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YLAA0180 - 0516 Style B 50 Hz Air-Cooled Scroll Chillers Brazed

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1. 1 J8 2 2 on 9 4 6 5 5 1 Gss 3 ADIS BRN POS SOA 7 PP J6 gt Om 9 Boar RD 6 BOAT SCR L 2 6 25 A NEG 5 ecra 9 a pos Ar aru 6 eawe ReD st 6 13 15 131 50 550 37 gt 36 9 1 0 1 BsP wit 1 1 2 1 TC PNK 52 21 21 S 1 Bse reo 6 1 G 1 8 135 13 G J 1 BsP scr 2 1 5 53 20 20 15 Moa m s 19A 19 198 2 BSP BLK 10 2 88 1 2 54 130 13 EE ue 18 18 188 5 2 BsP RED 6 2 7 2 B0P BLK 8 Xn 9 Ong j 2 Bsp scr 2 2 G 2 55 136 1514 SF 14 14 SFE BLR 138 13 SFE WHT ns 136 Jn pu 2 i es p m m 5 1 haa 13 14 Z R
2. FIGURE 11 ELEMENTARY WIRING DIAGRAM CONT D JOHNSON CONTROLS XP2 25 XTBC2 29 XTBC2 200 230V 3 60HZ G o 460V 3 60HZ XTBC2 2 4 575V 3 60H2 ay 239 380 415V 3 50 60HZ 43 43 13 23 sb XTB8 1 3 1 2 6 726 4 728 14 25 24 7 24 5 272 2 X 260 309 XTB8 3 5 Ne 5 275 XS 2 1 X XTBC2 5 107 27 12 31 i 13 13 13 23 woo L2KM3 2 2 2M 208 lt 7210 7210 4 14 29 24 1 ea ribs Rar TERN nan 2 32 93 xm 289 37 320 BDAT 2 ETERNE 15 2 11 gq 2 5 Il BLK YY YY YY 5 11 4 ad ag 3 11315 rq pe mp z2 KM3 LK1 lale 7210 2 4 6 8594 0 S9 Sg 2 5 k 5 8 2 5 TI TTT TENGS ullis E 27578 7 12 275 27578 J6 J11 J8 J10 3 2 EXT AMB 5 130 m t BSP t BDP 2
3. 1 2 1 What these numbers mean Example 1 lt follow wire no 1 2 is the DWG number on the bottom center of each page is the locator number across the top of the page At the top of the pages the numbers 1 to 11 go from left to right Find drawing number 2 and in column number 1 across the top of the page locate wire number 1 FIGURE 13 ELEMENTARY WIRING DIAGRAM 60 gt 1 5 5 K3 K4 K10 Kt5 K9 AMB n 2 A3 15 7 XTB8 XTB9 XTB8 XTB7 7 1 3 T 1 2 2 4 5 XP2 i 6 140 8 144 UP 1 14 2 1 2 XP3 131 237 1 2 3 1 2 FHP 0 2 Ps 4 Ps 4 oR EXE EXT 1 2 2 2 2 P gt P gt 4 6 7 1 1 1 J XP1 1 2 132 232 lS 34 1 1 2 1 X o4 SEXT 4ExT 3 nd gt gt 3 8 1 1 2 133 233 fo XP3 115 e 13 1 2 2 BMP2 lt EXT MIIN EXT MIMI KH 21 21 21 3 LU L4 Ly be 5e 14 1 1 NB58B 1 KM2 NB57B 1 KM3 5 6 6 8
4. gt 55 39 45 749 ud e 55 159 a 178 K20 185 18 10 Aq AB AB 19 XTBt0 4 3 1 7 6 6 1 2 4 5 3 7 18 218 XP3 XP2 3 14 14 XP2 KCR 2 KCR XP3 XP3 XP3 XP3 3 1 1 2 4 5 3 9 9 2 gt 120 2 220 143 1 1411 21 2 1 S 0 9 5 22 wo amp amp amp 2 amp 9 2 2 XTBF 1 XTBF 2 XTBF 2 D 2 120 1 224 225 226 2208 220 192 193 4 9 2 8CH1 2 8CH2 2 SCH3 EXT EXT EXT gt gt gt XTBC2 XTBC2 2 1 2 2 2 SEXT SEXT SEXT i 1 1 Til 1 1 1 1 51 51 X X N i i n EX X L 1 8 S2KMO A 2 UAR 1 Lynas 2 2 2 5 7 ExT N75 EX OV bw T ich ext EXT XTBC2 22 2 XTBC2 2 2 2 2 5 e d L 5A6 A6 A6 516 616 Las 5205 Hg 1016751 2 FIGURE 12 ELEMENTARY WIRING DIAGRAM CONT D JOHNSON CONTROLS 61 SECTION 5 TECHNICAL DATA FORM 150 72 614 ISSUE DATE 6 10 2014
5. OL 6 8 Ou eq jou pue Burjeos 00LX S ur Bureos yeu eyeorpur 0108 peubis jo 2 043002 ue Jj seJoui snf 3 1yOA se BY sesn IMIA 941 9 S I amp jop jenueyy suone4edo 1311149 ejqeordde ees S 199 sejnofojy Dx rx Hed Wdd sjeosed eg youl eenbs 199 sq Sd 2 Jed 1994 Nd 2 Jad 1994 9Iqn2 W4D 1 JO Seuou v sioe qo 21 0 uoneoyroN eoieg 9 9 z INO 0 sed 6 s s 1 55 9 uns EE SAS 1055949109 UNY 0 SAS 10 1905 9 uns 99 1055 y uns 06 1055 unu OOL 0 6 peo1 2 9599 10 jou SI yonpoid eu suoneoiunululoo NLY Snqpo y pue d1 SW JO jueuudinbe peseq XXX 08820 1 0 Nd
6. r MC 360A 362A 112 LS 350A 352A 3508 3518 3528 352C 1F 298 1 135 S E 38 1208 2208 1408 98880989 A O 1 4 1 F5 1278 1288 1298 amp amp 1 LC1D09 1811 LC1D09 1811 LC1D09 1811 C fe 1 1 1 2 9 69 69 69 69 9001 9 09 9 2 9 9 59699 1180 308 180 2K Q 2x81 x 149 144 244 E 0 0 0 0 0 350 351 352 360 361 362 uo Be an 18 oe u2 i568 1578 1588 144 44 eye aa 0 0R 131A 131 1318 E 1264126 126 20 e C 1 0 5 1 1 0 5 2 1 1L2A 1L3A 1128 1L3B Lic 1L2C 1L3C 149 4 135A 135 135 l OO BT p 13341133 90 91 132 1132 ee ad ic 1324 m fi 0 125 125 25 1244124 124 1 2AJ 2 po0 Zan 2 242 2AG 1 _ _ 2 2
7. 1 6 500 kCMIL 2 6 500 kCMIL 2 6 500 2 4 500 kCMIL AB eo eo 52 2 43 0 AWG 250 kCMIL 2 3 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 3 0 250 kCMIL 2 3 0 250 kCMIL 2 3 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 250 500 kCMIL 1 46 AWG 350 kCMIL 1 46 AWG 350 kCMIL 1 46 AWG 350 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 3 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 250 500 kCMIL 2 250 500 kCMIL ETL TB ETL NFDS ETL CB 1XX 2XX 3XX 1 46 AWG 350 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 3 0 250 kCMIL 2 3 0 250 kCMIL 2 3 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 1 46 AWG 350 kCMIL 1 46 AWG 350 kCMIL 1 46 AWG 350 kCMIL 1 46 AWG 350 kCMIL 1 46 AWG 350 kCMIL 1 46 AWG 350 kCMIL 2 3 0 AWG 250 kCMIL 2 3 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG
8. 1 SCH3 1 5 6 2 1 SCH1 EXT EXT EXT 126 125 wH 124A O 2 2AK 1 24 Ee 2 1 ECH3 2 1 2 1 1 106 Ona 800 198 On aK 100 ED BLK 1 LO 107 104 BRN 101 BLK 108 Quir BLU H 102 1 M3 1 cno _ ix 1 1 1 EXT 9 2 mo o OH m 135A 134 133 134A 133A n 132A ey FIGURE 17 COMPRESSOR WIRING CONT D JOHNSON CONTROLS 91 600 2 Ht 4 200V 3 60HZ 2 i 230V 3 60HZ D 240V2KVA 380V 3 60HZ 90 91 2 3KVA 2567 Ht 3567 21 H6l H7 2 x HEX L 120 2 00 400V 3 50HZ 90 1 9D aoovzkva 2567 3367F Hel T2 xi xa 1207 GND 460V 3 60HZ 90 ABOV2KVA L 120V LD16753 SECTION 5 TECHNICAL DATA 69 FORM 150 72 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 POWER OPTIONS CONNECTION DIAGRAM 035 21589 103 REV B 211 212 213 211 212 213 21 212 213 1L1 1L2 113 12
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11. 2393 OVERALL HEIGHT 2251 FRAME HEIGHT 2243 FRAME WIDTI 2255 OVERALL WIDTI 100 OUTLET Lg 592 3614 FRAME LENGTI 9 4237 OVERALL LENGTI LD18069 NOTE Placement on a level surface of free of obstructions including snow for winter operation or air circulation ensures rated performance reliable operation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance Johnson Controls s unit controls will optimize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 2m 6 rear to wall 2m 6 control panel to end wall 1 2m 40 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit JOHNSON CONTROLS 79 SECTION 5 TECHNICAL DATA DIMENSIONS YLAA0441HE SEVEN FAN UNITS 16 DIA MOUNTING HOLES TYP ILE d _ 4 4 i F
12. 64 FIGURE 16 Single And Dual Point Wiring 66 FIGURE 17 Pump Wining PHP C EE 67 FIGURE 18 Gompressor Wiring t o E E RH HE El eet dI ertet 68 FIGURE 19 Power Options Connection 70 FIGURE 20 Power Panel iro a a esee Vu 72 FIGURE 21 Micro Panel 74 FIGURE 22 Sample Printout Supplied In The Isolator Package And In The Chiller Panel Literature Packet 82 FIGURE 23 Unit Clearances All 83 FIGURE 24 Status Key Messages Quick Reference 56 106 FIGURE 25 Operation Data a eee 110 FIGURE 26 Setpoints Quick Reference 122 FIGURE 27 Unit Keys Options Programming Quick Reference 128 FIGURE 28 Micro Panel Coriniectioris cte i ted ti e Reb 130 FIGURE 29 Leaving Water Temperature Control 142 FIGURE 30 5 Setpoint AdIUst eot hee dtr teme e Ree dete odere 143 FIGURE 31 Co
13. valve and liquid line valve for each system The compressor oil level should be maintained so that an oil level is visible or splashing in the sight glass when fully loaded At shutdown the oil level should be between the bottom and middle of the oil equalizing sight glass Assure water pumps are ON Check and adjust wa ter pump flow rate and pressure drop across the cooler see Operational Limitations English Verify flow switch operation NOTE Excessive flow may cause catastroph ic damage to the heat exchanger evaporator eign material wires metal chips etc MUST meet N E C and local codes power panel on both sides of the motor contactors and overloads Check for proper size fuses in main and control circuits and verify overload setting corresponds with RLA and FLA values in electrical tables see Table 8 and Table JOHNSON CONTROLS 12 Assure 120VAC 110VAC for 50Hz units Control Power to TB1 has 15 amp minimum capacity 13 Be certain all water temp sensors are inserted com pletely in their respective wells and are coated with heat conductive compound 14 Assure that evaporator TXV bulbs are strapped onto the suction lines at 4 or 8 o clock positions or suction temp sensors if EEVs are installed B CO
14. When communications is required with a BAS or tiView Panel individual unit IDs are necessary for communications with specific chillers on a single RS 485 line ID 0 7 is selectable 121 SECTION 7 UNIT CONTROLS FORM 150 72 614 ISSUE DATE 6 10 2014 Quick Reference Programming Chart Setpoints Section Cooling Setpoints Key Schedule Program Mode press key to adv Advance Day Key press enter to adv Local Leaving Mon Sun Discharge Water Temp Control amp Pressure Display Only Holiday Cutout Schedule Chilled Liquid Suction Setpoint Pressure amp Cutout Range Remote Setpoint Low Ambient Temp amp Cutout Range Display Only Leaving Liquid EMS PWM Temperature Remote Temp Cutout Reset Setpoint Anti Recycle Table 12 provides a quick reference of the setpoints list for the Setpoints Keys Bie Fan Control On Pressure Fan Differential Off Pressure Total Numbers of Compressors Number of Fans Per System SYS Unit Trip Volts Option Remote Unit ID LD07404c FIGURE 26 SETPOINTS QUICK REFERENCE LIST 122 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 7 UNIT CONTROLS UNIT KEYS OPTIONS Options Key There
15. ENOID BYPASS FAN PUT XXX oO P STATUS TIME YYYYYYY AST STATI OFF VALVI OFF STAGE OFF 0 0 X AMPS X X VOLTS SYSTEM 2 DATA 1 2 3 ON 0 0 1 46 D H M S 0 0 0 0 D H M S U PRESSU RE 110 PSIG PRES SURE 320 PSIG PERATURE 49 3 DEGF TE 36 EFRIG 31 52 0 EAT 183 6 8 D D D D SO ENOID FAN PUT DAILY XXX X AMPS ON STAGE 3 63 2 X X VOLTS SCHEDULE 5 muonudzazuizuu lt JOHNSON CONTROLS START 00 00AM STOP 00 00AM START 00 00AM STOP 00 00AM START 00 00AM STOP 00 00AM START 00 00AM STOP 00 00AM START 00 00AM STOP 00 00AM START 00 00AM STOP 00 00AM START 00 00AM STOP 00 00AM START 00 00AM STOP 00 00AM HOLIDAY SECTION 7 UNIT CONTROLS See Optional Printer Installation on page 158 for Printer Installation information NOTE History Printout Pressing the PRINT key and then the HISTORY key allows the operator to obtain a printout of information relating to the last 9 Safety Shutdowns whic
16. 100 OUTLET LD18068 Placement on a level surface of free of obstructions including snow for winter operation or air circulation ensures rated performance reliable operation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance Johnson Controls s unit controls will optimize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 2m 6 rear to wall 2m 6 control panel to end wall 1 2m 40 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit 78 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA DIMENSIONS YLAA0350HE YLAA0390HE YLAA0435SE YLAA0485SE SIX FAN UNITS 15 875 DIA MOUNTING HOLES TYP POWER ENTRY 330 WIDE X 180 HIGH 21 2077 1102 e 2 NSS ie 51 CONTROL PANEL BOTTOM DETAIL 1753 1222 ORIGIN
17. 340A 340A 1057 Kema DONIN JO X Burzi esn OL 6 8 2 991 495 HOS 05920 1 0 pJeog CIN 0087 ysey 2Z0 LONWO 9 09920 1 0 pJeog OJN uoisJe pejooo 1MOA 0087 XXX XceL oNW O 6 x 0SS20 1 0 peog 008v OOK ysey OWN O Xxx 0S020 L 0 pJeog OJIN TWOA 0087 9222 100 67020 180 00 0 pJeog ONIN 008v 9796 100 67020 180 XXX 0G0Z0 L 0 pJeog ONIN 0087 00 67020 120 0 0 pneg unsy2eu d wa 09920 09020 20 p1eog NITE MEL OSSZ 0502 SIPPIN THOA V OYTA VNV TA TMO AJ IVO A 137 JOHNSON CONTROLS FORM 150 72 614 ISSUE DATE 6 10 2014 SECTION 7 UNIT CONTROLS TABLE 17 YORKTALK 2 COMMUNICATIONS DATA MAP CONT D jueuinooq pinoys Bursr epo ejeudouddy 941 310
18. OLJAN 9je2 09920 20 pjepueis 100 66 50 150 80 00 21 20 L ONWWO 0SS20 L 0 XXX 0 920 L 0 dHIAIN uopiseg 00 55 20 1 lt 0 90 6 2 00 9L OWW O Sjueuiuio2 wns Nd UOISJ9A WALI FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 TABLE 16 09920 10 M 05950 150 pyeog sdew ZN dL SW JOHNSON CONTROLS FORM 150 72 614 ISSUE DATE 6 10 2014 SECTION 7 UNIT CONTROLS TABLE 16 BACNET AND MODBUS COMMUNICATIONS DATA MAP CONT D sdew 3ALLVN II dl I 0105 eBeuuo jews eonou jeuoneuaeju JO 515 0 1 eju 60 20 10 962 vl AS 25 06 6 3 u pnb 5 5 V O 9 eju 6020 10 621 ASTI ZS 68 8 8 uns 5 6 L0 ag eju 602010 6621 ci 19 NAY 25 88
19. Discharge Pressure Limit Leaving Chilled Liquid Control nne Leaving Chilled Liquid Control Override To Reduce Leaving Chilled Liquid System Lead Lag And Compressor Sequencing Return Chilled Liquid 8 Return Chilled Liquid System Lead Lag And Compressor Sequencing TIMOR core acp HU le Anti Goincldence TIFIer ces cct d seed case tete Evaporator Pump Control And York Hydro Kit Pump Evaporator Heater P rrnpdowrnGODtrol to nbn t LB OR A Standard Condenser Fan koad LIMITING ere dus Compressor Alarm Status tue ete tetti iet cdd Remote BAS EMS Temperature Reset Using A Voltage Or Current Signal FORM 150 72 614 ISSUE DATE 6 10 2014 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 TABLE OF CONTENTS CONT D SECTION 9 SERVICE AND 5
20. SALON Lv 128409U 02 0c 07 eunjejeduue Joyesodeny 6L 6L 65 3ne4 OOdH dW 1 8 9 yney punoig jie Buluuny 10 949 09 1 1 Ze eunsseud leuad 9 9 95 JUSIIND 100W GL GL diN JO OW v ve uonejos eseug Dunuriuonons enuey ZL syg ze eunjejedue eun eu yey eS 0 e dsip eui sieedde 62 JUSIIND 100W 8 UNY 8 J jo 4 dund 82 eJnsseJjg 7 Uwopinus empeuos Aea y epo duj dung 22 einsseJd 1 9 umopynys 9 Jo sJojejedo OOdH dW 9c eunssejg abseyosiq uBiH 5 5 Jno ui sepoo abseyosiq Sz yun _ jsuieBe 99 4 205095 vc 3110 2291 pue jjne y xoeuo jeeujedngs
21. g 22 22 22 5 5 8 8 amp 8 1 2 1 1 1 7 7 134 234 1 124 125 126 t BMP3 2 EXT gt gt 5 75 1 SCH1 1 SCH2 1 8CH3 1 2 EXT EXT 135 235 OXIBE Pe Pe 29 149 e e 4 1 BMP2 1 BMP3 EXT EXT TIL TIL M 1 ETH a EEH Ai e M M Eg en E i 1 KCR A2 2 KCR A2 EHRHT EHRH2 EEHT KH A2 2 2 2 1 3 4 EXT 1 62 Ti Echo S2 T ecu 2 EXT EXT 2 T2IN 128 2 1 1 5 2 2 2 5 5 5 5 d BM B JEn 3 Etna 3X lem Ne 79 05 9 33 9 410 A3 4 43 44 43 44 43 44 13 M 3 14 13 14 1 lt 9 L 19 25 2 45 22 1016750 JOHNSON CONTROLS 150 24 613 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014
22. 20 FIGURE 2 Unit Components ced e og ede de eee o dee ped 21 FIGURE Power Panel 22 FIGURE 4 Power Panel Control 23 FIGURE 5 Process And Instrumentation 29 FIGURE 6 Unit Rigging Eifting iir t Dt ERA RE RR eR RR epe he 32 FIGURE 7 Wamitrg danh aeneae pabcssi 34 FIGURE 8 Chilled com Heart etu ettet tte e E e eee d donet i eet ert 37 FIGURE 9 Single Point Supply Connection Terminal Block Non Fused Disconnect Switch Or Circuit Breaker Or Circuit 39 FIGURE 10 Control Wining err t e rh a iege andi 40 FIGURE Control Wiring Outputs et eb T RR EE Eee 41 FIGURE 12 Elementary Wiring 58 FIGURE 13 Elementary Wiring 00 01 0000 60 FIGURE 14 Fan Wiring Standard Low Sound Or Ultra Quiet YLAAO180 516 62 FIGURE 15 Fan Wiring High Air
23. 8 8 uny 2 duo r s s 0 v ag eju 602010 LE Ig NAY 22 15 18 juo NU E S S SIS ISIS S dH yeop 5 1 0 eju 0 c0 10 162 0r I8 18 98 6 8 ssed g seo SAS L0 ag eju 602010 0621 6 I8 A89H 18 58 6 3 dH SAS 0 4 ag e u 60 20 10 6821 8 AS 15 78 6 3 u pnb SAS 0 eju 0 20 10 8851 119 ASTI IS 8 6 6 6 5 5 61 6 uns sks L0 eju 602010 2821 918 NAY LO 25 28 5 5 5 5 6 eu 0 NON TO IS i8 LI 5 5 5 5 smes dung o ag eu 0 o8 sisisisisisis snjejs 19jeeH 9 0 64 6 8 515 L O 0 cS 8 mmi S S S 0 0 LS 4 SLNIOd 9 GL 15 5 dH 1M2A pue od v9 40 OLX 70 50 0 5 LS IV 3185 tL 10 100 dS z1utodjes y od 9 OLX 70 50 695 95 IV ZS 138 dS Z 0 100 dS L1utodjes od 29 OLX 70 50 895 SG IV LS 138 dS e S SIS INININ N ju
24. Rte ge teen de di Ede dece d n Bed d au e e need de d n lene 153 TABLE 27 l O Analog Outpuls et Geo Ud teer Use Pee t EO Rte POET Pd dites bx take ad ud ite 153 TABLE 28 Outdoor Air Sensor 155 TABLE 29 Entering Leaving Chilled Liquid Temp Sensor Temperature Voltage Correlation 156 TABLE 30 Pressure TransdU cers a 157 TABLE 31 Troubleshooting Nees edd aE 160 TABLE 32 S a acter d apod eigen 167 JOHNSON CONTROLS 9 10 THIS PAGE INTENTIONALLY LEFT BLANK FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 1 GENERAL CHILLER INFORMATION AND SAFETY INTRODUCTION YORK YLAA chillers are manufactured to the highest design and construction standards to ensure high per formance reliability and adaptability to all types of air conditioning installations Rigging and lifting should only be done by a profes sional rigger in accordance with a written rigging and lifting plan The most appropriate rigging and lifting method will depend on job specific factors such as the rigging equipment available and site needs Therefore a professional rigger must determine the rigging and lifting me
25. 151 Clearing History B ffers cete 151 et ee aeta eme d 151 Service Mode pia TR METRE QURE CHE RU ROB KE RETRO 151 Service Mode Chiller 152 Service Mode Analog And Digital Inputs 152 Control IMputs Outputs se ee ore tete m 153 Checking And O P S 155 Optional Printer Installations 158 Troubleshooting sitine Ltd 160 SECTION 10 163 Compressors opt ede rds a E dpt eevee 163 Condenser Fan Motors oresar et ce REEL e ett 163 Condenser ROI a BREED eU ue 163 Operating Parameters crane Per dec ERR MI 164 On Board Battery BaCk UD eerte et ent d reget Rr IER A dedo 164 Brazed Plate Heat Exchanger Evaporator 164 Overall Unit InSDectiortc cce tto Ret ede diete ne d telae eet rd 164 THEE 167 JOHNSON CONTROLS 7 FORM 150 72 614 ISSUE DATE 6 10 2014 LIST OF FIGURES FIGURE 1 Unit Components Front erede ar Rae RR RR A AE RAE RR RR E ERR
26. GLYCOL COOLING 70 0 21 1 RETURN CHILLED LIQUID CONTROL RANGE 20 0 F 11 1 C MAX EMS PWM REMOTE TEMPERATURE RESET 40 F 22 0 C Refer to Engineering Guide for operation below 30 F 1 1 C Alternate thermal expansion valves must be used below 30 F 1 1 C When using glycol Leaving Chilled Liquid Setpoint should not be set below 20 F 6 7 C Do not exceed 55 F 12 8 C setpoint before contacting the nearest Johnson Controls Office for application guidelines MON START 00 AM 00 00 00 AM STOP The line under the 0 is the cursor If the value is wrong it may be changed by using 1 UP and DOWN arrow keys until correct Pressing the ENTER ADV key will enter the times and then move the cursor to the minute box The operation is then repeated if nec essary This process may be followed until the hour minutes and meridian AM or PM of both the START and STOP points are set After changing the meridian of the stop time pressing the ENTER ADV key will advance the schedule to the next day Whenever the daily schedule is changed for Monday all the other days will change to the new Monday schedule This means if the Monday times are not applicable for the whole week then the exceptional days would need to be reprogrammed to the desired schedule To page to a specific day press the SCHEDULE AD VANCE DAY key until the desired day appears The start an
27. N falda gt N wo 5 1 NIN aj ojo A p 166 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 The following factors can be used to convert from English to the most common SI Metric values TABLE 32 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effect ton Kilowatts KW Power Horsepower Kilowatts KW Flow Rate Gallons Minute gpm Liters Second 1 5 Feet ft Meters m Length Inches in Millimeters mm Weight Pounds lbs Kilograms kg Velocity Feet Second fps Meters Second m s Feet of Water ft Kilopascals kPa Pressure Drop Pounds Square Inch psi Kilopascals kPa TEMPERATURE To convert degrees Fahrenheit F to degrees Celsius To convert a temperature range i e a range of 10 F C subtract 32 and multiply by 5 9 or 0 5556 from Fahrenheit to Celsius multiply by 5 9 or 0 5556 Example 45 0 F 32 x 0 5556 27 2 Example 10 0 F range x 0 5556 5 6 C range JOHNSON CONTROLS 167 Johnson WK Controls P O Box 1592 York Pennsylvania USA 17405 1592 Tele
28. ved olojojojo iuo A33 1ndino A33 2846 82 dav 0L 00L ino JONUOIN V Zed 68 5 5 5 2 S S 2 66 96 1g j3unoo ceodiosiAo s JONUOIN V d 0101010 luo uopons 2 sfs 92 AAV S6 26 Finos JONUOIN V 05 0000 luo dH 2 546 Sz dav L6 98 Finos 1ANS V bed 6 6 juo 9 07 19 000 2 SfS vz AAV 18 v8 19 Finos V 82d 6 5 5 5 5 eissejg 2 S S Jav 8 08 Finos Lans ezodiosiAo u V 4 5 5 5 5 5 emssejg 2 545 22 SCV 62 97 Finos Lans V 8 5 5 5 5 spuo es unu 2 846 SV 62 21 Finos 1ANS zz0diosiAo u V 16 0000 iuo A33 uonons 846 02 40 12 89 19 9 09 051 JOIUOJN V ved Scd 5 5 5 5 5 19 v9 19 j3unoo SzodiosiAo s V 51515151 5 ajokooy NUY S S 81 Jav 9 09 Lg Jauno LANS vZ0dLOS LAO
29. ic rea Reo 36 Chilled Liquid PIPING 36 Pipework Arrangement x nune tinte tee tt eee 37 PAIN e ELDER 37 Relief Valv S 38 Highi Pressure GUtOUt oic eet Fa EA ANE A 38 Single Point Supply Connection Terminal Block Non Fused Disconnect Switch Or Circuit Breaker 1 retener e xe eed e PaL dated deep ue 39 SECTION 5 TECHNICAL 2 4 eerte a 43 Operational 2 o HE be deo ei 43 Physical Data YLAA0180 YLAA0516 502 46 48 Compressor Heaters airen e e dete te ee ete re ia eco 48 Electrical Notes tie Le reete qi e e deest deed aee eva to dee dot vues bee 53 Weight Distribution And Isolator Mounting nemen 82 9 A 83 Four Fam Isolator Locations iieiaei en ede eus o e uo 84 Five And SpcEan Isolatof Locations ern dente i e
30. 4040400 00 00 9 0 133 BACNET AND MODBUS COMMUNICATIONS DATA S OLAIP 91 90 0 Way S 2 ejou ees 241 0 iur peo1 eju 9 90 20 QvO1 5 eunssejd uogons 1uiodies SAS OLAP 91 90 0 LS dS Way dS S 3 04 4 07 66 Buljoog 1urodjes 95 90 60 4135 SINIOd ILON 33S S 3LON 33S 1 310 33S 0 16 8 4 9191 12 WNN ION N 1210180 PiSpueS S 1NIOd SUNA snaaow snaaow canon 3WVN jeu V8 aan JS 0L 6 8 15 96 SG IV PPV v00 SS 20 L 0 0 9L OWWO 1 15 96 SG IV PPV 00 SSZZ0 L 0 0 FL OWWO 9 15 96 SG IV PPV 100 SS 20 L 0 0 L OWWO 5 OS 9je2 09920 10 02920 1 60 dHIAIN 00 55720 lt 0 80 00 21 209 ONWWO v 99 5 JED snqpoy 1409920 1 0 M XXX 0 920 L 0 dH 00 SSZZ0 1 0 80 00 21 vL OWW2O 99 49
31. YHGSV HOT GAS SOLENOID VALVE INCLUDING COIL SUPPRESSOR LIQUID LINE SOLENOID VALVE FIELD YLLSV MOUNTED AND WIRED ON REMOTE EVAP UNITS ZCPR COMPRESSOR NOTE WELL SEE NOTE WIRING AND ITEMS SHOWN THUS ARE STANDARD YORK ACCESSORIES WIRING AND ITEMS SHOWN THUS ARE NOT SUPPLIED BY YORK ITEMS THUS ENCLOSED FORM A COM PONENTS OR SETS OF COMPONENTS 035 21966 101 REVG 55 FORM 150 72 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 ELECTRICAL NOTES AND LEGEND CONT D 035 21966 101 REV GENERAL This drawing is based on IEC symbols Field wiring to be in accordance with the relevant electrical code as well as all other applicable codes and specifica tions c sources of supply shown on this diagram to be taken from one main isolator not shown or supplied by YORK Green and yellow wire is used for earth multi colored cable used for low voltage Red wire used for AC Control blue wire for neutral black wire for AC and DC power Orange wire should be used for interlock control wiring supplied by external source Legend designation depicts component abbreviations Number prefix located if applicable on schematic circuit refers to system thereon E G lt 1 FHP2 refers to high pressure cutout no 2 on system 1 All wiring to control section voltage free contacts requires a supply provided by the customer maximum voltage 240 volts The customer must take particular care when deriving th
32. c eunje1eduje jueiquiy HO U91IMS ulejs S uo JOON 22 OVA D HO yams wun aq Jou Kew josey 4 IZ 0 UOHIPUOD ON 0 s po9 yneJ 1 4 a aav Ssed g SAS 9c eju 8020710 051 ez 18 25 16 5151515151515 oinyz Sc eju 0 C0 IO 5051 18 11 o1nv 96 S S S S S S S 15 0 SHUN 10 vc eju 80720710 ZOEL Wz 19 LINN 96 S S S S S S S 1 7 0 OUD 10 ez ag eju 6020 10 LOEL 18 11 2 76 8 8 PIS 0 _ 10 ag eju 020 10 0061 6L 18 6 S S S S S S S JOOAID 1 0 944 eju 0 c0 T0 6621 8L 18 3dAL 76 8 8 uns 9109 5 6 0 oz ag eju 8020110 8621 218 NOY 20 25 56 8 8 uns S S 10 6 ag eju 0 c0 10 2621 9L 18 20 LS 26 S S S S S S S 2 546 SAS 0 5 5 pes 10 84 ag eju 60 20 10 9621 SL 18 SAS
33. vL Suyuq vL uonejos l Buguriuonons l abseyosiq uBiH 21 cu JenueW zi ZL eimeredure uo uBiH m annoy epAoes nuv m Aiegeg 0 OL OL OL UOIONASTI 6 6 peo 002 ON 6 6 uang UBIH 8 8 UNY ON 8 8 55 2 2 umopynys 2 2 ainssaid jenuejeyiq 9 9 uwopinus 9 9 ejnsseJg YIH ueis S 6 pinbr y v jo ooi eJnjejeduje HO uejs sS _ uowwsmun 0 0 0 0 0 4 2 ssd 16 3000340 95 96 4 9po2 jeuone1edo 139 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 THIS PAGE INTENTIONALLY LEFT BLANK 140 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 8 UNIT OPERATION Unit Operating Sequence The operating sequence described below relates to op eration on a hot water start after power
34. 16 6 9 2 WAN 31IlHM Peuoddns 991 ON N euondo puepueIg s LNIOd S sejewW ZN 1suja2efqo 1sr11utod snadow snsaow 135 JOHNSON CONTROLS SECTION 7 UNIT CONTROLS Yorktalk 2 Communications Received Data Control Data The unit receives eight data values from the E Link Gateway The first four are analog values and the last four are digital values These eight data values are used as control parameters when in REMOTE mode When the unit is in LOCAL mode these eight values are ig nored If the unit receives no valid YorkTalk 2 trans mission for 5 minutes it will revert back to all local control values Table 17 on page 137 lists the control parameters These values are found under feature 54 in the E Link Gateway 136 FORM 150 72 614 ISSUE DATE 6 10 2014 Transmitted Data After receiving a valid transmission from the E Link Gateway the unit will transmit either operational data or history buffer data depending on the History Buffer Request on ENG PAGE 10 Data must be transmitted for every page under feature 54 If there 15 no value to be sent to a particular page a zero will be sent Table 17 on page 137 shows the data values and page list ings for this unit The latest point map
35. JOMUOW G 9 5 15 0 SPOW juerquv oz EZL 96 yams 1909 051 JOMUONWN 5 102 19 0 d L 6r yms LANS 009051 5151515 8 uny JosseJduio S S 8 LoL 56 YMS LANS 69041051 Joyuow Ltd 8td 51891515 8 ung JosseJduio S S 11 aga 021 96 YMS LANS 9vOdLOS LAO u JoyuoN 8rd Ltd 5 zs s SAS 0 91 611 s6 uowws LANS zvodioglAo u JONUONN A Std Ltd 5 1 pinbrqz s s SLL 96 yms Std 6 8 8 8 ung JosseJduio S S vl ag A 56 YMS LANS SYOdLOS LAOU JO uo etd Std 8 8 8 8 ung S S tL 9 96 YMS LANS 700105 LAO u eNeAssed g se9 SAS zi aa 56 yms LANS Lid 0 2 9 5 7 2 2 gt 1571 LNIOd uonisod SEN d L 3T8VIIVAV LON TvNOILdO 16 30021SI llNIOd sseippy NO 340A 340
36. SYSTEM 1 RUN CONTACTS CLOSE EVAPORATOR PUMP DRY CONTACTS CLOSE RUN BASED ON DAILY SCHEDULE INTERNAL 120 VAC WIRING TO F1 FUSE INTERNAL 120 VAC WIRING TYPICALLY FROM CONTROL TRANSFORMER INTERNAL NEUTRAL WIRING INTERNAL NEUTRAL WIRING TYPICALLY FROM CONTROL TRANSFORMER INTERNAL NEUTRAL WIRING LD13242 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 41 42 THIS PAGE INTENTIONALLY LEFT BLANK FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA OPERATIONAL LIMITATIONS TABLE 2 TEMPERATURES AND FLOWS NOMINAL EVAPORATOR WATER FLOW TEMPERATURE WATER FLOW 1 5 AIR ON CONDENSER MODEL ww we oo ow ow 4 4 YLAA0180SE YLAA0210SE YLAA0240SE YLAA0241SE YLAA0285SE YLAAO286SE YLAA0320SE YLAA0360SE YLAA0400SE YLAA0435SE YLAA0485SE HIGH EFFICIENCY YLAA0195HE YLAA0220HE YLAA0221HE YLAA0260HE YLAA0261HE YLAA0300HE YLAA0350HE YLAA0390HE YLAA0441HE YLAA0456HE YLAA0516HE NOTES 1 For leaving liquid temperature below 40 F 4 C to 10 F 12 C optional low temperature glycol kit required Contact your nearest
37. 2L1 2L2 2L35 12 13 211 212 213 211 212 213 411 112 113 O00 XTBC 1 QCB 050 050 GIOI 1L1 112 113 2 11 112 113 1L1 1L2 1L5 TRANSFORMER AND TERMINALS ARE FOUND ON POWER SIDE OF DIVDER PANEL 12 13 1 QCB R2 B2 JERE R 1L1 112 115 L LD13234A FIGURE 19 POWER OPTIONS CONNECTION DIAGRAM 70 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA 6 12 13 m QMMSP2 2020 POS 2 QCB 4 T O90 MM 1 62 0666 2 0008 O6 5 2 QCB 21 212 213 1013901 FIGURE 18 POWER OPTIONS CONNECTION DIAGRAM CONT D JOHNSON CONTROLS 71 FORM 150 72 ICOM7 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 POWER PANEL 035 21589 101 REV E
38. 5 Z Jav 691 99 LS F 3uno9 LANS JOU v Zld 5 juodjes ejoued 96 ACV 991 291 1s s noo zz0diosiAo s JOMUOIN V 04d 5 einsseJg se 191 891 09 unos 0 0 1 V 69 04d 5 Auo sinsseiq uonons MOT ve Jav 291 791 19 noo JOMUOJN V 89d 04d 69d 5 dH einssejg uogons MOT lt lt SAV 691 06 19 JOMUOIN V 19d 69d 99d 5 eimjejeduie jusiquiy ze Jav 9v4 1s s noo 909 051 JOMUOJN V 99d 89d 29 5 pinbr 6 Jav StL Ctl 19 unos 19d 99d 5 06 851 is squnoo 904061 V 9 1009 46 6 SIG Z AM 198 1 AM 1 0 epo OL IAY Zeb 09 unor Lans 9 S9d 6 IAY 96 16 3uno9 LANS v90dioS1Ao u JOJUO A 9 5 2 s S SEL
39. FEATURE FEATURE DESCRIPTION MODEL Model PIN 1 4 Capacity CAPACITY PIN 5 8 Unit Designator UNIT PIN 9 Refrigerant PIN 10 Voltage PIN 11 amp 12 Starter STARTER PIN 13 Design Series DESIGN PIN 14 Y 5 T Across the Line starter Soft Start Design Series A MicroChannel Copeland Compressor Design Series C MicroChannel CE ETL Panel Copeland Compressor Design Series D MicroChannel Bitzer Compressor Design Series F MicroChannel CE ETL Panel Bitzer Compressor OPTION OPTION DESCRIPTION 0180 0195 0210 0220 0221 0240 0241 0260 0261 0285 0286 0300 0320 0350 0360 0390 0400 0435 0441 0456 mU Devel t Level 24 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 2 PRODUCT DESCRIPTION TABLE 1 COMPLETE PIN NUMBER DESCRIPTION CONT D FEATURE FEATURE DESCRIPTION OPTION OPTION DESCRIPTION Power Field PIN 16 amp 17 POWER TRANS Cntrl Transformer PIN 18 PIN 19 Ambient Kits PIN 20 Bas Reset Offset PIN 21 Language PIN 22 Readout Kits PIN 23 RDOUT SAFETY Safety Codes PIN 24 sensor 25 RUME PIN 26 Remote Panel REMOTE PIN 27 Sequence Kit PIN 28 Power Factor Capacitor sx sPSwnytS Special Control TransformerRequired Special Power Capacitor required B Both Low High Ambient Kitw Sunshield SpecialAm
40. Verify the compressor heaters are energized If the am bient temperature is above 96 36 compres sor heaters must be on for at least 8 hours before start up to ensure all refrigerant liquid is driven out of the compressor and the oil If the ambient temperature is below 86 30 C allow 24 hours JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 Supersedes 150 72 CL1 1112 BY JOHNSON CONTROLS INSTALLATION CHECKLIST AND REQUEST FOR AUTHORIZED STARTUP ENGINEER CUSTOMER ADDRESS PHONE JCI TEL NO JCI ORDER CHILLER MODEL NO The work as checked below is in process and will be completed by SECTION 6 COMMISSIONING Form 150 72 CL1 113 MODEL YLAA JOB NAME LOCATION CUSTOMER ORDER NO JCI CONTRACT UNIT SERIAL NO Month The following work must be completed in accordance with installation instructions A PRE STARTUP Unit Checks No Power The following basic checks should be made with the customer power to the unit switched OFF 1 3 Visually check for refrigerant piping leaks Assure that all piping has been completed Open suction line ball valve discharge line ball Check the control panel to ensure it is free of for Visually inspect wiring power and control Wiring Check tightness of power wiring inside the Inspect the unit for shipping or installation
41. FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 3 HANDLING AND STORAGE DELIVERY AND STORAGE To ensure consistent quality and maximum reliability all units are tested and inspected before leaving the fac tory Units are shipped completely assembled and con taining refrigerant under pressure Units are shipped without export crating unless crating has been speci fied on the Sales Order If the unit is to be put into storage prior to installation the following precautions should be observed The chiller must be blocked so that the base is not permitted to sag or bow Ensure that all openings such as water connec tions are securely capped Do not store where exposed to ambient air tem peratures exceeding 110 F 43 C The condensers should be covered to protect the fins from potential damage and corrosion particu larly where building work is in progress Theunit should be stored in a location where there is minimal activity in order to limit the risk of ac cidental physical damage To prevent inadvertent operation of the pressure relief devices the unit must not be steam cleaned tis recommended that the unit is periodically in spected during storage JOHNSON CONTROLS INSPECTION Remove any transit packing and inspect the unit to en sure that all components have been delivered and that no damage has occurre
42. of the rated load amps for all other loads included in the circuit per N E C Article 440 22 Circuit breakers must be UL listed and CSA certi fied and maximum size is based on 225 of the rated load amps for the largest motor plus 100 LEGEND ACR LINE C B D E DISC SW FACT MOUNT CB FLA HZ MAX MCA MIN MIN NF RLA S P WIRE UNIT MTD SERV SW LRA JOHNSON CONTROLS ACROSS THE LINE START CIRCUIT BREAKER DUAL ELEMENT FUSE DISCONNECT SWITCH of the rated load amps for all other loads includ ed in the circuit Otherwise 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 the cir cuit The INCOMING WIRE RANGE is the mini mum and maximum wire size that can be ac commodated by the unit wiring lugs The 2 preceding the wire range indicates the number of termination points available per phase of the wire range specified Actual wire size and number of wires per phase must be determined based on the National Electrical Code using copper con nectors only Field wiring must also comply with local codes ground lug is provided for each compressor system to accommodate a field grounding con ductor per N E C Table 250 95 A control circuit grounding lug is also supplied The supplied disconnect is Disconnecting Means as def
43. 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2014 www johnsoncontrols com ALL RIGHTS RESERVED Form 150 72 ICOM7 614 Issue Date June 10 2014 Supersedes 150 72 ICOM7 414
44. Y14 ity with exception of the 2D 3280N and 2D 2870 2 Standard finish housing powder coated color 5 Refer to next page for installation instructions black spring powder coated color see table be Consult factory for concrete installation low hardware zinc electroplate 3 Equipment must be bolted welded to top plate to meet allowable seismic ratings MODEL Y2RSI 2D SEISMICALLY RESTRAINED VIBRATION ISOLATOR FOR 2 DEFLECTION SEISMIC RATED LOAD SPRING SOLID LOAD ERNST MOUNT SIZE LBS IN LBS IN LBS HORIZONTAL Y2RSI 2D 150 150 24 62 234 WHITE 34 7 Y2RSI 2D 320 Y2RSI 2D 460 460 2 3 200 688 Y2RSI 2D 710 DK BROWN Y2RSI 2D 870 RED Y2RSI 2D 1200N RED BLACK Y2RSI 2D 1450 Y2RSI 2D 1690 Y2RSI 2D 2000N PINK BLACK Y2RSI 2D 2640N PINK GRAY PINK GRAY ORANGE PINK GRAY DK BROWN Y2RSI 2D 2870N Y2RSI 2D 3280N 88 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA 2 DEFLECTION ISOLATOR INSTALLATION AND ADJUSTMENT Read instructions in their entirety before begin ning installation Isolators are shipped fully assembled and are to be positioned in accordance with the submittal draw ings or as otherwise recommended Set isolators on floor housekeeping pad or sub base ensuring that all isolator centerlines match the equipment m
45. on page 107 for specific information on the dis played information and specific use of the 1 UP and DOWN arrow keys The 4 UP arrow key and DOWN arrow key are also used for programming the control panel such as changing numerical or text values when programming cooling setpoints setting the daily schedule changing safety setpoints chiller options and setting the clock JOHNSON CONTROLS Setpoints COOLING SETPOINTS SCHEDULE ADVANCE DAY PROGRAM 00068VIP Enter Adv Key The ENTER ADV key must be pushed after any change 15 made to the cooling setpoints daily schedule safety setpoints chiller options and the clock Pressing this key enters the new values into memory If the EN TER ADV key is not pressed after a value is changed the changes will not be entered and the original val ues will be used to control the chiller Programming and a description on the use ofthe 1 UP arrow key and DOWN arrow and ENTER ADV keys are covered in detail under the SETPOINTS and UNIT keys 115 SECTION 7 UNIT CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SETPOINTS KEYS Setpoints COOLING SETPOINTS SCHEDULE ADVANCE DAY PROGRAM Programming of the cooling setpoints daily schedule and safeties is accomplished by using the keys located under the SETPOINTS section The three keys involved are labeled COOLING SETPOINTS SCHEDULE ADVANCE DAY and PROGRAM Following ar
46. order number and run hours starts Model and JOHNSON CONTROLS serial number information is printed on the unit identi fication plate The unit warranty will be void if any modification to the unit is carried out without prior written approval from Johnson Controls For warranty purposes the following conditions must be satisfied The initial start of the unit must be carried out by trained personnel from an Authorized Johnson Controls Service Center see SECTION 6 COM MISSIONING Only genuine YORK approved spare parts oils coolants and refrigerants must be used All the scheduled maintenance operations detailed in this manual must be performed at the specified times by suitably trained and qualified personnel see SECTION 10 MAINTENANCE Failure to satisfy any of these conditions will auto matically void the warranty see Warranty on page 11 HANDLING These units are shipped as completely assembled units containing full operating charge and care should be taken to avoid damage due to rough handling SAFETY AND QUALITY Standards for Safety and Quality YLAA chillers are designed and built within an ISO 9002 accredited design and manufacturing organiza tion The chillers comply with the applicable sections of the following Standards and Codes ANSI ASHRAE Standard 15 Safety Code for Mechanical Refrigeration ANSI NFPA Standard 70 National Electrical Code N E C ASME Boiler
47. unor 9 59 515151515 210 vel 16 unor LANS Z90dLOSLAOAU JOJUO A 09 s sS 910 EEL unor JO UON 515151518 cel 16 unor LANS 0904061 JOJUO A 89 6Sd 5191515 8 apo S S t lav LEL 19 3unoo LANS 609 051 JOHUO N 4 6Sd 89 51891515 8 2 515 051 LS F 3unoo LANS 8504 061 JOHUO N 9Sd 8Sd 49 51851515 8 sks 19 3unoo LANS 7504 061 JOHUOIN SSd 6 8 8 8 epo sks 851 15 3unoo LANS 9504 061 5 eNeAssed g 2 545 vc 221 56 LANS 660 051 JONUONN A 99 5 0 ez ag 921 96 yams LANS 9 5 16 1 leuedujzo Sel 96 yous 909105 1 5 18201 0 vel 96 yous 2909 051
48. 1 or 2 The non running compressor within a system with the lowest priority number will always be the next compressor to start The running compressor with priority number 1 will always be the next compressor to shut OFF Whenever a compressor is shut OFF the priority numbers of all compressors in each system will be decreased by 1 with the wrap around This control scheme assures the same com pressor does not repeatedly cycle ON and OFF ANTI RECYCLE TIMER The programmable anti recycle timer assures that sys tems do not cycle This timer is programmable under the PROGRAM key between 300 and 600 seconds Whenever possible to reduce cycling and motor heat ing the anti recycle timer should be adjusted to 600 seconds The programmable anti recycle timer starts the timer when the first compressor in a system starts The timer begins to count down If all of the compres sors in a circuit cycle OFF a compressor within the cir cuit will not be permitted to start until the anti recycle timer has timed out If the lead system has run for less than 5 minutes 3 times in a row the anti recycle timer will be extended to 10 minutes ANTI COINCIDENCE TIMER This timer is not present on single system units Two timing controls are present in software to assure com pressors within a circuit or between systems do not start simultaneously The anti coincidence timer as sures there is at least a one minute delay between sys tem starts on 2 cir
49. 10 2014 Option 9 Condenser Fan Control Mode FAN CONTROL DISCHARGE PRESSURE Condenser fans are controlled by discharge pressure only This mode must be chosen or FAN CONTROL AMBIENT amp DSCH PRESS Do not select this option on R 410A chillers Option 10 Manual Override Mode MANUAL OVERRIDE DISABLED MODE This option allows overriding of the daily schedule that is programmed MANUAL OVERRIDE MODE DISABLED indicates that override mode has no effect or MANUAL OVERRIDE MODE ENABLED Manual Override Mode is enabled This is a service function and when enabled will allow the unit to start when shut down on the daily schedule It will auto matically be disabled after 30 minutes Option 11 Current Feedback Options Installed CURRENT FEEDBACK NONE This mode should be selected when the panel is not equipped with current sensing capability or CURRENT FEEDBACK ONE PER UNIT This mode should be selected when an optional 2ACE Module is installed to allow combined current moni toring of all systems by sensing current on the incom ing line or JOHNSON CONTROLS SECTION 7 UNIT CONTROLS CURRENT FEEDBACK ONE PER SYSTEM This mode should be selected when an optional 2ACE module is installed to allow individual current moni toring of each system SYS 1 input is to J7 of the I O SYS 2 input is to J8 of the I O Option 12 Power Fail Restart POWER FAIL RESTAR
50. 150 72 ICOM7 614 ISSUE DATE 6 10 2014 FLOW SW REM START 913 5 1S This indicates that flow switch remote start input is connected to plug 13 pin 5 J13 5 on the microboard and is ON ON 30VDC unregulated input OFF OVDC input on digital inputs CONTROL INPUTS OUTPUTS Table 24 through Table 27 on page 153 are a quick reference list providing the connection points and a description of the inputs and outputs respectively input and output connections pertain to the connections at the microboard TABLE 24 I O DIGITAL INPUTS Unit ON OFF Switch Load Limit Stage 2 on 3 5 amp 6 Comp Units Load Limit Stage 1 Flow Switch and Remote Start Stop Spare Single System Select Jumper Single Sys No Jumper Two Sys CR1 Sys 1 Motor Protector High Pressure Cutout CR2 Sys 2 Motor Protector High Pressure Cutout TABLE 25 I O DIGITAL OUTPUTS SYS 1 Compressor 1 SYS 1 Liquid Line Solenoid Valve SYS 1 Compressor 2 SYS 1 Compressor 3 SYS 1 Hot Gas Bypass Valve SYS 2 Compressor 1 SYS 2 Liquid Line Solenoid Valve SYS 2 Compressor 2 SYS 2 Compressor 3 SYS 1 Condenser Fan Output 1 SYS 1 Condenser Fan Output 2 SYS 1 Condenser Fan Output 3 SYS 2 Condenser Fan Output 1 SYS 2 Condenser Fan Output 2 SYS 2 Condenser Fan Output 3 TB10 5 TB7 8 TB7 9 TB7 10 TB10 8 TB10 9 TB10 10 TB8 2 TB8 3 TB9 2 SYS 2 Alarm TB8 6 amp 7 Evaporator Pump Start
51. 250 kCMIL ETL BFDS WIINDIVIDUAL SYSTEM CBS 4XX 2 3 0 250 kCMIL 2 3 0 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 3 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 3 0 AWG 250 kCMIL 2 3 0 250 kCMIL 2 3 0 AWG 250 1 6 350 kCMIL 1 46 AWG 350 kCMIL 1 46 AWG 350 kCMIL 1 6 AWG 350 kCMIL 1 46 AWG 350 kCMIL 2 3 0 AWG 250 kCMIL 1 250 500 kCMIL amp 2 3 0 AWG 250 kCMIL 2 3 0 250 kCMIL 2 83 0 AWG 250 kCMIL 2 250 500 kCMIL 2 250 500 kCMIL FORM 150 72 614 ISSUE DATE 6 10 2014 CE NFDS W MMS 2 3 0 AWG 250 2 3 0 AWG 250 2 3 0 AWG 250 kCMIL 2 3 0 AWG 250 kCMIL 2 3 0 AWG 250 kCMIL 2 3 0 AWG 250 kCMIL 2 3 0 AWG 250 2 3 0 AWG 250 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 1 6 AWG 350 kCMIL 1 46 AWG 350 kCMIL 1 6 AWG 350 kCMIL 1 46 AWG 350 kCMIL 1 46 AWG 350 kCMIL 2 3 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL CE NFDS W MMS amp SS 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 3 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 3 0 250 kCMIL 1 4
52. 991 2 3 1 4 2 5 1 15 2 17 1 18 2 4 212 3 6 4 6 15 6 17 2 17 8 18 7 MM gt 113 31 4 2 51 15 2 171 182 588 5 3 3 2 213 56 4 6 15 6 18 7 ET 9 LU E 21 0 9 1 1 1 2 1 3 5 13 5 2 0 9 1 1 XA 118V 1 50 60HZ F3 L d d Cd d gt 1 gt gt gt 1 gt gt 1 gt 1 gt gt 1 gt 1 gt 4 ma 2 16 2 16 2 16 2 16 1 1815 1 a ls 1 3 5 1 3 5 x NA 25 124446 26 446 26 124446 29 924446 7210 4 NB56A e 20180207802 388 953 8 8 2 ND L3 4 v jT H 2 E gq lt 2 L1 L2 L3 PE L1 L2 L3 PE L1 L2 L3 PE L1 L2 L3 PE L1 L2 L3 PE 29 gt 2 MT M M 5 1 2 3 3 ho 3 1 8 1 2 1 12 2 EXLACC EXT EX EXT EXT EXT wa 1 1 XTBC1 L Pegs 13 13 21 5271 139 5 192 192 XP2 jo gt 2 2 2 1 3 2 4 2 5 14 1 15 2 17 2 17 9 18 2 6 PWM Mm i FS 1 2 lt POWER 50 i AE o 201 121151 1 ADIS mm 5 22 24V c o m la foo lo lo E 5 5 5 5 e o 41 GND izZiok zog9gp9
53. BSP EXT EXT EXT EXT EXT 1 34 2 1 33 33 is EXT 349 o gt OW yu eu 9 B TA Tc TATC TA S Xp4 15 4 Lt 4 IL 4 16 L 2 3 Lbp rilp p 4pnilbp 1 gt 5 lt lt 140 c SSS kz glg 18 19 ojo 8 ho 9 2 5 23324334 2 4 h2 6 4 4 4 TREIMI TUE AT 8 0 9 25 147 369 1 5 9 10 4 12 159 40 2 6 7 n 4 2 6 n v J13 J6 9 J1 TBi RS485 6 8232 KB Xj K6 7 18 K K20 KA E 23 Kaa 1203047 102959405069 M 5 5 Sount gt Je e e le oe mad 8 810 el 29 7240 7240 37 38 39 5 2 71210 747 748 749 157 158 158 ter M A78 7187 7189 71810 59 SECTION 5 TECHNICAL DATA 035 21583 102 REV J FORM 150 72 614 ISSUE DATE 6 10 2014
54. CONTROL ON PRESS 425 PSIG FAN DIFF OFF PRESS 125 PSIG NUMBER OF COMPRESSORS 6 NUMBER OF FANS PER SYSTEM 4 UNIT TRIP VOLTS 3 0 REFRIGERANT TYPE R 22 DEFROST INIT TEMP 41 0 DEGF DEFROST INITIATION TIME 60MIN DEFROST TERMINATION TIME 3MIN BIVALENT HEAT DELAY TIME 30 MIN REMOTE UNIT ID PROGRAMMED 2 YORK HYDRO KIT PUMPS 1 410a PUMP TOTAL RUN HOURS XXXXX 410a UNIT DATA RETURN LIQUID TEMP 58 2 DEGF LIQUID TEMP 53 0 DEGF DISCHARGE AIR TEMP 55 3 DEGF JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 COOLING RANGE EATING RANGE YS 1 SETPOINT YS 2 SETPOINT EMOTE SETPOIN MBIENT AIR TE SYSTEM EVAPORATOR PUM 42 0 2 EGF 122 0 2 EGF 70 SIG 70 SIG T 44 EGF ME 74 EGF SYS 2 P ON EVAPORATOR HEA TER OFF ACTIVE REMOTE LAST DEFROST SYS X DURATION XXXS TIME TO SYS X CONTROL NONI DEFROST XX MIN BIVALENT DELAY REMAINING MIN UNIT AM SOFTWARE VERSI o lt P STATUS UN ME 0 IMI 0 AST STATI 5 X X VOLTS ON C M02 13 00 SYSTEM 1 DATA 1 OFF 2 OFF 3 OFE 0 0 0 D H M S 0 0 0 D H M S U PRESS PSIG PRE PSIG P 1 DEGF EGF EGF EGF cououuocutrtH D D D D
55. System X MP HPCO Fault System X Switch Off System X System X HIGH MTR CURR No Cooling load Optional Incorrect Unit Type Unit Warning Message System X Comps Run System X AR Timer High Motor Current System X AC Timer System X Disch Limiting System X Suction Limiting System X Percentage Load Limiting Manual Overide Status System X Pumping Down on shutdown LD11297B FIGURE 24 STATUS KEY MESSAGES QUICK REFERENCE LIST 106 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 7 UNIT CONTROLS DISPLAY PRINT KEYS The Display Print keys allow user to retrieve sys tem and unit information that is useful for monitoring chiller operation diagnosing potential problems trou bleshooting and commissioning the chiller System and unit information unit options setpoints and scheduling can also be printed out with the use of a printer Both real time and history information are available Oper Data Key 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 remain on the display until another key is pressed After pressing the OPER DATA key the various operating data screens can be scrolled through by using the 1 UP and DOWN arrow keys or the ENTER ADV key located under the section System 2 information will only
56. YLAA HIGH EFFICIENCY UNITS 2417 25 23 25 23 25 25 25 25 28 24 29 29 33 28 38 28 37 36 40 40 we umo wm caps E JOHNSON CONTROLS 47 SECTION 5 TECHNICAL DATA FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 ELECTRICAL DATA TABLE 5 MICROPANEL POWER SUPPLY CONTROL TRANS 200 1 60 CONTROL OVER CURRENT PROTECTION UNIE VOLTAGE POWER SEE NOTE B NF DISC SW UNIT NOTE A MODELS W O VOLTAGE max 30 240V 230 1 60 30 A 240V MODELS W 30 480V CONTROL TRANS 460 1 60 30 480V 380 415 1 50 30A 415V 575 1 60 NOTE A Minimum 14 AWG 75 Copper Recommended 30 600 B Minimum and Maximum Over Current Protection Dual Element Fuse or Circuit Breaker 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 Voltage Limitations The following voltage limitations are absolute and operation beyond these limitations may cause serious damage to the compressor TABLE 6 VOLTAGE RANGE The unit evaporator heater uses 110VAC Disconnecting 120VAC power from the unit at or below freezing temperatures can resul
57. are many user programmable options under the OPTIONS key The OPTIONS key is used to scroll through the list of options by repeatedly pressing the OPTIONS key After the selected option has been dis played the 1 UP and DOWN arrow keys are then used to change that particular option After the option 15 changed the ENTER ADV key must be pressed to enter the data into memory Many of the OPTIONS displayed are only programmable under the SERVICE MODE and not under the OPTIONS key Options only programmable under the SERVICE MODE are noted in the details describing the option NOTE Figure 27 on page 128 shows the programmable op tions Following are the displays in the order they ap pear Option 1 Language DISPLAY LANGUAGE ENGLISH English Spanish French German and Italian can be programmed Option 2 System Switches two system units only Single System Display 15 similar SYS 1 SWITCH ON SWITCH ON SYS 2 JOHNSON CONTROLS 00070VIP This allows both systems to run or SYS 1 SYS 2 SWITCH ON SWITCH OFF This turns system 2 OFF 1 SYS 2 SWITCH OFF SWITCH ON This turns system 1 OFF or SYS 1 SYS 2 SWITCH SWITCH This turns systems 1 and 2 OFF Turning a system OFF with its system switch allows a pumpdown to be per formed prior to shutdown NOTE Option 3 Chilled Liquid Cooling Type CHILLED LIQUID WATER The
58. chilled liquid temperature cutout unloading occurs at a rate of 10 seconds if it is greater than 10 seconds In water cooling mode on R 410A chillers the mini mum low limit of the control range will be 40 0 F For leaving chilled liquid temperature setpoint and control range combinations that result in the low limit of the control range being below 40 0 F the low limit will be reset to 40 0 F 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 0 F This control will not affect glycol chillers Hot gas if present will be the final step of capacity Hot gas is energized when only a single compressor is run ning and LWT is less than SP Hot gas is turned OFF as temperature rises when LWT is more than SP plus CR 2 If temperature remains below the setpoint low limit on the lowest step of capacity the microprocessor will close the liquid line solenoid after turning off hot gas and pump the system down before turning off the last compressor in a system JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 8 UNIT OPERATION TABLE 18 SAMPLE COMPRESSOR STAGING FOR RETURN WATER CONTROL COMPRESSOR STAGING FOR RETURN WATER CONTROL 4 COMPRESSOR COOLING SETPOINT 45 7 2 C RANGE 10 F 5 6 C ET 45 F 46 25 F 47 5 F 50 0 F 52 5 55 0 72 7 9 8 6 10 0 1
59. e t uo RN e dede e 84 Seven And Eight Fan Isolator 85 Isolator Information thoi ehh eden eaaet tbe 86 JOHNSON CONTROLS 5 SECTION 6 Preparation Power Preparation Power din epp perii SECTION 7 UNIT CONTROLS esee AIUREA mt IPU IT Andil O Boards 72 IransfOrtmer au ir iene eatin et edunt Display iua paene tta e eate Mgr Unit SWItChiz i ee tte et e hee Palette Puit ode Battery ient eet eene Programming ES Display Print Keys Ritt Enty KOVE IsepIcAX cR ER Schedule Advance Day Program BOV i Deb ERU Eee ete ER Bg cc Bacnet Modbus 2 And Yorktalk 2 Communications SECTION 8 UNIT OPERATION eere nennen nnne nennen nnn neni nnn nennen Capacity Controls ntc ee Een b RU ee lel e eh EOD ER cer EHE Ree Suction Pressure Limit
60. if the suction pressure falls below the programmed cutout setting a transient protection routine is activated This sets the cutout at 1096 of the programmed value and ramps up the cut out over the next 30 seconds If at any time during this 30 seconds the suction pressure falls below the ramped cutout the system will stop SYS 1 FAULT SYS 2 FAULT SYS 1 MP HPCO INHIB SYS 2 MP HPCO INHIB The Motor Protector Mechanical High Pressure Cutout protect the compressor motor from overheating or the system from experiencing dangerously high discharge pressure This fault condition is present when SYS 1 CR2 SYS 2 relays de energize due to the HP switch or motor protector opening This causes the respective CR contacts to open causing to be read the inputs to the microboard The fault condition is cleared when a 30VDC signal is restored to the input 103 SECTION 7 UNIT CONTROLS The internal motor protector opens at 185 to 248 85 to 120 and auto resets The mechanical HP switch opens at 585 PSIG plus or minus 10 PSIG 27 92 barg plus or minus 69 barg and closes at 330 PSIG plus or minus 25 PSIG 22 75 barg plus or minus 1 72 barg The compressor is also equipped with a discharge temperature sensor for the purpose of sensing inter nal scroll temperature This sensor protects the scrolls from overheating due to inadequate cooling that may occur
61. information is listed on the Johnson Controls Equip ment Integration website http my johnsoncontrols com portal myportal cg prod na chiller in NOTE JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 7 UNIT CONTROLS TABLE 17 YORKTALK 2 COMMUNICATIONS DATA MAP 5 5 5 5 45 1 vi S6 YMS zvodiosiAom JOMUOW Lid 5 5 5 5 5 uny 205591909 zs s l 96 uows Q 65 5151515 8 uny 205591909 545 6 ag e 96 LANS OvOdLOS LAOAU Joyuow 85 65 5 5 snjejs WE s6 uows JONUONW Q 65 6 6 1845 JejeeH Jojejode 3 OLL 96 5 85 16 S S S S 5 2 SKS 9 601 96 5 LANS 1509 05 LAO u Joyuow 18 51515151 5 wely 546 80 96 LANS 9209 05 1 Joyuow a 95 5 5 sJossejdui jo equinn 62 Jav 201 01 19 ino JONUOW V 55
62. may be lost Contact factory service NOTE SERVICE MODE Service Mode is a mode that allows the user to enable or disable all of the outputs except compressors on the unit change chiller configuration setup parameters and view all the inputs to the microboard To enter Service Mode turn the Unit Switch OFF and press the following keys in the sequence shown PROGRAM UPARROW UPARROW DOWN ARROW DOWN ARROW ENTER Service Mode will time out after 30 minutes and return to normal control mode if the panel is accidentally left in this mode Otherwise turning the unit switch ON will take the panel out of Service Mode SERVICE MODE OUTPUTS After pressing the key sequence as described the con trol will enter Service Mode permitting the outputs except compressors operating hours refrigerant type expansion valve type and start hour counters to be viewed modified The ENTER ADV key is used to advance through the outputs Using the and UP DOWN arrow keys will turn the respective digital out put ON OFF or modify the value JOHNSON CONTROLS Following is the order of outputs that will appear as the ENTER ADV key 15 pressed SYS 1 COMP 1 STATUS 7 2 IS SYS 1 LLSV STATUS 7 3 IS SYS COMP 2 STATUS TB7 4 IS SYS 1 COMP 3 STATUS 7 5 IS SYS 1 HGBP STATUS 7 7 IS SYS 2 COMP 1 STATUS 10 2 IS SYS 2 LLSV STATUS 10 3 IS SYS 2 COMP 2 STATUS 10 4 IS SYS 2 COMP 3 STATUS
63. performance Johnson Controls s unit controls will optimize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 2m 6 rear to wall 2m 6 control panel to end wall 1 2m 40 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit 76 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 DIMENSIONS 2077 SECTION 5 TECHNICAL DATA YLAA0240SE 0285SE 0320SE 15 875 DIA MOUNTING HOLES TYP POWER ENTRY 330 WIDE X 180 HIGH Loo 21 1102 CONTROL PANEL ORIGIN 2393 OVERALL HEIGHT 51 FRAME HEIGHT 22 Ex N S BOTTOM DETAIL 2243 FRAME WIDTI 2255 OVERALL NOTE 75 OUTLET 2912 FRAME LENGTI 3404 OVERALL LENGTI LD18067 Placement on a level surface of free of obstructions including snow for winter operation or air circulation ensures rated performance reliable operation and ease of maintenance Site restr
64. technical in formation and any other changes in spelling grammar or formatting are not included ASSOCIATED LITERATURE Start Up Checklist Style A and B 150 72 CL1 Renewal Parts YLAA0180 YLAA0516 Style B 50 Hz 150 72 RP4 Limited Warranty Engineered Systems Equipment 50 05 NM2 JOHNSON CONTROLS FORM 150 72 614 ISSUE DATE 6 10 2014 NOMENCLATURE 4 5678 9 10 11 12 13 14 15 DUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE STARTER DESIGN DEVELOPMENT LEVEL mla L mE zo ol L YORK 0 2 5 Standard Efficiency R 410A 1 7 200 13 60 C Design Series C Scroll 1 8 High Efficiency 2 8 230 3 60 A Development Level A Air Cooled 60 HZ Nominal Tons 4 0 380 3 60 Shell amp Tube Evap Americas 50 HZ Nominal kW 4 6 460 3 60 B Dev Level B Europe 5 8 575 3 60 5 0 380 415 3 50 X Across the Line JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 TABLE OF CONTENTS SECTION 1 GENERAL CHILLER INFORMATION AND SAFETY 11 nigoro leleii to a mee HEEL 11 p 11 selle EE 11 Satety And Quality Deuce arai RR 11 s tet en tta etin entm fe citet centum dude 12 Mis se Of Eq lpment Ee OE etr p eco e Leo ete EID eh eS ET 12 SECTIO
65. tenance work should be attempted on the electrical equipment without first switching power OFF isolat ing and locking off the power supply Servicing and maintenance on live equipment must only be per formed by suitably trained and qualified personnel No attempt should be made to gain access to the control panel or electrical enclosures during normal operation of the unit Rotating Parts Fan guards must be fitted at all times and not removed unless the power supply has been isolated If ductwork is to be fitted requiring the wire fan guards to be re moved alternative safety measures must be taken to protect against the risk of injury from rotating fans Sharp Edges The fins on the air cooled condenser coils have sharp metal edges Reasonable care should be taken when working in contact with the coils to avoid the risk of minor abrasions and lacerations The use of gloves is recommended Frame rails brakes and other components may also have sharp edges Reasonable care should be taken when working in contact with any components to avoid risk of minor abrasions and lacerations JOHNSON CONTROLS SECTION 1 GENERAL CHILLER INFORMATION AND SAFETY Refrigerants and Oils Refrigerants and oils used in the unit are generally non toxic non flammable and non corrosive and pose no special safety hazards Use of gloves and safety glasses is however recommended when working on the unit The build up of refrigerant vapor fro
66. the display are Suction Pressure 400 PSIG 27 58 barg Discharge Pressure 650 PSIG 44 82 barg SYS HOURS 1 2 3 SYS STARTS X XX X X 1 2 XXXXX 3 The above two messages will appear sequentially for each system The first display shows accumulated run ning hours of each compressor for the specific system The second message shows the number of starts for each compressor on each system Run times and starts will only be displayed for the actual number of systems and compressors on the unit NOTE A total of 99 999 hours and starts can be logged before the counter rolls over to 0 LOAD UNLOAD TIMER 58 TIMER 0 SEC SEC This display of the load and unload timers indicate the time in seconds until the unit can load or unload Whether the systems loads or unloads is determined by how far the actual liquid temperature is from setpoint A detailed description of unit loading and unloading is covered under the topic of Capacity Control gt e FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 COOLING 2 OF 8 DEMAND STEPS The display of COOLING DEMAND indicates the current step in the capacity control scheme when in Return Water Control Mode The number of available steps are determined by how many compressors are in the unit In the above display the 2 does not mean that two compressor are running but only indicates that th
67. the displays for the values that may be modified DE MODIFIER ADDRESS XXXXX P2 PROTOCOL XXXXXXXXXX P2 MANUAL ADDRESS XXX DE MODIFIER OFFSET XX P1 PROTOCOL XXXXXX P2 BAUD RATE XXXXX P2 PARITY P1 MANUAL MAC ADDRESS XXX P1 BAUD RATE XXXXX P1 PARITY XXXXX P1 STOP BITS XXXXX P2 STOP BITS P2 HW SELECT BIT XXXXX REAL TIME ERROR RESET 1 YES 0 NO 0 Note See Table 15 on page 132 error descriptions JOHNSON CONTROLS 129 FORM 150 72 614 SECTION 7 UNIT CONTROLS ISSUE DATE 6 10 2014 SHLD GND 5V 5 0 RXD TXD CTS RIS QUO OX GJ SHIDREF 2 TB3 B4 TB1 42 J1 035 02550 Board 1014318 FIGURE 28 MICRO PANEL CONNECTIONS The table below shows the minimum maximum and default values TABLE 13 MINIMUM MAXIMUM AND DEFAULT VALUES ___ DE MODIFIER ADDRESS 41943 DE MODIFIER OFFSET 1 99 P1 BAUD RATE 1200 76800 1200 4800 9600 19200 38400 76800 AUTO SELECTABLE P2 BAUD RATE 1200 57600 1200 4800 9600 19200 38400 57600 SELECTABLE P1 P2 MANUAL Mac AD DRESS P1 P2 PARITY NONE IGNORE NONE NONE EVEN ODD IGNORE SELECTABLE P1 PROTOCOL BACNET API BACNET BACNET SELECTABLE P2 PROTOCOL TERMINAL MODBUS CLIENT TERMINAL MO
68. to sensor J6 9 VDC input signal to microboard See Table 28 on page 155 for voltage readings that correspond to specific outdoor tempera tures J6 3 drain shield connection return JOHNSON CONTROLS SECTION 9 SERVICE AND TROUBLESHOOTING TABLE 28 OUTDOOR AIR SENSOR TEMPERA TURE VOLTAGE CORRELATION VOLTAGE SIGNAL INPUT TO RETURN 155 SECTION 9 SERVICE AND TROUBLESHOOTING TABLE 29 ENTERING LEAVING CHILLED LIQ UID TEMP SENSOR TEMPERATURE VOLTAGE CORRELATION VOLTAGE SIGNAL INPUT TEMP TO RETURN 156 FORM 150 72 614 ISSUE DATE 6 10 2014 Liquid and Refrigerant Sensor Test Points See Table 29 on page 156 Entering Chilled Liquid Sensor 16 5 5VDC regulated supply to sensor 76 8 VDC input signal to the I O board See Table 29 on page 156 for voltage readings that cor respond to specific liquid temperatures 76 2 drain shield connection 0 Return Leaving Chilled Liquid Temperature Sensor 16 4 5 regulated supply to sensor 76 7 VDC input signal to the microboard See Table 29 on page 156 for voltage readings that cor respond to specific liquid temperatures J6 1 drain shield connection return Analog Inputs Pressure Refer to the u
69. u JOUN 0000 A33 A33 846 2 dav 69 9S Finos ezodiosiAo u V 9 Jav 99 ZS 15 LANS 2209 051 0 JOUN v sis s s s uo 2 0 19 000 SfS Jav 19 87 Finos V 6ld 5 5 eissejg 5 Jav Lt vv Finos ozodiosiAo u V 81 6 6 emssejg 846 SCV Or 09 Finos 1ANS JONUOIN V 6ld 5 5 5 5 5 uny 846 zi 6 9 Finos eiodiosiAo u V 81 0000 sfs Ze Finos V sis s s s eunjejeduje jusiquiy 01 dav 15 85 Finos 1ANS V tld 91 0000 6 19 vC 19 SiodiogiAo u JOIUOJN V Eld Sid tld 5 0 7 dwal ePjeuosig 8 0 EZ 0c 19 1ANS V tld Eld 0000
70. with all intercon necting refrigerant piping and internal wiring ready for field installation Prior to delivery the packaged unit is pressure tested evacuated and fully charged with Refrigerant R 410A and oil After assembly a complete operational test is performed with water flowing through the cooler to as sure that the refrigeration circuit operates correctly The unit structure is heavy gauge galvanized steel This galvanized steel 1s coated with baked on powder paint which when subjected to ASTM 117 1000 hour salt spray testing yields a minimum ASTM 1654 rating of 6 Units are designed in accordance with 70 National Electric Code ASHRAE ANSI 15 Safety code for mechanical refrigeration ASME and rated in accordance with ARI Standard 550 590 JOHNSON CONTROLS GENERAL SYSTEM DESCRIPTION Compressors The chiller has suction gas cooled hermetic scroll compressors The YLAA compressors incorporate a compliant scroll design in both the axial and radial direction All rotating parts are statically and dynami cally balanced A large internal volume and oil res ervoir provides greater liquid tolerance Compressor crankcase heaters are also included for extra protection against liquid migration Brazed Plate Evaporator The compact high efficiency Brazed Plate Heat Ex changer BPHE is constructed with 316L stainless steel corrugated channel plates with a filler material between each plate It off
71. 0 2 DNDN NINN 0210200 9 9 02 02 02 02 02 02 06 j 5 5 spuooes uny S S spuooes NOH LS S siepo A33 1eeuredng S S od 1218 15 S eJnje1eduue Jusiquy od 1 0 5 dwa uonons S S a dar 1205 16 S spun yosiq od 01 OLX 0 60 9 6 duie pinbr od 6 OLX 0 60 915 l1HOMH 8L S dw pinbr1 E 8 OLX 70 50 YLS Liv 11H91 2 SLNIOd 1 QV33 9L S S S S S S S 45 eunsseiq 5 2 5 5 0 eju l o0 Sl SO CO LO 095 2545 SS SL 4222 3 96 NY 666 Ajuo dH 1utodies 919070 lV3H dS W3H 515 5 dS eunsseid doses SAS 90 SL S0 0 LO LSAS SS 151515151515 ueis 015 LO eju 906 506070 8695 4018 1491 L SLNIOd ALIMM ASHVNIS LL Buyooo 0 uo dH epoW 91 90 0 5501 LAW OL 2 uonong 1urodies S S 91 90 60 25 dS Way dS 4040040 00 00 62 o 0404040 0000 nO 0100490 0040400 Njn o 4040400 00 Nnn DNDN DN ND nN
72. 1 150 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 If a 4 to 20mA signal is supplied it is applied to Ter minals A and A and jumper JP1 on the I O board must be installed between pin 1 and 2 To calculate the chilled liquid setpoint for values between 4mA and 20 mA use the following formula Setpoint Local Chilled Liquid Setpoint Reset Reset mA signal 4 x Reset Value Example Local Chilled Liquid Setpoint 45 7 22 Reset Value 10 F 5 56 Input Signal 12 mA English x 10 F 5 F Reset 16 Setpoint 45 F 5 F 50 F Metric Reset 8mA x 5 56 ae 2 78 C Reset Setpoint 7 22 C 2 78 C 10 0 C A 240 to 24 Volt Ratio Transformer T3 is used to derive nominal 12 volt output from the 120 volt supply NOTE JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 9 SERVICE AND TROUBLESHOOTING CLEARING HISTORY BUFFERS The history buffers may be cleared by pressing the HISTORY key and then repeatedly pressing the UP arrow key until you scroll past the last history buffer choice The following message will be displayed INITIALIZE ENTER HISTORY YES Pressing the ENTER ADV key at this display will cause the history buffers to be cleared Pressing any other key will cancel the operation DO NOT CLEAR BUFFERS Important information
73. 1 YZY wy Y 9 15 QMMSP1 1 3 5 143 131 2 t1 3 5 143131 H PEE a Lp o M 3e 3 55 A 32 e a 555 gt gt gt gx aly 2 14 16 2 16 1135 1 3 5 4 16 3 121446 GND GND 288 23 8 8 d 888 8 QMMSP1 QMMSP2 2 3 44 4 Ut 1 WIE Ut 1 4 MP1 M MP2 EXP x EXP 149 2 3 gt 2 023 7 XTB8 6 V 2 3 3 716 715 XTB8 Y XTB8 247 XTBC2 339 XTBC2 e 149 e e M M 2 KP1 A2 1 2 2 2 12 2 2 5 gt 1 1 L 2 L im 2 3774 5 6 5 6 Ts 3 DRE 134 12 1016758 FIGURE 17 PUMP WIRING JOHNSON CONTROLS 67 SECTION 5 TECHNICAL DATA 035 21589 106 REV L COMPRESSOR WIRING FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 1 PEST 3 4 5 EEH1 EE
74. 1 4 12 8 Unloading only The leaving chilled liquid setpoint is programmable If adding the setpoint adjust value to the setpoint high from 40 F to 70 F 4 4 C to 21 1 C in water chill limit causes the setpoint high limit to be greater than 50 ing mode and from 10 F to 70 F 12 2 C to 21 1 F the setpoint high limit will be set to 50 F and the C in glycol chilling mode In both modes the cool difference will be added to the setpoint low limit ing range can be from plus or minus1 5 F to plus or minus2 5 F plus or minus 83 C to 1 39 C leaving chilled liquid control Once a system runs for greater than 5 minutes the set point adjust will be set back to 0 This will occur while the system is still running LEAVING CHILLED LIQUID CONTROL OVERRIDE TO REDUCE CYCLING To avoid compressor cycling the microprocessor will adjust the setpoint upward temporarily The last run time of the system will be saved If the last run time was greater than 5 minutes no action is to be taken If the last run time for the lead system was less than 5 minutes the microprocessor will increase the setpoint high limit according to the chart at right with a maxi mum value allowed of 50 F see Figure 29 on page 152 0 1 2 3 4 5 6 LAST RUN TIME OF LEAD SYSTEM MINUTES LD11415 SETPOINT ADJUST DEG F FIGURE 30 SETPOINT ADJUST TABLE 19 RETURN CHILLED LIQUID CONTROL FOR 4 COMPRES
75. 10 5 IS SYS 1 FAN OUTPUT 1 7 8 IS SYS 1 FAN OUTPUT 2 7 9 IS SYS 1 FAN OUTPUT 3 7 10 IS SYS 2 FAN OUTPUT 1 TB10 8 IS SYS 2 FAN OUTPUT 2 TB10 9 IS SYS 2 FAN OUTPUT 3 10 10 IS EVAP HEATER STATUS 8 2 IS SYS 1 ALARM STATUS 8 3 IS SYS 2 ALARM STATUS TB9 2 IS EVAP PUMP STATUS 8 6 7 15 SYS 2 HGBV STATUS 10 7 IS SPARE DO 8 4 IS SPARE DO 8 5 IS SPARE DO 8 8 9 IS SPARE DO 9 4 IS SYS 1 EEV OUTPUT 5 1 2 XXX SYS 2 EEV OUTPUT TB6 1 2 XXX SYS 1 COND FAN SPEED 115 1 5 SYS 2 COND FAN SPEED J15 2 6 SPARE AO J15 3 7 XXX SPARE AO J15 4 8 DATA LOGGING MODE 1 ON 0 OFF DATA LOGGING TIMER X SECS SOFT START disabled REFRIGERANT TYPE R 410A only EXPANSION VALVE TYPE Thermostatic Only REMOTE TEMP RESET OPTION REMOTE INPUT SERVICE TIME NORTH AMERICAN FEATURE SET ENABLED HYDRO PUMP SELECTION EVAP PUMP TOTAL RUN HOURS SYS HOURS SYS 2 HOURS SYS 1 STARTS SYS 2 STARTS Each display will also show the output connection on the microboard for the respective output status shown For example 151 SECTION 9 SERVICE AND TROUBLESHOOTING SYS 1 LLSV TB10 3 18 STATUS OFF This display indicates that the system 1 liquid line sole noid valve is OFF and the output connection from the microboard is coming from terminal block 10 pin 3 Pressing 1 UP arrow key will energize the liquid line solenoid valve and OFF will change
76. 12 Program Key Limits And enne TABLE 13 Minimum Maximum And Default TABLE 14 Values Required For Bas TABLE 15 Real Time Error TABLE 16 Bacnet And Modbus Communications Data TABLE 17 Yorktalk 2 Communications Data TABLE 18 Sample Compressor Staging For Return Water Control TABLE 19 Return Chilled Liquid Control For 4 Compressors 6 TABLE 20 Lead Lag Return Chilled Liquid Control For 4 Compressors 6 TABLE 21 YLAA Standard Condenser Fan Control Using Discharge Pressure Only 2 3 0 4 Fans Per System doe cem i fete m era ahh e Ee RR rtp do 147 TABLE 22 YLAA Standard Condenser Fan Control Using Discharge Pressure Only 5 Or 6 Fans Per System te db DOR deperit 148 TABLE 23 Compressor Operation Load essen 149 TABLE 24 1 O Digital 2 2 re od eerie de etg eode 153 TABLE 25 VO Digita Outp ts 2 tte etr etit idee itat p 153 TABLE 26 O Analog Inp ts 1
77. 13 21 and PWM inputs XTBCI terminals 13 20 Stage 1 of load limiting involves closing the Load Limit input Stage 2 of load limiting involves closing both the Load Limit and PWM inputs The first stage of limiting is either 80 66 or 50 depending on the number of compressors on the unit The second stage of limiting is either 4096 or 3390 and is only available on 3 5 and 6 compressor units Table 23 on page 149 shows the load limiting permitted for the various numbers of compressors JOHNSON CONTROLS SECTION 8 UNIT OPERATION TABLE 23 COMPRESSOR OPERATION LOAD LIMITING COMPRESSORS IN UNIT STAGE 1 STAGE 2 Simultaneous operation of Remote Load Limiting and EMS PWM Temperature Reset described on following pages cannot occur NOTE COMPRESSOR RUN STATUS Compressor run status 15 indicated by closure of con tacts at XTBC2 Terminals 25 to 26 for system 1 and XTBC2 Terminals 27 to 28 for system 2 ALARM STATUS System or unit shutdown is indicated by normally open alarm contacts opening whenever the unit shuts down on a unit fault locks out on a system fault or experi ences a loss of power to the chiller electronics System 1 alarm contacts are located at XTBC2 Terminals 29 to 30 System 2 alarm contacts are located at XTBC2 Terminals 31 to 32 The alarm contacts will close when conditions allow the unit to operate or the fault 15 reset during a loss of power the contacts will rem
78. 15 3 15 ly Is s s s s s s bngeq 545 voto s3aooosd iS Is s s s s s s g uonuyed 2 545 x 9060 Les sez v 8000 11425 sisisisisisis y jeuonejedo sS ve 40 Lx 70 50 075 12 3409 dO 25 vy 5 6 6 6 6 6 6 uruomugeqg 546 Jav Lx 7060 655 92 34909 114 18 6 8 uruonugeq epoo jeuogejedo SAS Jav Lx 70 50 855 Sc IV 3409 dO 18 ey 5 6 6 6 6 6 6 5105591909 jojequnN Y junoo Le Jav Lx 70 50 166 ve SdWOO WAN 11 0 6 8 7 9 6 lt lt 9oue WAN N leuondO prepueis s LNIOd ALIYM SLNN 841928 Povoddns 991 3S uod avay snsaow JOHNSON CONTROLS 134 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 7 UNIT CONTROLS TABLE 16 BACNET AND MODBUS COMMUNICATIONS DATA MAP CONT D JAILYN 10 25 eBeuuo jews joefqns Jo
79. 15 not possible On a non safety non unit switch shutdown all com YLAAO220HE YLAAO240SE YLAAO180SE YLAAO195HE YLAAO260HE YLAAO285SE YLAAO300HE YLAAO360HE YLAAO350HE YLAA0435SE YLAA0400SE YLAA0485SE YLAA0210SE YLAA0320SE Va 2 2 YLAAO441HE 2 1 FIGURE 31 CONDENSER FAN LOCATIONS 146 FORM 150 72 614 ISSUE DATE 6 10 2014 pressors but one in the system will be shut OFF The LLSV will also be turned OFF The final compressor will be allowed to run until the suction pressure falls below the cutout or for 180 seconds whichever comes first STANDARD CONDENSER FAN CONTROL Condenser fan operation must be programmed with the OPTIONS key under Fan Control Condenser fan must be selected for Discharge Pressure only Fan control by discharge pressure will work according to the tables on the following pages see Zable 21 on page 147 and Table 22 on page 148 The fan control on pressure and fan differential off pressure are program mable under the PROGRAM key Standard fan control operates down to a temperature of 25 F The delay between turning ON and OFF fan stages is always fixed at 5 seconds When a fan stage is turned ON by pressure the on pressure for the next stage is increased 20 PSIG and ramped back to the programmed on pressure over the next 20 seconds Typically standard ambient control on pressure sh
80. 16 8 9 8 14 4 20 11 1 10 18 24 13 3 12 21 6 28 15 6 14 25 2 32 17 8 16 28 8 36 20 18 32 4 40 22 2 20 36 44 24 4 22 39 6 48 26 7 24 43 2 52 28 9 26 46 8 56 31 1 28 50 4 60 33 3 30 54 Pressure Conversion Chart Gauge or Differential PSI BAR BAR PSI 20 1 38 1 5 21 8 30 2 07 2 29 40 2 76 2 5 36 3 50 3 45 3 43 5 60 4 14 3 5 50 8 70 4 83 4 58 80 5 52 4 5 65 3 90 6 21 5 72 5 100 6 9 5 5 79 8 110 7 59 6 87 120 8 28 6 5 94 3 130 8 97 7 101 5 140 9 66 7 5 108 8 150 10 34 8 116 160 11 03 8 5 123 3 170 11 72 9 130 5 180 12 41 95 137 8 190 13 1 10 145 200 13 79 10 5 152 3 210 14 48 11 159 5 220 15 17 11 5 166 8 230 15 86 12 174 240 16 55 12 5 181 3 250 17 24 13 188 5 260 17 93 13 5 195 8 270 18 62 14 203 280 19 31 14 5 210 3 290 20 15 217 5 300 20 69 15 5 224 8 310 21 38 16 232 320 22 07 16 5 239 3 330 22 76 17 246 5 340 23 45 17 5 253 8 350 24 14 18 261 360 24 83 18 5 268 3 370 25 52 19 275 5 380 26 21 19 5 282 8 390 26 9 20 290 400 27 59 20 5 297 3 165 FORM 150 72 ICOM7 614 SECTION 10 MAINTENANCE ISSUE DATE 6 10 2014 R 410A PRESSURE TEMPERATURE CHART 1 1 N 1 dof KR zu 1 1 N eo 1 eo RR oO A A Co
81. 2 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 WIRING DIAGRAMS ELEMENTARY WIRING DIAGRAMS 035 21583 101 REV 200 230V 3 60HZ 200 230V 3 60HZ 460V 3 60HZ 460V 3 60HZ 460V 3 60HZ 575V 3 60HZ 75V 3 60HZ 575V 3 60HZ 380 415V 3 50 60HZ 380 415V 3 50 60HZ 380 415 3 50 60 2 TT T FTT FIT ias DAE PE kls i PE PE A Sw ull 1 2 QCB L1 18 18 18 Y 1 6 1 6 16 gt 1 gt 1 gt gt 1 gt 1 gt 21416 21416 AI A2 pa Y 77 A2 2 na Y 1 A EEE Sey og oe LIE RI Aa A2 n2 SIS 5655 02425 SSS 11 12 13 SJ 428 2 008 Y Y d d gt 1 gt 1 gt 7 gt 75 7 gt al d 2 4 16 2 4 6 3 1 9 1 1 3 1 4 2 5 15 2 17 1 18 2 YYY YYY 9 2L1 3 6 4 6 15 6 17 2 17 8 18 7 1L
82. 2 4961149 1016754 FIGURE 20 POWER PANEL 72 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 1 KT1 2 144 120 244 220 SECTION 5 TECHNICAL DATA 1E 318 15 25 3 9600260 CA2KN40 2 KCR 9 9 69 9 09 8 9 10 CDU 21 212 213 450A 451A 452A 4508 4518 4528 42 0220 Se 2278 2288 2098 6 9 GJ LC1D09 1811 LC1D09 1811 LC1D09 1811 2 2 KF2 2 KF3 9 2H 26 000 0020 0 OO 250 251 255 256 257 258 iem e 72702725 ME 2iic 226 2130 e WE 2 0 1 2 0 5 2 SRM SE e c 2 QMMSC3 2218 20 2V 1P 27B 27C FIGURE 19 POWER PANEL CONT D JOHNSON CONTROLS o 5009 224 201 202 203 204 205 2180 328 19 20 2 1016755 73 SECTION 5 TECHNICAL DATA 035 215
83. 2 Hl PANEL END ico 4 495 75 6 195 495 8 1920 8 VIEW LD17643 FIVE AND SIX FAN ISOLATOR LOCATIONS 14 86 4 85 4 2169 2 he oa e e PANEL END 14 1 36 4 48 1 1753 2 1221 7 17 5 d 444 8 194 6 NOTE All Dimensions In Inches Millimeters LD17644 84 JOHNSON CONTROLS FORM 150 12 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 SEVEN AND EIGHT FAN ISOLATOR LOCATIONS 1 4 _ 36 4 poga O G 1 k 4 E 85 4 2169 2 E b 14 77 69 0 75 5 33 3 36 4 194 6 1753 2 1917 9 845 6 1017645 NOTE Dimensions In Inches Millimeters JOHNSON CONTROLS 85 FORM 150 72 ICOM7 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 ISOLATOR INFORMATION One Inch Deflection Spring Isolator Cross referenc
84. 232 amp 239 Not fitted on compressors with internal motor protection For system 1 terminals 132 amp 133 133 amp 134 and 134 amp 135 are linked For system 2 terminals 232 amp 233 233 amp 234 and 234 amp 235 are linked gt 115V control circuit requires 115V supply unless control circuit transformer T2 amp F3 are fitted standard on CE units For optional hydro kit Heater EPH is fitted and wired as shown On single pump KP1 QMMSP1 amp MP1 are fitted amp wired as shown On two pump hydro kits KP2 QMMSP2 4 MP2 are also fitted and wired as shown Current measurement Onyftedonsysemswihsmgespeedtam O o 3 Optional compressor manual motors starters standard on 56 JOHNSON CONTROLS n h m 1 2 6 8 9 NIN N FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA ELECTRICAL NOTES AND LEGEND CONT D 27 28 29 30 s 32 33 43 When the compressors motor protection bmp includes phase reversal the extra bmp terminals and three wires are fitted as shown in the compressor terminal box as detailed for 1 zcpr1 44 When the compressors motor protection bmp includes phase reversal the extra bmp terminals and three wires are fitted as shown in the compressor terminal box as detailed for bitzer JOHNSON CONTROLS 57 FORM 150 7
85. 6 AWG 350 kCMIL 1 46 AWG 350 kCMIL 1 46 AWG 350 kCMIL 1 46 AWG 350 kCMIL 1 6 AWG 350 kCMIL 2 43 0 AWG 250 kCMIL 2 43 0 AWG 250 kCMIL 2 3 0 250 kCMIL 2 43 0 AWG 250 kCMIL 2 250 500 kCMIL 2 250 500 kCMIL JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 NOTES SECTION 5 TECHNICAL DATA ELECTRICAL NOTES 1 Minimum Circuit Ampacity MCA is based on 125 of the rated load amps the largest mo tor 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 pro viding power to the transformer 50 380 415 3 50 add 1 amps 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 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 ap plications where brown outs frequent starting and stopping of the unit and or operation at ambient temperatures in excess of 35 C 95 F 15 antici pated Maximum fuse size 15 based upon 225 of the rated load amps for the largest motor plus 100
86. 65 1 5 0 100 dS 1 od 8t JQv OLX 70 50 vss LS 4138 dS 85 1 5 juodies od OLX 70 50 ESS Ov IV dl3S 1000 45 6 8 eDueuosiq Y SOV OLX 70 50 256 6 02 d H 96 6 8 uo 1nojn2 einsseug MOT Sy 40 01 70 50 199 9 09 d 1216 1 95 6 lt dH eunssejg uogong MOT vv OLX 7060 055 Ze 1H OO d 1915 vS 515151515151 5 jnojn2 eunje1eduue od OLX 7050 674 9 Iv ino 64 515151515151 5 od cy OLX 00 8 6 Ge IV Ind 11H91 es 6 lt _ spuooss ly Jav OLX 70 50 175 ve INIL YY LS 6 33944 uonong e P 05 518 88 8 8 S 0 epowionuop wun junoo Ov Lx 7060 975 S S S S S 8 8 eBejs uey Jasuapuog S S junoo 6 Jav 70 50 574 ze 39715 NYJ ZS 6 6 lt z 546 85 Jav Lx 70 50 3d09 99d zs 8v lt lt uey 1 s S junoo 1 Lx 7060 0 307
87. 68 69 oo 9 2 2 2 2 1 000 G0 TEXT TEXT e 2 Qv 6 248 247 246 16 w Orr es di gt O ge 5 2 YESV Gn 620 Pla 23 234 yw 233 AW 9 234 233A O 232A ym LD16752 FIGURE 18 COMPRESSOR WIRING 68 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 11 575V 3 60HZ 90 GND ae 1 120A D gt LE NB32 1 ETXVH 2 ETXVH LES 1496 EEH 34 EXT EXT_ GND 2 Yusv 90 59 On ul 48 2 NB38 2204 L 1 S a T2 G uos 1 YESV 2 BSP a EXT JB1 2 BSP RED JB2 1 YEEV z1 1 BSP One MEY EMH 1 0 2 YLLSV 2 YEEV 2 1 5 2 22 FHP 1 1 BSP WHT BLCT 2 1 BDPO 2 BFDP 1 BFDPO Md S So S 1 BDP 2 BST EXT 1 BDA L 4 EXT EXT aST BIK 1 BOPLBLK 1 BDP RED 1320 d BDAT BLK Qoa 1 BOP WHT 121
88. 711 PIN 60 seme 28 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 Control Functions DV Display Value Fans CHT Chilled Liquid Temperature HPC High Pressure Cutout LPC Low Pressure Cutout HPL High Pressure Load Limiting LTC Low Temperature Cutout lt 585 PSIG ZCPR 3 ZCPR 2 Ambient Air Sensor DV HTC SECTION 2 PRODUCT DESCRIPTION Fans Components Pressure Relief Valve Service Ball Valve 5 G Expansion Valve gt lt Solenoid Valve Sight Glass Sensor Pressure or Temperature Service Stop Access Valve Pressure Switch Filter Drier Removable Core Chilled Liquid 450 PSIG Evaporator Chilled Liquid 1013139 FIGURE 5 PROCESS AND INSTRUMENTATION DIAGRAM Low pressure liquid refrigerant enters the cooler and 15 evaporated and superheated by the heat energy ab sorbed from the chilled liquid passing through the cooler shell Low pressure vapor enters at the compres sor where pressure and superheat are increased The JOHNSON CONTROLS high pressure vapor is fed to the air cooled condenser coll and fans where the heat is removed The fully con densed and subcooled liquid passes through the expan sion valve where pressure 15 reduced and further cool ing takes place before entering to the cooler 29 30 THIS PAGE INTENTIONALLY LEFT BLANK
89. 89 102 REV J MICRO PANEL CONNECTIONS 2 gt KO 19A ry 120A 1184 o 254 ON 2 Dz 578 oye rz 7 KO 5 28 20 Xe 2298 7 2 XP3 JETTA AMB a Kom 218A 027 OZN 222 219A 5 220A xP3 218c OZI 70 278 52 8 2198 578 8 02 Or OZ 278 2 58 5 4 gt 2 8 9 9 4 Qs 9 Cx s o o 2 ELINK 3 Q N 2 lt PORTIA HES 2 PORTS RAS 58 LLL ee og o vi 9 55 TB rnm 1234 85 55 Ot 5 lt lt 8 T5 ZZ 3 O1 2 zz 5 FIGURE 21 MICRO PANEL CONNECTIONS 74 FORM 150 72 614 ISSUE DATE 6 10 2014 223A 125A 33 32 30A 29 28 27A 26 25 24 AMB 0SS20 1 0 24 223 123 33 1016756 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA
90. A 1057 JOHNSON CONTROLS 138 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 7 UNIT CONTROLS TABLE 17 YORKTALK 2 COMMUNICATIONS DATA MAP CONT D Syg u amp noju enjeA yey ejdsip y ui epo y jo Aejdsip y si epo UJJIJUOO JO sJojeJedo 1 y sepoo pue y sjepoul uo eq jou sapo pepeus 9JON x einjejeduie jueiquiy 62 6c 82 8c 22 OOdH dW 92 9c 92 Sc yneysosues 2 vc jeeuledns wo1 ez EZ JOON 22 Mod LZ anou 02 02 eunjejeduje 1 61 6L 8l 81 dH peo1 8 81 jne4 punodio ZL uluuny suosseJduo Z4 ZL eunsseJg MOT 9 9L Buguripeo 9 9L peouejeqeuiodu juaun OJON SL Bugur1jueunoj SL UALIND MOT
91. A0360SE YLAA0390HE YLAA0400SE YLAA0435SE YLAA0485SE YLAA0441HE YLAAO456HE 0516 Reference 59 for Pump Model Use this table along with Pump Electrical Data to determine electrical data of the unit plus the pump Does not include control transformer TABLE 9 TRANSFORMER LOAD 50 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA SYSTEM 1 2 1 2 3 1 2 3 JOHNSON CONTROLS 51 SECTION 5 TECHNICAL DATA TABLE 10 WIRING LUGS MODEL YLAA VOLT 1 46 500 kCMIL 1 6 500 kCMIL 1 6 500 1 6 500 kCMIL 1 6 500 1 6 500 1 6 500 1 6 500 1 6 500 kCMIL 1 6 500 1 6 500 kCMIL 1 6 500 1 6 500 1 6 500 1 6 500 1 6 500 1 6 500 0180 400 02865 400 eo A 0400 400 A eo eo 0485SE 400 1 6 500
92. ACK ONE PER UNIT un FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 der the PROGRAM key the display will be the first display prior to the SYS 1 info If the microprocessor is programmed for CURRENT FEEDBACK NONE no current display will appear Displays for System starting with SYS X NUMBER OF COMPS RUNNING X through SYS X AMPS XXX X VOLTS X X will be displayed first fol lowed by displays for System 2 Further explanation of the above displays is cov ered under the STATUS OPER DATA COOLING SETPOINTS PROGRAM and OPTIONS keys Software Version The software version may be viewed by first pressing the HISTORY key and then repeatedly pressing the DOWN arrow key until you scroll past the first his tory buffer choice DISPLAY SAFETY SHUT NO 1 1T06 DOWN After the DOWN arrow key is pressed again the software version will appear CONTROL 1 0 C MXX ZZ Y Y C MXX 18 Y Y JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 7 UNIT CONTROLS ENTRY KEYS The Entry Keys allows the user to view change pro grammed values The ENTRY keys consist of an 1 UP arrow key DOWN arrow key and an ENTER ADV key Up and Down Arrow Keys Used in conjunction with the OPER DATA HISTORY COOLING SETPOINTS SCHEDULE ADVANCE DAY OPTIONS and CLOCK keys the 1 UP and DOWN arrow keys allow the user to scroll through the various data screens Refer to Display Print Keys
93. AD LOAD This message informs the operator that the chilled liq uid temperature is below the point determined by the setpoint and control range that the microprocessor will bring on a system or that the microprocessor has not loaded the lead system far enough into the loading sequence to be ready to bring the lag system ON The lag system will display this message until the loading sequence is ready for the lag system to start SYS 1 COMPS RUN X RUN X SYS 2 The COMPS RUNNING message indicates that the respective system is running due to demand The will be replaced with the number of compressors in that system that are running SYS 1 AR SYS 2 AR TIMER S TIMER 5 The anti recycle timer message shows the amount of time left on the respective systems anti recycle timer This message is displayed when the system is unable to start due the anti recycle timer being active SYS 1 AC SYS 2 AC TIMER XX S TIMER 5 The anti coincidence timer is a software feature that guards against 2 systems starting simultaneously This assures instantaneous starting current does not become excessively high due to simultaneous starts The mi croprocessor limits the time between compressor starts to 1 minute regardless of demand or the anti recycle timer being timed out The anti coincidence timer is only present on two system units SYS 1 SYS 2 DSCH DSCH LIMITING LIMITING When this me
94. ALOG AND DIGITAL INPUTS After entering Service Mode PROGRAM JV all digital and analog inputs to the microboard can be viewed by pressing the OPER DATA key After press ing the OPER DATA key 7 UP arrow and DOWN arrow keys are used to scroll through the analog and digital inputs Following is the order of analog and digital inputs that will appear when sequenced with the Down arrow key analog inputs SYS 1 SUCT PRESSURE UNIT TYPE SYS 1 DISCH PRESSURE SYS 1 SUCTION TEMP SYS 2 SUCTION TEMP AMBIENT AIR TEMP LEAVING LIQUID TEMP RETURN LIQUID TEMP SYS 2 SUCTION PRESSURE SYS 2 SPARE SYS 2 DISCH PRESSURE SYS 1 MTR VOLTS SYS 2 MTR VOLTS digital inputs PWM TEMP RESET INPUT LOAD LIMIT INPUT FLOW SW REM START SPARE SINGLE SYSTEM SELECT SYS 1 MP HPCO INPUT SYS 2 INPUT The discharge pressure transducer is optional on some models The suction temp sensor is on EEV units only The analog inputs will display the input connection the temperature or pressure and corresponding input voltage such as SYS 1 2 1 SUCT PR VDC 81 77 10 PSIG This example indicates that the system 1 suction pres sure input is connected to plug 7 pin 10 J7 10 on the board It indicates that the voltage is 2 1VDC which corresponds to 81 PSIG 5 6 bars suction pressure The digital inputs will display the input connection and ON OFF status such as JOHNSON CONTROLS FORM
95. AN PRESSURE XXX CONTROL ON PSIG Displays the programmed Fan On Pressure DIFFERENTIAL OFF PRESSURE PS1G Displays the programmed Fan Off Differential SYS1 TRIP VOLTS VOLTS Displays programmed High Current Trip Voltage SYS2 TRIP VOLTS VOLTS Displays programmed High Current Trip Voltage YORK HYDRO PUMPS Indicates Pump Control option is selected LCHLT RCHLT Displays Leaving and Return chilled Liquid Tem perature at the time of the fault SETPOINT RANGE Displays programmed Setpoint and Range if chiller is programmed for leaving chilled liquid control SETPOINT XXX X F Displays programmed Setpoint and Range if chiller is programmed for return chilled liquid control X TEMP e F Displays the Ambient Temp at the time of the fault JOHNSON CONTROLS SECTION 7 UNIT CONTROLS LEAD SYSTEM IS SYSTEM NUMBER X Displays which system is in the lead at the time of the fault TATUS 18 Displays status of the Evaporator Heater at time of the fault EVAPORATOR WATER STATUS PUMP XXXX Displays status of Evaporator Water Pump at the time of fault Status may read ON OFF or trip EVAP H
96. CHNICAL DATA DIMENSIONS YLAA0456HE YLAA0516HE EIGHT FAN UNITS 16 DIA MOUNTING HOLES TYP POWER ENTRY 330 WIDE X 178 HIGH pr 1102 T 21 CONTROL PANEL BOTTOM DETAIL 100 INLET uo 100 OUTLET TE S _ 85 BR NN TE me eus eiut 422 E 2 589 gt 1473 4 1519 n eae ee 2243 FRAME WIDTH LL 2255 OVERALL WIDTH FRAME LENGTH 5 LD18071 NOTE Placement on a level surface of free of obstructions including snow for winter operation or air circulation ensures rated performance reliable operation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance Johnson Controls s unit controls will optimize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 2m 6 rear to wall 2m 6 control panel to end wall 1 2m 40 top no obstruction
97. D Ki 138 M O2 5 MM 40 sre BRN lata 41 L J13 gt 5 2 O OE e a 19A AEN 1 J11 2 0o o gt 9 O 5 1016757 FIGURE 20 MICRO PANEL CONNECTIONS CONT D JOHNSON CONTROLS 75 FORM 150 72 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 DIMENSIONS FOUR FAN UNITS DIMENSIONS YLAA0180SE YLAA0195HE YLAA0210SE 15 875 DIA MOUNTING HOLES TYP POWER ENTRY 330 WIDE X 180 HIGH D p 1102 CONTROL PANEL BOTTOM DETAIL 2077 ORIGIN i Li 2243 FRAME WIDTI 2255 OVERALL WIDTI 2912 FRAME LENGTH 8 3404 OVERALL LENGTI 2251 FRAME HEIGHT e 2393 OVERALL HEIGHT 75 OUTLET Dimensions are in millimeters unless otherwise noted LD18066 NOTE Placement on a level surface of free of obstructions including snow for winter operation or air circulation ensures rated performance reliable operation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished
98. DBUS IO MODBUS SERVER API MODBUS CLIENT SELECTABLE 1 127 P1 P2 STOP BITS RESET REAL TIME ERROR 130 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 The table below shows set up requirements for each communication protocol SECTION 7 UNIT CONTROLS TABLE 14 VALUES REQUIRED FOR BAS COMMUNICATION PROTOCOL SETTING DESCRIPTION BACNET MS TP MODBUS YORKTALK2 N2 DE MODIFIER ADDRESS 0 to 41943 0 to 41943 0 to 994 DE MODIFIER OFFSET 0 to 99 P1 PROTOCOL BACNET 9n2 0 127 P1 MANUAL MAC ADDRESS 0 127 9600 To 76800 or P1 BAUD RATE Auto Selectable 9600 P1 PARITY NONE NONE P1 STOP BITS 1 N A 1 P2 PROTOCOL N A MODBUS SVR N A P2 MANUAL MAC ADDRESS N A P2 BAUD RATE 0 127 N A 19 200 P2 PARITY NONE P2 STOP BITS 1 P2 HW SELECT BIT RS 485 or 85 232 RESET REAL TIME ERROR N A P1 HW SELECT BIT N A CHILLER ID N A 1 As required by network 2 Or other as required by network 3 Number is multiplied by 100 set as required by network 4 Number is added to de modifier address set as required by network 5 Unit operating software version 13 03 or later required for Modbus Protocol 6 Unit operating software version 04 C MMC 13 04 C MMC 14 04 or C MMC 16 04 or higher required for N2 protocol functionality BACnet and Modbus Commun
99. DC voltage input to microprocessor Pressure pressure sensed by transducer Following are the I O board connections for the Suc tion Transducer System 1 Suction Transducer J7 5 5VDC regulated supply to transducer J7 10 VDC input signal to microboard See the formula above for voltage readings that cor respond to specific suction pressures J7 9 SVDC return 17 1 drain shield connection System 2 Suction Transducer 19 5 5VDC regulated supply to transducer J9 10 VDC input signal to the microboard See the formula above for voltage readings that correspond to specific suction pressures J7 9 5VDC return J7 11 drain shield connection Digital Outputs Refer to the unit wiring diagram and Figure 33 on page 158 The digital outputs are located on TB7 TB8 and TB9 and TB 10 of the microboard All outputs are 120VAC with the exception of TB8 6 to TB8 7 which are the contacts that can be used for a remote evapora tor pump start signal The voltage applied to either of these terminals would be determined by field wiring 157 SECTION 9 SERVICE AND TROUBLESHOOTING Each output is controlled by the microprocessor by switching 120VAC to the respective output connection energizing contactors evaporator heater and solenoids according to the operating sequence 120VAC 1s supplied to the I O board via connections at TB7 1 7 6 10 1 TB10 6 TB8 1 and 9 1 Fig
100. F 12 2 C to 21 1 C in glycol chilling mode In both modes the cooling range can be from 4 F to 20 F 2 2 to 11 1 As an example of compressor staging refer to Table 19 on page 143 a chiller with six compressors using a Cooling Setpoint programmed for 45 7 20 and a Range Setpoint of 10 F 5 56 C Using the formu las in Table 19 on page 143 the control range will be split up into six seven including hot gas segments with the Control Range determining the separation be tween segments Note also that the Cooling Setpoint is the point at which all compressors are OFF and Cool ing Setpoint plus Range is the point all compressors are ON Specifically if the return water temperature is 55 12 8 C then all compressors will be ON provid ing full capacity At nominal gpm this would provide approximately 45 F 7 2 C leaving water tempera ture out of the evaporator If the return water temperature drops to 53 4 F 11 9 one compressor would cycle OFF leaving five compressors running The compressors would contin ue to cycle OFF approximately every 1 7 F 94 C with the exception of hot gas bypass Notice that the hot gas bypass would cycle ON when the return water temperature dropped to 46 25 F 7 9 C At this point one compressor would be running with hot gas Should the return water temperature rise from this point to 46 7 F 8 2 C the hot gas bypass would shut OFF stil
101. FAN WIRING 035 21583 103 REV C DWG 3 1 11 2 11 163 11 E 120 L L3 1124 1 77 3142 5e 543 zya onm 562 553 1 74 5764 ee 22 ee J LD16765a FIGURE 14 FAN WIRING STANDARD LOW SOUND OR ULTRA QUIET YLAA0180 YLAA0516 62 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA 2L1 15 2L2 15 2L3 15 2 1 2 2 5 2 7 92 5 lEs 94 L 89 LAS LAS 94 9 197 gt 67 1 92 68 1 94 559 97 3 BT el ee el ee 15 2 154 2 154 2 es 4 LD16766a DWG 3 FIGURE 13 FAN WIRING STANDARD LOW SOUND OR ULTRA QUIET YLAA0180 YLAA0516 CONT D JOHNSON CONTROLS 63 FORM 150 72 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 FAN WIRING 035 21583 118 REV C Only fitted on systems with 3 or 4 fans 6 Only fitted on systems with 4 fans Only fitted on systems with 5 fans Only fitted on systems DWG 1 8 1016769 FIGURE 15 FAN WIRING HIGH AIR FLOW 64 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA Only fitted on systems with 3 or 4 fans 7 8 9 10 11 Only fitted on systems with 4 fans Only fitted on systems with 5 fans DWG 18 LD16770a FIGURE 14 FAN WIRING HIGH AIR FLOW CONT D JOHNSON CONTROLS 65 SECTION 5
102. H2 ETH1 1496 24 2 EHRH1 2 BLCT EXT ACC EXT BLCT BLK O _ 1 X TBF EHRH2 Lun 62 62 2 9 BAMBO BDAT O EHRH O 1 TXVH 1 YLLSV GND 300 301 302 2 TXVH F2 YLLSV we ter SFE WHT FAFE BPN SFE BLU 67 SFE GND 303 304 305 Kl PET XTBI C E SF OR E 4 ET 149F 398 RAO 2 O 2 BSP WE OQ O 1 BSP M 13 14 r 2 85 1 BSTO S 300 301 302 5 d a JB1 1 07 2 48 P T 2 zh 2 8 en ais GND GND 303 304 305 5 NS NS S 8 SS T E 1 YHGSV 2 YHGSV EXT te EXT 2 BDP GND GND EXT 2 FHP 3 po Gs 323 Ok 2 BOP BLK 2 BOP RED zx KD 9 0 2 BOP WHT 231A TB FSC 1 2 TB2 ox Ye lcm 9 Gi 6 22 22 5 2 2 SCH1 69 2 u wow 226 225A 224 H 8 lI 5 8 24P E 2 2 2 2 2 1 X TEXT 1 5 203 500 FT RED BLK RED BLK 144A KD oor 204 BRN 205 Quar TB 202 4 Gir 2 2 2 1 a ono
103. John son Controls Office for application requirements 2 For leaving liquid temperature higher than 55 F 13 C contact the nearest Johnson Controls Office for application guidelines 3 The evaporator is protected against freezing to 20 F 29 C with an electric heater as standard 4 For operation at temperatures above 115 F 46 C the optional High Ambient Kit will need to be installed on the system Excessive flow will cause damage to the cooler Do not exceed maximum cooler flow Special care should be taken when multiple chillers are fed by a single pump CAUTION JOHNSON CONTROLS 43 FORM 150 72 ICOM7 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 HEAT EXCHANGER FLOW GPM YLAA Evaporator Pressure Drop Metric Units 500 C 5 2 50 2 D 5 5 50 Water Flow Rate m h EVAPORATOR YLAA MODELS 1805 210SE 2405 241SE 285SE 2865 195HE 220HE 221HE 320SE 360SE 260HE 261HE 300HE 400SE 435SE 350HE 456HE 485SE 390HE 441HE 516HE TABLE 3 ETHYLENE AND PROPYLENE GLYCOL CORRECTION FACTORS ETHYLENE GLYCOL PROPYLENE GLYCOL FREEZE FREEZE WEIGHT PT WEIGHT PT NOTE Water Pressure Drop Curves may extend past the minimum and maximum water flow ranges 44 JOHNSON CONTROLS F
104. MPRESSOR HEATER Power On 24 Hours Prior To Start Apply 120VAC and verifiy its value between Terminals 5 and 2 of XTBC2 The voltage should be 120VAC 110VAC for 50Hz units plus or minus 1096 NOTE Power must be applied 24 hours prior to start up Each heater should draw approxi mately 0 5 to 1A STARTUP Panel checks Power On Both unit switch Off 1 Apply 3 phase power and verify its value Voltage imbalance should be no more than 296 of the aver age voltage 2 0 Apply 120VAC 110VAC for 50Hz units and verify its value on the terminal block in the Power Panel Make the measurement between Terminals 5 and 2 of XTBC2 The voltage should be 120VAC plus or minus 1096 Program verify the Cooling Setpoints Program Setpoints and unit Options Record the values in the following table see SETPOINTS KEYS and UNIT KEYS in Section 7 of Form 150 72 ICOM6 for programming instruction FORM 150 72 ICOM7 614 SECTION 6 COMMISSIONING ISSUE DATE 6 10 2014 SETPOINTS ENTRY LIST As each compressor cycles ON ensure that the discharge pressure rises and the suction pressure decreases If this does not occur the compressor Display Language being tested is operating in the reverse direction and must be corrected After verifying proper compressor Sys 1 Switch rotation turn the Unit Switch to OFF Sys 2 Switch NOTE This unit uses scroll compr
105. N 2 PRODUCT DESGCRIPTION ERES 15 zoo Aiea eae heel acetone MEE t MEME e 15 General System Description iius teet men eon e dra e au dee gae e e det de a gane e aede aane 15 COMMUNICATIONS oto io v e d P LR Roe ates Tee RET ee He 17 Building Automation System 17 Power Panel 17 Accessories And Options eate tete 17 SECTION 3 HANDLING AND 31 Delivery And Storage edades 31 E 31 Moving The stis cec 5 eee Gene 31 Lifting Using EUgs ied meo delata RIA RAE 33 Lifting Using Shackles eit edet dn e e Eder eder tegeret Ea rete etd 33 Lifting Weights i ee e ertt e UR to eee rc 34 SECTION 4 INSTALEATION PE 35 Installation Checklist E 35 Startup Commissioning aceite Dette tee eite 35 And Clearances cin ten eer e rtu n RM 35 Spring Solators aed Rte ne ROI Rte n RM 36 Compressor Mountilrig lero 36 Remote Cooler Optom tn
106. OLS setpoints program values options time schedule and history buffers will be lost These values will all be re set to their default values which may not be the desired operating values Once a faulty battery is detected the unit will be prevented from running until the PRO GRAM key 15 pressed Once PROGRAM is pressed the anti recycle timers will be set to the programmed anti recycle time to allow the operator time to check setpoints and if necessary reprogram programmable values and options If a low battery 15 detected it should be replaced as soon as possible The programmed values will all be lost 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 microboard INCORRECT UNIT TYPE This indicates the condensing unit jumper is installed between J11 12 and J11 7 This jumper must be re moved to operate the chiller 105 FORM 150 72 614 SECTION 7 UNIT CONTROLS ISSUE DATE 6 10 2014 STATUS KEY MESSAGES General Messages Fault Messages System Safeties Unit Safeties amp Warning Messages System X High Disch Pressure Low Ambient Temp System X Low Suct Pressure Low Liquid Temp System X MP HPCO Inhibit 115 Undervoltage Low Battery Check Prog Step Optn Unit Warning Message Unit Switch Off Shutdown Remote Controlled Shutdown Daily Schedule Shutdown Rem Stop No Run Permissive Flow Switch Open
107. ORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 JOHNSON CONTROLS THIS PAGE INTENTIONALLY LEFT BLANK 45 FORM 150 72 ICOM7 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 PHYSICAL DATA YLAA0180 YLAA0516 50HZ TABLE 4 PHYSICAL DATA ENGLISH YLAA STANDARD EFFICIENCY UNITS STANDARD EFFICENCYUNTS SSCS GENERAL UNIT DATA vztose 02405 02415 2855 28652 03205 0308 04005 04359 0456 E CES Number Of Circuits Refrigerant Charge Operating R 410A 2145 25 15 24 23 24 23 26 24 26 24 26 26 30 26 31 29 31 29 32 30 Ckt 1 Ckt 2 kg Oil charge pP tono 12 10 91 vene 2 Liters COMPRESSORS SCROLL TYPE cae CONDENSER CONDENSER FANS EVAPORATOR Water Volume Liters Volume Liters a Water Side Pressure Bar 31 31 31 31 31 31 31 31 31 31 31 Side Pressure Bar Water Connections 3 3 3 3 3 3 3 3 3 3 3 Size Inch NOTES 1 kW Compressor Input Power 2 EER Chiller EER includes power from compressors fans and the control panels 0 8 kW 3 Rated in accordance with AHRI Standard 550 590 at an air on condenser temperature of 95 F and a leaving chilled water temperature of 44 F 4 Additional rating information can be provided by your local Johnson Controls Sales Office 46 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA
108. OURS PUMP TOTAL RUN X X X X Evap Pump total run hours at the time of fault ACTIVE REMOTE XX X X CTRL Displays whether Remote Chiller Control was active when the fault occurred UNIT ACTUAL 5 This is only displayed when Current Feedback tion 15 one per unit SYS X 1 STATUS 22XXX Displays which Compressors were running in sys tem when the fault occurred SYS X RUN XX XX XX XX TIME D H M S Displays the system run time when the fault occurred SYS X SP XXXX PSIG PSIG DP XXXX Displays the system Suction and Discharge Pressure of the time of the fault 11 SECTION 7 UNIT CONTROLS S YS X SAT SUCT SUCT Displays System Suction Temp and Saturated Suc tion Temp when an EEV is installed SYS X HOT LLSV 18 SOL 18 GAS XXX Displays whether the System Liquid Line Solenoid or Hot Gas Solenoid was energized at the time of the fault SYS X FAN STAGE XXX Displays the number of Fan Stages in the system active at the time of the fault SYS ACTUAL AMPS DO 0 CD Displays the system Amperage calculated approxi mately at the time of the fault For this message to appear CURRENT FEEDBACK ONE PER SYSTEM must be programmed under the OPTIONS key If the microprocessor is programmed as one CURRENT FEEDB
109. Only Figure 27 provides a quick reference list for the Unit key setpoints FIGURE 27 UNIT KEYS OPTIONS PROGRAMMING QUICK REFERENCE LIST 128 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 LD07405d JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 BACNET MODBUS N2 AND YORKTALK 2 COMMUNICATIONS Data can be read and in some cases modified using a serial communication BACnet Modbus or YorkTalk 2 network connection This information allows commu nications of chiller operating parameters and external control changes to setpoint load limiting and start stop commands BACnet and YorkTalk 2 RS485 networks are wired to the and terminals of for port 1 communica tions Modbus network connection has the option of RS232 or RS485 connection port 2 communica tions Modbus network is wired to either TB2 or TB3 as follows SECTION 7 UNIT CONTROLS RS 485 connect to TB2 Network 1 to TB2 1 Network 1 to TB2 1 RS 232 connect to TB3 Network RX to TB3 TXD Network TX to TB3 RXD Network GND to TB3 GND Refer to Figure 28 on page 130 for TB1 TB2 and TB3 locations In most cases communication parameters will need to be modified Table 30 on page 131 lists setup parame ters for the available protocols Modification is accom plished by pressing the PROGRAM DOWN ARROW DOWN ARROW DOWN ARROW DOWN ARROW and ENTER keys in sequence The list below shows
110. PU II based units are configured for Native BAC net MS TP and Modbus RTU communications ALL OK E Link Gateway not required for these two com 1 DATUM TYPE OK TEST FAILED munication protocols 2 ENGLISH TEXT TOO LONG BACnet Object Types 3 FLOATING POINT EXCEPTION 4 GET PACKET FAILED 0 Analog In 5 Binary Value 5 GET TYPE FAILED 1 Analog Out 8 Device 6 INVALID UNIT CONVERSION 2 Analog Value 15 Alarm Notifica 7 INVALID HARDWARE SELECTION lt 7 tion 0 through 127 8 REAL TIME FAULT 3 Binary In are reserved ASHRAE 9 SPANISH TEXT TOO LONG 4 Binary Output Objects 0 THREAD EXITED THREAD FAILED THREAD STALLED WC Inches of water Pa Pascals IO BOARD RESET BRAM INVALID BACNET SETUP FAILED lion FPM Feet per Minute Reboot required cycle power after set tings are changed kJ kg Kilojoules per PSI Lbs per square Kilogram inch NOTE 4 Water Cooled Scroll units use the same firmware as Air Cooled Scroll units ignoring Fan Control The table below shows the real time error numbers that may be encountered during communication setup and a description of each 132 JOHNSON CONTROLS 90 V Sde N 3ALLVN 10 05 eDeuuo joefqngs Jo Auedoug SECTION 7 UNIT CONTROLS Jaw ejoAoes nuy SAS N
111. RATURE CONVERSION CHART Actual Temperatures Temperature Conversion Chart Differential Temperatures SECTION 10 MAINTENANCE oF oF 0 17 8 18 0 4 4 15 6 16 3 2 8 13 3 14 6 8 12 11 1 12 10 4 16 8 9 10 14 20 6 7 8 17 6 24 4 4 6 21 2 28 2 2 4 24 8 32 0 0 2 28 4 36 2 2 0 32 40 4 4 2 35 6 44 6 7 4 39 2 48 8 9 6 42 8 52 11 1 8 46 4 56 13 3 10 50 60 15 6 12 53 6 64 17 8 14 57 2 68 20 0 16 60 8 72 22 2 18 64 4 76 24 4 20 68 80 26 7 22 71 6 84 28 9 24 75 2 88 31 1 26 78 8 92 33 3 28 82 4 96 35 6 30 86 100 37 8 32 89 6 104 40 0 34 93 2 108 42 2 36 96 8 112 44 4 38 100 4 116 46 7 40 104 120 48 9 42 107 6 124 51 1 44 111 2 128 53 3 46 114 8 132 55 6 48 118 4 136 57 8 50 122 140 60 0 52 125 6 144 62 2 54 129 2 148 64 4 56 132 8 152 66 7 58 136 4 156 68 9 60 140 160 71 1 62 143 6 164 73 3 64 147 2 168 75 6 66 150 8 172 77 8 68 154 4 176 80 0 70 158 180 82 2 72 161 6 184 84 4 74 165 2 188 86 7 76 168 8 192 88 9 78 172 4 196 91 1 80 176 200 93 3 82 179 6 204 95 6 84 183 2 208 97 8 86 186 8 212 100 0 88 190 4 216 102 2 90 194 220 104 4 92 197 6 224 106 7 94 201 2 228 108 9 96 204 8 232 111 1 98 208 4 236 113 3 100 212 240 115 6 102 215 6 244 117 8 104 219 2 JOHNSON CONTROLS lt F 0 0 0 0 4 2 2 2 3 6 8 44 4 7 2 12 6 7 6 10 8
112. RIPTION 1 Fan Assemblies MCHX Condenser Control Panel Compressors Receiver Included with Optional Heat Recovery Condenser Filter Driers FIGURE 1 UNIT COMPONENTS FRONT 20 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 2 PRODUCT DESCRIPTION DESCRIPTION Fan Deck MCHX Condenser Coil Headers Control and Power Panels Compressors Brazed Plate Evaporator Formed Steel Base Rails Hydro Kit Pumps And Motors Optional FIGURE 2 UNIT COMPONENTS SIDE JOHNSON CONTROLS 21 FORM 150 72 ICOM7 614 SECTION 2 PRODUCT DESCRIPTION ISSUE DATE 6 10 2014 LD13248 ITEM DESCRIPTION Fan Contactor Fan Fuses Fan Contactor Disconnect Switch Optional XTBF1 Compressor Contactors Compressor Overloads FIGURE 3 POWER PANEL COMPONENTS 22 JOHNSON CONTROLS FORM 150 72 614 ISSUE DATE 6 10 2014 SECTION 2 PRODUCT DESCRIPTION LD13248 DESCRIPTION Fan Contactor Fan Fuses Control Relay Microcomputer Control Center Display Keypad XTBC1 Microboard XTCB2 XTBF2 Compressor Contactors Compressor Overloads FIGURE 4 POWER PANEL CONTROL COMPONENTS JOHNSON CONTROLS 23 SECTION 2 PRODUCT DESCRIPTION FORM 150 72 614 ISSUE DATE 6 10 2014 PRODUCT IDENTIFICATION NUMBER PIN TABLE 1 COMPLETE PIN NUMBER DESCRIPTION
113. SORS 6 STEPS SETPOINT SETPOINT 1 W HGB SP CR 8 Note 1 SETPOINT 1 NO HGB SP 4 SP CR 8 SP 2 CR 4 Note 2 SP 4 SP 2 CR 4 SP CR 4 Note 3 SP 3 CR A SP 2 CR 4 SP CR SP 3 CR 4 NOTES 1 Step 1 is Hot Gas Bypass and is skipped when loading occurs Hot Gas Bypass operation is inhibited during Pumpdown 2 Step 3 is skipped when loading occurs 3 Step 4 is skipped when unloading occurs STEP can be viewed using the OPER DATA key and scrolling to COOLING DEMAND JOHNSON CONTROLS 143 SECTION 8 UNIT OPERATION LEAVING CHILLED LIQUID SYSTEM LEAD LAG AND COMPRESSOR SEQUENCING A Lead Lag option may be selected to help equalize average run hours between systems with 2 refriger ant systems This may be programmed under the OP TIONS key Auto Lead Lag allows automatic Lead Lag of the two systems based on average run hours of the compressors in each system Manual Lead Lag se lects specifically the sequence which the microproces Sor starts systems On a hot water start once a system starts it will turn ON all compressors before the next system starts a compressor The microprocessor will sequence com pressors within each circuit to maximize individual compressor run time on individual compressors within a system to prevent short cycling Each compressor in a system will be assigned an arbi trary priority number 1 2 or 1 2 3 The non running compressor within a system
114. T AUTOMATIC Chiller auto restarts after a power failure POWER FAIL RESTART MANUAL After a power failure the UNIT switch must be tog gled before restart at the unit is allowed NORMALLY MANUAL RESTART should NOT BE SELECTED Option 13 Soft Start Enable Disable SOFT START DISABLED SOFT START DISABLED MUST be selected on all chillers This message may not be viewable on non European chillers Option 14 Unit U NIT TYPE LIQUID CHILLER The UNIT TYPE message cannot be modified under the unit keys Liquid CHILLER must be displayed or damage to compressors or other compo nents will occur if operated in the HEAT PUMP or CONDENSING UNIT modes CAUTION If unit type needs to be changed to make the unit a liquid chiller remove power and then remove the jumper between J11 7 and J11 12 on the I O Board Reapply power to the micro panel and the micropro cessor will store the change 125 SECTION 7 UNIT CONTROLS Option 15 Refrigerant Type REFRIGERANT 410 Refrigerant type 410 must be selected under Ser vice Mode Refrigerant type is displayed under the OPTIONS key but is only programmable in Service Mode Incorrect programming may cause dam age to compressors CAUTION gt Option 16 Expansion Valve EXPANSION VALVE TYPE THERMOSTATIC Expansion valve type thermostatic or electronic may be selected under Ser
115. TECHNICAL DATA SINGLE AND DUAL POINT WIRING OPTIONS 035 21583 116 REVA 208 230V 3 60HZ 60 380 41 5V 3 50 60HZ 460 5 60 7 575 5 60 m N 1 1L1 1 1 1L2 1 1 1L3 1 1 DWG 16 b E 2L2 1 5 2L3 1 5 2L1 1 4 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 208 230V 3 60HZ 460V 3 60HZ 75 5 60 380 415V 3 50 60HZ 27 T 050 121415 460 5 60 7 NB1 9V 5 60H ATN S 60HZ 208 230V 3 60HZ SINGLE POINT WIRING OPTIONS 208 230V 3 60HZ 460V 3 60HZ 9V 3 60H 380 415V 3 50 60HZ 1 i zm daa gt gt gt gt gt gt 1217416 1214 16 N 57 x So A Tee ne y 2 N xo C DUAL POINT WIRING OPTIONS FIGURE 16 SINGLE AND DUAL POINT WIRING OPTIONS 66 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA PUMP WIRING 035 21583 105 REV D 11 11 gt 2 112 11 E J11 13 11
116. TER ADV key at which time the day will be accepted and the cursor will move under the first digit of the 2 digit hour In a similar manner the hour minute meridian month day and year may be programmed whenever the cursor is under the first letter numeral of the item Press the 1 UP or DOWN arrow keys until the desired hour minute meridian day month and year are displayed Pressing the ENTER ADV key will save the valve and move the cursor on to the next programmable variable 127 SECTION 7 UNIT CONTROLS ea Options Ke ace Kay Expansion Valve Type to adv Thermoplastic or Electric Programmed under Service Mode Viewable Only Must be programmed for Thermostatic Display Language System Switches on off Flash Card Update Chilled Liquid Type water or glycol Remote Temp Reset Ambient Control Pump Control standard or low Pump Selection Local Remote Mode Unit Control Mode Return or Leaving Display Units English or Metric System Lead Lag Control Manual or Automatic Fan Control Mode Manual Override Mode Current Feedback Option Power Failure Restart Soft Start Option Unit Type Chiller MUST be Selected Via No Jumper Installed Viewable Only Refrigerant Type R 410A Programmed under Service Mode Viewable
117. TEST POINTS Suction Pressure System 1 HMM HH Microboard J7 10 to J7 9 System 2 HH Microboard J9 10 to J9 9 Discharge Pressure System 1 A Microboard J7 11 to J7 7 System 2 mem Microboard J9 11 to J9 7 V Pressure in PSIG x 01 5 or V Pressure BARG x 145 5 where V DC voltage output Pressure pressure sensed by transducer The I O board connections for the Discharge Transducers are as follows System 1 Discharge Transducer J7 6 5VDC regulated supply to transducer J7 11 VDC input signal to microboard See the formula above for voltage readings that cor respond to specific discharge pressures J7 7 5VDC return J7 2 drain shield connection System 2 Discharge Transducer 19 6 5VDC regulated supply to transducer 79 11 VDC input signal to microboard See the formula above for voltage readings that correspond to specific discharge pressures JOHNSON CONTROLS SECTION 9 SERVICE AND TROUBLESHOOTING 19 7 5VDC return 79 2 drain shield connection 0VDC The suction transducers have a range from 0 to 400 PSIG 27 5 barg The output will be linear from 0 5VDC to 4 5VDC over the 400 PSIG 27 5 barg range Following is a formula that can be used to verify the voltage output of the transducer voltage read ing are in reference to ground unit case V Pressure PSIG 02 5 V Pressure in barg x 29 5 where V
118. TU 100 INLET OT jr 53 100 OUTLET H 54 z i 85 38 38 es TT 5 5 589 gt 1473 1519 J 2 886 8 2243 FRAME WIDTH 2255 OVERALL WIDTH e M 4731 FRAME LENGTH FORM 150 72 614 ISSUE DATE 6 10 2014 POWER ENTRY 330 WIDE X 178 HIGH cad 1102 CONTROL PANEL BOTTOM DETAIL LD18070 Placement on a level surface of free of obstructions including snow for winter operation or air circulation ensures rated performance reliable operation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance Johnson Controls s unit controls will optimize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 2m 6 rear to wall 2m 6 control panel to end wall 1 2m 40 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit 80 JOHNSON CONTROLS FORM 150 72 614 ISSUE DATE 6 10 2014 SECTION 5 TE
119. V 15 S A33 1eeujedns uogons 2 515 spuooss 0 dav OLX 70760 965 c IV 110 A33 25 5 ajoAoay nuy SAS NV ZS 5 A33 1eeHJedns 2 5 6 HS LONS ZS S dH 15 SAS 43 25 5 19 u 19 009 SAS 25 S eunsseJg SAS 25 S eunsseJg uonong SAS 1205 ZS S spuooes uny SAS 5 25 S dwa uogons 5 5 dWaL LONS ZS lt 5 OV SIPPOW A33 4 A33 ueis s od 18 1 S S od dW3l 18 2408 19 009 SAS od 18 0 S S eJnsseJg uonons S S 15 Md 1206 15 00 00100 00400100400 0210000 0 100 00102100102100 1021 0210200 9 02 00 00100 0040000400 9 2 N DNDN 9 0210200 219 9 991 091 92 02 9 02 92 02 2 0 DNDN NINN Nin 0 00 9 91 21 02 9 02 92 02 0 0 92 9 2 0210200 9 19 00 00100 0010000400 9 2 0 DNDN Ninn 0210200 9 9 9 9 091 0 4000010 021000
120. Y key Printer Do not connect shield at printer end LD12723 FIGURE 34 PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS JOHNSON CONTROLS 159 SECTION 9 SERVICE AND TROUBLESHOOTING TABLE 31 TROUBLESHOOTING FORM 150 72 614 ISSUE DATE 6 10 2014 TROUBLESHOOTING PROBLEM CAUSE SOLUTION NO DISPLAY ON PANEL UNIT WILL NOT OPERATE FLOW SWITCH REM STOP NO RUN PERMISSIVE LOW SUCTION PRESSURE FAULT HIGH DISCHARGE PRESSURE FAULT 160 1 No 115VAC to 24VAC Transformer No 24VAC to Microboard Control Transformer defective no 24VAC output Short in wire to temp sensors or pressure transducers Defective II amp I O Board or the Display Board 1 No chilled liquid flow Flow switch improperly installed Defective flow switch 4 Remote cycling device open Improper suction pressure cutouts adjustments Low refrigerant charge Fouled filter dryer TXV defective Reduced flow of chilled liquid through the cooler Defective suction pressure transducer low pressure switch or wiring LLSV defective Condenser fans not operating or operating backwards 2 Too much refrigerant 3 Air in refrigerant system 4 Defective discharge pressure transducer 1a Check wiring and fuse 1FU 1b Check wiring emergency stop contacts 5 to L of XTBC2 Terminal Block 1c Replace Control Transformer 2 Check wiring Control Transforme
121. a suitable grounding point En sure that all unit internal ground connections are tight 93 SECTION 6 COMMISSIONING Supply Voltage Verify that the site voltage supply corresponds to the unit requirement and is within the limits given in SEC TION 5 TECHNICAL DATA Water System Verify the chilled liquid system has been installed cor rectly and has been commissioned with the correct direction of water flow through the cooler The inlet should be at the refrigerant piping connection end of the cooler Purge air from the top of the cooler using the plugged air vent mounted on the extension pipe Flow rates and pressure drops must be within the limits given in SECTION 5 TECHNICAL DATA Operation outside of these limits is undesirable and could cause damage If mains power must be switched OFF for extended maintenance or an extended shutdown period the com pressor suction discharge and economizer service stop valves should be closed clockwise If there 1s a pos sibility of liquid freezing due to low ambient tempera tures the coolers should be drained or power should be applied to the chiller This will allow the cooler heater to protect the cooler from freezing down to 20 F Be fore placing the unit back in service valves should be opened and power must be switched ON if power is removed for more than 8 hours for at least 8 hours 24 hours if ambient temperature is below 86 F 30 C before the unit i
122. achine is at its full operating weight Back off each of the 4 limit stop lock nuts on isolators 1 2 Adjust each isolator in sequence by turning spring adjusting nuts one full clockwise turn at a time Repeat this procedure on all isolators one at a time Check the limit stop lock nuts periodically to ensure that clearance between the washer and rubber grommet is maintained Stop adjustment of isolator only when the top plate has risen just above shim Remove all spacer shims Fine adjust isolators to level equipment Adjust all limit stop lock nuts per isolator maintaining a 1 4 to 3 8 inch gap The limit stop nuts must be kept at this gap to ensure uniform bolt loading during uplift as the case when equip ment is drained Installation 15 complete LD13763B 89 FORM 150 72 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 NEOPRENE ISOLATOR CROSS REFERENCE RD Style Sow Isolators MOLDED DURULENE AD THRU TYP 2 PLACES LD13760A 1 All dimensions are inches interpreted per ANSI 4 AL Mounting hole center to center spacing Te 5 Free height of mount prior to loading Op 2 Refer to next page for installation instructions erating height calculated by the free height less the static deflection under load All dimensions 3 Mount molded in weather r
123. ack this safety will operate as follows If the actual feedback voltage of the system proportional to currents exceeds the programmed trip voltage for 5 seconds the system will shutdown 104 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 This safety will shut down a system if either suction temperature or suction pressure sensors read out of range high or low This condition must be present for 3 seconds to cause a system shutdown The safety locks out a system after the first fault and will not allow au tomatic restarting Unit Safeties Unit safeties are faults that cause all running compres sors to be shut down Unit faults are auto reset faults in that the unit will be allowed to restart automatically after the fault condition is no longer present UNIT FAULT LOW AMBIENT TEMP The Low Ambient Temp Cutout is a safety shutdown designed to protect the chiller from operating in a low ambient condition If the outdoor ambient temperature falls below the programmable cutout the chiller will shut down Restart can occur when temperature rises 2 F above the cutoff UNIT FAULT LOW LIQUID TEMP The Low Leaving Chilled Liquid Temp Cutout protects the chiller form an evaporator freeze up should the chilled liquid temperature drop below the freeze point This situation could occur under low flow conditions or if the micro panel setpoint values are improperly pro grammed Anytime the leaving chilled liquid tempera ture water o
124. age to the unit or loss of performance and may invalidate the warranty JOHNSON CONTROLS SECTION 4 INSTALLATION When ducting is to be fitted to the fan discharge it is recommended that the duct should be the same cross sectional area as the fan outlet and straight for at least three feet 1 meter to obtain static regain from the fan Duct work should be suspended with flexible hang ers to prevent noise and vibration being transmitted to the structure A flexible joint is also recommended be tween the duct attached to the fan and the next section for the same reason Flexible connectors should not be allowed to concertina The unit is not designed to take structural loading No significant amount of weight should be allowed to rest on the fan outlet flange deck assemblies or con denser coil module No more than 3 feet 1 meter of light construction duct work should be supported by the unit Where cross winds may occur any duct work must be supported to prevent side loading on the unit If the ducts from two or more fans are to be combined into a common duct back flow dampers should be fit ted in the individual fan ducts This will prevent re circulation of air when only one of the fans is running Units are supplied with outlet guards for safety and to prevent damage to the fan blades If these guards are removed to fit duct work adequate alternative precau tions must be taken to ensure persons cannot be harmed or pu
125. ain open until power is reapplied and no fault conditions exist 149 SECTION 8 UNIT OPERATION REMOTE BAS EMS TEMPERATURE RESET USING A VOLTAGE OR CURRENT SIGNAL The Remote Reset Option allows the Control Center of the unit to reset the chilled liquid setpoint using a 0 to 1OVDC input or a 4 to 20mA input connected to XTBCI Terminals A and A4 Whenever a reset is called for the change may be noted by pressing the COOLING SETPOINTS key twice The new value will be displayed as REM SETP XXX F Ifa 0 to 10VDC signal is supplied it is applied to Ter minals and and jumper JP1 on the I O board must be inserted between pins 2 and 3 To calculate the reset chilled liquid setpoint for values between and 10VDC use the following formula Setpoint Local Chilled Liquid Setpoint Reset DC voltage signal x Reset Value 10 Example Local Chilled Liquid Setpoint 45 7 22 Reset Value 20 F 11 11 Input Signal GVDC English Reset 6VDC x 20 F 10 New Setpoint 45 F 12 F 57 F Metric Reset 6VDC x 11 11 10 New Setpoint 7 22 C 6 67 13 89 C Max Reset Value is EMS PWM Remote Temp Reset setpoint value described in Remote Setpoint Control on page 12 F Reset 6 67 Reset 117 under Cooling Setpoints Programmable values are from 2 F to 40 F 1 11 C to 11 1
126. al YORK AIR COOLED SCROLL CHILLER BY JOHNSON CONTROLS INSTALLATION OPERATION MAINTENANCE Supersedes 150 72 ICOM7 414 Form 150 72 ICOM7 614 035 23573 100 YLAA0180 YLAA0516 AIR COOLED SCROLL CHILLERS WITH BRAZED PLATE HEAT EXCHANGER STYLE B 50 HZ 4 8 FAN 50 150 TON 180 530 KW R 410A Zu ered CERTIFIED Issue Date June 10 2014 FORM 150 72 614 ISSUE DATE 6 10 2014 IMPORTANT READ BEFORE PROCEEDING GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus During installation operation maintenance or service individuals may be exposed to certain components or conditions including but not limited to refrigerants materials under pressure rotating components and both high and low voltage Each of these items has the potential if misused or handled improperly to cause bodily injury or death It is the obligation and respon sibility of operating service personnel to identify and recognize these inherent hazards protect themselves and proceed safely in completing their tasks Failure to comply with any of these requirements could result in serious damage to the equipment and the property in which it is situated as well as severe personal injury or death to themselves and people at the site This document is intended for use by owner authorized operating service personnel It is expected that these individuals possess independent training th
127. al inputs are connected to J13 1 of the I O board The term digital refers to two states either ON or OFF As an example when the flow switch is closed 30VDC will be applied to J13 pin 5 13 5 of the I O board If the flow switch is open OVDC will then be present at J13 5 Pin 1 of J13 15 an unregulated 30VDC source used to supply the DC voltage to the various user contacts unit switch flow switch etc This DC source 15 factory wired to XTBCI Terminal 13 Any switch or contact used as a digital input would be connected to this ter minal with the other end connecting to its respective digital input on the microboard Any time a switch or contact is closed 30VDC would be applied to that par ticular digital input Any time a switch or contact is open OVDC would be applied to that particular digital input Typically voltages of 24 to 36VDC could be measured for the DC voltage on the digital inputs This voltage is in reference to ground The unit case should be suffi cient as a reference point when measuring digital input voltages Analog Inputs Temperature Refer to the unit wiring diagram Temperature inputs are connected to the microboard on plug J6 These ana log inputs represent varying DC signals corresponding to varying temperatures All voltages are in reference to the unit case ground Following are the connec tions for the temperature sensing inputs Outside Air Sensor 76 6 5VDC regulated supply
128. al or up to two stages of demand load limiting depending on model The standard control panel can be directly con nected to a Johnson Controls Building Automated System POWER PANEL Each panel contains Compressor power terminals Compressor motor starting contactors per I E C Control power terminals to accept incoming for 110 1 50 control power Fan contactors and overload current protection The power wiring is routed through liquid tight con duit to the compressors and fans ACCESSORIES AND OPTIONS Power Options Compressor Power Connections Single point terminal block connection s are provid ed as standard The following power connections are available as options See electrical data for specific voltage and options availability Factory mounted Single Point Supply Terminal Block Includes enclosure terminal block and interconnecting wiring to the compressors Separate external protection must be supplied by others in the incoming compres sor power wiring Do not include this option if either the Single Point Non Fused Disconnect Switch or Sin gle Point Circuit Breaker options have been included 17 SECTION 2 PRODUCT DESCRIPTION Single Point Non Fused Disconnect Switch Unit mounted disconnect switch with external lockable handle in compliance with Article 440 14 of N E C can be supplied to isolate the unit power voltage for ser vicing Separate external fusing must be suppli
129. and Pressure Vessel Code Section VIII Division 1 ARI Standard 550 590 Positive Displacement Compressors and Air Cooled Rotary Screw Water Chilling Packages 11 SECTION 1 GENERAL CHILLER INFORMATION AND SAFETY ASHRAE 90 1 Energy Efficiency compliance Conform to Intertek Testing Services formerly ETL for construction of chillers and provide ETL cETL listing label Manufactured in facility registered to ISO 9002 e Occupational Safety and Health Act In addition the chillers conform to Underwriters Labo ratories U L for construction of chillers and provide U L cU L Listing Label Responsibility for Safety Every care has been taken in the design and manufac ture of the unit to ensure compliance with the safety requirements listed above However the individual rigging lifting maintaining operating or working on any machinery 15 primarily responsible for Personal safety safety of other personnel and the machinery Correct utilization of the machinery in accordance with the procedures detailed in the manuals ABOUT THIS MANUAL The following terms are used in this document to alert the reader to areas of potential hazard A WARNING is given in this document to identify a hazard which could lead to personal injury Usually an instruction will be given together with a brief expla nation and the possible result of ignoring the instruction WARNING A CAUTION identifi
130. are powered by 12V Keypad commands are actuated upon by the micropro cessor to change setpoints cutouts scheduling operat ing requirements and to provide displays The keypad and display are connected to the I O board The on board power supply converts 24VAC from 75 120 24VAC 50 60Hz UL listed class 2 power transformer to 12V 5V and 3 3V using switching and linear voltage regulators located on the I O and IPU II boards These voltages are used to operate integrated circuitry on the board The 40 character display and unit sensors transducers and temp sensors are sup 99 SECTION 7 UNIT CONTROLS plied power for the micro board 5V supply 24 is rectified but not regulated to provide unregulated to supply all of the digital inputs The I O board contains one green Power LED to in dicate that the board is powered up and one red Sta tus LED to indicate by blinking that the processor is operating The I O board also contains two sets of Receiver Transmit LED s one for each available serial communication port The receive LED s are green and the Transmit LED s are red A jumper on the I O board selects 4 to 20mA or 0 to 10VDC as the input type on the remote temperature reset analog input TRANSFORMER A 75VA 120 240VAC 50 60Hz transformer is pro vided to supply power to the Microprocessor Board which in turn rectifies filters and regulates as neces sary to supply pow
131. ase of single sys tem units all SYS 2 messages will be blank UNIT SWITCH SHUTDOWN This message informs operator the UNIT switch on the control panel is in the OFF position which will not allow the unit to run SHUTDOWN The REMOTE CONTROLLED SHUTDOWN mes sage indicates that either an ISN system or RCC has turned the unit OFF not allowing it to run JOHNSON CONTROLS 00066VIP DAILY SCHEDULE SHUTDOWN The DAILY SCHEDULE SHUTDOWN message in dicates that the daily holiday schedule programmed is keeping the unit from running REMOTE STOP NO RUN PERM REMOTE STOP NO RUN PERM shows that a remote start stop contact is open in series with the flow switch These contacts are connected to Terminals 51 and 13 of XTBCI A 3 second delay is built into the software to prevent nuisance shutdowns due to erroneous signals on the run permissive input FLOW SWITCH OPEN FLOW SWITCH OPEN indicates the flow switch con tacts connected to Terminals 13 and 14 of are open A 3 second delay is built into software to prevent nuisance shutdowns due to erroneous signals from the flow switch SYS 1 SYS 2 SYS SYS SWITCH SWITCH SYS SWITCH OFF tells that the system switch under OPTIONS is turned OFF The system will not be al lowed to run until the switch is turned back ON 101 SECTION 7 UNIT CONTROLS SYS 1 NO SYS 2 NO COOL COOL LO
132. at setting for a system is 10 F to 15 F 5 56 C to 8 33 18 46 cm from the Place the Unit Switch in the control panel to the ON heat exchanger position PEUT Superheat should typically be set for no less than NOTE The chilled liquid setpoint may need to 10 F with only a single compressor running on a be temporarily lowered to ensure all compres circuit The superheat is calculated as the difference sors cycle ON between the actual temperature of the returned refrig 96 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 6 COMMISSIONING erant gas in the suction line entering the compressor E Leak Checking and the temperature corresponding to the suction pressure as shown in a standard pressure tempera Leak check compressors fittings and piping to en ture chart sure noleaks aep Ree deni rid Example ae in Suction Temp 46 F If the unit is functioning satisfactorily during the ini minus Suction Press tial operating period no safeties trip and the com 105 PSIG converted to Temp 34 F pressors cycle to control water temperature to Superheat 12 F setpoint the chiller is ready to be placed into operation When adjusting the expansion valve TXV only the adjusting screw should be turned not more than one turn at a time allowing sufficient time approximately Owner s operating personnel 15 minutes between adjustments for the system and the thermal e
133. at will en able them to perform their assigned tasks properly and safely It 15 essential that prior to performing any task on this equipment this individual shall have read and understood this document and any referenced mate rials This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to specific situations Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken DANGER Indicates a potentially hazardous situa tion which will result in possible injuries or damage to equipment if proper care is not taken WARNING Identifies a hazard which could lead to damage to the machine damage to other equipment and or environmental pollu tion if proper care is not taken or instruc tions and are not followed CAUTION Highlights additional information useful to the technician in completing the work being performed properly NOTE External wiring unless specified as an optional connection in the manufacturer 5 product line is not to be connected inside the control cabinet Devices such as relays switches transducers and controls and any external wiring must not be installed inside the micro panel All wiring must be in accor WARNING dance with Johnson Controls published specifications a
134. ayed as shown below If the microprocessor is programmed for CURRENT FEEDBACK NONE no current display will appear JOHNSON CONTROLS SECTION 7 UNIT CONTROLS SYS X COMP STATUS 1 XXXK 2 SYS X TIME XX XX XX XX D H M S SYS X LLSV IS ON GAS SOL IS OFF HOT SYS X FAN STAGE 3 SYS 6 0 The preceding five messages will appear sequentially first for system 1 then for system 2 The first message indicates the system and the associ ated compressors which are running The second message indicates the system run time in days hours minutes seconds Please note that this is not accumulated run time but pertains only to the current system cycle The third message indicates the system and whether the liquid line solenoid or EEV pilot solenoid and hot gas solenoid are being turned ON by the microboard Please note that hot gas is not available for system 2 so there is no message pertaining to the hot gas solenoid when system 2 message 15 displayed The fourth message indicates the stage of condenser fan operation that is active See Standard Condenser Fan Control on page 146 for more information The fifth message displays current as sensed by the op tional current feedback circuitry The display reads out in amps along with the DC feedback voltage from the module Current is calculated by 225A x Actual Volts 5 Volts Individual displays will be present for
135. be dis played for 2 system units NOTE JOHNSON CONTROLS STATUS Display Print 00067VIP With the UNIT TYPE set as a liquid chiller no jumper from J11 7 to J11 12 on the I O Board the following list of operating data screens are viewable under the OPER DATA key in the order that they are displayed The DOWN arrow key scrolls through the displays in the order they appear below The chiller MUST be set to be a liquid chiller no jumper from J11 7 to J11 12 on the I O Board DO NOT operate the chiller if not properly set up NOTE LCHLT 46 2 F RCHLT f This display shows chilled leaving and return liquid temperatures The minimum limit on the display for these parameters are 2 2 F 19 C The maximum limit on the display is 140 F 60 C AMBIENT AIR 87 5 F TEMP This display shows the ambient air temperature The minimum limit on the display is 0 4 F 17 6 C The maximum limit on the display is 131 2 F 55 1 C 107 SECTION 7 UNIT CONTROLS SYS X SP 72 1 227 0 PSIG PSIG These displays show suction and discharge pressures for each system The discharge pressure transducer is optional on some models If the optional discharge transducer 15 not installed the discharge pressure would display 0 PSIG 0 barg The minimum limits for the display are Suction Pressure 0 PSIG 0 barg Discharge Pressure 0 PSIG 0 barg The maximum limits for
136. bient CS Special BAS ResevOtiset rearea Not Applicable to eLogia 271 B Botn Discharge Suction Pressure Transducer Readout required Fa Special Pressure Readoutrequied Q Motor Current Module Motor Current Module Q secan a Remote Panel X No Sequence Kirequred L Water TEMP ges 2030 emip Leaving Water Temp Deg JOHNSON CONTROLS 25 FORM 150 72 ICOM7 614 SECTION 2 PRODUCT DESCRIPTION ISSUE DATE 6 10 2014 TABLE 1 COMPLETE PIN NUMBER DESCRIPTION CONT D FEATURE FEATURE DESCRIPTION OPTION OPTION DESCRIPTION B Both chicago Code amp Dual Reiet Valves no Sueton Service Valve Europe ony a Special Chicago Code VALVES i a Special Optional Valves ees Special Hot Gas Bypass required X X GAUGE PIN 34 Special Quote X X OVERLOAD PIN 35 8 Special Quote X X PIN36 PIN 36 Special Quote Crankcase Heater H HTR Pin 37 DWP DWP PIN 38 Insulation PIN 39 Crankcase Heater Standard Special Crankcase Heater required X 150psig DWP Waterside Special Quote X Standard Insulation Z Double Thick Insulation Special Insulation required No Flanges required Flanges FLANGES PIN 40 Victaulic Flanges required Special Flanges required No Flow Switch required Flow Switch PIN 41 One F
137. chilled liquid is water The Cooling Setpoint can be programmed from 40 F to 70 F 4 4 C to 21 1 C or 123 SECTION 7 UNIT CONTROLS CHILLED LIQUID GLYCOL The chilled liquid is glycol The Cooling Setpoint can be programmed from 10 F to 70 F 12 2 C to 21 1 C Option 4 Ambient Control Type AMBIENT CONTROL STANDARD The low ambient cutout is adjustable from 25 F to 60 F 3 9 C to 15 6 C or AMBIENT CONTROL LOW AMBIENT The low ambient cutout is programmable down to 0 F 17 8 A low ambient kit MUST be installed for this option to be chosen If the kit is NOT installed and low ambient is selected low pressure faults and compressor damage may occur Option 5 Local Remote Control LOCAL REMOTE MODEL LOCAL When programmed for LOCAL an ISN or RCC con trol can be used to monitor only The micro panel will operate on locally programmed values and ignore all commands from remote devices or through the RS 485 inputs The chiller will communicate and send data to the remote monitoring devices or LOCAL REMOTE REMOTE MODE This mode should be selected when an ISN or RCC control is to be used to control the chiller This mode will allow the ISN to control the following items Re mote Start Stop Cooling Setpoint Load Limit and History Buffer Request If the unit receives no valid ISN transmission for 5 minutes it will revert back to the
138. compres sor When the compressor is running at stabilized con ditions the oil level must be between 1 4 and 3 4 in the oll sight glass At shutdown it is acceptable if the oil level falls to the bottom limit of the oil sight glass Use YORK V oil when adding oil NOTE Analysis The oil used in these compressors is pale yellow in color POE oil If the oil color darkens or exhibits a change in color this may be an indication of contami nants in the refrigerant system If this occurs an oil sample should be taken and analyzed If contaminants are present the system must be cleaned to prevent compressor failure AN CAUTION Never use the scroll compressor to pump the refrigerant system down into a vacu um Doing so will cause internal arcing of the compressor motor which will result in failure of compressor JOHNSON CONTROLS CONDENSER FAN MOTORS Condenser fan motors are permanently lubricated and require no maintenance Condenser MCHX Dirt should not be allowed to accumulate on the condenser surfaces Cleaning should be as often as necessary to keep coils clean Exercise care when cleaning the MCHX so that the fins are not damaged NOTE CONDENSER MCHX CLEANING The cleaning procedure for the condenser MCHX is significantly different than tube and fin type MCHX Care must be taken to understand the differences to avoid damage to the MCHX These differences require a number of DO NOT s t
139. ct operating personnel Have JCI representative contact Month Day Year Name Phone We understand that the services of the Johnson Controls Authorized Representative will be furnished in accordance with the contract for a period of time of not more than consecutive normal working hours and we agree that a charge of per diem plus travel expenses will be made to Johnson Con trols if services are required for longer than consecutive normal hours or if repeated calls are required through no fault of Johnson Controls Customer Contractor Signature Title Fompbempiwedbys _ _ Johnson Controls JOHNSON CONTROLS 97 98 THIS PAGE INTENTIONALLY LEFT BLANK FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 JOHNSON CONTROLS FORM 150 72 614 ISSUE DATE 6 10 2014 SECTION 7 UNIT CONTROLS Display OPER DATA INTRODUCTION The YORK Control Center is a microprocessor based control system designed to provide the entire control for the liquid chiller The control logic embedded in the microprocessor based control system will provide control for the chilled liquid temperatures as well as sequencing system safeties displaying status and daily schedules The MicroComputer Control Center consists of four basic components 1 IPU II and I O Boards 2 Transformer 3 Display 4 Keypad The keypad allows programming and accessing set points pressures temperatures cutouts daily sched ule
140. cuit systems This timer is NOT pro grammable The load timers further assure that there is a minimum time between compressor starts within a system 145 SECTION 8 UNIT OPERATION EVAPORATOR PUMP CONTROL AND YORK HYDRO KIT PUMP CONTROL The evaporator pump dry contacts XTBC2 Termi nals 23 and 24 are energized when any of the follow ing conditions are true 1 Low Leaving Chilled Liquid Fault 2 Any compressor is running 3 Daily Schedule is ON Unit Switch is ON and Re mote Stop is closed The pump will not run if the microprocessor panel has been powered up for less than 30 seconds or if the pump has run in the last 30 seconds to prevent pump motor overheating Whenever the option HYDRO KIT PUMPS 1 1s selected under the OPTIONS key the pump trol will be as described above DO NOT SELECT the option HYDRO KIT PUMPS 2 under the OPTIONS key If a dual pump option is installed the active pump 15 selected by the selector switch EVAPORATOR HEATER CONTROL The evaporator heater is controlled by ambient air tem perature When the ambient temperature drops below 40 F 4 4 the heater is turned ON When the tem perature rises above 45 7 2 C the heater 15 turned OFF An under voltage condition will keep the heater OFF until full voltage is restored to the system PUMPDOWN CONTROL Each system has a pump down feature upon shut off Manual pumpdown from the keypad
141. d during transit If any damage is evident it should be noted on the carrier s freight bill and a claim entered in accordance with the instructions given on the advice note Major damage must be reported immediately to your local Johnson Controls representative MOVING THE CHILLER Prior to moving the unit ensure that the installation site 1s suitable for installing the unit and is easily ca pable of supporting the weight of the unit and all as sociated services The unit must only be lifted by the base frame at the points provided Never move the unit on rollers or lift the unit using a forklift truck Care should be taken to avoid damaging the condenser cooling fins when moving the unit 31 SECTION HANDLING AND STORAGE c 65 o Y X LD18120 4 Fan Units Bu D E F I2 A 5 C X LD18121 5 10 Fan Units FIGURE 6 UNIT RIGGING LIFTING 32 FORM 150 72 614 ISSUE DATE 6 10 2014 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 LIFTING USING LUGS Units are provided with lifting holes in the base frame which accept the accessory lifting lug set as shown in the figure below The lugs RH and LH should be in serted into the respective holes in the base frame and turned so that the spring loaded pin engages into the hole and the flanges on the lug lock behind the
142. d for 44 PSIG 3 0 Bar suction pressure cutout the micropro cessor would inhibit loading of the affected system with the suction pressure less than or equal to 1 15 44 PSIG 3 0 Bar 50 PSIG 3 5 Bar The system will be allowed to load after 60 seconds and after the suc tion pressure rises above the suction pressure load limit point SYS 1 SYS 2 LOAD LIMIT LOAD LIMIT X X X X This message indicates that load limiting is in effect and the percentage of the limiting in effect This limit ing could be due to the load limit pwm input ISN or RCC controller sending a load limit command MANUAL OVERRIDE If MANUAL OVERRIDE mode is selected the STA TUS display will display this message This will indi cate that the Daily Schedule is being ignored and the chiller will start up when chilled liquid temperature allows Remote Contacts UNIT switch and SYSTEM switches permitting This is a priority message and can not be overridden by anti recycle messages fault mes sages etc when in the STATUS display mode There fore do not expect to see any other STATUS messages when in the MANUAL OVERRIDE mode MANUAL JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 OVERRIDE is to only be used in emergencies or for servicing Manual override mode automatically disables itself after 30 minutes SYS 1 SYS 2 PUMPING PUMPING DOWN DOWN The PUMPING DOWN message indicates that a com pressor in the respective sys
143. d stop time of each day may be programmed differently using 1 UP and DOWN arrow and ENTER ADV keys 118 After SUN Sunday schedule appears on the display a subsequent press of the SCHEDULE ADVANCE DAY key will display the Holiday schedule This is a two part display The first reads HOL START 00 00 AM STOP 00 00 The times may be set using the same procedure as de scribed above for the days of the week After chang ing the meridian of the stop time pressing the ENTER ADV key will advance the schedule to the following display S 5 HOLIDAY NOTED BY The line below the empty space next to the S is the cursor and will move to the next empty space when the ENTER ADV key 15 pressed To set the Holiday the cursor is moved to the space following the day of the week of the holiday and the 1 UP arrow key is pressed An will appear in the space signifying that day as a holiday The can be removed by pressing the DOWN arrow key The Holiday schedule must be programmed weekly once the Holiday schedule runs it will revert to the normal daily schedule JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 PROGRAM KEY There are several operating parameters under the PRO GRAM key that are programmable These setpoints can be changed by pressing the PROGRAM key and then the ENTER ADV key to enter Program Mode Continuing to press the ENTER ADV key will displa
144. ditions are true the pump will not run if the chiller has been powered up for less than 30 sec onds or if the pump has run in the last 30 seconds to prevent pump overheating EXTERNAL PUMP EXTERNAL EVAP PUMP should be selected if ternal pump is being controlled with the chiller pump contacts The operation will be the same as YORK HDRO KIT PUMPS 1 The following option should not be selected PUMPS 2 Option 20 Pump Selection The displays for this PUMP SELECTION option should only appear if YORK HYDRO KIT PUMPS 2 are selected under Option 19 Presently this option should not be used JOHNSON CONTROLS SECTION 7 UNIT CONTROLS Clock The CLOCK display shows the current day time and date Pressing the CLOCK key will show the current day time and date It is important that the date and time be correct other wise the daily schedule will not function as desired if programmed In addition for ease of troubleshooting via the History printouts the day time and date should be correct To change the day time and date press the CLOCK key The display will show something similar to the following The line under the F is the cursor If the day is correct press the ENTER ADV key The cursor will move un der the 0 in 08 hours If the day 15 incorrect press the 1 UP or DOWN arrow keys until the desired day is displayed and then press the EN
145. e CP EQUIPMENT BASE By Others POSITIONING MOUNT 5 8 LD13759A DIMENSION DATA INCHES 1 3 5 8 7 3 4 6 1 2 4 3 4 1 2 5 5 8 2 3 5 8 10 1 2 9 1 4 7 3 4 9 16 6 MODEL NUMBER RATED CAPACITY LBS DEFLECTION RATED IN COLOR CODE CP1 1D 85 85 1 360 LT PURPLE CP1 1D 120 120 1 200 DK YELLOW CP1 1D 175 DK BLUE CP1 1D 250 YELLOW CP1 1D 340 RED CP1 1D 510 BLACK CP1 1D 675 DK PURPLE CP1 1D 900 DK GREEN CP1 1D 1200 GRAY CP1 1D 1360 WHITE CP1 1D 1785N GRAY RED MODEL NUMBER RATED CAPACITY LBS DEFLECTION RATED IN COLOR CODE CP2 1D 1020 BLACK CP2 1D 1350 DK PURPLE CP2 1D 1800 DK GREEN CP2 1D 2400 GRAY CP2 1D 2720 WHITE CP2 1D 3570N 86 GRAY RED JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA ONE INCH DEFLECTION SPRING ISOLATORS INSTALLATION INSTRUCTIONS Read instructions in their entirety before begin ning installation Isolators are shipped fully assembled and are to be positioned in accordance with the submittal draw ings or as otherwise recommended Set isolators on floor housekeeping pad or sub base ensuring that all isolators centerlines match the equipment mounting holes The VMC group recommends that the isolator base be in stalled on a level surface Shim or grout as re qu
146. e Water or Glycol AMBIENT CONTROL XXXXXXXXXX Displays the type of Ambient Control Standard or Low Ambient LOCAL MODE XXXXXXXXX Displays Local or Remote control selection 112 FORM 150 72 614 ISSUE DATE 6 10 2014 CONTROL LEAVING MODE LIQUID Displays the type of chilled liquid control Leaving or Return LEAD LAG CONTROL XXXXXXXX Displays the type of lead lag control Manual System 1 Manual System 2 or Automatic This is only select able on 2 system chillers FAN CONTROL DISCHARGE PRESSURE Displays the type of fan control Discharge Pressure or Ambient and Discharge Pressure MANUAL OVERRIDE XXXXXXXXX MODE Displays whether Manual Override was Enabled or Disabled XXXXXXXXXXXXXXXX Displays type of Current Feedback utilized SOFT START XXXXXXX Displays whether the optional European Soft Start was installed and selected DISCHARGE PRESSURE Displays programmed Discharge Pressure Cutout SUCTION CUTOUT PRESSURE PSIG Displays programmed Suction Pressure Cutout LOW AMBIENT TEMP CUTOUT Displays the programmed Low Ambient Cutout JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 LEAVING CUTOUT LIQUID TEMP Displays Leaving Liquid Temp Cutout pro grammed F
147. e capacity control scheme is on step 2 of 8 Capacity Control is covered in more detail in this publication which provides specific information on compressor staging for Return Water Control only TEMP TEMP ERROR RATE xX F XXX X F M The COOLING DEMAND message will be replaced with this message when Leaving Chilled liquid control is selected This message indicates the temperature er ror and the rate of change of the chilled liquid tempera ture LEAD SYSTEM SYSTEM 18 2 This display indicates the current LEAD system In this example system 2 15 the LEAD system making system 1 the LAG system The LEAD system can be manually selected or automatic Refer to the program ming under the Options Key on page 123 The Lead System display will only appear on a two system unit A unit utilizing hot gas bypass should be programmed for MANUAL with system 1 as the lead system Failure to do so will prevent hot gas operation if system 2 switches to the lead system when pro grammed for AUTOMATIC LEAD LAG NOTE EVAPORATOR S TATUS IS HEATER XXX This display indicates the status of the evaporator heater The evaporator heater is controlled by ambient air temperature When the ambient temperature drops below 40 F the heater is turned ON When the tem perature rises above 45 F the heater is turned OFF An under voltage condition will keep the heater OFF until full voltage is restored to the
148. e composite blades molded into a low noise airfoil section They are designed for maximum effi ciency and are statically and dynamically balanced for vibration free operation They are directly driven by independent motors and positioned for vertical air dis charge The fan guards are constructed of heavy gauge rust resistant coated steel All blades are statically and dynamically balanced for vibration free operation Motors The fan motors are Totally Enclosed Air Over and are current protected They feature ball bearings that are double sealed and permanently lubricated Control Center controls are contained in a NEMA 12 cabinet with hinged outer door and includes a Liquid Crystal Display with Light Emitting Diode backlighting for outdoor viewing Two display lines Twenty characters per line Display Print Keys Color coded 12 button non tactile keypad with sec tions for display and print of typical information Chilled liquid temperatures Ambient temperature 16 FORM 150 72 614 ISSUE DATE 6 10 2014 System pressures each circuit Operating hours and starts each compressor Print calls up to the liquid crystal display Operating data for systems History of fault shutdown data for up to the last six fault shutdown conditions An RS 232 port in conjunction with this press to print button 15 provided to permit the capability of hard copy print outs via a sepa
149. e instructions for programming the respec tive setpoints The same instruction should be used to view the setpoints with the exception that the setpoint will not be changed Cooling Setpoints The Cooling Setpoint and Range can be programmed by pressing the COOLING SETPOINTS key The cooling mode leaving chilled liquid or return chilled liquid will be displayed for a few seconds and the set point display entry screen will appear 116 00069VIP Leaving Chilled Liquid Control SETPOINT 45 0 F RANGE 2 0 The above message shows current chilled water temperature SETPOINT at 45 0 notice the cursor positioned under the number 0 Pressing either the 1 UP or DOWN arrow will change the setpoint in 5 F increments After using the 1 UP or DOWN ar row keys to adjust to the desired setpoint the ENTER ADV key must be pressed to enter this number into memory and advance to the RANGE SETPOINT Entry of the setpoint will be indicated by the cursor moving under the current RANGE setpoint The 1 UP and DOWN arrow keys are used to set the RANGE in 5 increments to the desired RANGE setpoint After adjusting the setpoint the ENTER ADV key must be pressed to enter the data into memory Notice that the RANGE was programmed for X X F This indicates the SETPOINT to be in the center of JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 the control range If the co
150. e pressure for the next stage is increased 20 PSIG and ramped back to the programmed on pressure over the next 20 seconds When fan stage is turned off Programmed ON pressure minus the differential the OFF pressure for the next stage is decreased 20 PSIG and ramped back to the programmed OFF pressure minus the differential The time delay fan delay timer between turning fan stages on and off is fixed at 5 seconds NOTE JOHNSON CONTROLS 147 SECTION 8 UNIT OPERATION FANS PER SYSTEM PROGRAMMED FAN CONTROL ON PRESSURE lt FAN CONTROL ON PRESSURE MINUS PROGRAMMED FORM 150 72 614 ISSUE DATE 6 10 2014 TABLE 22 YLAA STANDARD CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONLY 5 OR 6 OUTPUT FAN CONTACTOR FAN SYS 1 SYS 2 SYS 1 SYS 2 SYS 1 SYS 2 DIFFERENTIAL PRESSURE DP lt PROGRAMMED FAN CONTROL ON PRESSURE MINUS PROGRAMMED DIFFERENTIAL PRESSURE AND FAN STAGE 1 15 ENERGIZED TB7 8 TB7 8 and TB7 9 TB10 8 1 KF1 2 KF1 1 MF1 2 MF1 2 KF1 and 2 KF2 PROGRAMMED FAN CONTROL ON PRESSURE AND FAN STAGE 115 ENERGIZED 1 KF1 nd 1 KF2 lt FAN CONTROL ON PRESSURE MINUS PROGRAMMED DIFFERENTIAL PRESSURE AND FAN STAGES 1 AND 2ARE ENERGIZED PROGRAMMED FAN CONTROL ON PRESSURE AND FAN STAGES 1 AND2 ARE ENERGIZED TB10 8 and TB10 9 and TB10 10 When a fan stage is turned on the pre
151. e supplies for the voltage free terminals with regard to a common point of isolation Thus these circuits when used must be fed via the common point of isolation the voltage to these circuits is removed when the common point of isolation to the unit is opened This common point of isolation is not supplied by YORK The YORK voltage free contacts are rated at 100va All inductive devices relays switch by the YORK voltage free contacts must have their coil suppressed using standard R C suppressors Customer voltage free contacts connected to terminal 13 must be rated at 30V 5ma No controls relays etc Should be mounted in any section of the control panel Additionally control wiring not con nected to the YORK control panel should not be run through the panel If these precautions are not followed electrical noise could cause malfunctions or damage to the unit and its controls Refer to installation commissioning operation and maintenance manual for customer connections and customer con nection notes non compliance to these instructions will invalidate unit warranty Wiring and components for compressor 3 only fitted when unit has 3 compressors on the system 1 BMP3 is replaced by a link across terminals 134 amp 135 2 BMP3 is replaced by a link across terminals 234 amp 235 FHP2 is only fitted on CE YLAA and above When fitted 1 FHP2 is replaced by a link across terminals 132 amp 139 2 FHP2 is replaced by a link across terminals
152. e wired in parallel with XTBC2 Termi nals 25 to 26 for system 1 and XTBC2 Terminals 27 to 28 for system 2 Refer to Figure 4 on page 23 Figure 11 on page 41 and umt wiring diagram 38 FORM 150 72 614 ISSUE DATE 6 10 2014 Alarm Status Contacts Normally open contacts are available for each re frigerant system These normally open contacts close when the system 1s functioning normally The respec tive contacts will open when the unit is shut down on a unit fault or locked out on a system fault Field con nections are at XTBC2 Terminals 29 to 30 system 1 and Terminals 31 to 32 system 2 Remote Start Stop Contacts To remotely start and stop the chiller dry contacts can be wired across terminals 13 and 51 on Refer to Figure 4 on page 23 Figure 10 on page 40 and unit wiring diagram Remote Emergency Cutoff Immediate shutdown of the chiller can be accom plished by opening a field installed dry contact to break the electrical circuit between Terminals 5 to L on terminal block XTBC2 The unit 1s shipped with a fac tory jumper installed between Terminals 5 to L which must be removed if emergency shutdown contacts are installed Refer to Figure 10 on page 40 and unit wiring diagram Remote Temp Reset Input The Remote Temp Reset input allows reset of the chilled liquid setpoint by supplying a voltage or current signal field wiring should be connected to XTBCI Terminals A to A A deta
153. each system if CURRENT FEEDBACK ONE PER SYSTEM is pro grammed under the OPTIONS key Combined com pressor current for each system is displayed 109 SECTION 7 UNIT CONTROLS Oper Data Quick Reference List The following table is a quick reference list for infor mation available under the OPER DATA key Oper Data Key Leaving amp Chilled Liquid Temps 1 Ambient Air Temperature System 1 Discharge amp Suction Pressure System X Accumulated Hours System X Accumulated Starts Load and Unload Timers Cooling Demand Steps Return Chilled Liquid Control Only Temp Rate amp Temp Error Leaving Chilled Liquid Control Only Lead System Indicator Evaporator Heater Status Evaporator Water Pump Status Active Remote Control Current Feedback One Per Unit System X Compressors Status System X Run Time Sys X LLSV amp HGSV Status System X Condenser Fan Stage Current Feedback One Per System Block of information repeats for each system pisses FIGURE 25 OPERATION DATA 110 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 Print Key The PRINT key allows the operator to obtain a printout of real time system operating data or a history print out of system data at the instant of the fault on the last six faults which occurred
154. ed by others in the power wiring which must comply with the National Electrical Code and or local codes Single Point Circuit Breaker A unit mounted circuit breaker with external lockable handle in compliance with N E C Article 440 14 can be supplied to 1solate the power voltage for servicing This option includes the Single Point Power connection Control Transformer Converts unit power voltage to 115 1 60 2 0 or 3 0 KVA capacity Factory mounting includes primary and secondary wiring between the transformer and the control panel Factory mounted Control Options Ambient Kit Low Units will operate to 25 F 3 9 C This accessory in cludes all necessary components to permit chiller opera tion to 0 F 18 C This option includes the Discharge Pressure Transducer Readout Capability option For proper head pressure control in applications below 30 F 1 C where wind gusts may exceed 5 mph it is recom mended that Optional Condenser Louvered Enclosure Panels also be included Factory mounted High Ambient Kit With Sunshield Allows units to operate when the ambient temperature is above 115 F 46 C Includes sun shield panels and discharge pressure transducers Language LCD and Keypad Display Spanish French German and Italian unit LCD con trols and keypad display available Standard language is English 18 FORM 150 72 614 ISSUE DATE 6 10 2014 Compressor Piping Evaporator Option
155. ence timer will be initiated to prevent multiple compressors from turning ON 142 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 If after 60 seconds of run time the leaving chilled liq uid temperature is still above the Setpoint High Limit the next compressor in sequence will be energized Additional compressors will be energized at a rate of once every 60 seconds if the chilled liquid temperature remains above the Setpoint High Limit and the chilled liquid temperature is dropping less than 3 F min The lag system will not be allowed to start a compressor until the lead system has run for 5 minutes If the chilled liquid temperature falls below the Set point High Limit but is greater than the Setpoint Low Limit loading and unloading do not occur This area of control is called the control range If the chilled liquid temperature drops to between Set point Low Limit and 0 5 F 0 28 C below the Set point Low Limit unloading a compressor turns OFF occurs at a rate of 1 every 30 seconds If the chilled liquid temperature falls to a value greater than 0 5 F 0 28 C below the Setpoint Low Limit but not greater than 1 5 F 0 83 C below the Setpoint Low Limit unloading occurs at a rate of 20 seconds If the chilled liquid temperature falls to a value greater than 1 5 F 0 83 C below the Setpoint Low Limit unloading oc curs at a rate of 10 seconds If the chilled liquid tem perature falls below 1 F above the low
156. eptions when the suc tion pressure is permitted to temporarily drop below the cutout point Details are explained under the topic of SYSTEM SAFETIES JOHNSON CONTROLS SECTION 7 UNIT CONTROLS LOW AMBIENT TEMP CUTOUT 25 00 The LOW AMBIENT TEMP CUTOUT allows user to select the chiller outside ambient temperature cutout point If the ambient falls below this point the chiller will shut down Restart can occur when temperature rises 2 F 1 11 C above the cutout setpoint LEAVING LIQUID TEMP CUTOUT 36 0 F The LEAVING LIQUID TEMP CUTOUT protects the chiller from an evaporator freeze up Anytime the leav ing chilled liquid temperature drops to the cutout point the chiller shuts down Restart will be permitted when the leaving chilled liquid temperature rises 2 F 1 11 C above the cutout setpoint When water cooling mode is programmed OPTIONS key the value is fixed at 36 0 F 2 22 C and cannot be changed Glycol cooling mode can be programmed to values listed in Table 12 on page 120 ANTI SEC TIMER 600 The programmable anti recycle timer assures that systems do not short cycle and the compressor mo tors have sufficient time to dissipate heat after a start This timer is programmable under the PROGRAM key between 300 and 600 seconds Whenever possible to reduce cycling and motor heating the anti recycle timer should be adjusted as high as possible The pro
157. er TB10 7 5 5 2 Hot Gas Bypass Valve Evaporator Heater SYS 1 Alarm JOHNSON CONTROLS SECTION 9 SERVICE AND TROUBLESHOOTING TABLE 26 ANALOG INPUTS SYS 1 Suction Transducer Or SYS 1 Low Pressure Switch Unit Type Chiller NO Jumper J11 12 to 24 VDC YCUL Condensing Unit Jumper J11 12 to 24 VDC Do NOT Use J11 12 SYS 1 Discharge Pressure Transducer Optional Ambient Air Temp Sensor Leaving Chilled Liquid Temp Sensor Return Chilled Liquid Temp Sensor SYS 2 Suction Pressure Transducer Or SYS 2 Low Pressure Switch SYS 2 Discharge Pressure Transducer 4911 Optional 47 12 Unit SYS 1 Voltage J9 12 SYS 2 Voltage J11 11 Remote Temperature Reset TABLE 27 ANALOG OUTPUTS N A Not Applicable 153 SECTION 9 SERVICE AND TROUBLESHOOTING FORM 150 72 614 ISSUE DATE 6 10 2014 BOARD J15 TEC E TB1 erp t3 prre Li Ex J3 TB8 e J5 iE im i i LEN IPU TB9 anti JC 4 e 414 J13 LD12721 FIGURE 32 MICROBOARD LAYOUT 154 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 CHECKING INPUTS AND OUTPUTS Digital Inputs Refer to the unit wiring diagram digit
158. er to the display sensors and trans ducers DISPLAY The 40 Character Display 2 lines of 20 characters is a liquid crystal display used for displaying system pa rameters and operator messages When a key is pressed such as the OPER DATA key system parameters will be displayed and will remain on the display until another key is pressed The system parameters can be scrolled with the use of 1 UP and DOWN arrow keys The display will update all information at a rate of about 1 a second Display Messages may show characters indicating greater than gt or less than lt These characters indicate the actual values are greater than or less than the limit values which are being displayed 100 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 KEYPAD The 12 button non tactile keypad allows the user to retrieve vitals system parameters such as system pres sures temperatures compressor running times and starts option information on the chiller and system setpoints This data is useful for monitoring chiller op eration diagnosing potential problems troubleshoot ing and commissioning the chiller It is essential the user become familiar with the use of the keypad and display This will allow the user to make full use of the capabilities and diagnostic features available UNIT SWITCH A unit ON OFF switch is just underneath the keypad This switch allows the operator to turn the entire unit OFF if des
159. erence can be tolerated JOHNSON CONTROLS 4 Bolt or anchor all isolators to supporting structure utilizing base thru holes Remove top bolt and top washer Place equip ment on top of isolators so that mounting holes in equipment or base line up with threaded hole Reinstall top bolt and washer and tighten down Installation is complete TOP BOLT TOP WASHER 6 SECTION D D LD13762B 91 92 THIS PAGE INTENTIONALLY LEFT BLANK FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 6 COMMISSIONING Commissioning of this unit should only be carried out by Johnson Controls Au thorized personnel AN CAUTION Commissioning personnel should be thoroughly famil iar with the information contained in this literature in addition to this section Perform the commissioning using the detailed checks outlined Refer to Equipment Pre Startup And Startup Checklist Form 150 72 CL1 as the commissioning procedure is carried out PREPARATION POWER OFF The following basic checks should be made with the customer power to the unit switched OFF Inspection Inspect unit for installation damage If found take ac tion and or repair as appropriate Refrigerant Charge Packaged units are normally shipped as standard with a full refrigerant operating charge Check that refrig era
160. ers excellent heat transfer performance with a compact size and low weight re ducing structural steel requirements on the job site The heat exchanger is manufactured in a precisely con trolled vacuum brazing process that allows the filler material to form a brazed joint at every contact point between the plates creating complex channels The ar rangement is similar to older plate and frame technol ogy but without gaskets and frame parts Water inlet and outlet connections are grooved for compatibility with field supplied ANSI AWWA C 606 couplings 15 SECTION 2 PRODUCT DESCRIPTION The evaporator is equipped with a thermostat con trolled heater The heater provides freeze protection for the evaporator down to 20 F 29 C ambient The evaporator is covered with 3 4 flexible closed cell foam insulation K 0 25 A 1 16 1 6mm mesh wye strainer is provided as standard for installation upstream of the heat exchang er to prevent clogging from water system debris Condenser Microchannel Condenser MCHX Condensers are made of a single material to avoid galvanic corrosion due to dissimilar metals MCHX and headers are brazed as one piece Integral sub cooling is included The design working pressure of the MCHX is 650 PSIG 45 bar MCHX Condenser is easily washable with clear water Fans The condenser fans are composed of corrosion resis tant aluminum hub and glass fiber reinforced poly propylen
161. es a hazard which could lead to damage to the machine damage to other equipment and or envi ronmental pollution Usually an instruc tion will be given together with a brief explanation and the possible result of ignoring the instruction A NOTE is used to highlight additional information which may be helpful to you but where there are no special safety implications NOTE FORM 150 72 614 ISSUE DATE 6 10 2014 The contents of this manual include suggested best working practices and procedures These are issued for guidance only and they do not take precedence over the above stated individual responsibility and or local safety regulations This manual and any other document supplied with the unit are the property of Johnson Controls which re serves all rights They may not be reproduced in whole or in part without prior written authorization from an authorized Johnson Controls representative MISUSE OF EQUIPMENT Suitability for Application The unit is intended for cooling water or glycol solu tions and 15 not suitable for purposes other than those specified in these instructions Any use of the equipment other than its intended use or operation of the equip ment contrary to the relevant procedures may result in injury to the operator or damage to the equipment The unit must not be operated outside the design pa rameters specified in this manual Structural Support Structural support of the unit mus
162. esistant duralene com for reference only pound as standard Also available in other materi als such as natural rubber extreme high tempera 6 Hardware zinc electroplated ture silicone high damped silicone nitrile and EDPM MOUNT TYPE w HF aD BT 5 16 18 UNC X 3 4 3 8 16 UNC X 1 1 2 13 UNC X 1 1 2 13 UNC X 1 MODEL MODEL NUMBER CAPACITY DEFLECTION NUMBER RD2 LIGHT BLUE WR 5 RD3 Brown WR RD2 BROWN WR RD3 Brick Red WR RD2 BRICK RED WR RD3 Lime WR RD 2 LIME WR Charcoal WR MODEL MODEL NUMBER CAPACITY DEFLECTION NUMBER RD2 LIGHT BLUE WR RD4 BROWN WR RD2 BROWN WR RD4 BRICK RED WR RD2 BRICK RED WR RD4 LIME WR RD 2 LIME WR RD4 CHARCOAL WR RD2 CHARCOAL WR 90 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA INSTALLATION OF NEOPRENE VIBRATION ISOLATORS 1 Read instructions in their entirety before begin ning installation Isolators are shipped fully assembled and are to be positioned in accordance with the submittal draw ings or as otherwise recommended Set isolators on floor housekeeping pad or sub base ensuring that all isolator centerlines match the equipment mounting holes The VMC group recommends that the isolator base be in stalled on a level surface Shim or grout as re quired leveling all isolator bases to the same elevation 1 32 inch maximum diff
163. essors which Chilled Liquid can only operate in one direction Failure to observe this will lead to compressor failure Ambient Control Local Remote Mode Turn system 1 OFF and system 2 ON refer to Op tion 2 System Switches two system units only under UNIT KEYS for more information on sys tem switches Control Mode Display Units Lead Lag Control Place the Unit Switch in the control panel to the ON Fan Control position Manual Override NOTE The chilled liquid setpoint may need to be temporarily lowered to ensure all compres Sors cycle ON As each compressor cycles ON ensure that the Unit Type discharge pressure rises and the suction pressure Refrigerant Type decreases If this does not occur the compressor being tested is operating in the reverse direction and Expansion Valve Type must be corrected After verifying proper co pressor COOLING SETPOINTS rotation turn the Unit Switch to OFF Cooling Setpoint Current Feedback Soft Start Range D CHECKING SUPERHEAT AND SUBCOOLING EMS PWM Max Setpoint The subcooling temperature of each system can be PROGRAM calculated by recording the temperature of the liquid line at the outlet of the condenser and subtracting it from the Discharge Pressure Cutout liquid line saturation temperature at the liquid stop valve Suct Pressure Cutout liquid line saturation temp is converted from a tempera ture pr
164. essure chart Low Amb Temp Cutout a Example Leaving Liquid Temp Cutout Liquid line pressure Anti Recycle Time 325 PSIG converted to temp 101 F minus liquid line temp 83 F Subcooling 18 F Fan Differential OFF Pressure The subcooling should be adjusted to 18 F 8 C at Total of Compressors design conditions Number of Fans System 1 Record the liquid line pressure and its corre Unit Sys Voltage sponding temperature liquid line temperature and subcooling beloW 1 2 SYS 1 SYS2 Line Press lt PSIG 4 Put the unit into Service Mode see SERVICE Saturated Temp F MODE in Section 9 of Form 150 72 ICOM6 and Lig cycle each condenser fan to ensure proper rota Subcooling F Fan Control ON Pressure Unit ID All Models Viewable Only After the subcooling is verified the suction super heatshould be checked The superheat should be Priorto this step turn system 2 OFF if applicable checked only after steady state operation of the chiller refer to Option 2 under UNIT KEYS on page 2 for has been established the leaving water temperature more information on system switches Connect a has been pulled down to the required leaving water manifold gauge to system 1 suction and discharge temperature and the unit is running in a fully loaded service valves condition Correct superhe
165. grammable anti recycle timer starts the timer when the first compressor in a system starts The timer begins to count down If all the compressors in the circuit cycle OFF a compressor within the circuit will not be per mitted to start until the anti recycle timer has timed out If the lead system has run for less than 5 minutes 3 times in a row the anti recycle timer will be extended to 10 minutes if currently programmed for less than 10 minutes FAN CONTROL ON PRESSURE PSIG The Fan Control On Pressure is programmed sure value that is used to stage the condenser fans on in relation to discharge pressure Refer to Standard Condenser Fan Control on page 146 in SECTION 7 UNIT CONTROLS and Table 21 on page 147 and Table 22 on page 148 119 SECTION 7 UNIT CONTROLS DIFFERENTIAL OFF PRESSURE XXX PSIG The Fan Differential Off Pressure is the programmed differential pressure value that is used to stage the con denser fans OFF in relation to discharge pressure Re fer to Standard Condenser Fan Control on page 146 in SECTION 8 UNIT OPERATION and Table 21 on page 147 and Table 22 on page 148 TOTAL NUMBER OF COMPRESSORS 6 The TOTAL NUMBER OF COMPRESSORS is the total quantity of compressors in the chiller and deter mines the stages of cooling available Note in Table 12 the chiller may have single or dual systems Single system units can have 2 or 3 compressors while dual sy
166. h occurred The information is stored at the instant of the fault re gardless of whether the fault caused a lockout to occur The information 15 also not affected by power failures long term internal memory battery backup is built into the circuit board or manual resetting of a fault lock out When the HISTORY key is pressed a printout is trans mitted of all system operating conditions which were stored at the instant the fault occurred for each of the 9 Safety Shutdowns buffers The printout will begin with the most recent fault which occurred The most recent fault will always be stored as Safety Shutdown No 1 identically formatted fault information will then be printed for the remaining safety shutdowns Information contained in the Safety Shutdown buffers 15 very important when attempting to troubleshoot a system problem This data reflects the system condi tions at the instant the fault occurred and often reveals other system conditions which actually caused the safety threshold to be exceeded The history printout is similar to the operational data printout shown in the previous section The differences are in the header and the schedule information The daily schedule is not printed in a history print One example history buffer printout 1s shown follow ing The data part of the printout will be exactly the same as the operational data print so it is not repeated here The difference 15 that the Daily Schedule is not pr
167. has been ap plied such as start up commissioning When a com pressor starts internal timers limit the minimum time before another compressor can start to 1 minute 1 For the chiller system to run the Flow Switch must be closed any remote cycling contacts must be closed the Daily Schedule must not be sched uling the chiller OFF and temperature demand must be present 2 When power 15 applied to the system micro processor will start a 2 minute timer This 15 the same timer that prevents an instantaneous start af ter a power failure 3 At the end of the 2 minute timer the micropro cessor will check for cooling demand If all con ditions allow for start a compressor on the lead system will start and the liquid line solenoid will open Coincident with the start the anti coinci dent timer will be set and begin counting down ward from 60 seconds to 0 seconds If the unit is programmed for Auto Lead Lag the system with the shortest average run time of the compressors will be assigned as the lead sys tem A new lead lag assignment is made whenever all systems shut down 4 Several seconds after the compressor starts that systems first condenser fan will be cycled ON outdoor air temperature more than 25 F 4 C or discharge pressure See Standard Condenser Fan Control on page 146 for details concerning condenser fan cycling 5 After 1 minute of compressor run time the next compressor in se
168. hat must be observed DO NOT use coil cleaners or any chemical on a MCHX This can cause severe damage to the coils DO NOT use a pressure washer to clean While it 15 possible to clean a the MCHX with a pressure washer it s also possible to de stroy it DO NOT contact the MCHX with a hard surface such as a hose nozzle or metal vacuum nozzle or any other tool Follow the three steps below for cleaning the MCHX 1 Remove surface debris such as dirt leaves insects fibers etc with a vacuum cleaner having a soft at tachment rather than a metal tube Compressed air blown from the inside out can also be used When brushing debris off the face of the MCHX a soft bristle not wire brush can be used Do not scrape the MCHX with the vacuum nozzle air nozzle or any other tool 163 SECTION 10 MAINTENANCE 2 Rinse the MCHX with tap water Do not use MCHX cleaners Rinse the coil from the inside out running water through every passage in the heat exchanger surface until it is clean Use a gen tle spray from a spray nozzle with a plastic end or put your finger on the end of the spray nozzle to reduce impact and provide a gentle spray 3 Because of the fin geometry the condenser retain water more than tube and fin style It is generally recommended to blow or vacuum out the rinse water from the MCHX to speed dry ing and prevent water pooling OPERATING PARAMETERS Regular checks of the sys
169. hole The lugs should be attached to the cables chains using shackles or safety hooks CORRECT INCORRECT 17 LIFTING HOLE IN BASE FRAME LOCKING PIN LIFTING HOLE IN BASE FRAME LUG LOCKING JOHNSON CONTROLS SECTION 3 HANDLING AND STORAGE LIFTING USING SHACKLES The shackles should be inserted into the respective holes in the base frame and secured from the inside Use spreader bars to avoid lifting chains hitting the chiller Various methods of spreader bar arrangements may be used keeping in mind the intent is to keep the unit stable and to keep the chains from hitting the chill er and causing damage Lifting Instructions are placed on a label on the chiller and on the shipping bag 33 SECTION 3 HANDLING AND STORAGE FORM 150 72 614 ISSUE DATE 6 10 2014 Failure to follow these instructions could result in death serious injury or equipment damage Follow all warnings and instructions the unit s Manual s E cuum T ae Instrukcja instalacji dia Installatiehandieiding Manuel d installation technika montera voor de vakman monteur pour le specialiste monteur p f r installat r mont r f r die Fachkraft Monteur C3 sara ei wenieo contratota 3STARSERARD 1 Follow applicable regulations and safety practices during rigging and lifting 2 Prepare and fo
170. ial Off Pressure High Limit will be lowered reduced to prevent going below 235 PSIG based on where the fan control On Pressure is programmed 120 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 Depending on the option the trip voltage for a specific system or unit high current trip can be programmed It also calibrates the current read out under the OPER DATA key The approximate programmed value is calculated using the following formulas System Trip Volts For individual system high current trip programming on chillers Add the sum of the compressor and fan RLA s in the system Multiply the sum by 1 25 Divide by 225A The resulting voltage is value that should programmed For example if fan and compressor RLA s total 100A 5V x 100A 625VA _ 225A ey 2 8V 1 25 225A The programmed value will be 2 8V A similar calcula tion and programming will be necessary for the other system in a 2 system chiller JOHNSON CONTROLS SECTION 7 UNIT CONTROLS Unit Trip Volts For total chiller high current trip programming on 460VAC chillers Add the sum of all the compressors and fan RLA s in the chiller Multiply the sum by 1 25 Divide by 225A The resulting voltage is the value that should be programmed For example if fan and compressor RLA s total 180A 5V x 180A _ 1125VA_ 225A 1 25 295A 5 0V The programmed value will be 5 0V REMOTE UNIT ID
171. ications Chiller data that can be read and modified using spe cific BACnet or Modbus Register Addresses and the data associated with the addresses is outlined in the following description Analog Write Points This data can be read and modified using a BACnet or Modbus network connection The Modbus Register Address for these points 15 1025 AV Binary Write Points This data can be read and modified using a BACnet or Modbus network connection The Modbus Register Address for these points is 1537 BV JOHNSON CONTROLS Analog Read Only Points This data can be read using a BACnet or Modbus net work connection and can NOT be modified using this connection The Modbus Register Address for these points is 513 Al Binary Monitor Only Points This data can be read using a BACnet or Modbus net work connection and can NOT be modified using this connection The Modbus Register Address for these points is 1281 BI Refer to Table 16 on page 133 for complete list of BACnet and Modbus registers The latest data map information is listed on the Johnson Controls Equipment In tegration website NOTE 131 FORM 150 72 614 SECTION 7 UNIT CONTROLS ISSUE DATE 6 10 2014 Communications Data Map Notes TABLE 15 REAL TIME ERROR NUMBERS column CFM Cubic Feet per Minute kPa Kilopascals PPM Part per Mil See Table 16 ERROR NUMBER DESCRIPTION 1 I
172. ictions may compromise minimum clearances indicated below resulting in unpredictable airflow patterns and possible diminished performance Johnson Controls s unit controls will optimize operation without nuisance high pressure safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 2m 6 rear to wall 2m 6 control panel to end wall 1 2m 40 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit JOHNSON CONTROLS 77 SECTION 5 TECHNICAL DATA FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 DIMENSIONS YLAA0300HE YLAA0360SE YLAA0400SE FIVE FAN UNITS 2393 OVERALL HEIGHT 2251 FRAME HEIGHT NOTE 2243 FRAME WIDTI 2255 OVERALL WIDTI 2077 ORIGIN 15 875 DIA MOUNTING HOLES TYP 1753 1770 588 3614 9 4237 OVERALL LENGTI 100 INLET POWER ENTRY 330 WIDE X 180 HIGH gt n cal 1102 M CONTROL PANEL BOTTOM DETAIL
173. iginal program will still be active When an error occurs assure the correct Flash Card was utilized Incorrect chiller soft 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 18 Remote Temperature Reset REMOTE TEMP RESET INPUT Remote Temp Reset input selection is programmable according to the type of input utilized The following options are available DISABLED default 0 0 10 0 DC e 2 0 10 0V DC e 0 0 20 0mA 4 0 20 0 mA The options display message for Remote Temp Reset Input only appears if the Temp Reset Option is enabled under Ser vice Mode The option must be enabled under the Service Mode for the Remote Temperature Reset to operate Option 19 Pump Control Pump Control is utilized to operate the optional on board pump kit or to control an external pump through dry contacts 23 and 24 on Terminal Block XTBC2 To use this option the following selection should be made in the Service Mode JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 YORK HYDRO PUMPS 1 When YORK HYDRO KIT PUMPS 1 controls will be closed to run the pumps whenever any one of the following conditions are true Low Leaving Chilled Liquid Fault compressor is running Daily Schedule is ON and Remote Stop is closed Even if one of the above con
174. iled explanation is provided in SECTION 7 UNIT CONTROLS Refer to Figure 3 on page 22 Figure 4 on page 23 and unit wiring diagram Load Limit Input Load limiting is a feature that prevents the unit from loading beyond a desired value The unit can be load limited either 3396 4096 5096 6690 or 8096 depend ing on the number of compressors on unit The field connections are wired to XTBCI Terminals 13 to 21 and work in conjunction with the PWM inputs A de tailed explanation is provided in SECTION 7 UNIT CONTROLS Refer to Figure 4 on page 23 Figure 10 on page 40 and unit wiring diagram When using the Load Limit feature the PWM feature will not function SIMUL TANEOUS OPERATION OF LOAD LIMITING AND TEMPERATURE RESET PWM INPUT CANNOT BE DONE JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 4 INSTALLATION SINGLE POINT SUPPLY CONNECTION TERMINAL BLOCK NON FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER Power Panel Control Panel 414 rT13 Terminal Block MICROPANEL Disconnect SW or Circuit Breaker Flow Switch 1L1 1L2 113 c aa B amp i 1 aE XTBC2 10 Micropanel Power Supply if 7 Field Provided 110 1 50 11 E Control Transformer not supplied i eer Field Field supplied control power
175. ined in the N E C 100 and is in tended for isolating the unit for the available pow er supply to perform maintenance and trouble shooting This disconnect is not intended to be a Load Break Device Field Wiring by others which complies to the Na tional Electrical Code amp Local Codes VOLTAGE CODE 50 380 415 3 50 FACTORY MOUNTED CIRCUIT BREAKER FULL LOAD AMPS HERTZ MAXIMUM MINIMUM CIRCUIT AMPACITY MINIMUM MINIMUM NON FUSED RATED LOAD AMPS SINGLE POINT WIRING UNIT MOUNTED SERVICE NON FUSED DISCONNECT SWITCH LOCKED ROTOR AMPS 53 54 THIS PAGE INTENTIONALLY LEFT BLANK FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA ELECTRICAL NOTES AND LEGEND NOT FITTED ON REMOTE EVAP UNITS FAN OPTION ONLY KF FAN CONTACTOR LINE INCLUDING COIL SUPPRESSOR KFH FAN CONTACTOR HIGH SPEED INCLUDING COIL SUPPRESSOR KFL FAN CONTACTOR LOW SPEED INCLUDING COIL SUPPRESSOR KFOL FAN OVERLOAD dd COMPRESSOR CONTACTOR INCLUD ING COIL SUPPRESSOR E PUMP CONTACTOR PART INCLUDING COIL SUPPRESSOR COMPRESSOR MOTOR JOHNSON CONTROLS PWM PULSE WIDTH MODULATION TEMP RE SET or REMOTE UNLOAD 2nd STEP fesso O O oOo ___ XP PLUGS BETWEEN POW MICROBOARD SECTION XTBC TERMINAL BLOCK CUSTOMER XTBF TERMINAL BLOCK FACTORY YESV EVAPORATOR SOLENOID VALVE
176. ing WEIGH TRONIX for purchase information at WEIGH TRONIX 2320 Airport Blvd Santa Rosa CA 95402 Phone 1 800 982 6622 or 1 707 527 5555 International Orders Only The part number for the printer that is packaged spe cifically for YORK is P N 950915576 The cable to connect the printer can either be locally assembled from the parts listed or ordered directly from WEIGH TRONIX under part number 287 040018 Parts The following parts are required 1 WEIGH TRONIX model 1220 printer 2 Desk top calculator paper 2 25 5 7cm wide 3 Twisted Pair Shielded Cable minimum 3 conduc tor 18 AWG stranded 300V minimum insula tion 25 ft 7 62m maximum length 4 One 25 pin Cannon connector and shell 5 Cannon P N DB 25P connector or equivalent 6 Cannon P N DB C2 J9 shell JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 Assembly and Wiring All components should be assembled and wired as shown in Figure 34 Strip the outside insulation back several inches and individual wires about 3 8 9 5 mm to connect the cable at the Microboard Do not connect the shield at the printer end of the cable Chiller Microboard TB3 3 TXD TB3 2 CTS TB3 5 GND Shield connect shield to Pin 5 of the connector SECTION 9 SERVICE AND TROUBLESHOOTING Obtaining a Printout A printout is obtained by pressing the PRINT key on the keypad and then pressing either the OPER DATA key or HISTOR
177. inted in the history print and the header will be as follows ERNATIONAL CORPO UM L QU D CH LLER R 1 S S HUTDOWN NUMB Q 3 56PM 2 HIGH DSCH PRES EP 07 SHUTDOWN NO FAULTS SECTION 7 UNIT CONTROLS History Displays The HISTORY key gives the user access to many unit and system operating parameters at the time of a unit or system safety shutdown When the HISTORY key is pressed the following message is displayed DISPLAY DOWN SAFETY NO SHUT 1 1109 While this message is displayed the 1 UP arrow key can be used to select any of the six history buffers Buf fer number 1 is the most recent and buffer number 6 15 the oldest safety shutdown that was saved After selecting the shutdown number pressing the EN TER key displays the following message which shows when the shutdown occurred SHUTDOWN OCCURRED 03 56 PM 29 JAN 02 The 1 UP and DOWN arrow keys are used 10 scroll forward and backward through the history buffer to display the shutdown conditions stored at the instant the fault occurred The DOWN arrow key scrolls through the displays in the order they appear below UNIT FAULT LOW LIQUID TEMP Displays the type of fault that occurred UNIT LIQUID CHILLER Displays the type of chiller Liquid Condensing Unit or Heat Pump CHILLED LIQUID XXX XX Displays the chilled liquid typ
178. iquid temp cutout glycol only Micro panel setpoint range values improperly programmed Chilled liquid flow too low Defective LWT RWT sensor assure the sensor is properly installed in the bottom of the well with a generous amount of heat conductive compound Compressor internal motor protector MP open External overload tripped HPCO switch open Defective HPCO switch Defective CR relay Demand not great enough Defective water temperature Sensor Contactor Overload failure 4 Compressor failure Fouled evaporator surface Low suction pressure will be observed Improper flow through the evaporator Low refrigerant charge Low suction pressure will be observed SECTION 9 SERVICE AND TROUBLESHOOTING 1 Re program the leaving chilled liquid temp cutout Re adjust setpoint range Increase chilled liquid flow Refer to Operational Limitations on page 43 Compare sensor against a known good Temperature sensing device Refer to Table 29 on page 156 Verify refrigerant charge is not low Verify superheat setting of 10 F to 15 F 5 6 C to 8 3 Verify correct compressor rotation Verify compressor is not overloaded Determine cause and reset See High Press Disch Fault Replace HPCO switch Replace relay No problem Consult Installation Manual to aid in understanding compressor operation and capaci
179. ired The switch must be placed in the ON position for the chiller to operate BATTERY BACK UP The IPU II contains a Real Time Clock integrated cir cuit chip with an internal battery backup The purpose of this battery backup is to assure any programmed values setpoints clock cutouts etc are not lost dur ing a power failure regardless of the time involved in a power cut or shutdown period PROGRAMMING OF COMPRESSORS The total number of compressors is programmable un der the PROGRAM key Dual 2 system chillers can have 4 5 or 6 compressors JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 7 UNIT CONTROLS STATUS KEY Unit Status Pressing the STATUS key will enable the operator to determine current chiller operating status The messag es displayed will include running status cooling de mand fault status external cycling device status The display will be a single message relating to the highest priority message as determined by the microprocessor Status messages fall into the categories of General Sta tus and Fault Status The following General Safety and Warning messages are displayed when the STATUS key 15 pressed Fol lowing each displayed message is an explanation per taining to that particular message General Status Messages In the case of messages which apply to individual systems SYS 1 and SYS 2 messages will both be dis played and may be different In the c
180. ired leveling all isolator bases to the same elevation 1 4 inch maximum difference can be tolerated Bolt or anchor all isolators to supporting structure utilizing base slotted holes Place equipment on top of isolators making sure that mounting holes of the equipment line up with isolator positioning pin UPPER HOUSING 6 6 The adjustment process only begin after equipment or machine is at its full operating weight 7 Adjust each isolator in sequence by turning spring adjusting one full counterclockwise turn at a time Repeat this procedure on all isola tors one at a time 8 Continue adjusting each isolator until a minimum of 1 4 clearance is achieved between the lower housing and upper housing See drawing below 9 Fine adjust isolators to level equipment 10 Installation 15 complete EQUIPMENT POSITIONING PIN BASE p E LOWER HOUSING NON SKID ELASTOMERIC PAD 1 4 MIN 1 2 MAX JOHNSON CONTROLS LD13790 87 FORM 150 72 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 2 DEFLECTION ISOLATOR CROSS REFERENCE Y2RS 3 8 ue 63 4 4 1 2 LIMIT STOP amp NUT 8 3 8 OPER HEIGHT LD13761A 1 dimensions are in inches interpret per ANSI 4 springs are designed for 50 overload capac
181. l leaving one compressor running As the load increased the compressors would stage ON every 1 7 94 Also note that Table 19 on page 143 not only provides the formulas for the loading ON POINT and unload ing OFF POINT of the system the STEP is also shown in the table The STEP is the increment in the sequence of the capacity control scheme that can be viewed under the OPER DATA key Refer to Display Print Keys on page 107 for specific information on the OPER DATA key RETURN CHILLED LIQUID SYSTEM LEAD LAG AND COMPRESSOR SEQUENCING A Lead Lag option may be selected to help equalize average run hours between systems with 2 refriger ant systems This may be programmed under the OP TIONS key Auto Lead Lag of the 2 systems based on JOHNSON CONTROLS SECTION 8 UNIT OPERATION average run hours of the compressors in each system Manual Lead Lag selects specifically the sequence which the microprocessor starts the systems The microprocessor will sequence compressors load and unload systems according to Zable 20 on page 144 The microprocessor will lead lag compressors within each circuit to maximize individual compres sor run time for the purpose of lubrication It will also prevent the same compressor from starting 2 times in a row The microprocessor will not attempt to equalize run time on individual compressors within a system Each compressor in a system will be assigned an ar bitrary number
182. llow written rigging and lifting plan 3 Rigging must be directed by trained professional rigger 4 Spreader bars must be used and be long enough to prevent rigging from contacting unit 5 Use all and only designated lift points according to units manual s 6 Locate center of gravity through trial lifts to account for possible variations in unit configuration T Use rigging and lifting techniques that keep unit stable and level B Keep clear of unit when lifted Installationsguide Installationsanleitung no 1018119 FIGURE 7 WARNING Rigging and lifting should only be done by LIFTING WEIGHTS a professional rigger in accordance with a Refer to the unit late f it shippi ight written rigging and lifting plan The most 22 2 00 MN Note that weight may vary depending on unit config appropriaie and meod uration at the time of lifting See page 46 for further 34 will depend on job specific factors such as the rigging equipment available and site needs Therefore a professional rig ger must determine the rigging and lifting method to be used and it is beyond the scope of the manual to specify rigging and lifting details information regarding shipping and operating weights JOHNSON CONTROLS FORM 150 72 ICOM7 614 SECTION 4 INSTALLATION ISSUE DATE 6 10 2014 To ensure warranty coverage this equip ment must be commissioned and serviced by a
183. loads and unloads according to return chilled liquid temperature Both LEAVING and RETURN control are described in detail under Capacity Control on page 141 Remote Setpoint Control Pressing the COOLING SETPOINTS key a second time will display the remote setpoint and cooling range This display automatically updates about every 2 seconds Notice that these setpoints are not locally programmable but are controlled by a remote device such as an ISN control remote reset option board or remote PWM signal These setpoints would only be valid if the unit was operating in the REMOTE mode JOHNSON CONTROLS SECTION 7 UNIT CONTROLS The following messages illustrate both leaving chilled liquid control and return chilled liquid control respec tively 44 0 RANGE 2 0 leaving chilled liquid control REM SETP 44 0 RANGE 10 0 F return chilled liquid control The low limit high limit and default values for the keys under SETPOINTS are listed in Table 18 on page 143 Pressing the COOLING SETPOINTS a third time will bring up the display that allows the Maximum EMS PWM Temperature Reset to be programmed This message is shown below MAX EMS PWM RESET 2 The Temp Reset value is the maximum allowable re mote reset of the temperature setpoint The setpoint can be reset upwards by the use of an Energy Man agement System or fr
184. locally programmed values Option 6 Unit Control Mode CONTROL MODE RETURN LIQUID 24 FORM 150 72 614 ISSUE DATE 6 10 2014 Unit control is based on return chilled liquid temp Return Chilled Liquid Control can only be selected on units that have 4 to 6 compressors dual system units or CONTROL MODE LEAVING LIQUID Option 7 Display Units DISPLAY UNITS IMPERIAL This mode displays system operating values in Impe rial units of F or PSIG or DISPLAY 1 UNITS This mode displays system operating values in Scien tific International Units of C or barg Option 8 Lead Lag Type two system units only LEAD LAG CONTROL SYS 1 LEAD MANUAL SYS 1 selected as lead compressor SYS 1 lead option MUST be chosen if Hot Gas Bypass is installed or LEAD LAG CONTROL MANUAL SYS 2 LEAD SYS 2 selected as lead compressor CONTROL AUTOMATIC Lead lag between systems may be selected to help equalize average run hours between systems on chillers with 2 refrigerant systems Auto lead lag allows auto matic lead lag of the two systems based on an average run hours of the compressors in each system A new lead lag assignment is made whenever all compressors shut down The microprocessor will then assign the lead to the system with the shortest average run time JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6
185. low Switch Required Flow Switch With Extension Kit ASME Pressure Vessel Codes Vessel Codes PED Pressure Vessel Codes trs PIN 42 e Postcodes Special Hot Gas Bypass required jSpealQute _ ee ______________ jSpealQute SpecialQuote CrankcaseHeaterStandard _ Special Crankcase Heater required X 160 5 DWP Waterside jSpealQute X Standard Insulation __ D Double Thick Insulation Special Insulation required __ X NoFlangesrequired V Flanges required __ __ Flanges required __ X NoFlow Switch required __________ S __ Flow Switch Required __ Y Switch With Extension A Pressure Vessel Codes O E Pressure Vessel Codes 26 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 2 PRODUCT DESCRIPTION TABLE 1 COMPLETE PIN NUMBER DESCRIPTION CONT D FEATURE FEATURE DESCRIPTION OPTION OPTION DESCRIPTION EE T No Option required HEAT Special Quote X TEAO Fan Motors FANMOTORS UNE 47 Special Fan Motors required No Enclosure required Wire Full Unit Enc Panels factory Wire Full Unit Encl Panels field Wire Louvered Encl Panels factory ENCL Lo
186. low switch and extension pipe kit is not selected the field installed flow switch must be installed so that there is a straight horizontal run of at least 5 di ameters on each side of the switch Adjust the flow switch paddle to the size of the pipe in which it is to be installed see manufacturer s instructions fur nished with the switch The switch is to be wired to Terminals 13 and 14 of XTBCI located in the control panel as shown on the unit wiring diagram The Flow Switch MUST NOT be used to start and stop the chiller i e starting and stopping the chilled water pump It is intended only as a safety switch JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 PIPEWORK ARRANGEMENT The following are suggested pipework arrangements for single unit installations for multiple unit installa tions each unit should be piped as shown Recommendations of the Building Services Re search Association HL TI gt 1006596 ISOLATING VALVE NORMALLY OPEN ISOLATING VALVE NORMALLY CLOSED FLOW REGULATING VALVE gt lt gt lt SUE 7 FLOW MEASUREMENT DEVICE STRAINER PRESSURE TAPPING FLOW SWITCH LD06597A FLANGED CONNECTION 4b FIGURE 8 CHILLED LIQUID SYSTEM Fan Discharge Ducting The following duct work recommendations are intend ed to ensure satisfactory operation of the unit Failure to follow these recommendations could cause dam
187. m a leak for ex ample does pose a risk of asphyxiation in confined or enclosed spaces and attention should be given to good ventilation High Temperature and Pressure Cleaning High temperature and pressure cleaning methods e g steam cleaning should not be used on any part of the pressure system as this may cause operation of the pressure relief device s Detergents and solvents which may cause corrosion should also be avoided Emergency Shutdown In case of emergency the control panel is fitted with a Unit Switch to stop the unit in an emergency When operated it removes the low voltage 120VAC electri cal supply from the unit controller thus shutting down the unit 13 14 THIS PAGE INTENTIONALLY LEFT BLANK FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 2 PRODUCT DESCRIPTION INTRODUCTION YORK YLAA Air Cooled Scroll Chillers provide chilled water for all air conditioning applications us ing central station air handling or terminal units They are completely self contained and are designed for out door roof or ground level installation Each complete packaged unit includes hermetic scroll compressors a liquid cooler air cooled condenser a charge of Zero Ozone Depletion Potential Refrigerant 410 and a weather resistant microprocessor control center all mounted on a rugged steel base The units are completely assembled
188. n authorized Johnson Controls service mechanic or a qualified service WARNING J person experienced in chiller installation Installation must comply with all appli cable codes particularly in regard to elec trical wiring and other safety elements such as relief valves HP cutout settings design working pressures and ventilation requirements consistent with the amount and type of refrigerant charge Lethal voltages exist within the control panels Before servicing open and tag all disconnect switches INSTALLATION CHECKLIST The following items through 6 must be checked be fore placing the units in operation 1 Inspect the unit for shipping damage 2 Rig unit using spreader bars 3 Open the unit only to install water piping sys tem Do not remove protective covers from water connections until piping is ready for attachment Check water piping to ensure cleanliness 4 Pipe unit using good piping practice see ASHRAE handbook section 215 and 195 5 Check to see that wiring is tight and meets NEC and local codes 6 Check to see that the unit is installed and operated within limitations Refer Operational Limitations on page 43 STARTUP COMMISSIONING The following pages outline detailed procedures to be followed to install and start up the chiller LOCATION AND CLEARANCES Units are designed for outdoor installations on ground level rooftop or beside a building Location should be selected for mi
189. nd must be performed only by a qualified electrician Johnson Controls will NOT be responsible for damage problems resulting from improper connections to the controls or application of improper control signals Failure to follow this warn ing will void the manufacturer 5 warranty and cause serious damage to property or personal injury JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 OF THIS DOCUMENT In complying with Johnson Controls policy for contin uous product improvement the information contained in this document is subject to change without notice Johnson Controls makes no commitment to update or provide current information automatically to the man ual owner Updated manuals if applicable can be ob tained by contacting the nearest Johnson Controls Ser vice office or accessing the Johnson Controls QuickLIT website at http cgproducts johnsoncontrols com Operating service personnel maintain responsibility for the applicability of these documents to the equipment If there is any question regarding the applicability of these documents the technician should verify whether the equipment has been modified and if current litera ture 15 available from the owner of the equipment prior to performing any work on the chiller CHANGE BARS Revisions made to this document are indicated with a line along the left or right hand column in the area the revision was made These revisions are to
190. ndenser Ean Locations eene ci ea ved te dote dice ue eR 146 FIGURE 32 Microboard Layout rH i ee d e e oed 154 FIGURE 33 I O Board Relay Contact emere 158 FIGURE 34 Printer To Microboard Electrical 159 8 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 LIST OF TABLES TABLE 1 Complete Pin Number TABLE 2 Temperatures And TABLE 3 Ethylene And Propylene Glycol Correction TABLE 4 Physical Data English nee t ba ze ee La e ba qe e TABLE 5 Micropanel Power 5 TABLE 6 Voltage i tete S Tto fin dace e debt oic nd TABLE 7 Pump Electrical Data 50 2 TABLE 8 Electrical Data Without TABLE 9 Transformer Load e d eee eee sae e dee cut xe eda de TABLE 10 Winng L ugs next pee ue UAI TABLE 11 Cooling Setpoint Programmable Limits And TABLE
191. nections chilled water pump starter contacts alarm contacts compressor run status contacts PWM input and load limit input Refer to SECTION amp UNIT OP ERATION for a detailed description of operation con cerning aforementioned contacts and inputs RELIEF VALVES Relief valves are located on both the high and low pressure side of the piping High side relief valve pres sure setting is 650 PSIG Low side relief valve pressure setting is 450 PSIG HIGH PRESSURE CUTOUT A high pressure cutout is installed in the discharge pip ing of each system The cutout opens at 585 PSIG plus or minus 10 PSIG and closes at 440 PSIG plus or mi nus 25 PSIG Evaporator Pump Start Contacts Terminal block XTBC2 Terminals 23 110VAC to 24 are normally open contacts that can be used to switch field supplied power to provide a start signal to the evaporator pump contactor The contacts will be closed when any of the following conditions occur 1 Low Leaving Chilled Liquid Fault 2 Any compressor is running 3 Daily schedule is not programmed OFF and the Unit Switch is ON The pump will not run if the micro panel has been powered up for less than 30 seconds or if the pump has run in the last 30 seconds to prevent pump motor overheating Refer to Figure on page 41 and unit wiring diagram System Run Contacts Contacts are available to monitor system status Nor mally open auxiliary contacts from each compressor contactor ar
192. nimum sun exposure and to insure adequate supply of fresh air for the condenser The units must be installed with sufficient clearances for air entrance to the condenser coil for air discharge away from the condenser and for servicing access JOHNSON CONTROLS In installations where winter operation is intended and snow accumulations are expected additional height must be provided to ensure normal condenser air flow Clearances are listed in Figure 23 on page 83 Foundation The unit should be mounted on a flat and level founda tion floor or rooftop capable of supporting the entire operating weight of the equipment See Physical Data YLAA0180 YLAA0516 50Hz on page 46 for oper ating weight If the unit is elevated beyond the normal reach of service personnel a suitable catwalk must be capable of supporting service personnel their equip ment and the compressors Ground Level Locations Itis important that the units be installed on a substantial base that will not settle A one piece concrete slab with footers extended below the frost line is highly recom mended Additionally the slab should not be tied to the main building foundations as noise and vibration may be transmitted Mounting holes 5 8 dia are provided in the steel channel for bolting the unit to its foundation see Dimensions on page 76 For ground level installations precautions should be taken to protect the unit from tampering by or injury to unauth
193. nit is shut down on the daily schedule the chilled water pump contacts Terminals 23 and 24 of XTBC2 will close to start the pump when the daily schedule start time has been reached Once flow has been es tablished and the flow switch closes capacity control functions are initiated if the remote cycling contacts wired in series with the flow switch are closed It should be noted that the chilled water pump contacts Terminals 23 and 24 of XTBC2 are not required to be used to cycle the chilled water pump However in all cases the flow switch must be closed to allow unit operation The control system will evaluate the need for cooling by comparing the actual leaving or return chilled liq uid temperature to the desired setpoint and regulate the leaving or return chilled liquid temperature to meet that desired setpoint 141 SECTION 8 UNIT OPERATION SUCTION PRESSURE LIMIT CONTROLS The anticipatory controls are intended to prevent the unit from ever actually reaching a low pressure cut out Loading 15 prevented if the suction pressure drops below 1 15 x suction pressure cutout 1590 below the cutout Loading may reoccur after suction pressure rises above the unload point and a period of one min ute elapses This control is only operable if the optional suction pressure transducers are installed DISCHARGE PRESSURE LIMIT CONTROLS The discharge pressure limit controls unload a system before it reaches a safety limit due t
194. nit wiring diagram Pressure inputs are connected to the microboard on plugs J7 and J9 These analog inputs represent varying DC signals corre sponding to varying pressures All voltages are in ref erence to the unit case ground System 1 discharge and suction pressures will be con nected to J7 of the microboard System 2 discharge and suction pressure transducers will be connected to J9 of the microboard The discharge transducers are optional on all units If the discharge transducers are not installed no connec tions are made to the microboard and the discharge pressure readout on the display would be zero The suction pressure transducers are standard on all YLAA s The suction pressure transducers have a range of 0 to 400 PSIG The output will be linear from 0 5VDC to 4 5VDC over the 400 PSIG 27 5 barg range The discharge transducers have a range from 0 to 650 PSIG The output will be linear from 0 5VDC to 4 5 VDC over the 600 PSIG 41 25 barg range Fol lowing is the formula that can be used to verify the voltage output of the transducer All voltage reading are in reference to ground unit case JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 TABLE 30 PRESSURE TRANSDUCERS 0 400 PSIG SUCTION 0 600 PSIG DISCHARGE PRESSURE PRESSURE TRANSDUCER TRANSDUCER PRESSURE VOLTAGE PRESSURE VOLTAGE PSIG VDC PSIG VDC RED WIRE 5V BLACK WIRE 0 WHITE GREEN WIRE SIGNAL
195. ns is present in the each refrigerant system Oil levels in the oil equal izing line sight glass should be between the bottom and the middle of the sight glass with the system OFF High oil levels may cause excessive oil carryover in the system High oil concentration in the system may cause nuisance trips resulting from incorrect readings on the level sensor and temperature sensors Tempera ture sensor errors may result in poor liquid control and resultant liquid overfeed and subsequent damage to the compressor While running a visible sign of oil splash ing in the sight glass is normal Fans Check that all fans are free to rotate and are not dam aged Ensure blades are at the same height when ro tated Ensure fan guards are securely fixed Isolation Protection Verify all sources of electrical supply to the unit are taken from a single point of isolation Check that the maximum recommended fuse sizes given in SECTION 5 TECHNICAL DATA has not been exceeded Control Panel Check the panel to see that it is free of foreign materi als wire metal chips etc and clean out if required Power Connections Check that the customer power cables are connected correctly to the terminal blocks or optional circuit breaker Ensure that connections of power cables with in the panels to the circuit breaker or terminal blocks are tight Grounding Verify that the unit s protective ground terminal s are properly connected to
196. nt pressure is present in both systems and that no leaks are apparent If no pressure is present a leak test must be undertaken the leak s located and repaired Remote systems and units are supplied with a nitrogen holding charge These systems must be evacuated with a suitable vacuum pump recovery unit as appropriate to below 500 microns Do not liquid charge with static water in the cooler Care must also be taken to liquid charge slowly to avoid excessive thermal stress at the charging point Once the vacuum is broken charge into the condenser coils with the full operating charge as given in SEC TION 5 TECHNICAL DATA Service and Oil Line Valves Open each compressor suction economizer and dis charge service valve If valves are of the back seat type open them fully counterclockwise then close one turn of the stem to ensure operating pressure is fed to pressure transducers Open the liquid line service valve and oil return line ball valve fully in each system JOHNSON CONTROLS Compressor Oil To add oil to a circuit connect a Johnson Controls hand oil pump Part No 470 10654 000 to the 1 4 oil charging connection on the compressors with a length of clean hose or copper line but do not tighten the flare nut Using clean oil of the correct type V oil pump oil until all air has been purged from the hose then tighten the nut Stroke the oil pump to add oil to the oil system Approximately 1 8 to 2 3 gallo
197. ntrol mode has been pro grammed for RETURN LIQUID control the message below would be displayed in place of the previous message When in leaving chilled liquid temperature control the microprocessor will attempt to control the leaving water temperature within the temperature range of the setpoint or the range In the above example control will be in the range of 43 to 47 F Return Chilled Liquid Control SETPOINT 45 0 XE RANGE 10 0 In return chilled liquid control range longer has F but only a F RANGE setpoint This indicates that the setpoint is not centered within the RANGE but could be described as the bottom of the control range A listing of the limits and the pro grammable values for the COOLING SETPOINTS are shown in Table 18 on page 143 The SETPOINT and RANGE displays just described were based on LOCAL control If the unit was pro grammed for REMOTE control under the OPTIONS key the above programmed setpoints would have no effect When in return chilled liquid temperature control the microprocessor will turn all compressors OFF at set point and will turn compressors ON as return chilled liquid temperature rises All compressors will be on at setpoint plus the range If the range equals the tem perature drop across the evaporator when fully loaded the leaving chilled liquid temperature will remain near the setpoint plus or minus a few degrees as the chiller
198. o high load or dirty condenser coils The microprocessor monitors dis charge pressure and unloads a system if fully loaded by one compressor when discharge pressure exceeds the programmed cutout minus 10 PSIG 0 69 barg Reloading will occur when the discharge pressure on the affected system drops to 85 of the unload pres sure and 10 minutes have elapsed This control is only applicable if optional discharge pressure transducers are installed LEAVING CHILLED LIQUID CONTROL The setpoint when programmed for Leaving Chilled Liquid Control is the temperature the unit will control to within plus or minus the control cooling range The Setpoint High Limit is the Setpoint plus the Cooling Range The Setpoint Low Limit is the Setpoint minus the Cooling Range Figure 30 below should be used to aid in understanding the following description of Leav ing Chilled Liquid Control 30 sec Contol Range 60 sec unloading no compressor staging loading LWT 44 0 F 46 0 F 48 0 F 6 7 C 7 8 C 8 9 C Low Limit Setpoint High Limit Leaving Water Temp Control Compressor Staging Setpoint 46 0 F 7 8 Range 2 F 1 1 LD14404 FIGURE 29 LEAVING WATER TEMPERATURE CONTROL EXAMPLE If the leaving chilled liquid temperature is above the Setpoint High Limit the lead compressor on the lead system will be energized along with the liquid line so lenoid Upon energizing any compressor the 60 sec ond Anti Coincid
199. om the Temperature Reset Op tion Board See Remote BAS EMS Temperature Reset Using A Voltage Or Current Signal on page 150 for a detailed explanation of this feature As with the other setpoints the 1 Up arrow and Down arrow keys are used to change the Temp Reset value After using the 1 UP and DOWN arrows to adjust to the desired setpoint the ENTER ADV key must be pressed to enter this number into memory SCHEDULE ADVANCE DAY KEY The SCHEDULE 15 a seven day daily schedule that allows one start stop time per day The schedule can be programmed Monday through Sunday with an al ternate holiday schedule available If no start stop times are programmed the unit will run on demand providing the chiller is not shut off on a unit or system shutdown The daily schedule is considered not pro grammed when the times in the schedule are all zeros 00 00 AM To set the schedule press the SCHEDULE ADVANCE DAY key The display will immediately show the fol lowing display 117 SECTION 7 UNIT CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 TABLE 11 COOLING SETPOINT PROGRAMMABLE LIMITS AND DEFAULTS SETPOINT KEY MODE _ LOWLIMIT HIGH LIMIT DEFAULT WATER COOLING 70 0 21 1 LEAVING CHILLED LIQUID SETPOINT GLYCOL COOLING 70 0 21 1 LEAVING CHILLED LIQUID CONTROL RANGE 2 5 1 4 WATER COOLING RETURNED CHILLED LIQUID SETPOINT 70 0 21 1
200. on measurements for each isolator Sample Isolator Location Drawings See Figure 22 below for sample printouts supplied in the isolator package and in the chiller panel literature packets UNIT SHIPPING WEIGHT Display on unit data nameplate NM 2R 2032 4480 R2 Top View OPERATING WEIGHT VENDOR NUMBER M LBS KG ND D Yellow 1092 495 3 19 5 495 3 86 86 2206 2 ND D Yellow 1406 637 8 96 1 2440 9 1 36 34 5 ND D Yellow 1015 460 4 96 1 2440 9 86 86 2206 2 ND D Yellow 1304 591 5 FIGURE 22 SAMPLE PRINTOUT SUPPLIED IN THE ISOLATOR PACKAGE AND IN THE CHILLER PANEL LITERATURE PACKET 82 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 CLEARANCES See Figure 23 below for minimum clearances for all YLAA units SECTION 5 TECHNICAL DATA EE UE SE 48 1 3 m 72 2 ZEE e ue ae vi 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 FIGURE 23 UNIT CLEARANCES ALL MODELS JOHNSON CONTROLS 83 FORM 150 72 614 SECTION 5 TECHNICAL DATA ISSUE DATE 6 10 2014 ISOLATOR LOCATIONS FOUR FAN ISOLATOR LOCATIONS 1 4 36 4 1 85 4 2169
201. on the unit An optional printer is required for the printout Operating Data Printout Pressing the PRINT key and then OPER DATA key allows the operator to obtain a printout of current sys tem operating parameters When the OPER DATA key is pressed a snapshot will be taken of system operat ing conditions and panel programming selections This data will be temporarily stored in memory and trans mission of this data will begin to the printer A sample Operating Data printout is shown below Note Not all values are printed for all models YORK INTERNATIONAL CORPORATION MILLENNIUM LIQUID CHILLER UNIT STATUS 2 04PM 01 OCT 07 SYS 1 NO COOLING LOAD SYS 2 COMPRESSORS RUNNING 2 OPTIONS CHILLED LIQUID WATER AMBIENT CONTROL STANDARD OCAL REMOTE MODE REMOTE CONTROL MODE LEAVING LIQUID EAD LAG CONTROL AUTOMATIC FAN CONTROL AMB amp DSCH PRESS CURRENT FEEDBACK NONE POWER FAILURE RESTART AUTOMATIC SOFT START ENABLED EXPANSION VALVE THERMOSTATIC REMOTE TEMP RESET 4 TO 20 MA PROGRAM VALUES DSCH PRESS CUTOUT 570 PSIG SUCT PRESS CUTOUT 80 PSIG SUCT PRESS CUT COOLING 42 PSIG SUCT PRESS CUT HEATING 31 PSIG LOW AMBIENT CUTOUT 25 0 DEGF RAVING LIQUID CUTOUT 25 0 DEGF ANTI RECYCLE TIME 600 SECS FAN
202. oooooopooooooo O x Ix Jo JO O O O 2 2 z Z j 2 e hb e ekekeke af As iih eee e CAA MIAH ATAHHAIH 1 29 v J14 J1 J2 AMB 1 Kt K2 K3 K5 K6 K7 K9 K10 Kn 5 3 1 amp 21 a 25 27 26 26 721 32 33 34 23 794 753 7610 041 743 743 144 1010 153 153 154 AT A73 182 184 7185 1 2 1 What these numbers mean Example 1 follow wire no 1 2 is DWG number on the bottom center of each page is the locator number across the top of the page At the top of the pages the numbers 1 to 11 go from left to right Find drawing number 2 and in DWG 1 column number 1 across the top of the page locate wire number 1 FIGURE 12 ELEMENTARY WIRING DIAGRAM 58 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA
203. options and fault information Remote cycling demand limiting and chilled liquid temperature reset can be accomplished by field sup plied contacts Compressor starting stopping and loading unload ing decisions are performed by the Microprocessor to maintain leaving or return chilled liquid temperature These decisions are a function of temperature devia tion from setpoint A Master ON OFF switch activates or deactivates the unit JOHNSON CONTROLS Setpoints SETPOINTS SCHEDULE ADVANCE DAY PROGRAM LD13283 IPU Il AND I O BOARDS The IPU and I O boards are assembled to function as a single microprocessor controller The IPU II board contains a microprocessor and is the controller The board handles all of the chiller I O Inputs and Outputs System inputs from pressure transducers and temperature sensors are connected to the I O board The I O board constantly scans inputs to monitor the chiller operating conditions The input values are trans mitted the IPU II microprocessor board From this in formation the IPU II then issues commands to the I O board relay outputs to control contactors solenoids etc for Chilled Liquid Temperature Control and to re act to safety conditions The I O board converts logic signals to operate relay outputs to 115VAC levels used by motor contactors fan contactors solenoid valves etc to control system operation The low voltage side of all relay coils on the I O board
204. orized persons Screws and or latches on access panels will prevent casual tampering However further safety precautions such as a fenced in enclosure or locking devices on the panels may be advisable Rooftop Locations Choose a spot with adequate structural strength to safely support the entire weight of the unit and service personnel Care must be taken not to damage the roof Consult the building contractor or architect if the roof is bonded Roof installations should have wooden beams treated to reduce deterioration cork rubber or spring type vibration isolators under the base to min imize vibration Noise Sensitive Locations Efforts should be made to assure that the chiller is not located next to occupied spaces or noise sensitive areas where chiller noise level would be a problem Chiller noise is a result of compressor and fan operation 35 SECTION 4 INSTALLATION SPRING ISOLATORS OPTIONAL When ordered isolators will be furnished Identify the isolator locate at the proper mounting point and adjust per instructions COMPRESSOR MOUNTING The compressors are mounted on four 4 rubber iso lators The mounting bolts should not be loosened or adjusted at installation of the chiller REMOTE COOLER OPTION Not available at this time CHILLED LIQUID PIPING General When the unit s has been located in its fi nal position the unit water piping may be connected Normal installation precautions
205. orking on equipment FIGURE 10 CONTROL WIRING INPUTS 40 1 UNLOAD STEP 1 d 1 PWM REMOTE TEMP RESET RE INTERNAL WIRING TO 2 KCR CONTROL RELAY SSS Sea Se INTERNAL WIRING TO 1 KCR CONTROL RELAY 1 START STOP 1013130 The unit evaporator heater uses 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 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 Normally jumpered Can be used as EMERGENCY STOP contacts from an external source NOTE SECTION 4 INSTALLATION USER CONTROL WIRING OUTPUTS XTBC2 All chiller supplied contacts are rated at 110VAC 100VA resistive load only and must be suppressed at the load by user if powering an inductive load Relay Contactor Coil Typical suppressor P N is 031 00808 000 The unit evaporator heater uses 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 FIGURE 11 CONTROL WIRING OUTPUTS JOHNSON CONTROLS WARNING INTERNAL WIRING TO EVAPORATOR HEATER INTERNAL WIRING TO HOT GAS SOLENOID VALVE SYSTEM 2 ALARM DRY CONTACTS OPEN ALARM SYSTEM 1 ALARM DRY CONTACTS OPEN ALARM E SYSTEM 2 RUN DRY CONTACTS CLOSE RUN
206. ould be programmed at 385 PSIG with a differential of 125 PSIG When a fan stage is turned OFF programmed on pres sure minus programmed differential the off pressure for the next stage is decreased 20 PSIG and ramped back to the programmed off pressure minus the differ ential over the next 20 seconds Condenser fan locations are shown in Figure 31 on page 146 Detailed Standard Fan Control operation is shown in Table 21 on page 147 and Table 22 page 148 0456 YLAA0516SE gt 1017081 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 8 UNIT OPERATION TABLE 21 YLAA STANDARD CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONLY 2 3 OR 4 FANS PER SYSTEM FAN Sud OUTPUT CONTACTOR FAN SYS 1 SYS 2 SYS 1 SYS 2 SYS 1 SYS 2 DP lt PROGRAMMED FAN CONTROL ON PRESSURE MINUS PROGRAMMED DIFFERENTIAL PRESSURE DP lt PROGRAMMED FAN CONTROL ON PRESSURE MINUS PROGRAMMED DIFFERENTIAL PRESSURE AND FAN STAGE 1 1 ENERGIZED DP PROGRAMMED FAN CONTROL ON PRESSURE DP PROGRAMMED FAN CONTROL ON PRESSURE AND FAN STAGE 1 IS ENERGIZED DP PROGRAMMED DP PROGRAMMED TB10 PRESSURE MINUS FAN CONTROL ON PROGRAMMED 8 and PRESSURE AND FAN TB10 9 DIFFERENTIAL STAGES 1 AND 2 ARE and ENERGIZED TB10 10 STAGES 1 AND 2 ARE ENERGIZED When a fan stage is turned on th
207. ounting holes The VMC group recommendis that the isolator base plates be installed on a level surface Shim or grout as re quired leveling all isolator base plates to the same elevation 1 4 inch maximum difference can be tolerated Bolt or anchor all isolators to supporting structure utilizing base plate thru holes weld base plate to supporting structure with 3 8 fillet weld 2 long 4 on center around entire base plate or as engineered for specific load and or field condi tions Isolators are shipped to the job site with 2 re movable spacer shims between the top plate and the housing These shims must be in place when the equipment is positioned over the isola tors With all shims in place position equipment on top of plate of isolator Bolt equipment securely to top plate of isolator using a minimum of 2 5 8 UNC A325 grade 5 SAE bolts or weld CE m nd tn in t4 r JOHNSON CONTROLS 10 11 12 13 1 4 3 8 2 WASHER equipment or bracket to the top plate of iso lator with a minimum of 3 8 fillet welds 2 long a 3 on center for a minimum total weld of 10 sides of equipment or bracket resting on top plate must be welded The adjustment process can only begin after the equipment or m
208. quence will start when a sys tem has to load Additional compressors will be started at 60 second intervals as needed to satisfy temperature setpoint 6 If demand requires the lag system will cycle ON with the same timing sequences as the lead system after the lead system has run for five min utes Refer to the section on Capacity Control for a detailed explanation of system and compressor staging JOHNSON CONTROLS 7 As the load decreases below setpoint the com pressors will be shut down in sequence This will occur at intervals of either 60 30 or 20 seconds based on water temperature as compared to set point and control mode See Leaving Chilled Liq uid Control on page 142 for a detailed explana tion 8 When the last compressor in a system two or three compressors per system is to be cycled OFF the system will initiate a pump down Each system 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 suction pressure cutout or for 180 seconds whichever comes first CAPACITY CONTROL To initiate the start sequence of the chiller all run per missive inputs must be satisfied flow remote start stop switch and no chiller or system faults exist The first phase of the start sequence is initiated by the Daily Schedule Start or any Remote Cycling Device If the u
209. quid flow is ensured The range MUST always be programmed to equal the temperature drop across the evaporator when the chiller is fully loaded Otherwise chilled liquid tem perature will over or under shoot Variable flow must never be used in return chilled liquid mode NOTE Normal loading will occur at intervals of 60 seconds according to the temperatures determined by the for mulas Unloading will occur at a rate of 30 seconds ac cording to the temperatures determined in the formulas used to calculate the ON and OFF points for each step of capacity TABLE 20 LEAD LAG RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS 6 STEPS LEAD SYSTEM LAG SYSTEM STEP COMP1 COMP2 OFF OFF SEE NOTE 1 COMP1 COMP2 OFF OFF SEE NOTE 2 SEE NOTE 3 NOTES 1 Step is Hot Gas Bypass and is skipped when loading occurs Hot Gas Bypass operation is inhibited during pumpdown For Leaving Chilled Liquid Control the Hot Gas Bypass solenoid is energized only when the lead compressor is running and the LWT SP the Hot Gas Bypass solenoid is turned off when the LWT more than SP CR 2 2 Step 3 is skipped when loading occurs 3 Step 4 is skipped when unloading occurs 144 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 The return chilled liquid setpoint is programmable from 40 F to 70 F 4 4 to 21 1 C in water chill ing mode and from 10 F to 70
210. r glycol drops below the cutout point the chiller will shutdown Restart can occur when chilled liquid temperature rises 2 F above the cutout UNIT FAULT UNDER VOLTAGE 115VAC The Under Voltage Safety assures that the system is not operated at voltages where malfunction of the mi croprocessor could result in system damage When the 115VAC to the micro panel drops below a certain level a unit fault is initiated to safely shut down the unit Re start is allowed after the unit is fully powered again and the anti recycle timers have finished counting down JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 UNIT FAULT HIGH MTR CURR When the CURRENT FEEDBACK ONE PER UNIT option is selected under the OPTIONS key the unit will shut down when the voltage exceeds the programmed trip voltage for 5 seconds The trip voltage is programmed at the factory accord ing to compressor or unit RLA Restart will occur after the anti recycle timer times out Unit Warning The following messages are not unit safeties and will not be logged to the history buffer They are unit warn ings and will not auto restart Operator intervention is required to allow a restart of the chiller 11 LOW BATTERY 11 CHECK PROG SETP OPTN The Low Battery Warning can only occur at unit pow er up On micro panel power up the RTC battery is checked If a low battery is found all programmed JOHNSON CONTROLS SECTION 7 UNIT CONTR
211. r to Microboard 3 Replace Control Transformer 4 Unplug connections at IPU amp I O Board to isolate 5 Replace II amp Board or the Display Board Contact Johnson Controls Service before replacing cir cuit Boards NOTE 1 Check chilled liquid flow Check that the flow switch is installed according to manufacturer s instructions Replace flow switch 4 Check cycling devices connected to terminals 13 and 14 of the XTBC1 Terminal Block Adjust per recommended settings Repair leak if necessary and add refrigerant Change dryer core Replace TXV Check GPM See Operational Limitations on page 43 Check operation of pump clean pump strainer purge chilled liquid system of air Replace transducer low pressure switch or faulty switch or wiring Refer to SECTION 9 SERVICE AND TROUBLESHOOTING for pressure voltage formula Replace LLSV Check fan motor and contactors Assure fan blows air upward 2 Remove refrigerant Evacuate and recharge system Replace discharge pressure transducer Refer to SECTION 9 SERVICE AND TROUBLESHOOTING for pressure voltage formula JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 TABLE 31 TROUBLESHOOTING CONT D PROBLEM CAUSE SOLUTION LOW LIQUID TEMP FAULT MP HPCO FAULT COMPRESSOR S WON T START LACK OF COOLING EFFECT JOHNSON CONTROLS Improperly adjusted leaving chilled l
212. rate printer by others Entry Keys This section is used to enter setpoints or modify system values Setpoints Keys Updating can be performed to Chilled liquid temperature setpoint and range Remote reset temperature range Set daily schedule holiday for start stop Manual override for servicing Low and high ambient cutouts Number of compressors Low liquid temperature cutout Low suction pressure cutout High discharge pressure cutout Anti recycle timer compressor start cycle time Anti coincident timer delay compressor starts Unit Keys This section is used to Set time Setunit options Oper Data Key The microprocessor control center is capable of dis playing the following Return and leaving liquid temperature Low leaving liquid temperature cutout setting Low ambient temperature cutout setting Outdoor air temperature English or Metric data Suction pressure cutout setting Each system suction pressure JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 Discharge pressure optional Liquid Temperature Reset via a Johnson Controls ISN DDC or Building Automation System by others via a 4 to 20 milliamp or 0 to10VDC input Anti recycle timer status for each system Anti coincident system start timer condition Compressor run status No cooling load condition Day date and time Daily start stop times Holiday status A
213. re mounted on the sides and ends of the MCHX condenser for protection Factory Mounted Louvered Panels Full Unit Louvered panels surround the front back and sides of the unit They prevent unauthorized access and visually screen unit components Unrestricted air flow is permitted through generously sized louvered openings This option is applicable for any out door design ambient temperature up to 115 46 Factory Mounted MCHX End Hail Guard Louvered panel attached to exposed MCHX end Fac tory Mounted Sound Attenuation One or both of the following sound attenuation options are recommended for residential or other similar sound sensitive locations Compressor Acoustic Sound Blanket Each compressor is individually enclosed by an acous tic sound blanket The sound blankets are made with one layer of acoustical absorbent textile fi ber of 5 8 15mm thickness one layer of anti vibrating heavy material thickness of 1 8 3mm Both are closed by two sheets of welded PVC reinforced for temperature and UV resistance Factory Mounted Ultra Quiet Fans Lower RPM 8 pole fan mo tors are used with steeper pitch fans Factory Mounted Vibration Isolators Level adjusting spring type 1 25 4mm or seismic deflection or neoprene pad isolators for mounting un der unit base rails Field mounted 19 FORM 150 72 ICOM7 614 SECTION 2 PRODUCT DESCRIPTION ISSUE DATE 6 10 2014 ITEM DESC
214. rodjes od 9 Jav OLX 70 50 198 dl3S 1009 6 6 6 6 6 6 65 duie od 09 Jav OLX 70 50 995 es LOH 1 04 6 6 6 6 6 6 65 4 pinbr1 od 65 OLX vO eO 999 eS LOH SNIAV31 69 5151515151515 A33 S S od 89 Jav OLX 0 lt 0 9 19 HS ZS 89 5151515151515 A33 eBueuosig S S od 45 SQV OLX v0 0 298 08 25 19 5151515151515 A33 S S od 96 4 OLX 00 296 6v IV lV3HS 15 99 8 A33 eBueuosig S S od 99 Jav OLX 00 198 15 59 1 BuneeH vs 40 OLX 70 50 095 1V3H 79 6 1 dS OLX 70 50 699 or IV 26 119 dS 9 S 28 Jav OLX 70 50 866 Sy 4138 29 5 0 100 dS 2 1 LS Jav OLX 70 50 198 25 4138 dS 19 1 dS 0 od 05 OLX v0 0 999 IV LS 119 dS 09 5 od 6v Jav OLX 70 50 999 cy lOHINOO
215. roprocessor and is backed up by a mechanical high pressure cutout switch located in the refrigerant circuit It assures that the system pressure does not ex ceed safe working limits The system will shutdown when the programmable cutout is exceeded and will be allowed to restart when the discharge pressure falls 40 PSIG below the cutout Discharge transducers must be installed for this function to operate JOHNSON CONTROLS SECTION 7 UNIT CONTROLS SYS 1 SYS 2 LOW LOW SUCT SUCT The Suction Pressure Cutout is software cutout that helps protect the chiller from an evaporator freeze up should the system attempt to run with a low refrigerant charge or a restriction in the refrigerant circuit Repeated starts after resetting a low suc tion pressure fault will cause evaporator freeze up Whenever a system locks out on this safety or any safety immediate steps should be taken to identify the cause NOTE At system start the cutout 1s set to 10 of programmed value During the next 3 minutes the cutout point is ramped up to the programmed cutout point If at any time during this 3 minutes the suction pressure falls below the ramped cutout point the system will stop This cutout is completely ignored for the first 30 sec onds of system run time to avoid nuisance shutdowns especially on units that utilize a low pressure switch in place of the suction pressure transducer After the first 3 minutes
216. s Low Temperature Glycol Replaces standard Thermostatic Expansion Valves with Electronic Expansion Valves to achieve leaving glycol temperatures as low as 10 F 12 C Required for any leaving liquid temperature below 30 F 1 C Electronic Expansion Valves permit operation at both low temperatures and comfort cooling applications without a capacity loss or derate at either condition Factory installed Chicago Code Relief Valves Unit will be provided with relief valves to meet Chi cago code requirements Factory Mounted Service Suction Isolation Valve Service suction ball type isolation valves are added to unit per system discharge service ball type isolation valve is standard on each circuit Factory Mounted Hot Gas By Pass Permits continuous stable operation at capacities below the minimum step of compressor unloading to as low as 590 capacity depending on both the unit and operat ing conditions by introducing an artificial load on the cooler Hot gas by pass is installed on only refrigerant system 1 on two circuited units Factory Mounted Flanges ANSI AWWA 606 couplings Consists of 2 Flange adapter for grooved end pipe stan dard 150 psi 10 5 bar cooler Not available on optional DX cooler 300 PSIG DWP waterside Field mounted Flow Switch A thermal dispersion type flow switch provides ac curate low maintenance flow proving and is included standard It 15 factory wired and in
217. s allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit JOHNSON CONTROLS 81 SECTION 5 TECHNICAL DATA WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS General Weights of specific chiller models vary significantly as options are added As a result total weights weights at individual isolator positions and actual isolator selec tion at each position cannot be published due to the vast number of possible combinations This informa tion will be available when the specific chiller option selection is made from the local Johnson Controls sales office Be aware weights will change with each op tion along with possible isolator changes Weights and isolators may need to be recalculated when the option selections are changed Control Panel X DISTANCE INCHES MM Y DISTANCE LOCATION INCHES MM 19 5 495 3 1 36 34 5 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 Whenever the isolator option is ordered the isolators will be shipped loose with the chiller Packed with the isolators and also in the control panel informa tion packet is a drawing and table specifically for each chiller based on the option selection The drawing and table will be similar to the two samples shown below and on the following page The drawing will show the isolator locations along with the weight in pounds and kilograms at the specific location isolator position and locati
218. s restarted Flow Switch Verify a chilled water flow switch is correctly fitted in the customer s piping on the cooler outlet and wired into the control panel correctly using shielded cable There should be a straight run of at least 5 pipe diam eters on either side of the flow switch The flow switch should be connected to terminals 13 and 14 of XTBCI on the panel 94 FORM 150 72 614 ISSUE DATE 6 10 2014 Temperature Sensor s Ensure the leaving liquid temperature sensor is coated with heat conductive compound Part No 013 00890 000 and is inserted to the bottom of the water outlet sensor well in the cooler This sensor also provides some freeze protection and must always be fully in serted in the water outlet sensor well PREPARATION POWER ON Perform the commissioning using the detailed checks outlined Refer to Equip ment Pre Startup And Startup Checklist Form 150 72 CL1 as the commissioning procedure is carried out Apply power to the chiller Turn on the option panel circuit breaker if supplied The machine is now live Switch Settings Assure the chiller OFF ON UNIT switch at the bottom of the keypad 1s OFF Place the optional circuit breaker handle on the panel door to ON The customer s dis connection devices can now be set to ON Verify the control panel display is illuminated Assure the system switches under the SYSTEM SWITCHES key are in the OFF position Compressor Heaters
219. should be observed in order to receive maximum operating efficiencies Pip ing should be kept free of all foreign matter All chilled water evaporator piping must comply in all respects with local plumbing codes and ordinances Since elbows tees and valves decrease pump capacity all piping should be kept as straight and as simple as possible piping must be supported independent of the chiller Consideration should be given to com pressor access when laying out water pip ing Routing the water piping too close to the unit could make compressor servicing replacement difficult Hand stop valves should be installed in all lines to fa cilitate servicing Piping to the inlet and outlet connections of the chiller should include high pressure rubber hose or piping loops to ensure against transmission of water pump vi bration The necessary components must be obtained in the field Drain connections should be provided at all low points to permit complete drainage of the cooler and system water piping A small valve or valves should be installed at the high est point or points in the chilled water piping to allow any trapped air to be purged Vent and drain connec tions should be extended beyond the insulation to make them accessible 36 FORM 150 72 614 ISSUE DATE 6 10 2014 The piping to and from the cooler must be designed to suit the individual installation It is important that the following considera
220. ssage appears discharge pressure limit ing is in effect The Discharge Pressure Limiting fea ture is integral to the standard software control howev er the discharge transducer is optional on some models Therefore it is important to keep in mind that this con trol will not function unless the discharge transducer is installed in the system 102 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 The limiting pressure is a factory set limit to keep the system from faulting on the high discharge pressure cutout due to high load or pull down conditions When the unload point is reached the microprocessor will automatically unload the affected system by de ener gizing one compressor The discharge pressure unload will occur when the discharge pressure gets within 10 PSIG 0 69 barg of the programmed discharge pres sure cutout This will only happen if the system is fully loaded and will shut only one compressor OFF If the system is not fully loaded discharge limiting will not go into effect Reloading the affected system will oc cur when the discharge pressure drops to 85 of the unload pressure and 10 minutes have elapsed SYS 1 SUCT SUCT LIMITING LIMITING SYS 2 When this message appears suction pressure limiting is in effect The suction pressure limit is a control point that limits the loading of a system when the suction pressure drops to within 15 above the suction pres sure cutout On a standard system programme
221. ssure for the next stage is increased 20 PSIG and ramped back to the programmed on pressure over the next 20 seconds When fan stage is turned off Programmed ON pressure minus the differential the OFF pressure for the next stage is decreased 20 PSIG and ramped back to the programmed OFF pressure minus the differential The time delay fan delay timer between turning fan stages on and off is fixed at 5 seconds NOTE 148 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 LOAD LIMITING Load Limiting is a feature that prevents the unit from loading beyond the desired value 2 and 4 compres sor units can be load limited to 5096 This would allow only 1 compressor per system to run 3 and 6 compres sor units can be load limited to 33 or 66 The 66 limit would allow up to 2 compressors per system to run and the 33 limit would allow only 1 compressor per system to run Five compressor units may be load limited to 40 1 compressor per system runs or 80 up to 2 compressors per system are permitted to run No other values of limiting are available There are two ways to load limit the unit The first is through remote communication via an ISN Load limit stages are sent through YORK Talk on pages 9 and 10 of feature 54 Page 9 is stage 1 load limit and page 10 is stage 2 load limit A second stage of load limiting the unit is accom plished by closing contacts connected to the Load Limit XTBCI terminals
222. stalled in the exten sion pipe between evaporator outlet and edge of chill er The extension pipe is secured to the chiller frame for shipping to avoid risk of damage to evaporator and is easily attached to the evaporator at startup us ing the supplied ANSI AWWA C 606 connector The flow switch can be deleted if alternate or existing flow switch 15 field supplied JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 Heat Recovery Condenser A partially condensing refrigerant to liquid condenser recovers heat off both refrigerant circuits and rejects into a single liquid circuit Factory installed between the compressor discharge and the condenser air coils to capture the maximum amount of heat Capable of recovering up to 85 total heat of rejection cooling load plus work input temperatures as high as 140 F 60 are possible Hydro Kit Factory installed Hydro Kit suitable for water and gly col systems with up to 35 glycol at leaving tempera tures down to 20 F The hydro kit option 1s available in a single or dual configuration dual as standby duty only with totally enclosed permanently lubricated pump motors The hydro kit option comes standard with a balancing valve discharge check valve discharge shutoff valve thermal dispersion flow switch pressure ports inlet wye strainer bleed and drain valves and frost protection Service shut off valves additional pressure ports and ex pansion tanks are op
223. stem units may have 4 or 6 compressors TABLE 12 PROGRAM KEY LIMITS AND DEFAULT PROGRAM VALUE DISCHARGE PRESSURE CUTOUT 22 4 BARG WATER COOLING FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 This MUST be programmed correctly to assure proper chiller operation NOTE NUMBER PER OF FANS SYSTEM X The Number of Fans Per System must be programmed as needed to match the number of fans on each system UNIT SYS X TRIP VOLTS X X VOLTS TRIP VOLTS X X VOLTS LOW LIMIT 325 PSIG HIGH LIMIT 575 PSIG 39 6 BARG 120 0 PSIG 8 27 BARG DEFAULT 570 PSIG 39 3 BARG 80 0 PSIG 5 52 BARG 80 0 PSIG 5 52 BARG SUCTION PRESSURE CUTOUT GLYCOL COOLING STANDARD AMBIENT LOW AMBIENT TEMP CUTOUT 42 0 PSIG 2 9 BARG 70 0 PSIG 4 83 BARG 44 0 PSIG 3 03 BARG LOW AMBIENT WATER COOLING LEAVING CHILLED LIQUID TEMP CUTOUT GLYCOL COOLING ANTI RECYCLE TIMER 36 0 F 2 2 300 SEC 600 5 600 SEC 360 PSIG 485 PSIG 385 PSIG FAN CONTROL ON PRESSURE 24 8 BARG 33 4 BARG 26 5 BARG FAN DIFFERENTIAL OFF PRESSURE 80 PSID 160 PSID 125 PSID 5 51 BARD 11 03 BARD 8 62 BARD NUMBER OF FANS PER SYSTEM SINGLE SYSTEM 2 3 3 TOTAL NUMBER OF COMPRESSORS DUAL SYSTEM 4 6 4 ee UNIT SYSTEM TRIP VOLTS CURRENT FEEDBACK 0 5 Volts 6 4 4 5 Volts 2 5 Volts The minimum discharge pressure allowed is 235 PSIG The Fan Different
224. system JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 EVAPORATOR WATER PUMP STATUS 2XXXX The evaporator pump dry contacts are energized when any compressor is running or the unit is not OFF on the daily schedule and the unit switch is ON or the unit has shutdown on a Low Leaving Chilled Liquid fault However even if one of above is true the pump will not run if the micro panel has been powered up for less than 30 seconds or if the pump has run in the last 30 seconds to prevent pump motor overheating EVAP PUMP TOTAL RUN X X X X X HOURS The Evaporator Pump Total Run Hours display indi cates the total pump run hours Total hours continu ally increments similar to Compressor Run Hours If dual pumps are fitted run hours indicates total hours on both pumps ACTIVE REMOTE NONE CTRL There are several types of remote systems that can be used to control or monitor the unit The following mes sages indicate the type of remote control mode active NONE no remote control active Remote monitoring may be via ISN LOAD LIM Load limiting enabled using contact clo sure PWM TEMP EMS temperature reset Refer to Remote BAS EMS Temperature Reset Using A Voltage Or Current Signal on page 150 If the microprocessor is programmed for CURRENT FEEDBACK ONE PER UNIT under the OPTIONS key the display will show up as the first display prior to the SYS 1 displays Total chiller current is displ
225. t at risk from rotating fan blades WIRING Liquid Chillers are shipped with all factory mounted controls wired for operation Field Wiring Power wiring must be provided through a fused disconnect switch to the unit terminals or optional molded disconnect switch in accordance with N E C or local code requirements Minimum cir cuit ampacity and maximum dual element fuse size are given in the Electrical Data tables Copper power wiring only should be used for supply ing power to the chiller This 15 recommended to avoid safety and reliability issues resulting from connection failure at the power connections to the chiller Alumi num wiring is not recommended due to thermal char acteristics that may cause loose terminations result ing from the contraction and expansion of the wiring Aluminum oxide may also build up at the termination causing hot spots and eventual failure If aluminum wiring is used to supply power to the chiller AL CU compression fittings should be used to transition from 37 SECTION 4 INSTALLATION aluminum to copper This transition should be done in an external box separate to the power panel Copper conductors can then be run from the box to the chiller A 110 1 50 15 amp source must be supplied for the control panel through a fused disconnect when a con trol panel transformer optional is not provided Refer to Figure 9 on page 39 See unit wiring diagrams for field and power wiring con
226. t be provided as in dicated in these instructions Failure to provide proper support may result in injury to the operator or damage to the equipment and or building Mechanical Strength The unit is not designed to withstand loads or stresses from adjacent equipment pipework or structures Ad ditional components must not be mounted on the unit Any such extraneous loads may cause structural failure and may result in injury to the operator or damage to the equipment General Access There are a number of areas and features which may be a hazard and potentially cause injury when working on the unit unless suitable safety precautions are taken It is important to ensure access to the unit 1s restricted to suitably qualified persons who are familiar with the potential hazards and precautions necessary for safe operation and maintenance of equipment containing high temperatures pressures and voltages JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 Pressure Systems The unit contains refrigerant vapor and liquid under pressure release of which can be a danger and cause injury The user should ensure that care is taken during installation operation and maintenance to avoid dam age to the pressure system No attempt should be made to gain access to the component parts of the pressure system other than by suitably trained and qualified per sonnel Electrical The unit must be grounded No installation or main
227. t in damage to the evaporator and unit as a result of the chilled liquid freezing CAUTION VOLTAGE RANGE VOLTAGE CODE UNTPOWER 200 208 3 60 230 3 60 380 3 60 460 3 60 380 415 3 50 575 3 60 COMPRESSOR HEATERS Compressor heaters are standard ZP180 compressors utilize 70W heaters ZP235 compressor use 120W heaters and ZP285 and ZP385 utilize 150W heaters If power is OFF more than two hours the crankcase heat 48 ers must be energized for 18 24 hours prior to restart ing a compressor This will assure that liquid slugging and oil dilution does not damage the compressors on start JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA TABLE 7 PUMP ELECTRICAL DATA 50 HZ 400V 3 50HZ PUMP MODEL 9i 59 so 48 x o 4 cce 7 ee JOHNSON CONTROLS 49 FORM 150 72 614 ISSUE DATE 6 10 2014 SECTION 5 TECHNICAL DATA TABLE 8 ELECTRICAL DATA WITHOUT PUMPS MCA DOES NOT MIN ELEM FUSE amp MAX DUAL ELEM CHILLER MODEL VOLT IDE MIN N F DISC SW FUSE MAX CB XFR AMPS YLAA0180SE 400 50 YLAA0195HE 400 50 YLAA0210SE 400 50 YLAA0220HE 400 50 400 50 YLAA0221HE YLAA0240SE YLAA0241SE YLAAO260HE YLAA0261HE YLAA0285SE YLAA0286SE YLAA0300HE YLAA0320SE YLAA0350HE YLA
228. tem is presently in the pro cess of pumping the system down When pumpdown is initiated on shutdown the liquid line solenoid or EEV will close and a compressor will continue to run When the suction pressure decreases to the suction pressure cutout setpoint or runs for 180 seconds whichever comes first the compressor will cycle OFF Fault Safety Status Messages Safety Status messages appear when safety thresholds in the unit have been exceeded Safeties are divided into two categories system safeties and unit safeties System safeties are faults that cause the individual sys tem to be shut down Unit safeties are faults that cause all running compressors to be shut down Following are display messages and explanations System Safeties System safeties are faults that cause individual systems to be shut down if a safety threshold is exceeded for 3 seconds They are auto reset faults in that the system will be allowed to restart automatically after the fault condition is no longer present However if 3 faults on the same system occur within 90 minutes that system will be locked out on the last fault This condition is then a manual reset The system switch under OP TIONS key must be turned OFF and then back on to clear the lockout fault Fault messages will be dis played whenever a system is locked out SYS 1 H IGH H IGH DSCH DSCH PRES PRES SYS 2 The Discharge Pressure Cutout is a software cutout in the mic
229. tem should be preformed to ensure that operating temperatures and pressures are within limitations and that the operating controls are set within proper limits Refer to SECTION 8 UNIT OPERATION SECTION 6 COMMISSIONING and SECTION 4 INSTALLATION of this manual ON BOARD BATTERY BACK UP The Real Time Clock chip U5 located on the 031 02630 IPU II board that maintains the date time and stores customer programmed setpoints The Real Time Clock is a 128K bram P N 031 02565 000 The IPU II board must have 1 1 installed when the 128K bram 15 installed Do not confuse on II 031 02630 board with JP1 the I O 031 02550 board NOTE 164 FORM 150 72 614 ISSUE DATE 6 10 2014 BRAZED PLATE HEAT EXCHANGER EVAPORATOR HEATER The internal power supply to the Evapo rator Heater is 120VAC Disconnecting 120VAC power from the unit at or below freezing temperatures can result in dam age to the evaporator and unit as a result of the chilled liquid freezing OVERALL UNIT INSPECTION In addition to the checks listed on this page periodic overall inspections of the unit should be accomplished to ensure proper equipment operation Items such as loose hardware component operation refrigerant leaks unusual noises etc should be investigated and corrected immediately JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 Temperature Conversion Chart TEMPE
230. thod to be used and it is beyond the scope of the manual to specify rigging and lifting details This manual contains all the information required for correct installation and commissioning of the unit to gether with operating and maintenance instructions The manuals should be read thoroughly before at tempting to operate or service the unit All procedures detailed in the manuals including in stallation commissioning and maintenance tasks must only be performed by suitably trained and qualified personnel The manufacturer will not be liable for any injury or damage caused by incorrect installation commission ing operation or maintenance resulting from a failure to follow the procedures and instructions detailed in the manuals WARRANTY Johnson Controls warrants all equipment and materi als against defects in workmanship and materials for a period of eighteen months from date of shipment or 12 months from date of start up whichever occurs first unless labor or extended warranty has been purchased as part of the contract The warranty is limited to parts only replacement and shipping of any faulty part or sub assembly which has failed due to poor quality or manufacturing errors claims must be supported by evidence that the failure has occurred within the warranty period and that the unit has been operated within the designed parameters specified warranty claims must specify the unit model serial number
231. tional within the hydro kit option Condenser and Cabinet Options MCHX Condenser protection against corrosive envi ronments is available by choosing any of the following options For additional application recommendations refer to FORM 150 12 ES1 Factory Mounted Post Coated Dipped MCHX Condenser The unit MCHX is constructed with post dipped epoxy condenser This is recommended for seashore and other corrosive applications with the exception of strong alkalies oxidizers and wet bromine chlorine and fluorine in concentrations greater than 100 ppm Enclosure Panels Unit Tamperproof Enclosure Panels prevent unauthorized access to units Enclosure Panels can provide an aes thetically pleasing alternative to expensive fencing Additionally for proper head pressure control Johnson Controls recommends the use of Condenser Louvered Panels for winter applications where wind gusts may exceed five miles per hour The following types of en closure panels are available JOHNSON CONTROLS SECTION 2 PRODUCT DESCRIPTION Wire Panels Full Unit Consists of welded wire mesh guards mounted on the exterior of the unit Prevents unauthorized access yet provides free air flow Factory Mounted Wire Louvered Panels Consists of welded wire mesh panels on the bottom part of unit and louvered panels on the condenser section of the unit Factory Mounted Louvered Panels MCHX Condenser Only Louvered Panels a
232. tions be observed 1 The chilled liquid piping system should be laid out so that the circulating pump discharges directly into the cooler The suction for this pump should be tak en from the piping system return line and not the cooler This piping scheme is recommended but 15 not mandatory 2 The inlet and outlet cooler connection sizes are pro vided in Zable 4 on page 46 Physical Data 3 A 1 16 mesh strainer is provided at the cooler inlet line just ahead of the cooler This is important to protect the cooler from entrance of large particles which could cause damage to the evaporator 4 chilled liquid piping should be thoroughly flushed to free it from foreign material before the system is placed into operation Use care not to flush any foreign material into or through the cooler 5 As an aid to servicing thermometers and pressure gauges should be installed in the inlet and outlet wa ter lines 6 The chilled water lines that are exposed to outdoor ambients should be wrapped with supplemental heater cable and insulated to protect against freeze up during low ambient periods and to prevent for mation of condensation on lines in warm humid locations As an alternative ethylene glycol should be added to protect against freeze up during low ambient periods 7 A chilled water flow switch either by Johnson Controls or others MUST be installed in the leav ing water piping of the cooler If the factory wired f
233. to ON in the display as the LLSV is energized Energizing and de energizing outputs may be useful during troubleshoot ing SERVICE MODE CHILLER CONFIGURATION After the Outputs are displayed the next group of displays relate to chiller configuration and start hour counters Data logging soft start refrigerant type pump control selection and expansion valve type all must be programmed to match actual chiller configura tion AN CAUTION Following 15 a list of chiller configuration selections in order of appearance Soft start disabled Refrigerant Type R 410A and Expansion Valve Type Thermostatic and North American Feature Enabled MUST be properly programmed or damage to compressors and other system components may result DATA LOGGING MODE DO NOT MODIFY DATA LOGGING TIMER DO NOT MODIFY SOFT START REFRIGERANT TYPE EXPANSION VALVE TYPE REMOTE TEMP RESET OPTION REMOTE INPUT SERVICE TIME FEATURE SET PUMP CONTROL SELECTION SYS 1 HOURS SYS 2 HOURS SYS 1 STARTS SYS 2 STARTS The last displays shown on the above list are for the ac cumulated run and start timers for each system All val ues can also be changed using 7 UP and Down arrow keys but under normal circumstances would not be required or advised After the last start display the microprocessor will display the first programmable value under the PROGRAM key 152 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SERVICE MODE AN
234. ty control Compare the display with a thermometer Should be within plus or minus 2 degrees Refer to Table 29 on page 156 for RWT LWT temp voltage table Replace defective part 4 Diagnose cause of failure and replace Contact the local Johnson Controls service representative Reduce flow to within chiller design specs See Operational Limitations on page 43 Check subcooling and add charge as needed 161 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 THIS PAGE INTENTIONALLY LEFT BLANK 162 JOHNSON CONTROLS FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 SECTION 10 MAINTENANCE It is the responsibility of the equipment owner to per form maintenance on the system Important If system failure occurs due to improper maintenance during the warranty period Johnson Controls will not be liable for costs incurred to return the system to sat isfactory 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 Johnson Controls System components should be maintained according to the individual manufacture s recommendations as their operation will affect the operation of the chiller COMPRESSORS Cil Level check The oil level can only be tested when the compressor is running in stabilized conditions to ensure that there is no liquid refrigerant in the lower shell of the
235. ure 34 illustrates the relay contact architecture on the microboard SYS 1 7872 Gomp 1 L 7 3 LLSV1 SYS 1 9 1874 Comp 2 SYS 1 1875 Gomp3 SYS 1 1877 esv SYS 1 218 SYS 1 9 1879 FAN 1 SYS 1 187 10 PAN SYS 2 9 78792 Compr 4 4 TB10 3 SYS 2 18104 CoMPR2 5 SYS 2 18105 Compr 6 SYS2 9 18107 TB10 8 SYS2 1810 9 SYS2 TB10 10 EA 7 TB7 TB10 TB10 ARANAN 6 TB8 TB8 7 PUMP LD12722 FIGURE 33 I O BOARD RELAY CONTACT ARCHITECTURE 158 FORM 150 72 ICOM7 614 ISSUE DATE 6 10 2014 OPTIONAL PRINTER INSTALLATION The micro panel is capable of supplying a printout of chiller conditions or fault shutdown information at any given time This allows operator and service per sonnel to obtain data and system status with the touch of the keypad In addition to manual print selection the micro panel will provide an automatic printout whenever a fault occurs Detailed explanation of the print function is given under Print Key on page 110 Johnson Controls recommends the field tested WEIGH TRONIX model 1220 printer or former IMP 24 This is a compact low cost printer that is ideal for service work and data logging The WEIGH TRONIX printer can be obtained by con tact
236. utomatic or manual system lead lag control Lead system definition Compressor starts and operating hours each compressor Status of hot gas valves evaporator heater and fan operation Run permissive status Number of compressors running Liquid solenoid valve status Load and unload timer status Water pump status Provisions are included for pumpdown at shutdown optional remote chilled water temperature reset and two steps of demand load limiting from an external building automation system Unit alarm contacts are standard The operating program is stored in non volatile memo ry battery backed RAM to eliminate chiller failure due to AC powered failure battery discharge Programmed setpoints are retained in lithium battery backed RTC memory for 5 years minimum COMMUNICATIONS Native communication capability for BACnet MS TP and Modbus Optional communication available for N2 and LON via eLink Gateway option ntensity of Protection European Standard nternational Electrotechnical Commission JOHNSON CONTROLS SECTION 2 PRODUCT DESCRIPTION BUILDING AUTOMATION SYSTEM INTERFACE The Microprocessor Board can accept a 4 to 20 mil liamp or 0 to10VDC input to reset the leaving chiller liquid temperature from a Building Automation Sys tem The standard unit capabilities include remote start stop remote water temperature reset via a PWM 4 to 20 milliamp or 0 to 1OVDC input sig n
237. uvered Cond only Panels fel 778 Lowered Full Unit Panels 1 ne Louver End Guard Panels aco Aesthetic Panel Kitony Aesthetic Panel Kit plus Hail Guards ado seeswEndoePants 71 ACOUSTIC PIN 49 Special Acoustic SRDOCS PIN 50 Q PIN 51 PIN 51 Special Quote pou Special Sound Fans required JOHNSON CONTROLS 27 FORM 150 72 614 SECTION 2 PRODUCT DESCRIPTION ISSUE DATE 6 10 2014 TABLE 1 COMPLETE PIN NUMBER DESCRIPTION CONT D FEATURE FEATURE DESCRIPTION OPTION OPTION DESCRIPTION No Isolators required 1 Deflection Isolators required ISOL p Neoprene Isolators required 2 Deflection Isolators required a Special Isolators required PIN 55 PIN 55 ______ Marketing Purposes Only PIN 56 PIN 56 Marketing Purposes Only No Containerization required with Shipping Bag Buy American Act Compliance with Shipping Bag EN OU T EM out Shipping Bag Factory Prep D Container Shipped with Shipping Bag Factory Load US Por PIN 57 Both Buy America Act Compliance and Container Shipped with G ee Shipping Bag Factory Prep Container Shipped without Shipping Bag Factory Load Mexico Port Container Shipped without Shipping Bag Factory Prep ewes
238. vice Mode Expansion valve type is displayed under the OPTIONS key but is only programmable in Service Mode YLAA chillers will typically always be equipped with thermostatic expan sion valves Incorrect programming may cause dam age to compressors CAUTION Also see the UNIT KEYS PROGRAMMING QUICK REFERENCE LIST in Figure 27 on page 128 Option 17 Flash Card Update F LASH CARD UPDATE DISABLED A Flash Card is used to input the operating program into the chiller IPU A Flash Card is used instead of an EPROM Normally a Flash Card update is not required and the message above will be displayed If the operating software is to be updated insert the Flash Card into the Flash Card input port Turn off the unit switch and set the FLASH CARD UPDATE TO ENABLED using the 1 and keys FLASH CARD UPDATE ENABLED 26 FORM 150 72 614 ISSUE DATE 6 10 2014 Press the ENTER key and the following message will 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 up date is completed LASH CARD UPDATING PLEASE WAIT After the update is completed an automatic reboot will occur If an error occurred the following message will appear with the error code and no reboot will occur F LASH CARD UPDATE If update resulted in an error the or
239. when refrigerant charge is low or superheat is too high When the sensor senses a high temperature it opens the motor protector circuit in the compressor causing the compressor to shut down During the first two faults an MP HP INHIBIT message will be displayed and the system will not be locked out Only after the third fault in 90 minutes will the MP HPCO FAULT message be displayed Whenever the motor protector or discharge sensor shuts down a compressor and the system the inter nal compressor contacts will open for a period of 30 minutes to assure that the motor or scroll temperatures have time to dissipate the heat and cool down The MP HP INHIBIT message will be displayed while these contacts are open or when the HPCO is open While this message is displayed the compressors will not be permitted to start After 30 minutes the contacts will close and the sys tem will be permitted to restart The microprocessor will not try to restart the compressors in a system that shuts down on this safety for a period of 30 minutes to allow the internal compressor to time out During the 30 minute timeout the MP HPCO INHIB message will be displayed The MP HPCO fault will only be displayed after 3 shutdowns in 90 minutes indicating the system is locked out and will not restart SYS SYS 1 HIGH MTR CURR 2 HIGH MTR CURR When the System Current Feedback option is installed and selected Option 11 under OPTIONS key Current Feedb
240. wiring Provided must be run in separate grounded ENDO Unit Power conduit Never run control wiring See electrical note 9 Supply in the same conduit with power wiring LD13141 It is possible that multiple sources of The unit evaporator heater uses 110VAC power can be supplying the unit power Disconnecting 110VAC power from the panel To prevent serious injury or death unit at or below freezing temperatures the technician should verify that NO can result in damage to the evaporator LETHAL VOLTAGES are present inside and unit as a result of the chilled liquid the panel AFTER disconnecting power freezing PRIOR to working on equipment FIGURE 9 SINGLE POINT SUPPLY CONNECTION TERMINAL BLOCK NON FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER OR CIRCUIT BREAKER JOHNSON CONTROLS 39 SECTION 4 INSTALLATION FORM 150 72 614 ISSUE DATE 6 10 2014 USER CONTROL WIRING INPUTS All externally supplied contacts must be capable of switching 24VDC 110 VAC Gold contacts are recommended If sup plied contacts are from a Relay Contac tor Inductive Load the coil of the Relay Contactor must be suppressed Typical suppressor is P N 031 00808 000 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 w
241. with the lowest priority number will always be the next compressor to start The running compressor with priority number 1 will al ways be the next to shut OFF Whenever a compressor is shut OFF the priority numbers of all compressors will be decreased by 1 with wrap around This control scheme assures the same compressor does not repeat edly cycle ON and OFF Once the second system starts a compressor on a 2 sys tem chillers the microprocessor will attempt to equally load each system as long as the system is not limit ing or pumping down Once this occurs loading and unloading will alternate between systems loading the lead system first or unloading the lag system first FORM 150 72 614 ISSUE DATE 6 10 2014 RETURN CHILLED LIQUID CONTROL Can be used on Dual System 4 5 and 6 Comp Units Only Return chilled liquid control is based on staging the compressors to match the cooling load The chiller will be fully loaded when the return water temperature is equal to the Cooling Setpoint plus the Range The chiller will be totally unloaded all compressors OFF when the return water temperature is equal to the Cool ing Setpoint See sample in Table 18 on page 143 At return water temperatures between the Cooling Setpoint and Cooling Setpoint plus Range compres sor loading and unloading will be determined by the formulas in Table 19 on page 143 Return Chilled Liquid Control MUST only be used when constant chilled li
242. xpansion valve to respond and stabilize Name Assure that superheat is set at a minimum of 10 F 5 56 C with a single compressor running on each Phone Number circuit Name Record the suction temperature suction pressure suction saturation temperature and superheat of Phone Number each system below eese Name SYS 1 SYS2 Suction Temp Phone Number Suction Pressure lt Saturation Temp lt Superheat CONTRACTOR S RESPONSIBILITIES AND INSTRUCTIONS TO USE FORM This installation checklist provides a quick way to check if all necessary installation work was completed in accordance with all applicable installation instructions in Form 150 72 ICOM6 and when completed acts as a request for Johnson Controls to furnish start up supervision Complete this form as follows 1 Fill out the top of the page Check off each item as required Cross out x items that do not apply 2 3 Enter names initials and date of the operating personnel who completed the checklist 4 Bottom of Form Enter the date that the Johnson Controls start up technician should be at the job site and the name s of the supervisor s to be contacted Retain one copy in files and send one copy to customer With reference to the terms of the above contract we are requesting the presence of your JCI Authorized Representative at the job site on 1 to start the system and instru
243. y each operating parameter While a particular parameter is being displayed the 1 UP and DOWN arrow keys can be used to change the value After the value is changed the ENTER ADV key must be pressed to en ter the data into memory 12 on page 120 shows the programmable limits and default values for each operating parameter Following are the displays for the programmable val ues in the order they appear DISCHARGE PRESSURE 395 PSIG CUTOUT DISCHARGE PRESSURE CUTOUT is the discharge pressure at which the system will shutdown as moni tored by the optional discharge transducer This is a software shutdown that acts as a backup for the me chanical high pressure switch located in the refrigerant circuit The system can restart when the discharge pres sure drops 40 PSIG 2 76 barg below the cutout point If the optional discharge pressure transducer is not in stalled this programmable safety would not apply It should be noted that every system has a mechanical high pressure cutout that protects against excessive high discharge pressure regardless of whether or not the optional discharge pressure is installed SUCTION CUTOUT 80 0 PRESSURE PSIG The SUCTION PRESSURE CUTOUT protects the chiller from an evaporator freeze up If the suction pressure drops below the cutout point the system will shut down Typically the cutout should be set to 80 PSIG 5 52 Bars form water cooling There are some exc

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