York YCWL0056SE, Installation Operation & Maintenance

Page 1: ...HROUGH 700KW INSTALLATION OPERATION MAINTENANCE WATER COOLED LIQUID CHILLERS HERMETIC SCROLL Supersedes 201 26 NM1 617 Form 201 26 NM1 118 035 21965 101 R410A Products are produced at a facility whose...

Page 2: ...ferenced 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 question SAFETY SYMBOLS The...

Page 3: ...an be obtained by contacting the nearest Johnson Controls Service office or accessing the John son Controls QuickLIT website at http cgproducts johnsoncontrols com Operating service personnel maintain...

Page 4: ...FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 4 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 5: ...ressors 15 Refrigerant Circuits 15 Evaporator 16 Condenser 16 Refrigerant Circuit 16 Microprocessor Control Center 16 Programmable setpoints 17 Displayed Data 17 System Safeties 17 Unit Safeties 17 Po...

Page 6: ...STORAGE 31 Delivery And Storage 31 Inspection 31 Moving The Unit 31 Lifting by Crane Hoist 32 Lifting Weights 32 SECTION 4 INSTALLATION 33 Installation Checklist 33 Location Requirements 33 Unit Isol...

Page 7: ...And Propolyne Glycol Correction Factors 47 Evaporator Pressure Drop 47 Physical Data Standard And High Efficiency 48 Single Point Electrical Data 50 Standard Efficiency Without External Compressor Ove...

Page 8: ...ture Sensor s 110 Unit Operating Sequence 114 SECTION 7 UNIT CONTROLS 115 Introduction 115 IPU II and I O Boards 115 Unit Switch 116 Display 116 Keypad 116 Battery Back up 116 Transformer 116 Single S...

Page 9: ...back Options Installed 141 Option 13 Power Fail Restart 141 Option 14 Soft Start Enable Disable 141 Option 15 Unit Type 142 Option 16 Refrigerant Type 142 Option 17 Expansion Valve Type 142 Option 18...

Page 10: ...onal Printer Installation 163 Acceptable Printers 163 Okidata OKIPOS 441 Printer 163 Printer Connections 163 Required Hardware 163 Cable 163 Connectors 163 Printer Setup 163 Okidata OKIPOS 441 Printer...

Page 11: ...Power Supply Connection Standard Unit 62 FIGURE 21 Dual Point Power Supply Connection Standard Unit 63 FIGURE 22 Control Circuit 4 Compressor 68 FIGURE 23 Control Circuit 5 And 6 Compressor 70 FIGURE...

Page 12: ...ference List 138 TABLE 14 Sample Compressor Staging For Return Water Control 149 TABLE 15 Return Chilled Liquid Control For 4 Compressors 6 Steps 150 TABLE 16 Return Chilled Liquid Control For 4 Compr...

Page 13: ...hours starts These de tails are printed on the unit identification plate The unit warranty will be void if any modification to the unit is carried out without prior written approval from Johnson Cont...

Page 14: ...alified per sonnel Electrical The unit must be grounded No installation or main tenance work should be attempted on the electrical equipment without first switching power OFF isolat ing and locking of...

Page 15: ...YCWL compressors incorporate a compliant scroll design in both the axial and radial direction All rotating parts are statically and dynami cally balanced A large internal volume and oil res ervoir pro...

Page 16: ...ctualic couplings The shell is constructed and tested in accordance with Section VII Division 1 of ASME Pressure Vessel Code The water side is exempt per paragraph U 1 C 6 of Section VII Division 1 of...

Page 17: ...om pressor Run permissive status Number of compressors running Liquid solenoid valve status Load and unload timer status Water pump status System Safeties Cause individual compressors to perform auto...

Page 18: ...iring between the transformer and the control panel Factory Mounted Compressor External Overloads Optional compressor motor overloads can be factory mounted in the unit control power panel This option...

Page 19: ...erating mode controlled by leaving condenser water temperature Temperature setpoint user adjust from 86 F to 122 F 30 C to 50 C default 122 F 50 C While operating in this mode chiller will stage compr...

Page 20: ...NM1 ISSUE DATE 1 19 2018 SECTION 2 PRODUCT DESCRIPTION JOHNSON CONTROLS 20 Figure 2 CONTROL PANEL COMPONENTS CONTROL POWER PANEL COMPONENTS DISPLAY UNIT SWITCH IPU II IO BOARD CTB1 Flow Switch Load Li...

Page 21: ...8 JOHNSON CONTROLS 21 2 CONTROL POWER PANEL COMPONENTS CONT D Figure 3 CONTROL POWER PANEL COMPONENTS LD12921 COMPRESSOR OVERLOAD COMPRESSOR CONTACTOR COMPRESSOR CONTACTOR COMPRESSOR OVERLOAD CR1 CR2...

Page 22: ...FORM 201 26 NM1 ISSUE DATE 1 19 2018 SECTION 2 PRODUCT DESCRIPTION JOHNSON CONTROLS 22 UNIT COMPONENTS Figure 4 UNIT COMPONENTS POWER PANEL MICRO PANEL COMPRESSORS CONDENSER EVAPORATOR LD12919...

Page 23: ...1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 23 2 UNIT COMPONENTS CONT D Figure 5 CONTROL POWER PANEL COMPONENTS DUAL SYSTEM UNITS EVAPORATOR INLET WATER LIQUID STOP VALVE LIQUID LINE DRIER LIQUID LINE SOL...

Page 24: ...TION CONTRACT Contract Number NUM Contract Number CONTRACT NUM ORDER Order quantity QTY Order quantity ORDER QTY MODEL Model PIN 1 4 YCWL YCWL CAP Capacity PIN 5 8 0056 0056 0064 0064 0074 0074 0084 0...

Page 25: ...Quote L LON E Link Kit Factory LCD Language PIN 22 X Standard English LCD and Keypad Display F French LCD and Keypad Display G German LCD and Keypad Display I Italian LCD and Keypad Display S Spanish...

Page 26: ...n Q Special Quote OVERLOAD Compressor Overloads PIN 35 X No option E Compressor External Overloads Q Special Quote PRESSURE Pressure Control PIN 36 X No option Q Special Quote PIN 37 PIN 37 X No optio...

Page 27: ...USTIC Acoustical Arrgt PIN 49 X No Acoustic Enclosure B Compressor Sound Blanket Q Special Quote SRDOCS SR Documents PIN 50 X No Documents Required A Base Material and Witness Documents B Base Documen...

Page 28: ...ough the evaporator shell Low pressure vapor en ters the compressor where pressure and superheat are increased High pressure vapor is passed through the condenser where heat is rejected to the con den...

Page 29: ...lled liquid passing through the cooler shell Low pressure vapor enters the compres sor where pressure and superheat are increased The high pressure superheat refrigerant enters the remote air cooled c...

Page 30: ...FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 30 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 31: ...ing storage Rigging and lifting should only be done by a professional rigger in accordance with a written rigging and lifting plan The most appropriate rigging and lifting method will depend on job sp...

Page 32: ...ee Fig ure 8 on page 32 LIFTING WEIGHTS HIGH EFFICIENCY HE YCWL MODEL LBS KG 0064HE 0074HE 0084HE 0094HE 0096HE 0118HE 0126HE 0127HE 0156HE 0157HE 4533 2056 4911 2228 5089 2308 5773 2619 6253 2836 590...

Page 33: ...ation and mainte nance of the unit and power and control panels Local health and safety regula tions or practical considerations for service replacement of large components may require larger clearanc...

Page 34: ...ges caused inadequate liquid flow The flow switch used must have gold plated contacts for low voltage current operation Paddle type flow switches suitable for 150 PSIG 10 barg working pressure and hav...

Page 35: ...ovided at all low points to permit com plete drainage of the evaporator s condenser s and system piping This is especially important if the unit is located in an unheated room where freezing could pre...

Page 36: ...drop allowed OPTION FLANGES One of two types of flanges may be fitted depending on the customer or local Pressure Vessel Code require ments These are ANSI AWWA C 606 adapter flanges or weld flanges A...

Page 37: ...e highest expected suction pressure or by also measur ing suction pressure and using differential control In either case condenser cooling liquid flow and tempera ture limits must also be observed LD1...

Page 38: ...LATING VALVE NORMALLY CLOSED FLOW REGULATING VALVE FLOW MEASUREMENT DEVICE STRAINER PRESSURE TAPPING FLOW SWITCH FLANGED CONNECTION Isolating Valve Normally Open Isolating Valve Normally Closed Flow R...

Page 39: ...ain a system alarm signal connect the alarm circuit to terminals 29 and 30 for No 1 system and terminals 31 and 32 for No 2 system FIELD WIRING All field wiring must comply with the National Elec tric...

Page 40: ...e bottom of the control panel For wiring specifications refer to SECTION 5 TECHNICAL DATA In accordance with National Electric Code N E C it is the responsibility of the user to install overcurrent pr...

Page 41: ...EATERS Compressor heaters are standard If power is OFF more than two hours the crankcase heaters must be energized for 18 to 24 hours prior to restarting a com pressor This will assured that liquid sl...

Page 42: ...lt in damage to the evaporator and unit as a result of the chilled liquid freezing It is possible that multiple sources of power can be supplying the unit power panel To prevent serious injury or deat...

Page 43: ...4 40 4 4 115 46 0198SE 200 12 6 650 41 0 260 16 4 700 44 2 40 4 4 50 10 65 18 130 54 40 4 4 115 46 DESIGN PARAMETERS HIGH EFFICIENCY HE MODEL EVAPORATOR FLOW GPM LPS CONDENSER FLOW GPM LPS LEAVING EVA...

Page 44: ...nd these limitations may cause serious damage to the compressor Excessive flow will cause damage to the cooler Do not exceed max cooler flow Special care should be taken when mul tiple chillers are fe...

Page 45: ...5 5 TECHNICAL DATA EVAPORATOR PRESSURE DROP CHARTS Figure 17 EVAPORATOR WATER PRESSURE DROP CURVES YCWL MODEL NUMBER EVAP 0056SE 0064SE 0074SE 0084SE A 0064HE 0094SE B 0104SE 0118SE C 0074HE 0084HE 00...

Page 46: ...ONTROLS 46 Figure 18 CONDENSER WATER PRESSURE DROP CURVES CONDENSER PRESSURE DROP CHARTS YCWL MODEL NUMBER EVAP 0056SE 0064SE 0074SE 0084SE A 0064HE 0094SE B 0104SE 0118SE C 0074HE 0084HE 0094HE 0118H...

Page 47: ...0 922 1 013 1 091 1 599 29 PROPYLENE GLYCOL WEIGHT TONS COMPR KW GPM PRESS DROP FREEZE PT 10 0 985 1 002 1 003 1 078 26 20 0 968 1 005 1 000 1 157 19 30 0 937 1 008 0 992 1 266 9 40 0 898 1 012 0 982...

Page 48: ...25 25 25 19 19 19 19 32 32 25 25 24 24 19 19 32 32 32 32 24 24 24 24 25 25 25 25 25 25 19 19 19 19 19 19 35 35 35 35 26 26 26 26 32 32 32 32 32 24 24 24 24 24 32 32 32 32 32 32 24 24 24 24 24 24 COND...

Page 49: ...5 20 20 19 19 15 15 15 15 15 15 15 15 11 11 11 11 11 11 32 32 25 25 24 24 19 19 20 20 20 20 20 20 15 15 15 15 15 15 20 20 20 32 32 15 15 15 23 23 25 25 25 25 25 25 19 19 19 19 19 19 35 35 35 35 26 26...

Page 50: ...75 60 105 150 125 125 1 10 300 KCM 0094SE 200 60 348 400 400 400 2 10 300 KCM 230 60 348 400 400 400 2 10 300 KCM 380 60 199 250 225 250 1 10 300 KCM 460 60 157 200 175 200 1 10 300 KCM 575 60 121 150...

Page 51: ...38 2 290 38 2 290 42 9 250 42 9 250 30 4 225 30 4 225 32 1 198 32 1 198 24 6 180 24 6 180 0104SE 89 1 500 89 1 500 89 1 500 89 1 500 89 1 500 89 1 500 89 1 500 89 1 500 54 5 305 54 5 305 54 5 305 54 5...

Page 52: ...50 1 10 300 KCM 460 60 157 200 175 200 1 10 300 KCM 575 60 121 150 150 150 1 10 300 KCM 0096HE 200 60 349 400 400 400 2 10 300 KCM 230 60 349 400 400 400 2 10 300 KCM 380 60 225 250 250 250 1 4 500 KC...

Page 53: ...36 0 239 36 0 239 36 0 239 36 0 239 26 9 187 26 9 187 26 9 187 26 9 187 26 9 187 26 9 187 23 7 148 23 7 148 23 7 148 23 7 148 23 7 148 23 7 148 0118HE 109 6 599 109 6 599 89 1 500 89 1 500 109 6 599...

Page 54: ...1 6 350 KCM 230 60 228 250 250 250 1 6 350 KCM 1 6 350 KCM 380 60 132 150 150 150 1 2 4 0 AWG 1 2 4 0 AWG 460 60 109 150 125 125 1 2 4 0 AWG 1 2 4 0 AWG 575 60 87 100 100 100 1 14 1 0 AWG 1 14 1 0 AW...

Page 55: ...80 0104SE 57 8 500 57 8 500 57 8 500 57 8 500 57 8 500 57 8 500 57 8 500 57 8 500 33 3 305 33 3 305 33 3 305 33 3 305 27 5 250 27 5 250 27 5 250 27 5 250 22 0 198 22 0 198 22 0 198 22 0 198 0118SE 79...

Page 56: ...00 300 300 1 250 500 KCM 1 250 500 KCM 380 60 161 200 175 175 1 6 350 KCM 1 4 300 KCM 460 60 133 150 150 150 1 6 350 KCM 1 2 4 0 AWG 575 60 109 150 125 125 1 2 4 0 AWG 1 2 4 0 AWG 0118HE 200 60 297 40...

Page 57: ...25 7 239 21 3 187 21 3 187 21 3 187 21 3 187 21 3 187 21 3 187 17 4 148 17 4 148 17 4 148 17 4 148 17 4 148 17 4 148 0118HE 79 0 599 79 0 599 59 8 500 59 8 500 79 0 599 79 0 599 57 8 500 57 8 500 45 5...

Page 58: ...90 58 60 70 80 460 60 53 60 60 70 48 60 60 60 575 60 42 60 50 60 39 60 45 50 0084SE 0084HE 208 60 111 150 125 150 111 150 125 150 230 60 111 150 125 150 111 150 125 150 380 60 64 100 80 90 64 100 80 9...

Page 59: ...49 1 505 1 2 4 0AWG 49 1 505 49 1 505 380 60 1 14 1 0AWG 28 3 290 28 3 290 1 14 1 0AWG 28 3 290 28 3 290 460 60 1 14 1 0AWG 23 4 225 23 4 225 1 14 1 0AWG 23 4 225 23 4 225 575 60 1 14 1 0AWG 18 7 180...

Page 60: ...175 200 380 60 92 100 100 110 92 100 100 110 460 60 76 100 90 90 76 100 90 90 575 60 61 100 70 70 61 100 70 70 0127HE 208 60 166 200 200 200 178 200 200 250 230 60 160 200 175 200 178 200 200 250 380...

Page 61: ...225 575 60 1 14 1 0AWG 18 7 180 18 7 180 18 7 180 1 14 1 0AWG 18 7 180 18 7 180 18 7 180 208 60 1 6 350KCMIL 51 1 505 51 1 505 51 1 505 1 6 350KCMIL 79 0 599 79 0 599 230 60 1 6 350KCMIL 49 1 505 49...

Page 62: ...rmer Circuit 1 Circuit 2 Micropanel Optional Term Block or NF Disc SW or Circuit Breaker GRD LEGEND Field Wiring Factory Wiring It is possible that multiple sources of power can be supplying the unit...

Page 63: ...ATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 63 5 DUAL POINT SUPPLY CONNECTION TERMINAL BLOCK NON FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER LD17112 Figure 21 DUAL POINT POWER SUPPLY CONN...

Page 64: ...VOLTAGE CODE UNIT POWER MINIMUM MAXIMUM 17 200 3 60 180 220 28 230 3 60 200 254 40 380 415 3 60 342 402 46 460 3 60 414 508 50 380 415 3 50 342 440 58 575 3 60 520 635 Table 7 MICRO PANEL POWER SUPPL...

Page 65: ...amps for all other loads included in the circuit per N E C Article 440 22 6 Circuit breakers must be UL listed and CSA certified and maximum size is based on 225 of the rated load amps for the largest...

Page 66: ...G 14 6 AWG 70A 14 1 0 AWG 14 6 AWG 80A 14 1 0 AWG 14 6 AWG 90A 14 1 0 AWG 14 6 AWG 100A 14 1 0 AWG 8 2 AWG 125A 14 1 0 AWG 8 2 AWG 125A 2 4 0 AWG 8 2 AWG 150A 2 4 0 AWG 8 2 AWG 175A 4 300 KCM 6 1 0 AW...

Page 67: ...SECTION 5 TECHNICAL DATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 67 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 68: ...A JOHNSON CONTROLS 68 ELEMENTARY WIRING DIAGRAM Figure 22 CONTROL CIRCUIT 4 COMPRESSOR YCWL0056 0064 0074 0084 0094 0104 0118 and 0132 STANDARD EFFICIENCY UNITS YCWL0064 0074 0084 0094 0096 and 0118 H...

Page 69: ...SECTION 5 TECHNICAL DATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 69 5 ELEMENTARY WIRING DIAGRAM CONT D FIGURE 22 CONTROL CIRCUIT 4 COMPRESSOR CONT D...

Page 70: ...JOHNSON CONTROLS 70 ELEMENTARY WIRING DIAGRAM Figure 23 CONTROL CIRCUIT 5 AND 6 COMPRESSOR YCWL0104 0118 0132 0156 0157 0177 and 0198 STANDARD EFFICIENCY UNITS YCWL0096 0118 0126 0127 0156 and 0157 H...

Page 71: ...SECTION 5 TECHNICAL DATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 71 5 ELEMENTARY WIRING DIAGRAM CONT D FIGURE 23 CONTROL CIRCUIT 5 AND 6 COMPRESSOR CONT D...

Page 72: ...TROLS 72 Figure 24 POWER CIRCUIT 4 COMPRESSOR WITH NON FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER ELEMENTARY WIRING DIAGRAM YCWL0056 0064 0074 0084 0094 0104 0118 and 0132 STANDARD EFFICIENCY UNITS YC...

Page 73: ...2018 JOHNSON CONTROLS 73 5 Figure 25 POWER CIRCUIT 4 COMPRESSOR WITH CIRCUIT BREAKER ELEMENTARY WIRING DIAGRAM YCWL0056 0064 0074 0084 0094 0104 0118 and 0132 STANDARD EFFICIENCY UNITS YCWL0064 0074 0...

Page 74: ...SECTION 5 TECHNICAL DATA JOHNSON CONTROLS 74 ELEMENTARY WIRING DIAGRAM YCWL0104 0118 0156 0177 and 0198 STANDARD EFFICIENCY UNITS YCWL0096 0126 and 0156 HIGH EFFICIENCY UNITS Figure 26 POWER CIRCUIT 5...

Page 75: ...1 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 75 5 ELEMENTARY WIRING DIAGRAM YCWL0104 0118 0177 and 0198 STANDARD EFFICIENCY UNITS YCWL0096 0126 and 0156 HIGH EFFICIENCY UNITS Figure 27 POWER CIRCUIT...

Page 76: ...OHNSON CONTROLS 76 CONNECTION WIRING DIAGRAM Figure 28 CONNECTION WIRING DIAGRAM 4 COMPRESSOR YCWL0056 0064 0074 0084 0094 0104 0118 and 0132 STANDARD EFFICIENCY UNITS YCWL0064 0074 0084 0094 and 0118...

Page 77: ...SECTION 5 TECHNICAL DATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 77 5 FIGURE 28 CONNECTION WIRING DIAGRAM 4 COMPRESSOR CONT D CONNECTION WIRING DIAGRAM CONT D...

Page 78: ...ICAL DATA JOHNSON CONTROLS 78 CONNECTION WIRING DIAGRAM Figure 29 CONNECTION WIRING DIAGRAM 4 COMPRESSOR YCWL0056 0064 0074 0084 0094 0104 0118 and 0132 STANDARD EFFICIENCY UNITS YCWL0064 0074 0084 00...

Page 79: ...SECTION 5 TECHNICAL DATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 79 5 FIGURE 29 CONNECTION WIRING DIAGRAM 4 COMPRESSOR CONT D CONNECTION WIRING DIAGRAM CONT D...

Page 80: ...N 5 TECHNICAL DATA JOHNSON CONTROLS 80 CONNECTION WIRING DIAGRAM Figure 30 CONNECTION WIRING DIAGRAM 5 AND 6 COMPRESSOR YCWL0104 0118 0156 0177 and 0198 STANDARD EFFICIENCY UNITS YCWL0096 0126 and 015...

Page 81: ...SECTION 5 TECHNICAL DATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 81 5 FIGURE 30 CONNECTION WIRING DIAGRAM 5 AND 6 COMPRESSOR CONT D CONNECTION WIRING DIAGRAM CONT D...

Page 82: ...ECHNICAL DATA JOHNSON CONTROLS 82 CONNECTION WIRING DIAGRAM Figure 31 CONNECTION WIRING DIAGRAM 6 COMPRESSOR YCWL0104 0118 0177 and 0198 STANDARD EFFICIENCY UNITS YCWL0096 0126 and 0156 HIGH EFFICIENC...

Page 83: ...SECTION 5 TECHNICAL DATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 83 5 FIGURE 31 CONNECTION WIRING DIAGRAM 6 COMPRESSOR CONT D CONNECTION WIRING DIAGRAM CONT D...

Page 84: ...n in the same conduit with any line volt age class 1 wiring 3 To cycle unit ON and OFF automatically with contact shown install a cycling device in series with the flow switch See note 2 for contact r...

Page 85: ...SECTION 5 TECHNICAL DATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 85 5 LD12929a FIGURE 32 ELEMENTARY WIRING DIAGRAM DETAILS 4 COMPRESSOR CONT D ELEMENTARY WIRING DIAGRAM DETAILS CONT D...

Page 86: ...mended Wiring shall not be run in the same conduit with any line voltage class 1 wiring 3 To cycle unit ON and OFF automatically with contact shown install a cycling device in series with the flow swi...

Page 87: ...SECTION 5 TECHNICAL DATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 87 5 FIGURE 33 ELEMENTARY WIRING DIAGRAM DETAILS 5 AND 6 COMPRESSOR CONT D ELEMENTARY WIRING DIAGRAM DETAILS CONT D...

Page 88: ...HNICAL DATA JOHNSON CONTROLS 88 Figure 34 ELEMENTARY WIRING DIAGRAM EEV CONTROLLER 4 AND 6 COMPRESSOR ELEMENTARY WIRING DIAGRAM YCWL0104 0118 0156 0177 and 0198 STANDARD EFFICIENCY UNITS YCWL0096 0126...

Page 89: ...SECTION 5 TECHNICAL DATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 89 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 90: ...1 16 449 3 17 11 16 449 3 17 11 16 449 3 17 11 16 449 3 17 11 16 449 3 17 11 16 449 3 17 11 16 449 3 K 8 15 16 227 0 8 15 16 227 0 8 15 16 227 0 8 15 16 227 0 12 1 4 311 2 12 1 4 311 2 12 1 4 311 2 12...

Page 91: ...SECTION 5 TECHNICAL DATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 91 5 UNIT DIMENSIONS FOUR COMPRESSOR CONT D LOW SIDE RELIEF VALVE LOCATION HIGH SIDE RELIEF VALVE LOCATIONS 5 8...

Page 92: ...36 6 29 736 6 29 736 6 J 17 11 16 449 3 17 11 16 449 3 17 11 16 449 3 17 11 16 449 3 17 11 16 449 3 17 11 16 449 3 17 11 16 449 3 K 17 25 32 451 6 17 25 32 451 6 17 25 32 451 6 17 25 32 451 6 17 25 32...

Page 93: ...SECTION 5 TECHNICAL DATA FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 93 5 5 8 UNIT DIMENSIONS FIVE AND SIX COMPRESSOR...

Page 94: ...SE RD 4 Charcoal C2P 1D 2720 White Pink Gray Orange 0157 SE RD 4 Charcoal C2P 1D 2720 White Pink Gray Orange 0177 SE RD 4 Charcoal C2P 1D 2720 White Pink Gray 0198 SE RD 4 Charcoal C2P 1D 3570 Gray R...

Page 95: ...434 Up thru 197 029 25334 002 CP 1D 900 DARK GREEN 435 thru 765 198 thru 347 029 25334 003 CP 1D 1200 GRAY 766 thru 1020 348 thru 463 029 25334 004 CP 1D 1360 WHITE 1021 thru 1156 464 thru 524 029 253...

Page 96: ...grout as re quired leveling all isolator bases to the same elevation 1 4 inch maximum difference can be tolerated 4 Bolt or anchor all isolators to supporting structure utilizing base slotted holes C...

Page 97: ...per ANSI Y14 2 Refer to Page 98 for installation instructions 3 Mount molded in weather resistant duralene compound as standard Also available in other materials such as natural rubber extreme high t...

Page 98: ...3 Set isolators on floor housekeeping pad or sub base ensuring that all isolator centerlines match the equipment mounting holes The VMC group recommends that the isolator base A be in stalled on a lev...

Page 99: ...5 2 3 4 12 1 4 8 3 8 OPER HEIGHT 14 5 8 3 8 3 4 TYP 4 3 1 2 5 8 11UNC TYP 4 2 3 4 3 4 7 8 1 1 8 3 8 GAP 5 1 2 LIMIT STOP NUT NOTES 1 ALL DIMENSIONS ARE IN INCHES INTERPRET PER ANSI Y14 2 STANDARD FIN...

Page 100: ...ned over the isola tors 6 With all shims E in place position equipment on top of plate A of isolator Bolt equipment securely to top plate of isolator using a minimum of 2 5 8 UNC A325 grade 5 SAE bolt...

Page 101: ...0118SE 627 627 524 524 YCWL0132SE 1467 1467 1253 1253 YCWL0132SE 665 665 568 568 YCWL0156SE 2102 2102 1556 1556 YCWL0156SE 953 953 706 706 HIGH EFFICIENCY ENGLISH HIGH EFFICIENCY SI Weight Distributio...

Page 102: ...A B C D Model A B C D YCWL0056SE ND D ND D ND D ND D YCWL0064HE ND D ND D ND D ND D YCWL0064SE ND D ND D ND D ND D YCWL0074HE ND D ND D ND D ND D YCWL0074SE ND D ND D ND D ND D YCWL0084HE ND D ND D N...

Page 103: ...64 to 1404 lbs 483 to 637 kg CIP B Black FOR UNITS WITH ANY POINT LOAD ABOVE 1404 LBS 637 KG Weight Range lbs Weight Range kg Model Number Color Up to 851 lbs Up to 386 kg CIP C Black 851 to 1149 lbs...

Page 104: ...the isolator To use the isolator as blocking for the equipment insert a 10mm 1 4 shim between the upper load plate and vertical uprights Lower the equipment on the blocking or shimmed isolators 5 Com...

Page 105: ...3 4 69 9 5 1 2 139 7 1 4 6 4 2 5 16 58 7 4 1 80 101 9 1 2 13 x 1 1 2 ND D 3 3 8 85 7 2 3 4 69 9 6 1 4 158 8 5 16 7 9 4 101 6 5 127 1 2 13 x 1 1 2 ND DS 4 1 2 114 3 4 3 4 120 7 7 3 8 187 3 1 4 6 4 5 1...

Page 106: ...ICAL DATA JOHNSON CONTROLS 106 ENGLISH SIZE H T D E L HCL W HCW MBD 2 C2 8 1 2 215 9 3 8 9 5 5 8 15 9 1 3 8 34 9 14 355 6 12 1 4 311 2 5 1 4 133 4 3 1 2 88 9 5 8 SLRS SEISMIC DEFLECTION SPRING ISOLATO...

Page 107: ...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 into position...

Page 108: ...38 57 65 68 67 66 59 73 YCWL0127HE 46 36 57 67 68 68 65 59 73 YCWL0156HE 72 65 71 78 79 76 72 58 82 YCWL0157HE 45 33 55 65 70 73 67 58 76 60 HZ MODELS COMPRESSOR BLANKETS INSTALLED STANDARD EFFICIENCY...

Page 109: ...ice valve and oil return line ball valve fully in each system Compressor Oil To add oil to a circuit connect a YORK hand oil pump Part No 470 10654 000 to the 1 4 of an inch oil charging connection on...

Page 110: ...flow through the cooler The inlet should be at the refrigerant piping connection end of the cooler Purge air from the top of the cooler using the plugged air vent mounted on the top of the cooler bod...

Page 111: ...all valve discharge line ball valve and liquid line valve for each system 5 The compressor oil level should be main tained so that an oil level is visible or splash ing in sight glass when fully loade...

Page 112: ...ontrolServiceandTroubleshootingsection andcy cle each condenser fan to ensure proper rotation 5 Prior to this step turn system 2 OFF and system 1 ON refer to Option 2 under Unit Keys section for more...

Page 113: ...on a circuit The superheat is calculated as the difference between the actual temperature of the returned refriger ant gas in the suction line entering the compressor and the temperature corresponding...

Page 114: ...e shortest average run time of the compressors will be assigned as the lead sys tem A new lead lag assignment is made whenever all systems shut down 4 After 1 minute of compressor run time the next co...

Page 115: ...e IPU II board contains a coldfire mi croprocessor and is the controller and decision maker in the control panel The I O board handles all of the chiller I O Inputs and Outputs System inputs from pres...

Page 116: ...ayed and will remain on the display until another key is pressed The system parameters can be scrolled with the use of the UP and DOWN arrow keys The display will update all information at a rate of a...

Page 117: ...e of single sys tem units 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 w...

Page 118: ...ting 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 microprocessor...

Page 119: ...d to the input when in the MANUAL OVERRIDE mode MANUAL OVERRIDE is to only be used in emergencies or for servicing MANUAL OVERRIDE mode automatically disables itself after 30 minutes S Y S 1 P U M P I...

Page 120: ...hen chilled liquid temperature rises 2 F above the cutout The internal motor protector opens at 185 F to 248 F 85 C to 120 C and auto resets On 60 Hz chillers the mechanical HP switch opens at 500 PSI...

Page 121: ...ngs and will not auto restart Operator intervention is required to allow a restart of the chiller L O W B A T T E R Y C H E C K P R O G S E T P O P T N The Low Battery Warning can only occur at unit p...

Page 122: ...isch Limiting 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...

Page 123: ...through by using the UP and 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 s...

Page 124: ...by how far the actual liquid temperature is from setpoint A detailed description of unit loading and unloading is covered under the topic of Capacity Control C O O L I N G D E M A N D 2 O F 8 S T E P...

Page 125: ...of the use of software common to both YCA and YCW chillers E V A P O R A T O R H E A T E R S T A T U S I S X X X This display indicates the status of the evaporator heater The evaporator heater is co...

Page 126: ...m is displayed Oper Data Quick Reference List The following table is a quick reference list for infor mation available under the OPER DATA key Table 10 OPERATION DATA Oper Data Key Leaving Chilled Liq...

Page 127: ...DEFROST INIT TEMP 41 0 DEGF DEFROST INITIATION TIME 60MIN DEFROST TERMINATION TIME 3MIN BIVALENT HEAT DELAY TIME 30 MIN REMOTE UNIT ID PROGRAMMED 2 YORK HYDRO KIT PUMPS 1 410a PUMP TOTAL RUN HOURS XX...

Page 128: ...ey allows the operator to obtain a printout of information relating to the last nine Safety Shutdowns which oc curred The information is stored at the instant of the fault regardless of whether the fa...

Page 129: ...the time of the fault L E A D S Y S T E M I S S Y S T E M N U M B E R X Displays Local or Remote control selection C O N T R O L M O D E L E A V I N G L I Q U I D Displays the type of chilled liquid c...

Page 130: ...on Temp when an EEV is installed 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 the fault S Y S...

Page 131: ...keys 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 changi...

Page 132: ...P O I N T 4 5 0 F R A N G E 2 0 F SETPOINTS KEYS 00069VIP The above message shows the current chilled water temperature SETPOINT at 45 0 F notice the cursor positioned under the number 0 Pressing eith...

Page 133: ...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 control will be in the range of 43 to 47...

Page 134: ...idian of the stop time pressing the ENTER ADV key will advance the schedule to the following display S __ M T W T F S H O L I D A Y N O T E D B Y The line below the empty space next to the S is the cu...

Page 135: ...ns when the suc tion pressure is permitted to temporarily 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 LOWAM...

Page 136: ...voltage is the value that should be programmed For example if fan and compressor RLA s total 100A 5V x 100A x 1 25 625VA 2 8V 225A 225A The programmed value will be 2 8V A similar calcula tion and pro...

Page 137: ...0 0 PSIG 80 0 PSIG 5 52 BARG 8 27 BARG 5 52 BARG GLYCOL COOLING 42 0 PSIG 70 0 PSIG 44 0 PSIG 2 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...

Page 138: ...nge Remote Setpoint Low Ambient Temp Cutout Range Display Only Leaving Liquid EMS PWM Temperature Remote Temp Cutout Reset Setpoint Anti Recycle Timer Fan Control On Pressure Fan Differential Off Pres...

Page 139: ...ons 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 option ha...

Page 140: ...lues and ignore all commands from remote devices or through the RS 485 inputs The chiller will communicate and send data to the remote monitoring devices or L O C A L R E M O T E M O D E R E M O T E T...

Page 141: ...e selected on all chillers This message may not be viewable on non European chillers or L E A D L A G C O N T R O L M A N U A L S Y S 2 L E A D SYS 2 selected as lead compressor or L E A D L A G C O N...

Page 142: ...SING UNIT modes Also see the UNIT KEYS PROGRAMMING QUICK REFERENCE LIST on Figure 35 on page 145 Option 18 Flash Card Update F L A S H C A R D U P D A T E D I S A B L E D A Flash Card is used to input...

Page 143: ...up for less than 30 sec onds or if the pump has run in the last 30 seconds to prevent pump overheating Hyrdo Kit pumps 1 should not be selected on a YCWL chiller E X T E R N A L E V A P P U M P EXTER...

Page 144: ...something similar to the fol lowing T O D A Y I S F R I 0 8 5 1 A M 2 5 J A N 0 2 The line under the F is the cursor If the day is correct press the ENTER ADV key The cursor will move un der the 0 in...

Page 145: ...turn or Leaving Display Units English or Metric System Lead Lag Control Manual or Automatic Fan Control Mode Not applicable to a YCWL Manual Override Mode Current Feedback Option Soft Start Option Uni...

Page 146: ...FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 146 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 147: ...EAVING CHILLED LIQUID CONTROL The setpoint when programmed for Leaving Chilled Liquid Control is the temperature the unit will control to within plus or minus the control cooling range The Setpoint Hi...

Page 148: ...emporarily The last run time of the system will be saved If the last run time was greater than 5 minutes no action is to be taken If the last run time for the lead system was less than 5 minutes the m...

Page 149: ...in water chill ing mode and from 10 F to 70 F 12 2 C to 21 1 C in glycol chilling mode In both modes the cooling range can be from 4 F to 20 F 2 2 to 11 1 C As an example of compressor staging refer...

Page 150: ...s of all compressors in each system will be decreased by 1 with the wrap around This control scheme assures the same com pressor does not repeatedly cycle ON and OFF Table 15 RETURN CHILLED LIQUID CON...

Page 151: ...is installed the active pump is selected by the selector switch EVAPORATOR HEATER CONTROL The evaporator heater is controlled by ambient air tem perature When the ambient temperature drops below 40 F...

Page 152: ...ed Liquid Setpoint based on a PWM input timed contact closure to the microboard This PWM input would typically be supplied by an Energy Management System A contact closure on the PWM Temp Reset input...

Page 153: ...unction never lowers the chilled liquid setpoint below the locally programmed value If a 0 10VDC signal is supplied it is applied to termi nals A and A and jumper JP1 on the I O board must be inserted...

Page 154: ...FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 154 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 155: ...by pressing the HISTORY key and then repeatedly pressing the UP arrow key until you scroll past the last history buffer choice The following message will be displayed I I N I T I A L I Z E H I S T O R...

Page 156: ...cumulated run and start timers for each system All val ues can also be changed using the UP and Down arrow keys but under normal circumstances would not be required or advised After the last start di...

Page 157: ...1 Compressor 1 TB7 3 SYS 1 Liquid Line Solenoid Valve TB7 4 SYS 1 Compressor 2 TB7 5 SYS 1 Compressor 3 TB7 7 SYS 1 Hot Gas Bypass Valve TB10 2 SYS 2 Compressor 1 TB10 3 SYS 2 Liquid Line Solenoid Val...

Page 158: ...DATE 1 19 2018 SECTION 9 SERVICE AND TROUBLESHOOTING JOHNSON CONTROLS 158 Figure 38 MICROBOARD LAYOUT TB5 TB1 TB6 TB7 TB8 TB9 TB10 J14 J13 J12 J15 J11 J10 J9 J8 J7 J6 J5 J3 I O BOARD IPU BOARD JP1 LD1...

Page 159: ...input would be connected to this ter minal with the other end connecting to its respective digital input on the microboard Any time a switch or contact is closed 30VDC would be applied to that par ti...

Page 160: ...7 VDC input signal to the microboard See Table 22 on page 160 for voltage readings that cor respond to specific liquid temperatures J6 1 drain shield connection 0VDC Return Table 22 ENTERING LEAVING...

Page 161: ...t can be used to verify the voltage output of the transducer All voltage readings are in reference to ground unit case Table 23 PRESSURE TRANSDUCERS 0 400 PSIG SUCTION PRESSURE TRANSDUCER 0 650 PSIG D...

Page 162: ...pond to specific suction pressures J7 9 5VDC return J7 11 drain shield connection 0VDC Digital Outputs Refer to the unit wiring diagram and Figure 39 on page 162 The digital outputs are located on TB7...

Page 163: ...on to print wide characters In some instances a printer will ignore a code it cannot interpret 3 The control center requires a busy signal from the printer when the printer receive buffer is full whic...

Page 164: ...ers Normal Shutdowns History Buffer 1 History Buffer 2 History Buffer 3 History Buffer 4 History Buffer 5 History Buffer 6 History Buffer 7 History Buffer 8 History Buffer 9 History Buffer 10 Cancel P...

Page 165: ...OP NO RUN PERMISSIVE 1 No chilled liquid flow 1 Check chilled liquid flow 2 Flow switch improperly installed 2 Check that the flow switch is installed according to manufac turer s instructions 3 Defec...

Page 166: ...in stalled in the bottom of the well with a generous amount of heat conductive compound 4 Compare sensor against a known good temperature sens ing device Refer to Service sec tion for temp voltage tab...

Page 167: ...ace Low suc tion pressure will be observed 1 Contact the local Johnson Con trols Service representative 2 Improper flow through the evaporator 2 Reduce flow to within chiller design specs See Limitati...

Page 168: ...FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 168 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 169: ...s pale yellow in color POE oil If the oil color darkens or exhibits a change in color this may be an indication of contami nants in the refrigerant system If this occurs an oil sample should be taken...

Page 170: ...ome cases BACnet parameters may need to be modified Set the unit switch to OFF then press the PROGRAM DOWN ARROW DOWN ARROW DOWN ARROW DOWN ARROW and ENTER keys in sequence The list below shows the di...

Page 171: ...DRESS 0 127 1 0 127 1 N A N A P2 MANUAL MAC ADDRESS N A N A 0 127 1 P1 PARITY None NONE N A N A P2 PARITY N A N A None 2 P1 PROTOCOL BACnet N2 API N A P2 PROTOCOL N A N A Modbus N A P1 STOP BITS 1 1 N...

Page 172: ...rk connection The Modbus Register Address for these points is 1537 BV Analog Read Only Points This data can be read using a BACnet or Modbus net work connection and can NOT be modified using this conn...

Page 173: ...s s e r P n o i t c u S 1 s y S R A B I S P 5 1 F D A 19 S1_DSCH_PR AI9 522 03 04 x10 ADF 16 PSI BAR Sys 1 Dischar S e r u s s e r P e g 20 S1_CIR_TEMP AI10 523 03 04 x10 ADF 17 F C Sys 1 Cooler Inlet...

Page 174: ...Temperature Anti Vacuum Low Pressure Cutout Low Evaporator Temperature Discharge Limiting Unit Motor Current Low Superheat Sensor Fault Discharge Inhibit MP HPCO Inhibit Load Limiting Compressor s Ru...

Page 175: ...Cnet MS TP Modbus RTU and N2 communications No external Gateway is required for these interfaces unless the customer is using Connected Services BACnet Object Types 0 Analog In 1 Analog Out 2 Analog V...

Page 176: ...Temperature Anti Vacuum Low Pressure Cutout Low Evaporator Temperature Discharge Limiting Unit Motor Current Low Superheat Sensor Fault Discharge Inhibit MP HPCO Inhibit Load Limiting Compressor s Ru...

Page 177: ...orktalk 2 Communications Data Map lists the con trol parameters These values are found under feature 54 in the MicroGateway or E Link Transmitted Data After receiving a valid transmission from the Mic...

Page 178: ...23 F C Discharge Air Temp Cond Unit Entering Liquid Temp Hot YCWL O O O P15 P13 A Monitor nvoYTS01p015 SNVT_count_f 51 24 27 F C Sys 1 Suction Temperature EEV O O O P16 P14 A Monitor nvoYTS01p016 SNV...

Page 179: ...p m o C 2 s y S 1 P50 P48 D Monitor nvoYTS01p050 SNVT_switch 95 122 0 1 0 1 Chilled Liquid Type 0 Water 1 Glycol S S S P51 P49 D Monitor nvoYTS01p051 SNVT_switch 95 123 0 1 0 1 Ambient Control Mode 0...

Page 180: ...iff C diff Sys 1 Discharge Superheat EEV O O O P78 P76 A Monitor nvoYTS01p078 SNVT_count_f 51 186 189 F C Sys 2 Discharge Temperature EEV O O O P79 P77 A Monitor nvoYTS01p079 SNVT_count_f 51 190 193 F...

Page 181: ...m o C 2 s y S e n o N e n o N 5 P28 P26 A Monitor nvoYTS02p028 SNVT_count_f 51 76 7 S S N s r u o H n u R 2 p m o C 2 s y S e n o N e n o N 9 P29 P27 A Monitor nvoYTS02p029 SNVT_count_f 51 80 8 S S N...

Page 182: ...1 154 157 N N N P71 P69 A Monitor nvoYTS02p071 SNVT_count_f 51 158 161 N N N P72 P70 A Monitor nvoYTS02p072 SNVT_count_f 51 162 165 N N N P73 P71 A Monitor nvoYTS02p073 SNVT_count_f 51 166 169 N N N P...

Page 183: ...it MP HPCO Inhibit MP HPCO Fault Pump Trip Pump Fail Make Flow High Ambient Temperature Anti Vacuum Low Pressure Cutout Low Evaporator Temperature Anti Recycle Timer Active Manual Override Suction Lim...

Page 184: ...88 9 78 172 4 196 91 1 80 176 200 93 3 82 179 6 204 95 6 84 183 2 208 97 8 86 186 8 212 100 0 88 190 4 216 102 2 90 194 220 104 4 92 197 6 224 106 7 94 201 2 228 108 9 96 204 8 232 111 1 98 208 4 236...

Page 185: ...30 120 41 20 28 125 43 22 26 130 45 24 24 135 47 26 20 140 49 28 18 145 51 30 16 150 53 32 14 160 57 34 12 170 60 36 10 180 64 38 8 190 67 40 6 200 70 42 4 210 73 44 3 220 76 46 2 225 78 48 0 235 80...

Page 186: ...FORM 201 26 NM1 ISSUE DATE 1 19 2018 JOHNSON CONTROLS 186 NOTES...

Page 187: ...elsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range Table 31 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Eff...

Page 188: ...Pennsylvania USA 17349 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2018 www johnsoncontrols com ALL RIGHTS RESERVED Form 201 26 NM1 118 Issue Date Januar...