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Johnson Controls YORK YCAL0041EC, Installation Operation & Maintenance, Page: 1 / 168

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YCAL0041EC - YCAL0071EC

AIR-COOLED

SCROLL CHILLERS

STYLE D

WITH IPU II & I/O BOARDS

(60 Hz)

35-60 TON

INSTALLATION, OPERATION, MAINTENANCE

AIR-COOLED LIQUID CHILLERS

HERMETIC SCROLL

Supersedes 150.66-NM1 (1005)

Form 150.66-NM1 (708)

LD10950

R-22 

035-20895-000

Summary of Contents for YORK YCAL0041EC

Page 1: ...R COOLED SCROLL CHILLERS STYLE D WITH IPU II I O BOARDS 60 Hz 35 60 TON INSTALLATION OPERATION MAINTENANCE AIR COOLED LIQUID CHILLERS HERMETIC SCROLL Supersedes 150 66 NM1 1005 Form 150 66 NM1 708 LD1...

Page 2: ...materials This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are...

Page 3: ...al owner that information if applicable can be obtained by contacting the nearest YORK Engineered Systems Service of ce It is the responsibility of operating service personnel to verify the applicabil...

Page 4: ...s and Oils 15 High Temperature and Pressure Cleaning 15 Emergency Shutdown 15 SECTION 2 PRODUCT DESCRIPTION 16 INTRODUCTION 16 GENERAL SYSTEM DESCRIPTION 16 Compressors 16 Cooler 16 Condenser 17 Mille...

Page 5: ...Input 35 Flow Switch Input 35 COMPRESSOR HEATERS 35 SINGLE POINT SUPPLY CONNECTION TERMINAL BLOCK NON FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER 0041 0071 36 SINGLE POINT SUPPLY CONNECTION 36 CONTROL...

Page 6: ...NOTES AND LEGEND 55 WIRING DIAGRAMS 56 CONNECTION DIAGRAMS 63 DIMENSIONS ENGLISH 66 DIMENSIONS SI 80 TECHNICAL DATA CLEARANCES 94 ISOLATORS 95 SECTION 7 UNIT CONTROLS 101 INTRODUCTION 101 MICROPROCESS...

Page 7: ...132 SUCTION PRESSURE LIMIT CONTROLS 132 DISCHARGE PRESSURE LIMIT CONTROLS 132 LEAVING CHILLED LIQUID CONTROL 132 LEAVING CHILLED LIQUID CONTROLOVERRIDE TO REDUCE CYCLING 133 LEAVING CHILLED LIQUID SYS...

Page 8: ...id 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 TROUBLESHOOTING 154 SE...

Page 9: ...DIAGRAM 64 FIG 11 CONNECTION DIAGRAM MICROBOARD PARTIAL 65 FIG 12 UNIT CLEARANCES 94 FIG 13 LEAVING WATER TEMPERATURE CONTROL EXAMPLE 133 FIG 14 SETPOINT ADJUST 133 FIG 15 YCAL0041 YCAL0071 FAN LOCATI...

Page 10: ...CONTROL 134 TABLE 20 RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS 6 STEPS 135 TABLE 21 RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS 6 STEPS 136 TABLE 22 YCAL0041 YCAL0071 CONDENSER FAN CONTROL...

Page 11: ...ON CONTROLS LIST OF TABLES CONT D TABLE 33 ISN RECEIVED DATA 159 TABLE 34 ISN TRANSMITTED DATA 159 TABLE 35 ISN OPERATIONAL AND FAULT CODES 161 TABLE 36 MINIMUM MAXIMUM AND DEFAULT VALUES 163 TABLE 37...

Page 12: ...JOHNSON CONTROLS 12 FORM 150 66 NM1 708 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 13: ...has occurred within the warranty period and that the unit has been operated within the designed parameters speci ed All warranty claims must specify the unit model serial number order number and run h...

Page 14: ...NOTE is used to highlight additional information which may be helpful to you but where there are no special safety implications The contents of this manual include suggested best working practices and...

Page 15: ...ss to the control panel or electrical enclosures during normal operation of the unit Rotating Parts Fan guards must be tted at all times and not removed unless the power supply has been isolated If du...

Page 16: ...h when subjected to ASTM B117 1000 hour 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 an...

Page 17: ...ermanently lubricated Millennium Control Center All controls are contained in a NEMA 3R 12 and equivalent to IP55 cabinet with hinged outer door and includes Liquid Crystal Display with Light Emitting...

Page 18: ...compressors running Liquid solenoid valve status Load unload timer status Water pump status Provisions are included for pumpdown at shutdown optional remote chilled water temperature reset and two st...

Page 19: ...be included Factory Mounted AMBIENT KIT HIGH Required if units are to operate when the ambient temperature is above 115 F 46 C Includes discharge pressure transducers This option includes the Discharg...

Page 20: ...SPDT 5 amp 125 250VAC switch Range 0 40 PSID deadband 0 5 0 8 psi with 1 4 NPTE Pressure Connections REMOTE DX COOLER Asplit system arrangement with the cooler leaving return water sensors liquid lin...

Page 21: ...BLANKET Each compressor is individually enclosed by an acous tic sound blanket The sound blankets are made with one layer of acoustical absorbent textile ber of 5 8 15mm thickness one layer of anti v...

Page 22: ...JOHNSON CONTROLS 22 FORM 150 66 NM1 708 Product Description COMPRESSORS HEAT EXCHANGER CONTROL POWER PANEL LD10950 COMPRESSORS CONDENSER COILS UNIT COMPONENTS LD11457 LD11464 LD11419 LD11419 LD11420...

Page 23: ...FORM 150 66 NM1 708 23 JOHNSON CONTROLS 2 TERMINAL BLOCK FAN FUSES CR1 CR2 COMPRESSOR CONTACTS TB1 CTB1 CONTROL POWER PANEL COMPONENTS LD11459 LD11460 LD11461 LD11458 LD11462 LD11463...

Page 24: ...7 200 3 60 28 230 3 60 40 380 3 60 46 460 3 60 58 575 3 60 STARTER Starter PIN 13 X Across The Line Starter DESIGN Design Series PIN 14 D Design Series D YCAL0041EC 46XBA BASIC UNIT NOMENCLATURE High...

Page 25: ...h Low Ambient Kits Required Q Special Ambient Kits Required BAS BAS Reset Offset PIN 21 X No BAS Reset Offset Required M ISN Microgateway Required T BAS Reset Offset Required Q Special BAS Reset Offse...

Page 26: ...on Required Q Special Quote OVERLOAD PIN 35 X No Option Required Q Special Quote PIN 36 PIN 36 X No Option Required Q Special Quote HTR Crankcase Heater PIN 37 X Crankcase Heater Standard Q Special Cr...

Page 27: ...rs Required ENCL Enclosure Panel PIN 48 1 Wire Enclosures Factory 7 Louvered Enclosure Factory 8 Louvered Enclosures Field Q Special Encolsures Panels ACOUSTIC Acoustic Blanket PIN 49 X No Acoustic Bl...

Page 28: ...2 2 Year Refrigerant 5 5 Year Refrigerant SHIP Ship Instructions PIN 57 X No Option Required A Buy American Act Compliance B Both Buy American Act Compliance and Container Shipping Kit C Container Shi...

Page 29: ...IAGRAM FIG 1 REFRIGERANT FLOW DIAGRAM OPTIONAL AIR COOLED CONDENSERS AIR COOLED CONDENSERS DISCHARGE LINE DISCHARGE LINE DISCHARGE LINE BALL VALVE BALL VALVE BALL VALVE HOT DISCHARGE GAS LINE SERVICE...

Page 30: ...mmended that the unit is periodically inspected during storage INSPECTION Remove any transit packing and inspect the unit to ensure that all components have been delivered and that no damage has occur...

Page 31: ...e 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 Instructions are placed o...

Page 32: ...procedures 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 d...

Page 33: ...Considerations should be made utilizing noise levels published in the YORK Engineering Guide for the specific chiller model Sound blankets for the compressors and low sound fans are available SPRING I...

Page 34: ...he switch is to be wired to terminals 13 14 of CTB1 located in the control panel as shown on the unit wiring diagram The Flow Switch MUST NOT be used to start and stop the chiller i e start ing and st...

Page 35: ...s 31 to 32 system 2 YCAL0041 YCAL0071 Refer to Fig 3 and unit wiring diagram Remote Start Stop Contacts To remotely start and stop the chiller dry contacts can be wired in series with the ow switch an...

Page 36: ...power from the unit at or below freezing temperatures can result in damage to the evaporator and unit as a result of the chilled liquid freezing Models YCAL0040 0071 Only Models YCAL0014 0034 are Sin...

Page 37: ...r panel To prevent serious injury or death the technician should verify that NO LETHAL VOLTAGES are present inside the panel AFTER disconnecting power PRIOR to working on equipment The unit evaporator...

Page 38: ...service 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 oil charging valve on the oil sep...

Page 39: ...ugh 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 body Flow rat...

Page 40: ...e to the evaporator EQUIPMENT STARTUP CHECKLIST 7 Check the control panel to ensure it is free of foreign material wires metal chips etc 8 Visually inspect wiring power and control Wir ing MUST meet N...

Page 41: ...system 1 OFF and system 2 ON refer to Option 2 under UNITKEYS section for more information on system switches Place the Unit Switch in the control panel to the ON position As each compressor cycles O...

Page 42: ...t should typically be set forno less than 10 F with only a single compressor running on a circuit The superheat is calculated as the difference between the actual temperature of the returned refrigera...

Page 43: ...down 4 Several seconds after the compressor starts that systems rst condenser fan will be cycled on out door air temperature 25 F 4 C or discharge pressure See the section on Operating Controls for d...

Page 44: ...contact your nearest YORK Of ce for application requirements 2 For leaving water temperature higher than 55 F 12 8 C contact the nearest YORK Of ce for application guidelines 3 The evaporator is prot...

Page 45: ...LYCOL kW P TON 10 994 997 1 03 24 1 26 20 986 993 1 06 24 9 16 30 979 990 1 09 25 9 5 40 970 985 1 13 27 3 10 50 959 980 1 16 29 0 32 TABLE 4 ETHYLENE GLYCOL CORRECTION FACTORS LD13280 MODEL YCAL COOL...

Page 46: ...requirements 2 For leaving water temperature higher than 55 F 12 8 C contact the nearest YORK Of ce for application guidelines 3 The evaporator is protected against freezing to 20 F 28 8 C with an el...

Page 47: ...6 20 986 993 1 06 24 9 16 30 979 990 1 09 25 9 5 40 970 985 1 13 27 3 10 50 959 980 1 16 29 0 32 TABLE 7 ETHYLENE GLYCOL CORRECTION FACTORS OPERATIONAL LIMITATIONS SI LD113281 SI 1 10 100 1000 1 10 10...

Page 48: ...in Coils Lbs Alumi num Fin Coils Lbs Copper Fin Coils Lbs Comp 1 Comp 2 Comp 3 Comp 4 Comp 5 Comp 6 0041 144 8 90 6 47 75 34 9 2 35 35 1 7 1 7 2942 3300 2967 3325 10 10 10 10 0045 144 8 90 6 47 75 38...

Page 49: ...w Rate GPM Nominal Water Connections Size Inches Ckt1 Ckt2 Ckt1 Ckt2 Ckt1 Ckt2 87 0 2 2 17 2 2 2 1140 47400 2 2 2 838 47400 2 7 300 450 40 200 3 87 0 2 2 17 2 2 2 1140 47400 2 2 2 838 47400 3 5 300 45...

Page 50: ...1 93 95 95 93 89 84 80 76 94 YCAL0065 94 94 95 93 89 84 80 75 94 YCAL0071 DATA NOT AVAILABLE 60Hz Line Frequency ULTRA QUIET FAN R 22 63 125 250 500 1000 2000 4000 8000 dBA YCAL0041 96 91 90 89 86 81...

Page 51: ...YCAL0061 93 95 95 93 89 84 80 76 94 YCAL0065 94 94 95 93 89 84 80 75 94 YCAL0071 DATA NOT AVAILABLE 60Hz Line Frequency ULTRA QUIET FAN OPTIONAL R 22 63 125 250 500 1000 2000 4000 8000 dBA YCAL0041 94...

Page 52: ...0 250 250 250 1 6awg 500MCM 2 3 0 250MCM 2 3 0 250MCM 230 212 250 225 250 225 250 1 6awg 500MCM 2 3 0 250MCM 2 3 0 250MCM 380 123 150 150 150 150 150 1 6awg 500MCM 1 6awg 350MCM 1 6awg 350MCM 460 103...

Page 53: ...350 37 0 350 2 45 8 316 49 8 374 2 6 2 17 5 6 9 22 8 21 3 195 21 3 195 2 26 4 199 28 7 235 2 3 8 23 0 4 5 12 7 17 6 167 17 6 167 2 21 8 158 23 7 187 2 2 8 17 5 3 4 21 0 14 1 125 14 1 125 2 17 4 126 1...

Page 54: ...1 MICRO PANEL POWER SUPPLY VOLTAGE RANGE VOLTAGE CODE UNIT POWER MIN MAX 17 200 3 60 180 220 28 230 3 60 207 253 40 380 415 3 60 342 440 46 460 3 60 414 506 50 380 415 3 50 342 440 58 575 3 60 517 633...

Page 55: ...mps for the largest motor plus 100 of the rated load amps for all other loads included in the circuit Otherwise an HACR type circuit breakers must be used Maximum HACR circuit breaker rating is based...

Page 56: ...JOHNSON CONTROLS 56 FORM 150 66 NM1 708 Technical Data ELEMENTARY DIAGRAM LD13247 FIG 4 CONTROL CIRCUIT DUAL 0041 0071 STANDARD LOW SOUND AND 460V ULTRA LOW SOUND...

Page 57: ...FORM 150 66 NM1 708 57 JOHNSON CONTROLS 6 ELEMENTARY DIAGRAM CON T LD13248 FIG 4 CON T CONTROL CIRCUIT DUAL...

Page 58: ...JOHNSON CONTROLS 58 FORM 150 66 NM1 708 Technical Data ELEMENTARY DIAGRAM FIG 5 CONTROL CIRCUIT DUAL 0041 0071 ULTRA LOW SOUND 200V 230V 380V 575V LD13259...

Page 59: ...FORM 150 66 NM1 708 59 JOHNSON CONTROLS 6 ELEMENTARY DIAGRAM CON T FIG 5 CON T CONTROL CIRCUIT DUAL LD13260...

Page 60: ...JOHNSON CONTROLS 60 FORM 150 66 NM1 708 Technical Data ELEMENTARY DIAGRAM LD13249 FIG 6 POWER CIRCUIT DUAL 0041 0071 STANDARD LOW SOUND AND 460V ULTRA LOW SOUND...

Page 61: ...FORM 150 66 NM1 708 61 JOHNSON CONTROLS 6 ELEMENTARY DIAGRAM FIG 7 POWER CIRCUIT DUAL LD13261 0041 0071 ULTRA LOW SOUND 200V 230V 380V 575V...

Page 62: ...JOHNSON CONTROLS 62 FORM 150 66 NM1 708 Technical Data ELEMENTARY DIAGRAM LD10958 FIG 8 WIRING DETAILS 0041 0071 ULTRA LOW SOUND ALL VOLTAGES...

Page 63: ...FORM 150 66 NM1 708 63 JOHNSON CONTROLS 6 CONNECTION DIAGRAM LD13250 FIG 9 CONNECTION DIAGRAM 0041 0071 STANDARD LOW SOUND AND 460V ULTRA LOW SOUND...

Page 64: ...JOHNSON CONTROLS 64 FORM 150 66 NM1 708 Technical Data CONNECTION DIAGRAM FIG 10 CONNECTION DIAGRAM 0041 0071 ULTRA LOW SOUND 200V 230V 380V 575V LD13262...

Page 65: ...FORM 150 66 NM1 708 65 JOHNSON CONTROLS 6 CONNECTION DIAGRAM LD10960A FIG 11 CONNECTION DIAGRAM MICROBOARD PARTIAL CONNECTION DIAGRAM ALL MODELS BACNET MICROGATEYWAY OPTION...

Page 66: ...ise minimum clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety...

Page 67: ...IN 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 16 25 3 8 13 5 8 B B...

Page 68: ...ise minimum clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety...

Page 69: ...GIN 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 16 25 3 8 13 5 8 B B...

Page 70: ...ise minimum clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety...

Page 71: ...GIN 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 16 25 3 8 13 5 8 B B...

Page 72: ...ise minimum clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety...

Page 73: ...RIGIN 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 25 3 8 28 9 16 B B CO...

Page 74: ...ise minimum clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety...

Page 75: ...RIGIN 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 25 3 8 28 9 16 B B C...

Page 76: ...ise minimum clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety...

Page 77: ...6 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 Z 1 1 16 1 1 16 L1 L2 R2 R1 ORIGIN 9 13 16 9 13 16 B B 9 16 DIA MOUNTING HOLES typ END CAP WID...

Page 78: ...and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls will opt...

Page 79: ...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 9 13 16 9 13 16 B B 9 16 DIA MOUNTING HOLES typ END CAP...

Page 80: ...ation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls wi...

Page 81: ...Y C G X 28 ORIGIN 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 COIL END COOLER EN...

Page 82: ...der 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 between adjacent...

Page 83: ...50 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 COIL END COOLER END CO...

Page 84: ...ation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls wi...

Page 85: ...50 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 COIL END COOLER END CO...

Page 86: ...ation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls wi...

Page 87: ...51 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 COIL END COOLER END CO...

Page 88: ...ation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls wi...

Page 89: ...00 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 COIL END COOLER END CO...

Page 90: ...ation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls wi...

Page 91: ...301 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 WIDTH COIL END COOLE...

Page 92: ...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 cooler end to...

Page 93: ...6 DIMENSIONS YCAL0071 SI CON T 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...

Page 94: ...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 be 10 feet 3 Mete...

Page 95: ...ked with the isolators and also in the control panel information packet is a drawing and table speci cally for each chiller based on the option selection The drawing and table will be similar to the o...

Page 96: ...8 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 ONE INCH DEFLECTION SPRING ISOLATOR CROSS REFERENCE Illustration shows...

Page 97: ...e 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 Comple...

Page 98: ...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 16 4 5 1 2 13...

Page 99: ...4585 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 C2 Silver w red 029 24...

Page 100: ...l washer 8 Turn adjustment bolt 8 turns on each mount 9 Take one additional complete turn on each adjustment bolt in sequence until the top plate lifts off of the lower restraining nuts Take no additi...

Page 101: ...pressure transducers and temperature sensors are connected directly to the Microprocessor Board The Microprocessor Board circuitry multiplexes the analog inputs digitizes them and scans them to keep...

Page 102: ...ratures compressor running times and starts option information on the chiller and system setpoints This data is useful for monitoring chiller operation diagnosing potential problems troubleshooting an...

Page 103: ...be blank This message informs the operator that the UNIT switch on the control panel is in the OFF position which will not allow the unit to run The REMOTE CONTROLLED SHUTDOWN message indicates that...

Page 104: ...rammed discharge pressure cutout This will only happen if the system is fully loaded and will shut only one compressor off If the system is not fully loaded discharge limiting will not go into effect...

Page 105: ...C T P R E S S The PUMPING DOWN message indicates that a compressor in the respective system is presently in the process of pumping the system down When pumpdown is initiated on shutdown the liquid li...

Page 106: ...ernal motor protector opens at 185 F 248 F 85 C 120 C and auto resets The mechanical HP switch opens at 405 PSIG 10 PSIG 27 92 barg 69 barg and closes at 330 PSIG 25 PSIG 22 75 barg 1 72 barg The comp...

Page 107: ...counting down When the CURRENT FEEDBACK ONE PER UNIT option is selected under the OPTIONS Key the unit will shut down when the voltage exceeds the programmed trip voltage for 5 seconds The trip voltag...

Page 108: ...tion 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 Disch Pressure Sys...

Page 109: ...or the ENTER ADV key located under the ENTRY section DISPLAY PRINT KEYS With the UNIT TYPE set as a liquid chiller via no jumper between J4 11 and J4 6 the following list of operating data screens are...

Page 110: ...dicate the time in seconds until the unit can load or unload Whether the systems loads or unloads is determined by how far the actual liquid temperature is from setpoint A detailed description of unit...

Page 111: ...that can be used to control or monitor the unit The following messages indicate the type of remote control mode active NONE no remote control active Remote monitoring may be via ISN ISN YORK Talk via...

Page 112: ...Block of information repeats for each system LD07381 Oper Data Key Leaving Chilled Liquid Temps Ambient Air Temperature System 1 Discharge Suction Pressure EEV Only SYS 1 Suction and SAT Suction Temp...

Page 113: ...PRESS CUTOUT 44 PSIG LOW AMBIENT CUTOUT 25 0 DEGF LEAVING LIQUID CUTOUT 36 0 DEGF ANTI RECYCLE TIME 600 SECS FAN CONTROL ON PRESS 240 PSIG FAN DIFF OFF PRESS 80 PSIG NUMBER OF COMPRESSORS 6 NUMBER OF...

Page 114: ...or manual resetting of a fault lock out When the HISTORY key is pressed a printout is transmitted of all system operating conditions which were stored at the instant the fault occurred for each of th...

Page 115: ...charge Pressure or Ambient and Discharge Pressure Displays whether Manual Override was Enabled or Disabled Displays type of Current Feedback utilized Displays whether the optional European Soft Start...

Page 116: ...ITundertheprogramkey the display will be the rst display prior to the SYS 1 info If the micro is programmed for CURRENT FEEDBACK NONE no current display will appear Displays for System 1 starting with...

Page 117: ...row 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 safety setpoints chiller option...

Page 118: ...ROL The above message shows the current chilled water temperature SETPOINT at 45 0 F notice the cursor po sitioned under the number 0 Pressing either the UP or DOWN arrow will change the setpoint in 5...

Page 119: ...xample control will be in the range of 43 47 F RETURN CHILLED LIQUID CONTROL In return chilled liquid control the range no longer has a X X F but only a X X F RANGE setpoint This indicates that the se...

Page 120: ...rrow 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 The rst reads T...

Page 121: ...to select the chiller outside ambient temperature cutout point If the ambient falls below this point the chiller will shut down Restart can occur when temperature rises 2 F 1 11 C above the cutout set...

Page 122: ...drop too low The Fan Differential Off Pressure is the programmed differential pressure value that is used to stage the condenserfansoff inrelationtodischargepressure Refer to Condenser Fan Control in...

Page 123: ...X X F UNIT TRIP VOLTS For total chiller high current trip programming on 460VAC chillers Add the sum of all the compressor and fan RLA s in the chiller Multiply the sum by 1 25 Divide by 225A The resu...

Page 124: ...EMP 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 WATER COOLING 36 F 2 2 C TEMP CUTOUT GLYCOL COOLING 8 0 F 3...

Page 125: ...w 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 Pressure Quick Reference P...

Page 126: ...r the selected option has been displayed the UP and DOWN arrow keys are then used to change that particular option After the option is changed the ENTER ADV key must be pressed to enter the data into...

Page 127: ...O T E A M B I E N T C O N T R O L L O W A M B I E N T L O C A L R E M O T E M O D E L L O C A L C O N T R O L M O D E R E T U R N L I Q U I D C O N T R O L M O D E L E A V I N G L I Q U I D A M B I E...

Page 128: ...10 Manual Override Mode This option allows overriding of the daily schedule that is programmed MANUAL OVERRIDE MODE DISABLED indicates that override mode has no effect or Manual Override Mode is enab...

Page 129: ...e keypad and display will not respond during the update DO NOT reset or power down the chiller until the update is completed After the update is completed an automatic reboot will occur If an error oc...

Page 130: ...duty pump with automatic change over to standby if a pump trip occurs CLOCK The CLOCK display shows the current day time and date Pressing the CLOCK key will show the current day time and date It is...

Page 131: ...RAMMING QUICK REFERENCE LIST Table 18 provides a quick reference list for the Unit key setpoints Programmed under Service Mode Programmed under Service Mode Viewable Only Viewable Only Chiller MUST be...

Page 132: ...tpoint Low Limit is the Setpoint minus the Cooling Range Fig 13 should be utilized to aid in understanding the following description of Leaving Chilled Liquid Control If the leaving chilled liquid tem...

Page 133: ...systems On a hot water start once a system starts it will turn on all compressors before the next system starts a compressor The microprocessor will Lead Lag compressors within each circuit to maximi...

Page 134: ...ling Setpoint is the point at which all compressors are off and Cooling Setpoint plus Range is the point all compressors are on Speci cally if the return water temperature is 55 F 12 8 C then all comp...

Page 135: ...ill be extended to 10 minutes ANTI COINCIDENCE TIMER Two timing controls are present in software to assure compressors within a circuit or between systems do not start simultaneously The anti coincide...

Page 136: ...arge Pressure is a feature that is integral to the standard software control If the optional discharge transducer is not installed the condenser fans will operate based on outdoor ambient temperature...

Page 137: ...ON OFF CONTACTOR MICRO BOARD OUTPUT 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 1 2 2 OAT 6...

Page 138: ...he fan contactor If pressure continues to fall VFD speed will decrease in an effort to maintain discharge pressure Speed may drop to the point where the VFD turns the fan completely off or virtually o...

Page 139: ...eady for operation when it arrives onsite A quick check of the settings is recommended The jumpers must be in the positions shown in the following Table Chillers built in 2005 and early 2006 were conf...

Page 140: ...rd direction AIR On chillers with the low ambient op tion wire 127 is removed from TB7 3 Wire 227 is removed from TB10 9 and connected to TB10 3 150A L1 T1 150 151A L2 T2 151 152A L3 T3 152 CONDENSER...

Page 141: ...CONTROL ON PRESSURE DISCHARGER PRESSURE 170 PSIG PRESSURE IS FAN CONTROL ON PRESSURE MINUS FAN DIFFERENTIAL PRESSURE 170 PSIG 7M 8M 10M 11M TB7 3 TB7 10 TB10 3 TB10 10 1 3 2 4 TABLE 24 INVERTER OPTION...

Page 142: ...gy Management System A contact closure on the PWM Temp Reset input at CTB1 terminals 13 20 will reset the chilled liquid setpoint based on the length of time the contacts remain closed The maximum tem...

Page 143: ...rogrammed in the SETPOINTS section under the Cooling Setpoints key The coil of any added relay used for re set must be suppressed to prevent pos sible component damage Use YORK PN 031 00808 000 suppre...

Page 144: ...JOHNSON CONTROLS 144 FORM 150 66 NM1 708 Unit Operation FIG 21 FIELD AND FACTORY ELECTRICAL CONNECTIONS OPTIONAL REMOTE TEMPERATURE RESET BOARD LD03875A 035 15961 000...

Page 145: ...mmed to match actual chiller con guration SECTION 9 SERVICE AND TROUBLESHOOTING CLEARING HISTORY BUFFERS The history buffers may be cleared by pressing the HIS TORY key and then repeatedly pressing th...

Page 146: ...YS 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 2 SPARE SYS 2 DISC...

Page 147: ...enser 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 Hot...

Page 148: ...HNSON CONTROLS 148 FORM 150 66 NM1 708 Service and Troubleshooting FIG 22 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 BOARD JP1 LD127...

Page 149: ...oltages as high as 34VDC could be measured for the DC voltage on the digital inputs This voltage is in reference to ground The unit case should be suf cient as a reference point when measuring digital...

Page 150: ...or voltage readings that correspond to speci c liquid temperatures J6 1 drain shield connection 0VDC Return TABLE 31 ENTERING LEAVING CHILLED LIQUID TEMP SENSOR COOLER INLET TEMPERATURE SENSOR AND SUC...

Page 151: ...ear from 0 5VDC to 4 0VDC over the 200 PSIG 13 79 BARG range The discharge transducers have a range from 0 to 400 PSIG The output will be linear from 0 5VDC to 4 5VDC over the 400 PSIG 27 5 BARG range...

Page 152: ...lated supply to transducer J9 10 VDC input signal to the microboard See the formula above for voltage readings that correspond to speci c suction pres sures J9 9 5VDC return J9 1 drain shield connecti...

Page 153: ...e 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 parts are required 1 WEIGH T...

Page 154: ...icroboard to isolate 5 Defective IPU I O board 5 Replace Microboard or Display board Contact YORK Service before Replacing circuit Boards FLOW SWITCH REM 1 No chilled liquid ow 1 Check chilled liquid...

Page 155: ...r upward 2 Too much refrigerant 2 Remove refrigerant 3 Air in refrigerant system 3 Evacuate and recharge system 4 Defective discharge 4 Replace discharge pressure pressure transducer transducer Refer...

Page 156: ...lt START Installation Manual to aid in understanding compres sor operation and capacity control 2 Defective water temperature 2 Compare the display with a sensor thermometer Should be within 2 degrees...

Page 157: ...be taken 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 w...

Page 158: ...addition to the checks listed on this page periodic overall inspections of the unit should be accomplished to ensure proper equipment operation Items such as loose hardware component operation refrig...

Page 159: ...ed The latest point map information is listed on the Johnson Controls Group Equipment Integration website ISN CONTROL DATA PAGE P03 SETPOINT 99 AUTO P04 LOAD LIMIT STAGE 0 1 2 P05 P06 P07 START STOP C...

Page 160: ...SYS 1 Fault Code P58 130 Coded SYS 2 Operational Code P59 131 Coded SYS 2 Fault Code ISN PAGE CHARACTER TYPE DATA P60 132 Coded P61 133 Coded SYS 1 Condenser Fan Stage P62 134 Coded P63 135 Coded SYS...

Page 161: ...HIGH MOTOR CURRENT 9 NO COOL LOAD 9 LLSV NOT ON 10 ANTI COINCIDENCE TIMER ACTIVE 10 LOW BATTERY WARNING 11 ANTI RECYCLE TIMER ACTIVE 11 HIGH OIL TEMPERATURE 12 MANUAL OVERRIDE 12 HIGH DISCHARGE TEMPER...

Page 162: ...meters may need to be 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 MA...

Page 163: ...TABLE P1 PROTOCOL BACNET API BACNET BACNET API SELECTABLE P2 PROTOCOL TERMINAL MODBUS CLIENT API TERMINAL MODBUS IO MODBUS SERVER API MODBUS CLIENT SELECTABLE P1 P2 STOP BITS 1 2 1 RESET REAL TIME ERR...

Page 164: ...Modbus network connection The Modbus Register Address for these points is 1537 BV BV BACNET NAME BINARY VALUE DESCRIPTION 1 START_STOP START STOP COMMAND 2 SS_SYS1 SYS 1 START STOP COMMAND SUCTION PR...

Page 165: ...UG CODE 32 S1_FAN_STAGE SYS 1 CONDENSER FAN STAGE 33 S2_DBG_CODE SYS 2 DEBUG CODE 34 S2_FAN_STAGE SYS 2 CONDENSER FAN STAGE 35 CONTROL_M0DE UNIT CONTROL MODE 1 LEAVING WATER 2 RETURN WATER 3 DISCHARGE...

Page 166: ...ID LINE SOLENOID VALVE 8 S1_MODE_SV SYS 1 MODE SOLENOID VALVE HP ONLY 9 S1_HGBV SYS 1 HOT GAS BYPASS VALVE 10 S1_BHS BIVALENT HEAT SOURCE HP ONLY 11 S1_C2_RUN SYS 1 COMP 2 RUN 12 S2_C2_RUN SYS 2 COMP...

Page 167: ...FORM 150 66 NM1 708 167 JOHNSON CONTROLS NOTES...

Page 168: ...2008 Johnson Controls Inc P O Box 423 Milwaukee WI 53203 www johnsoncontrols com Printed in USA 150 66 NM1 708 Supersedes 150 66 NM1 1005...

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