Professional Documents
Culture Documents
HERMETIC SCROLL
INSTALLATION, OPERATION, MAINTENANCE New Release Form 150.66-NM4 (608)
035-21552-001
YCAL0012EC - YCAL0032EC
AIR-COOLED
SCROLL CHILLERS
STYLE D
WITH IPU II & I/O BOARDS
(50 Hz)
9-1/2 - 28 TON
50091
R-22
FORM 150.66-NM4 (608)
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or
During installation, operation, maintenance or service, death to themselves and people at the site.
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants, This document is intended for use by owner-authorized
oils, materials under pressure, rotating components, and operating/service personnel. It is expected that this
both high and low voltage. Each of these items has the individual possesses independent training that will en-
potential, if misused or handled improperly, to cause able them to perform their assigned tasks properly and
bodily injury or death. It is the obligation and respon- safely. It is essential that, prior to performing any task
sibility of operating/service personnel to identify and on this equipment, this individual shall have read and
recognize these inherent hazards, protect themselves, understood this document and any referenced materials.
and proceed safely in completing their tasks. Failure This individual shall also be familiar with and comply
to comply with any of these requirements could result with all applicable governmental standards and regula-
in serious damage to the equipment and the property in 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:
2 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
In complying with YORKs policy for continuous product improvement, the information contained in this document
is subject to change without notice. While YORK makes no commitment to update or provide current information
automatically to the manual owner, that information, if applicable, can be obtained by contacting the nearest YORK
Engineered Systems Service ofce.
It is the responsibility of operating/service personnel to verify the applicability of these documents to the equip-
ment in question. If there is any question in the mind of operating/service personnel as to the applicability of these
documents, then prior to working on the equipment, they should verify with the owner whether the equipment has
been modied and if current literature is available.
JOHNSON CONTROLS 3
FORM 150.66-NM4 (608)
TABLE OF CONTENTS
GENERAL SAFETY GUIDELINES ......................................................................................................2
TABLE OF CONTENTS .......................................................................................................................4
LIST OF FIGURES ...............................................................................................................................9
LIST OF TABLES...............................................................................................................................10
SECTION 1 - GENERAL CHILLER INFORMATION & SAFETY ...................................................... 11
INTRODUCTION ......................................................................................................................................... 11
WARRANTY ................................................................................................................................................ 11
SAFETY ....................................................................................................................................................... 11
Standards for Safety ...........................................................................................................................11
RESPONSIBILITY FOR SAFETY ...............................................................................................................12
ABOUT THIS MANUAL ..............................................................................................................................12
MISUSE OF EQUIPMENT ...........................................................................................................................12
Suitability for Application ...................................................................................................................12
Structural Support ...............................................................................................................................12
Mechanical Strength ..........................................................................................................................12
General Access ....................................................................................................................................12
Pressure Systems ...............................................................................................................................13
Electrical...............................................................................................................................................13
Rotating Parts ......................................................................................................................................13
Sharp Edges.........................................................................................................................................13
Refrigerants and Oils ..........................................................................................................................13
High Temperature and Pressure Cleaning ........................................................................................13
Emergency Shutdown .........................................................................................................................13
SECTION 2 - PRODUCT DESCRIPTION ..........................................................................................14
INTRODUCTION .........................................................................................................................................14
GENERAL SYSTEM DESCRIPTION ..........................................................................................................14
Compressors .......................................................................................................................................14
Cooler ...................................................................................................................................................14
Condenser ............................................................................................................................................15
Millennium Control Center..................................................................................................................15
Power Panel .........................................................................................................................................16
ACCESSORIES AND OPTIONS .................................................................................................................17
Power Options: ....................................................................................................................................17
Control Options: ..................................................................................................................................17
Compressor, Piping, Evaporator Options .........................................................................................18
Condenser and Cabinet Options........................................................................................................18
Sound Reduction Options ..................................................................................................................19
UNIT COMPONENTS ..................................................................................................................................20
CONTROL / POWER PANEL COMPONENTS ...........................................................................................21
PRODUCT IDENTIFICATION NUMBER (PIN)............................................................................................22
UNIT NOMENCLATURE .............................................................................................................................22
REFRIGERANT FLOW DIAGRAM .............................................................................................................27
SECTION 3 - HANDLING AND STORAGE .......................................................................................28
DELIVERY AND STORAGE ........................................................................................................................28
INSPECTION ...............................................................................................................................................28
MOVING THE CHILLER ..............................................................................................................................28
Lifting Weights .....................................................................................................................................28
UNIT RGGING .............................................................................................................................................29
4 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
6 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
JOHNSON CONTROLS 7
FORM 150.66-NM4 (608)
8 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
LIST OF FIGURES
FIG. 1 UNIT COMPONENTS ....................................................................................................................20
FIG. 2 CONTROL/POWER PANEL COMPONENTS ...............................................................................21
FIG. 3 REFRIGERANT FLOW DIAGRAM ...............................................................................................27
FIG. 4 UNIT RIGGING/LIFTING ...............................................................................................................29
FIG. 5 SINGLE-POINT SUPPLY CONNECTION TERMINAL BLOCK, NON-FUSED
DISCONNECT SWITCH OR CIRCUIT BREAKER (0012 - 0032) .................................................34
FIG. 6 CONTROL WIRING ......................................................................................................................35
FIG. 7 CONTROL CIRCUIT ......................................................................................................................54
FIG. 8 POWER CIRCUIT ..........................................................................................................................56
FIG. 9 CONNECTION DIAGRAM - STANDARD LOW SOUND UNIT .....................................................57
FIG. 10 ELEMENTARY DIAGRAM DETAILS- ALL MODELS UNIT........................................................58
FIG. 11 CONNECTION DIAGRAM - STANDARD UNIT ..........................................................................59
FIG. 12 UNIT CLEARANCES ...................................................................................................................84
FIG. 13 SETPOINT ADJUST ..................................................................................................................123
FIG. 13A LEAVING WATER TEMPERATURE CONTROL EXAMPLE ..................................................123
FIG. 14 TYPICAL VFD LOCATION ........................................................................................................126
FIG. 15 LIQUID LINE SENSING BULB LOCATION ..............................................................................126
FIG. 16 POTENTIOMETER SETTINGS .................................................................................................126
FIG. 17 WIRING ......................................................................................................................................127
FIG. 18 TYPICAL VFD ENCLOSURE LOCATIONS ..............................................................................129
FIG. 19 TYPICAL VFD ENCLOSURE CONFIGURATIONS ..................................................................129
FIG. 20 INVERTER POWER WIRING SCHEMATIC ..............................................................................130
FIG. 21 POTENTIOMETER SETTINGS .................................................................................................130
FIG. 22 INVERTER WIRING ..................................................................................................................131
FIG. 23 FIELD AND FACTORY ELECTRICAL CONNECTIONS OPTIONAL REMOTE
TEMPERATURE RESET BOARD .............................................................................................134
FIG. 24 IPU II & I/O LAYOUT .................................................................................................................138
FIG. 25 I/O BOARD RELAY CONTACT ARCHITECTURE ....................................................................142
FIG. 26 PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS ................................................143
JOHNSON CONTROLS 9
FORM 150.66-NM4 (608)
LIST OF TABLES
TABLE 1 SETPOINTS ENTRY LIST ........................................................................................................39
TABLE 2 TEMPERATURES AND FLOWS ..............................................................................................42
TABLE 3 VOLTAGE LIMITATIONS ..........................................................................................................42
TABLE 4 ETHYLENE GLYCOL CORRECTION FACTORS ........................................................................43
TABLE 5 TEMPERATURES AND FLOWS (SI) .......................................................................................44
TABLE 6 VOLTAGE LIMITATIONS ..........................................................................................................44
TABLE 7 ETHYLENE GLYCOL CORRECTION FACTORS ........................................................................45
TABLE 8 PHYSICAL DATA (ENGLISH) ..................................................................................................46
TABLE 9 SOUND DATA (ENGLISH)........................................................................................................48
TABLE 10 YCAL012 - ELECTRICAL DATA (ENGLISH) .........................................................................50
TABLE 11 MICRO PANEL POWER SUPPLY ..........................................................................................52
TABLE 12 VOLTAGE RANGE .................................................................................................................52
TABLE 13 STATUS KEY MESSAGES QUICK REFERENCE LIST ........................................................99
TABLE 14 OPERATION DATA ...............................................................................................................103
TABLE 15 COOLING SETPOINTS, PROGRAMMABLE LIMITS AND DEFAULTS ............................. 111
TABLE 16 PROGRAM KEY LIMITS AND DEFAULTS .......................................................................... 114
TABLE 17 SETPOINTS QUICK REFERENCE LIST ............................................................................. 115
TABLE 18 UNIT KEYS PROGRAMMING QUICK REFERENCE LIST .................................................121
TABLE 19 YCAL0012 YCAL0032 CONDENSER FAN CONTROL USING OUTDOOR
AMBIENT TEMPERATURE AND DISCHARGE PRESSURE (DISCHARGE PRESSURE
CONTROLS WILL NOT FUNCTION AND FAN CONTROL WILL BE BASED ON
AMBIENT TEMPERATURES ONLY, UNLESS THE OPTIONAL DISCHARGE
PRESSURE .........................................................................................................................125
TABLE 20 YCAL0012 YCAL0032 CONDENSER FAN CONTROL USING DISCHARGE
PRESSURE ONLY................................................................................................................125
TABLE 21 YCAL0012 - 0021 VFD LOW AMBIENT OPTION - CONDENSER FAN CONTROL
OPERATION .........................................................................................................................128
TABLE 22 YCAL0025-0032 VFD LOW AMBIENT OPTION - CONDENSER FAN CONTROL
OPERATION .........................................................................................................................131
TABLE 23 COMPRESSOR OPERATION LOAD LIMITING ...............................................................132
TABLE 24 MICROBOARD DIGITAL INPUTS ........................................................................................137
TABLE 25 MICROBOARD DIGITAL OUTPUTS ....................................................................................137
TABLE 26 MICROBOARD ANALOG INPUTS ......................................................................................137
TABLE 27 MICROBOARD ANALOG OUTPUTS ..................................................................................137
TABLE 28 OUTDOOR AIR SENSOR TEMPERATURE/VOLTAGE/RESISTANCE CORRELATION....139
TABLE 29 ENTERING/LEAVING CHILLED LIQUID TEMP. SENSOR, COOLER INLET
TEMPERATURE SENSOR, AND SUCTION TEMPERATURE SENSOR:
TEMPERATURE/VOLTAGE CORRELATION ......................................................................140
TABLE 32 TROUBLESHOOTING ..........................................................................................................144
TABLE 31 ISN RECEIVED DATA...........................................................................................................149
TABLE 32 ISN TRANSMITTED DATA ...................................................................................................149
TABLE 33 ISN OPERATIONAL AND FAULT CODES ...........................................................................151
TABLE 34 MINIMUM, MAXIMUM AND DEFAULT VALUES .................................................................153
TABLE 35 REAL TIME ERROR NUMBERS ..........................................................................................153
10 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
The unit is intended for cooling water or glycol solu- Only genuine YORK approved spare parts, oils,
tions and is not suitable for purposes other than those coolants, and refrigerants must be used.
specied in this manual.
All the scheduled maintenance operations detailed in
This manual contains all the information required for this manual must be performed at the specied times
correct installation and commissioning of the unit, to- by suitably trained and qualied personnel
gether with operating and maintenance instructions. The (see Maintenance Section, Page 147).
manuals should be read thoroughly before attempting
to operate or service the unit. Failure to satisfy any of these conditions will
automatically void the warranty (see Warranty
All procedures detailed in the manuals, including in- Policy).
stallation, commissioning and maintenance tasks must
only be performed by suitably trained and qualied SAFETY
personnel.
Standards for Safety
The manufacturer will not be liable for any injury or
damage caused by incorrect installation, commission-
ing, operation or maintenance resulting from a failure YCAL chillers are designed and built within an ISO
to follow the procedures and instructions detailed in 9002 accredited design and manufacturing organization.
the manuals. The chillers comply with the applicable sections of the
following Standards and Codes:
WARRANTY
ANSI/ASHRAE Standard 15- Safety Code for Me-
chanical Refrigeration.
YORK warrants all equipment and materials against
defects in workmanship and materials for a period of ANSI/NFPA Standard 70- National Electrical Code
eighteen months from date of shipment, unless labor (N.E.C.).
or extended warranty has been purchased as part of the
contract. ASME Boiler and Pressure Vessel Code- Section
VIII Division 1.
The warranty is limited to parts only replacement and
shipping of any faulty part, or sub-assembly, which has ARI Standard 550/590-98- Water Chilling Packages
failed due to poor quality or manufacturing errors. All Using the Vapor Compression Cycle.
claims must be supported by evidence that the failure
has occurred within the warranty period, and that the ASHRAE 90.1- Energy Efciency compliance.
unit has been operated within the designed parameters
specied. ARI 370- Sound Rating of Large Outdoor Refrigera-
tion and Air Conditioning Equipment.
All warranty claims must specify the unit model, serial
number, order number and run hours/starts. Model and In addition, the chillers conform to Underwriters Labo-
serial number information is printed on the unit identi- ratories (U.L.) for construction of chillers and provide
cation plate. U.L./cU.L. Listing Label.
RESPONSIBILITY FOR SAFETY The contents of this manual include suggested best
working practices and procedures. These are issued for
Every care has been taken in the design and manufac- guidance only, and they do not take precedence over
ture of the unit to ensure compliance with the safety the above stated individual responsibility and/or local
requirements listed above. However, the individual safety regulations.
operating or working on any machinery is primarily
responsible for: This manual and any other document supplied with the
unit are the property of YORK which reserves all rights.
Personal safety, safety of other personnel, and They may not be reproduced, in whole or in part, without
the machinery. prior written authorization from an authorized YORK
representative.
Correct utilization of the machinery in ac-
cordance with the procedures detailed in the MISUSE OF EQUIPMENT
manuals.
Suitability for Application
ABOUT THIS MANUAL
The unit is intended for cooling water or glycol solu-
The following terms are used in this document to alert tions and is not suitable for purposes other than those
the reader to areas of potential hazard. specied in these instructions. Any use of the equipment
other than its intended use, or operation of the equipment
contrary to the relevant procedures may result in injury
to the operator, or damage to the equipment.
Mechanical Strength
Pressure Systems Frame rails, brakes, and other components may also have
sharp edges. Reasonable care should be taken when
The unit contains refrigerant vapor and liquid under working in contact with any components to avoid risk
pressure, release of which can be a danger and cause of minor abrasions and lacerations. 1
injury. The user should ensure that care is taken during
installation, operation and maintenance to avoid dam- Refrigerants and Oils
age to the pressure system. No attempt should be made
to gain access to the component parts of the pressure Refrigerants and oils used in the unit are generally non-
system other than by suitably trained and qualied toxic, non-ammable and non-corrosive, and pose no
personnel. special safety hazards. Use of gloves and safety glasses
is, however, recommended when working on the unit.
Electrical The build up of refrigerant vapor, from a leak for ex-
ample, does pose a risk of asphyxiation in conned or
The unit must be grounded. No installation or main- enclosed spaces and attention should be given to good
tenance work should be attempted on the electrical ventilation.
equipment without rst switching power OFF, isolating
and locking-off the power supply. Servicing and mainte- High Temperature and Pressure Cleaning
nance on live equipment must only be performed by suit-
ably trained and qualied personnel. No attempt should High temperature and pressure cleaning methods (e.g.
be made to gain access to the control panel or electrical steam cleaning) should not be used on any part of the
enclosures during normal operation of the unit. pressure system as this may cause operation of the pres-
sure relief device(s). Detergents and solvents, which may
Rotating Parts cause corrosion, should also be avoided.
Fan guards must be tted at all times and not removed Emergency Shutdown
unless the power supply has been isolated. If ductwork is
to be tted, requiring the wire fan guards to be removed, In case of emergency, the control panel is tted with
alternative safety measures must be taken to protect a Unit Switch to stop the unit in an emergency. When
against the risk of injury from rotating fans. operated, it removes the low voltage 120 VAC electri-
cal supply from the inverter system, thus shutting down
Sharp Edges the unit.
JOHNSON CONTROLS 13
Product Description
FORM 150.66-NM4 (608)
50091
INTRODUCTION
YORK Millennium Air-Cooled Scroll Chillers provide with Intertek Testing Services (ETL) and rated in ac-
chilled water for all air conditioning applications using cordance with ARI Standard 550/590-2003.
central station air handling or terminal units. They are
completely self-contained and are designed for outdoor All exposed power wiring is routed through liquid-tight,
(roof or ground level) installation. Each unit includes non-metallic conduit.
hermetic scroll compressors, a liquid cooler, air cooled
condenser, and a weather resistant microprocessor con- GENERAL SYSTEM DESCRIPTION
trol center, all mounted on a pressed steel base.
Compressors
The units are completely assembled with all intercon-
necting refrigerant piping and internal wiring, ready for The chiller has suction-gas cooled, hermetic, scroll
eld installation. compressors. The YCAL compressors incorporate a
compliant scroll design in both the axial and radial
Prior to delivery, the unit is pressure-tested, evacuated, direction. All rotating parts are statically and dynami-
and fully charged with Refrigerant-22 (HCFC-22) and cally balanced. A large internal volume and oil reservoir
includes an initial oil charge. After assembly, a complete provides greater liquid tolerance. Compressor crankcase
operational test is performed with water owing through heaters are also included for extra protection against
the cooler to assure that the refrigeration circuit oper- liquid migration.
ates correctly.
Cooler
The unit structure is heavy-gauge, galvanized steel. This
galvanized steel is coated with baked-on powder paint, The Brazed Plate Heat Exchanger is equipped with a
which, when subjected to ASTM B117 1000 hour, salt heater controlled by the microprocessor. The heater
spray testing, yields a minimum ASTM 1654 rating of provides freeze protection for the cooler down to -20F (-
6. Corrosion resistant wire mesh panels are added to 29C) ambient. The cooler is covered with 3/4 (19mm)
protect the condenser coil from incidental damage and exible, closed-cell, foam insulation (K~0.25).
restrict unauthorized access to internal components.
Units are designed in accordance with NFPA 70 (Na- Brazed plate heat exchangers shall be UL (Underwriters
tional Electric Code), ASHRAE/ANSI 15 Safety code Laboratories) listed. Installing contractor must include
for mechanical refrigeration, ASME, Listed and labeled accommodations in the chilled water piping to allow
14 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
proper drainage and venting of the heat exchanger. Water Operating hours and starts (each compressor)
inlet and outlet connections are grooved for compatibil- Print calls up to the liquid crystal display
ity with factory supplied victaulic connections. Operating data for the systems
History of fault shutdown data for up to
A strainer with a mesh size between .5 and 1.5 mm (40 the last six fault shutdown conditions.
mesh) is recommended upstream of the heat exchanger
to prevent clogging.
An RS-232 port, in conjunction with this 2
press-to-print button, is provided to permit
Condenser the capability of hard copy print-outs via a
separate printer (by others).
Coils Fin and tube condenser coils of seamless, inter-
nally-enhanced, high-condensing-coefcient, corrosion ENTRY section to:
resistant copper tubes are arranged in staggered rows, ENTER setpoints or modify system values.
mechanically expanded into aluminum ns. Integral
subcooling is included. The design working pressure
of the coil is 450 PSIG (31 bar). SETPOINTS: Updating can be performed to:
Chilled liquid temperature setpoint and range
Low Sound Fans The condenser fans are composed Remote reset temperature range
of corrosion resistant aluminum hub and glass-ber
Set daily schedule/holiday for start/stop
reinforced composite blades molded into a low noise
airfoil section. They are designed for maximum ef- Manual override for servicing
ciency and are statically and dynamically balanced Low and high ambient cutouts
for vibration free operation. They are directly driven Number of compressors
by independent motors, and positioned for vertical air Low liquid temperature cutout
discharge. All blades are statically and dynamically
Low suction pressure cutout
balanced for vibration-free operation. The fan guards
are constructed of heavy-gauge, rust-resistant, PVC High discharge pressure cutout
coated steel wire. Anti-recycle timer (compressor start cycle
time)
Motors The fan motors are Totally Enclosed Air- Anti-coincident timer (delay compressor
Over, squirrel-cage type, current protected. They feature starts)
ball bearings that are double-sealed and permanently
lubricated. UNIT section to:
Set time
Millennium Control Center
Set unit options
All controls are contained in a NEMA 3R/12 (and
equivalent to IP55*) cabinet with hinged outer door UNIT ON/OFF switch
and includes:
The microprocessor control center is capable of dis-
Liquid Crystal Display with Light Emitting Diode back- playing the following:
lighting for outdoor viewing:
Two display lines Return and leaving liquid temperature
Twenty characters per line Low leaving liquid temperature cutout setting
Color coded 12-button non-tactile keypad with sections Low ambient temperature cutout setting
for: Outdoor air temperature
DISPLAY/PRINT of typical information: English or Metric data
Chilled liquid temperatures Suction pressure cutout setting
Ambient temperature Each system suction pressure
System pressures (each circuit) Discharge pressure (optional)
JOHNSON CONTROLS 15
Product Description
FORM 150.66-NM4 (608)
Liquid Temperature Reset via a YORK ISN DDC Provisions are included for: pumpdown at shutdown;
or Building Automation System (by others) via: optional remote chilled water temperature reset and two
- a pulse width modulated (PWM) input as stan- steps of demand load limiting from an external building
dard. automation system. Unit alarm contacts are standard.
- a 4-20 milliamp or 0 -10 VDC input, or contact
The operating program is stored in non-volatile memory
closure with the optional B.A.S. interface option. (EPROM) to eliminate chiller failure due to AC powered
Anti-recycle timer status for each system failure/battery discharge. Programmed setpoints are
Anti-coincident system start timer condition retained in lithium battery-backed RTC memory for 5
Compressor run status years minimum.
No cooling load condition Power Panel
Day, date and time
Daily start/stop times Each panel contains:
Holiday status Compressor power terminals
Automatic or manual system lead/lag control Compressor motor starting contactors per l.E.C.**
Lead system denition Control power terminals to accept incoming for
Compressor starts & operating hours 115-1-60 control power
(each compressor) Fan contactors & overload current protection
Status of hot gas valves, evaporator heater
The power wiring is routed through liquid-tight conduit
and fan operation to the compressors and fans.
Run permissive status
Number of compressors running
Liquid solenoid valve status
Load & unload timer status
Water pump status
16 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL TRANSFORMER Converts unit power Suction Pressure Transducers: Permits unit to
voltage to 115-1-60 (0.5 or 1.0 KVA capacity). Fac- sense and display suction pressure. This capability
tory mounting includes primary and secondary wiring is standard.
between the transformer and the control panel (Fac-
tory-Mounted). MOTOR CURRENT MODULE Capable of moni-
toring compressor motor current. Provides extra protec-
POWER FACTOR CORRECTION CAPACITORS tion against compressor reverse rotation, phase-loss and
Will correct unit compressor power factors to a 0.90- phase imbalance. Option consists of one module per
0.95 (Factory-Mounted). electrical system (Factory-Mounted).
CONTROL OPTIONS:
OPTIVIEW REMOTE CONTROL PANEL - Graphi-
AMBIENT KIT (LOW) Units will operate to 25F (- cal interface panel to remotely control and monitor up to
4C). This accessory includes all necessary components 8 different units. (Refer to form 201.18-SG4 for detailed
to permit chiller operation to 0F (-18C). (This option information).
includes the Discharge Pressure Transducer / Readout
Capability option). For proper head pressure control MULTI-UNIT SEQUENCING A separate Sequenc-
in applications below 25F (-4C), where wind gusts ing Control Center is provided to handle sequencing
may exceed ve mph, it is recommended that Optional control of up to eight chillers in parallel based on mixed
Condenser Louvered Enclosure Panels also be included liquid temperature (interconnecting wiring by others).
(Factory-Mounted). (Only one of following options can be offered on a unit
at a time: BAS, Remote Control Panel or Multi-unit
Sequence Control) (Factory-Mounted).
JOHNSON CONTROLS 17
Product Description
FORM 150.66-NM4 (608)
18 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
JOHNSON CONTROLS 19
Product Description
FORM 150.66-NM4 (608)
UNIT COMPONENTS
FAN ASSEMBLIES
CONDENSER
COILS
HEAT EXCHANGER
LD12246
COMPRESSORS
20 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
2
CIRCUIT BREAKER KEYPAD & DISPLAY UNIT SWITCH
DSC02181A.JPG
JOHNSON CONTROLS 21
Product Description
FORM 150.66-NM4 (608)
YCAL0021EC 50XBA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE/STARTER DESIGN/DEVELOPMENT LEVEL
22 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
JOHNSON CONTROLS 23
Product Description
FORM 150.66-NM4 (608)
24 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
JOHNSON CONTROLS 25
Product Description
FORM 150.66-NM4 (608)
26 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
HOT DISCHARGE
GAS LINE
OPTIONAL
OPTIONAL
DISCHARGE LINE
BALL VALVE
OPTIONAL
OPTIONAL
SERVICE VALVE OPTIONAL
OPTIONAL
OPTIONAL
LD11417A
JOHNSON CONTROLS 27
Handling and Storage
FORM 150.66-NM4 (608)
To ensure consistent quality and maximum reliability, Prior to moving the unit, ensure that the installation site
all units are tested and inspected before leaving the is suitable for installing the unit and is easily capable
factory. Units are shipped completely assembled and of supporting the weight of the unit and all associated
containing refrigerant under pressure. Units are shipped services.
without export crating unless crating has been specied
on the Sales Order. The units are designed to be lifted using cables or an
appropriate forklift. Refer to the unit data plate for unit
If the unit is to be put into storage, prior to installation, weight. When using lifting cables, a spreader bar or
the following precautions should be observed: frame should be used in order to prevent damage to the
unit from the lifting chains.
The chiller must be blocked so that the base is not
permitted to sag or bow. Units are provided with lifting eyes in the sides of the
base frame, which can be attached to directly using
Ensure that all openings, such as water connections, shackles or safety hooks.
are securely capped.
The unit must only be lifted by the base
Do not store where exposed to ambient air tempera- frame at the points provided.
tures exceeding 110F (43C).
INSPECTION
28 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
LD11837
LD11838
Forks must extend beyond the width of the unit for proper lift. The thick-
ness of the fork blade must be smaller then the opening of the lifting
hole. Improper fork positioning could result in damage to the unit.
JOHNSON CONTROLS 29
Installation
FORM 150.66-NM4 (608)
SECTION 4 - INSTALLATION
To ensure warranty coverage, this INSPECTION
equipment must be commissioned
Immediately upon receiving the unit, it should be in-
and serviced by an authorized YORK
spected for possible damage which may have occurred
service mechanic or a qualied service during transit. If damage is evident, it should be noted
person experienced in chiller instal- in the carriers freight bill. A written request for inspec-
lation. Installation must comply with tion by the carriers agent should be made at once. See
all applicable codes, particularly in Instruction manual, Form 50.15-NM for more infor-
regard to electrical wiring and other mation and details.
safety elements such as relief valves,
HP cutout settings, design working LOCATION AND CLEARANCES
pressures, and ventilation require-
ments consistent with the amount and These units are designed for outdoor installations on
type of refrigerant charge. ground level, rooftop, or beside a building. Location
should be selected for minimum sun exposure and to
insure adequate supply of fresh air for the condenser.
Lethal voltages exist within the control
The units must be installed with sufcient clearances for
panels. Before servicing, open and tag air entrance to the condenser coil, for air discharge away
all disconnect switches. from the condenser, and for servicing access.
HANDLING
30 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
The unit should be mounted on a at and level founda- When ordered, four (4) isolators will be furnished.
tion, oor, or rooftop capable of supporting the entire
operating weight of the equipment. See PHYSICAL Identify the isolator, locate at the proper mounting point,
DATA for operating weight. If the unit is elevated beyond and adjust per instructions.
the normal reach of service personnel, a suitable catwalk
must be capable of supporting service personnel, their COMPRESSOR MOUNTING
equipment, and the compressors.
The compressors are mounted on four (4) rubber iso-
Ground Level Locations lators. The mounting bolts should not be loosened or
adjusted at installation of the chiller.
It is important that the units be installed on a substantial
base that will not settle. A one piece concrete slab with REMOTE COOLER OPTION
footers extended below the frost line is highly recom-
mended. Additionally, the slab should not be tied to For units using remote cooler option, refer to instructions 4
included with miscellaneous cooler parts kit.
the main building foundations as noise and vibration
may be transmitted. Mounting holes are provided in the The unit and remote cooler are shipped with a 6 lb. (2.7
steel channel for bolting the unit to its foundation (see kg) nitrogen holding charge. The nitrogen charge must
DIMENSIONS). be removed, and system evacuated, and the refrigerant
charge must be weighed-in according to the operating
For ground level installations, precautions should be charge listed under PHYSICAL DATA. Additional
taken to protect the unit from tampering by or injury to charge must also be added for the refrigerant lines.
unauthorized persons. Screws and/or latches on access
panels will prevent casual tampering. However, further CHILLED LIQUID PIPING
safety precautions such as a fenced-in enclosure or lock-
ing devices on the panels may be advisable. General When the unit(s) has been located in its
nal position, the unit water piping may be connected.
Rooftop Locations Normal installation precautions should be observed in
order to receive maximum operating efciencies. Pip-
ing should be kept free of all foreign matter. All chilled
Choose a spot with adequate structural strength to safely water evaporator piping must comply in all respects with
support the entire weight of the unit and service person- local plumbing codes and ordinances.
nel. Care must be taken not to damage the roof.
Since elbows, tees and valves decrease pump capacity,
Consult the building contractor or architect if the roof is all piping should be kept as straight and as simple as
bonded. Roof installations should have wooden beams possible. All piping must be supported independent
(treated to reduce deterioration), cork, rubber, or vibra- of the chiller.
tion isolators under the base to minimize vibration.
Consideration should be given to com-
Noise Sensitive Locations pressor access when laying out water
piping. Routing the water piping too
Efforts should be made to assure that the chiller is not close to the unit could make compres-
located next to occupied spaces or noise sensitive areas sor servicing/replacement difcult.
where chiller noise level would be a problem. Chiller
noise is a result of compressor and fan operation. Con-
Hand stop valves should be installed in all lines to fa-
siderations should be made utilizing noise levels pub- cilitate servicing.
lished in the YORK Engineering Guide for the specic
chiller model. Sound blankets for the compressors and Piping to the inlet and outlet connections of the chiller
low sound fans are available. should include high-pressure rubber hose or piping
loops to ensure against transmission of water pump
vibration. The necessary components must be obtained
in the eld.
JOHNSON CONTROLS 31
Installation
FORM 150.66-NM4 (608)
Drain connections should be provided at all low points The Flow Switch MUST NOT be used
to permit complete drainage of the cooler and system to start and stop the chiller (i.e. start-
water piping. ing and stopping the chilled water
A small valve or valves should be installed at the highest pump). It is intended only as a safety
point or points in the chilled water piping to allow any switch.
trapped air to be purged. Vent and drain connections
should be extended beyond the insulation to make them DUCT WORK CONNECTION
accessible.
General Requirements
The piping to and from the cooler must be designed to
suit the individual installation. It is important that the The following duct work recommendations are intended
following considerations be observed: to ensure satisfactory operation of the unit. Failure to
follow these recommendations could cause damage to
1. The chilled liquid piping system should be laid out the unit, or loss of performance, and may invalidate the
so that the circulating pump discharges directly warranty.
into the cooler. The suction for this pump should
be taken from the piping system return line and not When ducting is to be tted to the fan discharge it is
the cooler. This piping scheme is recommended, recommended that the duct should be the same cross-
but is not mandatory. sectional area as the fan outlet and straight for at least
three feet (1 meter) to obtain static regain from the fan.
2. The inlet and outlet cooler connection sizes are 2 Duct work should be suspended with exible hangers
(YCAL0012 - 0032). to prevent noise and vibration being transmitted to the
structure. A exible joint is also recommended between
the duct attached to the fan and the next section for the
3. A strainer, preferably 40 mesh, must be installed same reason. Flexible connectors should not be allowed
in the cooler inlet line just ahead of the cooler. This to concertina.
is important to protect the cooler from entrance of
large particles which could cause damage to the The unit(s) is not designed to take structural loading. No
evaporator. signicant amount of weight should be allowed to rest
on the fan outlet ange, deck assemblies or condenser
coil module. No more than 3 feet (1 meter) of light
4. All chilled liquid piping should be thoroughly
construction duct work should be supported by the unit.
ushed to free it from foreign material before the
Where cross winds may occur, any duct work must be
system is placed into operation. Use care not to ush
supported to prevent side loading on the unit.
any foreign material into or through the cooler.
5. As an aid to servicing, thermometers and pressure If the ducts from two or more fans are to be combined
gauges should be installed in the inlet and outlet into a common duct, back-ow dampers should be tted
water lines. in the individual fan ducts. This will prevent re-circula-
tion of air when only one of the fans is running.
6. The chilled water lines that are exposed to outdoor Units are supplied with outlet guards for safety and to
ambients should be wrapped with supplemental prevent damage to the fan blades. If these guards are
heater cable and insulated to protect against freeze- removed to t duct work, adequate alternative precau-
up during low ambient periods, and to prevent tions must be taken to ensure persons cannot be harmed
formation of condensation on lines in warm humid or put at risk from rotating fan blades.
locations.
A 120-1-60, 15 amp source must be supplied for the Remote Emergency Cutoff
control panel through a fused disconnect when a control
panel transformer (optional) is not provided (Refer to Immediate shutdown of the chiller can be accomplished
Fig. 5). by opening a eld-installed dry contact to break the elec-
trical circuit between terminals 5 to L on terminal block
See unit wiring diagrams for eld and power wiring TB1. The unit is shipped with a factory jumper installed
connections, chilled water pump starter contacts, alarm
between terminals 5 to L, which must be removed if
contacts, compressor run status contacts, PWM input,
and load limit input. Refer to section on UNIT OPERA- emergency shutdown contacts are installed. Refer to
TION for a detailed description of operation concerning Fig. 6 and unit wiring diagram.
aforementioned contacts and inputs.
PWM Input
Evaporator Pump Start Contacts
The PWM input allows reset of the chilled liquid set-
Terminal block TB1 terminals 23 to 24, are normally- point by supplying a timed contact closure. Field
open contacts that can be used to switch eld supplied wiring should be connected to CTB1 terminals 13
power to provide a start signal to the evaporator pump to 20. A detailed explanation is provided in the Unit 4
contactor. The contacts will be closed when any of the Control section.
following conditions occur:
Load Limit Input
1. Low Leaving Chilled Liquid Fault
2. Any compressor is running Load limiting is a feature that prevents the unit from
3. Daily schedule is not programmed OFF and the loading beyond a desired value. The unit can be load
Unit Switch is ON limited 50%. The eld connections are wired to CTB1
terminals 13 to 21, and work in conjunction with the
The pump will not run if the micro panel has been pow- PWM inputs. A detailed explanation is provided in the
ered up for less than 30 seconds, or if the pump has run in
Unit Control section.
the last 30 seconds, to prevent pump motor overheating.
Refer to Fig. 6 and unit wiring diagram.
When using the Load Limit feature,
System Run Contacts the PWM feature will not function
SIMULTANEOUS OPERATION
Contacts are available to monitor system status. Nor- OF LOAD LIMITING AND TEM-
mally-open auxiliary contacts from each compressor PERATURE RESET (PWM INPUT)
contactor are wired in parallel with TB1 terminals
25 to 26 for system 1. Refer to Fig. 6 and unit wiring CANNOT BE DONE.
diagram.
Flow Switch Input
Alarm Status Contacts
The ow switch is eld wired to CTB1 terminals 13
Normally-open contacts are available for each refrigerant - 14. See Fig. 6 and unit wiring diagram.
system. These normally-open contacts close when the
system is functioning normally. The respective contacts
COMPRESSOR HEATERS
will open when the unit is shut down on a unit fault, or
locked out on a system fault. Field connections are at
TB1 terminals 29 to 30 (system 1). Compressor heaters are standard. If power is OFF more
than two hours, the crankcase heaters must be energized
Remote Start/Stop Contacts for 18 - 24 hours prior to restarting a compressor. This
will assure that liquid slugging and oil dilution does not
To remotely start and stop the chiller, dry contacts can damage the compressors on start.
be wired in series with the ow switch and CTB1 - termi-
nals 13 to 14. Refer to Fig. 6 and unit wiring diagram.
JOHNSON CONTROLS 33
Installation
FORM 150.66-NM4 (608)
2
L
Terminal Block, MICROPANEL
NF Disconnect SW
or Circuit Breaker
13 14
CTB1
It is possible that multiple sources of power can be supplying the unit power panel. To prevent
serious injury or death, the technician should verify that NO LETHAL VOLTAGES are
present inside the panel AFTER disconnecting power, PRIOR to working on equipment.
The unit evaporator 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.
34 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL WIRING
CTB1
LD07725
4
*
TB1
LD13706
It is possible that multiple sources of power can be supplying the unit power panel. To prevent
serious injury or death, the technician should verify that NO LETHAL VOLTAGES are
present inside the panel AFTER disconnecting power, PRIOR to working on equipment.
The unit evaporator 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.
JOHNSON CONTROLS 35
Commissioning
FORM 150.66-NM4 (608)
SECTION 5 - COMMISSIONING
Commissioning of this unit should Compressor Oil
only be carried out by YORK Autho-
rized personnel. To add oil to a circuit - connect a YORK hand oil pump
(Part No. 470-10654-000) to the 1/4 oil charging valve
on the oil separator piping with a length of clean hose
or copper line, but do not tighten the are nut. Using
clean oil of the correct type (F oil), pump oil until
Commissioning personnel should be thoroughly familiar all air has been purged from the hose then tighten the
with the information contained in this literature, in ad- nut. Stroke the oil pump to add oil to the oil system.
dition to this section. The oil level should be between the middle of the lower
and middle of the upper sight glasses of the oil separa-
Perform the commissioning using the detailed checks tor. Approximately 4-5 gallons is present in the each
outlined in the EQUIPMENT START-UP CHECK LIST refrigerant system, with typically 1-2 gallons in each oil
(Page 38) as the commissioning procedure is carried separator. Oil levels in the oil separators above the top
out. sight glass in either oil separator should be avoided and
may cause excessive oil carryover in the system. High
PREPARATION POWER OFF oil concentration in the system may cause nuisance trips
resulting from incorrect readings on the level sensor and
The following basic checks should be made with the temperature sensors. Temperature sensor errors may
customer power to the unit switched OFF. result in poor liquid control and resultant liquid overfeed
and subsequent damage to the compressor.
Inspection
Fans
Inspect unit for installation damage. If found, take action
and/or repair as appropriate. Check that all fans are free to rotate and are not dam-
aged. Ensure blades are at the same height when rotated.
Ensure fan guards are securely xed.
Refrigerant Charge
Water System
JOHNSON CONTROLS 37
Commissioning
FORM 150.66-NM4 (608)
JOB NAME: ______________________________ 7. Check the control panel to ensure it is free of
foreign material (wires, metal chips, etc.).
SALES ORDER #: _________________________
8. Visually inspect wiring (power and control). Wir-
LOCATION: ______________________________ ing MUST meet N.E.C. and local codes.
SOLD BY: ________________________________ 9. Check tightness of power wiring inside the power
INSTALLING panel on both sides of the motor contactors and
CONTRACTOR: ___________________________ overloads.
START-UP 10. Check for proper size fuses in main and control
TECHNICIAN/ circuits, and verify overload setting corresponds
COMPANY: _______________________________ with RLA and FLA values in electrical tables.
11. Assure 120VAC Control Power to TB1 has 15
START-UP DATE : _________________________
amp minimum capacity.
12. Be certain all water temp sensors are inserted
CHILLER MODEL #: _______________________ completely in their respective wells and are coated
SERIAL #: ______________________________ with heat conductive compound.
13. Assure that evaporator TXV bulbs are strapped
onto the suction lines at 4 or 8 oclock positions
CHECKING THE SYSTEM or suction temp. sensors if EEVs are installed.
PRIOR TO INITIAL START (NO POWER)
COMPRESSOR HEATERS
Unit Checks
(POWER ON 24 HOURS PRIOR TO START)
1. Inspect the unit for shipping or installation dam-
age.
1. Apply 120VAC and verify its value between
2. Assure that all piping has been completed. terminals 5 and 2 of TB1. The voltage should be
3. Visually check for refrigerant piping leaks. 120VAC +/- 10%.
4. Open suction line ball valve, discharge line ball Power must be applied 24 hours prior to
valve, and liquid line valve for each system. start-up.
5. The compressor oil level should be maintained so Each heater should draw approximately 0.5-1A.
that an oil level is visible in the sight glass. The
oil level can only be tested when the compressor
is running in stabilized conditions, guaranteeing PANEL CHECKS
that there is no liquid refrigerant in the lower shell (POWER ON BOTH UNIT SWITCHES OFF)
of the compressor. In this case, the oil should be
between 1/4 and 3/4 in the sight glass. At shut- 1. Apply 3-phase power and verify its value. Volt-
down, the oil level can fall to the bottom limit of age imbalance should be no more than 2% of the
the oil sight glass. average voltage.
6. Assure water pumps are on. Check and adjust 2. Apply 120VAC and verify its value on the terminal
water pump ow rate and pressure drop across block in the Power Panel. Make the measurement
the cooler (see OPERATIONAL LIMITATIONS). between terminals 5 and 2 of TB1. The voltage
Verify ow switch operation. should be 120VAC +/- 10%.
3. Program/verify the Cooling Setpoints, Program
Excessive ow may cause catastrophic Setpoints, and unit Options. Record the values
damage to the evaporator. below (see sections on Setpoints and Unit Keys
for programming instruction) in Table 1.
4. Put the unit into Service Mode (as described under
the Control Service and Troubleshooting section)
and cycle each condenser fan to ensure proper
rotation.
38 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
TABLE 1 SETPOINTS ENTRY LIST The chilled liquid setpoint may need
OPTIONS to be temporarily lowered to ensure
Display Language all compressors cycle on.
Sys 1 Switch
Chilled Liquid
* Ambient Control
Local/Remote Mode
Control Mode This unit uses scroll compressors
Display Units
* Lead/Lag Control
which can only operate in one direc-
* Fan Control tion. Failure to observe this will lead
Manual Override to compressor failure.
Current Feedback
** Soft Start
** Unit Type
** Refrigerant Type
** Expansion Valve Type The chilled liquid setpoint may need
COOLING SETPOINTS to be temporarily lowered to ensure all
Cooling Setpoint compressors cycle ON.
Range
EMS-PWM Max. Setpoint
PROGRAM
Discharge Pressure Cutout
Suct. Pressure Cutout
Low Amb. Temp. Cutout 5
Leaving Liquid Temp. Cutout
Anti-Recycle Time
Fan Control On Pressure
Fan Differential Off Pressure
Total # of Compressors
* Number of Fans/System
* Unit/Sys Voltage
Unit ID
* Sys 1 Superheat Setpoint
JOHNSON CONTROLS 39
Commissioning
FORM 150.66-NM4 (608)
CHECKING SUPERHEAT AND SUBCOOLING When adjusting the expansion valve (TXV only), the
adjusting screw should be turned not more than one
The subcooling temperature of each system can be cal- turn at a time, allowing sufcient time (approximately
culated by recording the temperature of the liquid line 15 minutes) between adjustments for the system and the
at the outlet of the condenser and subtracting it from thermal expansion valve to respond and stabilize.
the liquid line saturation temperature at the liquid stop
valve (liquid line saturation temp. is converted from a Assure that superheat is set at a minimum of 10F (5.56C)
temperature/pressure chart). with a single compressor running on each circuit.
Example:
Liquid line pressure = 2. Record the suction temperature, suction pressure,
202 PSIG converted to temp. 102F suction saturation temperature, and superheat of
minus liquid line temp. - 87F each system below:
Subcooling = 15F
SYS 1
The subcooling should be adjusted to 15F at design
Suction Temp = _______ F
conditions.
Suction Pressure = _______ PSIG
1. Record the liquid line pressure and its correspond- Saturation Temp = _______ F
ing temperature, liquid line temperature and Superheat = _______ F
subcooling below:
LEAK CHECKING
SYS 1
Liq Line Press = _______ PSIG 1. Leak check compressors, ttings, and piping to
Saturated Temp = _______ F
ensure no leaks.
Liq Line Temp = _______ F
Subcooling = _______ F
If the unit is functioning satisfactorily during the initial
After the subcooling is veried, the suction superheat operating period, no safeties trip and the compressors
should be checked. The superheat should be checked only cycle to control water temperature to setpoint, the chiller
after steady state operation of the chiller has been estab- is ready to be placed into operation.
lished, the leaving water temperature has been pulled down
to the required leaving water temperature, and the unit is
running in a fully loaded condition. Correct superheat set-
ting for a system is 10F - 15F (5.56C - 8.33C) 18 (46
cm) from the cooler.
40 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
1. For the chiller system to run, the Flow Switch must 5. After 1 minute of compressor run time, the next
be closed, any remote cycling contacts must be compressor in sequence will start when a system
closed, the Daily Schedule must not be scheduling has to load. Additional compressors will be started at
the chiller off, and temperature demand must be 60 second intervals as needed to satisfy temperature
present. setpoint.
2. When power is applied to the system, the micropro- 6. If demand requires, the lag system will cycle
cessor will start a 2 minute timer. This is the same on with the same timing sequences as the lead
timer that prevents an instantaneous start after a system after the lead system has run for ve min-
power failure. utes. Refer to the section on Capacity Control for
a detailed explanation of system and compressor
3. At the end of the 2 minute timer, the microproces- staging.
sor will check for cooling demand. If all conditions 5
allow for start, a compressor on the lead system 7. As the load decreases below setpoint, the compres-
will start and the liquid line solenoid will open. sors will be shut down in sequence. This will occur
Coincident with the start, the anti-coincident timer at intervals of either 60, 30, or 20 seconds based
will be set and begin counting downward from 60 on water temperature as compared to setpoint, and
seconds to 0 seconds. control mode. See the section on Capacity Control
for a detailed explanation.
If the unit is programmed for Auto Lead/Lag, the
system with the shortest average run-time of the 8. When the last compressor in a system (two or three
compressors will be assigned as the lead system. compressors per system), is to be cycled off, the
A new lead/lag assignment is made whenever all system will initiate a pump-down. Each system
systems shut down. has a pump-down feature upon shut-off. On a non-
safety, non-unit switch shutdown, the LLSV will be
turned off, and the last compressor will be allowed
to run until the suction pressure falls below the suc-
tion pressure cutout or for 180 seconds, whichever
comes rst.
JOHNSON CONTROLS 41
Technical Data
FORM 150.66-NM4 (608)
ENGLISH
LEAVING WATER HEAT EXCHANGER
AIR ON CONDENSER (F)
YCAL TEMPERATURE (F) FLOW (GPM)
MIN MAX MIN MAX MIN MAX
0012 40 55 12 47 0 125
0018 40 55 17 68 0 125
0021 40 55 21 84 0 125
0025 40 55 25 100 0 125
0027 40 55 30 121 0 125
0032 40 55 34 136 0 125
NOTES:
1. For leaving brine temperature below 40F (4.4C), contact your nearest YORK Ofce for application requirements.
2. For leaving water temperature higher than 55F (12.8C), contact the nearest YORK Ofce for application guidelines.
3. The evaporator is protected against freezing to -20F (-28.8C) with an electric heater as standard.
4. For operation at temperatures below 25F (-3.9C), the optional Low Ambient Kit will need to be installed on the system.
5. For operation at temperatures above 115F (46.1C), the optional High Ambient Kit will need to be installed on the system.
42 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
ENGLISH
1000.0
100.0
PRESSURE DROP, Ft H2O
10.0
1.0 C
0.1
1 10 100 1000
FLOW, GPM LD11835
Note: Water Pressure Drop Curves may extend past the minimum and maximum water ow ranges.
% WT FACTORS FREEZE
ETHYLENE POINT
COMPR. DELTA GPM/F/
GLYCOL TONS (F)
kW P TON
10 .994 .997 1.03 24.1 26
20 .986 .993 1.06 24.9 16
30 .979 .990 1.09 25.9 5
40 .970 .985 1.13 27.3 -10
50 .959 .980 1.16 29.0 -32
JOHNSON CONTROLS 43
Technical Data
FORM 150.66-NM4 (608)
SI UNITS
LEAVING WATER HEAT EXCHANGER
YCAL AIR ON CONDENSER (C)
TEMPERATURE (DC) FLOW (L/S)
MIN MAX MIN MAX MIN MAX
0012 4.4 12.8 0.7 3.0 -17.7 51.7
0018 4.4 12.8 1.1 4.3 -17.7 51.7
0021 4.4 12.8 1.3 5.3 -17.7 51.7
0025 4.4 12.8 1.6 6.3 -17.7 51.7
0027 4.4 12.8 1.9 7.6 -17.7 51.7
0032 4.4 12.8 2.2 8.6 -17.7 51.7
NOTES:
1. For leaving brine temperature below 40F (4.4C), contact your nearest YORK Ofce for application requirements.
2. For leaving water temperature higher than 55F (12.8C), contact the nearest YORK Ofce for application guidelines.
3. The evaporator is protected against freezing to -20F (-28.8C) with an electric heater as standard.
4. For operation at temperatures below 25F (-3.9C), the optional Low Ambient Kit will need to be installed on the system.
5. For operation at temperatures above 115F (46.1C), the optional High Ambient Kit will need to be installed on the system.
44 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
SI
1000.0
B
D
100.0
PRESSURE DROP, kPA
10.0 A
1.0
E
0.1
0.1 1 10 100
FLOW, L/S LD11836
Note: Water Pressure Drop Curves may extend past the minimum and maximum water ow ranges.
% WT FACTORS FREEZE
ETHYLENE POINT
COMPR. DELTA GPM/F/
GLYCOL TONS (F)
kW P TON
10 .994 .997 1.03 24.1 26
20 .986 .993 1.06 24.9 16
30 .979 .990 1.09 25.9 5
40 .970 .985 1.13 27.3 -10
50 .959 .980 1.16 29.0 -32
JOHNSON CONTROLS 45
Technical Data
FORM 150.66-NM4 (608)
50Hz
* Shipping & Operating weights shown are for units without pump options.
46 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
50Hz
Condenser Condenser Fans, Low Sound Condenser Fans, Ultra Quiet Evaporator
JOHNSON CONTROLS 47
Technical Data
FORM 150.66-NM4 (608)
48 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
JOHNSON CONTROLS 49
FORM 150.66-NM4 (608)
DUAL
CIRCUIT
ELEMENT
BREAKER
FUSE
TERMINAL DISC. CIRCUIT
MIN
MIN BLOCK SWITCH BREAKER
CHILLER VOLT/ CKT LUG/ LUG/
N/F LUG LUG LUG
MODEL 50 Hz AMPS PHASE PHASE
DISC SW WIRE WIRE WIRE
(MCA) MIN MAX MIN MAX RANGE RANGE RANGE
NOTE: Values shown in the table above are for models without optional pump package.
50 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
1 5kA 5kA 5kA/65kA 15.5 114 15.5 114 2 1.3 2.5 --- ---
1 5kA 5kA 5kA/65kA 17.2 125 17.2 125 2 1.3 2.5 --- ---
1 5kA 5kA 5kA/65kA 21.8 158 21.8 158 2 3.4 17.2 3.4 21
1 5kA 5kA 5kA/65kA 23.7 187 21.8 158 2 3.4 17.2 3.4 21
1 5kA 5kA 5kA/65kA 23.7 187 23.7 187 2 3.4 17.2 3.4 21
JOHNSON CONTROLS 51
Technical Data
FORM 150.66-NM4 (608)
ELECTRICAL DATA
TABLE 11 MICRO PANEL POWER SUPPLY
It is possible that multiple sources of power can be supplying the unit power panel. To pre-
vent serious injury or death, the technician should verify that NO LETHAL VOLTAGES are
present inside the panel AFTER disconnecting power, PRIOR to working on equipment.
The unit evaporator 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.
VOLTAGE RANGE
VOLTAGE CODE UNIT POWER MIN. MAX.
-50 380-415/3/50 342 440
52 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
1. Minimum Circuit Ampacity (MCA) is based on 125% of the rated load amps for the largest motor plus 100% of
the rated load amps for all other loads included in the circuit, per N.E.C. Article 430-24. If the optional Factory
Mounted Control Transformer is provided, add the following MCA values to the electrical tables for the system
providing power to the transformer: -17, add 2.5 amps; -28, add 2.3 amps; -40, add 1.5 amps, -46, add 1.3 amps;
-58, add 1 amps.
2. The minimum recommended disconnect switch is based on 115% of the rated load amps for all loads included
in the circuit, per N.E.C. Article 440.
3. Minimum fuse size is based upon 150% of the rated load amps for the largest motor plus 100% of the rated load
amps for all other loads included in the circuit to avoid nuisance trips at start-up due to lock rotor amps. It is not
recommended in applications where brown outs, frequent starting and stopping of the unit, and/or operation at
ambient temperatures in excess of 95F (35C) is anticipated.
4. Maximum fuse size is based upon 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, per N.E.C. Article 440-22.
5. Circuit breakers must be UL listed and CSA certied and maximum size 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. 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 by the
unit wiring lugs. The (2) preceding the wire range indicates the number of termination points available per phase
of the wire range specied. Actual wire size and number of wires per phase must be determined based on the
National Electrical Code, using copper connectors only. Field wiring must also comply with local codes. 6
7. A ground lug is provided for each compressor system to accommodate a eld grounding conductor per N.E.C.
Table 250-95. A control circuit grounding lug is also supplied.
8. The supplied disconnect is a Disconnecting Means as dened in the N.E.C. 100, and is intended for isolating the
unit for the available power supply to perform maintenance and troubleshooting. This disconnect is not intended
to be a Load Break Device.
9. Field Wiring by others which complies to the National Electrical Code & Local Codes.
LEGEND:
JOHNSON CONTROLS 53
Technical Data
FORM 150.66-NM4 (608)
ELEMENTARY DIAGRAM
STANDARD LOW SOUND UNITS (0012 - 0021)
STANDARD LOW AND ULTRA LOW SOUND UNITS (0025 - 0032)
FOR LOW AMBIENT KIT, REMOVE WIRE 127 FROM CONTROL CIRCUIT TERMINAL
TB7-9 AND RECONNECT IT TO TB7-3.
LD13257
54 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
LD13258
JOHNSON CONTROLS 55
Technical Data
FORM 150.66-NM4 (608)
ELEMENTARY DIAGRAM
STANDARD LOW SOUND UNITS (0012 - 0021)
STANDARD LOW AND ULTRA LOW SOUND UNITS (0025 - 0032)
LD13256
56 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONNECTION DIAGRAM
STANDARD LOW SOUND UNITS (ALL MODELS)
035-21472-104
REV. A
LD13254
JOHNSON CONTROLS 57
Technical Data
FORM 150.66-NM4 (608)
ALL MODELS
LD13253
58 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONNECTION DIAGRAM
ALL MODELS
6
BACNET MICROGATEWAY OPTION
LD11796A
JOHNSON CONTROLS 59
Technical Data
FORM 150.66-NM4 (608)
3 1/4"
6 3/4"
7/8" TYP.
2" DIA
(2) 3.0 X 1.50
46 1/16"
B B RIGGING HOLES
45 1/4" BOTH ENDS
2 1/4"
11 5/8"
LEFT END
LD11811
NOTE:
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reli-
able operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
airow patterns and possible diminished performance. YORKs unit controls will optimize operation without nuisance high-pressure safety
cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall
6'; rear to wall 6'; cooler end to wall 4'0"; coil end to wall - 6'; top no obstructions allowed; distance between adjacent units 10'.
No more than one adjacent wall may be higher than the unit. 1" nominal deection isolators (not shown) will increase overall unit height by
6".
60 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL
PANEL COMPR
44 3/8"
END CAP END END
WIDTH
32 1/8"
6 1/8"
1 1/16"
ORIGIN 2 1/4"
Y 5"
17" TOP VIEW
C
G X
1"
9 1/16"
CONTROL PANEL
6
38 3/16"
2 1/4" 3 3/8"
13 3/4"
Z 109 3/16"
FRONT VIEW
C
G X
LD11812
JOHNSON CONTROLS 61
Technical Data
FORM 150.66-NM4 (608)
3 1/4"
6 3/4"
7/8" TYP.
2" DIA
(2) 3.0 X 1.50
46 1/16"
B B RIGGING HOLES
45 1/4" BOTH ENDS
2 1/4"
11 5/8"
LEFT END
LD11813
NOTE:
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reli-
able operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
airow patterns and possible diminished performance. YORKs unit controls will optimize operation without nuisance high-pressure safety
cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall
6'; rear to wall 6'; cooler end to wall 4'0"; coil end to wall - 6'; top no obstructions allowed; distance between adjacent units 10'.
No more than one adjacent wall may be higher than the unit. 1" nominal deection isolators (not shown) will increase overall unit height by
6".
62 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL
PANEL COMPR
44 3/8"
END CAP END END
WIDTH
32 1/8"
6 1/8"
1 1/16"
ORIGIN 2 1/4"
Y 5"
17" TOP VIEW
C
G X
1"
9 1/16"
CONTROL PANEL 6
38 3/16"
2 1/4" 3 3/8"
13 3/4"
Z 109 3/16"
FRONT VIEW
C
G X
LD11814
JOHNSON CONTROLS 63
Technical Data
FORM 150.66-NM4 (608)
3 1/4"
6 3/4"
7/8" TYP.
2" DIA
(2) 3.0 X 1.50
46 1/16"
B B RIGGING HOLES
45 1/4" BOTH ENDS
2 1/4"
11 5/8"
LEFT END
LD11815
NOTE:
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reli-
able operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
airow patterns and possible diminished performance. YORKs unit controls will optimize operation without nuisance high-pressure safety
cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall
6'; rear to wall 6'; cooler end to wall 4'0"; coil end to wall - 6'; top no obstructions allowed; distance between adjacent units 10'.
No more than one adjacent wall may be higher than the unit. 1" nominal deection isolators (not shown) will increase overall unit height by
6".
64 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL
PANEL COMPR
44 3/8"
END CAP END END
WIDTH
32 1/8"
6 1/8"
1 1/16"
ORIGIN 2 1/4"
Y 5"
17" TOP VIEW
C
G X
1"
9 1/16"
CONTROL PANEL
6
38 3/16"
2 1/4" 3 3/8"
13 3/4"
Z 109 3/16"
FRONT VIEW
C
G X
LD11816
JOHNSON CONTROLS 65
Technical Data
FORM 150.66-NM4 (608)
82
171
22 TYP.
51 DIA
1272 B B (2) 76 X 38
1250 RIGGING HOLES
BOTH ENDS
216
58 394
LEFT END
LD11817
NOTE:
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reli-
able operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
airow patterns and possible diminished performance. YORKs unit controls will optimize operation without nuisance high-pressure safety
cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall
6'; rear to wall 6'; cooler end to wall 4'0"; coil end to wall - 6'; top no obstructions allowed; distance between adjacent units 10'.
No more than one adjacent wall may be higher than the unit. 1" nominal deection isolators (not shown) will increase overall unit height by
6".
66 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL
PANEL COMPR
44 3/8"
END END
END CAP
WIDTH
32 1/8"
6 1/8"
1 1/16"
ORIGIN 1 7/8"
Y 5"
17"
TOP VIEW
C
G X
1"
9"
CONTROL PANEL
6
42 1/8"
3 3/8"
17 3/4" 2 1/4"
C
G X FRONT VIEW
LD11818
JOHNSON CONTROLS 67
Technical Data
FORM 150.66-NM4 (608)
3 1/4"
6 3/4"
7/8" TYP.
2" DIA
50 1/16" B B (2) 3.0 X 1.50
49 1/4" RIGGING HOLES
BOTH ENDS
8 1/2"
2 1/4" 15 1/2"
LEFT END
LD11819
NOTE:
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reli-
able operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
airow patterns and possible diminished performance. YORKs unit controls will optimize operation without nuisance high-pressure safety
cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall
6'; rear to wall 6'; cooler end to wall 4'0"; coil end to wall - 6'; top no obstructions allowed; distance between adjacent units 10'.
No more than one adjacent wall may be higher than the unit. 1" nominal deection isolators (not shown) will increase overall unit height by
6".
68 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL
PANEL COMPR
44 3/8"
END END
END CAP
WIDTH
32 1/8"
6 1/8"
1 1/16"
ORIGIN 1 7/8"
Y 5"
17"
TOP VIEW
C
G X
1"
9"
CONTROL PANEL
6
42 1/8"
3 3/8"
17 3/4" 2 1/4"
C
G X FRONT VIEW
LD11820
JOHNSON CONTROLS 69
Technical Data
FORM 150.66-NM4 (608)
82
171
22 TYP.
51 DIA
1272 B B (2) 76 X 38
1250 RIGGING HOLES
BOTH ENDS
216
58 394
LEFT END
LD11821
NOTE:
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reli-
able operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
airow patterns and possible diminished performance. YORKs unit controls will optimize operation without nuisance high-pressure safety
cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall
6'; rear to wall 6'; cooler end to wall 4'0"; coil end to wall - 6'; top no obstructions allowed; distance between adjacent units 10'.
No more than one adjacent wall may be higher than the unit. 1" nominal deection isolators (not shown) will increase overall unit height by
6".
70 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL
PANEL COMPR
44 3/8"
END END
END CAP
WIDTH
32 1/8"
6 1/8"
1 1/16"
ORIGIN 1 7/8"
Y 5"
17"
TOP VIEW
C
G X
1"
9"
CONTROL PANEL
6
42 1/8"
3 3/8"
17 3/4" 2 1/4"
C
G X FRONT VIEW
LD11822
JOHNSON CONTROLS 71
Technical Data
FORM 150.66-NM4 (608)
82
171
22 TYP.
51 DIA
(2) 76 X 38
1170
B B RIGGING HOLES
1149 BOTH ENDS
58
295
LEFT END
LD11823
72 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL
PANEL COMPR
1128
END CAP END END
WIDTH
815
156
28
ORIGIN 58
Y 126
431 TOP VIEW
C
G X
25
230
CONTROL PANEL 6
970
58 86
350
(2) 178 X 57
FORKLIFT HOLES
BOTH SIDES (2) 76 X 38
398 RIGGING HOLES
1130 BOTH SIDES
1892
2466
Z 2774
FRONT VIEW
C
G X
LD11824
JOHNSON CONTROLS 73
Technical Data
FORM 150.66-NM4 (608)
82
171
22 TYP.
51 DIA
(2) 76 X 38
1170
B B RIGGING HOLES
1149 BOTH ENDS
58
295
LEFT END
LD11825
74 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL
PANEL COMPR
1128
END CAP END END
WIDTH
815
156
28
ORIGIN 58
Y 126
431 TOP VIEW
C
G X
25
230
CONTROL PANEL
970
58 86
350
(2) 178 X 57
FORKLIFT HOLES
BOTH SIDES (2) 76 X 38
398 RIGGING HOLES
1130 BOTH SIDES
1892
2466
Z 2774
FRONT VIEW
C
G X
LD11826
JOHNSON CONTROLS 75
Technical Data
FORM 150.66-NM4 (608)
82
171
22 TYP.
51 DIA
(2) 76 X 38
1170
B B RIGGING HOLES
1149 BOTH ENDS
58
295
LEFT END
LD11827
76 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL
PANEL COMPR
1128
END CAP END END
WIDTH
815
156
317 512 28
ORIGIN 58
Y 126
431 TOP VIEW
C
G X
25
230
CONTROL PANEL
6
970
58 86
350
(2) 178 X 57
FORKLIFT HOLES
BOTH SIDES (2) 76 X 38
398 RIGGING HOLES
1130 BOTH SIDES
1892
2466
Z 2774
FRONT VIEW
C
G X
LD11828
JOHNSON CONTROLS 77
Technical Data
FORM 150.66-NM4 (608)
82
171
22 TYP.
51 DIA
1272 B B (2) 76 X 38
1250 RIGGING HOLES
BOTH ENDS
216
58 394
LEFT END
LD11829
78 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL
PANEL COMPR
1128
END END
END CAP
WIDTH
815
156
28
ORIGIN 47
Y 126
431
TOP VIEW
C
G X
25
229
CONTROL PANEL
1070
86
450 58
(2) 178 X 57
FORKLIFT HOLES
398 BOTH SIDES (2) 76 X 38
RIGGING HOLES
1282 BOTH SIDES
2044
Z 2669
3005
C
G X FRONT VIEW
LD11830
JOHNSON CONTROLS 79
Technical Data
FORM 150.66-NM4 (608)
82
171
22 TYP.
51 DIA
1272 B B (2) 76 X 38
1250 RIGGING HOLES
BOTH ENDS
216
58 394
LEFT END
LD11831
80 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL
PANEL COMPR
1128
END END
END CAP
WIDTH
815
156
28
ORIGIN 47
Y 126
431
TOP VIEW
C
G X
25
229
CONTROL PANEL
1070
86
450 58
(2) 178 X 57
FORKLIFT HOLES
398 BOTH SIDES (2) 76 X 38
RIGGING HOLES
1282 BOTH SIDES
2044
Z 2669
3005
C
G X FRONT VIEW
LD11832
JOHNSON CONTROLS 81
Technical Data
FORM 150.66-NM4 (608)
82
171
22 TYP.
51 DIA
1272 B B (2) 76 X 38
1250 RIGGING HOLES
BOTH ENDS
216
58 394
LEFT END
LD11833
82 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CONTROL
PANEL COMPR
1128
END END
END CAP
WIDTH
815
156
28
ORIGIN 47
Y 126
431
TOP VIEW
C
G X
25
229
CONTROL PANEL
6
1070
86
450 58
(2) 178 X 57
FORKLIFT HOLES
398 BOTH SIDES (2) 76 X 38
RIGGING HOLES
1282 BOTH SIDES
2044
Z 2669
3005
C
G X FRONT VIEW
LD11834
JOHNSON CONTROLS 83
Technical Data
FORM 150.66-NM4 (608)
(2 m)
(1.3 m) (2 m)
(2 m)
LD11301A
NOTES:
1. No obstructions allowed above the unit.
2. Only one adjacent wall may be higher than the unit.
3. Adjacent units should be 10 feet (3 Meters) apart.
84 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
YCAL0018 Neoprene ND-C ND-C ND-C ND-C ND-C ND-C ND-C ND-C
SLRS- SLRS- SLRS- SLRS- SLRS- SLRS-2- SLRS-2- SLRS-
Seismic
2-C2-420 2-C2-660 2-C2-420 2-C2-660 2-C2-420 C2-660 C2-420 2-C2-660
YCAL0021 Neoprene ND-C ND-C ND-C ND-C ND-C ND-C ND-C ND-C
SLRS- SLRS- SLRS- SLRS- SLRS-2 SLRS-2- SLRS-2- SLRS-2-
Seismic
2-C2-420 2-C2-660 2-C2-420 2-C2-660 -C2-520 C2-660 C2-520 C2-660
1 Deection CIP-B-450 CIP-B-1000 CIP-B-450 CIP-B-750 CIP-B-750 CIP-B-1000 CIP-B-750 CIP-B-1000
YCAL0025 Neoprene ND-C ND-C ND-C ND-C ND-C ND-C ND-C ND-C
SLRS- SLRS- SLRS- SLRS- SLRS- SLRS-2- SLRS-2- SLRS-2-
Seismic
2-C2-520 2-C2-920 2-C2-420 2-C2-920 2-C2-520 C2-920 C2-520 C2-920
YCAL0032 Neoprene ND-C ND-C ND-C ND-C ND-C ND-C ND-C ND-C
CONTROL
PANEL
END
R1 R2
LD12283
JOHNSON CONTROLS 85
Technical Data
FORM 150.66-NM4 (608)
Weights of specic chiller models vary signicantly as Whenever the isolator option is ordered, the isolators
options are added. As a result, total weights, weights at will be shipped loose with the chiller. Packed with the
individual isolator positions, and actual isolator selec- isolators and also in the control panel information packet
tion at each position cannot be published due to the is a drawing and table specically for each chiller, based
vast number of possible combinations. This informa- on the option selection. The drawing and table will be
tion will be available when the specic chiller/ option similar to the ones shown below. The drawing will show
selection is made from the local YORK sales ofce. the isolator locations along with the weight in pounds
Be aware, weights may change with each option along and kilograms at the specic location, isolator position,
with possible isolator changes. Weights and isolators and location measurements for each isolator.
may need to be recalculated when the option selections
are changed.
ISOLATOR LOCATIONS
L2 R2
Y L1 R1
CONTROL
PANEL END
C X
LD12283A
G
SAMPLE PRINTOUT SUPPLIED IN THE ISOLATOR PACKAGE AND IN THE CHILLER PANEL LITERATURE PACKET
86 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
CIP-X-
NON-SKID NEOPRENE
ACOUSTICAL ISOLATION PAD L
(Bolting to floor is not necessary for
indoor applications)
T
W
SBC
HCL
MAX BOLT
DIA. - MBD
6
Slot Width - SW
All springs have additional
HCW
travel to solid equal to 50%
of the rated deflection.
ENGLISH
Size A T L W SW HCL HCW MBD FREE HT MIN HT
CIP-2 5 - 3/4 8 - 1/ 4 1/ 2 2 - 3/ 4 7/16 6 - 1/2 1 - 1/2 3/ 8 6 - 1/8 5 - 1/4
SI
CIP-2 146.0 209.5 12.7 69.8 11.1 165.1 38.1 3/8 155.5 133.3
JOHNSON CONTROLS 87
Technical Data
FORM 150.66-NM4 (608)
3. Lubricate the threads of adjusting bolt. Loosen the 8. Turn the leveling bolt of all mountings in either direc-
hold down bolts to allow for isolator adjustment. tion in order to level the installation.
4. Block the equipment 10mm (1/4) higher than the 9. Tighten the nuts on hold down bolts to permit a clear-
specied free height of the isolator. To use the iso- ance of 2mm (1/8) between resilient washer and
lator as blocking for the equipment, insert a 10mm underside of channel cap plate.
(1/4) shim between the upper load plate and vertical
uprights. Lower the equipment on the blocking or
10. Installation is now complete.
shimmed isolators.
88 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
ND-C
BC
H L
W
T 6
ND.eps
ENGLISH
Size D H L T W BC CS MBD
ND-C 2 9/16 2 3/ 4 5 1/ 2 1/ 4 2 5/16 4 1/80 1/2- 13 x 1 1/ 2"
SI
ND-C 65.1 69.9 139.7 6.4 58.7 101.9 1/2- 13 x 1 1/ 2"
JOHNSON CONTROLS 89
Technical Data
FORM 150.66-NM4 (608)
HCL Adjustment
HCW L Bolt
W
ENGLISH
SIZE H T D E L HCL W HCW MBD
2-C2 8-1/2 3/8 5/8 1-3/8 14 12-1/4 5-1/4 3-1/ 2 5/8"
SI
SIZE H T D E L HCL W HCW MBD
2-C2 215.9 9.5 15.9 34.9 355.6 311.2 133.4 88.9 5/8"
90 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
6
"D" Tap - 4 Holes unless
otherwise requested
Vertical Limit
Stops-Out of
contact during LIMIT STOP
normal operation BOLT
Adjustment
Bolt
LD10568
JOHNSON CONTROLS 91
Unit Controls
FORM 150.66-NM4 (608)
00065VIP
A Master ON/Off switch is available to activate or de- 24VAC is rectied and ltered to provide unregulated
activate the unit. +30VDC to supply the ow switch, PWM remote tem-
perature reset, and demand limit circuitry which is
available to be used with eld supplied contacts. The
Microprocessor Board energizes on-board relays to
output 120VAC to motor contactors, solenoid valves,
etc. to control system operation. 120VAC is supplied
to the optimal T3 Transformer, which supplies 12VAC
to the bridge diode module. The Bridge Diode Module
recties the voltage to -12V unreg. The +12V unreg
voltage supplies power to the Remote Temp. Reset
Circuit Board.
92 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
A unit ON/OFF switch is just underneath the keypad. The Microprocessor Board contains a Real Time Clock
This switch allows the operator to turn the entire unit integrated circuit chip with an internal battery backup.
OFF if desired. The switch must be placed in the ON The purpose of this battery backup is to assure any
position for the chiller to operate. programmed values (setpoints, clock, cutouts, etc.) are
not lost during a power failure regardless of the time
DISPLAY involved in a power cut or shutdown period.
When a key is pressed, such as the OPER DATA key, The control software is common between single (1) and
system parameters will be displayed and will remain dual (2) system units. A jumper is installed between ter-
on the display until another key is pressed. The system minals 13 and 17 on the user terminal block to congure
parameters can be scrolled with the use of the (UP) a unit for a single system. Dual (2) system chillers do
and (DOWN) arrow keys. The display will update all not have a jumper installed. The jumper is only checked
information at a rate of about 1 a second. by the micro on power-up.
Display Messages may show characters indicating The total number of compressors is programmable un-
greater than (>) or less than (<). These characters der the Program Key. Single (1) system chillers have 2
indicate the actual values are greater than or less than compressors.
the limit values which are being displayed. 7
KEYPAD
JOHNSON CONTROLS 93
Unit Controls
FORM 150.66-NM4 (608)
STATUS KEY
00066VIP
UNIT STATUS R E MO T E C O N T R O L L E D
S H U T D OWN
Pressing the STATUS key will enable the operator to
determine current chiller operating status. The messages
displayed will include running status, cooling demand, The REMOTE CONTROLLED SHUTDOWN message
fault status, external cycling device status. The display indicates that either an ISN system or RCC has turned
will be a single message relating to the highest priority the unit OFF, not allowing it to run.
message as determined by the micro. Status messages
fall into the categories of General Status and Fault D A I L Y S C H E D U L E
Status. S H U T D OWN
S Y S 1 D S C H L I M I T I N G M A N U A L
O V E R R I D E
When this message appears, discharge pressure limiting If MANUAL OVERRIDE mode is selected, the STATUS
is in effect. The Discharge Pressure Limiting feature is display will display this message. This will indicate that
integral to the standard software control; however the the Daily Schedule is being ignored and the chiller will
discharge transducer is optional on some models. There- start-up when chilled liquid temperature allows, Remote
fore, it is important to keep in mind that this control will Contacts, UNIT switch and SYSTEM switches permit-
not function unless the discharge transducer is installed ting. This is a priority message and cannot be overridden
in the system. by anti-recycle messages, fault messages, etc. when in
the STATUS display mode. Therefore, do not expect to
see any other STATUS messages when in the MANUAL
OVERRIDE mode. MANUAL OVERRIDE is to only be
used in emergencies or for servicing. Manual override
mode automatically disables itself after 30 minutes.
JOHNSON CONTROLS 95
Unit Controls
FORM 150.66-NM4 (608)
S Y S 1 P U M P I N G D OWN S Y S 1 L OW S U C T P R E S S
Safety Status messages appear when safety thresholds in At system start, the cutout is set to 10% of programmed
the unit have been exceeded. Safeties are divided into value. During the next 3 minutes the cutout point is
two categories system safeties and unit safeties. Sys- ramped up to the programmed cutout point. If at any time
tem safeties are faults that cause the individual system during this 3 minutes the suction pressure falls below the
to be shut down. Unit safeties are faults that cause all ramped cutout point, the system will stop. This cutout is
running compressors to be shut down. Following are completely ignored for the rst 30 seconds of system run
display messages and explanations. time to avoid nuisance shutdowns, especially on units
that utilize a low pressure switch in place of the suction
System Safeties pressure transducer.
System safeties are faults that cause individual systems After the rst 3 minutes, if the suction pressure falls
to be shut down if a safety threshold is exceeded for 3 below the programmed cutout setting, a transient
seconds. They are auto reset faults in that the system protection routine is activated. This sets the cutout at
will be allowed to restart automatically after the fault 10% of the programmed value and ramps up the cutout
condition is no longer present. However, if 3 faults on over the next 30 seconds. If at any time during this 30
the same system occur within 90 minutes, that system seconds the suction pressure falls below the ramped
will be locked out on the last fault. This condition is then cutout, the system will stop.
a manual reset. The system switch (under OPTIONS
key) must be turned off and then back on to clear the S Y S 1 M P / H P C O F A U L T
lockout fault. Fault messages will be displayed whenever
a system is locked out.
S Y S 1 H I G H D S C H P R E S S Y S 1 M P / H P C O I N H I B
The Discharge Pressure Cutout is a software cutout in The Motor Protector/Mechanical High Pressure Cutout
the microprocessor and is backed-up by a mechanical protects the compressor motor from overheating or the
high pressure cutout switch located in the refrigerant system from experiencing dangerously high discharge
circuit. It assures that the system pressure does not pressure.
exceed safe working limits. The system will shutdown
when the programmable cutout is exceeded and will be This fault condition is present when CR1 (SYS 1) relay
allowed to restart when the discharge pressure falls 40 de-energizes due to the HP switch or motor protector
PSIG below the cutout. Discharge transducers must be opening. This causes the respective CR contacts to open
installed for this function to operate. causing 0VDC to be read on the inputs to the microboard.
The fault condition is cleared when a 30VDC signal is
restored to the input.
96 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
JOHNSON CONTROLS 97
Unit Controls
FORM 150.66-NM4 (608)
U N I T F A U L T : UNIT WARNING
L OW A M B I E N T T E M P
The following messages are not unit safeties and will
The Low Ambient Temp Cutout is a safety shutdown not be logged to the history buffer. They are unit warn-
designed to protect the chiller from operating in a low ings and will not auto-restart. Operator intervention is
ambient condition. If the outdoor ambient temperature required to allow a restart of the chiller.
falls below the programmable cutout, the chiller will
shut down. Restart can occur when temperature rises ! ! L OW B A T T E R Y ! !
C H E C K P R O G / S E T P / O P T N
2F above the cutoff.
The Low Battery Warning can only occur at unit
U N I T F A U L T : power-up. On micro panel power-up, the RTC battery
L OW L I Q U I D T E M P is checked. If a low battery is found, all programmed
setpoints, program values, options, time, schedule, and
The Low Leaving Chilled Liquid Temp Cutout protects history buffers will be lost. These values will all be reset
the chiller form an evaporator freeze-up should the to their default values which may not be the desired op-
chilled liquid temperature drop below the freeze point. erating values. Once a faulty battery is detected, the unit
This situation could occur under low ow conditions will be prevented from running until the PROGRAM key
or if the micro panel setpoint values are improperly is pressed. Once PROGRAM is pressed the anti-recycle
programmed. Anytime the leaving chilled liquid tem- timers will be set to the programmed anti-recycle time to
perature (water or glycol) drops below the cutout point, allow the operator time to check setpoints, and if neces-
the chiller will shutdown. Restart can occur when chilled sary, reprogram programmable values and options.
liquid temperature rises 2F above the cutout.
If a low battery is detected, it should be replaced as
U N I T F A U L T : soon as possible. The programmed values will all be lost
1 1 5 V A C U N D E R V O L T A G E and the unit will be prevented from running on the next
power interruption. The RTC/battery (031-02565-000)
is located at U5 on the IPU2.
The Under Voltage Safety assures that the system is not
operated at voltages where malfunction of the micropro-
I N C O R R E C T
cessor could result in system damage. When the 115VAC
U N I T T Y P E
to the micro panel drops below a certain level, a unit
fault is initiated to safely shut down the unit. Restart This indicates the condensing unit jumper is installed
is allowed after the unit is fully powered again and the between J4-11 and J4-6, on a liquid chiller. This jumper
anti-recycle timers have nished counting down. must be removed to operate the chiller.
98 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
System X
No Cooling load System X HIGH MTR CURR
7
(Optional) Incorrect Unit Type
System X Comps Run (Unit Warning Message)
LD11297
Manual Overide Status
JOHNSON CONTROLS 99
Unit Controls
FORM 150.66-NM4 (608)
DISPLAY/PRINT KEYS
00067VIP
The Display/Print keys allow the user to retrieve system With the UNIT TYPE set as a liquid chiller (via no
and unit information that is useful for monitoring chiller jumper between J4-11 and J4-6), the following list of
operation, diagnosing potential problems, troubleshoot- operating data screens are viewable under the Oper Data
ing, and commissioning the chiller. key in the order that they are displayed. The (DOWN)
arrow key scrolls through the displays in the order they
System and unit information, unit options, setpoints, appear below:
and scheduling can also be printed out with the use of
a printer. Both real-time and history information are The chiller MUST be set to be a liquid
available. chiller via no jumper between J11-
7 and J11-12. DO NOT operate the
OPER DATA Key chiller if not properly set up.
The OPER DATA key gives the user access to unit and
system operating parameters. When the OPER DATA
key is pressed, system parameters will be displayed and L C H L T = 4 6 . 2 F
remain on the display until another key is pressed. After R C H L T = 5 7 . 4 F
pressing the OPER DATA key, the various operating data
screens can be scrolled through by using the (UP) and
(DOWN) arrow keys or the ENTER/ADV key located This display shows chilled leaving and return liquid
under the ENTRY section. temperatures. The minimum limit on the display for
these parameters are 9.2F (-12.7C). The maximum
limit on the display is 140F (60C).
A M B I E N T A I R T E M P
= 8 7 . 5 F
S Y S 1 S T A R T S 1 = X X X X X
2 = X X X X X, 3 = X X X X X
A C T I V E R E MO T E C T R L
S Y S 1 F A N S T A G E 3
N O N E
NONE no remote control active. Remote monitoring The preceding ve messages will appear sequentially,
may be via ISN. rst for system 1, then for system 2.
ISN YORK Talk via ISN allows remote load limiting The rst message indicates the system and the associated
and temperature reset through an ISN system. compressors which are running.
*LOAD LIM load limiting enabled. Can be either The second message indicates the system run time in
stage 1 or stage 2 of limiting. days hours minutes seconds. Please note that this
is not accumulated run time but pertains only to the
*PWM TEMP EMS-PWM temperature reset current system cycle.
See the section on Condenser Fan Control in the UNIT TABLE 14 OPERATION DATA
OPERATION section for more information.
Oper Data Key
The fth message displays current as sensed by the Leaving & Chilled Liquid Temps
optional current feedback circuitry. The display reads
out in amps along with the DC feedback voltage from Ambient Air Temperature
the module. Current is calculated by:
System 1 Discharge & Suction Pressure
225A Actual Volts
EEV Only
5 Volts
SYS 1 Suction and SAT Suction Temp
The following table is a quick reference list for informa- *System 1 Accumulated Starts
tion available under the OPER DATA key.
Load and Unload Timers
PRINT KEY
LEAVING LIQUID TEMP 53.0
The PRINT key allows the operator to obtain a printout DEGF
of real-time system operating data or a history printout COOLING RANGE 42.0 +/- 2.0 DEGF
AMBIENT AIR TEMP 74.8 DEGF
of system data at the instant of the fault on the last six LEAD SYSTEM SYS 2
faults which occurred on the unit. An optional printer is EVAPORATOR PUMP ON
required for the printout. EVAPORATOR HEATER OFF
ACTIVE REMOTE CONTROL NONE
UNIT XXX.X AMPS X.X VOLTS
OPERATING DATA PRINTOUT SOFTWARE VERSION C.MMC.03.03
Pressing the PRINT key and then OPER DATA key al- SYSTEM 1 DATA
COMP STATUS 1=OFF 2=OFF 3=OFF
lows the operator to obtain a printout of current system RUN TIME 0- 0- 0- 0 D-H-M-S
operating parameters. When the OPER DATA key is SUCTION PRESSURE 66 PSIG
pressed, a snapshot will be taken of system operating DISCHARGE PRESSURE 219 PSIG
SUCTION TEMPERATURE 52.8 DEGF
conditions and panel programming selections. This data SAT SUCTION TEMP 40.0 DEGF
will be temporarily stored in memory and transmission SUCTION SUPERHEAT 12.8 DEGF
of this data will begin to the printer. A sample Operating COOLER INLET REFRIG 31.6 DEGF
LIQUID LINE SOLENOID OFF
Data printout is shown below. (Note: Not all values are HOT GAS BYPASS VALVE OFF
printed for all models.) CONDENSER FAN STAGES OFF
EEV OUTPUT 0.0 %
SYSTEM XXX.X AMPS X.X VOLTS
YORK INTERNATIONAL CORPORATION
MILLENNIUM LIQUID CHILLER
DAILY SCHEDULE
UNIT STATUS S M T W T F S *=HOLIDAY
2:04PM 01 JAN 08 MON START=00:00AM
STOP=00:00AM
SYS 1 NO COOLING LOAD TUE START=00:00AM
SYS 2 COMPRESSORS RUNNING 2 STOP=00:00AM
WED START=00:00AM
OPTIONS STOP=00:00AM
CHILLED LIQUID WATER THU START=00:00AM
AMBIENT CONTROL STANDARD STOP=00:00AM
LOCAL/REMOTE MODE REMOTE FRI START=00:00AM
CONTROL MODE LEAVING LIQUID STOP=00:00AM
LEAD/LAG CONTROL AUTOMATIC SAT START=00:00AM
FAN CONTROL AMB & DSCH PRESS STOP=00:00AM
CURRENT FEEDBACK NONE HOL START=00:00AM
SOFT START ENABLED STOP=00:00AM
EXPANSION VALVE THERMO-
STATIC
PROGRAM VALUES
DSCH PRESS CUTOUT 395 PSIG See Service And Troubleshooting sec-
SUCT PRESS CUTOUT 44 PSIG
LOW AMBIENT CUTOUT 25.0 tion for Printer Installation informa-
DEGF tion.
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
Pressing the PRINT key and then the HISTORY key The HISTORY key gives the user access to many unit
allows the operator to obtain a printout of information and system operating parameters at the time of a unit
relating to the last 6 Safety Shutdowns which occurred. or system safety shutdown. When the HISTORY key is
The information is stored at the instant of the fault, pressed the following message is displayed.
regardless of whether the fault caused a lockout to
occur. The information is also not affected by power D I S P L A Y S A F E T Y S H U T-
failures (long-term internal memory battery backup D OWN N O . 1 ( 1 TO 6 )
is built into the circuit board) or manual resetting of a
fault lock-out. While this message is displayed, the (UP) arrow key can be
used to select any of the six history buffers. Buffer number
When the HISTORY key is pressed, a printout is trans- 1 is the most recent, and buffer number 6 is the oldest safety
mitted of all system operating conditions which were shutdown that was saved.
stored at the instant the fault occurred for each of the
6 Safety Shutdowns buffers. The printout will begin After selecting the shutdown number, pressing the ENTER
with the most recent fault which occurred. The most key displays the following message which shows when the
recent fault will always be stored as Safety Shutdown shutdown occurred.
No. 1. identically formatted fault information will then
be printed for the remaining safety shutdowns. S H U T D OWN O C C U R R E D
0 3 : 5 6 P M 2 9 J A N 0 2
Information contained in the Safety Shutdown buffers is
very important when attempting to troubleshoot a system Pressing the (DOWN) arrow key repeatedly from the DIS-
problem. This data reects the system conditions at the PLAY SAFETY SHUTDOWN NO. X displays the software
instant the fault occurred and often reveals other system version.
conditions which actually caused the safety threshold
to be exceeded. S O F T WA R E V E R S I O N
C . MM C . 0 4 . 0 1
The history printout is similar to the operational data
printout shown in the previous section. The differences 7
The (UP) and (DOWN) arrow keys are used to scroll
are in the header and the schedule information. The daily
forward and backward through the history buffer to
schedule is not printed in a history print.
display the shutdown conditions stored at the instant the
fault occurred. The (DOWN) arrow key scrolls through
One example history buffer printout is shown following.
the displays in the order they appear below:
The data part of the printout will be exactly the same as
the operational data print so it is not repeated here. The
difference is that the Daily Schedule is not printed in the U N I T F A U L T :
history print and the header will be as follows. L OW L I Q U I D T E M P
SYS 1 HIGH DSCH PRESS SHUTDOWN Displays the type of chiller; Liquid, Condensing Unit
or Heat Pump.
C H I L L E D L I Q U I D
X X X X X
A M B I E N T C O N T R O L L OW A M B I E N T T E M P
X X X X X X X X X X C U T O U T = X X X . X F
Displays the type of Ambient Control; Standard or Low Displays the programmed Low Ambient Cutout.
Ambient.
L E A V I N G L I Q U I D T E M P
C U T O U T = X X X . X F
L O C A L / RE MO T E MO D E
X X X X X X X X X
Displays the Leaving Liquid Temp. Cutout pro-
grammed.
Displays Local or Remote control selection.
F A N C O N T R O L O N
C O N T R O L MO D E P R E S S U R E = X X X P S I G
L E A V I N G L I Q U I D
Displays the programmed Fan On Pressure.
Displays the type of chilled liquid control; Leaving or
Return. F A N D I F F E R E N T I A L OFF
P R E S S U R E = PS I G
L E A D / L A G C O N T R O L
X X X X X X X X Displays the programmed Fan Off Differential.
M A N U A L O V E R R I D E MO D E S E T P O I N T = X X X . X F
X X X X X X X X X R A N G E = + / - F
Displays whether Manual Override was Enabled or Displays the programmed Setpoint and Range, if the
Disabled. chiller is programmed for leaving chilled liquid con-
trol.
C U R R E N T F E E D B A C K
X X X X X X X X X X X X X X X X S E T P O I N T = X X X . X F
R A N G E = + X X . X F
Displays type of Current Feedback utilized.
Displays the programmed Setpoint and Range, if the
S O F T S T A R T chiller is programmed for return chilled liquid control.
X X X X X X X
A M B I E N T A I R T E M P
= X X X . X F
Displays whether the optional European Soft Start was
installed and selected. Displays the Ambient Temp. at the time of the fault.
D I S C H A R G E P R E S S U R E
C U T O U T = X X X X P S I G
E V A P P U M P I S X X X S Y S 1 F A N S T A G E X X X
E V A P H E A T E R I S X X X
Displays status of the Evaporator Pump and Heater at Displays the number of Fan Stages in the system active
the time of the fault. at the time of the fault.
A C T I V E R E MO T E C T R L S Y S 1 AC T U A L A M P S
X X X X = X X X . X A M P S
Displays whether Remote Chiller Control was active Displays the system Amperage (calculated approxi-
when the fault occurred. mately) at the time of the fault.
U N I T A C T U A L A M P S
For this message to appear, CURRENT FEEDBACK
= X X X . X A M P S
ONE PER SYSTEM must be programmed under the op-
This is only displayed when the Current Feedback Op- tions key. If the micro is programmed as one CURRENT
tion is one per unit. FEEDBACK ONE PER UNIT under the program key, the
display will be the rst display prior to the SYS 1 info. If
S Y S 1 C OM P S T A T U S the micro is programmed for CURRENT FEEDBACK
1 = X X X 2 = X X X 3 = X X X NONE, no current display will appear.
Displays which Compressors were running in the system Displays for System 1 starting with SYS 1 NUMBER
when the fault occurred. OF COMPS RUNNING X through SYS 1 AMPS =
XXX.X VOLTS = X.X will be displayed.
S Y S 1 R U N T I M E
X X - X X - X X - X X D - H - M - S
Further explanation of the above displays is covered
under the STATUS, OPER DATA, COOLING SET-
Displays the system run time when the fault occurred.
POINTS, PROGRAM, and OPTIONS keys.
S Y S 1 S P = X X X X P S I G
D P = X X X X P S I G SOFTWARE VERSION
Displays the system Suction and Discharge Pressure of The software version may be viewed by rst pressing the 7
the time of the fault. HISTORY key and then the (DOWN) arrow key.
S Y S 1 S U C T = X X X . X F
S A T S U C T = X X X . X F
After pressing the HISTORY key, the display safety
shutdown message will be displayed.
Displays the System Suction Temp and Saturated Suc- D I S P L A Y S A F E T Y S H U T -
tion Temp when an EEV is installed. D OWN N O . 1 ( 1 T O 6 )
S Y S 1 E E V = X X X . X %
S U C T S H E A T = X X X . X F After the (DOWN) arrow key is pressed, the software
version will appear.
Displays the EEV signal % and Suction Superheat when S O F T WA R E V E R S I O N
an EEV is installed.
C . MM C . 0 3 . 0 6
S Y S 1 C O O L E R I N L E T
R E F R I G T E M P = X X X . X F
ENTRY KEYS
00068VIP
The Entry Keys allows the user to view, change programmed ENTER/ADV KEY
values. The ENTRY keys consist of an (UP) arrow key,
(DOWN) arrow key, and an ENTER/ADV key. The ENTER/ADV key must be pushed after any change
is made to the cooling setpoints, daily schedule, safety
UP AND DOWN ARROW KEYS setpoints, chiller options, and the clock. Pressing this
key enters the new values into memory. If the EN-
Used in conjunction with the OPER DATA, HISTORY, TER/ADV key is not pressed after a value is changed,
COOLING SETPOINTS, SCHEDULE/ADVANCE the changes will not be entered and the original values
DAY, OPTIONS and CLOCK keys, the (UP) and will be used to control the chiller.
(DOWN) arrow keys allow the user to scroll through
the various data screens. Refer to the section on DIS- Programming and a description on the use of the (UP)
PLAY/PRINT keys for specic information on the arrow key, and (DOWN) arrow, and ENTER/ADV
displayed information and specic use of the (UP) keys are covered in detail under the SETPOINTS, and
and (DOWN) arrow keys. UNIT keys.
The (UP) arrow key, and (DOWN) arrow key are also
used for programming the control panel such as chang-
ing numerical or text values when programming cooling
setpoints, setting the daily schedule, changing safety
setpoints, chiller options, and setting the clock.
SETPOINTS KEYS
00069VIP
Programming of the cooling setpoints, daily schedule, LEAVING CHILLED LIQUID CONTROL
and safeties is accomplished by using the keys located 7
under the SETPOINTS section. S E T P O I N T = 4 5 . 0 F
R A N G E = +/- 2 . 0 F
The three keys involved are labeled COOLING
SETPOINTS, SCHEDULE/ADVANCE DAY, and The above message shows the current chilled water
PROGRAM. temperature SETPOINT at 45.0F (notice the cursor po-
sitioned under the number 0). Pressing either the (UP)
Following are instructions for programming the respec- or (DOWN) arrow will change the setpoint in .5F
tive setpoints. The same instruction should be used to increments. After using the (UP) or (DOWN) arrow
view the setpoints with the exception that the setpoint keys to adjust to the desired setpoint, the ENTER/ADV
will not be changed. key must be pressed to enter this number into memory
and advance to the RANGE SETPOINT.
COOLING SETPOINTS
Entry of the setpoint will be indicated by the cursor mov-
ing under the current RANGE setpoint. The (UP) and
The Cooling Setpoint and Range can be programmed by (DOWN) arrow keys are used to set the RANGE, in
pressing the COOLING SETPOINTS key. The cooling .5 F increments, to the desired RANGE setpoint. After
mode (leaving chilled liquid or return chilled liquid) will adjusting the setpoint, the ENTER/ADV key must be
be displayed for a few seconds, and the setpoint display pressed to enter the data into memory.
entry screen will appear.
Notice that the RANGE was programmed for +/- X.X F.
This indicates the SETPOINT to be in the center of the
control range. If the control mode has been programmed
for RETURN LIQUID control, the message below
would be displayed in place of the previous message.
JOHNSON CONTROLS 109
Unit Controls
FORM 150.66-NM4 (608)
Both LEAVING and RETURN control are described in SCHEDULE/ADVANCE DAY KEY
detail under the section on CAPACITY CONTROL.
The SCHEDULE is a seven day daily schedule that al-
REMOTE SETPOINT CONTROL lows one start/stop time per day. The schedule can be
programmed Monday through Sunday with an alternate
Pressing the COOLING SETPOINTS key a second time holiday schedule available. If no start/stop times are
will display the remote setpoint and cooling range. This programmed, the unit will run on demand, providing the
display automatically updates about every 2 seconds. chiller is not shut off on a unit or system shutdown. The
Notice that these setpoints are not locally program- daily schedule is considered not programmed when
mable, but are controlled by a remote device such as an the times in the schedule are all zeros (00:00 AM).
ISN control, remote reset option board, or remote PWM
signal. These setpoints would only be valid if the unit To set the schedule, press the SCHEDULE/ADVANCE
was operating in the REMOTE mode. DAY key. The display will immediately show the fol-
lowing display.
The following messages illustrate both leaving chilled
liquid control and return chilled liquid control respec- MO N S T A R T = 0 0 : 0 0 A M
tively. S T O P = 0 0 : 0 0 A M
PROGRAM KEY L OW A M B I E N T T E M P
C U T O U T = 2 5 . 0 F
There are several operating parameters under the PRO-
GRAM key that are programmable. These setpoints can The LOW AMBIENT TEMP CUTOUT allows the user
be changed by pressing the PROGRAM key, and then the to select the chiller outside ambient temperature cutout
ENTER/ADV key to enter Program Mode. Continuing point. If the ambient falls below this point, the chiller
to press the ENTER/ADV key will display each oper- will shut down. Restart can occur when temperature
ating parameter. While a particular parameter is being rises 2F (1.11C) above the cutout setpoint.
displayed, the (UP) and (DOWN) arrow keys can
be used to change the value. After the value is changed, L E A V I N G L I Q U I D T E M P
the ENTER/ADV key must be pressed to enter the data C U T O U T = 3 6 . 0 F
into memory. Table 16 shows the programmable limits
and default values for each operating parameter. The LEAVING LIQUID TEMP CUTOUT protects the
chiller from an evaporator freeze-up. Anytime the leav-
Following are the displays for the programmable values ing chilled liquid temperature drops to the cutout point,
in the order they appear: the chiller shuts down. Restart will be permitted when
the leaving chilled liquid temperature rises 2F (1.11C)
d D I S C H A R G E P R E S S U R E above the cutout setpoint.
C U T O U T = 3 9 5 P S I G
When water cooling mode is programmed (OPTIONS
DISCHARGE PRESSURE CUTOUT is the discharge key), the value is xed at 36.0F (2.22C) and cannot
pressure at which the system will shutdown as monitored be changed. Glycol cooling mode can be programmed
by the optional discharge transducer. This is a software to values listed in Table 15.
shutdown that acts as a backup for the mechanical high
pressure switch located in the refrigerant circuit. The A N T I R E C Y C L E T I M E R
system can restart when the discharge pressure drops = 6 0 0 S E C
40 PSIG (2.76 BARG) below the cutout point.
The programmable anti-recycle timer assures that sys-
If the optional discharge pressure transducer is not tems do not short cycle, and the compressor motors have
installed, this programmable safety would not apply. sufcient time to dissipate heat after a start. This timer is
It should be noted that every system has a mechanical programmable under the PROGRAM key between 300
high pressure cutout that protects against excessive - 600 seconds. Whenever possible, to reduce cycling and
high discharge pressure regardless of whether or not the motor heating, the anti-recycle timer should be adjusted
optional discharge pressure is installed. as high as possible. The programmable anti-recycle timer
starts the timer when the rst compressor in a system
S U C T I O N P R E S S U R E starts. The timer begins to count down. If all the com-
C U T O U T = 4 4 . 0 P S I G pressors in the circuit cycle off, a compressor within the
circuit will not be permitted to start until the anti-recycle
The SUCTION PRESSURE CUTOUT protects the timer has timed out. If the lead system has run for less
chiller from an evaporator freeze-up. If the suction pres- than 5 minutes, 3 times in a row, the anti-recycle timer
sure drops below the cutout point, the system will shut will be extended to 10 minutes, if currently programmed
down. Typically, the cutout should be set to 44 PSIG for < 10 minutes.
(3.03 Bars) form water cooling.
F A N C O N T R O L O N
There are some exceptions when the P R E S S U R E = XX X P S I G
suction pressure is permitted to tem-
porarily drop below the cutout point. The Fan Control On-Pressure is the programmed pres-
Details are explained under the topic sure value that is used to stage the condenser fans on,
of SYSTEM SAFETIES. in relation to discharge pressure. Refer to Condenser
Fan Control in the UNIT OPERATION section and
Tables 19-22,
A single system chiller MUST have a The programmed value will be 2.8V. A similar calcula-
jumper between terminals 13 - 17 on tion and programming will be necessary for the other
terminal block CTB1. If the jumper system in a 2-system chiller.
is not installed, the unit will act as a
2-system chiller. The jumper is only
checked by the micro at unit power-up.
If the jumper is removed, power must
be removed and re-applied to register
the change in memory.
CURRENT FEEDBACK
UNIT/SYSTEM TRIP VOLTS OPTION ENABLED 0.5 4.5 2
ONE PER UNIT
REMOTE UNIT ID 0 7 0
EEV 10.0F 15.0F 12.0F
SYSTEM 1 SUPERHEAT SETPOINT
5.5C 8.3C 6.6C
* The minimum discharge pressure allowed is 160 PSIG. The fan differential Off Pressure will be lowered to prevent going below 160
PSIG based on where the fan control On Pressure is programmed.
Leaving Liquid
EMS - PWM Temperature
Remote Temp Cutout
Reset Setpoint
Anti-Recycle
Timer
Table 17 provides a quick reference of the setpoints list for the Setpoints Keys.
Fan Control
On-Pressure
Fan Differential 7
Off-Pressure
Total Numbers
of
Compressors
SYS / Unit
Trip Volts Option
Remote Unit ID
SYS 1
Superheat Setpoints
LD07404a
UNIT KEYS
00070VIP
OPTIONS KEY
There are many user programmable options under the Turning a system off with its system
OPTIONS key. The OPTIONS key is used to scroll switch allows a pumpdown to be per-
through the list of options by repeatedly pressing the formed prior to shutdown.
OPTIONS key . After the selected option has been dis-
played, 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 Option 3 Chilled Liquid Cooling Type:
enter the data into memory. Table 18 shows the program-
mable options. Following are the displays in the order C H I L L E D L I Q U I D
they appear: WA T E R
Option 1 Language: The chilled liquid is water. The Cooling Setpoint can be
programmed from 40F to 70F (4.4C to 21.1C)
D I S P L A Y L A N G U A G E or
E N G L I S H C H I L L E D L I Q U I D
G L Y C O L
English, Spanish, French, German, and Italian can be
programmed. The chilled liquid is glycol. The Cooling Setpoint can be
programmed from 10F to 70F (-12.2C to 21.1C).
Option 2 System Switches:
S Y S 1 SW I T C H O N
S Y S 1 SW I T C H O F F
A M B I E N T C O N T R O L C O N T R O L MO D E
S T A N D A R D L E A V I N G L I Q U I D
Option 5 Local/Remote Control Type: This mode displays system operating values in Scientic
International Units of C or BARG.
L O C A L / R E MO T E MO D E L
L O C A L
Option 8 Lead/Lag Type (two system units
only):
When programmed for LOCAL, an ISN or RCC control
can be used to monitor only. The micro panel will operate L E A D / L A G C O N T R O L
on locally programmed values and ignore all commands M A N U A L S Y S 1 L E A D
from remote devices, or through the RS-485 inputs. The
chiller will communicate and send data to the remote SYS 1 selected as lead compressor. SYS 1 lead option
monitoring devices. MUST be chosen on single system units.
or
or
7
L O C A L / R E MO T E MO D E
L E A D / L A G C O N T R O L
R E MO T E
A U T OM A T I C
Option 6 Unit Control Mode: Condenser fans are controlled by discharge pressure
only. This mode may only be chosen when discharge
C O N T R O L MO D E pressure transducers are installed.
R E T U R N L I Q U I D
Condenser fans are controlled by ambient temperature Chiller auto restarts after a power failure.
and discharge pressure. This mode must be chosen if the
discharge pressure transducers are not installed. P O W E R F A I L R E S T A R T
M A N U A L
Option 10 Manual Override Mode:
M A N U A L O V E R R I D E MO D E
After a power failure, the UNIT switch must be toggled
D I S A B L E D
before restart at the unit is allowed. NORMALLY
MANUAL RESTART should NOT BE SELECTED.
This option allows overriding of the daily schedule that
is programmed. MANUAL OVERRIDE MODE DIS- Option 13 Unit Type:
ABLED indicates that override mode has no effect.
or U N I T T Y P E
L I Q U I D C H I L L E R
M A N U A L O V E R R I D E MO D E
E N A B L E D
The UNIT TYPE message cannot be modied under
the unit keys.
Manual Override Mode is enabled. This is a service
function and when enabled, will allow the unit to start LIQUID CHILLER must be dis-
when shut down on the daily schedule. It will automati- played, or damage to compressors or
cally be disabled after 30 minutes. other components will occur if oper-
ated in the HEAT PUMP or CON-
Option 11 Current Feedback Options In- DENSING UNIT modes.
stalled:
This mode should be selected when an optional 2ACE Refrigerant type R-22, R410A or R-407C may be se-
Module is installed to allow combined current monitor- lected under Service Mode. Refrigerant type is displayed
ing of all systems by sensing current on the incoming under the Options Key, but is only programmable in
line. Current input is to J8-5 of the micro. On a single Service Mode.
system chiller per system and per unit performs the
same function. Either may be selected.
or
C U R R E N T F E E D B A C K
O N E P E R S Y S T E M
Incorrect programming may cause Press the ENTER key and the following message will
damage to compressors. be displayed until the update has been completed. The
keypad and display will not respond during the update.
DO NOT reset or power down the chiller until the update
is completed.
F L A S H C A R D U P D A T I N G
Option 15 Expansion Valve Type: P L E A S E WA I T . . .
E X P A N S I O N V A L V E T Y P E
After the update is completed, an automatic reboot will
T H E R M O S T A T I C
occur. If an error occurred, the following message will
Expansion valve type, thermostatic or electronic appear with the error code and no reboot will occur:
may be selected under Service Mode. Expansion valve F L A S H C A R D U P D A T E
type is displayed under the Options key, but is only E R R O R XXXXX
programmable in Service Mode. YCAL 0012 0032
chillers will typically always be equipped with thermo-
static expansion valves. If the update resulted in an error, the original program
will still be active. When an error occurs, assure the
Incorrect programming may cause correct Flash Card was utilized. Incorrect chiller soft-
damage to compressors. ware will cause an error. If this is not the case, the Flash
Card is most likely defective or the IPU and I/O combo
board is bad.
Option 16 Flash Card Update: Remote Temp Reset input selection is programmable
according to the type of input utilized. The following
F L A S H C A R D U P D A T E
options are available:
7
D I S A B L E D
DISABLED (default)
A Flash Card is used to input the operating program 0.0 10.0V (DC)
into the chiller IPU. A Flash Card is used instead of an 2.0 10.0V (DC)
EPROM. Normally, a Flash Card update is not required 0.0 20.0 mA
and the message above will be displayed.
4.0 20.0 mA
If the operating software is to be updated, insert the
Flash Card into the Flash Card input port. Turn off the
The options display message for Re-
unit switch and set the FLASH CARD UPDATE TO mote Temp Reset Input only appears if
ENABLED using the and keys. the Temp reset Option is enabled under
Service Mode.
F L A S H C A R D U P D A T E
E N A B L E D
Y O R K H Y D R O
P U M P S E L E C T I O N
K I T P U M P S = 1
A U T OM A T I C
Even if one of the above conditions The CLOCK display shows the current day, time, and
date. Pressing the CLOCK key will show the current
are true, the pump will not run if the
day, time, and date.
chiller has been powered up for less
than 30 seconds; or if the pump has It is important that the date and time be correct, other-
run in the last 30 seconds to prevent wise the daily schedule will not function as desired if
pump overheating. programmed. In addition, for ease of troubleshooting
via the History printouts, the day, time, and date should
E X T E R N A L be correct.
E V A P P U M P
To change the day, time, and date press the CLOCK
key. The display will show something similar to the fol-
EXTERNAL EVAP PUMP should be selected if an lowing:
external pump is being controlled with the chiller pump
contacts. The operation will be the same as YORK T O D A Y I S F R I 0 8 : 5 1 A M
HDRO KIT PUMPS = 1 2 5 J A N 0 8
The following option should not be selected. The line under the F is the cursor. If the day is correct,
press the ENTER/ADV key. The cursor will move un-
Y O R K H Y D R O
der the 0 in 08 hours. If the day is incorrect, press the
K I T P U M P S = 2
(UP) or (DOWN) arrow keys until the desired day is
displayed and then press the ENTER/ADV key at which
Option 19 Pump Selection: time the day will be accepted and the cursor will move
under the rst digit of the 2 digit hour. In a similar
The displays for this PUMP SELECTION option should manner, the hour, minute, meridian, month, day, and
only appear if YORK HYDRO KIT PUMPS = 2 are year may be programmed, whenever the cursor is under
selected under Option 19. the rst letter/numeral of the item. Press the (UP) or
(DOWN) arrow keys until the desired hour, minute,
P U M P S E L E C T I 0 N meridian; day, month, and year are displayed. Pressing
M A N U A L P U M P N O 1 the ENTER/ADV Key will save the valve and move the
cursor on to the next programmable variable.
Selecting Manual Pump 1 allows pump 1 to operate
as the duty pump without automatic change over to
pump 2.
Unit Type
("Chiller" MUST be Selected
Via No Jumper Installed)
(Viewable Only)
Table 18 provides a quick reference list for the Unit key setpoints.
SUCTION PRESSURE LIMIT CONTROLS If the chilled liquid temperature falls below the Setpoint
High Limit but is greater than the Setpoint Low Limit,
The anticipatory controls are intended to prevent the unit loading and unloading do not occur. This area of control
from ever actually reaching a low-pressure cutout. Load- is called the control range.
ing is prevented, if the suction pressure drops below 1.15
x suction pressure cutout. Load may reoccur after suction If the chilled liquid temperature drops to between Set-
pressure rises above the unload point and a period of point Low Limit and 0.5F (.28C) below the Setpoint
one minute elapses. This control is only operable if the Low Limit, unloading (a compressor turns off) occurs at
optional suction pressure transducers are installed. a rate of 1 every 60 seconds. If the chilled liquid tempera-
ture falls to a value greater than 0.5F (.28C) below the
Setpoint Low Limit but not greater than 1.5F (.83C)
DISCHARGE PRESSURE LIMIT CONTROLS
below the Setpoint Low Limit, unloading occurs at a rate
The discharge pressure limit controls unload a system of 30 seconds. If the chilled liquid temperature falls to
before it reaches a safety limit due to high load or dirty a value greater than 1.5F (.83C) below the Setpoint
condenser coils. The micro monitors discharge pressure Low Limit, unloading occurs at a rate of 20 seconds. If
and unloads a system, if fully loaded, by one compres- the chilled liquid temperature falls below 1F above the
sor when discharge pressure exceeds the programmed low chilled liquid temperature cutout, unloading occurs
cutout minus 15 PSIG. Reloading will occur when the at a rate of 10 seconds.
discharge pressure on the affected system drops to 85%
For leaving chilled liquid temperature setpoint and con-
of the unload pressure and 10 minutes have elapsed.
trol range combinations that result in the low limit of the
This control is only applicable if optional discharge control range being below 40.0F, the low limit will be
pressure transducers are installed. reset to 40.0F and the difference will be added to the
high limit. This will result in a control range the same
size as programmed but not allow the unit to run below
40.0F. This control will not affect glycol chillers.
cycle off, a compressor within the circuit will not be The EEV pilot solenoid is also used as a low superheat
permitted to start until the anti-recycle timer has timed safety device when the EEV is selected as the expan-
out. If the lead system has run for less than 5 minutes, sion valve type. While the system is running and not in
3 times in a row, the anti-recycle timer will be extended a pumpdown mode, the EEV pilot solenoid will close
to 10 minutes. if the suction superheat falls below 4F. The EEV pilot
solenoid will open again when the superheat rises above
ANTI-COINCIDENCE TIMER 7.0F. This safety device is ignored for the rst 30 sec-
onds of system run time. If the EEV pilot solenoid is
This timer is not present on single-system units. Controls closed 10 times in 2 minutes on the safety device, the
in software assure compressors within a circuit do not start low superheat safety will be triggered.
simultaneously. The anti-coincidence timer assures there
is at least a one minute delay between system starts on
2-circuit systems. This timer is NOT programmable. The CONDENSER FAN CONTROL
load timers further assure that there is a minimum time (YCAL0012 YCAL0032 CHILLERS)
between compressor starts within a system. Condenser fan operation must be programmed with the
Options key under Fan Control. Condenser fan con-
trol can be selected for Ambient Temp. and Discharge
EVAPORATOR PUMP CONTROL
Pressure, or Discharge Pressure only.
The evaporator pump dry contacts (CTB2 terminals
The condenser fan control by Ambient Temperature
23 - 24) are energized when any of the following condi-
and Discharge Pressure is a feature that is integral to
tions are true:
the standard software control. If the optional discharge
1. Low Leaving Chilled Liquid Fault transducer is not installed, the condenser fans will op-
2. Any compressor is running erate based on outdoor ambient temperature only. See
3. Daily Schedule is not programmed OFF and Table 19.
Unit Switch is ON
The pump will not run if the micro panel has been The condenser fan control by Discharge Pressure is
powered up for less than 30 seconds or if the pump a feature that can be selected if the discharge pressure
has run in the last 30 seconds to prevent pump motor transducer is installed and fan recycling is not a concern.
overheating. Fan control by discharge pressure will work accord-
ing to Table 20. The fan control on-pressure and fan
differential off-pressure are programmable under the
EVAPORATOR HEATER CONTROL PROGRAM key.
The evaporator heater is controlled by ambient air
temperature. When the ambient temperature drops A low ambient kit MUST be installed
below 40F (4.4C) the heater is turned on. When the when AMBIENT CONTROL LOW
temperature rises above 45F (7.2C) the heater is turned AMBIENT is selected under the OP-
off. An under voltage condition will keep the heater off TIONS key.
until full voltage is restored to the system.
MICROBOARD
FAN CONTACTOR FAN #
ON OFF OUTPUT TB-4
STAGE
SYS 1 SYS 1 SYS 1
OAT > 25F (-3.9C) OAT < 20F (6.7C)
1 or and
7M TB7-9 TB10-9
DP> Fan Crtl On DP < Fan Ctrl On
Press Press - (Diff.Press)
OAT > 65F (18.3C) OAT < 60F (15.6C)
2 or and
7M TB7-9 TB10-9
DP > Fan Ctrl On DP < Fan Ctrl On
& & &
Press Press -
8M TB7-10 TB10-10
+40 PSIG (2.76 Bars) (Diff. Press + 40 PSIG
(2.76 Bars))
TABLE 20 YCAL0012 YCAL0032 CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONLY
MICROBOARD
FAN CONTACTOR FAN #
ON OFF OUTPUT TB-4
STAGE
SYS 1 SYS 1 SYS 1
DP > Fan Ctrl DP < Fan Ctrl On
1 7M TB7-9 TB10-9
On Press Press - (Diff. Press.)
DP > Fan Ctrl On DP < Fan Ctrl On
7M TB7-9 TB10-9
2 Press + Press - ((Diff. Press.)
& & &
40 PSIG (2.76 Bars) + 40 PSIG
8M TB7-10 TB10-10
(2.76 Bars))
FAN #2
8
FAN #1
LD12211
LOW AMBIENT FAN CONTROL OPTION The VFD control signal is sent from a liquid temperature
YCAL0012-0021 UNTS sensor connected to a condenser coil return bend. The
sensor is connected to S1 and COM terminals of the VFD
in the control panel. The sensor must always be insu-
General lated. The location of the sensor is shown in Fig. 15.
The low ambient option consists of a single phase Vari-
The VFD will not only control fan speed in low ambi-
able Frequency Drive (VFD) that controls the speed of
ent conditions, but in all ambients based on the liquid
the rst fan (Fan 1) in the fan staging sequence. The
line temperature. Speed control of the fan will occur
VFD is located in the control panel. An example of the
whenever the liquid line solenoid is energized.
VFD location is shown in Fig. 14
Potentiometer Conguration
BULB
50094
50093b
The VFD is pre-congured from the factory prior to
FIG. 14 TYPICAL VFD LOCATION shipping and should be ready for operation when the
chiller arrives on site. Potentiometers allow adjustment
The VFD will control fan speed based on the liquid tem- of the minimum speed and for selection of the tempera-
perature of the system. As liquid line temperature rises ture control range. A quick check of the potentiometer
and falls, the fan speed will operate between minimum setting is recommended. The potentiometer settings
and full speed RPM. should be in the position shown in Fig. 16.
As liquid temperature rises, the VFD will ramp the speed
of the fan from a minimum speed of about 200 Hz to
maximum RPM while attempting to control liquid line
temperature between 65-75 F. If the liquid temperature
is below 65-75 F, the VFD will shut off the motor even
though the VFD is powered by 7M.
50095
Wiring
VFD wiring is simple and requires only single phase
power in, single phase power out and a 2-wire signal
from the liquid line temperature sensor. No start, stop or
other alternate power requirements are needed to operate
the VFD. Fig. 17 shows the power and control wiring
schematically as well as the actual connections.
LD11799A
NOTE: Wiring on the power side must run the fan in the forward direction.
FIG. 17 WIRING
PROGRAMMING
YCAL0012 - 0021 UNITS
TABLE 21 YCAL0012 - 0021 VFD LOW AMBIENT OPTION - CONDENSER FAN CONTROL OPERATION
CONTACTOR MICROBOARD FAN #
FAN STAGE ON OFF
SYS 1 SYS 1 SYS 1
Fan Speed
1: Is A Function Of FAN Will Turn OFF
VFD Control Liquid Temperature When Liquid
7M TB7-3 1
(1 fan Fan will turn on when Temperature Drops
Variable Speed) liquid temperature is Below 65F
above 65 F
Discharge
Pressure
2: < 200 PSIG (Pressure Is
1 Fan VFD < Fan Control ON Pres-
280 PSIG,
Control sure of
Both Fans
2nd Fan 280 PSIG Minus Fan 7M & 8M TB7-3 & TB7-10 1&3
Will Be Running Full
Full Speed Differential
Speed
Under Contactor Pressure of 80 PSIG =
Control 200 PSIG)
Fan 1 Will Still
Be Running
LOW AMBIENT FAN CONTROL OPTION If discharge pressure falls, VFD speed will decrease in an
YCAL0025-0032 UNITS effort to maintain discharge pressure. Speed may drop to the
point where the VFD turns the fan completely off or virtually
General off with a continued drop in pressure.
The low ambient option consists of a VFD (Variable Fre- The VFD control input signal is from the discharge pressure
quency Drive) that controls the speed of the rst fan (Fan 1) transducer in the respective system. The transducer signal
in the fan staging sequence. The VFD is located on the top feeds both the chiller microprocessor board and the VFD.
of chiller above the compressor section. Examples of the
typical VFD location and enclosure mountings are shown in The VFD will control the fan speed not only in low ambient
Figs. 18 & 19. conditions, but in all ambients based on discharge pressure.
Speed control of the respective system will occur when-
The VFD will control fan speed when only a single fan is ever high voltage power is applied to the VFD power inputs
running on a system. As discharge pressure rises and falls, through the 7M contactor. The chiller microprocessor will
the fan speed will be increased from zero RPM to full speed. energize the 7M contactor whenever the system liquid line
As discharge pressure continues to rise, the VFD will operate solenoid is energized.
the fan at full speed and the second fan will be brought on in a
system, if needed. Whenever the second fan is brought on, the The VFD controls the speed of the fan based on a discharge
inverter will already be running the rst fan at full speed. pressure setpoint and a differential control range. When a
compressor starts in a system, the inverter is activated through
the 7M contactor, which is controlled from the respective liq-
uid line solenoid valve control signal. At discharge pressures
below 160 PSIG, the VFD will turn the fan off or speed will
be reduced to all but small movements in fan rotation.
LD12080
VFD Enclosure Location The VFD will ramp up the speed of the fan as pressure rises
above the low end of the speed control range. Throughout
FIG. 18 TYPICAL VFD ENCLOSURE LOCATIONS
the pressure control range, the VFD controls the speed of
the fan based on a discharge pressure in the range of approx
160-180 PSIG. At pressures above 180 PSIG, the VFD will
run the system fan at full speed. 8
As pressure drops below 180 PSIG, the VFD will slow the
speed of the fan to try to maintain discharge pressure within
the control range. The VFD will try to maintain pressure in
the range of 160-180 PSIG by raising and lowering the speed
of the fan. If pressure drops below 160 PSIG, the VFD will
virtually turn the system fan completely off. Some slight fan
movement or very slow rotation may be noted, although the
fan may appear to stop completely.
LD12081
VFD Enclosure
VFD JUMPERS
J2 REMOVE
J3 IN
J4 REMOVE
J5 IN P1 P2
J6 IN LD11300A
J7 IN
J8 IN FIG. 21 POTENTIOMETER SETTINGS
J9 IN FOR 60 HZ REMOVE FOR 50 HZ
Wiring
Potentiometer settings are also preset at the factory. VFD wiring is simple and requires only 3-phase power
The potentiometers should be in the positions shown in, 3-phase power out, and a 2-wire signal from the
in the following table. The pots do not have numerical transducer. No start, stop, or other alternate power
settings and are set according to the arrow positions requirements are needed to run the VFD. Figs 20 and
indicated. DO NOT change the potentiometer settings 22 show the power and control wiring schematically as
unless they do not match the positioning of the poten- well as the actual connections. The VFD controlled fan
tiometers shown in Fig. 21. P1 should be full CW (180 will operate whenever the liquid line solenoid on the
PSIG) and P2 should be full CCW (20 PSIG). Modify- respective system is energized
ing these settings may cause damage to the chiller or
control problems. On chillers with the low ambient option,
wire 127 is removed from TB7-9 and con-
The P1 pot sets the setpoint which is the top end of the nected to TB7-3.
control range. This setting is the discharge pressure at
which the fan will be operating at full speed. The P2
pot sets the range. This is the range of pressure where
the VSD modulates the fan speed from 0 RPM to full
speed. The range is subtracted from the setpoint to
calculate the 0 RPM pressure.
7M
150A L1 T1 150
151A L2 T2 151
SPEED CONDENSER
CONTR. FAN NO. 1
152A L3 T3 152
LD11301a
FIG. 20 INVERTER POWER WIRING SCHEMATIC
TABLE 22 YCAL0025-0032 VFD LOW AMBIENT OPTION - CONDENSER FAN CONTROL OPERATION
CONTACTOR MICRO FAN #
FAN STAGE ON OFF BOARD
SYS 1 SYS 1 SYS 1
Fan Speed
Is A Function Of FAN Will Turn Very 8
Discharge Slowly or Display Only
1: Slight Movement When
Pressure.
VFD Control Pressure Drops Below
When The Liquid 7M TB7-3 1
(1 fan 160 PSIG. Fan Will
Line Solenoid Is Turn Completely Off
Variable Speed) Energized. Speed When Liquid Line Sole-
Increases With noid De-energizes
Pressure
Discharge
2: Pressure
< 200 PSIG (Pressure
1 Fan VFD
280 PSIG, Is
Control 7M TB7-3 1
Both Fans < Fan Control ON Pres-
2nd Fan & & &
Will Be Running Full sure of
Full Speed 8M TB7-10 3
Speed 280 PSIG Minus Fan
Under Contactor Differential
Control Pressure of 80 PSIG =
180 PSIG)
(Metric)
(6 sec - 1) * (5.56C/10) = 2.78C
Reset Cooling Setpoint = 7.22C + 2.78C = 10.0C
The new Reset Cooling Setpoint = 7.22 C + 2.78C = 10C.
This can be viewed by pressing the Cooling Setpoints key
twice. The new value will be displayed as REM SETP =
10.0C.
* Max Reset Value is the Max EMS-PWM Remote Temp. Reset setpoint
value described in the programming section under Cooling Setpoints.
Programmable values are from 2F to 40F (1.11C to 11.11C).
Setpoint = Local Chilled Liquid Setpoint + Reset If the Contact Closure input is used. The connections
are made to terminals C and D and only jumper JUI
Reset = (DC voltage signal) x (*Max Reset Value) must be in place on the reset board. This input is used 8
10 when a single reset value is needed. When the contacts
Example: are closed, the remote temperature reset board will con-
Local Chilled Liquid Setpoint = 45F (7.22C) vert this contact closure to a PWM signal that is applied
*Max Reset Value = 20F (11.11C) to CTB1 terminals 13 - 20.
Input Signal = 6VDC
To set the PWM output, the contacts must be closed
(English) on inputs C - D, and potentiometer R11 (located on the
Reset = 6VDC x 20F = 12F Reset front edge of the PC board) is adjusted to 10VDC as
10 measured at TP3 to terminal 10 on the circuit board. The
New Setpoint = 45F + 12F = 57F reset value will be the Max EMS-PWM Remote Temp.
Reset setpoint value programmed in the SETPOINTS
(Metric) section under the Cooling Setpoints key.
Reset = 6VDC x 11. 11C = 6.67C Reset
10 The coil of any added relay used for re-
New Setpoint = 7.22C + 6.67C = 13.89C set must be suppressed to prevent pos-
sible component damage. Use YORK
* Max Reset Value is the Max EMS-PWM Remote Temp. Reset setpoint PN 031-00808-000 suppressor.
value described in the programming section under Cooling Setpoints.
Programmable values are from 2F to 40F (1.11C to 11.11C).
035-15961-000
LD03875a
S Y S 1 L L S V S T A T U S
T B 7 - 3 I S O F F
SERVICE MODE
This display indicates that the system 1 liquid line sole-
Service Mode is a mode that allows the user to enable noid valve is OFF, and the output connection from the
or disable all of the outputs (except compressors) on the microboard is coming from terminal block 3 - pin 2.
unit, change chiller conguration setup parameters and
view all the inputs to the microboard. Pressing the (UP) arrow key will energize the liquid
line solenoid valve and OFF will change to ON in
To enter Service Mode, turn the Unit Switch off and the display as the LLSV is energized. Energizing and
press the following keys in the sequence shown; PRO- de-energizing outputs may be useful during trouble-
GRAM, UP ARROW, UP ARROW, DOWN ARROW, shooting.
DOWN ARROW, ENTER. Service Mode will time out
after 30 minutes and return to normal control mode, if SERVICE MODE CHILLER CONFIGURATION
the panel is accidentally left in this mode. Otherwise,
turning the unit switch on will take the panel out of After the Outputs are displayed, the next group of
Service Mode. displays relate to chiller conguration and start/hour
counters. Data logging, soft start, refrigerant type, and 9
SERVICE MODE OUTPUTS expansion valve type all must be programmed to match
actual chiller conguration.
After pressing the key sequence as described, the control
will enter Service Mode permitting the outputs (except Soft start, Refrigerant Type, and Ex-
compressors), operating hours, refrigerant type, expan- pansion Valve Type MUST be properly
sion valve type, and start/hour counters to be viewed/ programmed or damage to compres-
modied. The ENTER/ADV key is used to advance sors and other system components
through the outputs. Using the and (UP/DOWN ) ar- may result.
row keys will turn the respective digital output on/off
or modify the value.
Following is a list, in order of appearance: The analog inputs will display the input connection,
DATA LOGGING MODE = : DO NOT MODIFY the temperature or pressure, and corresponding input
DATA LOGGING TIMER = : DO NOT MODIFY voltage such as:
SOFT START
S Y S 1 S U C T P R J 7 - 1 0
REFRIGERANT TYPE
2 . 1 V D C = 8 1 P S I G
EXPANSION VALVE TYPE
SYS 1 HOURS
This example indicates that the system 1 suction pres-
SYS 1 STARTS
sure input is connected to plug 4 - pin 10 (J7-10) on
The last displays shown on the above list is for the accu- the microboard. It indicates that the voltage is 2.1 volts
mulated run and start timers for each system. All values dc which corresponds to 81 PSIG (5.6 bars) suction
can also be changed using the (UP) and (Down) pressure.
arrow keys, but under normal circumstances would
not be advised. After the last start display, the micro The digital inputs will display the input connection and
will display the rst programmable value under the ON/OFF status such as:
PROGRAM key.
F L OW SW / R E M S T A R T
SERVICE MODE INPUTS J 13 - 5 I S O N
Tables 24 through 27 are a quick reference list providing J7-10 Sys 1 Suction Pressure Transducer
the connection points and a description of the inputs and or
outputs respectively. All input and output connections Sys 1 Low Pressure Switch
pertain to the connections at the microboard. J11-12 Unit Type Select: Chiller, Cond Unit, Heatpump
J7-11 Sys 1 Discharge Pressure Transducer (Optional)
TABLE 24 MICROBOARD DIGITAL INPUTS J11-11 Remote Temperature Reset
J8-7 Sys 1 Suction Temp Sensor (Non-MMHP Cond
J13-2 Unit Switch Unit - Optional)
J13-4 Load Limit Stage 1 Sys 1 Discharge Temp Sensor (R22 - Optional)
J13-5 Flow Switch and Remote Start / Stop J8-8 Sys 1 Suction Temp Sensor (EEV Option &
(Sys 1 Zone Thermostat) MMHP Cond Unit)
J13-7 Single System Select (jumper = single sys, no J6-9 Ambient Air Temp sensor
jumper = two sys) J6-7 Leaving Chilled Liquid Temp Sensor
J13-8 CR1 (Sys 1 MP/HPCO) J6-8 Return Chilled Liquid Temp Sensor / Discharge
J13-9 Spare Air Temp Sensor
TB1
TB7
J3
TB8
J5
IPU
BOARD
TB9
J6
J7
J8
TB10
J9
J10
LD12721
J14 JP1
J13 J11
J12
LD12721
Refer to the unit wiring diagram. All digital inputs are VOLTAGE
connected to J9 of the microboard. The term digital re- TEMPF (Signal Input TEMPC
fers to two states either on or off. As an example, when to Return)
the ow switch is closed, 30 volts DC will be applied to 0 0.7 -18
J13, pin 5 (J13-5) of the microboard. If the ow switch 5 0.8 -15
is open, 0 volts DC will then be present at J13-5.
10 0.9 -12
Pin 1 of J13 is an unregulated 30VDC source used to 15 1.0 -9
supply the DC voltage to the various user contacts, unit 20 1.1 -7
switch, ow switch, etc. This DC source is factory wired
25 1.2 -4
to CTB1, terminal 13. Any switch or contact used as a
digital input would be connected to this terminal, with 30 1.4 -1
the other end connecting to its respective digital input on 35 1.5 2
the microboard. Any time a switch or contact is closed, 40 1.7 4
30VDC would be applied to that particular digital input.
45 1.8 7
Any time a switch or contact is open, 0VDC would be
applied to that particular digital input. 50 2.0 10
55 2.2 13
Typically, voltages as high as 34VDC could be measured 60 2.3 16
for the DC voltage on the digital inputs. This voltage
is in reference to ground. The unit case should be suf- 65 2.5 18
cient as a reference point when measuring digital input 70 2.6 21
voltages. 75 2.8 24
80 2.9 27
Analog Inputs Temperature
85 3.1 29
Refer to the unit wiring diagram. Temperature inputs are 90 3.2 32
connected to the microboard on plug J6. These analog 95 3.4 35
inputs represent varying DC signals corresponding to
100 3.5 38
varying temperatures. All voltages are in reference to
the unit case (ground). Following are the connections 105 3.6 41
for the temperature sensing inputs: 110 3.7 43
115 3.8 46
Outside Air Sensor
120 3.9 49
J6-6 = +5VDC regulated supply to sensor. 125 4.0 52 9
J6-9 = VDC input signal to the microboard.
See Table 28 for voltage readings that corre 130 4.1 54
spond to specic outdoor temperatures.
J6-3 = drain (shield connection = 0VDC) Return
TABLE 29 ENTERING/LEAVING CHILLED LIQUID Liquid & Refrigerant Sensor Test Points
TEMP. SENSOR, COOLER INLET TEM- (Table 29)
PERATURE SENSOR, AND SUCTION
TEMPERATURE SENSOR: TEMPERA- Entering Chilled Liquid Sensor
TURE/VOLTAGE CORRELATION
J6-5 = +5VDC regulated supply to sensor.
VOLTAGE J6-8 = VDC input signal to the microboard. See
TEMPF (Signal Input TEMPC Table 29 for voltage readings that corre
to Return) spond to specic liquid temperatures.
J6-2 = drain (shield connection = 0VDC) Return
10 1.33 -12
12 1.39 -11 Leaving Chilled Liquid Temperature Sensor
14 1.46 -10 J6-4 = +5VDC regulated supply to sensor.
16 1.51 -9 J6-7 = VDC input signal to the microboard. See
Table 29 for voltage readings that corre
18 1.58 -8 spond to specic liquid temperatures.
20 1.65 -7 J6-1 = drain (shield connection = 0VDC) Return
22 1.71 -6
24 1.78 -4
26 1.85 -3
28 1.91 -2
30 1.98 -1
32 2.05 0
34 2.12 1
36 2.19 2
38 2.26 3
40 2.33 4
42 2.40 6
44 2.47 7
46 2.53 8
48 2.60 9
50 2.65 10
52 2.73 11
54 2.80 12
56 2.86 13
58 2.92 14
60 2.98 16
62 3.05 17
64 3.11 18
66 3.17 19
68 3.23 20
70 3.29 21
72 3.34 22
74 3.39 23
76 3.45 24
78 3.5 26
80 3.54 27
140 JOHNSON CONTROLS
FORM 150.66-NM4 (608)
SYS 1
TB7-7 HGSV
SYS 1
TB7-8 FAN 2
TB7
SYS 1
TB7-9 FAN 1
SYS 1
TB7-10 FAN 3
TB8-6 EVAP
TB8-7 PUMP
TB8
HEAT EXCH
TB8-2 HEATER
LD13277
TB3-3 TXD 2 RD
9
TB3-2 CTS 5 CTS
TB3-5 GND 7 SG
LD13278
TROUBLESHOOTING
TABLE 32 TROUBLESHOOTING
c. Replace 1T
TROUBLESHOOTING (CONTD)
HIGH DISCHARGE 1. Condenser fans not operating 1. Check fan motor, fuses,
PRESSURE FAULT or operating backwards. and contactors. Assure fan
blows air upward.
TROUBLESHOOTING (CONTD)
LACK OF COOLING EFFECT 1. Fouled evaporator surface. 1. Contact the local YORK
Low suction pressure will service representative.
be observed.
SECTION 10 - MAINTENANCE
It is the responsibility of the equipment owner to provide CONDENSER COILS
maintenance on the system.
Dirt should not be allowed to accumulate on the con-
IMPORTANT denser coil surfaces. Cleaning should be as often as
necessary to keep coils clean.
If system failure occurs due to improper maintenance
during the warranty period, YORK will not be liable Exercise care when cleaning the coil
for costs incurred to return the system to satisfactory so that the coil ns are not damaged.
operation. The following is intended only as a guide and
covers only the chiller unit components. It does not cover
other related system components which may or may not
be furnished by YORK. System components should be
maintained according to the individual manufactures
recommendations as their operation will affect the op-
eration of the chiller. OPERATING PARAMETERS
The oil used in these compressors is pale yellow in color Do not confuse JP1 on the IPU II
(mineral oil). If the oil color darkens or exhibits a change (031-02630) board with JP1 on the I/O
in color, this may be an indication of contaminants in the (031-02550) board.
refrigerant system. If this occurs, an oil sample should
be taken and analyzed. If contaminants are present, the
system must be cleaned to prevent compressor failure.
ISN CONTROL
ISN ISN
CHARACTER TYPE DATA CHARACTER TYPE DATA
PAGE PAGE
Evaporator Heater P60 132 Coded ----
P38 110 Digital
Status SYS 1 Condenser
P61 133 Coded
Evaporator Pump Fan Stage
P39 111 Digital
Status P62 134 Coded ----
SYS 1 P63 135 Coded ----
P40 112 Digital
Comp. 2 Run
P64 136 Coded ----
P41 113 Digital ----
Unit Control Mode
SYS 1 Liquid Line (0=Leaving Water,
P42 114 Digital Solenoid Valve or 1=Return Water,
EEV Pilot Solenoid P65 137 Coded 2=Discharge Air,
SYS 1 Hot Gas 3=Suction Press.,
P43 115 Digital
Bypass Valve 4=Cooling
SYS 1 5=Heating)
P44 116 Digital
Comp. 2 Run P66 138-141 Analog Anti-Recycle Timer
P45 117 Digital ---- Leaving Chilled Liquid
P67 142-145 Analog
P46 118 Digital ---- Temp. Cutout
* The operational and fault codes sent to pages 56 through 59 are dened in Table 33. Note that this table of fault and operational codes is for
all DX products.
10
Data can be read and in some cases modied using In some cases, BACnet parameters may need to be
a serial communication BACnet or Modbus network modied. Modication is accomplished by pressing
connection. This information allows communications the PROGRAM, DOWN ARROW, DOWN ARROW,
of chiller operating parameters and external control DOWN ARROW, DOWN ARROW, and ENTER keys
changes to setpoint, load limiting, and start/stop com- in sequence. The list below shows the displays for the
mands. values that may be modied:
P1 STOP BITS
X
The table below shows the minimum, maximum, and default values.
The table below shows the real time error numbers and a description of each.
Chiller data that can be read and modied using specic Modbus Register Addresses; and the data associated with
the addresses, is outlined in the following description:
This data can be read and modied using a BACnet or Modbus network connection. The Modbus Register Address
for these points is 1025 + AV #.
This data can be read and modied using a BACnet or Modbus network connection. The Modbus Register Address
for these points is 1537 + BV #.
This data can be read using a BACnet or Modbus network connection and can NOT be modied using this connec-
tion. The Modbus Register Address for these points is 513 + AI #.
This data can be read using a BACnet or Modbus network connection and can NOT be modied using this connec-
tion. The Modbus Register Address for these points is 1281 + BI #.
2008 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53203 Printed in USA 150.66-NM4 (608)
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