Johnson Controls YORK YCAL0043E Series Installation Operation & Maintenance Download Page 116

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JOHNSON CONTROLS

116

FORM 150.62-NM9 (709)

HANDLING AND STORAGE

TROUBLESHOOTING CHARTS

PROBLEM

CAUSE

SOLUTION

No display on panel.

1. No 115VAC to 1T.

1a. Check wiring and fuse

Unit will not operate.

3FU

b. Check wiring emergency

stop contacts 5 to L of CTB2

Terminal Block.

c. Replace 1T

2. No 24VAC to I/O Board

2. Check wiring 1T to

I/O Board.

3. 1T defective, no

3. Replace 1T

24VAC output.

4. Short in wire to temp. sensors

4. Unplug connections at

or pressure transducers.

I/O Board to isolate.

5. Defective I/O & IPU2 Board

5. Replace I/O Board & IPU2

or Display board.

Board.

NOTE: Contact Johnson

Controls Service before

Replacing circuit Boards!

“FLOW SWITCH/REM

1. No chilled liquid flow.

1. Check chilled liquid flow.

STOP NO RUN PERMISSIVE”

2. Flow switch improperly

2. Check that the flow switch

installed.

is installed according to

manufacturer’s

instructions.

3. Defective flow switch.

3. Replace flow switch.

4. Remote cycling device open.

4. Check cycling devices

connected to terminals

13 and 14 of the CTB1

Terminal Block.

“LOW SUCTION PRESSURE”

1. Improper suction pressure

1. Adjust per recommended

FAULT

cutouts adjustments.

settings.

2. Low refrigerant charge.

2. Repair leak if necessary

and add refrigerant.

3. Fouled filter dryer.

3. Change dryer/core.

TABLE 35 –

TROUBLESHOOTING

CONT’d

Summary of Contents for YORK YCAL0043E Series

Page 1: ...STYLE C 50 Hz WITH IPU II AND I O BOARDS Standard Glycol Metric Models Combined 380 415 3 50 MODELS ONLY INSTALLATION OPERATION Maintenance AIR COOLED LIQUID CHILLERS HERMETIC SCROLL New Release Form 150 62 NM9 709 29224 R A 035 22321 000 ...

Page 2: ...dual will also be familiar with and comply with all applicable governmental standards and regula tions pertaining to the task in question safety symbols The following symbols are used in this document to alert the reader to areas of potential hazard CAUTION identifies a hazard which could lead to damage to the machine damage to other equipment and or environmental pollution Usually an instruction ...

Page 3: ...sonnel as to the applicability of these documents then prior to working on the equip ment they should verify with the owner whether the equipment has been modified and if current literature is available TABLE OF CONTENTS PRODUCT IDENTIFICATION NUMBER PIN 7 REFRIGERANT FLOW DIAGRAM 9 SECTION 1 INSTALLATION 10 ELECTRICAL DATA 20 OPERATIONAL LIMITATIONS ENGLISH 26 PHYSICAL DATA ENGLISH 30 DIMENSIONS ...

Page 4: ...pressor Staging for Return Water Control 94 table 19 Return Chilled Liquid Control for 5 6 Compressors 7 8 steps 94 table 20 Return Chilled Liquid Control for 4 Compressors 6 steps 95 table 21 YCAL0043 YCAL0107 Condenser Fan Control Using Discharge Pressure 98 table 22 YCAL0043 YCAL0107 Condenser Fan Control Using Discharge Pressure Only 98 table 23 YCAL0117 YCAL0253 Condenser Fan Control Using Ou...

Page 5: ...rcuit breakers YCAL0287 0377 16 Fig 5 optional single point power wiring 17 Fig 6 control wiring 18 fig 7 setpoint adjust 93 Fig 8 LEAVING WATER TEMPERATURE CONTROL example 93 Fig 9 YCAL0043 YCAL0107 Fan Location Typical 98 Fig 10 YCAL0117 YCAL0253 Fan Location Typical 99 Fig 11 YCAL0287 YCAL0377 Fan Location 101 FIG 12 FIELD AND FACTORY ELECTRICAL CONNECTIONSOPTIONAL REMOTE TEMPERATURE RESET BOAR...

Page 6: ...0197e_ ycal0253e_ REMOTE COOLER 156 fig 29 elementary diagram POWER CIRCUIT ycal0197e_ ycal0253e_ 158 fig 30 connection diagram middle market ycal0197e_ ycal0253e_ 160 fig 31 ELEMENTARY diagram middle market ycal0197e_ ycal0253e_ 162 fig 32 elementary diagram control circuit ycal0287E_ ycal0317e_ 164 fig 33 elementary diagram power circuit ycal0287E_ ycal0317e_ 166 fig 34 connection diagram middle...

Page 7: ...nit A Air Cooled C Chiller Y YORK Scroll VOLTAGE STARTER X 5 0 380 415 3 50 Across the Line DESIGN DEVELOPMENT LEVEL C Design Series A Engineering Change or PIN Level E High Efficiency UNIT DESIGNATOR B R407C C R22 REFRIGERANT NOMINAL CAPACITY 0 1 Even Number 60 HZ Nominal Tons Odd Number 50 HZ Nominal Kw 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ...

Page 8: ...ll contain info based on the first 14 characters only Low Ambient Kit factory High Ambient Kit factory Both Low High Ambient factory BAS EMS Temp Reset Offset Spanish LCD Keypad Display French LCD Keypad Display German LCD Keypad Display Discharge Pressure Transducers Readout Kit Suction Pressure Transducers Readout Kit Both Discharge Suction Pressure Transducers Readout N American Safety Code cU ...

Page 9: ...SUCTION PRESSURE TRANSDUCER LEAVING CHILLED WATER TEMP SENSOR RETURN WATER TEMP SENSOR OPTIONAL DISCHARGE LINE BALL VALVE HOT DISCHARGE GAS LINE LIQUID LINE SERVICE VALVE LIQUID LINE FILTER DRIER LIQUID LINE SOLENOID VALVE SIGHT GLASS MOISTURE INDICATOR SOLENOID OPERATED HOT GAS BY PASS VALVE OPTIONAL SUCTION LINE BALL VALVE EQUALIZER LINE TXV OPTIONAL RELIEF VALVE 300 PSIG 20 68 BARG YCAL REFRIGE...

Page 10: ...tailed 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 due to rough handling The unit should be lifted by inserting hooks through the holes provided in unit base rails Spreader bars should be used to avoid crushing the unit frame rails with the lift...

Page 11: ...occupied spaces or noise sensitive areas where chiller noise level would be a problem Chiller noise is a result of compressor 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 fans are available SPRING ISOLATORS OPTIONAL When ordered four 4 isolators will b...

Page 12: ...d to servicing thermometers and pressure gauges should be installed in the inlet and outlet water lines 6 The chilled water lines that are exposed to outdoor ambients should be wrapped with supplemental heater cable and insulated to protect against freeze up during low ambient periods and to prevent formation of condensation on lines in warm humid locations 7 A chilled water flow switch either by ...

Page 13: ... termi nals 13 to 14 Refer to Figure 6 and unit wiring diagram Remote Emergency Cutoff Immediate shutdown of the chiller can be accomplished by opening a field installed dry contact to break the elec trical circuit between terminals 5 to L on terminal block TB1 The unit is shipped with a factory jumper installed between terminals 5 to L which must be removed if emergency shutdown contacts are inst...

Page 14: ...heater uses 120VAC Disconnecting 120VAC 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 LD07719 Power Panel Control Panel Terminal Block NF Disconnect SW or Circuit Breaker 1L1 1L2 1L3 GRD MICROPANEL 2 L CTB2 13 14 CTB1 Field Provided Unit Power Supply Field Provided 120 1 60 Micropanel Power Supply if...

Page 15: ...he unit at or below freezing temperatures can result in damage to the evaporator and unit as a result of the chilled liquid freezing Power Panel Control Panel Terminal Block1 Terminal Block2 1L1 1L2 1L3 2L1 2L2 2L3 GRD GRD MICROPANEL 2 L CTB2 13 14 CTB1 Field Provided Unit Power Supply Field Provided 120 1 60 Micropanel Power Supply if Control Transformer not Supplied Flow Switch See electrical no...

Page 16: ...freezing temperatures can result in damage to the evaporator and unit as a result of the chilled liquid freezing LD07721 Power Panel Control Panel Terminal Block1 NF Disconnect SW1 or Circuit Breaker1 Terminal Block2 NF Disconnect SW2 or Circuit Breaker2 1L1 1L2 1L3 2L1 2L2 2L3 GRD GRD MICROPANEL 2 L CTB2 13 14 CTB1 Field Provided Unit Power Supply Field Provided 120 1 60 Micropanel Power Supply i...

Page 17: ...the unit at or below freezing temperatures can result in damage to the evaporator and unit as a result of the chilled liquid freezing Power Panel Control Panel Terminal Block or NF Disconnect SW 1L1 1L2 1L3 GRD MICROPANEL 2 L CTB2 13 14 CTB1 Field Provided Unit Power Supply Field Provided 120 1 60 Micropanel Power Supply if Control Transformer not Supplied Flow Switch See electrical note 9 Circuit...

Page 18: ...rify that NO LETHAL VOLTAGES are present inside the panel AFTER disconnecting power PRIOR to working on equipment The unit evaporator heater uses 120VAC Disconnecting 120VAC 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 CTB1 21 13 20 13 14 13 FLOW SW REMOTE START STOP PWM INPUT LOAD LIMIT INPUT Facto...

Page 19: ... must have the optional factory overloads installed to use a standard circuit breaker 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 the rated load amps for all other loads included in the circuit 6 The INCOMING WIRE RANGE is the minimum and maximum wire size that can be accommodated ...

Page 20: ...ator heater uses 120VAC Disconnecting 120VAC 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 OVER CURRENT PROTECTION UNIT VOLTAGE UNIT VOLTAGE CONTROL POWER MCA SEE NOTE B NF DISC Sw NOTE A MIN MAX MODELS w o CONTROL TRANS 115 1 60 50 15A 10A 15A 30 A 240V MODLES W CONTROL TRANS 50 380 415 3 50 15A 10A...

Page 21: ...JOHNSON CONTROLS 21 FORM 150 62 NM9 709 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 22: ...19 9 167 19 9 167 2 4 0 0217 380 415 50 73 100 80 90 80 90 10 1 19 9 167 19 9 167 19 9 167 2 4 0 0237 380 415 50 86 100 100 100 100 100 10 1 23 9 198 23 9 198 23 9 198 2 4 0 0253 380 415 50 86 100 100 100 100 100 10 1 23 9 198 23 9 198 23 9 198 2 4 0 See Notes and Legend on page 19 YCAL0043 YCAL0253 SINGLE POINT POWER SUPPLY CONNECTIONS see Fig 2 SINGLE POINT STANDARD ON YCAL0043 0107 MODELS OPTIO...

Page 23: ...43 0107 MODELS DUAL POINT ON YCAL0117 0253 MODELS See Fig 2 or 3 One or Two Field Provided Power Supply Circuits to the chiller Field connections to Factory Provided Terminal Block s per system YCAL0043 YCAL0253 SINGLE POINT POWER SUPPLY CONNECTIONS see Fig 2 SINGLE POINT STANDARD ON YCAL0043 0107 MODELS OPTIONAL ON YCAL0117 0253 MODELS DISCONNECT AND BREAKERS OPTIONAL ON ALL MODELS SYSTEM 1 COMPR...

Page 24: ... MIN N F DISC SW2 D E FUSE CKT BKR 5 INCOMING LUGS WIRE RANGE6 COMPR 1 COMPR 2 COMPR 3 FANS TERMINAL BLOCK std NF DISC SWITCHES opt CIR BREAKERS opt MIN3 MAX4 MIN MAX RLA LRA RLA LRA RLA LRA QTY FLA EA 0287 380 415 50 118 150 150 150 150 150 14 2 0 6 350 6 350 32 6 215 32 6 215 32 6 215 3 3 8 0317 380 415 50 118 150 150 150 150 150 14 2 0 6 350 6 350 32 6 215 32 6 215 32 6 215 3 3 8 0347 380 415 5...

Page 25: ...CA1 MIN N F DISC SW2 D E FUSE CKT BKR 5 INCOMING LUGS WIRE RANGE6 COMPR 1 COMPR 2 COMPR 3 FANS TERMINAL BLOCK std NF DISC SWITCHES opt CIR BREAKERS opt MIN3 MAX4 MIN MAX RLA LRA RLA LRA RLA LRA QTY FLA EA 111 150 150 150 150 150 6 400 6 350 6 350 44 2 270 44 2 270 3 3 8 118 150 150 150 150 150 14 2 0 6 350 6 350 32 6 215 32 6 215 32 6 215 3 3 8 118 200 175 200 175 200 14 2 0 6 350 6 350 32 6 215 3...

Page 26: ...imitations may cause serious damage to the compressor table 3 VOLTAGE limitations UNIT POWER MIN MAX 200 3 60 180 220 230 3 60 207 253 380 3 60 355 415 460 3 60 414 506 575 3 60 517 633 Excessive flow will cause damage to the cooler Do not exceed max cooler flow Special care should be taken when multiple chillers are fed by a single pump NOTES 1 For leaving brine temperature below 40 F 4 4 C conta...

Page 27: ... 2 1 247 25 ETHYLENE GLYCOL WEIGHT TONS COMPR GPM F TON PRESS FREEZE PT kW DROP 10 0 985 0 997 24 1 1 034 26 20 0 981 0 996 24 9 1 062 16 30 0 974 0 995 26 1 1 096 5 40 0 966 0 991 27 5 1 134 10 50 0 957 0 989 29 1 1 172 32 Note Water Pressure Drop Curves may extend past the minimum and maximum water flow ranges See Table 2 for minimum and maximum flow points MODEL YCAL COOLER CURVE 0043 0057 A 00...

Page 28: ...tected 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 will need to be installed on the system for YCAL0043 0253 models only 5 For operation at temperatures above 115 F 46 1 C the optional High Ambient Kit will need to be installed on the system YCAL LEAVING WATER TEMPERATURE C COOLER FLOW l s3 AIR ON...

Page 29: ... 984 27 2 1 247 25 ETHYLENE GLYCOL WEIGHT TONS COMPR GPM F TON PRESS FREEZE PT kW DROP 10 0 985 0 997 24 1 1 034 26 20 0 981 0 996 24 9 1 062 16 30 0 974 0 995 26 1 1 096 5 40 0 966 0 991 27 5 1 134 10 50 0 957 0 989 29 1 1 172 32 1 0 10 0 100 0 1000 0 Press Drop kPA Flow L S 1 0 10 0 100 0 A B C D E F G MODEL YCAL COOLER CURVE 0043 0057 A 0073 B 0087 0107 C 0117 0133 0147 0157 0173 D 0197 0217 02...

Page 30: ... 5363 5433 5517 Compressors scroll type Compressors per circuit 2 2 2 2 3 2 2 2 2 Compressors per unit 2 2 2 2 3 4 4 4 4 Nominal Tons per compressor 7 5 10 13 15 13 10 10 13 10 13 13 15 13 Condenser Total Face Area ft2 47 2 47 2 66 1 66 1 66 1 128 0 128 0 128 0 128 0 Number of Rows 2 2 2 3 3 2 2 2 2 Fins per Inch 13 13 13 13 13 13 13 13 13 Condenser Fans Number of Fans total 2 2 2 2 2 4 4 4 4 Fan ...

Page 31: ...rs per circuit 2 3 3 3 3 3 2 3 3 3 Compressors per unit 4 6 6 6 6 5 6 6 6 Nominal Tons per compressor 15 15 13 10 13 13 15 13 15 15 20 25 20 20 25 20 25 25 Condenser Total Face Area ft2 128 0 149 3 149 3 149 3 149 3 167 9 167 9 190 5 190 5 Number of Rows 3 2 3 3 3 3 3 3 3 Fins per Inch 13 13 13 13 13 13 13 13 13 Condenser Fans Number of Fans total 4 4 4 4 4 6 6 6 6 Fan hp kw 2 1 4 2 1 7 2 1 7 2 1 ...

Page 32: ... 2433 2464 2502 Compressors scroll type Compressors per circuit 2 2 2 2 3 2 2 2 2 Compressors per unit 2 2 2 2 3 4 4 4 4 Nominal kWo per compressor 26 35 46 53 46 35 35 46 35 46 46 53 46 Condenser Total Face Area meters2 4 4 6 6 6 12 12 12 12 Number of Rows 2 2 2 3 3 2 2 2 2 Fins per m 512 512 512 512 512 512 512 512 512 Condenser Fans Number of Fans total 2 2 2 2 2 4 4 4 4 Fan hp kw 2 1 4 2 1 4 2...

Page 33: ...3 3 3 3 2 3 3 3 Compressors per unit 4 6 6 6 6 5 6 6 6 Nominal kWo per compressor 53 53 46 35 46 46 53 46 53 53 70 88 70 70 70 88 88 88 Condenser Total Face Area meters2 12 14 14 14 14 16 16 18 18 Number of Rows 3 2 2 3 3 3 3 3 3 Fins per m 512 512 512 512 512 512 512 512 512 Condenser Fans Number of Fans total 4 4 4 4 4 6 6 6 6 Fan hp kw 2 1 4 2 1 7 2 1 7 2 1 7 2 1 7 2 1 8 2 1 8 2 1 8 2 1 8 Fan R...

Page 34: ...erformance reliable 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 controls will optimize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control cent...

Page 35: ... 80 7 16 105 1 8 X Z C G SIDE VIEW HOLES EACH SIDE 2 3 X 3 RIGGING 3 WATER INLET WATER OUTLET A A ORIGIN X G C Y TOP VIEW 3 4 DIA MOUNTING HOLES TYP CONTROL PANEL POWER PANEL ALUMINUM COPPER YCAL Center of Gravity in X Y Z 0043 44 8 24 1 28 3 0057 44 8 24 1 28 3 YCAL Center of Gravity in X Y Z 0043 45 4 24 2 28 8 0057 45 4 24 2 28 8 ...

Page 36: ... maintenance Site restrictions 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 pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on ...

Page 37: ...W HOLES EACH SIDE 2 3 X 3 RIGGING 3 4 WATER INLET WATER OUTLET A A ORIGIN X G C Y TOP VIEW 3 4 DIA MOUNTING HOLES TYP CONTROL PANEL POWER PANEL Refers to Model YCAL0073 Refers to Model YCAL0087 and YCAL0107 ALUMINUM COPPER YCAL Center of Gravity in X Y Z 0073 45 0 24 4 35 3 0087 45 0 24 4 34 9 0107 45 0 25 5 33 8 YCAL Center of Gravity in X Y Z 0073 45 8 24 5 36 2 0087 45 8 24 5 35 8 0107 45 7 25 ...

Page 38: ...ze operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 6 rear to wall 6 control panel to end wall 4 0 top no obstructions allowed distance between adjacent units 10 No more than one adjac...

Page 39: ... 1 2 TOP VIEW C G Y X 50 1 1 2 HOLES TYP MOUNTING 15 1 4 1 1 2 POWER PANEL CONTROL PANEL ORIGIN 9 3 4 99 1 2 A B C D ALUMINUM COPPER YCAL Center of Gravity in X Y Z 0117 58 7 40 2 41 2 0133 58 3 40 4 39 7 0147 58 4 40 2 39 5 0157 58 4 40 4 39 5 0173 58 5 40 2 39 4 YCAL Center of Gravity in X Y Z 0117 58 3 40 2 40 3 0133 58 4 40 4 40 1 0147 58 5 40 2 39 9 0157 58 5 40 4 39 9 0173 58 6 40 2 39 8 ...

Page 40: ...mize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 6 rear to wall 6 control panel to end wall 4 0 top no obstructions allowed distance between adjacent units 10 No more than one adj...

Page 41: ...2 1 1 2 C G Z X A A SIDE VIEW 2 1 16 9 POWER MULTIPLE POINT WITH TERMINAL BLOCKS CONTROL PANEL 9 3 4 ORIGIN Y 99 1 2 POWER PANEL TOP VIEW C G X A B C D ALUMINUM COPPER YCAL Center of Gravity in X Y Z 0197 56 5 45 8 39 4 0217 56 6 45 4 39 4 0237 56 6 45 7 39 5 0253 56 6 45 4 39 0 YCAL Center of Gravity in X Y Z 0197 56 7 45 7 40 0 0217 56 8 45 5 40 0 0237 56 8 45 7 40 1 0253 56 8 45 5 39 6 ...

Page 42: ...ulting in unpredictable airflow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 6 rear to wall 6 contro...

Page 43: ...JOHNSON CONTROLS 43 FORM 150 62 NM9 709 1 ALUMINUM COPPER YCAL Center of Gravity in X Y Z 0287 70 9 44 1 42 1 YCAL Center of Gravity in X Y Z 0287 70 4 44 1 44 4 ...

Page 44: ...able airflow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 6 rear to wall 6 control panel to end wall...

Page 45: ... 1 ALUMINUM COPPER YCAL Center of Gravity in X Y Z 0317 70 9 44 1 42 1 0347 79 5 44 1 40 7 0377 79 5 44 1 40 7 YCAL Center of Gravity in X Y Z 0317 70 4 44 1 44 4 0347 79 5 44 1 42 7 0377 79 5 44 1 42 7 REFERS TO YCAL0347 REFERS TO YCAL0377 ...

Page 46: ... nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 2m rear to wall 2m control panel to end wall 1 2m top no obstructions allowed distance between adjacent units 3m No more than one adjacent wall may be h...

Page 47: ... 2670 X Z C G SIDE VIEW HOLES EACH SIDE 2 76 X 76 RIGGING 3 WATER INLET WATER OUTLET A A ORIGIN X G C Y TOP VIEW 19 DIA MOUNTING HOLES TYP CONTROL PANEL POWER PANEL ALUMINUM COPPER YCAL Center of Gravity mm X Y Z 0043 1138 612 719 0057 1138 611 719 YCAL Center of Gravity mm X Y Z 0043 1153 615 731 0057 1153 615 731 ...

Page 48: ...touts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 2m rear to wall 2m control panel to end wall 1 2m top no obstructions allowed distance between adjacent units 3m No more than one adjacent wall may be higher than the unit Refers to Mod...

Page 49: ...E 2 76 X 76 RIGGING 3 4 WATER INLET WATER OUTLET A A ORIGIN X G C Y TOP VIEW 19 DIA MOUNTING HOLES TYP CONTROL PANEL POWER PANEL Refers to Model YCAL0073 Refers to Model YCAL0087 and YCAL0107 ALUMINUM COPPER YCAL Center of Gravity mm X Y Z 0073 1143 619 897 0087 1144 620 887 0107 1143 646 860 YCAL Center of Gravity mm X Y Z 0073 1162 623 920 0087 1163 623 909 0107 1160 647 882 ...

Page 50: ...sance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 2m rear to wall 2m control panel to end wall 1 2m top no obstructions allowed distance between adjacent units 3m No more than one adjacent wall may be highe...

Page 51: ...5 TOP VIEW C G Y X 1270 38 HOLES TYP MOUNTING 387 38 POWER PANEL CONTROL PANEL ORIGIN 248 2527 A B C D ALUMINUM COPPER YCAL Center of Gravity mm X Y Z 0117 1490 1021 1047 0133 1481 1026 1009 0147 1483 1021 1004 0157 1484 1025 1003 0173 1485 1021 1001 YCAL Center of Gravity mm X Y Z 0117 1482 1021 1023 0133 1483 1026 1018 0147 1485 1021 1013 0157 1486 1025 1012 0173 1487 1021 1010 ...

Page 52: ...sance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 2m rear to wall 2m control panel to end wall 1 2m top no obstructions allowed distance between adjacent units 3m No more than one adjacent wall may be highe...

Page 53: ...LES TYP 2473 737 859 38 38 C G Z X A A SIDE VIEW 53 229 CONTROL PANEL 248 ORIGIN Y 2527 POWER PANEL TOP VIEW C G X A B C D ALUMINUM COPPER YCAL Center of Gravity mm X Y Z 0197 1435 1162 1001 0217 1437 1154 1002 0237 1438 1161 1003 0253 1437 1154 991 YCAL Center of Gravity mm X Y Z 0197 1440 1162 1016 0217 1442 1154 1017 0237 1443 1160 1018 0253 1442 1154 1006 ...

Page 54: ...patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 2m rear to wall 2m control panel to end wall 1 2m top n...

Page 55: ...JOHNSON CONTROLS 55 FORM 150 62 NM9 709 1 ALUMINUM COPPER YCAL Center of Gravity mm X Y Z 0287 1801 1120 1069 YCAL Center of Gravity mm X Y Z 0287 1788 1120 1128 ...

Page 56: ...inished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 2m rear to wall 2m control panel to end wall 1 2m top no obstructions allowed di...

Page 57: ...MINUM COPPER YCAL Center of Gravity mm X Y Z 0317 1801 1120 1069 0347 2019 1120 1033 0377 2019 1120 1033 YCAL Center of Gravity mm X Y Z 0317 1788 1120 1128 0347 2019 1120 1085 0377 2019 1120 1085 Refers to Model YCAL0347 Refers to Model YCAL0377 ...

Page 58: ...tightness of power wiring inside the power panel on both sides of the motor contactors and overloads 10 Check for proper size fuses in main and control circuits and verify overload setting corresponds with RLA and FLA values in electrical tables 11 Assure 120VAC Control Power to CTB2 has 15 amp minimum capacity See Table 1 page 20 12 Be certain all water temp sensors are inserted completely in the...

Page 59: ... both Systems are programmed for ON refer to Option 2 under Unit Keys section for more information on system switches INITIAL START UP After the preceding checks have been completed and the control panel has been programmed as required in the pre startup checklist the chiller may be placed into operation 1 Place the Unit Switch in the control panel to the ON position 2 The first compressor will st...

Page 60: ...after steady state operation of the chiller has been estab lished theleavingwatertemperaturehasbeenpulleddown to the required leaving water temperature and the unit is running in a fully loaded condition Correct superheat set ting for a system is 10 F 15 F 5 56 C 8 33 C 18 46 cm from the cooler Superheat should typically be set forno less than 10 F with only a single compressor running on a circui...

Page 61: ...the compressor starts that systems first condenser fan will be cycled on out door air temperature 25 F 4 C or discharge pressure See the section on Operating Controls for details concerning condenser fan cycling YCAL0287 YCAL0377 cycle fans on discharge pressure only 5 After 1 minute of compressor run time the next compressor in sequence will start when a system has to load Additional compressors ...

Page 62: ...h is available to activate or de activate the unit Introduction Microprocessor Board The Microprocessor Board is the controller and deci sion maker in the control panel System inputs such as 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 a constant...

Page 63: ...an These characters indicate the actual values are greater than or less than the limit values which are being displayed Keypad The 12 button non tactile keypad allows the user to re trieve vitals system parameters such as system pressures temperatures compressor running times and starts option information on the chiller and system setpoints This data is useful for monitoring chiller operation diag...

Page 64: ...s in the OFF position which will not allow the unit to run R E M O T E C O N T R O L L E D S H U T D O W N The REMOTE CONTROLLED SHUTDOWN message indicates that either an ISN system or RCC has turned the unit off not allowing it to run D A I L Y S C H E D U L E S H U T D O W N The DAILY SCHEDULE SHUTDOWN message in dicates that the daily holiday schedule programmed is keeping the unit from running...

Page 65: ...I M I T I N G When this message appears discharge pressure limiting is in effect The Discharge Pressure Limiting feature is integral to the standard software control however the discharge transducer is optional on some models There fore it is important to keep in mind that this control will not function unless the discharge transducer is installed in the system The limiting pressure is a factory s...

Page 66: ...ithin 90 minutes that system will be locked out on the last fault This condition is then a manual reset The system switch under OPTIONS key must be turned off and then back on to clear the lockout fault S Y S 1 H I G H D S C H P R E S S Y S 2 H I G H D S C H P R E S The Discharge Pressure Cutout is a software cutout in the microprocessor and is backed up by a mechanical high pressure cutout switch...

Page 67: ...tive when EEVis selected as the expansion valve type in SERVICE Mode This safety is ignored for the first 15 seconds of system runtime S Y S 1 M P H P C O I N H I B S Y S 2 M P H P C O I N H I B The Motor Protector Mechanical High Pressure Cutout protects the compressor motor from overheating or the system from experiencing dangerously high discharge pressure This fault condition is present when C...

Page 68: ...icropro cessor could result in system damage When the 115VAC to the micro panel drops below a 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 counting down U N I T F A U L T H I G H M T R C U R R When the CURRENT FEEDBACK ONE PER UNIT option is selected under the OPTIONS Key the ...

Page 69: ...er System X Disch Limiting System X Suction Limiting System X Percentage Load Limiting Manual Overide Status System X Pumping Down on shutdown Unit Safeties System Safeties Low Ambient Temp System X High Disch Pressure System X Low Suct Pressure Low Liquid Temp System X MP HPCO Fault Inhibit 115VAC Undervoltage Low Battery Check Prog Step Optn Unit Warning Message System X No Cooling load System X...

Page 70: ... 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 no jumper between J11 7 and J11 12 on the I O Board the following list of operating data screens are view able under the Oper Data key in the order that they are displayed The arrow key scrolls through the displays in the order they appe...

Page 71: ...hich provides specif ic information on compressor staging for Return Water Control only t e m p e r r o r x x x x f t e m p r a t e x x x x f m The COOLING DEMAND message will be replaced with this message when Leaving Chilled liquid control is selected This message indicates the temperature error and the rate of change of the chilled liquid tem perature s y s X s p 7 2 1 p s i g d p 2 2 7 0 p s i...

Page 72: ... LEAD system In this example system 2 is the LEAD system making system 1 the LAG system The LEAD system can be manually selected or automatic Refer to the programming under the Options key The Lead System display will only appear on a two system unit A unit utilizing hot gas bypass should be programmed for MANUAL with system 1 as the lead system Failure to do so will prevent hot gas operation if s...

Page 73: ...stem is displayed table 13 OPERATION DATA OPER DATA Quick Reference List The following table is a quick reference list for informa tion available under the OPER DATA key Block of information repeats for each system LD07381A Oper Data Key Leaving Chilled Liquid Temps Ambient Air Temperature System 1 Discharge Suction Pressure EEV Only SYS 1 Suction and SAT Suction Temp EEV Only SYS 1 EEV Output Suc...

Page 74: ...G SUCT 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 FANS PER SYSTEM 4 UNIT TRIP VOLTS 3 0 REFRIGERANT TYPE R 22 REMOTE UNIT ID PROGRAMMED 2 UNIT DATA RETURN LIQUID TEMP 58 2 DEGF LEAVING LIQUID TEMP 53 0 DEGF COOLING RANGE 42 0 2 0 DEGF AMBIENT ...

Page 75: ...so not affected by power failures long term internal memory battery backup is built into the circuit board or manual resetting of a fault lock out When the HISTORY key is pressed a printout is trans mitted of all system operating conditions which were stored at the instant the fault occurred for each of the 6 Safety Shutdowns buffers The printout will begin with the most recent fault which occurre...

Page 76: ... used to scroll forward and backward through the history buffer to display the shutdown conditions stored at the instant the fault oc curred The arrow key scrolls through the displays in the order they appear below U N I T F A U L T L O W L I Q U I D T E M P Displays the type of fault that occurred U N I T T Y P E L I Q U I D C H I L L E R Displays the type of chiller Liquid Condensing Unit or Hea...

Page 77: ...he time of the fault A C T I V E R E M O T E C T R L X X X X Displays whether Remote Chiller Control was active when the fault occurred u n i t a c t u a l a m p s x x x x a m p s This is only displayed when the Current Feedback Op tion is one per unit S Y S X c o m p s t a t u s 1 x x x 2 x x x 3 x x x Displays which compressors were running in the system when the fault occurred S Y S X R U N T I...

Page 78: ...K ONE PER SYSTEM must be programmed under the op tions key If the micro is programmed as one CURRENT FEEDBACKONEPERUNITundertheprogramkey the display will be the first 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 SYS X NUMBER OF COMPS RUNNING X through SYS X AMPS XXX X VOLTS X X will be displ...

Page 79: ... The UP and DOWN arrow keys are also used for pro gramming the control panel such as changing numerical or text values when programming cooling setpoints setting the daily schedule changing safety setpoints chiller options and setting the clock ENTER ADV key The ENTER key must be pushed after any change is made to the cooling setpoints daily schedule safety setpoints chiller options and the clock ...

Page 80: ...ows the current chilled water temperature SETPOINT at 45 0 F notice the cursor positioned under the number 0 Pressing either the UP or DOWN arrow will change the setpoint in 5 F incre ments After using the UP and DOWN arrows to adjust to the desired setpoint the ENTER ADV key must be pressed to enter this number into memory and advance to the RANGE SETPOINT This will be indicated by the cursor mov...

Page 81: ...pectively r e m s e t p 4 4 0 f r a n g e 2 0 f leaving chilled liquid control r e m s e t p 4 4 0 f r a n g e 1 0 0 f return chilled liquid control The low limit high limit and default values for the keys under SETPOINTS are listed in Table 14 Pressing the COOLING SETPOINTS a third time will bring up the display that allows the Maximum EMS PWM Temperature Reset to be programmed This mes sage is s...

Page 82: ...fter 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 first reads h o l s t a r t 0 0 0 0 a m s t o p 0 0 0 0 a m The times may be set using the same procedure as described above for the days of the week After changing the meridian of the stop time pressing the ENTER ADV key will advance t...

Page 83: ... leaving chilled liquid temperature rises 2 F 1 11 C above the cutout setpoint When water cooling mode is programmed Options key the value is fixed at 36 0 F 2 22 C and cannot be changed Glycol cooling mode can be programmed to values listed in Table 14 a n t i r e c y c l e t i m e r 6 0 0 s e c The programmable anti recycle timer assures that sys tems do not cycle This timer is programmable unde...

Page 84: ...d It also calibrates the current readout under the OPER DATA key The approximate programmed value is calculated using the following formulas 460VAC system trip volts For individual system high current trip programming on 460VAC chillers Add the sum of the compressor and fan RLA s in the system Multiply the sum by 1 25 Divide by 225A The resulting voltage is the value that should be programmed For ...

Page 85: ...TANDARD 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 36 0 F 36 0 F 13 3 C 2 2 C 2 2 C ANTI RECYCLE TIMER 300 SEC 600 SEC 600 SEC FAN CONTROL ON PRESSURE 225 PSIG 260 PSIG 240 PSIG 15 5 BARG 17 9 BARG 16 5 BARG FAN DIFFERENTIAL OFF PRESSURE 50 PSIG 100 PSID 80 PSID 3...

Page 86: ...mp Control Pressure Display Only Holiday Cutout Schedule Chilled Liquid Suction Setpoint Pressure Cutout Range 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 Pressure Quick Reference Programming Chart Setpoints Section SYS Unit Trip Volts Option Number of...

Page 87: ...key There are many programmable options under the OP TIONS key The OPTIONS key is used to scroll through the list of options by repeatedly pressing the OPTIONS key After 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 memory Table 17 shows the progra...

Page 88: ...Chilled Liquid Control can only be selected on units that have 4 to 6 compressors dual system units or C O N T R O L M O D E L E A V I N G L I Q U I D Unit control is based on leaving chilled liquid temp Refer to section on Capacity Control for details on load ing and unloading sequences Option 7 Display Units D I S P L A Y U N I T S I M P E R I A L This mode displays system operating values in Im...

Page 89: ... n a b l e d This should only be enabled on European units with soft start on 2 compressors This feature modifies the compressor lead lag to start the compressor s furthest from the control panel last to minimize current inrush These compressors will be equipped with a soft starter Soft start is only viewable under OP TIONS key and must be programmed from the Service Mode On 2 compressor chillers ...

Page 90: ... under the first letter numeral of the item Press the Up or Down ar row keys until the desired hour minute meridian day month and year are displayed Pressing the ENTER ADV Key will save the valve and move the cursor on to the next programmable variable s o f t s t a r t d i s a b l e d This MUST be selected on all chillers without the soft start option Option 13 Unit Type u n i t t y p e l i q u i...

Page 91: ...RAMMING QUICK REFERENCE LIST Table 17 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 Selected Via No Jumper Installed Viewable Only Unit Type LD07405A ...

Page 92: ...iquid Control The setpoint when programmed for Leaving Chilled Liquid Control is the temperature the unit will control to within the cooling range The Setpoint High Limit is the Setpoint plus the Cooling Range The Setpoint Low Limit is the Setpoint minus the Cooling Range See Figure 8 Figure 8 should be utilized to aid in understanding the remainder of the description of Leaving Chilled Liquid Con...

Page 93: ...OINT ADJUST DEG F 6 5 4 3 2 1 0 Return Chilled Liquid Control Can be used on Dual System 4 5 6 Comp Units Only Return chilled liquid control is based on staging the com pressors to match the cooling load The chiller will be fully loaded when the return water temperature is equal to the Cooling Setpoint plus the Range The chiller will be totally unloaded all compressors off when the re turn water t...

Page 94: ... off still leaving one compressor running As the load increased the compressors would stage on every 1 7 F 94 C Also notice that Tables 18 19 and 20 not only provide the formulas for the loading ON POINT and unload ing OFF POINT of the system the STEP is also shown in the tables The STEP is that sequence in the capacity control scheme that can be viewed under the OPER DATA key Please refer to the ...

Page 95: ...g the anti recycle timer should be 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 compressors in a circuit cycle off a compressor within the circuit will not be permitted to start until the anti recycle timer has timed out If the lead system has run for less than 5 minutes 3 time...

Page 96: ...le gain scheduling varies the proportional gain based on the superheat error As the superheat gets smaller the proportional gain gets smaller The output of the PI controller may be viewed on the display and printouts as the EEV output percentage This output is converted to a PWM signal that is used to control the EEV It can over and under drive the heat motor for faster valve response This PWM out...

Page 97: ...ed if the discharge pressure transducer is installed and fan recycling is not a concern Fan control by discharge pressure will work accord ing to Table 24 The fan control on pressure and fan differential off pressure are programmable under the PROGRAM key condenser fan control ycal0287 ycal0377 YCAL0287 YCAL0377 fan control will be by dis charge pressure only See Table 26 Low Ambient Condenser Fan...

Page 98: ...table 22 YCAL0043 YCAL0107 Condenser Fan Control Using Discharge Pressure Only FAN STAGE ON OFF CONTACTOR MICROBOARD OUTPUT FAN SYS 1 SYS 1 SYS 1 1 DP Fan Ctrl On Press DP Fan Ctrl On Press Diff Press 7M TB7 9 1 2 DP Fan Ctrl On Press and Fan Stage 1 is energized DP Fan Ctrl On Press Diff Press 7M 8M TB7 9 TB7 10 1 3 When a fan stage is turned on the on pressure for the next stage is increased 20 ...

Page 99: ...S 2 1 1 FAN FWD 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 8M 11M TB7 9 TB10 9 3 4 3 2 FANS FWD OAT 65 F 18 3 C OR DP Fan Ctrl On Press 40 PSIG 2 76 Bars OAT 60 F 15 6 C AND DP Fan Ctrl On Press Diff Press 40 PSIG 2 76 Bars 7M 8M 10M 11M TB7 8 TB7 9 TB10 8 TB10 9 1 3 2 4 FAN STAGE ON OFF CONTACTOR I O BOARD OUTPUT FAN SYS 1 SYS 2 SYS 1 SYS 2 SYS 1 SYS...

Page 100: ... only FAN STAGE ON OFF CONTACTOR I O BOARD OUTPUT FAN SYS 1 SYS 2 SYS 1 SYS 2 SYS 1 SYS 2 1 1 FAN REV DP Fan Ctrl On Press DP Fan Ctrl On Press Diff Press 7M 10M TB7 8 TB10 8 1 REV 2 REV 2 1 FAN FWD DP Fan Ctrl On Press 20 PSIG 1 38 Bars DP Fan Ctrl On Press Diff Press 20 PSIG 1 38 Bars 8M 11M TB7 9 TB10 9 3 FWD 4 FWD 3 2 FANS FWD DP Fan Ctrl On Press 40 PSIG 2 76 Bars DP Fan Ctrl On Press Diff Pr...

Page 101: ...encing for the various models These models are equipped to operate to 0 F ambient as a standard Fig 11 YCAL0287 YCAL0377 Fan Location LD07828A FAN STAGE ON OFF CONTACTOR I O BOARD OUTPUT FAN SYS 1 SYS 2 SYS 1 SYS 2 SYS 1 SYS 2 1 1 FAN FWD DP Fan Ctrl On Press DP Fan Ctrl On Press Diff Press 10M 14M TB7 8 TB10 8 7 8 2 2 FANS FWD DP Fan Ctrl On Press 20 PSIG 1 38 Bars DP Fan Ctrl On Press Diff Press...

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Page 103: ... input Stage 2 of load limiting involves closing both the Load Limit and PWM inputs The first stage of limiting is either 80 66 or 50 depending on the number of compressors on the unit The second stage of limit ing is either 40 or 33 and is only available on 3 5 6 compressor units Table 27 shows the load limiting permitted for the various number of compressors Simultaneous operation of Load Lim it...

Page 104: ...ng Setpoint 7 22 C 2 78 C 10 C ThiscanbeviewedbypressingtheCoolingSetpoints key twice The new value will be displayed as REM SETP 10 0 C BAS EMS TEMPERATURE RESET OPTION The Remote Reset Option allows the Control Center of the unit to reset the chilled liquid setpoint using a 0 10VDC input a 4 20mA input or a contact closure input The Remote Reset circuit board converts the signals mentioned above...

Page 105: ... made to terminals C and D and only jumper JUI must be in place on the reset board This input is used when a single reset value is needed When the contacts are closed the remote temperature reset board will convert this contact closure to a PWM signal that is applied to CTB1 terminals 13 20 To set the PWM output the contacts must be closed on inputs C D and potentiometer R11 located on the front e...

Page 106: ...fers may be cleared by pressing the HIS TORY key and then repeatedly pressing the UP arrow key until you scroll past the last history buffer choice The following message will be displayed Pressing the ENTER ADV key at this display will cause the history buffers to be cleared Pressing any other key will cancel the operation DO NOT CLEAR BUFFERS Impor tant information may be lost Contact factory ser...

Page 107: ...is the order of analog and digital inputs that will appear when sequenced with the Down AR ROW key analog inputs SYS 1 SUCT PRESSURE UNIT TYPE SYS 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 f l o w s w r e m s t a r t j 1 3 5 i s o n s y s 1 s u c t p r j 7 1 0 2 1 v d c 8 1 p s i g The s...

Page 108: ...VALVE OR EEV PILOT SOLENOID TB10 4 SYS 2 COMPRESSOR 2 TB10 5 SYS 2 COMPRESSOR 3 TB7 8 SYS 1 CONDENSER FAN output 1 TB7 9 SYS 1 CONDENSER FAN output 2 TB7 10 SYS 1 CONDENSER FAN output 3 TB10 8 SYS 2 CONDENSER 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 TB8 7 EVAPORATOR PUMP STARTER TB10 7 SY...

Page 109: ...JOHNSON CONTROLS 109 FORM 150 62 NM9 709 3 Fig 13 I O BOARD 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 ...

Page 110: ...e DC voltage on the digital inputs This voltage is in refer ence to ground The unit case should be sufficient as a reference point when measuring digital input voltages ANALOG INPUTS Temperature Refer to the unit wiring diagram Temperature inputs are connected to the I O Board on plug J6 These analog inputs represent varying dc signals corresponding to varying temperatures All voltages are in refe...

Page 111: ...Temp Sensor EEV only J10 2 Drain shield connection 0VDC TEMP F VOLTAGE RESISTANCE TEMP C 0 1 71 25619 18 2 1 78 24046 17 4 1 85 22580 16 6 1 93 21214 14 8 2 00 19939 13 10 2 07 18749 12 12 2 15 17637 11 14 2 22 16599 10 16 2 30 15629 9 18 2 37 14721 8 20 2 45 13872 7 22 2 52 13077 6 24 2 59 12333 4 26 2 67 11636 3 28 2 74 10982 2 30 2 81 10370 1 32 2 88 9795 0 34 2 95 9256 1 36 3 02 8750 2 38 3 08...

Page 112: ...and the suction pressure readout on the display will be 0 PSIG when the LP switch is open and 200 PSIG 13 79 BARG when the LP switch is closed The discharge transducers have a range from 0 to 400 PSIG The output will be linear from 5VDC to 4 5VDC over the 400 PSIG 27 5 BARG range Following is the formula that can be used to verify the voltage output of the transducer All voltage reading are in ref...

Page 113: ...eld connection 0VDC System 2 Low Pressure Switch J9 5 5VDC regulated supply to LP switch J9 10 input signal to the I O Board 0VDC open switch 5VDC closed switch J9 1 drain shield connection 0VDC DIGITAL OUTPUTS Refer to the unit wiring diagram and Fig 14 The digital outputs are located on TB7 TB8 TB9 and TB10 of the I O Board ALL OUTPUTS ARE 120VAC with the exception of TB8 6 to TB8 7 which are th...

Page 114: ...ing a continuity check across two specif ic points or pins that represent one of twelve buttons on the keypad Table 34 lists the key pin assignments for the keypad Power to the I O Board must be turned off and the ribbon cable disconnected from the I O Board prior to conducting the tests or component damage may result After the ribbon cable is disconnected from I O Board ohmmeter leads are connect...

Page 115: ... Only The part number for the printer that is packaged specif i cally forYORK 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 parts are required 1 WEIGH TRONIX model 1220 printer 2 2 25 5 7cm wide desk top calculator paper 3 25 ft 7 62m maximum length of Tw...

Page 116: ...rd IPU2 or Display board Board NOTE Contact Johnson Controls Service before Replacing circuit Boards FLOW SWITCH REM 1 No chilled liquid flow 1 Check chilled liquid flow STOP no run permissive 2 Flow switch improperly 2 Check that the flow switch installed is installed according to manufacturer s instructions 3 Defective flow switch 3 Replace flow switch 4 Remote cycling device open 4 Check cyclin...

Page 117: ...SURE FAULT or operating backwards and contactors Assure fan blows air 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 to Service section for pressure voltage formula low liquid temp 1 Improperly adjusted leaving 1 Re program the leaving Fault chilled...

Page 118: ...ult 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 Refer to Service section for RWT LWT temp voltage table 3 Contactor Overload failure 3 Replace defective part 4 Compressor failure 4 Diagnose cause of failure and replace LACK OF COOLING EFFECT 1 Fo...

Page 119: ... 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 will cause internal arcing of the compressor motor which will result in failure of compressor CONDENSER FAN MOTORS Condenser fan motors are permanently lubricated and require no maintenance CONDENSER C...

Page 120: ...log SYS 1 Suction Superheat EEV Only P18 Analog SYS 1 Run Time seconds P19 Analog SYS 1 Suction Pressure P20 Analog SYS 1 Discharge Pressure P21 Analog SYS 1 Cooler Inlet Refrigerant Temp R 407c Only P22 Analog P23 Analog SYS 1 EEV Output EEV Only P24 Analog SYS 1 Anti Recycle Timer P25 Analog Anti Coincidence Timer P26 Analog SYS 2 Suction Temp EEV Only P27 Analog SYS 2 Run Time seconds P28 Analo...

Page 121: ...r Fan Stage P62 Coded P63 Coded SYS 2 Condenser Fan Stage P64 Coded P65 Coded Unit Control Mode 0 Leaving Water 1 Return Water 2 Discharge Air 3 Suction Press 4 Cooling 5 Heating ISN TYPE DATA PG P66 Analog Anti Recycle Time Programmed P67 Analog Leaving Chilled Liquid Temp Cutout P68 Analog Low Ambient Temp Cutout P69 Analog P70 Analog Low Suction Pressure Cutout P71 Analog High Discharge Pressur...

Page 122: ...HARGE PRESSURE 6 REMOTE SHUTDOWN 6 HIGH DIFFERENTIAL OIL PRESSURE 7 DAILY SCHEDULE SHUTDOWN 7 LOW SUCTION PRESSURE 8 NO RUN PERMISSIVE 8 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 TEMPERATE 13 SUCTION LIMITING 13 IMPROPER PHASE ROTATION 14 DISCHARGE...

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Page 124: ...NSON CONTROLS 124 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0043E_ YCAL0087E_ fig 16 elementary diagram control circuit ycal0043e_ ycal0087e_ SECTION 4 WIRING DIAGRAMS 035 21613 101 REV A ...

Page 125: ...JOHNSON CONTROLS 125 FORM 150 62 NM9 709 4 ...

Page 126: ...SON CONTROLS 126 FORM 150 62 NM9 709 WIRING DIAGRAMS fig 16A elementary diagram control circuit ycal0043e_ ycal0087e_ REMOTE COOLER ELEMENTARY DIAGRAM YCAL0043E_ YCAL0087E_ REMOTE COOLER 035 21620 101 REV A ...

Page 127: ...JOHNSON CONTROLS 127 FORM 150 62 NM9 709 4 ...

Page 128: ...JOHNSON CONTROLS 128 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0043E_ YCAL0087E_ fig 17 elementary diagram power circuit ycal0043e_ ycal0087e_ 035 19203 102 REV A ...

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Page 130: ...JOHNSON CONTROLS 130 FORM 150 62 NM9 709 WIRING DIAGRAMS connection DIAGRAM YCAL0043E_ YCAL0087E_ fig 18 connection diagram middle market ycal0043e_ ycal0087e_ LD08854 ...

Page 131: ...JOHNSON CONTROLS 131 FORM 150 62 NM9 709 4 LD08855 035 21627 000 REV B ...

Page 132: ...JOHNSON CONTROLS 132 FORM 150 62 NM9 709 WIRING DIAGRAMS elementary DIAGRAM YCAL0043E_ YCAL0087E_ fig 19 elementary diagram middle market ycal0043e_ ycal0087e_ ...

Page 133: ...JOHNSON CONTROLS 133 FORM 150 62 NM9 709 4 035 19213 106 REV C ...

Page 134: ...JOHNSON CONTROLS 134 FORM 150 62 NM9 709 WIRING DIAGRAMS elementary DIAGRAM YCAL0107E_ fig 20 elementary diagram middle market YCAL0107E_ 035 21612 101 REV A ...

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Page 136: ...JOHNSON CONTROLS 136 FORM 150 62 NM9 709 WIRING DIAGRAMS elementary DIAGRAM YCAL0107E_ REMOTE COOLER fig 20A elementary diagram middle market YCAL0107E_ REMOTE COOLER 035 21621 101 REV A ...

Page 137: ...JOHNSON CONTROLS 137 FORM 150 62 NM9 709 4 ...

Page 138: ...JOHNSON CONTROLS 138 FORM 150 62 NM9 709 WIRING DIAGRAMS elementary DIAGRAM YCAL0107E_ fig 21 elementary diagram power circuit YCAL0107E_ 035 19202 102 REV A ...

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Page 140: ...JOHNSON CONTROLS 140 FORM 150 62 NM9 709 WIRING DIAGRAMS connection DIAGRAM YCAL0107E_ fig 22 connection diagram middle market YCAL0107E_ ...

Page 141: ...JOHNSON CONTROLS 141 FORM 150 62 NM9 709 4 035 21628 000 REV B ...

Page 142: ...JOHNSON CONTROLS 142 FORM 150 62 NM9 709 WIRING DIAGRAMS elementary DIAGRAM YCAL0107E_ fig 23 elementary diagram middle market YCAL0107E_ ...

Page 143: ...JOHNSON CONTROLS 143 FORM 150 62 NM9 709 4 035 19213 105 REV C ...

Page 144: ...JOHNSON CONTROLS 144 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0117E_ YCAL0173E_ fig 24 elementary diagram control circuit ycal0117e_ ycal0173e_ 035 21617 101 REV A ...

Page 145: ...JOHNSON CONTROLS 145 FORM 150 62 NM9 709 4 ...

Page 146: ...SON CONTROLS 146 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0117E_ YCAL0173E_ REMOTE COOLER fig 24a elementary diagram control circuit ycal0117e_ ycal0173e_ REMOTE COOLER 035 21618 101 REV A ...

Page 147: ...JOHNSON CONTROLS 147 FORM 150 62 NM9 709 4 ...

Page 148: ...JOHNSON CONTROLS 148 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0117E_ YCAL0173E_ fig 25 elementary diagram power circuit ycal0117e_ ycal0173e_ 035 19201 102 REV A ...

Page 149: ...JOHNSON CONTROLS 149 FORM 150 62 NM9 709 4 ...

Page 150: ...JOHNSON CONTROLS 150 FORM 150 62 NM9 709 WIRING DIAGRAMS connection DIAGRAM YCAL0117E_ YCAL0173E_ fig 26 connection diagram middle market ycal0117e_ ycal0173e_ ...

Page 151: ...JOHNSON CONTROLS 151 FORM 150 62 NM9 709 4 035 21625 000 REV B ...

Page 152: ...JOHNSON CONTROLS 152 FORM 150 62 NM9 709 WIRING DIAGRAMS elementary DIAGRAM YCAL0117E_ YCAL0173E_ fig 27 elementary diagram middle market ycal0117e_ ycal0173e_ ...

Page 153: ...JOHNSON CONTROLS 153 FORM 150 62 NM9 709 4 035 19213 104 REV C ...

Page 154: ...JOHNSON CONTROLS 154 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0197E_ YCAL0253E_ fig 28 elementary diagram control circuit ycal0197e_ ycal0253e_ 035 21614 101 REV A ...

Page 155: ...JOHNSON CONTROLS 155 FORM 150 62 NM9 709 4 ...

Page 156: ...SON CONTROLS 156 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0197E_ YCAL0253E_REMOTE COOLER fig 28A elementary diagram control circuit ycal0197e_ ycal0253e_ REMOTE COOLER 035 21615 101 REV A ...

Page 157: ...JOHNSON CONTROLS 157 FORM 150 62 NM9 709 4 ...

Page 158: ...JOHNSON CONTROLS 158 FORM 150 62 NM9 709 WIRING DIAGRAMS elementary DIAGRAM YCAL0197E_ YCAL0253E_ fig 29 elementary diagram POWER CIRCUIT ycal0197e_ ycal0253e_ 035 19200 102 REV C ...

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Page 160: ...JOHNSON CONTROLS 160 FORM 150 62 NM9 709 WIRING DIAGRAMS connection DIAGRAM YCAL0197E_ YCAL0253E_ fig 30 connection diagram middle market ycal0197e_ ycal0253e_ ...

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Page 162: ...JOHNSON CONTROLS 162 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0197E_ YCAL0253E_ fig 31 ELEMENTARY diagram middle market ycal0197e_ ycal0253e_ ...

Page 163: ...JOHNSON CONTROLS 163 FORM 150 62 NM9 709 4 035 19213 103 REV C ...

Page 164: ...JOHNSON CONTROLS 164 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0287E_ YCAL0317E_ fig 32 elementary diagram control circuit ycal0287E_ ycal0317e_ 035 21610 101 REV A ...

Page 165: ...JOHNSON CONTROLS 165 FORM 150 62 NM9 709 4 ...

Page 166: ...JOHNSON CONTROLS 166 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0287E_ YCAL0317E_ fig 33 elementary diagram power circuit ycal0287E_ ycal0317e_ LD08832 035 18150 103 REV ...

Page 167: ...JOHNSON CONTROLS 167 FORM 150 62 NM9 709 4 LD08833 ...

Page 168: ...JOHNSON CONTROLS 168 FORM 150 62 NM9 709 WIRING DIAGRAMS connection DIAGRAM YCAL0287E_ YCAL0317E_ fig 34 connection diagram middle market high performance ycal0287E_ ycal0317e_ ...

Page 169: ...JOHNSON CONTROLS 169 FORM 150 62 NM9 709 4 035 21610 104 REV ...

Page 170: ...JOHNSON CONTROLS 170 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0287E_ YCAL0317E_ fig 35 elementary diagram middle market ycal0287E_ ycal0317e_ ...

Page 171: ...JOHNSON CONTROLS 171 FORM 150 62 NM9 709 4 035 18150 102 REV D ...

Page 172: ...JOHNSON CONTROLS 172 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0347E_ YCAL0377E_ fig 36 elementary diagram control circuit ycal0347E_ ycal0377e_ 035 21606 101 REV A ...

Page 173: ...JOHNSON CONTROLS 173 FORM 150 62 NM9 709 4 ...

Page 174: ...JOHNSON CONTROLS 174 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0347E_ YCAL0377E_ fig 37 elementary diagram power circuit ycal0347E_ ycal0377e_ 035 18109 103 REV A ...

Page 175: ...JOHNSON CONTROLS 175 FORM 150 62 NM9 709 4 ...

Page 176: ...JOHNSON CONTROLS 176 FORM 150 62 NM9 709 WIRING DIAGRAMS connection DIAGRAM YCAL0347E_ YCAL0377E_ fig 38 connection diagram middle market high performance ycal0347E_ ycal0377e_ ...

Page 177: ...JOHNSON CONTROLS 177 FORM 150 62 NM9 709 4 035 21606 104 REV ...

Page 178: ...JOHNSON CONTROLS 178 FORM 150 62 NM9 709 WIRING DIAGRAMS ELEMENTARY DIAGRAM YCAL0347E_ YCAL0377E_ fig 39 elementary diagram middle market high performance ycal0347E_ ycal0377e_ 035 18109 102 REV D ...

Page 179: ...1 593 1 797 1 597 6 779 0287 1 573 836 1 129 1 573 836 1 126 7 073 0317 1 615 840 1 146 1 615 840 1 144 7 201 0347 1 360 1 162 880 829 1 360 1 162 882 832 8 466 0377 1 401 1 199 909 856 1 399 1 197 906 854 8 721 YCAL Aluminum Fin Coil Weight Distribution kg A B C D E F G H Total 0043 303 238 345 270 1 156 0057 305 239 347 272 1 163 0073 352 279 392 311 1 333 0087 344 309 382 343 1 377 0107 400 358...

Page 180: ... 903 1 704 1 907 1 708 7 222 0287 1 760 933 1 258 1 760 933 1258 7 902 0317 1 800 937 1 278 1 800 937 1278 8 030 0347 1 511 1 291 979 922 1 511 1 291 979 922 9 407 0377 1 553 1 327 1 001 948 1 553 1 327 1 005 948 9 662 YCAL Copper Fin Coil Weight Distribution kg A B C D E F G H Total 0043 326 263 367 297 1 253 0057 327 265 369 299 1 260 0073 387 319 427 352 1 486 0087 377 352 414 387 1 529 0107 43...

Page 181: ... 26 CP 2 26 CP 2 28 CP 2 27 CP 2 26 CP 2 26 0377 CP 2 28 CP 2 27 CP 2 26 CP 2 26 CP 2 28 CP 2 27 CP 2 26 CP 2 26 Aluminum Fin Seismic Isolator Selections YCAL VMC Model AEQM xxxx A B C D E F G H 0043 AEQM 97 AEQM 96 AEQM 98 AEQM 97 0057 AEQM 97 AEQM 96 AEQM 98 AEQM 97 0073 AEQM 98 AEQM 97 AEQM 98 AEQM 98 0087 AEQM 98 AEQM 97 AEQM 98 AEQM 98 0107 AEQM 98 AEQM 98 AEQM 99 AEQM 98 0117 AEQM 1300 AEQM ...

Page 182: ... 0087 3 Gray 3 Grn 3 Gray 3 Grn 0107 3 Gray 3 Grn 3 Gray 3 Grn 0117 4 Blk 4 Blk 4 Blk 4 Blk 0133 4 Blk 4 Blk 4 Blk 4 Blk 0147 4 Blk 4 Blk 4 Blk 4 Blk 0157 4 Blk 4 Blk 4 Blk 4 Blk 0173 4 Blk 4 Blk 4 Blk 4 Blk 0197 4 Red 4 Red 4 Red 4 Red 0217 4 Red 4 Red 4 Red 4 Red 0237 4 Red 4 Red 4 Red 4 Red 0253 4 Red 4 Red 4 Red 4 Red 0287 4 Red 3 Gray 3 Gray 4 Red 3 Gray 3 Gray 0317 4 Red 3 Gray 3 Gray 4 Red ...

Page 183: ... CP 2 26 CP 2 28 CP 1 27 CP 2 26 CP 2 26 Copper Fin Seismic Isolator Selections YCAL VMC Model AEQM xxxx A B C D E F G H 0043 AEQM 97 AEQM 96 AEQM 98 AEQM 97 0057 AEQM 97 AEQM 96 AEQM 98 AEQM 97 0073 AEQM 98 AEQM 97 AEQM 99 AEQM 98 0087 AEQM 98 AEQM 97 AEQM 99 AEQM 98 0107 AEQM 99 AEQM 98 AEQM 99 AEQM 98 0117 AEQM 1600 AEQM 1600 AEQM 1600 AEQM 1300 0133 AEQM 1600 AEQM 1600 AEQM 1600 AEQM 1300 0147...

Page 184: ...7 3 Gray 3 Gray 3 Gray 3 Gray 0107 3 Gray 3 Gray 3 Gray 3 Gray 0117 4 Blk 4 Blk 4 Blk 4 Blk 0133 4 Blk 4 Blk 4 Blk 4 Blk 0147 4 Blk 4 Blk 4 Blk 4 Blk 0157 4 Blk 4 Blk 4 Blk 4 Blk 0173 4 Blk 4 Blk 4 Blk 4 Blk 0197 4 Red 4 Red 4 Red 4 Red 0217 4 Red 4 Red 4 Red 4 Red 0237 4 Red 4 Red 4 Red 4 Red 0253 4 Red 4 Red 4 Red 4 Red 0287 4 Red 3 Gray 4 Blk 4 Red 3 Gray 4 Blk 0317 4 Red 3 Gray 4 Blk 4 Red 3 G...

Page 185: ...308439 26 PURPLE AEQM 96 301055 96 BLACK CP 1 27 308439 27 ORANGE AEQM 97 301055 97 WHITE CP 1 28 308439 28 GREEN AEQM 98 301055 98 GRAY CP 1 31 308439 31 GRAY AEQM 99 301055 99 BLUE CP 2 25 308439 25 RED AEQM 1000 30106 1000 GREEN CP 2 26 308692 26 PURPLE AEQM 1300 30106 1300 YELLOW CP 2 27 308962 27 ORANGE AEQM 1600 301060 1600 GRAY CP 2 28 308692 28 GREEN AEQM 1625 301060 1625 RED CP 2 31 30869...

Page 186: ... 8 1 4 7 1 4 5 8 3 8 AEQM 98 7 5 1 2 4 1 2 2 1 2 5 8 1 4 7 1 4 5 8 3 8 AEQM 99 7 5 1 2 4 1 2 2 1 2 5 8 1 4 7 1 4 5 8 3 8 AEQM 1000 8 1 2 6 1 2 6 4 1 2 3 4 3 8 8 3 8 7 8 1 2 AEQM 1300 8 1 2 6 1 2 6 4 1 2 3 4 3 8 8 3 8 7 8 1 2 AEQM 1600 8 1 2 6 1 2 6 4 1 2 3 4 3 8 8 3 8 7 8 1 2 AEQM 1625 8 1 2 6 1 2 6 4 1 2 3 4 3 8 8 3 8 7 8 1 2 AEQM 1628 8 1 2 6 1 2 6 4 1 2 3 4 3 8 8 3 8 7 8 1 2 ...

Page 187: ...floor in any way If required bolt mountings to floor through slots 4 Set the machine or base on the mountings The weight of the machine will cause the upper housing of the mount to go down possibly resting on the lower housing 5 If clearance X is less than 1 4 on any mounting with wrench turn up one complete turn on the ad justing bolt of each mounting Repeat this procedure until 1 4 clearance at ...

Page 188: ... level all isolator base plates A A1 4 maximum difference in elevation can be tolerated 4 Anchor all isolators to floor or subbase as required For installing on concreteVMC recommends HILTI type HSL heavy duty anchors or equal 5 Remove cap screw C and save Gently place machine or machine base on top of bolt B Install cap screw C but DO NOT tighten 6 The weight of the machine will cause the spring ...

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