York YVAA Style A Page 1 Installation Operation & Maintenance Download

Page: 1 / 184

Air-Cooled Screw Liquid Chillers

Installation, Operation, Maintenance

Supersedes: 201.28-NM1.1 (321)

Form 201.28-NM1.1 (821)

HFC-134A or R-513A

525 kW to 1750 kW

2 Compressor

50 Hz and 60 Hz

Model YVAA Style A

Air-Cooled Screw Liquid Chillers with Variable Speed Drive

Frame Sizes 015 – 052

150 ton to 500 ton

035-23219-100

Issue Date:

August 6, 2021

Summary of Contents for YVAA Style A

Page 1: ...persedes 201 28 NM1 1 321 Form 201 28 NM1 1 821 HFC 134A or R 513A 525 kW to 1750 kW 2 Compressor 50 Hz and 60 Hz Model YVAA Style A Air Cooled Screw Liquid Chillers with Variable Speed Drive Frame Si...

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

Page 3: ...il 2012 201 28 RP1 YVAA Style A Frame Size 015 052 2 Compressor 50 60 Hz 150 500 Tons Manufactured after April 2012 to before September 2014 201 28 RP2 YVAA Style B Frame Size 015 052 2 Compressor 50...

Page 4: ...remove the AC supply feeding the chiller and verify using a non contact voltage sensor The DC voltage on the VSD DC Bus will take 5 minutes to bleed off after AC power is removed Always check the DC...

Page 5: ...ssories and options 19 Fan options 19 Condenser coils 19 Section 3 Rigging handling and storage 23 Lifting weights 23 Delivery and storage 23 Inspection 24 Moving the chiller 24 Unit removal from ship...

Page 6: ...inch deflection restrained spring isolator specifications 95 Section 6 Commissioning 97 Preparation 97 First time startup 100 General operation 100 Section 7 Operation 103 Operating controls 103 Basic...

Page 7: ...rigerant removal evacuation and charging a YVAA chiller 166 Microchannel coil cleaning 167 Thermal dispersion flow switch 169 Maintenance requirements for YVAA chillers 170 R 134a conversion table 174...

Page 8: ...evaporator minimum allowable flow rate 41 Figure 11 Suggested layout for applications with a flow rate greater than the evaporator maximum allowable flow rate 41 Figure 12 Grooved nozzle 41 Figure 13...

Page 9: ...data map 118 Table 17 Flash card update error XXXXX 123 Table 18 Low differential oil pressure cutout 128 Table 19 Discharge pressure load limiting unloading 129 Table 20 Suction pressure load limiti...

Page 10: ...JOHNSON CONTROLS 10 FORM 201 28 NM1 1 ISSUE DATE 12 18 2020 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 11: ...to Form 50 05 NM2 Johnson Controls warrants all equipment and materials against defects in workmanship and ma terials for a period of eighteen months from date of shipment or 12 months from date of s...

Page 12: ...ted time of 100 years based on IPCC 5th report 2013 Table 8 A 1 The refrigerant quantity is as stated in Table 5 on page 64 of this document The fluorinated greenhouse gases in this equip ment may not...

Page 13: ...designed and manufactured for use in an industrial environment in accordance with EN 61000 6 2 2005 and EN 61000 6 4 2007 with EN 55011 2007 limits It is not intended to be used on a low voltage publ...

Page 14: ...pply circuit breaker with a red and yel low handle which can be used as the emergency stop device When operated it removes the electrical supply to the inverter fans and control circuit thus shutting...

Page 15: ...t General system description The YVAA Chiller combines the best of modern screw compressor design with the latest technology in vari able speed drives The result is superior control and efficiency in...

Page 16: ...et the load and the compressors to the speed requested by the chiller mi croprocessor The basic system control and VSD system architecture is shown in Figure 2 on page 16 Figure 2 Chiller control syst...

Page 17: ...blades molded into low noise full airfoil cross sec tions providing vertical air discharge from extended orifices for efficiency and low sound Fan motors are Totally Enclosed Air Over TEAO squirrel c...

Page 18: ...equency ranging from 30 seconds to almost continu ous monitoring The microprocessor controls the unit s capacity by matching the actual leaving chilled water tempera ture LCWT to the user defined setp...

Page 19: ...r power motors suitable for high external static pressure up to 100 Pa 0 4 water across condenser coils This option should be selected if ad ditional airflow resistance may be present due to flow rest...

Page 20: ...rements for protection against freeze damage Controls Options High Ambient Operation This provides special control logic coupled with high airflow fans to permit high ambient up to 52 C 125 F operatio...

Page 21: ...rcuit breaker is sized to provide motor branch circuit protec tion short circuit protection and ground fault protec tion for the motor branch circuit conductors the motor control apparatus and the mot...

Page 22: ...JOHNSON CONTROLS 22 FORM 201 28 NM1 1 ISSUE DATE 12 18 2020 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 23: ...r connec tions are securely capped Do not store where exposed to high ambient air temperatures that may exceed relief valve set tings Refer to Long Term Storage Requirement Field Preparation Form 50 2...

Page 24: ...p Slightly lift the front of the unit to remove some weight from the floor of the container Continue pulling the unit with an operator on each side to guide the lift truck operator 4 Pull the unit unt...

Page 25: ...Section 3 Rigging handling and storage JOHNSON CONTROLS 25 FORM 201 28 NM1 1 ISSUE DATE 12 18 2020 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 26: ...60 143 227 272 mm 464 1533 3636 5761 6920 019 8 B Rigging hole location in 18 60 137 215 302 mm 464 1533 3484 5455 7670 020 0 C Rigging hole location in 18 60 131 214 mm 464 1518 3332 5430 021 3 A Ri...

Page 27: ...on in 18 60 143 227 272 mm 464 1533 3636 5761 6920 019 8 B Rigging hole location in 18 60 137 215 302 mm 464 1533 3484 5455 7670 020 0 C Rigging hole location in 60 131 214 mm 1518 3332 5430 021 3 A R...

Page 28: ...70 027 3 D Rigging hole location in 12 73 121 181 264 324 mm 314 1845 3073 4601 6717 8217 027 5 E Rigging hole location in 12 73 121 181 264 324 mm 314 1845 3073 4601 6717 8218 027 8 E Rigging hole lo...

Page 29: ...670 027 3 D Rigging hole location in 12 73 121 181 264 324 mm 314 1845 3073 4601 6717 8218 027 5 E Rigging hole location in 12 73 121 181 264 324 mm 314 1845 3073 4601 6717 8218 027 8 E Rigging hole l...

Page 30: ...254 306 391 mm 314 1845 4144 6443 7765 9942 034 3 E Rigging hole location in 12 73 121 181 243 296 391 mm 314 1845 3073 4602 6170 7511 9942 034 5 E Rigging hole location in 12 73 121 181 243 353 435...

Page 31: ...254 306 391 mm 314 1845 4144 6443 7765 9942 034 3 E Rigging hole location in 12 73 121 181 243 296 391 mm 314 1845 3073 4602 6170 7511 9942 034 5 E Rigging hole location in 12 73 121 181 243 353 435...

Page 32: ...290 435 478 545 mm 314 1845 4602 6039 7662 11059 12135 13835 047 5 J Rigging hole location in 12 73 181 238 290 435 494 572 mm 314 1845 4602 6039 7358 11059 12546 14541 048 3 G Rigging hole location i...

Page 33: ...n 12 73 181 238 290 435 478 545 mm 314 1845 4602 6039 7358 11059 12135 13835 047 5 J Rigging hole location in 12 73 181 238 290 435 494 572 mm 314 1845 4602 6039 7358 11059 12546 14541 048 3 G Rigging...

Page 34: ...JOHNSON CONTROLS 34 FORM 201 28 NM1 1 ISSUE DATE 12 18 2020 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 35: ...m mended for rooftop locations Mounting holes 5 8 in are provided in the base rails for bolting the unit to its foundation See Table 10 on page 84 for location of the mounting holes Any ductwork or at...

Page 36: ...ond Evap in mm in mm in mm 015 3 B 26 663 36 914 132 3353 016 5 B 26 663 36 914 132 3353 017 8 C 26 663 36 914 156 3962 018 3 A 26 663 36 914 144 3658 019 5 A 26 663 36 914 144 3658 019 8 B 26 663 36...

Page 37: ...ed to Terminals 2 and 13 on the 1TB terminal block A flow switch is required to prevent damage to the evaporator caused by the unit operating without adequate liquid flow The flow switch used must hav...

Page 38: ...r power loss Johnson Controls requires that the evaporator is drained or that water in the chilled water circuit be replaced with an appropriate water to glycol concentration Any debris left in the wa...

Page 39: ...ure 6 Two pass water pressure drop English units Figure 7 Three pass water pressure drop English units 200 400 600 800 1000 1200 0 0 10 0 20 0 30 0 40 0 50 0 Water Temperature 50 F Water Pressure Drop...

Page 40: ...ed water loop This increases the thermal mass and flywheel effect within the system that is the more the better which in turn promotes stable water temperature control and increases reliabil ity by re...

Page 41: ...lso can result in significant energy cost sav ings The YVAA has special control logic to be able to pro duce chilled leaving brine temperatures below 4 4 C 40 F so as to supply a storage tank with chi...

Page 42: ...2 027 5 E 8 DN200 221 5 27 345 298 5 22 270 8 2 027 8 E 8 DN200 221 5 27 345 298 5 22 270 8 2 029 5 E 8 DN200 221 5 27 345 298 5 22 270 8 2 030 3 C 6 DN150 170 5 27 280 241 5 22 216 8 2 030 5 C 6 DN1...

Page 43: ...ding The size of any piping attached to a relief valve must be of sufficient diameter so as not to cause resistance to the operation of the valve Unless otherwise specified by local regulations Intern...

Page 44: ...er Caulk power and control wiring conduit entering the power panel to ensure moist air from the building cannot enter the panel Power supply wiring Units require only one 3 phase supply plus earth Con...

Page 45: ...p of the horizontal pipes only if the pipe is fully filled with liquid Mount the thermal dispersion flow switch on the bottom of the horizontal pipes only if the pipe is free from buildup Ensure that...

Page 46: ...tage Utilization range 200 60 3 180 220 230 60 3 208 254 380 60 3 342 418 400 60 3 360 440 460 60 3 414 508 575 60 3 520 635 400 50 3 360 440 Power supply wiring Single point wiring LD18588a UNIT MOUN...

Page 47: ...M 1 COMPRESSOR SYSTEM 1 COMPRESSOR SYSTEM 2 L1 L2 L3 PE GND PE GND L1 L2 L3 380 415 3 50 460 3 60 380 415 3 50 460 3 60 SEE NOTE 1 SEE NOTE 1 SEE NOTE 1 FIELD PROVIDED UNIT POWER SUPPLY FIELD PROVIDED...

Page 48: ...OR CUSTOMER CONNECTIONS TERMINAL BLOCK FOR YORK CONNECTIONS WIRING AND COMPONENTS BY YORK OPTIONAL EQUIPMENT WIRING AND OR COMPONENTS BY OTHERS RELAY BOARD No 2 RELAY BOARD No 1 CONTROL BOARD Customer...

Page 49: ...1 1 2 IN PIPE COUPLING 1 13 1 88 13 2 2 VSD RED WHT RED BLK RED YEL NOT USED RED TO 115 V AC SUPPLY TO FLOW SWITCH INPUT TERMINALS 2 AND 13 Flow switch connections Wire color Connection in VSD panel R...

Page 50: ...der low ambient The customer needs to break the reserved customer wiring entry as shown in Figure 19 with the wiring going through an appropriate 90 degrees con duit After connecting the wires water p...

Page 51: ...en the evaporator is filled with water in waterside The recommended power supply wiring size is 18 4 AWG Before turning on the breaker make sure the evaporator is filled with water Misop eration will...

Page 52: ...0 kcmil 3 2 600 kcmil 400 50 2 2 600 kcmil 2 1 500 kcmil 3 2 600 kcmil 460 60 2 2 600 kcmil 2 1 500 kcmil 2 2 600 kcmil 575 60 2 2 600 kcmil 2 1 500 kcmil 2 2 600 kcmil 019 5 A 200 60 4 2 600 kcmil 23...

Page 53: ...600 kcmil 400 50 3 2 600 kcmil 3 3 0 400 kcmil 3 2 600 kcmil 460 60 2 2 600 kcmil 2 1 500 kcmil 3 2 600 kcmil 575 60 2 2 600 kcmil 2 1 500 kcmil 2 2 600 kcmil 019 5 A 200 60 4 1 0 700 kcmil 230 60 4 2...

Page 54: ...2 600 kcmil 400 50 3 2 600 kcmil 3 3 0 400 kcmil 3 2 600 kcmil 460 60 2 2 600 kcmil 2 1 500 kcmil 3 2 600 kcmil 575 60 2 2 600 kcmil 2 1 500 kcmil 2 2 600 kcmil 026 3 B 200 60 4 2 600 kcmil 230 60 4...

Page 55: ...3 0 400 kcmil 3 2 600 kcmil 460 60 3 2 600 kcmil 3 3 0 400 kcmil 3 2 600 kcmil 575 60 2 2 600 kcmil 2 1 500 kcmil 2 2 600 kcmil 026 3 B 200 60 4 1 0 700 kcmil 230 60 4 2 600 kcmil 4 4 0 500 kcmil 380...

Page 56: ...il 4 4 0 500 kcmil 4 2 600 kcmil 400 50 3 2 600 kcmil 4 4 0 500 kcmil 3 2 600 kcmil 460 60 3 2 600 kcmil 3 3 0 400 kcmil 3 2 600 kcmil 575 60 3 2 600 kcmil 3 3 0 400 kcmil 3 2 600 kcmil 031 8 E 200 60...

Page 57: ...00 50 4 2 600 kcmil 4 4 0 500 kcmil 4 2 600 kcmil 460 60 3 2 600 kcmil 4 4 0 500 kcmil 3 2 600 kcmil 575 60 3 2 600 kcmil 3 3 0 400 kcmil 3 2 600 kcmil 031 8 E 200 60 230 60 380 60 4 2 600 kcmil 4 4 0...

Page 58: ...l 3 3 0 400 kcmil 3 3 0 400 kcmil 400 50 3 2 600 kcmil 3 3 0 400 kcmil 3 3 0 400 kcmil 460 60 2 2 600 kcmil 2 1 500 kcmil 2 1 500 kcmil 575 60 2 2 600 kcmil 2 1 500 kcmil 2 1 500 kcmil 041 3 H 200 60...

Page 59: ...3 2 600 kcmil 3 3 0 400 kcmil 3 3 0 400 kcmil 460 60 2 2 600 kcmil 3 3 0 400 kcmil 3 3 0 400 kcmil 575 60 2 2 600 kcmil 2 1 500 kcmil 2 1 500 kcmil 041 3 H 200 60 230 60 380 60 3 2 600 kcmil 3 3 0 40...

Page 60: ...500 kcmil 2 1 500 kcmil 575 60 2 2 600 kcmil 2 1 500 kcmil 2 1 500 kcmil 49 0 K 200 60 230 60 380 60 3 2 600 kcmil 3 3 0 400 kcmil 3 3 0 400 kcmil 400 50 3 2 600 kcmil 3 3 0 400 kcmil 3 3 0 400 kcmil...

Page 61: ...phase Lug wire range Wires per phase Lug wire range Wires per phase Lug wire range Frame Cond Evap Dual point wiring 048 3 G 200 60 230 60 380 60 3 2 600 kcmil 3 3 0 400 kcmil 3 3 0 400 kcmil 400 50 3...

Page 62: ...JOHNSON CONTROLS 62 FORM 201 28 NM1 1 ISSUE DATE 12 18 2020 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 63: ...a shown within the tables of this chapter are applicable to selected typical configurations Other configurations are available through our configuration and selection software Contact your nearest Joh...

Page 64: ...10 Chassis Dimensions Length in mm 203 3 5163 247 2 6280 291 2 7397 247 6274 291 2 7397 335 2 8514 226 5741 291 2 7397 291 2 7397 335 2 8514 Chassis Dimensions Width in mm 88 3 2242 88 3 2242 88 3 22...

Page 65: ...94 6 2403 94 6 2403 94 6 2403 94 6 2403 94 6 2403 94 6 2403 94 6 2403 94 6 2403 94 6 2403 94 6 2403 Compressors semi hermetic screw Qty per Chiller 2 Condenser fans Number Ckt 1 Ckt 2 7 5 8 6 8 8 7 7...

Page 66: ...0 Minimum Load 10 Chassis Dimensions Length in mm 423 1 10748 423 1 10748 467 1 11865 379 2 9631 423 1 10748 423 1 10748 467 1 11865 511 12979 467 1 11864 Chassis Dimensions Width in mm 88 3 2242 88 3...

Page 67: ...mm 94 7 2405 94 7 2405 94 7 2405 94 7 2405 94 7 2405 94 7 2405 94 7 2405 94 7 2405 94 6 2403 94 7 2405 94 7 2405 Compressors semi hermetic screw Quantity in each chiller 2 Condenser fans Number Ckt 1...

Page 68: ...3 0 14 0 11 4 Minimum Load 10 Chassis Dimensions Length in mm 203 3 5163 247 6274 226 5740 291 2 7397 291 2 7397 335 2 8514 291 2 7397 335 2 8514 379 2 9631 Chassis Dimensions Width in mm 88 3 2242 88...

Page 69: ...403 94 6 2403 94 7 2405 94 7 2405 94 7 2405 94 7 2405 94 6 2403 94 7 2405 94 7 2405 Compressors semi hermetic screw Qty per Chiller 2 Condenser fans Number Ckt 1 Ckt 2 8 8 9 9 9 9 13 7 12 8 12 12 13 1...

Page 70: ...0 138 18 3 19 8 503 17 7 450 56 8 1443 6 48 182 400 25 1230 77 19 5 19 8 503 61 5 1562 56 7 1440 6 48 182 400 25 1230 77 19 8 21 533 117 3 2979 56 1 1425 8 58 220 500 32 1970 124 20 0 20 8 528 1 7 43...

Page 71: ...0 138 26 3 21 533 117 1 2974 56 1 1425 8 58 220 500 32 1970 124 27 0 21 533 16 8 427 51 9 1318 8 82 310 590 37 2190 138 27 3 21 533 42 9 1090 70 1778 8 82 310 590 37 2190 138 27 5 22 5 572 44 7 1135 7...

Page 72: ...810 51 3200 202 33 3 21 533 166 9 4239 70 1778 8 71 269 590 37 2190 138 34 3 22 5 572 132 6 3368 71 8 1824 10 113 428 810 51 3200 202 34 5 22 5 572 176 21 4476 71 8 1824 10 113 428 810 51 3200 202 36...

Page 73: ...6 1090 69 3420 215 44 3 22 3 566 287 1 7292 94 2 2393 10 96 363 840 53 3320 209 47 5 23 3 592 308 4 7833 71 5 1816 10 147 556 1090 69 3420 215 48 3 22 3 566 331 2 8412 94 2 2393 10 96 363 840 53 3320...

Page 74: ...790 50 19 5 14 1 358 11 4 290 61 5 1562 6 56 7 1440 48 182 200 13 790 50 19 8 15 3 389 11 4 290 117 3 2979 6 56 1 1425 58 220 250 16 980 62 20 0 15 1 384 11 4 290 1 7 43 6 38 1 968 71 269 300 19 1170...

Page 75: ...980 62 27 0 15 3 388 11 4 290 16 8 427 6 51 9 1318 82 310 300 19 1170 74 27 3 15 3 389 11 4 290 42 9 1090 6 70 1778 82 310 300 19 1170 74 27 5 15 5 394 14 356 44 3 1125 8 71 8 1824 113 428 410 26 160...

Page 76: ...3 389 11 4 290 166 9 4239 6 83 4 2118 71 269 300 19 1170 74 34 3 15 5 394 14 356 132 2 3358 8 83 4 2118 113 428 410 26 1600 101 34 5 15 5 394 14 356 176 2 4475 8 83 4 2118 113 428 410 26 1600 101 36 8...

Page 77: ...3 330 287 1 7292 282 5 7177 8 94 2 2393 89 7 2278 96 363 420 26 1660 105 47 5 16 3 414 14 356 308 4 7833 8 71 5 1816 147 556 550 35 2160 136 48 3 15 8 401 13 330 331 2 8412 326 6 8296 8 94 2 2393 89 7...

Page 78: ...33 19 5 14 1 358 25 5 648 61 5 1562 56 7 1440 5 48 182 130 8 520 33 19 8 15 3 389 26 7 678 117 3 2979 56 1 1425 5 58 220 170 11 650 41 20 0 15 1 384 26 53 674 1 7 43 38 1 968 6 71 269 200 13 780 49 21...

Page 79: ...49 26 3 15 3 389 26 7 678 117 1 2974 56 1 1425 5 58 220 170 11 650 41 27 0 15 3 388 26 7 678 16 8 427 51 9 1318 6 82 310 200 13 780 49 27 3 15 3 389 26 7 678 42 9 1090 70 1778 6 82 310 200 13 780 49 2...

Page 80: ...15 3 389 26 7 678 166 9 4239 70 1778 6 71 269 200 13 780 49 34 3 15 5 394 29 5 749 132 6 3368 71 8 1824 6 113 428 270 17 1060 67 34 5 15 5 394 29 5 749 176 2 4475 71 8 1824 6 113 428 270 17 1060 67 36...

Page 81: ...4 3 15 8 401 28 8 732 287 1 7292 94 2 2393 6 94 356 280 18 1100 69 47 5 16 3 414 30 3 770 308 4 7833 71 5 1816 8 147 556 370 23 1440 91 48 3 15 8 401 28 8 732 331 2 8412 94 2 2393 6 94 356 280 18 1100...

Page 82: ...s A pipe water outlet A pipe water inlet C B Power entry 10 in 254 mm wide X 13 in 330 mm high View B B View A A Control entry 3 0 in 76 mm wide X 11 5 in 292 mm high LD16178 VSD control panel 88 3 in...

Page 83: ...Section 5 Technical data JOHNSON CONTROLS 83 FORM 201 28 NM1 1 ISSUE DATE 12 18 2020 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 84: ...43 118 3000 157 3985 209 5299 308 7823 Isolator Y Dimension 1 34 020 0 C Isolator X Dimension 10 263 76 1943 118 3000 157 3985 209 5299 281 7136 Isolator Y Dimension 1 34 021 3 A Isolator X Dimension...

Page 85: ...ion 87 2206 020 0 C Isolator X Dimension 10 263 76 1943 118 3000 157 3985 209 5299 281 7136 Isolator Y Dimension 87 2206 021 3 A Isolator X Dimension 10 263 81 2057 149 3779 187 4756 251 6368 Isolator...

Page 86: ...187 4748 245 6232 339 8608 Isolator Y Dimension 1 34 030 5 C Isolator X Dimension 10 260 81 2057 144 3663 187 4755 277 7047 383 9726 Isolator Y Dimension 1 34 030 8 E Isolator X Dimension 10 260 81 20...

Page 87: ...5 C Isolator X Dimension 10 260 81 2057 144 3663 187 4755 277 7047 383 9726 Isolator Y Dimension 87 2206 030 8 E Isolator X Dimension 10 260 81 2054 161 4081 201 5102 298 7579 383 9723 Isolator Y Dime...

Page 88: ...J Isolator X Dimension 10 260 81 2054 145 3677 205 5216 284 7215 427 10839 505 12817 562 14262 Isolator Y Dimension 1 34 044 3 G Isolator X Dimension 10 263 81 2057 154 3907 206 5219 284 7218 427 1084...

Page 89: ...J Isolator X Dimension 10 260 81 2054 145 3677 205 5216 284 7215 427 10839 505 12817 562 14262 Isolator Y Dimension 87 2206 044 3 G Isolator X Dimension 10 263 81 2057 154 3907 206 5219 284 7218 427 1...

Page 90: ...ines match the equipment mounting holes The VMC group recommends that the isolator base A be installed on a level surface Shim or grout as required leveling all isolator bases to the same elevation 0...

Page 91: ...D DW Type A 029 25335 001 434002 5 50 139 7 3 38 85 85 2 88 73 15 4 13 104 90 0 56 14 22 0 25 6 35 1 2 13 UNC X 1 M27 X 3 2 50 63 50 Type B 029 25335 002 434004 Type B 029 25335 004 434005 6 25 158 75...

Page 92: ...isolator base B be in stalled on a level surface Shim or grout as re quired leveling all isolator bases to the same elevation 0 25 in maximum difference can be tolerated 3 Bolt or anchor all isolator...

Page 93: ...334 003 433669 Dark green 435 765 198 347 029 25334 003 029 25334 004 433670 Gray 766 1020 348 463 029 25334 004 029 25334 005 433871 White 1021 1156 464 524 029 25334 005 029 25334 006 433872 Gray Re...

Page 94: ...ousing These shims must be in place when the equipment is positioned over the isola tors 5 With all shims E in place position equipment on top of plate A of isolator 6 Bolt equipment securely to top p...

Page 95: ...tings 3 All springs are designed for 50 overload capacity with exception of the 029 25336 013 and 029 25336 014 4 Consult JCI for concrete installation Weight range lb Weight range kg Model P N Color...

Page 96: ...JOHNSON CONTROLS 96 FORM 201 28 NM1 1 ISSUE DATE 12 18 2020 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 97: ...Stable conditions are defined as operation without fan cycling economizer cycling VI solenoid cycling or any other system transient conditions Ideal refrigerant charge will be reached when the refrig...

Page 98: ...ify the chilled liquid system has been installed cor rectly and has been commissioned with the correct direction of water flow through the evaporator The inlet should be at the bottom connection on a...

Page 99: ...ure sensor is coated with heat conductive compound Part No 013 00890 000 and is inserted to the bottom of the water outlet sensor well in the evaporator This sensor is part of the pump control freeze...

Page 100: ...ure change If a high heat load is present the control ler will increase the speed of the compressors Condenser and fan rotation Once a compressor is running discharge pressure rises as refrigerant is...

Page 101: ...inuous power to the chiller control panel chilled fluid circuit pumps and evaporator heaters can be guaranteed during periods of subfreezing ambient temperatures then one of the freeze damage protec t...

Page 102: ...JOHNSON CONTROLS 102 FORM 201 28 NM1 1 ISSUE DATE 12 18 2020 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 103: ...s LD10605 Unit switch Keypad Display Figure 26 Keyboard and display The keypad also contains keys in the center section for data entry in the various program modes These keys are as follows 0 9 Keys N...

Page 104: ...mode and the numeric value entered was out of range the following message will appear for 2 seconds followed by the original data display XXXXXXXXXXX OUT OF RANGE TRY AGAIN XXXXXXXXXXXXXXXXXXXXXXXXXX...

Page 105: ...th the chilled water pump running and with the evaporator heaters well maintained are extremely crucial especially in subfreezing regions Chilled water pump control contains the logic of preventative...

Page 106: ...loped as a direct replacement for the 031 02478 xxx line of microboards No adapter harness is required when replacing a 02478 with the new 03478 The 03478 uses the IPUII processor card and provides so...

Page 107: ...ers the dis play and backlight and is regulated to become the 5 V TP5 15 V 11 3 VDC to 16 6 VDC powers the analog outputs to the EEV valves Configuration jumpers The same configuration jumpers that ex...

Page 108: ...cription Number Description 1 TP3 5 V 6 Power LED 11 Port 2 RX2 TX2 16 Port 1 Native BAS BACnet and N2 2 TP2 3 3 V 7 Status LED 12 PORT 2 RS 232 Printer or Modbus 17 TP1 GND 3 SD Card 8 Power LED 13 V...

Page 109: ...s number entered is multiplied by 100 set as required by network 2 DE Modifier Offset number entered is added to DE Modifier Address as required by network see 8 3 P1 Protocol set to BACNET Default Se...

Page 110: ...ired by the Modbus network 7 P2 Parity Set to NONE or as required by Modbus network 8 P2 Stop Bits Set to 1 9 P2 Hw Select Bit Set to RS 485 or RS 232 as required by Modbus network Cycle power to the...

Page 111: ...N A 9600 or 19200 N A P1 parity NONE N A NONE N A P1 stop bits 1 N A 1 N A P2 protocol N A MODBUS SVR N A N A P2 manual mac address N A 0 127 1 N A N A P2 baud rate N A 19 200 2 N A N A P2 parity N A...

Page 112: ...network connection The BACnet Name is a 12 character or shorter name used to identify the data in BACnet The AI AV BI and BV columns are indexes used to select the data The AI AV BI and BV number asso...

Page 113: ...the chiller will transmit either operational data or history buffer data depending on the History Buffer Request ENG PAGE 10 found in Table 13 on page 114 Data must be transmitted for every page If t...

Page 114: ...x10 ADF 14 F C Sys 1 Eductor Temperature S O O O O O 19 S2_EDT_TEMP AI11 524 03 04 x10 ADF 15 F C Sys 2 Eductor Temperature S O O O O O 20 S1_OIL_PRESS AI12 525 03 04 x10 ADF 16 PSI BAR Sys 1 Oil Pres...

Page 115: ...Sys 1 Subcooling Microchannel O O O O O O 56 S1_EVAP_LL AI48 561 03 04 x10 ADF 52 Sys 1 Evaporator Liquid Level Round Tube S S S S S S 57 S2_SUBCOOL AI49 562 03 04 x10 ADF 53 F diff C diff Sys 2 Subco...

Page 116: ...87 01 02 03 N A BD10 0 1 0 1 Sys 2 Compressor Run Status S S S S S S 98 S1_VI_STEP1 BI7 1288 01 02 03 N A BD11 0 1 0 1 Sys 1 VI Step Solenoid Valve 1 Status S S S S S S 99 S2_VI_STEP1 BI8 1289 01 02 0...

Page 117: ...oltage Unit 74 No Run Permissive 11 Low DC Bus Voltage Unit 75 Anti Recycle Timer Active 12 DC Bus Voltage Imbalance Unit 76 System Switch OFF 13 High VSD Ambient Temperature 77 System Not Running 14...

Page 118: ...Sys 1 Suction Pressure S S S S S S S P20 AV14 YT2_ S01_ P20 nvoYTS01p020 SNVT_count_f 51 ADF 14 0014 x10 PSI BAR Sys 1 Discharge Pressure S S S S S S S P21 AV15 YT2_ S01_ P21 nvoYTS01p021 SNVT_count_...

Page 119: ...S S S S S P61 MV6 YT2_ S01_ P61 nvoYTS01p061 SNVT_count_f 51 ADI 6 0035 x1 None None Sys 1 Condenser Fan Speed VSD O O O O O O O P62 MV7 YT2_ S01_ P62 nvoYTS01p062 SNVT_count_f 51 ADI 7 0036 x1 None...

Page 120: ...YT2_ S02_ P27 nvoYTS02p027 SNVT_count_f 51 ADF 64 0121 N N N N N N N P28 AV122 YT2_ S02_ P28 nvoYTS02p028 SNVT_count_f 51 ADF 65 0122 N N N N N N N P29 AV123 YT2_ S02_ P29 nvoYTS02p029 SNVT_count_f 5...

Page 121: ...2_ S02_ P71 nvoYTS02p071 SNVT_count_f 51 ADF 78 0145 x10 Volts Volts DC Bus Voltage 2 Frame E F N N O O O O O P72 AV136 YT2_ S02_ P72 nvoYTS02p072 SNVT_count_f 51 ADF 79 0146 N N N N N N N P73 AV137 Y...

Page 122: ...Fault DC Bus Voltage Imbalance Unit High VSD Ambient Temperature Single Phase Input Unit VSD Power Supply Fault System Not Running System Running Discharge Pressure Limiting Suction Pressure Limiting...

Page 123: ...he update an error mes sage will be displayed where XX is the Error Code See Table 16 on page 123 for error code definitions 9 After the update is completed and the controller reboots the keypad and d...

Page 124: ...e control cabinet To start the Data Logging insert the SD card into the SD card slot on the 03478 IPUII board The label on the SD card should be facing outwards Once the SD card is inserted and the un...

Page 125: ...emperature is causing a fault condition The following is a sample display UNIT YYYYYYYY HIGH AMBIENT TEMP The unit will also be inhibited from starting any time the temperature is above 53 9 C 129 F L...

Page 126: ...e displayed to the operator when the STATUS key is pressed In some cases a control panel fault will occur after a VSD fault possibly during system shutdown or at some later time This is known as an AL...

Page 127: ...This safety fault is set when the Suction Pressure pro grammable Suction Pressure Override Threshold lon ger than the programmable Smart Freeze Timer SYS X YYYYYYYY LOW SUCTION PRESSURE This safety f...

Page 128: ...rge temperature cutout fault The High Discharge Temperature Cutout protects the motor and compressor from overheating A system will fault and shut down with a controlled ramped shutdown when its Disch...

Page 129: ...vent loading of the compressors Suction pres sure limit unloading will not occur until the system run time reaches 5 minutes of operation to allow the sys tem to stabilize Table 19 Suction pressure lo...

Page 130: ...e of the systems is missing This could be due to a system fuse that has been removed or is blown The affected system will fault and shut down immediately when the 115 VAC supply is lost The safety wil...

Page 131: ...ate and time will be displayed for 2 seconds followed by the appropriate general status message C 2004 YORK INTERNATIONAL CORPORATION C XXX XX XX 18 SEPT 2010 12 45 AM Unit status messages occupy 2 li...

Page 132: ...ING This message indicates the system is not running be cause the chilled liquid is below the setpoint or the micro has not loaded the lead system far enough into the loading sequence to bring the lag...

Page 133: ...E TEMP LIMITING The VSD Baseplate Temp Limiting message indicates the VSD Baseplate temp is high and load limit or un loading is in effect SYS X VSD INTERNAL AMBIENT TEMP LIMITING The VSD Internal Amb...

Page 134: ...SEC UNLOAD TIMER XXX SEC The next key press displays the error in temperature between the actual leaving chilled liquid temperature and the setpoint temperature The display also shows the rate of cha...

Page 135: ...is providing re mote control The chiller is in remote mode ISN YorkTalk using ISN The chiller in remote mode CURR Remote Current Limiting is enabled TEMP Remote Temperature Reset is enabled SOUND Rem...

Page 136: ...ays all of the measured system pressures oil and dis charge SYS 1 PRESSURES OIL XXXX PSIG DISCHARGE XXXX PSIG The second key press of the SYSTEM DATA key or the DOWN ARROW key displays system suction...

Page 137: ...the dis play will indicate fan speed signal control voltage to the VSD and the fan speed 0 to 100 SYS 1 CONDENSER FANS ON X VSD FAN SPEED XX X V XXX The next key press will indicate the state of the...

Page 138: ...evel Switch Low High Condenser Liquid Temp Thermistor 4 1 F 20 06 C 155 6 F 68 67 C Leaving Chilled Liquid Temp Thermistor 19 1 F 28 49 C 110 2 F 43 44 C Return Chilled Liquid Temp Thermistor 19 1 F 2...

Page 139: ...imit values set locally on the panel under the PROGRAM key re motely by an ISN and remotely by the Current Limit input Any current limits that are inactive will display XXX instead of a numeric value...

Page 140: ...338 338 283 283 YVAA0275 YVAA0965 338 338 338 338 283 283 YVAA0278 YVAA0988 334 334 317 317 276 276 YVAA0295 YVAA1015 412 334 412 317 392 276 YVAA0303 YVAA1093 412 334 412 317 392 276 YVAA0305 YVAA106...

Page 141: ...rating hours Start counter key Compressor operating hours and compressor starts are displayed with a single key press The maximum value for both hours and starts is 99 999 at which point they will rol...

Page 142: ...selection Normal shutdowns history If the NORMAL SHUTDOWNS history is selected the following screen will be displayed NORM HIST XX 18 JUN 2004 10 34 58 AM YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY XX is...

Page 143: ...ly Fault Display All Fault Display Unit Data VSD Data System Data Operating Hours Starts Setpoints Options and Program Values at the time of the fault Status fault type SYS X COMPRESSOR RUNNING SYS X...

Page 144: ...indicates that sound limiting was in ef fect the amount and whether it was local or remotely limited VSD data VSD actual and command frequency VSD FREQUENCY ACTUAL XXX X HZ COMMAND XXX X HZ This messa...

Page 145: ...emperatures at the time of the fault SYS 1 DISCHARGE TEMP XXX X F SUPERHEAT XXX X SAT TEMP XXX X F This message displays the system discharge discharge superheat and saturated discharge temperatures a...

Page 146: ...X F This message displays the programmed Control Range at the time of the fault Remote setpoint and range SETPOINTS REMOTE SETPOINT XXX X F REMOTE CONTROL RANGE X X F This message displays the remote...

Page 147: ...lt and if active the type of reset signal selected If the option is not factory enabled the option will not appear Program values Suction pressure cutout PROGRAM SUCTION PRESSURE CUTOUT XXX XPSIG This...

Page 148: ...Eductor differential temperature PROGRAM DEF XXXXX LO XXXXX HI XXXXX EDUCTOR DIFFERENTIAL XXX F This message indicates the programmed eductor dif ferential temperature at the time of the fault Eductor...

Page 149: ...XXXXX LOCAL CONTROL RANGE X X F Pressingthe SETPOINTSkeyorthe ARROW key a third time will display the remote setpoint and cool ing range This display automatically updates about every 2 seconds The f...

Page 150: ...0 0 F 60 0 F 44 0 F 4 4 C 15 6 C 6 7 C Glycol cooling 15 0 F 70 0 F 44 0 F 9 4 C 15 6 C 6 7 C Leaving chilled liquid control range 1 5 F 2 5 F 2 0 F 0 8 C 1 4 C 1 1 C Maximum remote temperature reset...

Page 151: ...user is in the pro gram mode PROGRAM MODE XXXX PRESS ENTER KEY TO CONTINUE To display the first programmable selection press the ENTER key again Suction pressure cutout PROGRAM DEF XXXXX LO XXXXX HI X...

Page 152: ...down current limit time is programmable This allows the microprocessor to limit a system on pulldown limiting for a defined period of time for the purpose of peak time energy savings The pulldown limi...

Page 153: ...C 240 0 F is recommended to ensure the system does provides maximum capacity Default values A listing of the low limits high limits and default values for each of the programmable values is noted in e...

Page 154: ...d Display language selection The display language can be selected for English Ital ian Polish Hungarian German French Portuguese and Spanish OPTIONS DISPLAY LANGUAGE XXXXXXXXXXXXXXXXXX The default lan...

Page 155: ...appear as OPTIONS LEAD LAG CONTROL MODE MANUAL SYS 1 LEAD OPTIONS LEAD LAG CONTROL MODE MANUAL SYS 2 LEAD Remote temperature reset selection Remote temperature reset from an external source may be ti...

Page 156: ...IT INPUT 2 0 TO 10 0 VOLTS DC OPTIONS REMOTE SOUND LIMIT INPUT 0 0 TO 20 0 MILLIAMPS OPTIONS REMOTE SOUND LIMIT INPUT 4 0 TO 20 0 MILLIAMPS The default setting for Remote Sound Limit is DISABLED This...

Page 157: ...ssing the or Arrow keys allows scrolling to the next programmed item Pressing the DOWN ARROW key scrolls to the next item that can be pro grammed and the UP ARROW key scrolls to the previous item The...

Page 158: ...10 15 33 AM TIME FORMAT XXXXXXX The time format may be displayed in either a 12 hour or 24 hour format Selection can be changed by press ing the or ARROW keys The ENTER key must be pressed to store th...

Page 159: ...hen pressed and an will appear in the space signifying that day as a holiday The Holiday schedule must be programmed weekly If there is no holiday the key is also used to delete the The ENTER key is u...

Page 160: ...s being ignored and the chiller will start when chilled liquid temperature allows Remote Contacts UNIT switch and SYSTEM switches permitting This is a priority message and cannot be overridden by anti...

Page 161: ...by selecting the CANCEL PRINTING option The following message is displayed when the PRINT key is pressed PRINT CHOOSE PRINT REPORT XXXXXXXXXXXXXXXXXXXXX After pressing the PRINT key the printout type...

Page 162: ...EGF MOTOR CURRENT LIMIT 100 FLA PULLDOWN CURRENT LIMIT 100 FLA PULLDOWN LIMIT TIME 0 MIN SUBCOOLING SETPOINT 12 0 DEGF UNIT ID NUMBER 0 SOUND LIMIT SETPOINT 100 if Sound Limiting enabled UNIT DATA LEA...

Page 163: ...00AM STOP 00 00AM SAT START 00 00AM STOP 00 00AM HOL START 00 00AM STOP 00 00AM SOUND LIMIT SCHEDULE if enabled MON START 00 00AM STOP 00 00AM TUE START 00 00AM STOP 00 00AM WED START 00 00AM STOP 00...

Page 164: ...d it s ON OFF reset switch status The ARROW keys allow scrolling to the next and previous system switch System 1 and 2 SYSTEM SWITCHES SYS 2 ON OFF RESET XXXXXXXXXXXXXX The LEFT ARROW or RIGHT ARROW k...

Page 165: ...ure that no fault messages are displayed Refrigerant leaks Visually check the heat exchangers compressors and pipework for damage and gas leaks SECTION 9 Maintenance Operating conditions Read the oper...

Page 166: ...pose 4 Connect the recovery unit to a recovery cylinder sitting on an accurate scale Turn the recovery unit ON and observe the liquid refrigerant flow ing from the line into the cylinder The flow of l...

Page 167: ...aning process take care to avoid damage to the coils and the pro tective coatings The following care points must be followed during cleaning DO NOT use high pressure water such as a pres sure washer t...

Page 168: ...nd water in accordance with the manufacturer s directions on the container Use a hand held pump sprayer to apply the solution on the coils Ensure that the entire surface of the coils are wetted with t...

Page 169: ...aters are not damaged Failure to remove power will cause the evaporator immersion heaters to fail Evaporator freeze damage Power must remain on the chiller when ever the ambient temperature drops belo...

Page 170: ...Oil check for Acid and replace if necessary X Disconnect Power Source and Lock Out Check tightness of Power Wiring connections X Check Glycol concentration on Low Temp or other applications where free...

Page 171: ...ating limit Check the programmed cutout and determine if it is programmed correctly Ambient Sensor is defective Check the panel against the thermometer reading of ambient temperature Chiller fault Hig...

Page 172: ...discharge pressure Check subcooling High Superheat Drain Feed Valves NOT controlling Isolate cause Motor Sensor reading incorrectly Program panel to ignore a single sensor Economizer Solenoid energize...

Page 173: ...ect Normal response Excess charge in system adjust charge Condenser coils dirty Clean condenser Fans not operating Check fans VSD fault High baseplate temperature Coolant level low Add coolant Glycol...

Page 174: ...79 58 1 14 5 190 0 13 10 126 9 52 7 325 0 22 41 166 2 74 6 60 0 4 14 62 0 16 7 195 0 13 44 128 7 53 7 330 0 22 75 167 4 75 2 65 0 4 48 65 7 18 7 200 0 13 79 130 4 54 7 335 0 23 10 168 6 75 9 70 0 4 8...

Page 175: ...186 4 40 40 4 170 116 4 300 157 7 430 187 4 45 45 1 175 118 4 305 159 0 435 188 4 50 49 5 180 120 3 310 160 3 440 189 4 55 53 7 185 122 2 315 161 6 445 190 3 60 57 7 190 124 0 320 162 9 450 191 3 65...

Page 176: ...293 44 70 11 17 6 12 63 82 96 67 158 301 01 68 10 93 8 13 85 84 100 20 160 308 72 66 10 68 10 15 11 86 103 82 162 316 58 64 10 41 12 16 41 88 107 51 164 324 58 62 10 13 14 17 76 90 111 30 166 332 74...

Page 177: ...38 61 9 16 6 3 05 22 7 5 2 1 74 42 1 5 6 2 40 62 5 16 9 3 07 23 3 4 8 1 76 42 7 5 9 2 42 63 2 17 3 3 09 23 9 4 5 1 78 43 3 6 3 2 44 63 8 17 7 3 11 24 5 4 2 1 80 43 9 6 6 2 46 64 5 18 1 3 13 25 0 3 9...

Page 178: ...1 09 62 6 17 2 41 110 9 43 8 3 72 20 0 6 7 1 12 63 5 17 5 2 44 112 3 44 6 3 75 21 2 6 1 15 64 4 18 2 47 113 8 45 4 3 78 22 3 5 4 1 18 65 3 18 5 2 50 115 2 46 2 3 81 23 4 4 8 1 21 66 3 19 1 2 52 116 7...

Page 179: ...sure and discharge pressure transducer 400 psig Pressure Voltage Pressure Voltage 0 0 50 0 0 50 5 0 66 25 0 75 10 0 82 50 1 00 15 0 98 75 1 25 20 1 14 100 1 50 25 1 30 125 1 75 30 1 46 150 2 00 35 1 6...

Page 180: ...63 8 250 95 35 6 531 2 70 6 354 6 707 104 40 5 326 3 00 5 166 5 485 113 45 4 368 3 25 4 226 4 510 122 50 3 602 3 50 3 476 3 728 131 55 2 986 3 75 2 874 3 098 140 60 2 488 4 00 2 389 2 588 149 65 2 083...

Page 181: ...ntioned above Isolate the unit heat exchanger from the external wa ter systems and drain the heat exchanger section of the system If no isolation valves are installed it may be necessary to drain the...

Page 182: ...wer 0 7457 Kilowatts kW Flow rate Gallons Minute gpm 0 0631 Liters Second l s Length Feet ft 0 3048 Meters m Inches in 25 4 Millimeters mm Weight Pounds lb 0 4536 Kilograms kg Velocity Feet Second fps...

Page 183: ...JOHNSON CONTROLS 183 Form 201 28 NM1 1 Issue date 08 06 2021 Notes...

Page 184: ...nnsylvania USA 17349 Subject to change without notice Printed in USA Copyright by Johnson Controls 2021 ALL RIGHTS RESERVED Form 201 28 NM1 1 821 Issue Date August 6 2021 Supersedes 201 28 NM1 1 321 1...

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