York YCAL Series, Installation Operation & Maintenance

Page 1: ...CHILLERS STYLE D WITH IPU II and I O BOARDS 50 Hz 29 TON TO 65 TON INSTALLATION OPERATION MAINTENANCE AIR COOLED LIQUID CHILLERS HERMETIC SCROLL Supersedes 150 66 NM3 110 Form 150 66 NM3 920 R 410A 03...

Page 2: ...this document and any referenced materials This in dividual shall also be familiar with and comply with all applicable industry and governmental standards and regulations pertaining to the task in qu...

Page 3: ...y the applicability of these documents to the equipment If there is any question regarding the applicability of these documents rig ging lifting and operating service personnel should verify whether t...

Page 4: ...JOHNSON CONTROLS 4 FORM 150 66 NM3 ISSUE DATE 09 25 2020 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 5: ...port 14 Mechanical Strength 14 General Access 14 Pressure Systems 14 Electrical 15 Rotating Parts 15 Sharp Edges 15 Refrigerants and Oils 15 High Temperature and Pressure Cleaning 15 Emergency Shutdow...

Page 6: ...OR MOUNTING 34 REMOTE COOLER OPTION 34 CHILLED LIQUID PIPING 34 DUCT WORK CONNECTION 35 General Requirements 35 WIRING 35 Evaporator Pump Start Contacts 36 System Run Contacts 36 Alarm Status Contacts...

Page 7: ...IONAL LIMITATIONS SI 47 Voltage Limitations 47 PHYSICAL DATA ENGLISH 50 SOUND DATA ENGLISH 52 ELECTRICAL DATA 54 ELECTRICAL NOTES AND LEGEND 57 WIRING DIAGRAMS 58 DIMENSIONS 64 TECHNICAL DATA CLEARANC...

Page 8: ...ON PRESSURE LIMIT CONTROLS 131 DISCHARGE PRESSURE LIMIT CONTROLS 131 LEAVING CHILLED LIQUID CONTROL 131 LEAVING CHILLED LIQUID SYSTEM COMPRESSOR SEQUENCING 132 LEAVING CHILLED LIQUID CONTROL OVERRIDE...

Page 9: ...149 Liquid Refrigerant Sensor Test Points 150 Analog Inputs Pressure 151 Digital Outputs 152 OPTIONAL PRINTER INSTALLATION 153 Parts 153 Assembly and Wiring 153 Obtaining a Printout 153 SECTION 10 MAI...

Page 10: ...3 FIG 9 UNIT CLEARANCES 92 FIG 10 LEAVING WATER TEMPERATURE CONTROL EXAMPLE 132 FIG 11 SETPOINT ADJUST 132 FIG 12 YCAL0041 YCAL0071 FAN LOCATION TYPICAL 136 FIG 13 TYPICAL INVERTER LOCATION 137 FIG 14...

Page 11: ...PROGRAMMING QUICK REFERENCE LIST 129 TABLE 19 COMPRESSOR STAGING FOR RETURN WATER CONTROL 133 TABLE 20 RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS 6 STEPS 134 TABLE 21 RETURN CHILLED LIQUID CONTRO...

Page 12: ...ABLE 33 MINIMUM MAXIMUM AND DEFAULT VALUES 159 TABLE 34 VALUES REQUIRED FOR BAS COMMUNICATION 160 TABLE 35 REAL TIME ERROR NUMBERS 160 TABLE 36 BACNET AND MODBUS COMMUNICATIONS DATA MAP 162 TABLE 37 Y...

Page 13: ...at the unit has been operated within the designed parameters specified All warranty claims must specify the unit model serial number order number and run hours starts Model and serial number informati...

Page 14: ...an authorized Johnson Controls representative MISUSE OF EQUIPMENT Suitability for Application The unit is intended for cooling water or glycol solu tions and is not suitable for purposes other than t...

Page 15: ...minor abrasions and lacerations The use of gloves is recommended Frame rails brakes and other components may also have sharp edges Reasonable care should be taken when working in contact with any com...

Page 16: ...JOHNSON CONTROLS 16 FORM 150 66 NM3 ISSUE DATE 09 25 2020 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 17: ...our salt spray testing yields a minimum ASTM 1654 rating of 6 Corrosion resistant wire mesh panels are added to protect the condenser coil from incidental damage and restrict unauthorized access to in...

Page 18: ...rust resistant PVC coated steel wire Motors The fan motors are Totally EnclosedAir Over squirrel cage type current protected They feature ball bearings that are double sealed and permanently lubricate...

Page 19: ...control Lead system definition Compressor starts operating hours each compres sor Intensity of Protection European Standard International Electrotechnical Commission Status of hot gas valves evaporato...

Page 20: ...condary wiring between the transformer and the control panel Factory Mounted Power Factor Correction Capacitors Will correct unit compressor power factors to a 0 90 0 95 Factory Mounted Control Option...

Page 21: ...nts Factory Mounted Service Isolation Valve Service suction and discharge ball type isolation valves are added to unit per system This option also includes a system high pressure relief valve in compl...

Page 22: ...oils The unit s coils are constructed with copper fins This is not recommended for units in areas where they may be exposed to acid rain Enclosure Panels Unit Tamperproof Enclosure Panels prevent unau...

Page 23: ...3 ISSUE DATE 09 25 2020 23 JOHNSON CONTROLS SECTION 2 PRODUCT DESCRIPTION 2 UNIT COMPONENTS COMPRESSORS HEAT EXCHANGER CONTROL POWER PANEL LD10950 COMPRESSORS CONDENSER COILS LD11457 LD11464 LD11419 L...

Page 24: ...LS 24 FORM 150 66 NM3 ISSUE DATE 09 25 2020 SECTION 2 PRODUCT DESCRIPTION TERMINAL BLOCK FAN FUSES CR1 CR2 COMPRESSOR CONTACTS TB1 CTB1 CONTROL POWER PANEL COMPONENTS LD11459 LD11460 LD11461 LD11458 L...

Page 25: ...uit Breaker QQ Special Power Option Required TRANS Cntrl Transformer PIN 18 X No Control Transformer Required T Control Transformer Required Q Special Control Transformer Required PFC Power Factor Cap...

Page 26: ...O OptiView Remote Panel Required Q Special Remote Panel Required SEQ Sequence Kit PIN 28 X No Sequence Kit Required S Sequence Kit Required SEQ S Q Special Sequence Required TEMP Leaving Water Temp P...

Page 27: ...ired F Three Differential Pressure Switches Re quired Q Special Flow Switch Required VESSEL Vessel Codes PIN 42 X UL Pressure Code Vessel A ASME Pressure Vessel Code Q Special Pressure Vessel Code CLR...

Page 28: ...Y Warranty PIN 55 X 1st Year Parts Only B 1st Year Parts Labor C 2nd Year Parts Only D 2nd Parts Labor E 5 Year Compressor Parts Only F 5 Year Compressor Parts Labor G 5 Year Unit Parts Only H 5 Year...

Page 29: ...2 Pump C 1 Pump w Expansion Tank D 2 Pump w Expansion Tank E 1 Pump w Buffer Tank F 2 Pump w Buffer Tank G 1 Pump w Expans Tank Buffer Tank H 2 Pump w Expans Tank Buffer Tank Q Special Quote MFG Plant...

Page 30: ...NM3 ISSUE DATE 09 25 2020 SECTION 2 PRODUCT DESCRIPTION LD11417 FIG 1 REFRIGERANT FLOW DIAGRAM OPTIONAL OPTIONAL DISCHARGE LINE BALL VALVE HOT DISCHARGE GAS LINE OPTIONAL SERVICE VALVE REFRIGERANT FLO...

Page 31: ...y in spected during storage INSPECTION Remove any transit packing and inspect the unit to en sure that all components have been delivered and that no damage has occurred during transit If any damage i...

Page 32: ...STORAGE UNIT RIGGING Use spreader bars to avoid lifting chains hitting the chiller Never lift the chiller using a forklift or by hooking to the top rails Use only the lifting holes provided Lifting I...

Page 33: ...cedures to be followed to install and start up the chiller HANDLING These units are shipped as completely assembled units containing full operating charge and care should be taken to avoid damage due...

Page 34: ...pressor and fan operation Con siderations should be made utilizing noise levels pub lished in the YORK Engineering Guide for the specific chiller model Sound blankets for the compressors and low sound...

Page 35: ...switch Adjust the flow switch paddle to the size of the pipe in which it is to be installed see manufacturer s in structions furnished with the switch The switch is to be wired to terminals 13 and 14...

Page 36: ...or locked out on a system fault Field connec tions are at TB1 terminals 29 to 30 system 1 and ter minals 31 to 32 system 2 YCAL0041 YCAL0071 Remote Start Stop Contacts To remotely start and stop the...

Page 37: ...orator heater uses 120 VAC Disconnecting 120 VAC power from the unit at or below freez ing temperatures can result in damage to the evaporator and unit as a result of the chilled liquid freezing LD077...

Page 38: ...be supplying the unit power panel To prevent serious in jury or death the technician should verify that NO LETHALVOLTAGES are present inside the panel AFTER disconnecting power PRIOR to work ing on eq...

Page 39: ...system Compressor Oil To add oil to a circuit connect a YORK hand oil pump Part No 470 10654 000 to the 1 4 in oil charging valve on the oil separator piping with a length of clean hose or copper lin...

Page 40: ...ooler Purge air from the top of the cooler using the plugged air vent mounted on the top of the cooler body Flow rates and pressure drops must be within the limits given in the Technical Data Section...

Page 41: ...control panel to ensure it is free of foreign material wires metal chips or similar materials 8 Visually inspect wiring power and control Wir ing MUST meet N E C and local codes 9 Check tightness of p...

Page 42: ...it Keys for more information on system switches Place the Unit Switch in the control panel to the ON position As each compressor cycles ON ensure that the discharge pressure rises and the suction pres...

Page 43: ...6 cm from the cooler Set superheat for no less than 10 F with only a sin gle compressor running on a circuit The superheat is calculated as the difference between the actual tem perature of the return...

Page 44: ...t is made whenever all systems shut down 4 Several seconds after the compressor starts that sys tems first condenser fan will be cycled on outdoor air temperature more than 25 F 4 C or discharge press...

Page 45: ...e higher than 55 F 12 8 C contact the nearest Johnson Controls Office for application guidelines 3 The evaporator is protected against freezing to 20 F 28 8 C with an electric heater as standard 4 For...

Page 46: ...ng Guide 150 64 EG1 for minimum and maximum flowpoints MODEL YCAL COOLER CURVE 0041 A 0045 0051 B 0055 C 0061 0065 0071 D ENGLISH 1 10 100 10 100 1000 FLOW GPM Press Drop Ft H 2 O A B C D HEAT EXCHANG...

Page 47: ...r application guidelines 3 The evaporator is protected against freezing to 20 F 28 8 C with an electric heater as standard 4 For operation at temperatures below 25 F 3 9 C the optional Low Ambient Kit...

Page 48: ...B 0055 C 0061 0065 0071 D Note Water Pressure Drop Curves may extend past the minimum and maximum water flow ranges See Design Parameters in Engineering Guide 150 64 EG1 for minimum and maximum flowpo...

Page 49: ...FORM 150 66 NM3 ISSUE DATE 09 25 2020 49 JOHNSON CONTROLS SECTION 6 TECHNICAL DATA THIS PAGE INTENTIONALLY LEFT BLANK...

Page 50: ...ils lbs Alumi num Fin Coils lbs Cop per Fin Coils lbs Comp 1 Comp 2 Comp 3 Comp 4 Comp 5 Comp 6 0041 144 81 90 56 47 75 29 6 2 35 35 1 8 1 8 2942 3300 2967 3325 8 8 8 8 0045 144 81 90 56 47 75 32 3 2...

Page 51: ...Water Flow Rate GPM Nominal Water Connec tions Size inches Ckt1 Ckt2 Ckt1 Ckt2 Ckt1 Ckt2 87 0 2 2 17 2 2 1 2 950 39500 2 2 1 2 698 39500 2 7 300 450 40 200 3 87 0 2 2 17 2 2 1 2 950 39500 2 2 1 2 698...

Page 52: ...73 69 87 YCAL0051 88 89 89 86 82 77 73 69 88 YCAL0055 89 92 92 89 85 80 76 72 90 YCAL0061 90 91 91 89 85 80 76 72 90 YCAL0065 90 91 91 89 85 80 77 72 90 YCAL0071 DATA NOT AVAILABLE 50 HZ LINE FREQUEN...

Page 53: ...FORM 150 66 NM3 ISSUE DATE 09 25 2020 53 JOHNSON CONTROLS SECTION 6 TECHNICAL DATA THIS PAGE INTENTIONALLY LEFT BLANK...

Page 54: ...CKT BKR 5 FIELD WIRING LUGS6 TERMINAL BLOCK STD FIELD WIRING LUGS6 NF DISC SWITCH OPT REC MAX4 REC MAX LUGS PHASE LUG WIRE RANGE LUGS PHASE LUG WIRE RANGE YCAL0041 380 87 100 100 100 125 125 1 6AWG 5...

Page 55: ...RLA LRA QTY FLA LRA FLA LRA 1 6AWG 350MCM 17 2 125 17 2 125 2 17 2 125 17 2 125 2 3 7 22 3 4 21 1 6AWG 350MCM 17 6 125 17 6 125 2 17 2 125 17 2 125 2 3 7 22 3 4 21 1 6AWG 350MCM 17 6 125 17 6 125 2 2...

Page 56: ...it at or below freez ing temperatures can result in damage to the evaporator and unit as a result of the chilled liquid freezing ELECTRICAL DATA TABLE 11 MICRO PANEL POWER SUPPLY UNIT VOLTAGE UNIT VOL...

Page 57: ...other loads included in the circuit Otherwise an HACR type circuit breakers must be used Maximum HACR circuit breaker rating is based on 225 of the rated load amps for the largest motor plus 100 of th...

Page 58: ...JOHNSON CONTROLS 58 FORM 150 66 NM3 ISSUE DATE 09 25 2020 SECTION 6 TECHNICAL DATA ELEMENTARY DIAGRAM WIRING DIAGRAMS LD13247 FIG 4 CONTROL CIRCUIT...

Page 59: ...FORM 150 66 NM3 ISSUE DATE 09 25 2020 59 JOHNSON CONTROLS SECTION 6 TECHNICAL DATA 6 ELEMENTARY DIAGRAM CONT D LD13248 FIG 4 CONT D CONTROL CIRCUIT...

Page 60: ...JOHNSON CONTROLS 60 FORM 150 66 NM3 ISSUE DATE 09 25 2020 SECTION 6 TECHNICAL DATA ELEMENTARY DIAGRAM LD13249 FIG 5 POWER CIRCUIT...

Page 61: ...FORM 150 66 NM3 ISSUE DATE 09 25 2020 61 JOHNSON CONTROLS SECTION 6 TECHNICAL DATA 6 LD10958 FIG 6 WIRING DETAILS ELEMENTARY DIAGRAM CONT D...

Page 62: ...JOHNSON CONTROLS 62 FORM 150 66 NM3 ISSUE DATE 09 25 2020 SECTION 6 TECHNICAL DATA CONNECTION DIAGRAM LD13250 FIG 7 CONNECTION DIAGRAM...

Page 63: ...FORM 150 66 NM3 ISSUE DATE 09 25 2020 63 JOHNSON CONTROLS SECTION 6 TECHNICAL DATA 6 CONNECTION DIAGRAM LD10960 FIG 8 CONNECTION DIAGRAM MICROBOARD PARTIAL BACNET MICROGATEWAY OPTION...

Page 64: ...ompromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure...

Page 65: ...6 Y C G X 1 1 16 ORIGIN END CAP WIDTH 21 13 16 TOP VIEW R1 9 13 16 1 1 16 R2 9 13 16 L1 L2 9 16 DIA MOUNTING HOLES typ 144 13 16 15 1 16 13 15 16 TWO LIFTING HOLES BOTH SIDES FRONT VIEW C G X Z 38 5 5...

Page 66: ...may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pre...

Page 67: ...16 Y C G X 1 1 16 ORIGIN END CAP WIDTH 20 1 16 TOP VIEW R1 9 13 16 1 1 16 R2 9 13 16 L1 L2 9 16 DIA MOUNTING HOLES typ 144 13 16 15 1 16 13 15 16 TWO LIFTING HOLES BOTH SIDES FRONT VIEW C G X Z 38 5 5...

Page 68: ...may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pre...

Page 69: ...16 Y C G X 1 1 16 ORIGIN END CAP WIDTH 20 1 16 TOP VIEW R1 9 13 16 1 1 16 R2 9 13 16 L1 L2 9 16 DIA MOUNTING HOLES typ 144 13 16 15 1 16 13 15 16 TWO LIFTING HOLES BOTH SIDES FRONT VIEW C G X Z 38 5 5...

Page 70: ...may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pre...

Page 71: ...5 16 Y C G X 1 1 16 ORIGIN END CAP WIDTH 18 7 16 TOP VIEW R1 9 13 16 1 1 16 R2 9 13 16 L1 L2 9 16 DIA MOUNTING HOLES typ 144 13 16 15 1 16 14 TWO LIFTING HOLES BOTH SIDES FRONT VIEW C G X Z 38 5 3 16...

Page 72: ...may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pre...

Page 73: ...5 16 Y C G X 1 1 16 ORIGIN END CAP WIDTH 16 11 16 TOP VIEW R1 9 13 16 1 1 16 R2 9 13 16 L1 L2 9 16 DIA MOUNTING HOLES typ 144 13 16 15 1 16 14 TWO LIFTING HOLES BOTH SIDES FRONT VIEW C G X Z 38 5 3 16...

Page 74: ...may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pre...

Page 75: ...5 16 16 11 16 38 5 3 16 153 5 8 15 1 16 16 25 3 8 28 9 16 CONTROL PANEL TWO LIFTING HOLES BOTH SIDES Y TOP VIEW C G X FRONT VIEW C G X Z 1 1 16 1 1 16 L1 L2 R2 R1 ORIGIN 9 13 16 9 13 16 B B 9 16 DIA...

Page 76: ...ls will optimize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Recommended minimum clearances front to wall 6 rear...

Page 77: ...NSIONS YCAL0071 ENGLISH CONT D 90 9 16 43 5 16 16 11 16 38 5 3 16 153 5 8 15 1 16 16 25 3 8 28 9 16 CONTROL PANEL TWO LIFTING HOLES BOTH SIDES Y TOP VIEW C G X FRONT VIEW C G X Z 1 1 16 1 1 16 ORIGIN...

Page 78: ...eliable operation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance YORK s uni...

Page 79: ...HNICAL DATA 6 2301 1150 Y C G X 28 ORIGIN END CAP WIDTH 554 TOP VIEW R1 249 28 R2 249 L1 L2 14 DIA MOUNTING HOLES typ 3678 383 355 TWO LIFTING HOLES BOTH SIDES FRONT VIEW C G X Z 965 135 645 346 B B C...

Page 80: ...r must consider potential performance degradation Recommended minimum clearances front to wall 2m rear to wall 2m cooler end to wall 1 2m coil end to wall 2m top no obstructions allowed distance betwe...

Page 81: ...HNICAL DATA 6 2301 1150 Y C G X 28 ORIGIN END CAP WIDTH 509 TOP VIEW R1 249 28 R2 249 L1 L2 14 DIA MOUNTING HOLES typ 3678 383 355 TWO LIFTING HOLES BOTH SIDES FRONT VIEW C G X Z 965 135 645 346 B B C...

Page 82: ...liable operation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance YORK s unit...

Page 83: ...HNICAL DATA 6 2301 1150 Y C G X 28 ORIGIN END CAP WIDTH 509 TOP VIEW R1 249 28 R2 249 L1 L2 14 DIA MOUNTING HOLES typ 3678 383 355 TWO LIFTING HOLES BOTH SIDES FRONT VIEW C G X Z 965 135 645 346 B B C...

Page 84: ...liable operation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance YORK s unit...

Page 85: ...HNICAL DATA 6 2301 1151 Y C G X 28 ORIGIN END CAP WIDTH 468 TOP VIEW R1 249 28 R2 249 L1 L2 14 DIA MOUNTING HOLES typ 3678 383 356 TWO LIFTING HOLES BOTH SIDES FRONT VIEW C G X Z 965 131 645 726 B B C...

Page 86: ...liable operation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance YORK s unit...

Page 87: ...HNICAL DATA 6 2301 1100 Y C G X 28 ORIGIN END CAP WIDTH 424 TOP VIEW R1 249 28 R2 249 L1 L2 14 DIA MOUNTING HOLES typ 3678 383 356 TWO LIFTING HOLES BOTH SIDES FRONT VIEW C G X Z 965 131 645 726 B B C...

Page 88: ...liable operation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance YORK s unit...

Page 89: ...6 TECHNICAL DATA 6 2301 1100 424 965 131 3902 383 406 645 726 CONTROL PANEL TWO LIFTING HOLES BOTH SIDES Y TOP VIEW C G X FRONT VIEW C G X Z 28 28 ORIGIN 249 249 B B 14 DIA MOUNTING HOLES typ END CAP...

Page 90: ...e operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Recommended minimum clearances front to wall 2m rear to wall 2m co...

Page 91: ...TION 6 TECHNICAL DATA 6 DIMENSIONS YCAL0071 SI CONT D 2301 1100 424 965 131 3902 383 406 645 726 CONTROL PANEL TWO LIFTING HOLES BOTH SIDES Y TOP VIEW C G X FRONT VIEW C G X Z 28 28 ORIGIN 249 249 B B...

Page 92: ...25 2020 SECTION 6 TECHNICAL DATA TECHNICAL DATA CLEARANCES 1 3 m 2 m 2 m 2 m NOTES 1 No obstructions allowed above the unit 2 Only one adjacent wall may be higher than the unit 3 Adjacent units should...

Page 93: ...oose with the chiller Packed with the isolators and also in the control panel informa tion packet is a drawing and table specifically for each chiller based on the option selection The drawing and tab...

Page 94: ...24583 011 2028 to 2254 lbs 920 to 1022 kg CIP C Red w Red 029 24583 012 2254 to 2936 lbs 1022 to 1332 kg CIP C Red w Green 029 24583 013 CIP X Illustration shows single spring CIP B or CIP C mount HC...

Page 95: ...d free height of the isolator To use the isolator as blocking for the equipment insert a 10 mm 1 4 in shim between the upper load plate and vertical uprights Lower the equipment on the blocking or shi...

Page 96: ...D Max Bolt Dia Steel Plate Top Bottom Neoprene covered to prevent corrosion L T H W D ENGLISH SIZE D H L T W BC CS MBD ND C 2 9 16 2 3 4 5 1 2 1 4 2 5 16 4 1 80 1 2 13 x 1 1 2 ND D 3 3 8 2 3 4 6 1 4 5...

Page 97: ...g SLRS 2 C2 Gray 029 24585 011 1497 to 2058 lbs 679 to 933 kg SLRS 2 C2 Silver 029 24585 012 2058 to 2619 lbs 933 to 1188 kg SLRS 2 C2 Gray w red 029 24585 013 2619 to 3180 lbs 1188 to 1442 kg SLRS 2...

Page 98: ...and the steel washer D Tap 4 Holes unless otherwise requested Adjustment Bolt Vertical Limit Stops Out of contact during normal operation Non Skid Neoprene Pad Pad can be removed if mounts are welded...

Page 99: ...directly to the Microprocessor Board The Microprocessor Board circuitry multiplexes the analog inputs digitizes them and scans them to keep a con stant watch on the chiller operating conditions From...

Page 100: ...emperatures compressor running times and starts option information on the chiller and system setpoints This data is useful for monitoring chiller op eration diagnosing potential problems troubleshoot...

Page 101: ...s all SYS 2 messages will be blank U N I T S W I T C H O F F S H U T D O W N This message informs the operator that the UNITswitch on the control panel is in the OFF position which will not allow the...

Page 102: ...m The limiting pressure is a factory set limit to keep the system from faulting on the high discharge pressure cutout due to high load or pull down conditions When the unload point is reached the micr...

Page 103: ...input when in the MANUAL OVERRIDE mode MANUAL OVERRIDE is to only be used in emergencies or for servicing Manual override mode automatically dis ables itself after 30 minutes S Y S 1 P U M P I N G D O...

Page 104: ...ioning properly This safety is only active when EEV is selected as the expansion valve type in SER VICE Mode This safety is ignored for the first 15 sec onds of system runtime The internal motor prote...

Page 105: ...certain level a unit fault is initiated to safely shut down the unit Restart is allowed after the unit is fully powered again and the anti recycle timers have finished count ing down U N I T F A U L...

Page 106: ...g System X Suction Limiting System X Percentage Load Limiting Manual Overide Status System X Pumping Down on shutdown Unit Safeties Warning Messages System Safeties Low Ambient Temp System X High Disc...

Page 107: ...DOWN arrow keys or the ENTER ADV key located under the ENTRY section System 2 information will only be dis played for 2 system units DISPLAY PRINT KEYS With the UNIT TYPE set as a liquid chiller via...

Page 108: ...entially for each system The first display shows accumulated run ning hours of each compressor for the specific system The second message shows the number of starts for each compressor on each system...

Page 109: ...T R L N O N E There are several types of remote systems that can be used to control or monitor the unit The following mes sages indicate the type of remote control mode active NONE no remote control a...

Page 110: ...Time Sys 1 LLSV HGSV Status System 1 Condenser Fan Stage Current Feedback One Per System The fourth message indicates what stage of condenser fan operation is active For YCAL0041 to YCAL0071 unless a...

Page 111: ...N TEMP 40 0 DEGF SUCTION SUPERHEAT 12 8 DEGF COOLER INLET REFRIG 31 6 DEGF LIQUID LINE SOLENOID OFF HOT GAS BYPASS VALVE OFF CONDENSER FAN STAGES OFF EEV OUTPUT 0 0 SYSTEM XXX X AMPS X X VOLTS SYSTEM...

Page 112: ...printout of information relating to the last 6 Safety Shutdowns which occurred The information is stored at the instant of the fault re gardless of whether the fault caused a lockout to occur The info...

Page 113: ...liquid control A M B I E N T A I R T E M P X X X X F Displays the Ambient Temp at the time of the fault Displays the type of Ambient Control Standard or Low Ambient L O C A L R E M O T E M O D E X X...

Page 114: ...mperature will be displayed only on R 407c units S Y S X L L S V I S X X X H O T G A S S O L I S X X X Displays whether the System Liquid Line Solenoid or Hot Gas Solenoid was energized at the time of...

Page 115: ...s The UP arrow key and DOWN arrow key are also used for programming the control panel such as changing numerical or text values when programming cooling setpoints setting the daily schedule changing s...

Page 116: ...uid Control S E T P O I N T 4 5 0 F R A N G E 2 0 F The above message shows the current chilled water temperature SETPOINT at 45 0 F notice the cursor positioned under the number 0 Pressing either the...

Page 117: ...illed liquid temperature control the microprocessor will attempt to control the leaving water temperature within the temperature range of the setpoint plus or minus the range In the above example cont...

Page 118: ...UP and DOWN arrow and ENTER ADV keys After SUN Sunday schedule appears on the display a subsequent press of the SCHEDULE ADVANCE DAY key will display the Holiday schedule This is a two part display T...

Page 119: ...porarily drop below the cutout point Details are explained under the topic of SYSTEM SAFETIES L O W A M B I E N T T E M P C U T O U T 2 5 0 F The LOWAMBIENT TEMP CUTOUT allows the user to select the c...

Page 120: ...NTROL DIFFERENTIAL OFF PRESSURE below 160 psig This ensures discharge pressure does not drop too low F A N D I F F E R E N T I A L O F F P R E S S U R E X X X P S I G The Fan Differential Off Pressure...

Page 121: ...to 15 F is recom mended Unit Trip Volts For total chiller high current trip programming on 460VAC chillers Add the sum of all the the compressor and fan RLA s in the chiller Multiply the sum by 1 25...

Page 122: ...9 barg 4 83 BARG 3 03 BARG LOW AMBIENT TEMP CUTOUT STANDARD AMBIENT 25 0 F 60 0 F 25 0 F 3 9 C 15 6 C 3 9 C LOW AMBIENT 0 F 60 0 F 25 0 F 17 8 C 15 6 C 3 9 C LEAVING CHILLED LIQUID TEMP CUTOUT WATER...

Page 123: ...Mon Sun Discharge Water Temp Control Pressure Display Only Holiday Cutout Schedule Chilled Liquid Suction Setpoint Pressure Cutout Range Remote Setpoint Low Ambient Temp Cutout Range Display Only Lea...

Page 124: ...KEYS Options Key There are many user programmable options under the OPTIONS key The OPTIONS key is used to scroll through the list of options by repeatedly pressing the OPTIONS key After the selected...

Page 125: ...nsmission for 5 minutes it will revert back to the locally programmed values Option 6 Unit Control Mode C O N T R O L M O D E R E T U R N L I Q U I D Unit control is based on return chilled liquid tem...

Page 126: ...ontrol Mode F A N C O N T R O L D I S C H A R G E P R E S S U R E Condenser fans are controlled by discharge pressure only This mode may only be chosen when discharge pressure transducers are installe...

Page 127: ...update is not required and the message above will be displayed If the operating software is to be updated insert the Flash Card into the Flash Card input port Turn off the unit switch and set the FLAS...

Page 128: ...ump 2 P U M P S E L E C T I 0 N M A N U A L P U M P N O 2 Selecting Manual Pump 2 allows pump 2 to operate as the duty pump without automatic change over to pump 1 P U M P S E L E C T I O N A U T O M...

Page 129: ...cal Remote Mode Unit Control Mode Return or Leaving Display Units English or Metric System Lead Lag Control Manual or Automatic Fan Control Mode Manual Override Mode Current Feedback Option Soft Start...

Page 130: ...JOHNSON CONTROLS 130 FORM 150 66 NM3 ISSUE DATE 09 25 2020 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 131: ...ogrammed for Leaving Chilled Liquid Control is the temperature the unit will control to within plus or minus the control cooling range The Setpoint High Limit is the Setpoint plus the Cooling Range Th...

Page 132: ...set point adjust will be set back to 0 This will occur while the system is still running FIG 10 LEAVING WATER TEMPERATURE CONTROL EXAMPLE Leaving Water Temp Control Compressor Staging Setpoint 46 0 F...

Page 133: ...a Cooling Setpoint programmed for 45 F 7 20 C and a Range Setpoint of 10 F 5 56 C Using the formulas in Table 20 the control range will be split up into six seven in cluding hot gas segments with the...

Page 134: ...adjusted to 600 seconds The programmable anti recycle timer starts the timer when the first compressor in a system starts The timer begins to count down If all of the compres sors in a circuit cycle...

Page 135: ...rogrammed with the Options key under Fan Control Condenser fan con trol can be selected for Ambient Temp and Discharge Pressure or Discharge Pressure only The condenser fan control by Ambient Temperat...

Page 136: ...PUT FAN SYS 1 SYS 2 SYS 1 SYS 2 SYS 1 SYS 2 1 OAT 25 F 3 9 C OR DP Fan Ctrl On Press OAT 20 F 6 7 C AND DP Fan Ctrl On Press Diff Press 7M 10M TB7 9 TB10 9 3 4 2 OAT 65 F 18 3 C OR DP Fan Ctrl On Pres...

Page 137: ...off by de energizing the fan contactor If pressure continues to fall VFD speed will decrease in an effort to maintain discharge pres sure Speed may drop to the point where the VFD turns the fan comple...

Page 138: ...gs is recommended The jumpers must be in the positions shown in the fol lowing Table Chillers built in 2005 and early 2006 were configured with J4 IN This jumper must be removed Also be sure to check...

Page 139: ...o run the VFD Fig s 16 and 17 show the power and control wiring schematically as well as the actual connections The VFD controlled fan will operate whenever the liquid line solenoid on the respective...

Page 140: ...9 1 2 2 Inverter control 1 fan full speed under inverter control and 2nd fan full speed under contactor control 280 psig both fans will be running full speed Discharge pres sure 200 psig pres sure is...

Page 141: ...the contacts remain closed The maximum temperature reset is achieved at a contact closure of 11 seconds This is the longest con tact closure time allowed One second is the shortest time allowed and ca...

Page 142: ...6VDC x 11 11 C 6 67 C Reset 10 New Setpoint 7 22 C 6 67 C 13 89 C MaxResetValueisthe MaxEMS PWMRemoteTemp Reset setpoint valuedescribedintheprogram mingsectionunderCoolingSetpoints Programmable values...

Page 143: ...FORM 150 66 NM3 ISSUE DATE 09 25 2020 143 JOHNSON CONTROLS SECTION 8 UNIT OPERATION 8 FIG 18 FIELD AND FACTORY ELECTRICAL CONNECTIONS OPTIONAL REMOTE TEMPERATURE RESET BOARD LD03875B 035 15961 000...

Page 144: ...JOHNSON CONTROLS 144 FORM 150 66 NM3 ISSUE DATE 09 25 2020 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 145: ...rant type and expansion valve type all must be programmed to match actual chiller configuration CLEARING HISTORY BUFFERS The history buffers may be cleared by pressing the HIS TORY key and then repeat...

Page 146: ...1 DISCH PRESSURE SYS 1 COOLER INLET REFRIG TEMP SYS 2 COOLER INLET REFRIG TEMP SYS 1 SUCTION TEMP SYS 2 SUCTION TEMP AMBIENT AIR TEMP LEAVING LIQUID TEMP RETURN LIQUID TEMP SYS 2 SUCTION PRESSURE SYS...

Page 147: ...denser Fan Output 1 TB10 9 Sys 2 Condenser Fan Output 2 TB10 10 Sys 2 Condenser Fan Output 3 TB8 2 Evaporator Heater TB8 3 Sys 1 Alarm TB9 2 Sys 2 Alarm TB8 6 7 Evaporator Pump Starter TB10 7 Sys 2 Ho...

Page 148: ...148 FORM 150 66 NM3 ISSUE DATE 09 25 2020 SECTION 9 SERVICE AND TROUBLESHOOTING FIG 19 IPU II I O LAYOUT LD12721 TB5 TB1 TB6 TB7 TB8 TB9 TB10 J14 J13 J12 J15 J11 J10 J9 J8 J7 J6 J5 J3 I O BOARD IPU B...

Page 149: ...lar digital input Typically voltages as high as 34 VDC could be mea sured for the DC voltage on the digital inputs This voltage is in reference to ground The unit case should be sufficient as a refere...

Page 150: ...See Table 31 for voltage readings that correspond to specific liquid temperatures J6 1 drain shield connection 0 VDC Return TABLE 31 ENTERING LEAVING CHILLED LIQUID TEMP SENSOR COOLER INLET TEMPERATU...

Page 151: ...output will be linear from 0 5 VDC to 4 5 VDC over the 400 psig 27 58 barg range The discharge transducers have a range from 0 psig to 650 psig The output will be linear from 0 5 VDC to 4 5 VDC over...

Page 152: ...respond to specific suction pressures J9 9 5 VDC return J9 1 drain shield connection 0 VDC Digital Outputs Refer to the unit wiring diagram and Fig 20 The digi tal outputs are located on TB 7 TB 8 TB...

Page 153: ...r YORK is P N 950915576 The cable to connect the printer can either be locally assembled from the parts listed or ordered directly from WEIGH TRONIX under part number 287 040018 Parts The following pa...

Page 154: ...led liquid flow 2 Flow switch improperly installed 2 Check that the flow switch is installed according to manufacturer s instructions 3 Defective flow switch 3 Replace flow switch 4 Remote cycling dev...

Page 155: ...e LWT or RWT sensor ensure the sensor is properly installed in the bottom of the well with a generous amount of heat conductive compound 4 Compare sensor against a known good temperature sensing devic...

Page 156: ...face Low suction pressure will be observed 1 Contact the local Johnson Controls Service representative 2 Improper flow through the evaporator 2 Reduce flow to within chiller design specs See Limitatio...

Page 157: ...n and analyzed If contaminants are present the system must be cleaned to prevent compressor failure Never use the scroll compressor to pump the refrigerant system down into a vacuum Doing so will caus...

Page 158: ...e option of DE MODIFIER ADDRESS XXXXX DE MODIFIER OFFSET XX P1 PROTOCOL XXXXXX P1 MANUAL MAC ADDRESS XXX P1 BAUD RATE XXXXX P1 PARITY XXXXX P1 STOP BITS X P2 PROTOCOL XXXXXXXXXX P2 MANUAL MAC ADDRESS...

Page 159: ...1200 76800 4800 1200 4800 9600 19200 38400 76800 AUTO SELECTABLE P2 BAUD RATE 1200 57600 1200 1200 4800 9600 19200 38400 57600 SELECTABLE P1 P2 MANUAL Mac AD DRESS 1 127 1 P1 P2 PARITY NONE IGNORE NON...

Page 160: ...1 N A N A P1 BAUD RATE 9600 to 76800 or Auto Selectable 1 N A N A P1 PARITY NONE N A N A P1 STOP BITS 1 N A N A P2 PROTOCOL N A MODBUS SVR N A P2 MANUAL MAC ADDRESS N A 0 127 1 N A P2 BAUD RATE N A 19...

Page 161: ...inary Monitor Only Points This data can be read using a BACnet or Modbus net work connection and can NOT be modified using this connection The Modbus Register Address for these points is 1281 plus BI...

Page 162: ...IR_TEMP AI10 523 03 04 x10 ADF 17 F C Sys 1 Cooler Inlet Refrigerant Temp R 407c O O O 21 S1_DEF_TEMP AI11 524 03 04 x10 ADF 18 F C Sys 1 Defrost Temperature HP O O O 22 S1_EEV_OUT AI12 525 03 04 x10...

Page 163: ...4 x10 ADF 56 F diff C diff Sys 1 Discharge Superheat EEV O O O 60 S2_DSCH_TEMP AI50 563 03 04 x10 ADF 57 F C Sys 2 Discharge Temperature EEV O O O 61 S2_DSCH_SH AI51 564 03 04 x10 ADF 58 F diff C diff...

Page 164: ...dbus Data Type Supported Modbus Scaling See Note 5 N2 Metasys Engineering Units Point List Code S Standard O Optional N Not Available NOTES Units have Native BACnet MS TP Modbus RTU and N2 communicati...

Page 165: ...essure No Abnormal Condition No Fault Code Low Ambient Temperature Unit Switch OFF System Switch OFF Low Suction Pressure System Fault Remote Shutdown Daily Schedule Shutdown No Run Permissive No Cool...

Page 166: ...lo cal control values Table 36 Yorktalk 2 Communica tions Data Map lists the control parameters These values are found under feature 54 in the MicroGateway or E Link Transmitted Data After receiving...

Page 167: ...S01p015 SNVT_count_f 51 ADF 9 0009 x10 F C Sys 1 Suction Temperature EEV O O O O O P16 AV10 YT2_ S01_ P16 nvoYTS01p016 SNVT_count_f 51 ADF 10 0010 x10 F C Ambient Air Temperature S S S S S P17 AV11 YT...

Page 168: ...0076 N A 0 1 0 1 Lead System 0 Sys1 1 Sys2 S S S S S P48 BV17 YT2_ S01_ P48 nvoYTS01p048 SNVT_switch 95 BD 17 0077 N A 0 1 0 1 Sys 1 Comp 3 Run S S S S S P49 BV18 YT2_ S01_ P49 nvoYTS01p049 SNVT_swit...

Page 169: ...51 ADF 40 0050 x10 F C Sys 1 Discharge Temperature EEV O O O O O P77 AV41 YT2_ S01_ P77 nvoYTS01p077 SNVT_count_f 51 ADF 41 0051 x10 F diff C diff Sys 1 Discharge Superheat EEV O O O O O P78 AV42 YT2_...

Page 170: ...T2_ S02_ P25 nvoYTS02p025 SNVT_count_f 51 ADF 62 0119 N N N N N P26 AV124 YT2_ S02_ P26 nvoYTS02p026 SNVT_count_f 51 ADF 63 0120 N N N N N P27 AV125 YT2_ S02_ P27 nvoYTS02p027 SNVT_count_f 51 ADF 64 0...

Page 171: ...0142 N N N N N P69 AV133 YT2_ S02_ P69 nvoYTS02p069 SNVT_count_f 51 ADF 76 0143 N N N N N P70 AV134 YT2_ S02_ P70 nvoYTS02p070 SNVT_count_f 51 ADF 77 0144 N N N N N P71 AV135 YT2_ S02_ P71 nvoYTS02p0...

Page 172: ...hedule Shutdown Low Suction Pressure No Run Permissive No Cool Load High Ambient Temperature Anti Vacuum Low Pressure Cutout Anti Recycle Timer Active Manual Override Suction Limiting Discharge Limiti...

Page 173: ...FORM 150 66 NM3 ISSUE DATE 09 25 2020 173 JOHNSON CONTROLS 10 NOTES...

Page 174: ...nnsylvania USA 17349 Subject to change without notice Printed in USA Copyright by Johnson Controls 2020 ALL RIGHTS RESERVED Form 150 66 NM3 920 Issue Date September 25 2020 Supersedes 150 66 NM3 110 1...