Johnson Controls York YCRL0064 Installation Operation & Maintenance Download Page 1

Page: 1 / 162

Issue Date:

September 30, 2015

YCRL0064 - 0198

REMOTE CONDENSER SCROLL LIQUID CHILLERS

STYLE A (60 Hz)

50 - 170 TONS

175kW THROUGH 597kW

R410A

035-22148-101

Products are produced at a

f acility whose quality-

management systems are

ISO9001 certified.

WATER-COOLED LIQUID CHILLERS

HERMETIC SCROLL

INSTALLATION, OPERATION, MAINTENANCE

Supersedes 150.27-NM1 (511)

Form 150.27-NM1 (915)

Summary of Contents for York YCRL0064

Page 1: ...STYLE A 60 Hz 50 170 TONS 175kW THROUGH 597kW R410A 035 22148 101 Products are produced at a facility whose quality management systems are ISO9001 certified WATER COOLED LIQUID CHILLERS HERMETIC SCROL...

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

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

Page 4: ...JOHNSON CONTROLS 4 FORM 150 27 NM1 ISSUE DATE 09 30 2015 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 5: ...ompressors 17 Refrigerant Circuits 17 Evaporator 18 Condenser 18 Refrigerant Circuit 18 Millennium Control Center 18 Programmable Setpoints 19 Displayed Data 19 System Safeties 19 Unit Safeties 19 Pow...

Page 6: ...ng the Unit 31 Lifting by Crane Hoist 31 Lifting Weights 32 SECTION 4 INSTALLATION 33 Installation Checklist 33 Location Requirements 33 Unit Isolation Noise Sensitive Location 33 Foundation 33 Instal...

Page 7: ...47 Pressure Drop Charts 48 Ethylene and Propolyne Glycol Correction Factors 49 Evaporator Pressure Drop 49 Physical Data Standard And High Efficiency English 50 Electrical Data Single Point 52 Electri...

Page 8: ...95 Panel Checks Power On Unit switch Off 95 Checking Superheat And Subcooling 97 Leak Checking 97 Unit Operating Sequence 98 SECTION 7 UNIT CONTROLS 99 Introduction 99 IPU II and I O Boards 99 Unit S...

Page 9: ...e Disable 125 Option 14 Unit Type 125 Option 15 Refrigerant Type 126 Option 16 Expansion Valve Type 126 Option 17 Flash Card Update 126 Option 18 Remote Temperature Reset 126 Option 19 Pump Control 12...

Page 10: ...puts 143 Optional Printer Installation 144 Parts 144 Assembly and Wiring 144 Obtaining a Printout 144 Troubleshooting 145 SECTION 10 MAINTENANCE 147 Important 147 Compressors 147 Oil Level Check 147 O...

Page 11: ...d Power And Single Point Power Circuit 4 Compressor Unit 66 FIGURE 21 Multiple Point Power Circuit 4 Compressor Unit 67 FIGURE 22 Standard Power And Single Point Power Circuit 6 Compressor Unit 68 FIG...

Page 12: ...points Programmable Limits And Defaults 118 TABLE 15 Program Key Limits And Default 121 TABLE 16 Sample Compressor Staging For Return Water Control 131 TABLE 17 Return Chilled Liquid Control For 4 Com...

Page 13: ...ny injury or damage caused by incorrect installation commission ing operation or maintenance resulting from a failure to follow the procedures and instructions detailed in the manuals WARRANTY Johnson...

Page 14: ...nd is not suitable for purposes other than those specified in these instructions Any use of the equip ment other than its intended use or operation of the equipment contrary to the relevant procedures...

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

Page 16: ...JOHNSON CONTROLS 16 FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 1 GENERAL CHILLER INFORMATION AND SAFETY THIS PAGE INTENTIONALLY LEFT BLANK...

Page 17: ...pressors The YCRL compressors incorporate a com pliant scroll design in both the axial and radial direction All rotating parts are statically and dynamically balanced A large internal volume and oil r...

Page 18: ...ANT CIRCUIT Two independent refrigerant circuits will be furnished on each unit All piping will be copper with brazed joints The liquid line will include a shutoff valve with charging port sight glass...

Page 19: ...ly start stop times Holiday status Automatic or manual system lead lag control Lead system definition Compressor starts and operating hours each com pressor Run permissive status Number of compressors...

Page 20: ...secondary wiring between the transformer and the control panel Factory Mounted Compressor External Overloads Optional compressor motor overloads can be factory mounted in the unit control power panel...

Page 21: ...us tic sound blanket The sound blankets are made with one layer of acoustical absorbent textile fiber of 5 8 15mm thickness one layer of anti vibrating heavy material thickness of 1 8 3mm Both are clo...

Page 22: ...LS 22 FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 2 PRODUCT DESCRIPTION Figure 2 CONTROL PANEL COMPONENTS CONTROL POWER PANEL COMPONENTS DISPLAY UNIT SWITCH IPU II IO BOARD CTB1 Flow Switch and Load...

Page 23: ...DATE 09 30 2015 2 CONTROL POWER PANEL COMPONENTS CONT D Figure 3 CONTROL POWER PANEL COMPONENTS CONTROL RELAY CONTROL RELAY TRANSFORMER FUSE BLOCK CONTROL TRANSFORMER GROUND LUG CTB2 FTB LD14533 OPTIO...

Page 24: ...OMPRESSORS POWER PANEL EVAPORATOR FORMED STEEL BASE RAILS LIQUID LINE STUB OUT FILTER DRIERS LIQUID LINE SOLENOID VALVE CONTROL PANEL WITH KEYPAD AND DISPLAY SIGHT GLASS TXV VALVE OPTIONAL ISOLATION V...

Page 25: ...7 0177 0198 0198 UNIT UNIT DESIGNATOR PIN 9 H HIGH EFFICIENCY UNIT REF REFRIGERANT PIN 10 E R 410A VOLTS VOLTAGE PIN 11 AND 12 17 200 3 60 28 230 3 60 40 380 3 60 46 460 3 60 50 380 415 3 50 58 575 3...

Page 26: ...ESSURE TRANSDUCERS READOUT STANDARD Q SPECIAL QUOTE SAFETY SAFETY CODES PIN 24 C EUROPEAN SAFETY CODE CE L N AMERICAN SAFETY CODE CUL CETL Q SPECIAL QUOTE HPUMP HEAT PUMP PIN 25 X NO OPTION Q SPECIAL...

Page 27: ...CH D ONE DIFFERENTIAL PRESSURE SWITCH PER CHILLER E TWO DIFFERENTIAL PRESSURE SWITCHES PER CHILLER F THREE DIFFERENTIAL PRESSURE SWITCHES PER CHILLER S ONE FLOW SWITCH PER CHILLER T TWO FLOW SWITCHES...

Page 28: ...SHIP SHIP INSTRUCTIONS PIN 57 X NO CONTAINERIZATION REQUIRED WITH SHIPPING BAG A BUY AMERICA ACT COMPLIANCE WITH SHIPPING BAG B BOTH BUY AMERICA ACT COMPLIANCE AND CONTAINER SHIPPED WITHOUT SHIPPING...

Page 29: ...enters the compres sor where pressure and superheat are increased The high pressure superheat refrigerant enters the remote air cooled condenser where heat is rejected via the condenser coil and fans...

Page 30: ...b cooled liquid leaves the remote air cooled condenser and enters the expansion valve where pressure reduc tion and further cooling takes place The low pressure liquid refrigerant then returns to the...

Page 31: ...pressure relief devices the unit must not be steam cleaned It is recommended that the unit is periodically in spected during storage INSPECTION Immediately upon receiving the unit it should be in spe...

Page 32: ...etails of weights and weight distribution see Table below Figure 7 CHILLER RIGGING AND LIFTING WEIGHTS LIFTING WEIGHTS High Efficiency HE YCRL 60 HZ MODEL lbs kg 0064HE 0074HE 0084HE 0096HE 0118HE 012...

Page 33: ...e of the unit and power and control panels Local health and safety regula tions or practical considerations for service replacement of large components may require larger clearances than those given i...

Page 34: ...unit wiring diagram This is to prevent damage to the exchanges caused inadequate liquid flow The flow switch used must have gold plated contacts for low voltage current op eration Paddle type flow sw...

Page 35: ...and con denser field piping Drain connections should be provided at all low points to permit complete drainage of the evaporator s condenser s and system piping This is especially important if the un...

Page 36: ...nges or weld flang es Victaulic adapter flanges are supplied loose for field installation and weld flanges are factory fitted Flange dimensions are to ISO 7005 NP10 BS 4504 NP10 LD06602 Figure 8 VICTA...

Page 37: ...STRAINER PRESSURE TAPPING FLOW SWITCH FLANGED CONNECTION Isolating Valve Normally Open Isolating Valve Normally Closed Flow Regulating Valve Flow Measurement Device Strainer Flow Switch Flanged Conne...

Page 38: ...nce and oil return for system reliability PRESSURE DROP CONSIDERATIONS Pressure drop calculations are determined as pressure changes associated with a change in saturation temper ature of the refriger...

Page 39: ...ated A minimum of 70 of the calculated complete system charge must be installed before attempting to operate a system Final adjustment of refrigerant charge should be verified by subcooling values ref...

Page 40: ...29 80 6228 40 6 1 8 1054 47 1099 10 1141 87 1180 91 1216 24 1244 13 6 1 8 371 10 4383 70 9980 43 STEEL IPS SCH IPS SCH 3 8 80 0 81 0 84 0 88 0 91 0 93 0 95 3 8 80 00 1 90 3 40 7 60 1 2 80 1 59 1 66 1...

Page 41: ...3 5 8 4 1 8 AREA IN2 1 780 3 094 4 770 6 812 9 213 11 970 410A 80 110 6 80 13 56 23 30 36 38 53 06 73 60 140 6 31 12 60 21 64 33 79 49 28 68 36 170 5 67 11 32 19 44 30 35 44 27 61 41 90 120 6 91 13 8...

Page 42: ...wiring must comply with the National Elec tric Code and all applicable local codes YORK liquid chiller units are factory wired for optimum reliability Therefore the unit controls must not be modified...

Page 43: ...VDC must be run in screened cable with the screen earthed at the panel end only Run screened cable separately from mains cable to avoid electrical noise pick up The voltage free contacts connected to...

Page 44: ...hase 60 Hz 380 VAC 3 phase 60 Hz 460 VAC 3 phase 60 Hz 575 VAC 3 phase 60 Hz ground Connect each of the 3 phase supplies to the door inter locked circuit breakers located in the power sections using t...

Page 45: ...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 free...

Page 46: ...JOHNSON CONTROLS 46 FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 4 INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK...

Page 47: ...0 450 40 50 80 130 40 115 0084 140 450 40 50 80 130 40 115 0096 150 700 40 50 80 130 40 115 0118 140 700 40 50 80 130 40 115 0126 200 700 40 50 80 130 40 115 0156 200 700 40 50 80 130 40 115 0177 200...

Page 48: ...ENGLISH AND SI YCRL Model Number Evap 0064HE A 0074HE 0084HE 0118HE B 0096HE C 0126HE 0156HE 0177SE 198SE D YCRL Evaporator Pressure Drop English Units 1 0 10 0 100 0 10 100 1000 Water Flow Rate GPM...

Page 49: ...35 8 50 0 922 1 013 1 091 1 599 29 PROPYLENE GLYCOL WEIGHT TONS COMPR KW GPM PRESS DROP FREEZE PT 10 0 985 1 002 1 003 1 078 26 20 0 968 1 005 1 000 1 157 19 30 0 937 1 008 0 992 1 266 9 40 0 898 1 01...

Page 50: ...S 2883 3261 3439 3753 3705 4587 4989 4418 4773 OPERATING LBS 3090 3547 3725 4195 3991 5030 5432 4773 5128 COMPRESSORS SCROLL QUANTITY PER CHILLER 4 4 4 6 4 6 6 5 6 NOMINAL SIZE CKT 1 CKT 2 15 15 15 15...

Page 51: ...JOHNSON CONTROLS 51 SECTION 5 TECHNICAL DATA FORM 150 27 NM1 ISSUE DATE 09 30 2015 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 52: ...6HE 208 60 349 400 400 400 1 250 500 KCM 2 10 300 KCM 230 60 349 400 400 400 1 250 500 KCM 2 10 300 KCM 380 60 225 250 250 250 1 6 350 KCM 1 4 500 KCM 460 60 168 200 175 175 1 4 300 KCM 1 4 500 KCM 57...

Page 53: ...9 250 49 4 239 49 4 239 32 1 198 32 1 198 0096HE 55 8 425 55 8 425 55 8 425 55 8 425 55 8 425 55 8 425 55 8 425 55 8 425 55 8 425 55 8 425 55 8 425 55 8 425 36 0 239 36 0 239 36 0 239 36 0 239 36 0 23...

Page 54: ...5 60 70 70 55 60 70 70 0118HE 208 60 247 400 300 350 200 250 225 250 230 60 247 400 300 350 200 250 225 250 380 60 156 200 175 200 123 150 150 175 460 60 123 150 150 175 97 100 110 125 575 60 111 150...

Page 55: ...0118HE 208 1 6 350KCMIL 109 6 599 0 109 6 599 0 1 6 350KCMIL 89 1 500 0 89 1 500 0 230 1 6 350KCMIL 109 6 599 0 109 6 599 0 1 6 350KCMIL 89 1 500 0 89 1 500 0 380 1 2 4 0AWG 69 2 358 0 69 2 358 0 1 2...

Page 56: ...ormer Circuit 1 Circuit 2 Micropanel Optional Term Block or NF Disc SW or Circuit Breaker GRD LEGEND Field Wiring Factory Wiring It is possible that multiple sources of power can be supplying the unit...

Page 57: ...SUPPLY 1 2 Control Transformer Circuit Breaker Circuit 1 Circuit 2 Circuit Breaker GRD Micropanel It is possible that multiple sources of power can be supplying the unit power panel To prevent serious...

Page 58: ...0V 28 230 1 60 15A 10A 15A 30 A 240V 40 380 1 60 15A 10A 15A 30 A 480V 46 460 1 60 15A 10A 15A 30 A 480V 50 380 415 1 60 15A 10A 15A 30A 415V 58 575 1 60 15A 10A 15A 30 A 600V A Minimum 14 AWG 75 C Co...

Page 59: ...ated load amps 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 ratin...

Page 60: ...300 KCM 6 1 0 AWG 200A 4 300 KCM 6 1 0 AWG 225A 4 300 KCM 6 1 0 AWG 250A 6 350 KCM 4 3 0 AWG 400A 250 500 KCM 2 4 0 AWG 400A 2 3 0 250 KCM 2 6 1 0 AWG 600A 2 250 500 KCM 2 2 4 0 AWG TERMINAL BLOCK OPT...

Page 61: ...JOHNSON CONTROLS 61 SECTION 5 TECHNICAL DATA FORM 150 27 NM1 ISSUE DATE 09 30 2015 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 62: ...150 27 NM1 ISSUE DATE 09 30 2015 SECTION 5 TECHNICAL DATA ELEMENTARY WIRING DIAGRAM Figure 18 STANDARD POWER SINGLE POINT AND MULTIPLE POINT CONTROL PANEL WIRING 4 COMPRESSOR UNIT WIRING DIAGRAMS YCR...

Page 63: ...JOHNSON CONTROLS 63 SECTION 5 TECHNICAL DATA FORM 150 27 NM1 ISSUE DATE 09 30 2015 5 5 FIGURE 18 STANDARD POWER SINGLE POINT AND MULTIPLE POINT CONTROL PANEL WIRING 4 COMPRESSOR UNIT CONT D...

Page 64: ...FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 5 TECHNICAL DATA ELEMENTARY WIRING DIAGRAM Figure 19 STANDARD POWER SINGLE POINT AND MULTIPLE POINT CONTROL PANEL WIRING 6 COMPRESSOR UNIT YCRL0096 0126...

Page 65: ...JOHNSON CONTROLS 65 SECTION 5 TECHNICAL DATA FORM 150 27 NM1 ISSUE DATE 09 30 2015 5 5 FIGURE 19 STANDARD POWER SINGLE POINT AND MULTIPLE POINT CONTROL PANEL WIRING 6 COMPRESSOR UNIT...

Page 66: ...NTROLS 66 FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 5 TECHNICAL DATA Figure 20 STANDARD POWER AND SINGLE POINT POWER CIRCUIT 4 COMPRESSOR UNIT ELEMENTARY WIRING DIAGRAM LD 12925 YCRL0064 0074 0084...

Page 67: ...NSON CONTROLS 67 SECTION 5 TECHNICAL DATA FORM 150 27 NM1 ISSUE DATE 09 30 2015 5 5 Figure 21 MULTIPLE POINT POWER CIRCUIT 4 COMPRESSOR UNIT LD 13998 ELEMENTARY WIRING DIAGRAM YCRL0064 0074 0084 and 0...

Page 68: ...CONTROLS 68 FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 5 TECHNICAL DATA ELEMENTARY WIRING DIAGRAM YCRL0096 0126 0156 0177 and 0198 Figure 22 STANDARD POWER AND SINGLE POINT POWER CIRCUIT 6 COMPRESS...

Page 69: ...ONTROLS 69 SECTION 5 TECHNICAL DATA FORM 150 27 NM1 ISSUE DATE 09 30 2015 5 5 LD14000 Figure 23 MULTIPLE POINT POWER CIRCUIT 6 COMPRESSOR UNIT ELEMENTARY WIRING DIAGRAM CONT D YCRL0096 0126 0156 0177...

Page 70: ...S 70 FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 5 TECHNICAL DATA CONNECTION WIRING DIAGRAM Figure 24 STANDARD POWER AND SINGLE POINT CONNECTION WIRING DIAGRAM 4 COMPRESSOR UNIT LD12926 YCRL0064 007...

Page 71: ...JOHNSON CONTROLS 71 SECTION 5 TECHNICAL DATA FORM 150 27 NM1 ISSUE DATE 09 30 2015 5 5 FIGURE 24 STANDARD POWER AND SINGLE POINT CONNECTION WIRING DIAGRAM 4 COMPRESSOR UNIT LD12927...

Page 72: ...N CONTROLS 72 FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 5 TECHNICAL DATA Figure 25 MULTIPLE POINT POWER CONNECTION WIRING DIAGRAM 4 COMPRESSOR UNIT CONNECTION WIRING DIAGRAM YCRL0064 0074 0084 and...

Page 73: ...JOHNSON CONTROLS 73 SECTION 5 TECHNICAL DATA FORM 150 27 NM1 ISSUE DATE 09 30 2015 5 5 FIGURE 25 MULTIPLE POINT POWER CONNECTION WIRING DIAGRAM 4 COMPRESSOR UNIT CONT D LD13999...

Page 74: ...LS 74 FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 5 TECHNICAL DATA CONNECTION WIRING DIAGRAM Figure 26 STANDARD POWER AND SINGLE POINT CONNECTION WIRING DIAGRAM 6 COMPRESSOR UNIT YCRL0096 0126 0156...

Page 75: ...JOHNSON CONTROLS 75 SECTION 5 TECHNICAL DATA FORM 150 27 NM1 ISSUE DATE 09 30 2015 5 5 FIGURE 26 STANDARD POWER AND SINGLE POINT CONNECTION WIRING DIAGRAM 6 COMPRESSOR UNIT CONT D...

Page 76: ...ON CONTROLS 76 FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 5 TECHNICAL DATA Figure 27 MULTIPLE POINT CONNECTION WIRING DIAGRAM 6 COMPRESSOR UNIT CONNECTION WIRING DIAGRAM YCRL0096 0126 0156 0177 and...

Page 77: ...JOHNSON CONTROLS 77 SECTION 5 TECHNICAL DATA FORM 150 27 NM1 ISSUE DATE 09 30 2015 5 5 FIGURE 27 MULTIPLE POINT CONNECTION WIRING DIAGRAM 6 COMPRESSOR UNIT CONT D LD14001...

Page 78: ...Contacts must be suitable for switching 24VDC gold contacts recommended Wiring shall not be run in the same conduit with any line voltage class 1 wiring 3 To cycle unit ON and OFF automatically with c...

Page 79: ...TION 5 TECHNICAL DATA FORM 150 27 NM1 ISSUE DATE 09 30 2015 5 5 FIGURE 28 STANDARD POWER SINGLE POINT AND MULTIPLE POINT ELEMENTARY WIRING DIAGRAM DETAILS 4 COMPRESSOR CONT D LD12929 ELEMENTARY WIRING...

Page 80: ...s 2 Contacts must be suitable for switching 24VDC gold contacts recommended Wiring shall not be run in the same conduit with any line voltage class 1 wiring 3 To cycle unit ON and OFF automatically wi...

Page 81: ...SECTION 5 TECHNICAL DATA FORM 150 27 NM1 ISSUE DATE 09 30 2015 5 5 FIGURE 29 STANDARD POWER SINGLE POINT AND MULTIPLE POINT ELEMENTARY WIRING DIAGRAM DETAILS 6 COMPRESSOR CONT D ELEMENTARY WIRING DIA...

Page 82: ...JOHNSON CONTROLS 82 FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 5 TECHNICAL DATA Figure 30 EEV CONTROLLER WIRING ELEMENTARY WIRING DIAGRAM DETAILS CONT D...

Page 83: ...29 29 29 J 17 7 17 7 17 7 17 7 K 12 3 12 8 12 8 12 8 M 12 3 12 3 12 3 12 3 N 12 3 12 3 12 3 12 3 R 85 83 83 83 YCrL 4 Comp 0064HE 0074HE 0084HE 0118HE S 3 5 4 5 4 5 4 5 T 116 7 115 7 118 3 115 7 U 24...

Page 84: ...3 12 3 12 3 R 102 102 102 102 0 102 0 H for 200 230 volt units which require a larger electrical enclosure YCrL 6 Comp 0096HE 0126HE 0156HE 0177SE 0198SE S 7 7 7 7 0 7 0 T 135 8 137 6 135 8 135 8 135...

Page 85: ...RED BLACK 0074HE 3261 3531 797 913 CP 1D 1200 GRAY RD 4 BRICK RED RED BLACK 0084HE 3439 3709 821 977 CP 1D 1200 GRAY RD 4 BRICK RED RED BLACK 0096HE 3753 4043 896 1112 CP 1D 1360 WHITE RD 4 BRICK RED...

Page 86: ...1D 510 510 1 02 BLACK CP1 1D 675 675 1 32 DK PURPLE CP1 1D 900 900 1 02 DK GREEN CP1 1D 1200 1200 0 9 GRAY CP1 1D 1360 1360 0 77 WHITE CP1 1D 1785N 1785 0 88 GRAY RED MODEL NUMBER RATED CAPACITY LBS R...

Page 87: ...uired leveling all isolator bases to the same elevation 1 4 inch maximum difference can be tolerated 4 Bolt or anchor all isolators to supporting structure utilizing base slotted holes C 5 Place equip...

Page 88: ...3000 0 5 60 RD 2 Lime WR 380 0 5 60 RD4 Charcoal WR 4000 0 5 70 RD2 Charcoal WR 550 0 5 70 LD13760A L AL DW BT HF AD THRU TYP 2 PLACES MOLDED DURULENE CD W Notes 1 All dimensions are inches interpret...

Page 89: ...SO THAT MOUNTING HOLES IN EQUIPMENT OR BASE LINE UP WITH THREADED HOLE C 6 REINSTALL TOP BOLT AND WASHER AND TIGHTEN DOWN 7 INSTALLATION IS COMPLETE INSTALLATION OF DURALENE VIBRATION ISOLATORS 1 Read...

Page 90: ...S IN SOLID LOAD LBS COLOR CODE ALLOWABLE G RATING HORIZONTAL Y2RSI 2D 150 150 2 42 62 234 WHITE 34 7 Y2RSI 2D 320 320 2 29 140 490 YELLOW 16 3 Y2RSI 2D 460 460 2 30 200 688 GREEN 11 3 Y2RSI 2D 710 710...

Page 91: ...INIMUM 3 8 FILLET WELDS 2 LONG 3 O C FOR A MINIMUM TOTAL WELD OF 10 ALL SIDES OF EQUIPMENT OR BRACKET RESTING ON TOP PLATE A MUST BE WELDED LD13763A SEISMIC ISOLATOR INSTALLATION AND ADJUSTMENT 1 Read...

Page 92: ...JOHNSON CONTROLS 92 FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 5 TECHNICAL DATA THIS PAGE INTENTIONALLY LEFT BLANK...

Page 93: ...ating pressure is fed to pressure transducers Open the liquid line 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...

Page 94: ...w through the cooler The inlet should be at the refrigerant piping connection end of the cooler Purge air from the top of the cooler using the plugged air vent mounted on the top of the cooler body Fl...

Page 95: ...metal chips etc EQUIPMENT PRE START UP AND START UP CHECKLIST 8 Visually inspect wiring power and control Wiring MUST meet N E C and local codes 9 Check tightness of power wiring inside the power pane...

Page 96: ...to compressor failure 6 Turn system 1 OFF and system 2 ON refer to Option 2 under Unit Keys on Page 123 for more information on system switches Place the Unit Switch in the control panel to the ON po...

Page 97: ...56 C 8 33 C 18 46 cm from the heat exchanger Superheat should typically be set for no less than 10 F with only a single com pressor running on a circuit The superheat is calculated as the difference b...

Page 98: ...he system with the shortest average run time of the compressors will be assigned as the lead sys tem A new lead lag assignment is made whenever all systems shut down 4 After 1 minute of compressor run...

Page 99: ...led to function as a single microprocessor controller requiring no addi tional hardware The IPU II board contains a coldfire microprocessor and is the controller and decision mak er in the control pan...

Page 100: ...ating parameters as well as access programmed information already in memory The display has a lighted background for night viewing and for viewing in direct sunlight When a key is pressed such as the...

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

Page 102: ...scharge Pressure Cutout due to high load or pull down conditions When the unload point is reached the microprocessor will automatically unload the affected system by de ener gizing one compressor The...

Page 103: ...inputs to the microboard The fault condition is cleared when a 30VDC signal is restored to the input S Y S 1 P U M P I N G D O W N S Y S 2 P U M P I N G D O W N The PUMPING DOWN message indicates tha...

Page 104: ...is allowed after the unit is fully powered again and the anti recycle timers have finished counting down The internal motor protector opens between 185 F and 248 F 85 C and 120 C and auto resets On 6...

Page 105: ...o panel power up the RTC battery is checked If a low battery is found all programmed setpoints program values options time schedule and history buffers will be lost These values will all be re set to...

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

Page 107: ...d through by using the UP and DOWN arrow keys or the ENTER ADV key located under the ENTRY section System 2 information will only be dis played for 2 system units DISPLAY PRINT KEYS With the UNIT TYPE...

Page 108: ...iled description of unit loading and unloading is covered under the topic of Capacity Control L O A D T I M E R 5 8 S E C U N L O A D T I M E R 0 S E C C O O L I N G D E M A N D 2 O F 8 S T E P S The...

Page 109: ...t of the use of software common to YCA YCRL and YCW chillers E V A P O R A T O R H E A T E R S T A T U S I S X X X This display indicates the status of the evaporator heater The evaporator heater is c...

Page 110: ...he following figure is a quick reference list for infor mation available under the OPER DATA key Figure 32 OPERATION DATA Block of information repeats for each system LD12585B Oper Data Key Leaving an...

Page 111: ...2 DEFROST INIT TEMP 41 0 DEGF DEFROST INITIATION TIME 60MIN DEFROST TERMINATION TIME 3MIN BIVALENT HEAT DELAY TIME 30 MIN REMOTE UNIT ID PROGRAMMED 2 YORK HYDRO KIT PUMPS 1 410a PUMP TOTAL RUN HOURS X...

Page 112: ...ressing the PRINT key and then the HISTORY key allows the operator to obtain a printout of information relating to the last nine Safety Shutdowns which oc curred The information is stored at the insta...

Page 113: ...of the fault L E A D S Y S T E M I S S Y S T E M N U M B E R X Displays which system is in the lead at the time of the fault C O N T R O L M O D E L E A V I N G L I Q U I D Displays the type of chille...

Page 114: ...d S Y S X L L S V I S X X X H O T G A S S O L I S X X X Displays whether the System Liquid Line Solenoid or Hot Gas Solenoid was energized at the time of the fault S Y S X F A N S T A G E X X X This m...

Page 115: ...The UP arrow key and DOWN arrow key are also used for programming the control panel such as changing numerical or text values when programming ENTRY KEYS Cooling Setpoints setting the Daily Schedule...

Page 116: ...uid will be displayed for a few seconds and the set point display entry screen will appear SETPOINTS KEYS 00069VIP Leaving Chilled Liquid Control S E T P O I N T 4 5 0 F R A N G E 2 0 F The above mess...

Page 117: ...the SETPOINT to be in the center of the control range If the control mode has been pro grammed for RETURN LIQUID control the message below would be displayed in place of the previous message When in L...

Page 118: ...scribed above for the days of the week After changing the meridian of the stop time pressing the ENTER ADV key will advance the schedule to the following display S __ M T W T F S H O L I D A Y N O T E...

Page 119: ...form water cooling There are some exceptions when the suc tion pressure is permitted to temporarily drop below the cutout point Details are explained under the System Safeties topic L O W A M B I E N...

Page 120: ...or RLA s total 100A 5V x 100A x 1 25 625VA 2 8V 225A 225A The programmed value will be 2 8V A similar calcula tion and programming will be necessary for the other system in a 2 system chiller T O T A...

Page 121: ...ALUE MODE LOW LIMIT HIGH LIMIT DEFAULT Discharge Pressure Cutout 325 PSIG 575 PSIG 570 PSIG 22 4 BARG 39 6 BARG 39 3 BARG Suction Pressure Cutout Water Cooling 80 0 PSIG 120 0 PSIG 80 0 PSIG 5 52 BARG...

Page 122: ...Temp Control and Pressure Display Only Holiday Cutout Schedule Chilled Liquid Suction Setpoint Pressure and Cutout Range Remote Setpoint Low Ambient Temp and Cutout Range Display Only Leaving Liquid E...

Page 123: ...er programmable options under the OPTIONS key The OPTIONS key is used to scroll through the list of options by repeatedly pressing the OPTIONS key After the selected option has been dis played the UP...

Page 124: ...E T U R N L I Q U I D Unit control is based on return chilled liquid temp Return 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...

Page 125: ...ller Option 10 Manual Override Mode M A N U A L O V E R R I D E M O D E D I S A B L E D This option allows overriding of the Daily Schedule that is programmed MANUAL OVERRIDE MODE DISABLED indicates t...

Page 126: ...h Card is used instead of an EPROM Normally a Flash Card update is not required and the message above will be displayed If the operating software is to be updated insert the Flash Card into the Flash...

Page 127: ...er Option 20 Pump Selection The displays for this PUMP SELECTION option should only appear if YORK HYDRO KIT PUMPS 2 are selected under Option 19 This option should not be used on a YCRL chiller Clock...

Page 128: ...Leaving Display Units English or Metric System Lead Lag Control Manual or Automatic Fan Control Mode Manual Override Mode Current Feedback Option Soft Start Option Unit Type Chiller MUST be Selected...

Page 129: ...loading will occur when the discharge pressure on the affected system drops to 85 of the unload pres sure and 10 minutes have elapsed This control is only applicable if optional discharge pressure tra...

Page 130: ...time was greater than 5 minutes no action is to be taken If the last run time for the lead system was less than 5 min utes the microprocessor will increase the setpoint high limit according to the ch...

Page 131: ...e cooling range can be from 4 F to 20 F 2 2 to 11 1 C As an example of compressor staging refer to Table 18 on page 132 a chiller with six compressors using a Cooling Setpoint programmed for 45 F 7 20...

Page 132: ...o times in a row The microprocessor will not attempt to equalize run time on individual compressors within a system Each compressor in a system will be assigned an ar bitrary number 1 or 2 The non run...

Page 133: ...s but one in the system will be shut off The LLSV will also be turned off The final compressor will be allowed to run until the suction pressure falls below the cutout or for 180 seconds whichever com...

Page 134: ...e locally programmed value The new Chilled Liquid Setpoint is calculated by the following equation Setpoint Local Chilled Liquid Setpoint reset Reset Contact Closure 1 x Max Reset Value 10 Example Loc...

Page 135: ...n a Johnson Controls remote condenser type VDC is used with a YCRL chiller the VDC must be ordered and installed with the Head Pressure Control High Pressure option which provides Johnson Controls mod...

Page 136: ...JOHNSON CONTROLS 136 FORM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 8 UNIT OPERATION THIS PAGE INTENTIONALLY LEFT BLANK...

Page 137: ...e respective output status shown For example SECTION 9 SERVICE AND TROUBLESHOOTING CLEARING HISTORY BUFFERS The history buffers may be cleared by pressing the HISTORY key and then repeatedly pressing...

Page 138: ...TIME FEATURE SET PUMP CONTROL SELECTION HOT GAS TYPE UNIT TYPE SYS 1 HOURS SYS 2 HOURS SYS 1 STARTS SYS 2 STARTS The last displays shown on the above list are for the accumulated run and start timers...

Page 139: ...3 8 CR1 Sys 1 Motor Protector High Pressure Cutout J13 10 CR2 Sys 2 Motor Protector High Pressure Cutout Table 21 I O DIGITAL OUTPUTS TB7 2 SYS 1 Compressor 1 TB7 3 SYS 1 Liquid Line Solenoid Valve TB...

Page 140: ...RM 150 27 NM1 ISSUE DATE 09 30 2015 SECTION 9 SERVICE AND TROUBLESHOOTING Figure 37 MICROBOARD LAYOUT TB5 TB1 TB6 TB7 TB8 TB9 TB10 J14 J13 J12 J15 J11 J10 J9 J8 J7 J6 J5 J3 I O BOARD IPU BOARD JP1 LD1...

Page 141: ...nit case ground Following are the connec tions for the temperature sensing inputs Liquid and Refrigerant Sensor Test Points Entering Chilled Liquid Sensor J6 5 5VDC regulated supply to sensor J6 8 VDC...

Page 142: ...0 100 1 5 162 5 1 5 150 2 0 243 75 2 0 200 2 5 325 2 5 250 3 0 406 25 3 0 300 3 5 487 75 3 5 350 4 0 568 75 4 0 400 4 5 650 4 5 Red Wire 5V Black wire 0V White Green Wire signal TEST POINTS Suction Pr...

Page 143: ...spond to specific suction pressures J7 9 5VDC return J7 11 drain shield connection 0VDC Digital Outputs Refer to the unit wiring diagram and Figure 38 on page 143 The digital outputs are located on TB...

Page 144: ...ontrols is P N 950915576 The cable to connect the printer can either be locally as sembled from the parts listed or ordered directly from WEIGH TRONIX under part number 287 040018 Parts The following...

Page 145: ...rer 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 F...

Page 146: ...r rotation Verify compressor is not overloaded 2 External overload tripped 2 Determine cause and reset 3 HPCO switch open 3 See High Press Disch Fault 4 Defective HPCO switch 4 Replace HPCO switch 5 D...

Page 147: ...OE oil If the oil color darkens or exhibits a change in color this may be an indication of contami nants in the refrigerant system If this occurs an oil sample should be taken and analyzed If contamin...

Page 148: ...S 232 connect to TB3 Network RX to TB3 TXD Network TX to TB3 RXD Network GND to TB3 GND Refer to Figure 40 on page 149 Micro Panel Con nections for TB1 TB2 and TB3 locations In most cases communicatio...

Page 149: ...76800 4800 1200 4800 9600 19200 38400 76800 Auto Selectable P2 Baud Rate 1200 57600 1200 1200 4800 9600 19200 38400 57600 Selectable P1 P2 Manual Mac Address 1 127 1 P1 P2 Parity None Ignore None None...

Page 150: ...RIPTION Protocol BACnet MS TP Modbus RTU5 YorkTalk 2 DE Modifier Address 0 to 41943 3 1 1 DE Modifier Offset 0 to 99 4 0 N A P1 Protocol BACNET N A N A P1 Manual Mac Address 0 127 1 N A N A P1 Baud Ra...

Page 151: ...itor Only Points This data can be read using a BACnet or Modbus net work connection and can NOT be modified using this connection The Modbus Register Address for these points is 1281 BI Refer to Table...

Page 152: ...1_CIR_TEMP AI_10 523 03 04 F R Sys 1 Cooler Inlet Refrigerant Temp R 407c Models Only S S S S S S S S S S 28 S1_DEF_TEMP AI_11 524 03 04 F R Sys 1 Defrost Temperature HP Only S S S S S S S S S S 29 S1...

Page 153: ...57 03 04 F R Setpoint 2 SP Control S S S S S S S S S S 62 HEAT_SETP AI_45 558 03 04 F R Heating Setpoint HP Only S S S S S S S S S S 63 SP_CTL_RG_S2 AI_46 559 03 04 F R Cooling Range 2 SP Control S S...

Page 154: ...y not be available on all models Please check the Fault and Operational codes against the codes published in your operators manual or confirm Code is available through the display of your unit If the...

Page 155: ...trol values Table 31 on page 156 Yorktalk 2 Communications Data Map lists the con trol parameters These values are found under feature 54 in the MicroGateway or E Link Transmitted Data After receiving...

Page 156: ...8 51 ADF 15 Sys 1 Cooler Inlet Refrigerant Temperature R 407c Only S S S S S P21 P22 P20 A Monitor nvoYTS01p022 SNVT_count_f 51 52 55 ADF 16 P22 P23 P21 A Monitor nvoYTS01p023 SNVT_count_f 51 56 59 AD...

Page 157: ...3 SNVT_count_f 51 135 ADI 8 Sys 2 Condenser Fan Stage S S S S S P63 P64 P62 Code Monitor nvoYTS01p064 SNVT_count_f 51 136 ADI 9 P64 P65 P63 Code Monitor nvoYTS01p065 SNVT_count_f 51 137 ADI 10 Unit Co...

Page 158: ...hase Rotation 14 14 Discharge Limiting 14 14 Low Motor Current MP HPCO 15 15 Current Limiting 15 15 Motor Current Inpomabalanced 16 16 Load Limiting 16 16 Low Differntail Oil Pressure 17 17 Compressor...

Page 159: ...4 196 91 1 80 176 200 93 3 82 179 6 204 95 6 84 183 2 208 97 8 86 186 8 212 100 0 88 190 4 216 102 2 90 194 220 104 4 92 197 6 224 106 7 94 201 2 228 108 9 96 204 8 232 111 1 98 208 4 236 113 3 100 2...

Page 160: ...30 120 41 20 28 125 43 22 26 130 45 24 24 135 47 26 20 140 49 28 18 145 51 30 16 150 53 32 14 160 57 34 12 170 60 36 10 180 64 38 8 190 67 40 6 200 70 42 4 210 73 44 3 220 76 46 2 225 78 48 0 235 80 5...

Page 161: ...ange Table 32 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effect ton 3 516 Kilowatts kW Power Horsepower 0 7457 Kilowatts kW Flow R...

Page 162: ...USA 17405 1592 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2015 www johnsoncontrols com ALL RIGHTS RESERVED Form 150 27 NM1 915 Issue Date September 30...

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