R310AD switch does not work
ou un dysfonctionnement du electronic lube oil
                                                            when the control’s anti-short cycle delay timer is set
control risque de provoquer des blessures ou
d'endommager l'équipement contrôlé ou un autre              at 0 seconds. You must set the timer to 35, 65, or
                                                            100 seconds. See Anti-Short Cycle Delay for further
équipement, la conception du système de contrôle
doit intégrer des dispositifs de protection                 information.
supplémentaires. Veiller dans ce cas à intégrer de
façon permanente d'autres dispositifs, tels que des        Anti-short Cycle Delay
systèmes de supervision ou d'alarme, ou des                Anti-short cycle delay establishes the minimum time
dispositifs de sécurité ou de limitation, ayant une        that the controlled equipment is de-energized before
fonction d'avertissement ou de protection en cas de        restarting. After the P545 control has de-energized the
défaillance ou de dysfonctionnement du electronic          equipment, the anti-short cycle delay is activated and
lube oil control.                                          the yellow LED lights. The equipment remains
                                                           de-energized for the selected amount of delay time.
Low Oil Pressure Timing Circuit Operation                  The anti-short cycle delay on the P545 control may be
                                                           set to 0, 35, 65, or 100 seconds.
All P545 control timing functions are designed to
comply with compressor manufacturer requirements.
Standard control models de-energize the compressor         Backwards Compatibility
contactor if the low-pressure condition lasts longer       The P545 control and P400 switch offer backwards
than the factory-set time delay.                           compatibility with previous offerings in the
                                                           Johnson Controls/Penn product line and operate as
The oil pressure monitoring circuit on the P545 control    shown in Table 1.
compares the amount of time that the oil pressure is
above opening point to the amount of time that the oil
pressure is below opening point. If the oil pressure is
above opening point more than it is below opening
point, the control does not shut down the compressor.
If the oil pressure drops continuously below the
opening point, the control times out in either 90 or
120 seconds, depending on the model. If the oil
pressure is below opening point more than half of the
time, the control times out but the timing is extended.
This allows the control to protect the compressor when
there are repeated low oil pressure signals interrupted
by short periods of sufficient oil pressure.

                                            P545 Series Electronic Lube Oil Control Product/Technical Bulletin       3
Table 1: Control and Sensor/Switch Compatibility
Test                      P345 or P445 Control P345 or P445 Control P545 Control and                                      P545 Control and
                          with P300 Sensor     with P400 Switch     P300 Sensor                                           P400 Switch
Wiring Harness1           WHA-P300-xxx Only               WHA-P300-xxx or                WHA-P300-xxx Only                WHA-P300-xxx or
                                                          WHA-P400-xxx                                                    WHA-P400-xxx
Test Switch               6-8 Second Delay                Does not function2             Immediate                        Immediate
1.   WHA-P300-xxx is the 3-wire harness supplied with the P345 or P445 control and the P300 sensor.
     WHA-P400-xxx is the 2-wire harness supplied with the P545 control and the P400 switch.
2.   When the P445 control is wired to a P400 switch, The Test button may operate when first powered up; however, after a
     couple minutes of operation, the Test Switch function no longer works. All other control functions operate normally.

Installation
                   Two 10-32 UNF-2B
                    Mounting Holes         3/16 (5) x 3/8 (10)
                                          Slot for No. 10 Screw                                                          Wiring Harness
                                                                                                                           for Switch
                                 5-11/16 (145)
   3/16 (5)                                                                                             5/16 (8)
   Hole for
 No. 10 Screw

                                                                                           3-3/8 (86)                P400AD-1 and
                                                            1                                                        P400AD-2
       7/16                                                (25)                                 1 (25) Hex           Switch
       (11)
                            3-7/16 (87)                                                                            9/16 (14)
           13/16
            (24)                                                                                                    3/4-16 UNF
                                                                                                                    2A Thread
                   5/16
                    (8)

                                                                                         2-7/8 (73)                P400BD-1
                                                                                                                   Switch
       1-1/8                                                                                  1 (25) Hex
       (29)                    7/8 (22) Conduit Hole
                                                           3-5/16
                                                            (85)                                             9/16 (14)

                                                                    12011012_3.cdr
                                                                                                                   M20 x 1.5 Thread

                                                                                                                                          12011012_4.cdr
                                   Opening for
               1-1/8 (29)          wiring harness cable

        Figure 3: Control Dimensions, in. (mm)
                                                                                     Figure 4: P400 Switch Dimensions, in. (mm)

4    P545 Series Electronic Lube Oil Control Product/Technical Bulletin
Mounting                                                               Wiring
                                                                       See Figure 7 through Figure 12 for typical wiring
Mount the P545 Control
                                                                       diagrams, or refer to the compressor manufacturer’s
Use the mounting holes shown in Figure 5 for                           specifications. Make all wiring connections using
mounting the control on a flat vertical surface. Two                   copper conductors only. Ensure all wiring conforms to
No. 10 screws are provided for this purpose. Do not                    the National Electrical Code and local regulations.
use longer screws, as damage to internal components
may occur. Mount the control in an upright position,
and avoid warping or bending the case.                                    !       WARNING: Risk of Electric Shock.
Use the Universal Mount (Part No. 271-51) to mount                      Disconnect the power supply before making electrical
the control to a vertical or horizontal surface. This                   connections. Contact with components carrying
requires two 10-32 UNF-2B screws (not included).                        hazardous voltage can cause electric shock and may
                          Mounting Holes for a                          result in severe personal injury or death.
                          Flat Vertical Surface
                                                                        AVERTISSEMENT: Risque de décharge
                                                                        électrique. Débrancher l'alimentation avant de réaliser
                                                                        tout branchement électrique. Tout contact avec des
     No. 10 Screws                                                      composants conducteurs de tensions dangereuses
      (2 provided)
                                                                        risque d'entraîner une décharge électrique et de
                                                                        provoquer des blessures graves, voire mortelles.

                                 Mounting Holes                        Wire the P400 Switch
                                   for UMB                             Use this procedure to connect the P400 switch to the

                                                      12011012_5.cdr
                                                                       control:
     Universal Mounting
      Bracket (UMB)         10-32 UNF-2B Screw                         1. Insert the plug into the connector until it snaps and
                               (not provided)                             locks in place. See Figure 6.

        Figure 5: Mounting the P545 Control                            2. Connect the wiring harness to the P545 control at
                                                                          P2. See Figure 13 for the location and orientation
Mount the P400 Switch                                                     of the differential oil pressure switch connection.
If you modify an existing refrigeration compressor to                  Note: The control does not function properly if the
accept the P400 switch, it may involve installing a                    wiring harness is connected improperly at the circuit
sensor block (such as a Johnson Controls®                              board.
CST29A-600C) or other part. For proper installation,                                                            Gasket
follow all procedures recommended by the compressor
                                                                                            Lube Oil Switch
manufacturer.
To mount the P400 switch:
                                                                                                              Switch
                                                                         Wiring
1. Wet the switch nozzle and gasket with oil.                            Harness
                                                                                                              Nozzle

                                                                                                                            12011012_6.cdr
2. Fit the gasket over the nozzle as shown in
                                                                                               Insert
   Figure 6.                                                                                   Plug

3. Install the switch in the lube oil port according to                   To P2 Connector
   the compressor manufacturer’s instructions.
                                                                         Figure 6: Connecting the Wiring Harness to the
4. Hand-tighten the switch until the surfaces of                                         P400 Switch
   gasket and compressor housing meet.
5. Use a torque wrench to tighten the sensor until
   sealed (40 lb⋅ft recommended torque).

                                                  P545 Series Electronic Lube Oil Control Product/Technical Bulletin                         5
Internal Wiring Diagram

                                                                           P545
                                               NOA                   NCA
                                                        CMA
                                          M2
                                                                            M1        Do not connect circuit interrupts here.

           Factory-Mounted
         External Metal Jumper                                                        Circuit interrupts are permitted here.

                                            L2           120           240

                                                                                                                                12011012_7.cdr

                                 Figure 7: Internal Wiring Diagram for the P545 Control

Ladder Diagrams for the P545 Control
        L1                                                                                                 L2 L3
                                                                                             Alarm
                                                                                           Connection
                                                                             P545
                                                 NOA       CMA        NCA

                                                M2     Wire Jumper
                                                                                 M1           Compressor
                                                                                               Contactor

               High          Low                            120             240
                                                 L2
             Pressure      Pressure

                                                                                                                                                 12011012_8.cdr
              Control       Control

             Figure 8: Typical P545 Control Application with Alarm Circuit Powered by Line Voltage

        L1              Power           Alarm                                                                  L2 L3
                        for Alarm     Connection
                        Circuit
                                                                             P545
                                                NOA                   NCA
                                                          CMA
                                           M2
                                                                             M1                Compressor
                                                                                                Contactor

               High          Low                           120             240
                                                L2
             Pressure      Pressure

                                                                                                                                                 12011012_9.cdr
              Control       Control

         Figure 9: Typical P545 Control Wiring with Alarm Circuit Powered by a Separate Voltage

6   P545 Series Electronic Lube Oil Control Product/Technical Bulletin
                                                                                                                         L2   L3
                                                                                              Optional Alarm
L1                                                                                             Connection

                                                                              P545
                                                 NOA                   NCA                                     Liquid Line
                                                              CMA                                Temp.          Solenoid
                                            M2                                                    Ctrl
                                                                               M1                          Compressor
                                                                                                            Contactor

        High               Low                                120
                                                 L2                          240
      Pressure

                                                                                                                                                        12011012_10.cdr
                         Pressure                     W1 W2
       Control            Control

                 Figure 10: Typical P545 Control Application with Liquid Line Solenoid Valve

     L1                 Power         Optional Alarm                                                            L2 L3
                        for Alarm      Connection
                        Circuit
                                                                                   P545
                                                   NOA                      NCA
                                                               CMA
                                              M2
                                                                                   M1         Compressor
                                                                                               Contactor

            High            Low
                          Pressure                L2 W1 W2 120                240
          Pressure
           Control         Control                                                            R310AD

                                                                                                                                   12011012_11.cdr
                                                                                               Switch
           R39       Remove resistor R39 when
                     using the R310AD switch.

      Figure 11: Typical P545 Control Application with an R310AD-1 Current Sensing Switch

     L1                                    Liquid Line                                             L2           L3
                             Temperature    Solenoid
                             Control
                     Optional Alarm
                                                                                          P545
                      Connection                         NOA                       NCA
                                                                     CMA
                                                       M2
                           Compressor                                                     M1
                            Contactor

                                                         L2           120               240
                                                              W1 W2

                                                                                                                                            12011012_12.cdr
       High             Low
     Pressure         Pressure
      Control          Control

          Figure 12: Typical P545 Control Application with Control after Compressor Contactor

                                                  P545 Series Electronic Lube Oil Control Product/Technical Bulletin                                                      7
Setup and Adjustments
The anti-short cycle delay timer is factory-set to                        Note: If the jumper is removed, the P545 control
100 seconds. For a different delay, move the jumper at                    operates at the default delay of 100 seconds.
P1 to the desired position. (See Figure 13, Inset B.)

                                                      Anti-short Cycle
                                                       Delay Setting

                                                        100                   M1 NOA CMA NCA
                                                        65
                                                        35
                                                        0

                                                        P1                    240    120     L2      M2
      Correct
                                                                   P2
                                   Differential Oil Pressure
                                      Switch Connection
                                                           R39

                                                          W1             W2
                                                                                                              10            100
                                                                                                             65 0          65
                                                                                                            35            35
                                                                                                           0             0

                                                                                                          0 seconds     35 seconds
                    Incorrect
                                     Cut and
                                 discard resistor                                          Inset B
                                R39 when installing
                                                       Inset A
                                                                                                                             10
                                 R310AD switch.
                                                                                                              100           65 0
                                                                                                             65            35

                                                                                                                                      12011012_13.cdr
                                                                                                            35            0
                                                                                                                        100 seconds
                                                                                                           0

                                                                                                           65 seconds
                                         R39

                Figure 13: Terminal Designations and Jumper Positions for Anti-short Cycle Delay

Operating Status                                                          Electrical Checkout Procedure
Front panel LEDs display the operating status of the                      Use the following procedure to test the P545 control
system and assist in troubleshooting (see Table 2).                       during initial installation and maintenance:
Status conditions are as follows:
                                                                          1.        De-energize the supply voltage to the control and
•   Green (RUN) LED only: The compressor                                            the compressor circuit. Make certain that any
    contactor is energized, and the system’s net oil                                disconnect switches or circuit breakers feeding
    pressure is at or above the opening point of the                                the circuit are open.
    P400 switch.
•   Green (RUN) and Yellow (TIMING) LEDs: The
    compressor contactor is energized, but the lube oil
                                                                                !    WARNING: Risk of Electric Shock.
    pressure is below the opening point. Timing circuit                    Disconnect the power supply before making electrical
    is active.                                                             connections. Contact with components carrying
                                                                           hazardous voltage can cause electric shock and may
•   Yellow (TIMING) LED only: Power to the control                         result in severe personal injury or death.
    has been interrupted and restored before the
    anti-short cycle delay has elapsed. The                                AVERTISSEMENT: Risque de décharge
    compressor contactor remains de-energized until                        électrique. Débrancher l'alimentation avant de réaliser
    the anti-short cycle delay is complete, and then                       tout branchement électrique. Tout contact avec des
    restarts automatically.                                                composants conducteurs de tensions dangereuses
                                                                           risque d'entraîner une décharge électrique et de
•   Red (LOCKOUT) LED: The P545 control has                                provoquer des blessures graves, voire mortelles.
    de-energized the compressor contactor (lockout
    condition), because it detected a lubrication
    problem at the compressor.

8   P545 Series Electronic Lube Oil Control Product/Technical Bulletin
2. Disconnect the contactor from the compressor              6.   Re-energize the supply voltage. If operating and
   motor, or disconnect power to the compressor.                  limit controls are closed and power has been
                                                                  removed for longer than the anti-short cycle
     Note:   On systems using the R310AD switch,
                                                                  delay, the compressor starts and both the green
             remove relay connections to control
                                                                  and yellow LEDs light up. The yellow LED turns
             terminals W1 and W2, and connect a
                                                                  off when the lube oil pressure level reaches the
             jumper between those two terminals. (See
                                                                  opening point, usually within seconds of starting
             Figure 13.)
                                                                  the compressor.
3.   Re-energize the supply voltage to the
     P545 control. Verify that all operating and limit       Operational Control Test
     controls are closed.                                    Use this test to verify the P545 control is operating
                                                             correctly. This test simulates a low oil pressure
     Note:   The compressor contactor circuit                condition and initiates an immediate lockout of the
             energizes and both the yellow and green         compressor.
             LEDs light up after the short-cycle delay
             has expired. The green LED indicates            1. With power to the control, adequate oil pressure
             that the compressor contactor is                   available, and contactor energized (only the green
             energized. The yellow LED indicates that           LED is on), press and hold down the Test button.
             net oil pressure is low and that the timing          Note: The red LED lights up and the control
             circuit is activated.                                de-energizes (locks out) the compressor
             When the low pressure time delay                     contactor. The control alarm circuit (NOA contact –
             elapses, the control de-energizes (locks             see Figure 7) is energized.
             out) the contactor. The red LED lights up       2. Wait 100 seconds and press the Reset button to
             and the yellow and green LEDs turn off.             energize the contactor and restart the motor.
             The control’s alarm contacts (Terminals
                                                             Note: The P545 control cannot be reset without
             CMA to NOA) close and the liquid line
                                                             power. The control remains in a lockout condition
             solenoid contacts (Terminals CMA to
                                                             (compressor contactor de-energized) until the Reset
             NCA) open.
                                                             button is pressed, even if power is removed from the
4.   Press RESET. The red LED turns off and the              control.
     green and yellow LEDs turn on. The contactor is
     now energized.
5.   De-energize the supply voltage. Reconnect the
     compressor leads to the contactor, or reset the
     disconnect. If an R310AD switch is used,
     reconnect the compressor leads to the contactor.
     See Figure 13.

                                              P545 Series Electronic Lube Oil Control Product/Technical Bulletin      9
Troubleshooting
See Table 2 to troubleshoot the P545 control.
Table 2: Troubleshooting P545 Control Problems
 LED Status                                          Troubleshooting Procedure
 No LEDs are lit.                                    Check the power source.
 Red LED is On.                                      Use these steps to resolve the problem:
                                                     1. Connect pressure gauges at the oil pump discharge and at the crankcase.
                                                     2. Press RESET on the control.
                                                        a. If the green and yellow LEDs light but the compressor remains off,
                                                        inspect the wiring and check for an overheated motor. If the compressor motor is
                                                        overheated, determine the cause and correct the problem. (An R310AD current

                                 12011012_plug.cdr
                                                        sensing switch may be installed along with the control to provide a controlled
                                                        shutdown caused by thermal overload.)
                                                        b. If both the green and yellow LEDs turn on for the duration of the time
          Common       Signal                           delay and the system shuts down, observe the crankcase and oil pump
         WHA-P400-xxx                                   pressure gauges.
       Wiring Harness Plug                                   - If the system does not reach sufficient oil pressure by the end of the time
                                                               delay, check the compressor and system for problems.
                                                             - If the system does reach sufficient pressure:
                                                               1. Disconnect the wiring harness at the P400 switch.
                                                               2. Use a single piece of 22-gauge wire as a jumper between the common
                                                                    and signal terminals of the wiring harness.
                                                               3. Press RESET.
                                                               4. If the green LED lights and the yellow LED turns off, replace the P400
                                                                    switch. Otherwise, replace the P545 control.
 Yellow LED is dim and flickering.                   Use these steps to resolve the problem:
                                                     1. Check the power source.
                                                     2. Confirm that the compressor is operating at sufficient pressure and without
                                                         excessive pressure fluctuations.
                                                     3. Check the wiring harness for loose connections.
                                                     4. If the oil pressure is sufficient, the cable connections are good, and the yellow
                                                         LED still flickers, replace the P400 switch.
 Control does not lock out the                       Use these steps to resolve the problem:
 compressor when lube oil                            1. Press the test button.
 pressure is low.
                                                        a. If the P545 control does not lock out in 8 seconds or less, replace the
                                                               control.
                                                        b. If the P545 control locks out properly, go to Step 2.
                                                     2. Disconnect the wiring harness from the P545 control. Press the Reset button.
                                                     3. If the compressor starts and runs through the time delay (yellow and green LEDs
                                                         lit) and then locks out, check the wiring harness for shorted condition. If the
                                                         wiring harness tests okay, replace the P400 switch.
 Control does not respond to                         Make sure that the anti-short cycle delay is not set at 0 seconds.
 R310AD switch. (Control locks
 out the compressor after
 compressor shutdown. Red LED
 is lit.)

10   P545 Series Electronic Lube Oil Control Product/Technical Bulletin
 LED Status (Cont.)                    Troubleshooting Procedure
 Control does not respond to           Use these steps to resolve the problem:
 R310AD switch. (Indicated by the      1. Check that resistor R39 has been cut and discarded.
 green LED turning on for
 approximately 4 seconds,              2. Check the R310AD switch; replace if necessary.
 followed by the yellow LED
 turning on for the duration of the
 selected anti-short cycle time
 delay. This process repeats
 indefinitely.)
 Contactor energizes for 3 or          Insufficient current to the R310AD switch is the most likely cause of this condition.
 4 seconds. It remains off for the     Use these steps to resolve the problem:
 duration of the anti-short cycle      1. Check compressor for internal overloads.
 time delay, and then repeats
 (compressor is unable to start        2. Check the compressor wiring.
 during the 3 to 4 second period).     3. Check compressor’s contactor.
                                       4. Check compressor for general failure.

Ordering Information
Use the following tables to order the P545 control, the P400 switch, or accessories.

Table 3: P545 Electronic Lube Oil Control Ordering Information
 Product Code        Lube Oil Delay       P400 Switch             Wiring Harness         Fits Compressors
 Number              (Seconds)                                                           Manufactured by
 P545NCB-22C*        120                  P400AD-2                WHA-P400-100           Copeland®
 P545NCB-25C*        90                   P400BD-1                WHA-P400-125           Bitzer
 P545NCB-82C*        120                  P400AD-1                WHA-P400-100           Carlyle
 *   Switch and wiring harness included

Table 4: P400 Single-Point Differential Oil Pressure Switch Ordering Information
 Product Code      Open Point                    Close Point                                 Threads          Wiring
 Number            (Differential Pressure)       (Differential above Open Point)                              Harness
 P400AD-1C*        7 ± 1.0 psid                  Less than or equal to 2.0 psid              3/4-16 UNF       WHA-P400-100
 P400AD-2C*        12.75 ± 0.75 psid             Less than or equal to 1.5 psid
 P400BD-1C*        10 ±1.5 psid                  Less than or equal to 3.0 psid              M20 x 1.5        WHA-P400-125
 *   Wiring harness included

                                              P545 Series Electronic Lube Oil Control Product/Technical Bulletin               11
Table 5: Wiring Harnesses and Other Accessories Ordering Information
 Product Code       Description
 Number
 KITP545-82C        CST29A-600C Sensor Block (for Carlyle Compressor Series O6CC, O6D, and O6E);
                    includes Allen-head bolts*.
                    P545NCB-82 Electronic Lube Oil Control;
                    includes P400AD-1C switch and WHA-P400-100C wire harness
 WHA-P400-100C      3 1/3 ft (1 m) length wiring harness
 WHA-P400-125C      4 ft (1 1/4 m) length wiring harness
 WHA-P400-250C      8 ft (2 1/2 m) length wiring harness
 WHA-P400-430C      14 ft (4 1/3 m) length wiring harness
 R310AD-1C          Low-Voltage Current Sensing Switch
 271-51             Universal Mounting Bracket
 *   Contact Carlyle Compressor Co. at (800) 462-2759 to order Sensor Block Gasket 06DA680063.

Repair and Replacement
Do not attempt field repairs or calibration. Switches,
alternate length wiring harnesses, and replacement
controls are available as separate items through local
Johnson Controls wholesalers and the original
equipment manufacturer.

12   P545 Series Electronic Lube Oil Control Product/Technical Bulletin
Technical Specifications
 Product                            P545NCB Electronic Lube Oil Control; manual reset with alarm and liquid line solenoid
                                    outputs
 Power Requirements                 120 or 240 VAC, 50/60 Hz +10%, -15%; power consumption: 3 VA
 Open Point                         P545NCB-22/P400AD-2: 12.75 ± 0.75 psid (87.9 ± 5.17 kPa)
 (Differential Pressure)            P545NCB-25/P400BD-1: 10 ± 1.5 psid (68.9 ± 10.3 kPa)
                                    P545NCB-82 P400AD-1: 7 ± 1.0 psid (48.2 ± 6.9 kPa)
 Lube Oil Time Delay                P545NCB-22:                   120 ± 15 seconds
 (Factory Settings)                 P545NCB-25:                   90 ± 12 seconds
                                    P545NCB-82:                   120 ± 15 seconds
 Anti-short Cycle Timer             Four selectable positions: 0, 35, 65, and 100 seconds (nominal times)
 Type of Refrigerant                Non-corrosive refrigerants only
 Electrical Connections             Control: Screw type terminals on a barrier terminal strip
                                    Sensor: Snap-connect at sensor end, 3-pin plug at control end
 Maximum Electrical Rating          Isolated relay output to compressor contactor (M-1 and M-2)
                                    Pilot duty 375 VA at 120 VAC, 750 VA at 240 VAC
 Alarm Circuit (Relay)              NOA contact:        Pilot duty 125 VA at 120/240 VAC; 60 W tungsten at 120/240 VAC
                                    NCA contact:        Pilot duty 125 VA at 120 VAC, 250 VA at 240 VAC
 Backplate Material                 Cold rolled steel
 Case and Cover Material            High impact thermoplastic
 Ambient Operating                  -40 to 131°F (-40 to 55°C)
 Conditions
 Ambient Storage                    -40 to 185°F (-40 to 85°C)
 Conditions
 Approximate Shipping               1.80 lb (0.82 kg)
 Weight
 Agency Listings                    UL Listed, File SA516, CCN SDFY
                                    UL Listed for Canada, File SA516, CCN SDFY7
The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these
specifications, consult the local Johnson Controls office or Johnson Controls/PENN Application Engineering at (414) 524-5535 or
1-800-275-5676 (1-800-ASK-JNSN). Johnson Controls shall not be liable for damages resulting from misapplication or misuse of its products.

European Single Point of Contact:           NA/SA Single Point of Contact:            APAC Single Point of Contact:
JOHNSON CONTROLS                            JOHNSON CONTROLS                          JOHNSON CONTROLS
WESTENDHOF 3                                507 E MICHIGAN ST                         C/O CONTROLS PRODUCT MANAGEMENT
45143 ESSEN                                 MILWAUKEE WI 53202                        NO. 22 BLOCK D NEW DISTRICT
GERMANY                                     USA                                       WUXI JIANGSU PROVINCE 214142
                                                                                      CHINA

                                                                                                                   www.penncontrols.com

                                                        ® Johnson Controls and PENN are registered trademarks of Johnson Controls in the
                                           United States of America and/or other countries. All other trademarks used herein are the property
                                                       of their respective owners. © Copyright 2018 by Johnson Controls. All rights reserved.

                                                   P545 Series Electronic Lube Oil Control Product/Technical Bulletin                    13

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