Home

5 - Johnson Controls

1. JOHNSON CONTROLS 75 SECTION 5 TECHNICAL DATA FORM 150 72 811 ISSUE DATE 8 15 2011 CONNECTION WIRING DIAGRAMS YLAA0195 035 21589 202 REV D 1 1 2 1 2 5 1 2 500 501 502 506 507 508 350 551 552 2 350A 351A 352A 2 F 350 551 352A 2G G 350B 351B 352B 2H 144 144B 135 m 2CG 57 2CF 500 501 502 3508 351B 3528 GND GND 62 2 4 9 2CE 58 506 507 508 2CD FIG 22 CONNECTION WIRING DIAGRAM YLAA0195 SHT 2 76 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA 204 59 512 513 514 2c 20 60 2CG 512A 515A 514A 2CH 2CJ 1 1 2 1 MF4 112 115 13 28 JOHNSON CONTROLS 77 FORM 150 72 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA CONNECTION WIRING DIAGRAMS YLAA0195 035 21589 203 REV D end GND COND 62 62 2 O 6 OOO 89 2CQ 68 530 531 532 73 2CP 2CN 69 536 537 538 2CR 70 542 543 544 2CR 2CQ 2 2CN 205 542A 543A 544A 2 GND FIG 23 CONNECTION WIRING DIAGRAM YLAA0195 SHT 3 78 JOHNSON CONTROLS
2. 48 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 TABLE OF CONTENTS CONT D 49 E 50 32__33 3 2 lt 2 lt __ _ 51 WMO LUGS It 52 ELECTRICAL NOTES AND LEGEND ive doo aka saa recie ore cons 53 WIRING DIAGRAMS 56 Elementary Wiring Diagrams YLAA0195 U 56 Connection Wiring Diagrams YLAA0195 U u u 74 Elementary Wiring Diagrams YLAA0220 YLAA0515 88 Connection Diagrams YLAA0220 YLAA0515 nenne nenne nnn nnn nnn nnn nnn nnn 96 DIMENSIONS ENGLISH 5 51858852 Pede 65 223 82522220 222 20 8 281520 aut 111 TECHNICAL DATA CLEARANTQGES 22 2 120 WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING 05III0M 121 124 One Inch Deflection Spring Isolator Cross reference 124 One
3. _____ _ _ _ _3 22 33_ 3_ _ _ _ _ 23 _ _ ___ _ 3_ 2 _ I 153 Up and DOWN Arrow Keys 5 153 ____ __ 2 _3 _ _ 153 KEYS C 154 um u NI 154 Leaving Chilled Liquid Control uu avec o Cx v Dens E 154 Return Chilled Liquid Control 155 Remote S tpoI tS Control uu usai m bua 155 __ gt lt 2 lt 2 993 155 PROGRAM RR 157 VONS wa 158 Unit THp un uu 159 PROGRAM KEY LIMITS AND DEFAULLI U u YE CO cu PY ERR EE Ba 159 SETPOINTS QUICK REFERENCE 160 gt gt gt gt _ _ 161 Options
4. _ 161 _ _ _ lt _ _ ___ _ __ 233 3 _ 22 2222 __ 4 165 UNIT KEYS OPTIONS PROGRAMMING QUICK REFERENCE LISTI 166 JOHNSON CONTROLS FORM 150 72 811 ISSUE DATE 8 15 2011 TABLE OF CONTENTS CONT D SECTIONS UNIT _ _ _ _ 3 _ __ _ __ 9 167 CAPACITY CONTROL aaa a a ua 167 SUCTION PRESSURE LIMIT CONTROLS inside um EXER dw aS xS xw u u CER u 167 DISCHARGE PRESSURE LIMIT CONTROLS o Pre lon 167 LEAVING CHILLED LIQUID CONTROL u u uuu rco uaa na 167 LEAVING CHILLED LIQUID SYSTEM LEAD LAG AND COMPRESSOR SEQUENCING 168 LEAVING CHILLED LIQUID CONTROLOVERRIDE TO REDUCE CYCLING 168 RETURN CHILLED LIQUID CONTROLL U U U U u u u 169 RETURN CHILLLED LIQUID SYSTEM LEAD LAG AND COMPRESSOR SEQUENCING 170 ANTEPRECY CUE TIMER D odi 171 ANTIECOINCIDENCE TIMER uuu u
5. gt lt WG gt e CA gt 10 08820 160 lt gt lt gt N N N gt 31 30 27 26 25 24 25 5 L 2 5 qe 228 24 23 229 035 21589 102 REV C ol lel lo 3 1 2 I LD13240A 33 CONNECTION DIAGRAM YLAA0220 YLAA0515 SHT 2 98 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA ALD GND OND RAD IAD CIS RIS oooooloooooo Q TB4 182 TBS F NEG O 7 4 s 1 m 1 BSP BLK 10 1 BSP WHT 11 1 BDP WHT 2 i TC PNK 52 1 BSP SCR 2 5 Di Tc BRN 53 cce 5 LD13241A JOHNSON CONTROLS 99 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 CONNECTION DIAGRAMS YLAA0220 YLAA0515 POWER OPTIONS CONNECTION DIAGRAM 035 21589 103 REV B 2L1 2L2 213 Or 202 2L3 01 22 213 111 41 2 113 12 113 111 211 212 213 111 112 113 211 212 23 211 2 2 213 1111 52 21 9 1L3 O 1L1 1L2 1L3 1L1 1L2 1L3 o 111 141 2 153 XTBC TRANSFORMER AND TERMINALS ARE FOUND ON POWER SIDE OF DIVIDER PANEL 2
6. MV 9 79 owy 64 Sd 90 068 546 59 09 wow 69 99 OW 9130 5 6 mowy d __ mowy icd __ 2v vv OW Id ckJdQv 66 98 OW XXV 96 26 MIVIV Sid 16 82 JwoN 94 eoa duer 630v 22 7 Sd 84 62 02 mowy id vid 72V 6 9 OW Hd __ sza Old __ uwy 60d Hd H 1 80d Old 60d tod 60d 80d 1 0 80d dd 04 208 __ OV 90d ooy 604 904 __ 204 5d 0116849 921 M0I1 I9 590 157 LNIOd d L 318VTIVAV LON N TWNOILdO O 5 3000 157 1 4 sSseJppy joefqo 340A NSI 2199 125 INI 19IIIV e o JOje SUEJ 1X IIOSV Durzinn 10
7. 81 LD13234A FIG 34 CONNECTION DIAGRAM YLAA0220 YLAA0515 SHT 3 100 JOHNSON CONTROLS SECTION 5 TECHNICAL DATA FORM 150 72 3 811 ISSUE DATE 8 15 2011 4 L1 2L3 L2 2 QCB 2 2 212 2L1 2L2 L1 2 21922 L1 2L1 LD13901 101 JOHNSON CONTROLS FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 CONNECTION DIAGRAMS YLAA0220 YLAA0515 COMPRESSOR WIRING 035 21589 106 REVE vor En 3599 2 1 FSC EXT loooo 000 gt i 148 147 146 150 151 153 5005 3 g 1 5 I EXT AV dE TBS 1 2 loooo 248 247 246 250 251 253 8 GND 2 5 244 1 AW FIG 35 CONNECTION DIAGRAM YLAA0220 YLAA0515 SHT 6 LD13900 102 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 EXT R2 SECTION 5 TECHNICAL DATA 1 TxvH 1 VLL5V 2 IXV F2 YLLSV 2 FHP1 EXT MI O 2 FHP1 F1 FHP1 2 3 2 ECH2 1 ECH3 226A EXT EXT 2 2 206 L1 106 2 3 207 HL EXT 107 208 3 108 D GND 235A 2344 231A exec 2 80 2 2 2 BHP 1 2
8. 41 FIOW OWIECIE IR DUE isis eese gie Fees aso ga Pagus Sea RUE FE 41 COMPRESSOR HEAT 41 RELIEF VALVES u uu ym u P 41 HIGH PRESSURE CUTOUT uuu a 41 SINGLE POINT SUPPLY CONNECTION TERMINAL BLOCK NON FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER u DE GE S SS a 0 42 USER CONTROL WIRING INPUTS 43 USER CONTROL WIRING OUTPULTS u 44 SEGTION5 TECHNICAL DATA 45 OPERATIONAL LIMITATIONS 44 460440060 4 45 Temperatures and FIOWS na E Olai UG pew sedans 45 M 45 HEAT EXCHANGER FLOW uu 46 Ethylene amp Propylene Glycol Correction Factors 46 PHYSICAE DATA 32222 lt _ __ _ _ _ _ _ _ __ _ 47 Standard Efficiency YLAA0285 0485 47 High Efficiency YLAA0195 YLAA0515
9. 1 XP8 SOA RED o u o o o n n n n n 0 XP8 SOA BLU OI pK Oe XP9 gt 2 109 33 34 25 26 29 30 23 24 27 28 31 32 14 16 13 18 21 20 5 6 025 42095 000 ez ee 55 we we we 21117 27 27 127 7 gt gt gt gt gt gt 120 I 0 C J13 XP7 BRN D K SF ARB BL 1 SF ARB SCR IF 09 SF ARB RE FIG 24 CONNECTION WIRING DIAGRAM YLAA0195 SHT 4 80 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA 149C 27 _ E 6 i BDP RED 7 1 B0P BLK XTBC1 5 9 2 85 01 0 2 BSP WHT 1 2 80 1 2 5 2 BSP RED 2 RED 7 2 BDP BLK 1 2 85 5 2 SCR 3 e J11 XP10 BLK 15 9 20 10 EN px raver fe JOHNSON CONTROLS 81 SECTION 5 TECHNICAL DATA CONNECTION WIRING DIAGRAMS YLAA0195 035 21589 205 REV D 1408 140 2 Com X 2 YESV SF ARB RED SF ARB BLK N gt 9 S
10. 135 134 JOHNSON CONTROLS GND 1 5 H EXT 120A 8 9 w E 220A s i cL L 234 2 Ee 9 LD13233A 103 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 CONNECTION DIAGRAMS YLAA0220 YLAA0515 CONDENSER FAN MAPPING AND SEQUENCING 035 21589 107 REVA EXT GND 4 6 516 59 563A v2 562 565A 2 561 564 82 560 013147 36 CONNECTION DIAGRAM YLAA0220 YLAA0515 SHT 7 104 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA YLAA0070SE YLAAQOBOSE YLAAO100SE YLAAO101HE YLAA0090SE YLAAO125HE YLAAO135SE YLAAO141HE 01505 YLAAO155SE e 1 75 YLAAO156HE LD13232 JOHNSON CONTROLS 105 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 WIRING DIAGRAM POWER SUPPLY m 220 230V 3 60HZ2 00270 60HZ 220 230 3 60 2 75V 3 60H 460V 3 60H7 575 3 60 7 380 415V 3 50 60HZ 75V 3 60H 3807415V 3 50 60HZ 75V 60H 380 41 5 3 50 60 7 ATT T 008 121416 Om 1L1 1 1 1L2 1 1 1L3 1 1 2L1 1 4 2L2 1 5 2L3 1 5 SINGLE POINT WIRING OPTIONS FIG 37 WIRING DIAGRAM SINGLE POINT WIRING OPTIONS 106 JOHN
11. 169 TABLE 15 RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS 6 STEPS 170 TABLE 16 RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS 6 STEPS 170 TABLE 17 YLAA STANDARD CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONLY 12 3 OR 4 FANS SYSIEN 173 TABLE 18 YLAA STANDARD CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONLY 5 OR 6 FANS PER 5 174 TABLE 19 COMPRESSOR OPERATION LOAD LIMIIIMC 175 __ lt 2 lt lt 223 3 3 3_ _ _ _ _ _ _ 3 625 179 TABLE 21 1 0 DIGITAL 179 TABLE 22 ANAEOG INPUTS uu n u u ul ees u 179 TABLE 23 ANALOG OUTPUTS icio otek u 179 TABLE 24 OUTDOOR tito gsasaspasiaqapastayaunsappaqayaaasaaquyaqatapaypapuspasaus 181 TABLE 25 ENTERING LEAVING CHILLED LIQUID TEMP SENSOR TEMPERATURE VOLTAGE CORRELATION 182 TABLE 26 PRESSURE TRANSDUCERS Rer eae NM EU Dee ERR 183 TABLE 27 TROUBLESHOOTING _ _ _ gt gt 9 9
12. sis voeo ees sew 3909408 Siosseidwog p woso SdNOO WIN S ue WAN dd dA LNIOd FUAM STINT 3333999 3VIVM 19u2 vg Wa ied SNAGOW 9p02 157 1VI0 1 LL LL IL LL II IL 6000C 90C C Continued on next page JOHNSON CONTROLS 196 SECTION 10 MAINTENANCE FORM 150 72 3 811 ISSUE DATE 8 15 2011 5 0 sdey 19V V9 3ALLVN II ICVICI1CVII91VI JO 0 4 0 _ 6 _ 9 P E ue J seJouDi 160111 IM se sesn 1M2A SUL 9 IIC180 10 suoneJedo 1341149 ejqeordde ees Jed Hed sjeosedojly egy sjeoseg eg 5 Jed sq Sd 199 1994 Jed 1994 I N40 JO seuou OM t 912990 3V IHSV 72 0 uoneoynoN 8 enjeA z Dojeuy uj 0 9
13. ainpeyds 1 9 9 Pi io ui p de sp pei J 7 s vp 2251 3 V9IM b PRION 0 0 Cpu ON O 21175025 39Vd 39Vd 9po2 IIOSV jeuoneJedo IIOSV 201 JOHNSON CONTROLS FORM 150 72 811 SECTION 10 MAINTENANCE ISSUE DATE 8 15 2011 TEMPERATURE CONVERSION CHART Temperature Conversion Chart Temperature Conversion Chart Actual Temperatures Differential Temperatures F G F F C G F 4 15 6 16 3 2 4 2 2 2 3 6 8 13 3 14 6 8 8 4 4 4 7 2 12 242 10 4 12 6 7 6 10 8 16 8 9 10 14 16 8 9 8 14 4 20 67 28 176 20 11 1 10 18 24 4 4 6 212 24 13 3 12 21 6 28 159 4 24 8 28 15 6 14 25 2 32 0 0 2 28 4 32 17 8 16 28 8 36 22 0 32 36 20 18 32 4 40 4 4 2 35 6 40 22 2 20 36 44 6 7 4 39 2 44 24 4 22 39 6 48 8 9 42 8 48 24 43 2 52 11 1 8 46 4 52 26 46 8 56 13 3 10 50 56 28 50 4 60 15 6 12 53 6 60 30 54 64 17 8 14 57 2 68 20 0 16 60 8 72 22 2 18 64 4 Pressure Conversion Chart 2 Gauge or Differential 80 26 7 22 71 6 84 28 9 24 75 2 PSI BAR BAR PSI 88 31 1 26 78 8 20 1 38 1 5 21 8 92 33 3 28 82 4 30 2 07 2 29 96 35 6 30 86 40 2 76 2 5 36 3 100 37 8 32 89 6 50 3 45 3 43 5 104 40 0 34
14. ted seo 20486 91 OW 0L 6 8 NOlLdl42S3G 15 LNIOd uonisog 1X8 L d L 139 318VTIVAV LON N TWNOILdO O QHVONVIS 5 3000 LSITLNIOd 5 joefqo CM 340A NSI 340A 2199 125 Continued on next JOHNSON CONTROLS 200 SECTION 10 MAINTENANCE FORM 150 72 811 ISSUE DATE 8 15 2011 Continued from previous page OO ting e 92 92 i se anes 2 1 ze ee 1 4 1 7 2 i i E 123 8k dH Sumur peog 8 8 EM 2 Bujuuny 8 086 4 2 71 ZL 9 Pupu peo 9L 9k 12 j AE __ _ i G F Y Pumu 5 ek eee EE 40 10 020150 enjoy j 054 gd 0 0 0532 7 777 I 8 11228224 ainssalq 7
15. 138 138 cse c 138 IC meme 138 Programming Of Compressors U U U u 138 STATUS KEY ge 139 LIC E 139 General Status Messages _ 139 Fault Safety Status 3 __ _ _ _ 141 Status Key 55 ett 144 __ lt ___ lt 3 __ __ _ _ _ 23 _ lt _ 145 Oper Data t 145 Oper Data Quick Reference List 148 dli d m M 149 Operating Data _ _ gt 149 uu RN 150 55 M 150 SoftWare Version 152
16. 179 MICROBOARD LEAYOUT _2222 lt 6 180 CHECKING INPUTS AND OUTPUITS U U u u nna ia 181 Digital 181 Analog Inputs Temperature 181 181 Liquid 4 Refrigerant Sensor Test Points 182 Analog Inputs 183 Digital C 184 OPTIONAL PRINTER INSTALLATION u u uu 185 Wo 185 Assembly Wiring uu 2 42 p 185 Obtaining a 185 TROUBLESHOOTING _ gt 186 8 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 TABLE OF CONTENTS CONT D SECTION 10 MAINTENANCE 189 189 COMPRESSORS 189 _ lt 2 2 6
17. A a a 38 ___ M 38 Noise Sensitive Locations u u u u u 38 SPRING ISOLATORS OPTIONAL les oa aad apa 38 COMPRESSOR MOUNTING u u 38 REMOTE 38 t 38 PIPEWORK ARRANGEMENTI r SPORE CEP EE Rea Ug acu deu 39 DUCI WORK CONNECTION R twee Pa ure mae Codd Saa 40 General Requiremehls 40 WIRING t Ee 40 Evaporator Pump Start Contacts 40 System RUN gt gt gt gt gt 40 Alatm Status COMCA I 41 Remote Start Stop CODILACES 41 Remote Emergency 41 reset In DUE gt 2 _ _ 41 Load i u D
18. sn 05620 160 preog UoISJ9 ISEM TMOA masma mam mm 2 098 5 0 lt 020 60 peog CIN 008 9202 0607 40 0050 0 lt 020 60 peog COIN 00 9796 06000 0 0 0 lt 020 60 04909 CIN TWOA 00 0996 50604 40 20 0 S1N3WWOO pneg 0 0 0 020 6M8155015IIIV MEL 0662 0502 M APPIN VV TIA TMOA TVO A TIN Continued on next page 199 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 10 MAINTENANCE Continued from previous page jueuunooq Auedwosoy pinous epo ayeudouddy 94 310 ved 6688 86 ON ced fed ed 47 6 d oond led 684 ON BA Wed eto osa Pet OW VM0V 66 06 mowy 64 cvdjav 68 98 owy 9 d 8d 8 28 __ 8 2 OW 9 4
19. 80 FIG 25 CONNECTION WIRING DIAGRAM YLAA0195 SHT 5 82 FIG 26 CONNECTION WIRING DIAGRAM YLAA0195 6 84 FIG 27 CONNECTION WIRING DIAGRAM YLAA0195 SHT 7 86 FIG 28 ELEMENTARY WIRING DIAGRAM YLAA0220 YLAA0515 SHT 1 88 FIG 29 ELEMENTARY WIRING DIAGRAM YLAA0220 YLAA0515 SHT 2 90 FIG 30 ELEMENTARY WIRING DIAGRAM YLAA0220 YLAA0515 SHT 92 FIG 31 ELEMENTARY WIRING DIAGRAM YLAA0220 YLAA0515 SHT 4 94 FIG 32 CONNECTION DIAGRAM 0220 YLAA0515 SHT 1 96 FIG 33 CONNECTION DIAGRAM 0220 YLAA0515 SHT 2 98 FIG 34 CONNECTION DIAGRAM YLAA0220 YLAA0515 SHT 100 FIG 35 CONNECTION DIAGRAM YLAA0220 YLAA0515 SHT 6 102 FIG 36 CONNECTION DIAGRAM 0220 0515 SHT 7 104 FIG 37 WIRING DIAGRAM SINGLE POINT WIRING OPTIONS
20. ey WAN C ageren ion N 42006 O prepueis s LNIOd TUUM Ssutno fqo Wall 9p02 1571 7 O 6000C 9C C 197 JOHNSON CONTROLS SECTION 10 MAINTENANCE FORM 150 72 811 ISSUE DATE 8 15 2011 YORKTALK 2 COMMUNICATIONS Received Data Control Data The unit receives eight data values from the MicroGateway or E Link The first four are analog values and the last four are digital values These eight data values are used as con trol parameters when in REMOTE mode When the unit is in LOCAL mode these eight values are ignored If the unit receives no valid YorkTalk 2 transmission for 5 minutes it will revert back to all local control values Table 32 Yorktalk 2 Communications Data Map lists the control parameters These values are found under feature 54 in the MicroGateway or E Link 198 Transmitted Data After receiving a valid transmission from the MicroGateway or E Link the unit will transmit either operational data or his tory buffer data depending on the History Buffer Request on ENG PAGE 10 Data must be transmitted for every page under feature 54 If there is no value to be sent to a particular page a zero will be sent Table 32 Yorktalk 2 Communica tions Data Map shows the data values and page listings for this unit The latest point map informat
21. 4 1000 S eassejg eDueuosiq 4060 29 4 6 4 9 SHUN uo Bu looO eunsseig uopons 95 95050 19 009410751 99 dH NONI einssejg uonons voeo 09 2 4 10 5 tS iqu voeo 6m ind voeo es sew I 0 11001 8 9I9 9 MVV Spucoes 70050 275 I9 002 6894 uonong e 194 M M 0 043409 70 50 gt IV JOHINOO 2546 Y govisNvzs CV apoo 6545 pu ws 9909 zs e 064 1546 oew N amp 4iS sfS voto zrs 61 3900 998 o EL 585 094296 y voeo 300019 B 906 ees spoojeuwemdo 2V voeo os 9009408 w 990 905 46 xeu voeo 00 536 apoo
22. 811 ISSUE DATE 8 15 2011 Digital Outputs Refer to the unit wiring diagram and Fig 62 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 evaporator pump start signal The voltage applied to either of these terminals would be determined by field wiring Each output is controlled by the microprocessor by switching 120 to the respective output connection energizing contactors evaporator heater and solenoids according to the operating sequence see Fig 62 120VAC is supplied to the I O board via connections at TB7 1 TB7 6 TB10 1 TB10 6 TB8 1 and TB9 1 Fig 62 illustrates the relay contact architecture on the microboard SYS 1 7872 COMP 7 3 SYS 1 874 2 SYS 1 187 65 SYS 1 877 SYS 1 SYS 1 TB7 9 SYS 1 E 7187 10 Fan SYS 2 TB10 2 4 10 3 LLSV 2 SYS 2 10 4 2 5 SYS 2 10 5 6 SYS2 TB10 7 HGSV TB10 8 SYS 2 18109 352 SYS 2 LLSV 1 TB TB ARAR t 188 6 TEL EMT HEAT EXCH 5 188 HEATER LD12722 FIG 62 BOARD RELAY CONTACT ARCHITECTURE JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 9 SERVICE AND TROUBLES
23. Ie 2 14 6 37 11 13 15 530 536 G O eB 21416 2 4 16 2 4 16 2 2 KFL1 2 2 2 KFL2 77 6 313355 12 M 3 5 13 1135 CC 2 MF1 2 MF2 EXT EXT x W2 VV2 eel Wee FIG 19 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 8 70 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA JOHNSON CONTROLS 71 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 ELEMENTARY WIRING DIAGRAMS YLAA0195 035 21583 209 REV D SS SSS SSS SS SSS SS G ue 120 2 7 122 149 149 22 6 148 12 14 NS 21 1 115 3 4 N B 1 144 201 EXT EXT CN A1 1 1 2 GND EXT EXT 1 5 _ 1 2 x Do ER 22028 1 5 2 2 12 gt 2 4 4 2 lege 2 Ma 6 24 9 e SS v T __ FIG 20 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 9 72 JOHNSON CONTROLS SECTION 5 TECHNICAL DATA FORM 150 72 3 811 ISSUE DATE
24. XLI0CC70 0 M 06920 160 0I60 00 99 20 80 20 14 20vVONNO 9 99 05 JED XXX OGGZO LEO oJI 1 100 84 20 160 80 20 14 S 0 lt lt 00 160 06920 160 THIN 700 99720 120 90 62 009VONWO p OSSZO TEO M 06920 160 Pog 00 SS2Z0 L 0 90 6 OOVLONWO OSSZO TEO M 06900 160 YM 200 99220 120 90 62 0O00SVONWO OSSTO TEO 06920 160 L00 SSZZ0 L 0 QO AON 6Z 0O0 VONWO 151 1VI0 unsy uo NdwoA a ___ O0SSZ0 LE0 06920 160 pJeog sde 2UDVg pue VV IASI 600 Continued on next page 195 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 10 MAINTENANCE Continued from previous page 9 geq 3ALLVN II JOVEW 9IPPIIN 6V0CI16VII81LII _ PIS 0
25. gt gt gt gt gt gt gt 186 TABLE 28 MINIMUM MAXIMUM AND DEFAULT VALUES 192 TABLE 29 VALUES REQUIRED FOR BAS CC MMVMIC II0M 193 TABLE 30 REAL TIME ERROR NUMBERS U U u u u 193 TABLE 31 BACNET AND MODBUS COMMUNICATIONS DATA 195 TABLE 32 YORKTALK 2 COMMUNICATIONS DATA MV 199 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 1 GENERAL CHILLER INFORMATION AND SAFETY INTRODUCTION YORK 0195 0515 57 142 ton 200 500kW chillers are manufactured to the highest design and construction standards to ensure high performance reliability and adaptability to all types of air conditioning installations The unit 15 intended for cooling water or glycol solutions and is not suitable for purposes other than those specified in this manual This manual contains all the information required for correct installation and commissioning of the unit together with operating and maintenance instructions The manual should be read thoroughly before attempting to operate or service the unit All procedures detailed in the manuals including installation commissioning and maintenance tasks must only
26. 189 SIS 189 ___ ___ _ __ 189 __ __ _ _ _ 3_ 33 __ __ lt _ _3 _ _33 3 233_ 189 OPERATING PARAMETERS disc T Sukan pasu 189 ON BOARD BATIERY BACKSUP uuu y EE vaa En e FERE 189 PLATE AND FRAME HEAT EXCHANGER EVAPORATOR 189 OVERALLUNIT INSPEC HON 189 MICROCHANNEL COIL CLEANING 190 BACNET MODBUS AND YORKTALK 2 C0MMVMIC II0CM 191 BACnet and Modbus Communications 194 Communications Data Map Notes 194 YORKTAEK 2 COMMUNICATIONS 198 Received Data 6 198
27. 2 es 171 EVAPORATOR PUMP CONTROL amp U U u u u u 171 FY DRO PUMP GCONTR OL uu 171 EVAPORATOR HEATER CONTROL u u u u auqa 171 IX _ _ _ _33_ _ _ 2 3 _ __ _ _ ___ _ 171 STANDARD CONDENSER FAN CONTROL U U uu 171 _ gt gt gt gt gt gt gt gt _ 175 COMPRESSOR RUN 175 _ _ __ _ __3 3___ ___3 lt _ lt 175 BAS EMS TEMPERATURE RESET USINGA VOLTAGE OR CURRENT SIGNAL 176 SECTION 9 SERVICE AND TROUBLESHOOTING nennen nennen u u 177 CLEARING HISTORY 177 SERVICE ejnt 177 SERVICE MODE OUTPUTS asn ee Reed euni red aves DEA 177 SERVICE MODE CHILLER CONFIGURATION 178 SERVICE MODE ANALOG amp DIGITAL INPUTS u 178 CONTROL INPUTSIOUT PUTS 2 iiie asi eese dra
28. 811 ISSUE DATE 8 15 2011 ELEMENTARY WIRING DIAGRAMS YLAA0220 YLAA0515 035 21583 103 REV B 1L1 1 1 1L2 1 1 111 15323151 350 Se 7j 352 1 MF2 EXT 2d Vee LEa 13 T 13 T Ae ely ee ely ee ely ee 30 ELEMENTARY WIRING DIAGRAM YLAA0220 YLAA0515 SHT 3 92 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA a eS SS a eS SS 2L1 1 5 Pr 22775 2L3 15 Ey 2 F4 450 1 5 452 N er qe 1218 7 E 97 7 9 8 94 9 97 5 6 5 5 Hire LJ 92 8 94 29 97 13 14 13 14 3 213 22 AL 22 215 S 2 94 JOHNSON CONTROLS 93 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 ELEMENTARY WIRING DIAGRAMS YLAA0220 YLAA0515 035 21583 104 REV B 1 11 27 112 1 1 1 13 1L3 1 1 350 1 i 2 1 2 2258 113 D 116 E 22 113 jJ 16 e 3 m3 4 716 el I ely el ee FIG 31 ELEMENTARY WIRING DIAGRAM YLAA0220 YLAA0515 SHT 4 94 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA ee 21
29. CHICAGO CODE RELIEF VALVES Unit will be provided with relief valves to meet Chicago code requirements Factory mounted SERVICE ISOLATION VALVE Service suction and discharge ball type isolation valves are added to unit per system discharge service ball type isolation valve is standard on each circuit JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 HOT GAS BY PASS Permits continuous stable operation at capacities below the minimum step of compressor unloading to as low as 5 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 DX COOLER 300 21 BAR PSIG DWP WATERSIDE The waterside will be of 300 PSIG 21 bar instead of the standard 150 PSIG DWP 300 PSIG R F flanges are in cluded on the DX cooler nozzles Factory mounted The companion flanges will be field supplied by others FLANGES ANSI AWWA C 606 COUPLINGS TYPE Consists of 2 flange adapters for grooved end pipe standard 10 5 bar 150 psi cooler Not available on optional DX cooler 21 bar 300 psi DWP waterside Field mounted FLOW SWITCH The flow switch or its equivalent must be furnished with each unit 150 PSIG 10 5 BAR DWP For standard units Johnson Controls model F61MG IC Vapor proof SPDT NEMA 3R switch 10 5 bar 150 psig DWP 29 C to 121 C 20 F to 2
30. JOHNSON CONTROLS JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA ELECTRICAL NOTES AND LEGEND Designation DESCRIPTION ACC ACCESSORY ADIS DISPLAY BOARD 8 BOARD BAMB AMBIENT oo _ DISCHARGE AIR TEVPERATURE _ 222277 71 NOT FITTED ON REMOTE UNITS BMP MOTOR PROTECTOR COMPRESSOR BSP SUCTION PRESSURE EEH EVAPORATORHEATER EHRH HEATRECOVERY EPH PUMPHEATER EXT CONTROL _ ________ FHP HIGH PRESSURE CUTOUT FSC FAN SPEED CONTROLLER FAN SPEED INHIBIT TWO SPEED FAN OPTION ONLY GND GROUND G Y GREEN YELLOW PLUG BOARD CONNECTOR ORCUTT BOARD RELAY KF INCLUDING COIL SUPPRESSOR KFH FAN CONTACTOR HIGH SPEED INCLUDING COIL SUPPRESSOR FAN CONTACTOR LOW SPEED INCLUDING COIL SUPPRESSOR KFOL FANOVERLOAD KFS REAYFANSPEED HEATERREAY _ KM COMPRESSOR CONTA CTOR INCLUDING COIL SUPPRESSOR CONTROLREAY PUMP CONTACTOR PART INCLUDING COIL SUPPRESSOR KT REAYTMR M COMPRESSOR MOTOR O MOTOREAN WP MOTOR PUMP NOT USED 1 EARTH PWM PULSE WIDTH MODULATION TEMP RESET or REMOTE UNLOAD 2nd STEP Designation DESCRIPTION
31. 3 811 ISSUE DATE 8 15 2011 SECTION 8 UNIT OPERATION CAPACITY CONTROL To initiate the start sequence of the chiller all run permissive inputs must be satisfied flow remote start stop switch and no chiller or system faults should exist The first phase of the start sequence is initiated by the Daily Schedule Start or any Remote Cycling Device If the unit 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 established 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 liquid temperature to the desired setpoint and regulate the leaving or return chilled liquid temperature to meet that desired setpoint SUCTION PRESSURE LIMIT CONTROLS The anticipatory controls are intended to prevent the unit from ever actually reaching a low pressure cutout Loading 1s prevented if the suction pressure drops below 1 15 x suction pressure cutout 15 below th
32. END LOUVER END HAIL GUARD ENCL PANELS FACTORY A END LOUVER END HAIL GUARD ENCL PANELS FIELD AESTHETIC PANEL KIT ONLY FACTORY AESTHETIC PANEL KIT ONLY FIELD AESTHETIC PANEL KIT PLUS HAIL GUARDS FACTORY E AESTHETIC PANEL KIT PLUS HAIL GUARDS FIELD SPECIAL ENCLOSURE PANELS NO ACOUSTIC BLANKET REQUIRED ACOUSTIC BLANKET REQUIRED ACOUSTIC ENCLOSURE SPECIAL ACOUSTIC BLANKET REQUIRED NO DOCUMENTS REQUIRED BASE MATERIAL amp WITNESS DOCUMENTS BASE DOCUMENT BASE amp MATERIAL DOCUMENTS BASE amp WITNESS DOCUMENTS SPECIAL QUOTE X X C X X C X E lt gt JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 2 PRODUCT DESCRIPTION PRODUCT IDENTIFICATION NUMBER PIN CON T FEATURE FEATURE DESCRIPTION PIN 51 PIN 51 FANS SOUND FANS PIN 52 PAINT PIN 53 FEATURE FEATURE DESCRIPTION VIBRATION ISOLATORS ISOL PIN 54 55 PIN 55 PIN 56 PIN 56 SHIP SHIP INSTRUCTIONS PIN 57 PIN 58 PIN 58 JOHNSON CONTROLS OPTION X X SPECIAL QUOTE STANDARD LOW SOUND FANS REQUIRED HIGH AIRFLOW FANS REQUIRED VENDOR SPECIFIC LOW SOUND FANS REQUIRED VENDOR SPECIFIC ULTRA QUIET FANS REQUIRED HIGH STATIC FANS REQUIRED VENDOR SPECIFIC ULTRA QUIET FANS REQUIRED VENDOR SPECIFIC TWO SPEED FANS REQUIRED VENDOR SPECIFIC SPECIAL SOUND FANS REQUIRED X SPECIAL QUOTE OPTION OPTION DESCRIPTION X NO ISOLATORS REQUIRED 1 DEFLEC
33. EXT EXT EXT L EXT EXT L 1 o o C C 2 4 FERR 17 gt 5 17 4 88 lt lt 3 6 9 1 15 9 10 ole ly ht le enm ke 6 11 x WE TOR NS J6 J9 J11 RS485 RS232 K15 K16 K17 418 K19 K20 K21 K23 24 19293949 129594957697 uo OO J 8855 4 4483 2 2 2 L 2 a gt 3 8 3 9 a es NB8 47 48 4 9 715 7 7158 7159 LD13144A JOHNSON CONTROLS 89 FORM 150 72 3 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 ELEMENTARY WIRING DIAGRAMS YLAA0220 YLAA0515 035 21583 102 REV D K15 K13 17 16 2 XP3 AMB 1 2 x XTBC2 XTBC2 2 Duis B a 24 23 1 5 4 2 XTBF 231 131 A N 3 3 3 P gt FZ 2 1 1 140 144 M 1 6 1 8 1 10 1 12 1 1 2 1 2 FIG 29 ELEMENTARY WIRING DIAGRAM YLAA0220 YLAA0515 SHT 2 90 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 XP3 N 220 14 11 2 XTB10 2 KCR cl JOHNSON CONTROLS 123 SECTION 5 TECHNICAL DATA 4 3 13 1 KCR 2 120 14 3 91 SECTION 5 TECHNICAL DATA FORM 150 72
34. 090 00 ekia 66 _ oo lp 1919M 0 602010 662 8318 6 11111111 446 000 862 ig NM CO 16 jo L LL 915 o 460 wig 06 I I E 2 5 6 545 0 wass k o 000 960 9189 SAS avai 6 _ Plous os 2 95 sezi 300025 88 948 7621 eria 28 9955 98 ptt tt usan e 5 C EM 00909 wezi Orid 88815 L seo 5 5 10 02010 64 68 _ dH SAS 0 680 0 IS 20 946 02010 zia 18 _ o NMOS 08 L E 1 1010 982 88 _ Snes 101610909 0 00010 680 vig _ 8 Eu Snes b o 009
35. Improperly adjusted leaving chilled liquid temp cutout glycol only Micropanel setpoint range values improperly programmed Chilled liquid flow too low Defective LWT or RWT sensor assure the sensor is properly installed in the bottom of the well with a generous amount of heat conductive compound Replace TXV Check GPM See Limita tions liquid through the cooler in Installation section Check operation of pump clean pump Strainer purge chilled liquid system of air Replace transducer low pressure switch or faulty wiring Refer to Service section for pressure voltage formula Replace LLSV Check fan motor and contactors Assure fan blows air upward Remove refrigerant Evacuate and recharge system Replace discharge pressure transducer Refer to Service section for pressure voltage formula Re program the leaving chilled liquid temp cutout Re adjust setpoint range Increase chilled liquid flow refer to Limitations in Instal lation section Compare sensor against a known good temperature sensing device Refer to Service section for temp voltage table CONT D 187 FORM 150 72 3 811 SECTION 9 SERVICE AND TROUBLESHOOTING ISSUE DATE 8 15 2011 TROUBLESHOOTING CONT D PROBLEM CAUSE SOLUTION MP HPCO FAULT COMPRESSOR S WON T START LACK OF COOLING EFFECT 188 Compressor int
36. 2641 2207 N A R N A R 495 36 2461 36 N A YLAAO260HE Isolator Weights kg if selected YLAAO260HE Isolator Locations 3 __1_ 2 3 L N A L 495 2207 2641 2207 N A R N A R 495 36 2461 36 N A YLAA0285SE Isolator Weights kg if selected YLAA0285SE Isolator Locations mm 3 __ 2 L N A L 495 2207 2641 2207 N A R N A R 495 36 2461 36 N A YLAA0320SE Isolator Weights kg if selected YLAAO320SE Isolator Locations mm 3 __ 2 FIG 51 WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS continued on next page JOHNSON CONTROLS 121 FORM 150 72 3 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 L1 L2 L3 continued from previous page X R1 R2 R3 G Y YLAAO300HE Isolator Weights kg if selected YLAAO300HE Isolator Locations mm 1 2 0350 Isolator Locations mm a3 2 1 3 03605 Isolator Locations mm YLAAO390HE Isolator Weights kg if selected 0390 Isolator Locations 1 2 3 FIG 51 WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS 122 YLAAOAOOSE Isolator Locations mm 193 2207 3170 2207 193 36 3170 36 193 2207 3170 2207 193 36 3170 36 __ 2 3 193 2207 3170 2207 N A 193 36 3170 36 N A JOHNSON CONTROLS continued on next page
37. 4 c w 8 RE 13 13 4 23 24 24 eee _ JOHNSON CONTROLS 63 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 ELEMENTARY WIRING DIAGRAMS YLAA0195 035 21583 205 REV D 1L1 1 8 12 12418 13 2 13416 2 14 16 21416 1 1 KFL1 1 2 755 11 3 15 52 113 15 5 6 1 MF1 gt 1 2 EXT EXT PE PE W1 W2 W1 W2 16 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 5 64 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA 1 KF3 34 1 3 15 2 14 6 2 14 6 1 4 4 KFL4 1 1 KFL3 51 111315 53 11 13 15 58 111315 54 1 1315 1 MF3 1 MF4 EXT EXT PE PE VV1 VV2 VV1 VV2 V1 02 JOHNSON CONTROLS 65 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 ELEMENTARY WIRING DIAGRAMS YLAA0195 035 21583 206 REV D 111 1L1 1 8 1L2 1 8 PF m 1L3 1 8 350 352 21416 21416 1 KF1 A 1 KF2 32 11 13 15 33 P 39575 500 506 501 507 x 502 12508 1 21416 2 14 16 2 14 6 2 14 6 1 KFH1 1 KFL1 1 KFH2 1 KFL2 755 111315 52 43 13 19 756 111315 752 11 13
38. DOWN arrow keys are used to set the RANGE in 5 F 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 plus or minus X X F This indicates the SETPOINT to be in the center of the control range If the control mode has been programmed for RETURN LIQUID control the message below would be displayed in place of the previous message JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 When in leaving chilled liquid temperature control the microprocessor board will attempt to control the leaving water temperature within the temperature range of the setpoint plus or minus the range In the above example control will be in the range of 43 F 47 F 6 1 C 8 3 C Return Chilled Liquid Control SETPOINT RANGE SECTION 7 UNIT CONTROLS The following messages illustrate both leaving chilled liquid control and return chilled liquid control respectively In return chilled lquid control the range no longer has a X X F but only a X X 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 programmable values for the COOLING SETPOINTS are shown in Table 10 The SETPOINT and RANGE displays just described were based on LOCAL control If the unit was
39. Unit Sys Voltage Unit ID I j NOT ON ALL MODELS VIEWABLE ONLY 14 the unit into Service Mode as described un der the Service and Troubleshooting section of this IOM and cycle each condenser fan to ensure proper rotation 15 Prior to this step turn system 2 off if applicable refer to Option 2 under the Unit Keys sec tion of this IOM for more information on system switches Connect a manifold gauge to system 1 suction and discharge service valves Place the Unit Switch in the control panel to the ON position As each compressor cycles on ensure that the discharge pressure rises and the suction pressure decreases If this does not oc cur the compressor being tested is operating in the reverse direction and must be corrected After verifying proper compressor rotation turn the Unit Switch to OFF 134 FORM 150 72 811 ISSUE DATE 8 15 2011 The chilled liquid setpoint may need to be temporarily lowered to ensure all compressors cycle on CAUTION This unit uses scroll compressors which can only operate in one direc tion Failure to observe this will lead to compressor failure NOTE 16 Turn system 1 OFF and system 2 refer to Option 2 under the Unit Keys section of this IOM for more information on system switches Place the Unit Switch in the control panel to the ON position As each compressor cycles ON ensure that the di
40. 1082 AW W 2 2 2 2 SS 27 II wrz 2 safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 6 rear to wall 6 control panel to end wall 4 0 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit 111 SECTION 5 TECHNICAL DATA FORM 150 72 811 ISSUE DATE 8 15 2011 DIMENSIONS YLAA0220HE 0260 0285SE amp 320SE ENGLISH 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 1082 CN TR 7 2 22 N 9 SS 37 4 YE 2222 A MI e 2 77 381 457
41. 982 SAS Hu 000 680 WeSC 55 880 vig 18 S S LNIOd YOLINOW j C C M74 duonon prb umes a d esw 0 eorva duo woso 6 69 180 26 a 4 voeo Guo veo t9 OS 2 Kuo eowedns d voeo zos is 99 uo 3 woso 108 awarWosdis S9 180 I 4 08 59 as 4 woso 6 ow 28 CM uods 9 180 wodes voeo ess 21 46 s od voeo ze ww 9 as 4 tri 09 S 8 as voeo ww 99 ___ gt C C C
42. C Reset 10 New Setpoint 7 22 C 6 67 C 13 89 C Max Reset Value is the Max EMS PWM Remote Temp Reset setpoint value described in the programming section under Cooling Setpoints Programmable values are from 2 F to 40 F 1 11 C to 11 11 C 176 FORM 150 72 3 811 ISSUE DATE 8 15 2011 Ifa 4 20mA signal is supplied it 15 applied to terminals A and A and jumper 1 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 Reset Value 16 Example Local Chilled Liquid Setpoint 45 7 22 C Max Reset Value 10 F 5 56 C Input Signal 12 mA English Reset 8mA x 10 F 5 F Reset 16 Setpoint 45 F 5 F 50 F Metric Reset 8mA x 5 56 C 2 78 C Reset 16 Setpoint 7 22 C 2 78 C 10 0 C A 240 24V Ratio Transformer T3 is used to derive nominal 127 output from 1207 supply NOTE JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 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 HISTORY YE
43. Display Value CHT Chilled Liquid Temperature HPC High Pressure Cutout LPC Low Pressure Cutout HPL High Pressure Load Limiting LTC Low Temperature Cutout Control Functions Fans 4 5 Components Pressure Relief Valve Service Ball Valve Expansion Valve Solenoid Valve Sight Glass Sensor Pressure or Temperature DV 585 PSIG Mus P Service Stop Access Valve DO PS 650 PSIG Pressure Switch ZCPR 3 Compressors DV Ambient Air Sensor DV HTC LTC YLLSV Low pressure liquid refrigerant enters the cooler and is evaporated and superheated by the heat energy absorbed from the chilled liquid passing through the cooler shell Low pressure vapor enters the compressor where pressure and superheat are increased The high pressure XL Filter Drier Removable Core Chilled Liquid 450 PSIG Evaporator ARK Chilled Liquid LD13139 vapor 15 fed to the air cooled condenser coil and fans where the heat is removed The fully condensed and subcooled liquid passes through the expansion valve where pressure is reduced and further cooling takes place before returning to the cooler FIG 6 PROCESS AND INSTRUMENTATION DIAGRAM 34 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 3 HANDLING AND STORAGE DELIVERY AND STORAGE To ensure consistent quality and maximum reliability all
44. FAIL RESTART AUTOMATIC POWER Chiller auto restarts after a power failure POWER FAIL RESTART MANUAL After a power failure the UNIT switch must be toggled 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 Type U NIT TYPE LIQUID CHILLER The UNIT TYPE message cannot be modified under the unit keys LIQUID CHILLER must be dis played or damage to compressors or other components will occur if oper ated in the HEAT PUMP or CON DENSING UNIT modes Ifunit 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 micropanel and the microprocessor will store the change 163 SECTION 7 UNIT CONTROLS Option 15 Refrigerant REFRIGERANT TYPE 410 Refrigerant type R 410A must be selected under Service Mode Refrigerant type is displayed under the OPTIONS Key but is only programmable in Service Mode Incorrect programming may cause damage to compressors CAUTION Option 16 Expansion Valve Type EXPANSION VALVE TYPE THERMOSTATIC Expansion valve type thermostatic or electronic may be selected under Ser
45. 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 pressure cutout On a standard system programmed for 44 PSIG 3 0 Bar suction pressure cutout the microprocessor board would inhibit loading of the affected system with the suction pressure less than or equal to 1 15 x 44 PSIG 3 0 Bar 50 PSIG 3 5 Bar The system will be allowed to load after 60 seconds and after the suction pressure rises above the suction pressure load limit point SYS 1 LOAD LIMIT LOAD LIMIT X X X X SYS 2 This message indicates that load limiting is in effect and the percentage of the limiting in effect This limiting 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 STATUS display will show this message This will indicate 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 cannot be overridden by anti recycle messages fault messages etc when in the STATUS display mode Therefore do not expect to see any other STATUS messages when in the MANUAL OVERRIDE mode MANUAL OVERRIDE is only to be used in emergencies or for servicing Manual override mode automatically disables itself after 30 m
46. K I I 1 x I CCI CI Ol Hl CI O e be 1 46 nis ake 39 09 210 224 72 10 7211 2 9 37 10 7 38 108 BACNET 710 fee JOHNSON CONTROLS 57 FORM 150 72 NM3 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 ELEMENTARY WIRING DIAGRAMS YLAA0195 035 21583 202 REV D K10 K15 K9 K1 K3 15 717 14 AMB 12 XTB9 4 XTB7 4 1 3 2 1 2 1 1 1 C 2 131 3 1 XTBF 4 2 4 131 231 3 3 3 3 EY 1 FHP gt EZ 2 V V 1 1 1 2 a 1 2 16 13 isi A de A3 2 FIG 13 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 2 58 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA 118 21 2 220 2 2 2 IN 9 11 2 d 220 2 YLLSV EXT 6 110 10 S x ay 25 on eee JOHNSON CONTROLS 59 FORM 150 72 3 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 ELEMENTARY WIRING DIAGRAMS YLAA0195 035 21583 203 REV D 1L 1 1 8 112 1 8 13 1L3 1 8 350 AMB __ LK2 J 2 1 2 E p 2 62 E p 3 64 L p 4 67 gt es QE o 5 64 ANS EI 5 6 2 62 jT e 3 64 5 6 4
47. QCB CIRCUIT BREAKER QMMSC I MANUAL MOTOR STARTER COMPRESSOR QMMSP MANUAL MOTOR STARTER PUMP QSD SWITCH DISCONNECT RESISTOR RED RED RUN PERMISSIVE REMOTE UNLOAD Ist STEP SCH THERMOSTAT CRANKCASE HEATER SCREEN FLOW SWITCH KEYPAD SOA SWITCH OFF AUTO SZT ZONE THERMOSTAT TRANSFORMER TRANSFORMER CURRENT UR BRIDGE RECTIFIER WHT PLUGS BETWEEN POW MICRO SECTION TERMINAL BLOCK CUSTOMER TERMINAL BLOCK FACTORY EVAPORATOR SOLENOID VALVE HOT GAS SOLENOID VALVE INCLUDING COIL SUPPRESSOR LIQUID LINE SOLENOID VALVE FIELD MOUNTED AND WIRED ON REMOTE EV AP UNIT ZCPR COMPRESSOR NOTE WELL SEE NOTE WIRING AND ITEMS SHOWN THUS ARE STANDARD Y ORK ACCESSORIES WIRING AND ITEMS SHOWN THUS ARE NOT SUPPLIED BY YORK ITEMS THUS ENCLOSED FORM COMPONENTS OR SETS OFCOMPONENTS 035 21966 101 REV G 53 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 ELECTRICAL NOTES AND LEGEND CONTINUED 035 21966 101 REV G 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 specifications All 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 fo
48. SECTION 7 UNIT CONTROLS The on board power supply converts 24VAC from 75 120 24 VAC 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 temperature sensors are supplied power for the microprocessor board 5V supply 24VAC is rectified but not regulated to provide unregulated 30 VDC to supply all of the digital inputs The IPU II board contains one green Power LED to indicate that the board is powered up and one red Status LED to indicate by blinking that the processor is operating The I O board contains one green Power LED to indicate that the board is powered up and one red Status 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 20mA or 0 10 VDC as the input type on the remote temperature reset analog input Unit Switch A unit ON OFF switch is located below the keypad This switch allows the operator to turn the entire unit OFF if desired The switch must be placed in the ON position in order for the chiller to operate Display The 4
49. _ _ 132 PREPARATION POWER 132 VIIC60I 50 00 06 uuu yu nh erras Mo rc 132 Compressor Heaters uu 4 22015544 82052558 28554485 gt _ 132 Water SySle 3 3 lt __ 8 132 132 5 5 132 EQUIPMENT PRE STARTUP 8 STARTUP CHECKLIST 133 M 133 STARTUP RA 133 __ 2 134 6 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 TABLE OF CONTENTS CONT D CHECKING SUPERHEAT AND 50 135 LEAK CHECKING uu uyu hp s 135 UNIT OPERATING SEQUENGCEuiu 55415 136 SECTION 7 UNIT CONTROLS 137 INTRODUC TON R 51220 atc La us 137 IPU u kas asas aus asua 137 8
50. __ owy 223 Sid 62 08 OW td 22 691 991 OW d 5 96 30 99 29 now 24 Ge 30 1917890 69d dH 541005 9109591 uopons ve 4 uow 894 04 910959 uogons MOT ee 691 091 uow y 29 69d ze 97 MM V 994 894 duel Duwes 30 94 2 7 OW v 994 494 88 v9d 994 994 S S S S S AM H nM 1 0 PON CHOW APCD p 0 80 12082003 4 69d 5 5 5 5 90518 ueq 195 98 s cd 094 led 555650658 5 694 094 5 5 4 ce 654 5 5 845 bek 694 99
51. chiller Never lift the chiller using a forklift or by hooking to the top rails Use only the lifting holes provided CAUTION Lifting Instructions are placed on a label on the chiller and on the shipping bag JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 4 INSTALLATION To ensure warranty coverage this equipment must be commissioned and serviced by an authorized Johnson Controls service mechanic or a quali fied service person experienced in chiller installation Installation must comply with all applicable codes par ticularly in regard to electrical wiring and other safety elements such as re lief valves HP cutout settings design working pressures and ventilation re quirements 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 1 through 5 must be checked before 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 system Do not remove protective covers from water con nections until piping 1s 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 the unit 1s installed and operated within limitations Refer
52. ensuring that all isolator centerlines match the maximum difference can be tolerated Bolt or anchor all isolators to supporting structure utilizing base thru holes B Remove top bolt and top washer Place equipment on top of isolators so that mounting holes in equip ment or base line up with threaded hole C equipment mounting holes The VMC group rec 6 ommends that the isolator base be installed on a level surface Shim or grout as required leveling Reinstall top bolt and washer and tighten down 7 Installation is complete TOP BOLT TOP WASHER C A SECTION D D LD13762B FIG 57 INSTALLATION OF DURULENE VIBRATION ISOLATORS INSTRUCTIONS JOHNSON CONTROLS 129 FORM 150 72 NM3 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 THIS PAGE INTENTIONALLY LEFT BLANK 130 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 6 COMMISSIONING COMMISSIONING Commissioning of this unit should only be carried out by Johnson Con trols Authorized personnel CAUTION Commissioning personnel should be thoroughly familiar with the information contained in this literature in addition to this section Perform the commissioning using the detailed checks outlined in the Equipment Pre startup amp Startup Check List Page 133 as the commissioning procedure 15 carried out PREPARATION POWER OFF The following basic checks sh
53. gt gt gt 9 09 0 198 TEMPERATURE CONVERSION CHARTI A 202 R410APRESSURE TEMPERATURE CHART 203 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 LIST OF FIGURES 1 UNIT COMPONENTS FRONT iu ua 23 FIG 2 UNIT GOMPONENISSIDE uu uuu uuu lee 22 rater 24 FIG 3 POWER PANEL COMPONENTS u ces ix Do geo seca GER u ss 25 4 POWER PANEL CONTROL 26 FIG 5 REFRIGERANT FLOW DIAGRANMN eaa eoo peto U U cce 33 FIG 6 PROCESS AND INSTRUMENTATION DIAGRAM 4 1 2 34 FIG I 36 FIG 8 CHILEED LIQUID SYSTEM 39 FIG 9 SINGLE POINT SUPPLY CONNECTION TERMINAL BLOCK NON FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER u 42 10 CONTROL WIRING INPUTS u u 43 FIG 11 CONTROL WIRING OUTPUTS 44 FIG 12 ELE
54. 106 FIG 38 DUAL PUMP WIRING Deed bi 58 024545 S tee E Uus Ao aaa 107 10151 21 2 8 2 0 1 01 41 1 18 861351 01010 51056005 80305421 105 015518 108 40 LAYOUT POWER BLOCKS AND 5 110 FIG 41 DIMENSIONS ENGLISH 0195 4 4 4 2 111 FIG 42 DIMENSIONS ENGLISH YLAA0220HE 0260HE 02855 amp 3205 112 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG LIST OF FIGURES CONT 43 DIMENSIONS ENGLISH YLAA0300HE YLAA0360SE YLAAOAOOSE 113 44 DIMENSIONS ENGLISH YLAA0435SE CMCLI lt ILI 114 45 DIMENSIONS ENGLISH YLAA0350HE CMCLI ILI 115 46 DIMENSIONS ENGLISH YLAAO390HE 04856 116 47 DIMENSIONS ENGLISH YLAA0440HE u 117 48 DIMENSIONS ENGLISH 455 118 49
55. 18 shown On two pump hydro kits KP2 QMMSP2 amp MP2 are also fitted and wired as shown 0 Current measurement option wired as show N 54 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA ELECTRICAL NOTES AND LEGEND CONTINUED Low ambient kit FSC for fan MF1 is only fitted on systems with less than 4 fans ZI 2 2 2 NETT E 1 2 3 4 5 6 7 8 9 30 31 32 33 34 35 36 37 38 JOHNSON CONTROLS 55 FORM 150 72 3 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 WIRING DIAGRAMS ELEMENTARY WIRING DIAGRAMS YLAA0195 035 21583 201 REV D 400 3 50 7 x I 1 35 gt WI 1 _ C SOA E sm mcs m 23668 2526 2728 XP1 ARB K20 2 1 2 2 1 3 2 4 1 9 1 10 2 Sais ES 2 A IVA aa 210 qu 01 ADIS SKP a Cr 0 gt GND Ia lt T la la lw la In la In Io la la 19 JO Z Z 2 Z Z Z Z 2 Z Z 11213 5 8 19 13 I4 5 06 dh 12 1 14156 16 17 18 19 II 15 WZ lee 5 6 9 10 TEF 94944 19943 J
56. 2 7 f IS pz 5 8 DIA MOUNTING HOLES TYP 5 2 2 27 2 2 SS EY SZ SZ S VG 25 Z Mi LL 2 LL SSS I SN js 27 NES 28 TYP ORIGIN P di 5 193 TOP VIEW X 1 WATER INLET dE OUTLET k o 1082 2X 438 y y 562 3 RIGGING HOLES 4 1578 EACH SIDE 588 lt 1473 1675 S 4731 FRONT VIEW POWER SINGLE POINT SUPPLY WITH TERMINAL BLOCK 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 FIG 49 DIMENSIONS ENGLISH YLAA0515HE JOHNSON CONTROLS 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 wal
57. 2 KFL5 2 1 1 138 13 7 139 138 gt ars 7 13 8 2 13 7 13 13 12 22002 3 217 7 JOHNSON CONTROLS 2 KFS2 2 21 2 KFL5 8 22 r A1 A1 2 5 A2 z2 KFS1 2 _1 7 139 T3 139 2 215 21 53 4 54 614 62 71 72 81 82 A Po 1 2 KFS2 2 08 1013239 109 FORM 150 72 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA LAYOUT POWER BLOCKS AND TRANSFORMERS g g g 9 2 9 I m amu CIC C IC 212 1 1 ZT 1 612 2 14 12 FIG 40 LAYOUT POWER BLOCKS AND TRANSFORMERS JOHNSON CONTROLS 110 FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA DIMENSIONS ENGLISH YLAA0195HE 2398 822 2242 Placement 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 FIG 41 DIMENSIONS ENGLISH YLAA0195HE JOHNSON CONTROLS 2251
58. 30 seconds 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 if the suction pressure falls below the programmed cutout setting a transient protection routine is activated This sets the cutout at 10 of the programmed value and ramps up the cutout 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 SYS 2 FAULT FAULT INH IB INH IB SYS 1 SYS 2 The Motor Protector Mechanical High Pressure Cutout protects the compressor motor from overheating or the system from experiencing dangerously high discharge pressure This fault condition 15 present when SYS 1 or CR2 SYS 2 relays de energize due to the HP switch or motor protector opening This causes the respective CR contacts to open causing OVDC to be read on the inputs to the microboard The fault condition is cleared when a 30VDC signal is restored to the input 141 SECTION 7 UNIT CONTROLS The internal motor protector opens at 185 F 248 F 85 C 120 C and auto resets The mechanical HP switch opens at 585 PSIG 10 PSIG 27 92 barg 69 barg and closes at 330 PSIG 25 PSIG 22 75 barg 1 72 barg The compressor is also equipped with a discharge t
59. 46 C 115 Includes discharge pressure transducers All controls are contained in a NEMA 3R 12 cabinet with hinged outer door and include Liquid Crystal Display with Light Emitting Diode backlighting for outdoor viewing Two display lines Twenty characters per line A color coded 12 button non tactile keypad provides user access to 18 FORM 150 72 811 ISSUE DATE 8 15 2011 DISPLAY PRINT of typical information e Chilled liquid temperatures Ambient temperature System pressures each circuit Operating hours and starts each compressor Print calls up to the liquid crystal display Operating data for the 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 is provided to permit the capability of hard copy print outs via a separate printer by others ENTRY section to ENTER setpoints or modify system values SETPOINTS 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 e 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
60. 5 x 2 ta Lo 1 75 aes FIG 17 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 6 66 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA KFLA 58 1 3 5 54 11 13 15 x CI CN c 1 MF3 2 1 4 EXT EX T PE PE W1 W2 W1 W2 vi 7 7 1 1 KFL3 A 3 57 1 3 5 53 1 GND JOHNSON CONTROLS 67 FORM 150 72 3 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 ELEMENTARY WIRING DIAGRAMS YLAA0195 035 21583 207 REV D 1 1 2 2 1 2 IL 183 LL L 2 yen 83 86 88 8 11 eS 83 E 86 d 98 fall 7 SEE s EE E FIG 18 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 7 68 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA JOHNSON CONTROLS 69 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 ELEMENTARY WIRING DIAGRAMS YLAA0195 035 21583 208 REV D 1L1 1 8 1L 2 112 18 1L 3 1L3 1 8 450 4 7 m
61. 56 29 JAN 02 The 7 UP and DOWN arrow keys are used to 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 TYPE CHILLER Displays the type of chiller Liquid Condensing Unit or Heat Pump CHILLED LIQUID Displays the chilled liquid type Water or Glycol AMBIENT CONTROL X X X X X X X X X X Displays the type of Ambient Control Standard or Low Ambient LOCAL REMOTE MODE X X X X X X X X X Displays Local or Remote control selection JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 CONTROL MODE LEAVING LIQUID Displays the type of chilled liquid control Leaving or Return LEAD LAG CONTROL X X XX X X X X Displays the type of lead lag control Manual System 1 Manual System 2 or Automatic This is only selectable on 2 system chillers F AN CONTROL DISCHARGE PRESSURE Displays the type of fan control Discharge Pressure or Ambient and Discharge Pressure MANUAL OVERRIDE MODE X X X X X X X X X SECTION 7 UNIT CONTROLS FAN CONTROL ON PRESSURE XXXK PSIG Displays the programmed Fan On Pressure FAN DIFFERENTIAL OFF PRESSURE PSI1G Displays the programmed Fan
62. 67 22 22 22 x x 14 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 3 60 JOHNSON CONTROLS FORM 150 72 NM3 811 ISSUE DATE 8 15 2011 l 222 7 82 gt 7 82 7 82 5 k JOHNSON CONTROLS 1 YE 5 6 et 8 84 8 84 8 84 L 57 0187 3 4 9 87 576 9 87 20 SECTION 5 TECHNICAL DATA 61 SECTION 5 TECHNICAL DATA FORM 150 72 811 ELEMENTARY WIRING DIAGRAMS YLAA0195 035 21583 204 REV D ISSUE DATE 8 15 2011 1L1 1 8 12 18 1L3 1 8 MP1 EXT 1 1 1 5 1 1 MEF L 2 2 27 22 5 22 15 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 4 62 24 5 ARB K23 6 2 2 8 gt XP9 U 2 1 ARB K24 3 33 13 33 13 NEE 4 14 34 14 ARB K23 5 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA ELEMENTARY WIRING DIAGRAMS YLAA0195 w Sa ee lt 1 1 3 5 1 E i 7 121 4 6 2 Ir 1 gt gt ete se um 125 121 12 M A1 M IM A1 A1 TI 3 14 45 2 ass 1 5 2 A2 4 dj af
63. 811 ISSUE DATE 8 15 2011 NOTES 204 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 The following factors can be used to convert from English to the most common SI Metric values TABLE 1 5 METRIC CONVERSION S Length t Inches in Millimeters mm Weight Pounds Ibs 0 4538 Kilograms kg Velocity Feet Second fps 0 3048 Meters Second m s Feet of Water ft 2 989 Kilopascals kPa Pressure Drop Pounds Square Inch psi 6 895 Kilopascals kPa TEMPERATURE To convert degrees Fahrenheit F to degrees Celsius C subtract 32 and multiply by 5 9 or 0 5556 Example 45 0 F 32 x 0 5556 27 2 C To convert a temperature range 1 a range of 10 F from Fahrenheit to Celsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range JOHNSON CONTROLS 205 Johnson J Controls P O Box 1592 York Pennsylvania USA 17405 1592 Copyright by Johnson Controls 2011 Form 150 72 NM3 811 Issue Date August 15 2011 Supersedes 150 72 NM3 909 Tele 800 861 1001 www johnsoncontrols com Subject to change without notice Printed in USA ALL RIGHTS RESERVED
64. 93 2 60 4 14 3 5 50 8 108 42 2 36 96 8 70 4 83 4 58 112 44 4 38 100 4 80 5 52 4 5 65 3 116 46 7 40 104 90 6 21 5 72 5 120 48 9 42 107 6 100 6 9 5 5 79 8 124 51 1 44 111 2 110 7 59 6 87 128 53 3 46 114 8 120 8 28 6 5 94 3 132 55 6 48 118 4 130 8 97 7 101 5 136 57 8 50 122 140 9 66 7 5 108 8 140 60 0 52 125 6 150 10 34 8 116 144 62 2 54 129 2 160 11 03 8 5 123 3 148 64 4 56 132 8 170 11 72 9 130 5 152 66 7 58 136 4 180 12 41 9 5 137 8 156 68 9 60 140 190 13 1 10 145 160 71 1 62 143 6 200 13 79 10 5 152 3 164 73 3 64 147 2 210 14 48 11 159 5 168 75 6 66 150 8 220 15 17 11 5 166 8 172 77 8 68 154 4 230 15 86 12 174 176 80 0 70 158 240 16 55 12 5 181 3 180 82 2 72 161 6 250 17 24 13 188 5 184 84 4 74 165 2 260 17 93 13 5 195 8 188 86 7 76 168 8 270 18 62 14 203 192 88 9 78 172 4 280 19 31 14 5 210 3 196 91 1 80 176 290 20 15 217 5 200 93 3 82 179 6 300 20 69 15 5 224 8 204 95 6 84 183 2 310 21 38 16 232 208 97 8 86 186 8 320 22 07 16 5 239 3 212 100 0 88 190 4 330 22 76 17 246 5 216 102 2 90 194 340 23 45 17 5 253 8 220 104 4 92 197 6 350 24 14 18 261 224 106 7 94 201 2 360 24 83 18 5 268 3 228 108 9 96 204 8 370 25 52 19 275 5 232 111 1 98 208 4 380 26 21 19 5 282 8 236 113 3 100 212 390 26 9 20 290 240 115 6 102 215 6 400 27 59 20 5 297 3 244 117 8 104 219 2 202 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 10 MAINTENANCE R410A PRESSURE TEMPERATURE CHART JOHNSON CONTROLS 203 FORM 150 72
65. 98 256 900 166 HOSA 05 ainsseld 256 V0 90 oes LONS S 5 uny 545 66 NM 25 140 due uonongzweisks d 4060 anarionses spuooss voeo IV spuooas voeo 909 enw 9IL uv IS o juo siepow 43 toso 99 600 Quo a vs anaras 140 Spo 270 weena e 1 846 3 voeo es ainsseig 546 osd voso Md Hosqis 8 osa voeo ws sw XC Spuooes unu LV8 voso e 110 1 A d 99 sw 5 d toso tons 06 sepon un 1 99 due A voeo 99 CV 000 Bu
66. CONTROLS SYS COMP 3 STATUS TB7 5 IS SYS 1 HGBP STATUS 7 7 IS SYS 2 COMP 1 STATUS TB10 2 IS SYS 2 LLSV STATUS TB10 3 IS SYS 2 COMP 2 STATUS TB10 4 IS SYS 2 COMP 3 STATUS 10 5 IS SYS 1 FAN OUTPUT 1 TB7 8 IS SYS 1 FAN OUTPUT 2 TB7 9 IS SYS 1 FAN OUTPUT 3 TB7 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 TB8 2 IS SYS 1 ALARM STATUS TB8 3 IS SYS 2 ALARM STATUS TB9 2 IS EVAP PUMP STATUS TB8 6 7 IS SYS 2 HGBV STATUS TB10 7 IS SPARE DO TB8 4 IS SPARE DO TB8 5 IS SPARE DO TB8 8 9 IS SPARE DO TB9 4 IS SYS 1 EEV OUTPUT 5 1 2 XXX SYS 2 EEV OUTPUT TB6 1 2 XXX SYS 1 COND FAN SPEED J15 1 5 SYS 2 COND FAN SPEED J15 2 6 SPARE AO J15 3 7 SPARE AO J15 4 8 DATA LOGGING MODE 1 ON 0 OFF DATA LOGGING TIMER X SECS SOFT START disabled REFRIGERANT TYPE R410A 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 1 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 SYS 1 LLSV STATUS OFF T B10 3 IS This display indicates that the system 1 liquid line solenoid valve is OFF and the output connection from the microboard is coming from
67. DIMENSIONS ENGLISH YLAA0515HE U 119 50 UNIT CLEARANCES ALL MODELS 42 2 40 120 51 WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING 8 1 121 52 ONE INCH DEFLECTION SPRING ISOLATOR CROSS REFERENCE 1 124 53 ONE INCH DEFLECTION SPRING ISOLATORS INSTALLATION INSTRUCTIONS 125 54 SEISMIC ISOLATOR CROSS REFERENGCGE u 126 55 SEISMIC ISOLATOR INSTALLATION AND ADJUSTMENT INSTRUCTIONS 127 56 DURALENE ISOLATOR 5 128 57 INSTALLATION DURULENE VIBRATION ISOLATORS INSTRUCTIONS 129 58 LEAVING WATER TEMPERATURE CONTROL 168 59 SETPOINT ADJUST ioter es ecelesie 168 60 CONDENSER FAN LOCATIONS WIRING 85 172 61 MICROBOARD LAYOUT e a a 180 62 I O BOARD RELAY CONTACT 184 63 PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS 185 64 MICROPANEL CONNECTIONS iie
68. FAN DIFFERENTIAL OFF PRESSURE The minimum discharge pressure allowed is 235 PSIG The Fan Differential Off Pressure High Limit will be lowered reduced to prevent going below 235 PSIG based on where the fan control On Pressure is programmed JOHNSON CONTROLS 159 FORM 150 72 811 SECTION 7 UNIT CONTROLS ISSUE DATE 8 15 2011 TABLE 12 SETPOINTS QUICK REFERENCE LIST 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 Table 12 provides a quick reference of the setpoints list for the Setpoints Keys 25 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 160 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 7 UNIT CONTROLS UNIT KEYS Options Key There 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 OP
69. FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA 62 225 2cT 71 2 260 2965 2CU 2 2 1 2 930 531 532 1 NE 556 537 538 450 451 452 450A 451A 452A gt gt gt SS CORE OREO GND GND JOHNSON CONTROLS CO 9 9 2 KF2 2 6 62 62 450A 451A 452A 450B 451B 452B NN 458 4528 GND GND GND 79 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 CONNECTION WIRING DIAGRAMS YLAA0195 035 21589 204 REV D 7 gt SHLD GND 5V 5V GND RXD TXD CTS RTS 1 OOOO 6 0 0 099002 499 O cO J15 SHLDREF B2 TBS 12 z S S m Ho Oa ch J s Os CA CA O c 7 s 1 O 9 2 i TB10 06640 1 0 X1B9 4 Joo T 1149 gt O Ts N W a iem O 23 Geo XP10 2 GND _ 1 stt 2 xer0 2 ReD m 222 J1 2 XP10 2 BLK 2 7 3 m xeto RED 4 1 XP10 BLK J13 XP7 RED NN gt
70. Inch Deflection Spring Isolators Installation Instructions 125 Seismic Isolator Cross referencce 4 U u u u 126 Seismic Isolator Installation and Adjustment INSTRUCTIONS 127 Duralene Isolator Cross reference u 128 Installation of Durulene Vibration Isolators INSTRUCTIONS 129 SECTION6 COMNISSIONING 131 COMMISSIONING u Z 22 u i ives 131 PREPARATION POWER OFF uu 2 131 Recent 131 Ielrigerant ava eid 131 SErvice andiOil 131 Compressor _3 131 Gli ERI CL C TI 131 Isolation T Protection 25552055 5522 01205255 8 5 05508224 a DID LIA LLLI scence 131 ee u 131 POWER G ONC CU uu 131 genteel 131 33333
71. Off Differential TRIP VOLTS VOLTS SYS 1 Displays the programmed High Current Trip Voltage SYS 2 TRIP VOLTS VOLTS Displays the programmed High Current Trip Voltage YORK HYDRO PUMPS X Displays whether Manual Override was Enabled or Disabled CURRENT FEEDBACK X X X X X X X X X X X X X X X X Displays type of Current Feedback utilized SOFT START Indicates the Pump Control option is selected F F LCHLT RCHLT Displays the Leaving and Return chilled Liquid Temperature at the time of the fault SETPOINT RANGE Displays whether the optional European Soft Start was Installed and selected DISCHARGE CUTOUT PRESSURE PSIG Displays the programmed Discharge Pressure Cutout SUCTION CUTOUT PRESSURE PSIG Displays the programmed Suction Pressure Cutout LOW AMBIENT TEMP CUTOUT F Displays the programmed Low Ambient Cutout LEAVING LIQUID TEMP F CUTOUT Displays the Leaving Liquid Temp Cutout programmed JOHNSON CONTROLS Displays the programmed Setpoint and Range if the chiller is programmed for leaving chilled liquid control SETPOINT XXX RANGE XX X Displays the programmed Setpoint and Range if the chiller is programmed for return chilled liquid control AMBIENT AIR TEMP F Displays the Ambien
72. Pressure Systems Electrical Rotating Parts Sharp Edges Refrigerants and Oils High Temperature and Pressure Cleaning Emergency Shutdown SECTION 2 PRODUCT DESCRIPTION INTRODUCTION GENERAL SYSTEM DESCRIPTION Compressors Cooler Evaporator Condenser HIGH AMBIENT KIT BUILDING AUTOMATION SYSTEM INTERFACE POWER PANEL ACCESSORIES AND OPTIONS Power Options Control Options Compressor Piping Evaporator Options Condenser and Cabinet Options UNIT COMPONENTS CONTROL POWER PANEL COMPONENTS PRODUCT IDENTIFICATION NUMBER PIN BASIC UNIT NOMENCLATURE PROCESS AND INSTRUMENTATION DIAGRAM SECTION 3 HANDLING AND STORAGE DELIVERY AND STORAGE INSPECTION MOVING THE CHILLER Lifting Weights TABLE OF CONTENTS SECTION 1 GENERAL CHILLER INFORMATION amp SAFETY INTRODUCTION SAFETY AND QUALITY Standards for Safety and Quality FORM 150 72 3 811 ISSUE DATE 8 15 2011 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 TABLE OF CONTENTS CONT D SECTION 4 INSTAELADTIQN 2 37 INSTALLATION CHECKLIST leuc oes uu u aS un 37 EE 37 lt _ _ 3 3 3 322233 3333 3 _ _ 37 LOCATION AND CLEARANCES u u 37 a e a a a 38 Ground
73. Return Chilled Liquid Control can only be selected on units that have 4 to 6 compressors dual system units 162 FORM 150 72 3 811 ISSUE DATE 8 15 2011 CONTROL MODE LIQUID LEAVING Unit control 15 based on leaving chilled liquid temp Leaving Chilled Liquid Control can only be selected on units that have 4 to 6 compressors dual system units Option 7 Display Units DISPLAY UNITS IMPERIAL This mode displays system operating values in Imperial units of F or PSIG or DISPLAY UNITS S This mode displays system operating values in Scientific International Units of C or barg Option 8 Lead Lag Type two system units only LEAD LAG CONTROL MANUAL SYS 1 LEAD 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 Or LEAD LAG 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 automatic 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 board will then assign the lead to the system with the shortest average run time JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 O
74. SECTION 2 PRODUCT DESCRIPTION The evaporator is constructed tested and stamped in accordance with applicable sections of ASME pressure vessel code for minimum 31 0 barg 450 psig refrigerant side design working pressure and 10 3 barg 150 psig water side design working pressure A strainer with a mesh size between 5 and 1 5 mm 40 mesh is recommended upstream of the heat exchanger to prevent clogging from water system debris Condenser Coils Condenser coils are Microchannel type and made of a single material to avoid galvanic corrosion due to dissimilar metals Coils and headers are brazed as one piece Integral subcooling 15 included The design working pressure of the coil is 100 barg 1500 psig Fans The condenser fans are composed of corrosion resistant aluminum hub and glass fiber reinforced polypropylene composite blades molded into a low noise airfoil section They are designed for maximum efficiency and are statically and dynamically balanced for vibration free operation They are directly driven by independent motors and positioned for vertical air discharge The fan guards are constructed of heavy gauge rust resistant coated steel Motors The IP54 fan motors are Totally Enclosed Air Over squirrel cage type current protected They feature ball bearings that are double sealed and permanently lubricated Ambient Kit High Required if units are to operate when the ambient temperature is above
75. START 00 00AM STOP 00 00AM REMOTE UNIT ID PROGRAMMED 2 SAT START 00 00AM STOP 00 00AM YORK HYDRO KIT PUMPS 410a HOL START 00 00AM STOP 00 00AM PUMP TOTAL RUN HOURS 410a JOHNSON CONTROLS 149 SECTION 7 UNIT CONTROLS See the Service And Troubleshooting section of this IOM for Printer Installa tion 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 which occurred The information is stored at the instant of the fault regardless of whether the fault caused a lockout to occur The information is 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 transmitted 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 conditions at the instant the fault occurred and often reveals o
76. WITH TERMINAL BLOCK 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 6 rear to wall 6 control panel to end wall 4 0 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit FIG 43 DIMENSIONS ENGLISH YLAA0300HE YLAAO360SE YLAA0400SE JOHNSON CONTROLS 113 SECTION 5 TECHNICAL DATA FORM 150 72 3 811 ISSUE DATE 8 15 2011 DIMENSIONS YLAA0435SE ENGLISH 525 POWER ENTRY EN 14012 L 8712 WIDE X 178 HIGH BOTOM OF PANEL VIEW B B 749 TO CLR CONN 2242 BASE WIDTH 2261 FRONT VIEW WATER 5 8 DIA MOUNTING HOLES TYP 40 2977 y TOP VIEW amp 2 RIGGING HOLES EACH SIDE 3613 RIGHT VIEW POWER SINGLE POINT SUPPLY WITH TERMINAL BLOCK NOTE Placement o
77. X C X SEQ SEQUENCE KIT PIN 28 28 JOHNSON CONTROLS FORM 150 72 3 811 SECTION 2 PRODUCT DESCRIPTION ISSUE DATE 8 15 2011 FEATURE TEMP CHICAGO VALVES HGBP GAUGE OVERLOAD PIN36 HTR DWP INS FLANGES FLOW VESSEL PRODUCT IDENTIFICATION NUMBER PIN CON T NUM X OPTION DESCRIPTION LEAVING WATER TEMP TEMP NUM DEGREES SPECIAL LWT REQUIREMENTS NO CHICAGO CODE KIT REQUIRED BOTH CHICAGO CODE amp SERV ISOLATION CHICAGO CODE KIT REQUIRED BOTH SUCTION SERVICE VALVE AND DUAL RELIEF VALVE EUROPE ONLY DUAL RELIEF VALVES NO SUCTION SERVICE VALVE EUROPE ONLY SERVICE ISOLATION VALVES SPECIAL CHICAGO CODE KIT REQUIRED STANDARD VALVES REQ D SPECIAL OPTIONAL VALVES REQ D NO HOT GAS BYPASS REQUIRED HOT GAS BYPASS REQUIRED 1 CIRCUIT SPECIAL HOT GAS BYPASS REQUIRED X X CIM 34 X X PIN 35 SPECIAL QUOTE X X CIM 36 LI CRANKCASE HEATER STANDARD CRANKCASE HEATER PIN 37 SPECIAL CRANKCASE HEATER REQUIRED X DWP PIN 38 150PSIG DWP WATERSIDE INSULATION PIN 39 LEAVING WATER TEMP 29 30 C CHICAGO CODE KIT PIN 31 S X VALVES PIN 32 gt lt HOT GAS BYPASS PIN 33 SPECIAL QUOTE STANDARD INSULATION DOUBLE THICK INSULATION SPECIAL INSULATION REQUIRED NO FLANGES REQUIRED VICTAULIC FLANGES REQUIRED SPECIAL FLANGES REQUIRED NO FLOW SWITCH REQUIRED ONE FLOW SWITCH REQUIRED TWO FLOW SWITCHES REQUIRED THREE FLOW SWITCHES
78. all refrigerant liquid 15 driven out of the compressor and the oil If the ambient temperature is below 86 F 30 C allow 24 hours Water System Verify the chilled liquid system has been installed correctly 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 top of the cooler body 132 FORM 150 72 811 ISSUE DATE 8 15 2011 Flow rates and pressure drops must be within the limits given in the Technical Data section of ths IOM Operation outside of these limits is undesirable and could cause damage If main power must be switched OFF for extended maintenance or an extended shutdown period the compressor suction discharge and economizer service stop valves should be closed clockwise If there is a possibility of liquid freezing due to low ambient temperatures 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 Before placing the unit back in service valves should be opened and power must be switched on if power 15 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 is restarted Flow Switch Verify a chilled water flow switch is corre
79. are taken It is important to ensure access to the unit is 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 3 811 ISSUE DATE 8 15 2011 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 damage 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 personnel Electrical The unit must be grounded No installation or maintenance work should be attempted on the electrical equipment without first switching power OFF isolating and locking off the power supply Servicing and maintenance on live equipment must only be performed 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 1s to be fitted requiring the wire fan guards to be removed alternative safety measures must be taken to protect against the risk of injury from r
80. flushed to free it from foreign material before the system 15 placed into operation Use care not to flush any foreign material into or through the cooler ISOLATING VALVE NORMALLY OPEN ISOLATING VALVE NORMALLY CLOSED 5 an aid to servicing thermometers and pressure gauges should be installed in the inlet and outlet water lines FLOW REGULATING VALVE 6 The chilled water lines that are exposed to outdoor ambients should be wrapped with supplemental heater cable and insulated to protect against freeze up during low ambient periods and to prevent formation of condensation on lines in warm humid locations As an alternative ethylene glycol should be added to protect against freeze up during low ambient periods FLOW MEASUREMENT DEVICE STRAINER 7 A chilled water flow switch either by YORK or others MUST be installed in the leaving water piping of the cooler There should be a straight horizontal run of at least 5 diameters 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 furnished with the switch The switch is to be wired to Terminals 13 14 of located in the control panel as shown on the unit wiring diagram PRESSURE TAPPING FLOW SWITCH 0 04 FLANGED CONNECTION 1006597 FIG 8 CHILLED LIQUID SYSTEM JOHNSON CONTROLS 39 SECTION 4 INSTALLATION DUCT WORK CONNECTION Gener
81. from 1 5 F to 2 5 F 83 C to 1 39 C leaving chilled liquid control LEAVING CHILLED LIQUID CONTROL OVERRIDE TO REDUCE CYCLING To avoid compressor cycling the microprocessor board 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 with a maximum value allowed of 50 F 10 C See Fig 59 If adding the setpoint adjust value to the setpoint high limit causes the setpoint high limit to be greater than 50 F the setpoint high limit will be set to 50 F and the difference will be added to the setpoint low limit Once a system runs for greater than 5 minutes the setpoint adjust will be set back to 0 This will occur while the system is still running 30 sec Control Range 60 sec unloading no compressor staging loading LWT 44 0 F 46 0 F 48 0 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 C Range 2 F 1 1 C FORM 150 72 3 811 ISSUE DATE 8 15 2011 O NW FOO 0 1 2 3 4 5 6 LAST RUN TIME OF LEAD SYSTEM MINUTES FIG 59 SETPOINT ADJUST TM SETPOINT ADJUST DEG F LEAVING CHILLED LIQUID SYSTEM LEAD LAG AND COMPRESSOR SEQUENCING A Lead Lag option may b
82. glycol The Cooling Setpoint can be programmed from 10 F to 70 F 12 2 C to 21 1 C 161 SECTION 7 UNIT CONTROLS Option 4 Ambient Control 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 C Alow 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 Type LOCAL REMOTE MODEL LOCAL When programmed for LOCAL an ISN or RCC control can be used to monitor only The micropanel 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 MODE REMOTE 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 Remote 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 locally programmed values Option 6 Unit Control Mode CONTROL MODE RETURN LIQUID Unit control is based on return chilled liquid temperature
83. is not provided Refer to Fig 9 See unit wiring diagrams for field and power wiring connections chilled water pump starter contacts alarm contacts compressor run status contacts PWM input and load limit input Refer to the section on Unit Operation located in this IOM for a detailed description of operation concerning aforementioned contacts and inputs Evaporator Pump Start Contacts Terminal Block XTBC2 Terminals 23 to 24 are nor mally 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 15 running 3 Daily schedule is not programmed OFF and the Unit Switch is ON The pump will not run if the micropanel 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 Fig 10 and unit wiring dia gram System Run Contacts Contacts are available to monitor system status Normally open auxiliary contacts from each compressor contactor are wired in parallel with XTBC2 Terminals 25 to 26 for system 1 and 2 Terminals 27 to 28 for system 2 Refer to Fig 4 10 and unit wiring diagram JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 Alarm Status Contacts Normally open contacts are available for each refrigerant
84. 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 satisfactory 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 Oil 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 compressor When the compressor is running at stabilized conditions the oil level must be between 1 4 and 3 4 in the oil sight glass At shutdown the oil level can fall to the bottom limit of the oil sight glass Use YORK V oil when adding oil NOTE Oil Analysis The oil used in these compressors is pale yellow in color POE oil Ifthe oil color darkens or exhibits a change in color this may be an indication of contaminants 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 Never use the scroll compressor to pump the refrigerant system down into a
85. or local safety regulations This manual and any other document supplied with the unit are the property of Johnson Controls which reserves 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 solutions and is 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 equipment 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 parameters specified in this manual Structural Support Structural support of the unit must be provided as indicated 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 1s not designed to withstand loads or stresses from adjacent equipment pipework or structures Additional 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
86. 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 ENTRY section System 2 information will only be dis played for 2 system units NOTE JOHNSON CONTROLS 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 4 DOWN arrow key scrolls through the displays in the order they appear below 7 The chiller MUST be set to be a liquid 7 chiller no jumper J11 7 to JIL 12 on the YO Board DO NOT oper ate the chiller if not properly set up 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 TEMP 87 5 F 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 1s 131 2 F 55 1 C 145 SECTION 7 UNIT CONTROLS These displays show suction and discharge pressures for each system The discharge pressure transducer 15 optional on some models If the optional discharge transducer 1s not installed the discharge pressure would display 0 PSIG 0 b
87. 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 from water cooling There are some exceptions when the suction pressure is permitted to tem porarily drop below the cutout point Details are explained under the topic of SYSTEM SAFETIES JOHNSON CONTROLS SECTION 7 UNIT CONTROLS LOW AMBIENT TEMP 0 F CUTOUT 25 The LOW AMBIENT TEMP CUTOUT allows the 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 36 0 F CUTOUT The LEAVING LIQUID TEMP CUTOUT protects the chiller from an evaporator freeze up Anytime the leaving 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 11 ANTI RECYCLE SEC TIMER 600 The programmable anti recycle timer assures that systems do not short cycle and the compressor motors have sufficient time to dissipate hea
88. the suction pressure cutout or for 180 seconds whichever comes first JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 7 UNIT CONTROLS YORK MILLENNIUM CONTROL CENTER Display Prini 21 DATA PRINT IL HIS CHHY INTRODUCTION The YORK MicroComputer 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 e IPU II amp I O Boards Transformer Display Keypad The keypad allows programming and accessing setpoints pressures temperatures cutouts daily schedule options and fault information Remote cycling demand limiting and chilled liquid temperature reset can be accomplished by field supplied contacts Compressor starting stopping and loading unloading decisions are performed by the microprocessor to maintain leaving or return chilled liquid temperature These decisions are a function of temperature deviation from setpoint A master ON Off switch 1s available to activate or deactivate the unit JOHNSON CONTROLS Selpoints SETPOINTS 4 SCHEDULE ADVANCE DAY PROGRAM LD13283 IPU II and I O Boar
89. to a specific day press the SCHEDULE ADVANCE DAY key until the desired day appears The start and stop time of each day may be programmed differently using the 1 UP and DOWN arrow and ENTER ADV keys 156 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 After the 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 The times may be set using the same procedure as described above for the days of the week After changing the meridian of the stop time pressing the ENTER ADV key will advance the schedule to the following display S M T W T F S 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 1s moved to the space following the day of the week of the holiday and the 1 UP arrow key 15 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 3 811 ISSUE DATE 8 15 2011 PROG
90. units are tested and inspected before leaving the factory Units are shipped completely assembled and containing refrigerant under pressure Units are shipped without export crating unless crating has been specified 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 15 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 particularly where building work is in progress The unit should be stored in a location where there 15 minimal activity in order to limit the risk of accidental physical damage To prevent inadvertent operation of the pres sure relief devices the unit must not be steam cleaned It is recommended that the unit is periodically inspected during storage INSPECTION Remove any transit packing and inspect the unit to ensure that all components have been delivered and that no damage has occurred during transit If any damage is evident it should be noted 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 Con
91. 0 character liquid crystal display 2 lines of 20 characters 1s used for displaying system parameters and operator messages The display in conjunction with the keypad allows the operator to view system operating parameters as well as access programmed information already in memory The display has a lighted background for night viewing and for viewing in direct sunlight When a key 15 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 the 1 UP and DOWN arrow keys The display will update all information at a rate of about 1 per second 138 FORM 150 72 811 ISSUE DATE 8 15 2011 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 Keypad The 12 button non tactile keypad allows the user to retrieve vitals system parameters such as system pressures temperatures compressor running times and starts option information on the chiller and system setpoints This data is useful for monitoring chiller operation diagnosing potential problems troubleshooting and commissioning the chiller It is essential the user become familiar with using the keypad and display This will allow the user to make full use of the capabilit
92. 1 1 15 2 gt 1 1 1 3 5 5 1 50 80 2 NM LEXLACC XP1 2 2 1 3 2 4 2 5 14 15 2 V ADIS _ BRN NEG _ COL1 COL2 COL3 COL4 ROW1 ROW2 Q 2 Le 5V R W E Loo 081 rss Es ms ms RAN LED PWR LED GND 5 6 1 XP4 12 CI 15 O IO IO JO O 10 IO IO O lt 2 z 2 2 2 z Z 2 2 CI 2L 1 3 6 4 6 9 2 13 1 15 6 2L 2 3 6 4 6 9 2 13 1 15 6 2L 3 3 6 4 6 9 2 13 1 15 6 2 2 1 3 5 33 1 KCR 722 44 TT 510 507 18 11213 4 B 19 IJ 12 13 14 15 116 1 2 13 14 5 16 17 18 19 10 H 4 15 16 17 18 PE WS s See HAH HAA J14 J1 J2 J13 AMB Exc Ee LI Es I e K1 K2 K3 4 K5 K6 K7 K8 K9 10 K11 K412 K14 ee Ecc 701 72 11 72 10 72 10 29 L 3 3 a 2 3 2 2 5 3 6 10 722 840 53 ur LD13143A FIG 28 ELEMENTARY WIRING DIAGRAM YLAA0220 YLAA0515 SHT 1 88 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA 29 7 SP _ XTBC2 299 22 2 2 XTBC2 5 15 XP3 T3 XTBC2 5 12 270831 2 KCR 2 1 XE 1 KM1 2 1 2 KM1 2 7 yL 090 2 m m E BAMB 1 BSP 4 BDP 2 BSP 2 BDP
93. 1 15 TE 212 15 21 3 1 5 450 45 G GEM 4 AMB AMB AMB 1 9 1 10 7110 10 8 9 10 N CN CN CN A1 A1 A1 2 KF 1 2 2 2 A2 2 2 1 1 1 e d 131 gt 133 136 7 3 8 7133 L 9 36 5 6 5 6 5 6 7 A34 8 133 9 136 aT ely 20 214 22 JOHNSON CONTROLS 95 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 CONNECTION DIAGRAMS YLAA0220 YLAA0515 POWER PANEL 035 21589 101 REV C 351 352 350 1568 1578 1588 035 21589 101 REV B GND GND GND LD13235A FIG 32 CONNECTION DIAGRAM YLAA0220 YLAA0515 SHT 1 96 JOHNSON CONTROLS SECTION 5 TECHNICAL DATA FORM 150 72 3 811 ISSUE DATE 8 15 2011 5 68 49 450 2 450 450 451 452 450 451 45 0000109 0 8A 256A 257A 25 5 25 2544 2 2 GND GND GND GND GND 090000 2 QMMSC2 Ti CN 60 C CND 201 202 200 LD13236A 97 JOHNSON CONTROLS FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 CONNECTION DIAGRAMS YLAA0220 YLAA0515 MICROPANEL CONECTIONS 035 21589 102 REV D 2 ES gt gt lt 4 N gt N
94. 14 J1 J2 J13 1 dE 4 2 1 0 oe a 2 K3 5 K6 K7 K8 K9 10 Kile KIS 2 6 2 1 2 6 2 6 2 8 32 7102 33 103 734 104 7013 21 74 3 75 10 6 42 FIG 12 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 1 56 JOHNSON CONTROLS SECTION 5 TECHNICAL DATA FORM 150 72 3 811 ISSUE DATE 8 15 2011 1L1 3 1 4 1 6 1 8 1 10 1 is 1L 2 3 1 4 1 6 1 8 1 10 1 1L3 3 1 4 1 6 1 8 1 10 1 1 UU 2324 2930 3132 mi ARB K 1 2 2 ARB K20 ARB K21 2 1 BECT BLCT BAMB 1 BSP 1 BDP 2 BSP 2 BDP 617 7 gt 9 gt gt gt 9 O 0 T o 9 9 9 99 0 9 90 9 5 0 uo 3 1 2 4 1 gt 7 lt lt ru MM 3 259502 2 MODBUS Semis Sloe r m m lt al al Oo O WM 2 15 8 1 4 7 16 9 11519 ho 2 16 7 H 1 5 9 MO 2 6 7 H 600020 6 1 XTB8 28 a vu ETLE 6 17 n 21518 7 6 9 J7 J9 J11 LL I iE dS E RS485 27 KI 20 621 Nee 14 K15 416
95. 15 ae ae emm ar 521 NE HE ABE X 4807 2235 2242 2242 2242 2242 2393 2 qz gt 2 1 2 37 35 40 41 eae 6 5 8 3 10 4 10 4 12 6 10 4 12 6 20 4 18 9 3488 3489 3779 373 L 5 I 4 4 p 5 5 6 20 1 4 4 25 2 2 2 2 2 2 2 wn 19 26 26 325 39 39 455 52 52 185 185 194 193 208 293 250 208 293 I 6 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA ELECTRICAL INFORMATION TABLE 5 MICROPANEL POWER SUPPLY CONTROL OVER CURRENT PROTECTION UNIT VOLTAGE MCA POWER SEE NOTE B NF DISC Sw MODELS w o VOLTAGE CONTROL TRANS TRANS s s A Minimum 14 AWG 75 C Copper Recommended B Minimum and Maximum Over Current Protection Dual Element Fuse or Circuit Breaker II is possible that multiple sources of The unit evaporator heater uses power can be supplying the unit power 120VAC Disconnecting 120 panel To prevent serious injury or power from the unit at or below freez death the technician should verify ing temperatures can result in damage that NO LETHAL VOLTAGES are to the evaporator and unit as a result present inside the panel AFTER di
96. 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 HEAT EXCHANGER FLOW GPM YLAA Evaporator Pressure Drop SI Units 1000 100 10 j IIIII Water Rate 5 00 CURVE MODEL YLAA A 240SE 195HE 220HE B 320SE 360SE 260HE 300HE C 400SE 435SE 350HE 455HE D 485SE 440HE E 390HE 515HE TABLE 3 ETHYLENE amp PROPYLENE GLYCOL CORRECTION FACTORS ETHYLENE GLYCOL PROPYLENE GLYCOL TONS PRESS 5 TONS GPM F PRESS 50 0 957 0 989 1172 32 50 0 928 0 984 1 247 25 Note Water Pressure Drop Curves may extend past the minimum and maximum water flow ranges 46 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA PHYSICAL DATA ENGLISH STANDARD EFFICIENCY YLAA0285 YLAA0485 50Hz TABLE 4 PHYSICAL DATA ENGLISH Refrigerant R 410A General Unit Data YLAA Nominal Kw R 410A Length mm Width mm Height mm Number of Refrigerant Circuits ____ Refrigerant Charge Operating R 410A ckt2 KG Oil Charge ckt1 ckt2 LITERS Shipping Weight Operating Weight Compressors scroll type Compressors per circuit Compressors per unit Condenser Total Face Area Number of Rows Condenser Fans Low Sound Number of Fans ckt1 ckt2 Fan hp Fan RPM Total Chiller Evaporator Water Volume liters Maximum Water Side Pressure bar Maximum Refrigerant Side Press
97. 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA SEISMIC ISOLATOR INSTALLATION AND ADJUSTMENT INSTRUCTIONS 1 Read instructions their entirety before beginning installation 2 Isolators are shipped fully assembled and are to be positioned accordance with the submittal draw ings or as otherwise recommended 3 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 plates B be installed on a level surface Shim or grout as required leveling all isolator base plates to the same elevation 1 4 inch maximum difference can be tolerated 4 Bolt or anchor all isolators to supporting structure utilizing base plate thru holes C or 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 5 Isolators are shipped to the job site with 2 remov able spacer shims E between the top plate and the housing These shims must be in place when the equipment 15 positioned over the isolators 6 With all shims in place position equipment on top of plate CA 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 P 1 EHE VIA A LI LI W
98. 2011 MOUNT TYPE RD1 WR RD2 WR RD3 WR RD4 WR DURALENE ISOLATOR CROSS REFERENCE RD Style Isolators MOLDED DURULENE HF AD THRU TYP 2 PLACES Notes 1 All dimensions are inches interpreted per ANSI Y14 2 Refer to next page for installation instructions 3 Mount molded in weather resistant duralene compound as standard Also available in other materials such as natural rubber extreme high temperature silicone high damped silicone nitrile and EDPM 4 AL Mounting hole center to center spacing 5 HF Free height of mount prior to loading Operating height calculated by the free height less the static deflection under load All dimensions for reference only 6 Hardware zinc electroplated DIMENSION DATA INCHES L 108 A A s 5 16 18 UNC VMC PART NUMBER WEIGHT RANGE KGS RD 3 CHARCOAL WR UP TO 374 RD 4 BRICK RED WR 375 766 RD 4 CHARCOAL WR 767 1814 FIG 56 DURALENE ISOLATOR CROSS REFERENCE 128 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA INSTALLATION OF DURULENE VIBRATION ISOLATORS INSTRUCTIONS 1 Read instructions their entirety before beginning all isolator bases to the same elevation 1 32 inch 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
99. 2105 YLAA 220 2405 26 2855 3205 YLAA 560SE 4005 YLAAS9OHE YLAA 350 4 555 4855 YLAA440HE YLAA 455 515HE 85 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 CONNECTION WIRING DIAGRAMS YLAA0195 035 21589 207 REV D 350 991 352 2F 350A 351A 352A 2C 350A 351A 352A 2G 3508 3518 3528 2H 4504 451A 4524 21 4508 4518 4528 2M 10 122 1N 122A 1 IN 4 35 105 104 105 FIG 27 CONNECTION WIRING DIAGRAM YLAA0195 SHT 7 86 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA 18 4048 G 4N Z 05 4048 1 IOS LJA 51 15 0 034 4048 1 v pa m gt zo zo 4508 451 4528 208 206 207 205 203 204 87 JOHNSON CONTROLS SECTION 5 TECHNICAL DATA FORM 150 72 811 ISSUE DATE 8 15 2011 ELEMENTARY WIRING DIAGRAMS YLAA0220 YLAA0515 035 21583 101 REV D 168 16 8 16 5 165 16 3 16 3 16 1 162 111 112 16 8 16 5 16 3 162 1L3 16 9 16 6 16 3 16 2 211 16 9 16 6 16 4 162 2L2 16 9 16 6 164 162 213 1L1 3 1 4 2 5 1 7 2 11 1 15 2 1L 2 3 1 4 2 5 1 7 2 11 1 15 2 1L3 3 1 4 2 5 1 7 2 1
100. 2159 safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 6 rear to wall 6 control panel to end wall 4 0 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit FIG 42 DIMENSIONS ENGLISH YLAA0220HE 0260 0285SE amp 320SE 112 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA DIMENSIONS YLAA0300HE YLAA0360SE VI 04005 ENGLISH 5 8 DIA MOUNTING HOLES TYP 2 2 p 525 DD y 2 lr 1 NS 7 E POWER ENTRY Om 8712 WIDE 178 HIGH V VIEW B B 3 1 2 OF PANEL 0 yy j 2977 VIEW X 2393 6 WATER 4 INLET 7 1086 1 2 Dou 2 RIGGING HOLES 780 EACH SIDE TO CLR CONN 993 588 2242 BASE WIDTH 2261 3613 gt RIGHT VIEW FRONT VIEW POWER SINGLE POINT SUPPLY
101. 5 035 21589 206 REV D 1 1 EXT EEE 1 GND 2 1 EXT fee GEG E 1 GND D LI 2 MF1 BLK cN 1 1 1 2 EXT EXT GND GND 2 1 2 2 1 2 3 1 8 4 5 GND 1 2 5 4 5 GND ee petal fe x II K ADJ 1 1 1 2 1 GND GND 2 MFi EXT V1 V1 W1 U2 V2 W 1 U2 V2 W TW PE FIG 26 CONNECTION WIRING DIAGRAM YLAA0195 SHT 6 84 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 1 3 EXT TT TeTeTe 2 3 4 5 1 GND 2 MF3 EXT 2 5 4 5 1 GND 1 MF 3 TT TeTeTeTe 2 5 6 7 8 4 5 1 GND 2 U1 VI VII U2 V2 TW TW 1 2 6 7 8 4 5 JOHNSON CONTROLS 1 4 EXT 2 3 4 5 1 GND 2 4 EXT 2 3 4 5 1 GND 1 4 EXT 2 3 6 7 8 4 5 1 GND 2 MF4 EXT V1 Vi VII W2 U2 V2 TW TW PE 1 2 3 6 7 8 4 5 SECTION 5 TECHNICAL DATA YLAA 1805 195 amp
102. 5 925 C2P 1D 2400 695 925 C2P 1D 2720 326 1049 C2P 1D 3570N 1050 1619 FIG 52 ONE INCH DEFLECTION SPRING ISOLATOR CROSS REFERENCE 124 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA ONE INCH DEFLECTION SPRING ISOLATORS INSTALLATION INSTRUCTIONS 1 Read instructions their entirety before beginning installation 2 Isolators are shipped fully assembled and are to be positioned In accordance with the submittal draw ings or as otherwise reccomended 3 Set isolators on floor housekeeping pad or sub base ensuring that all isolators centerlines match the equipment mounting holes The VMC group reccomends that the isolator base B be installed level surface Shim or grout as required level ing all isolatorbases to the same elevation 1 4 inch maximum difference can be tolerated 4 Bolt or anchor all isolators to supprting structure utilizing base slotted holes C UPPER HOUSING Br L LOWER HOUSING 5 Place equipment on top of isolators making sure that mounting holes of the equipment line up with isolator positioning pin H 6 The adjustment process can only begin after the equipment or machine 15 at its full operating weight 7 Adjust each isolator in sequence by turning spring adjusting bolt D one full counterclockwise turn at a time Repeat this procedure on all isolators one at a time 8 Continue ad
103. 50 F with 1 NPT connection for upright mounting in horizontal pipe Field mounted FLOW SWITCH ACCESSORY Vapor proof SPDT NEMA 3R switch 10 3 barg 150 psig DWP 7 C to 121 C 20 F to 250 F with 1 NPT IPS connection for upright mounting in horizontal pipe this flow switch or equivalent must be furnished with each unit Field mounted DIFFERENTIAL PRESSURE SWITCH Alternative to an above mentioned flow switch Vapor proof SPDT NEMA 3R switch 10 3 barg 150 psig DWP 7 C to 121 C 20 F to 250 F with 1 NPT IPS connection for upright mounting in horizontal pipe This flow switch or equivalent must be furnished with each unit JOHNSON CONTROLS SECTION 2 PRODUCT DESCRIPTION HYDRO KIT Factory installed Hydro Kit suitable for water glycol systems with up to 35 glycol at leaving temperatures down to 20 F The Hydro kit option is 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 balanc ing valve flow switch pressure ports suction guide strainer bleed and drain valves and frost protection Expansion tanks are optional within the Hydro Kit option CONDENSER AND CABINET OPTIONS Condenser coil protection against corrosive environ ments is available by choosing any of the following options For additional application recommendations refer to FORM 150 1 ESI Factory mou
104. 599 10 jou s 3onpoud NLY SNGPOW pue d L SIN 19uOV8 20 SHUN 1 09559 II L SALON p C geeuedns mor JOJON WU ejnjie4 10 02 6L 11 5 9 1u8JJn2 1010 109 I MOT 6 juano Joo YBIH 8 einsselq uonons MOT _ 2 Ie u jJ iqu6iH 9 ansseid S a dum MOT ned iun 6 waqu 8059907 8I 6C199LV8 jueiquiv 2 OVA L gt ON s poo _ 2 I spa de 202 10 eooo 606 2018 96 sensn 6 1 0 602010 zoek 96 33 E 12207 0 SPO 602010 106 oziga HNO 76
105. 6 Units are designed in accordance with NFPA 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 dynamically balanced A large internal volume and oil reservoir provides greater liquid tolerance Compressor crankcase heaters are also included for extra protection against liquid migration The motor terminal boxes have IP54 weather protection Cooler Evaporator The cooler is a direct expansion type with refrigerant inside high efficiency copper tubes The liquid flowing through the cooler is forced over the tubes by water baffles The water baffles are constructed of brass to resist corrosion The removable heads allow access to the internally enhanced seamless copper tubes Vent and drain connections are included Water inlet and outlet connections are grooved for compatibility with field supplied ANSI AWWA C 606 couplings The cooler is equipped with a heater controlled by a separate thermostat The heater provides freeze protection for the cooler down to 29 C 20 F ambient The cooler is covered with 3 4 flexible closed cell foam insulation K 0 25 17
106. 6 o 975 High Efficiency 40 5 10 35 0 15 YLAAO20HE _ 40 5 10 355 0 15 YLAAO260HE _ 40 5 125 YLAAOS00HE _ 40 5 125 YLAAOS0HE _ 40 5 120 625 125 YLAAO390HE 40 _ 55 125 0440 _ 40 55 0 0 125 0445 _ 40 5 10 65 0 125 YLAAOMSHE _ 40 5 125 1 For leaving brine temperature below 4 C 40 F contact your nearest Johnson Controls Office for application requirements 2 For leaving water temperature higher than 13 C 55 F contact the nearest Johnson Controls Office for application guidelines 3 The evaporator is protected against freezing to 29 C 20 F with an electric heater as standard 4 For operation at temperatures below 4 C 25 F the optional Low Ambient Kit will need to be installed on the system 5 For operation at temperatures above 46 C 115 F the optional High Ambient Kit will need to be installed on the system Excessive flow will cause damage to VOLTAGE LIMITATIONS the cooler not exceed max cooler The following voltage limitations are absolute and flow Special care should be taken operation beyond these limitations may cause serious when multiple chillers are fed by a damage to the compressor single pump TABLE 2 VOLTAGE LIMITATIONS JOHNSON CONTROLS 45 Pressure Drop kPa FORM
107. 8 15 2011 220721 220 N 2 KT A2 PPEP asa gt 7 CV a I CN N 1117 u s gt ES LN a LO E x gt lt gt gt L 222 TT d x zB gt iL el 2 gt 255 ME I UNES gt 1 S 12522 lt 8 I REL C EE 73 JOHNSON CONTROLS FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 CONNECTION WIRING DIAGRAMS YLAA0195 035 21589 201 REV D Ce IC IC el 0302219639420 2 FIG 21 CONNECTION WIRING DIAGRAM YLAA0195 SHT 1 74 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA 035 215889 205 035 215889 206 035 215889 203 035 215889 204 9 ry U I 0 IL I IIII
108. AGE Signal Input to Return 182 FORM 150 72 811 ISSUE DATE 8 15 2011 Liquid amp Refrigerant Sensor Test Points Table 25 Entering Chilled Liquid Sensor J6 5 5VDC regulated supply to sensor J6 8 VDC input signal to the I O board See Table 25 for voltage readings that correspond to specific liquid temperatures J6 2 drain shield connection Return Leaving Chilled Liquid Temperature Sensor J6 4 5VDC regulated supply to sensor J6 7 VDC input signal to the microboard See Table 25 for voltage readings that correspond to specific liquid temperatures J6 1 drain shield connection Return JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 Analog Inputs Pressure Refer to the unit wiring diagram Pressure inputs are connected to the microboard on plugs J7 and J9 These analog inputs represent varying DC signals corresponding to varying pressures All voltages are in reference to the unit case ground System 1 discharge and suction pressures will be connected 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 connections 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
109. AGE OPTIONS PIN 60 me PLANT OF MFG PIN 61 5 MFG CUR MEX LOC MFG LOCATION MTY SAT CV YORKWORKS VERSION UV Q SPECIAL QUOTE 32 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 2 PRODUCT DESCRIPTION PRODUCT IDENTIFICATION NUMBER PIN CON T AIR COOLED CONDENSERS gt Im YLAA REFRIGERANT FLOW DIAGRAM INCLUDING TEMPERATURE SENSORS amp PRESSURE TRANSDUCERS HOT GAS OPTION SYSTEM 1 ONLY SIGHT GLASS MOISTURE INDICATOR LIQUID LINE FILTER DRIER LIQUID LIN p p SERVICE VALVE LIQUID LINE SOLENOID VALVE HOT DISCHARGE GAS LINE OPTIONAL DISCHARGE LINE BALL VALVE SOLENOID OPERATED HOT GAS BY PASS VALVE OPTIONAL DISCHARGE V PRESSURE TRANSDUCER SE EQUALIZER SERVICE VALVE OPTIONAL LINE SUCTION LINE HIGH PRESSURE BALL VALVE CUTOUT SWITCH OPTIONAL RELIEF VALVE OPTIONAL SERVICE VALVE LOW PRESSURE SWITCH OR RETURN WATER SUCTION TRANSDUCER RETURN WATER LEAVING ENTERING CHILLED WATER 8 2 LEAVING CHILLED WATER CHILLED WATER gt TEMP SENSOR OIL EQUALIZING LINE 2 OR 3 COMPRESSORS PER SYSTEM LD13138A FIG 5 REFRIGERANT FLOW DIAGRAM JOHNSON CONTROLS 33 SECTION 2 PRODUCT DESCRIPTION FORM 150 72 3 811 ISSUE DATE 8 15 2011 PROCESS AND INSTRUMENTATION DIAGRAM DV
110. AN CONTROL ON PROGRAMMED 7 8 8 TB10 8 amp 1 KF1 amp 2 KF1 amp PRESSURE AND FAN DIFFERENTIAL TB7 9 amp TB10 9 amp 1 KF2 amp 2 amp STAGES 18 2 PRESSURE amp FAN TB10 10 ENERGIZED STAGES 1 amp 2ARE ENERGIZED When a fan stage is turned on the pressure for the next stage is increased 20 PSIG and ramped back to the programmed on pressure over the next 20 seconds When a 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 be tween turning fan stages on and off is fixed at 5 seconds NOTE JOHNSON CONTROLS 173 FORM 150 72 811 SECTION 8 UNIT OPERATION ISSUE DATE 8 15 2011 TABLE 18 YLAA STANDARD CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONLY 5 OR 6 FANS PER SYSTEM FAN OFF IO OUTPUT FAN CONTACTOR FAN SYS 1 SYS2 SYS 1 SYS2 SYS 1 SYS 2 DP lt PROGRAMMED DP gt FAN CONTROL PROGRAMMED ON PRESSURE EAN CONTROL MINUS 10 8 1 KF 1 2 KF 1 1 MF1 ON PRESSURE PROGRAMMED DIFFERENTIAL PRESSURE DP PROGRAMMED DP gt FAN CONTROL PROGRAMMED ON PRESSURE FAN CONTROL MINUS TB7 8 amp 10 88 1 KF1 amp 2 KF1 amp ON PRESSURE amp PROGRAMMED TB7 9 TB10 9 1 KF2 2 KF2 FAN STAGE 1 15 DIFFERENTIAL ENERGIZED PRESSURE amp FAN STAGE 1 IS ENERGIZED STA
111. AND SAFETY Responsibility for Safety Every care has been taken in the design and manufacture of the unit to ensure compliance with the safety requirements listed above However the individual operating or working on any machinery is primarily responsible for Personal safety safety of other personnel and the machinery Correct utilization of the machinery In accordance with the procedures detailed the manuals ABOUT THIS MANUAL The following terms are used In this document to alert the reader to areas of potential hazard WARNING A WARNING 15 given in this document to identify a hazard which could lead to personal injury Usually an instruction will be given together with a brief explanation and the possible result of ignoring the instruction CAUTION A CAUTION identifies a hazard which could lead to damage to the machine damage to other equipment and or environmental pollution Usually an instruction will be given together with a brief explanation and the possible result of ignoring the instruction NOTE A NOTE 15 used to highlight additional information which may be helpful to you but where there are no special safety implications 14 FORM 150 72 811 ISSUE DATE 8 15 2011 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
112. ATING RANGE 122 0 2 0 DEGF ee SYS 1 SETPOINT 70 3 PSIG SiS A 70 3 PSIG Operating Data Printout REMOTE SETPOINT 44 0 DEGF AMBIENT TEMP 74 8 DEGF Pressing the PRINT key and then OPER DATA key LEAD SYSTEM 55 2 allows the operator to obtain a printout of current system operating parameters When the OPER DATA key is ACTIVE REMOTE CONTROL NONE pressed a snapshot will be taken of system operating LAST DEFROST SYS X DURATION 5 conditions and panel programming selections This data TIME TO SYS X DEFROST XX MIN 11 be t dt BIVALENT DELAY REMAINING XX MIN will be temporarily stored in memory and transmission UNIT AMPS X X VOLTS ofthis data will begin to the printer A sample Operating SOFTWARE VERSION 2 13 200 Data printout is shown below Note Not all values are SYSTEM 1 DATA printed for all models COMP STATUS 1 2 OFF 3 OFF RUN TIME 0 0 0 0 D H M S TIME YYYYYYY 0 0 0 0 D H M S LAST STATE YYYYYYY YORK INTERNATIONAL CORPORATION SUCTION PRESSURE 165 Pare MILLENNIUM LIQUID CHILLER DISCHARGE PRESSURE 315 PSIG SUCTION TEMPERATURE 46 0 DEGF UNIT STATUS SAT SUCTION TEMP 34 0 DEGF 2 04PM 01 AUG 09 SUCTION SUPERHEAT 12 0 DEGF COOLER INLET REFRIG 31 6 DEGF 5X5 1 NO COOLING LOAD DEFROST TEMPERATURE 52 8 DEGF SYS 2 COMPRESSORS RUNNING 2 LIQUID LINE SOLENOID OFF MODE SOLENOID OFF OPTIONS HOT GAS BYPASS VALVE OFF CHILLED LIQUID WATER CONDENSER FAN STAGE OF
113. Anti Coincidence timer will be initiated to prevent multiple compressors from turning on If after 60 seconds of run time the leaving chilled liquid 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 one 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 16 1 C per minute 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 Setpoint High Limit but is greater than the Setpoint Low Limit loading and unloading will not occur This area of control is called the control range If the chilled liquid temperature drops to between the Setpoint Low Limit and 0 5 F 28 C below the Setpoint Low Limit unloading a compressor turns off occurs at a rate of one every 30 seconds If the chilled liquid temperature falls to a value greater than 0 5 F 28 C below the Setpoint Low Limit but not greater than 1 5 F 16 9 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 16 9 C below the Setpoint Low Limit unloading occurs at a rate of 10 seconds If the chilled liquid temperature falls below 1 F above the low chilled liquid temperat
114. C to 21 1 C in water chilling mode and from 10 F to 70 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 C SECTION 8 UNIT OPERATION As an example of compressor staging refer to Table 14 a chiller with six compressors using a Cooling Setpoint programmed for 45 F 7 20 C and a Range Setpoint of 10 F 5 56 C Using the formulas in Table 15 the control range will be split up into six seven including hot gas segments with the Control Range determining the separation between segments Note also that the Cooling Setpoint is the point at which all compressors are off and Cooling Setpoint plus Range is the point all compressors are on Specifically if the return water temperature is 55 F 12 8 C then all compressors will be on providing full capacity At nominal gpm this would provide approximately 45 F 7 2 C leaving water temperature out of the evaporator If the return water temperature drops to 53 4 F 11 9 C one compressor would cycle off leaving five compressors running The compressors would continue 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 p
115. Center see Commissioning section of this IOM Only genuine YORK approved spare parts oils coolants and refrigerants must be used the scheduled maintenance operations detailed in this manual must be performed at the specified times by suitably trained and qualified personnel see Maintenance Section of this IOM Failure to satisfy any of these conditions will automatically void the warranty SAFETY AND QUALITY Standards for Safety and Quality YLAA chillers are designed and built within an ISO 9002 accredited design and manufacturing organization The chillers comply with the applicable sections of the following Standards and Codes e ANSI ASHRAE Standard 15 Safety Code for Mechanical Refrigeration e ANSI NFPA Standard 70 National Electrical Code N E C ASME Boiler and Pressure Vessel Code Section VIII Division 1 ARI Standard 550 590 Positive Displacement Compressors and Air Cooled Rotary Screw Water Chilling Packages 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 Occupational Safety and Health Act In addition the chillers conform to Underwriters Laboratories U L for construction of chillers and provide U L cU L Listing Label 13 SECTION 1 GENERAL CHILLER INFORMATION
116. DDRESS XXXXX DE MODIFIER OFFSET XX P1 PROTOCOL XXXXXX P1 MANUAL MAC ADDRESS XXX P1 BAUD RATE XXXXX P1 PARITY XXXXX P1 STOP BITS JOHNSON CONTROLS RS 232 connect to TB3 Network RX to TB3 TXD Network TX to TB3 RXD Network GND to TB3 GND Refer to Fig 64 Micropanel Connections for TBI TB2 and TB3 locations In most cases communication parameters will need to be modified Table 29 Values Required for BAS Communication lists setup parameters for the available protocols Modification 15 accomplished by pressing the PROGRAM DOWN ARROW DOWN ARROW DOWN ARROW DOWN ARROW and ENTER keys in sequence The list below shows the displays for the values that may be modified P2 PROTOCOL XXXXXXXXXX P2 MANUAL MAC ADDRESS XXX P2 BAUD RATE XXXXX P2 PARITY XXXXX P2 STOP BITS P2 HW SELECT BIT XXXXX REAL TIME ERROR RESET 1 YES 0 NO 0 Note See Table 30 for error descriptions 191 FORM 150 72 3 811 SECTION 10 MAINTENANCE ISSUE DATE 8 15 2011 SHLD GND oV oVGND RAD IXD CIS RIS LX 184 2182 185 035 02550 1 Board FIG 64 MICROPANEL CONNECTIONS The table below shows the minimum maximum and default values DESCRIPTION MMM M BEFAUT _ DEVODIFEERADDRESS 4 _ 9600 16200 38400 76800 AUTO
117. ETL CB 3XX CHILLER MODEL ETL NFDS wl Individual ETL Dual Pt CB per Sys 5XX ETL NFDS 2 System CBs 4xx VOLT ETL TB 1xx 400 1 4 500kCMIL 2 3 0 AWG 250 KCMIL 1 6 AWG 350kCMIL 2 3 0 AWG 250 400 1 4 500kCMIL 2 3 0 AWG 250 KCMIL 2 3 0 AWG 250 KCMIL 2 3 0 AWG 250 KCMIL 50 YLAA0285SE YLAA0320SE 48 so yinawc amici wa 1 250 500 YLAA0350HE 1 4 500 KCMIL 2 30 AWG 250 2 3 0 AWG 250KCMIL 2 43 0 AWG 250 YLAA0390HE 1 4 500 2 3 0 AWG 250 880 AWG 250 YLAA0440HE 2 3 0 AWG 250 kCMIL 3 0 AWG 250 KCMIL 3 0 AWG 250 2 2 2 2 YLAA0455HE YLAA0515HE 4 500 2 250 500kCMIL 4 500 0 250 500 52 FORM 150 72 NM3 811 ISSUE DATE 8 15 2011 CE NFDS WI MMS 2 3 0 AWG 250 2 3 0 AWG 250 2 3 0 AWG 250 2 3 0 AWG 250 2 3 0 AWG 250 2 250 500 1 6 AWG 350 KCMIL 1 6 AWG 350 KCMIL 1 6 AWG 350 KCMIL 2 3 0 AWG 250 2 3 0 AWG 250 2 3 0 AWG 250 kCMIL 2 3 0 AWG 250 2 250 500 2 250 500
118. ETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS 6 STEPS D LEAD SYSTEM LAG SYSTEM COMP1 COMP2 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 lt SP the Hot Gas Bypass solenoid is turned off when the LWT gt SP CR 2 1 Step 1 is not used for loading or unloading 2 Step 3 is skipped when loading occurs 3 Step 4 is skipped when unloading occurs 170 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 ANTI RECYCLE TIMER The programmable anti recycle timer assures that systems do not cycle This timer is programmable under the PROGRAM key between 300 600 seconds Whenever possible to reduce cycling and motor heating the anti recycle timer should be adjusted to 600 seconds The programmable anti recycle timer starts the timer when the first compressor a system starts The timer begins to count down If all of the compressors in a circuit cycle off a compressor within the circuit will not be permitted to start until the anti recycle timer has timed out If the lead system has run for less than 5 minutes 3 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 timi
119. F AMBIENT CONTROL STANDARD FEV OUTPUT 0 0 LOCAL REMOTE MODE REMOTE SYSTEM XXX X AMPS VOLTS CONTROL MODE LEAVING LIQUID LEAD LAG CONTROL AUTOMATIC SYSTEM 2 DATA FAN CONTROL AMB C DSCH PRESS COMP STATUS 1 ON 2 OFF 3 ON CURRENT FEEDBACK NONE RUN TIME POWER FAILURE RESTART AUTOMATIC TIME YYYYYYY p M 8 SOFT START ENABLED LAST STATE YYYYYYY EXPANSION VALVE THERMOSTATIC SUCTION PRESSURE TO Pere REMOTE TEMP RESET ATO 20 MA DISCHARGE PRESSURE 320 PSIG SUCTION TEMPERATURE 49 3 DEGF PROGRAM VALUES SAT SUCTION TEMP 36 0 DEGF DSCH PRESS CUTOUT 270 PSIG SUCTION SUPERHEAT 13 3 DEGF SUCT PRESS CUTOUT 80 PSIG COOLER INLET REFRIG 31 6 DEGF SUCT PRESS CUT COOLING 42 PSIG DEFROST TEMPERATURE 52 8 DEGF SUCT PRESS CUT HEATING 31 LIQUID LINE SOLENOID ON LOW AMBIENT CUTOUT 25 0 DEGF MODE SOLENOID ON LEAVING LIQUID CUTOUT 25 0 DEGF CONDENSER FAN STAGE 3 ANTI RECYCLE TIME 600 SECS EEV OUTPUT 63 90 FAN CONTROL ON PRESS 425 PSIG SYSTEM AMPS VOLTS FAN DIFF OFF PRESS 125 PSIG NUMBER OF COMPRESSORS 6 DAILY SCHEDULE NUMBER OF FANS PER SYSTEM 4 gt HOLIDAY UNIT TRIP VOLTS 3 0 SUN START 00 00AM STOP 00 00AM REFRIGERANT TYPE R 22 MON START 00 00AM STOP 00 00AM DEFROST INIT TEMP 41 0 TUE START 00 00AM STOP 00 00AM DEEROST INITIATION TIME 60MIN WED START 00 00AM STOP 00 00AM DEFROST TERMINATION TIME 3MIN THU START 00 00AM STOP 00 00AM BIVALENT HEAT DELAY TIME 30 MIN FRI
120. FORM 150 72 3 811 ISSUE DATE 8 15 2011 continued from previous page L1 YLAAOAAOHE Isolator Weights kg if selected 3 L 576 R 535 3 L 595 R 533 3 L 641 R 574 SECTION 5 TECHNICAL DATA L3 R3 0440 Isolator Locations mm 1 2 3863 2207 3863 36 0455 Isolator Locations mm __ 2 193 2207 3170 2207 3863 2207 193 36 3170 36 3863 36 YLAAO515HE Isolator Locations mm Ca 2 8 193 2207 3170 2207 3863 2207 193 36 3170 36 3863 36 FIG 51 WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS JOHNSON CONTROLS 123 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 ISOLATOR DATA ONE INCH DEFLECTION SPRING ISOLATOR CROSS REFERENCE CP EQUIPMENT BASE By Others 5 8 POSITIONING LD13759A Mount Dimension Data Inches PP ws c B T H CP2 10 1 2 9 1 4 7 3 4 9 16 6 RATED CAPACITY FOR UNITS WITH ALL LOAD POINTS LESS THAN 1785 LBS 810 KG MODEL NUMBER COLOR CODE LBS KG CP 1D 900 198 thru 347 CP 1D 1200 348 thru 463 CP 1D 1360 464 thru 524 CP 1D 1785N 525 thru 810 RATED CAPACITY FOR UNITS WITH ANY LOAD POINT ABOVE 1518 LBS 689 KG MODEL NUMBER COLOR CODE LBS KG C2P 1D 1350 DARK PURPLE Up thru 1148 Up to 521 C2P 1D 1350 DARK PURPLE Up thru 1148 Up to 521 2 10 1800 522 694 C2P 1D 2400 69
121. GE DP PROGRAMMED DP gt FAN CONTROL PROGRAMMED ON PRESSURE FAN CONTROL MINUS 10 8 amp ON PRESSURE PROGRAMMED 10 9 amp AND FAN DIFFERENTIAL TB10 10 STAGES 182 PRESSURE amp ARE ENERGIZED FAN STAGES 1 2 ENERGIZED When a fan stage is turned on the pressure for the next stage is increased 20 PSIG and ramped back to the programmed on pressure over the next 20 seconds When a fan stage is turned off Programmed ON pressure minus the differential the OFF pressure for the next stage 15 decreased 20 PSIG and ramped back to the programmed OFF pressure minus the differential The time delay fan delay timer be tween turning fan stages on and off is fixed at 5 seconds NOTE 174 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 LOAD LIMITING Load Limiting is a feature that prevents the unit from loading beyond the desired value Two and four compressor units can be load limited to 50 This would allow only one compressor per system to run Three and six compressor units can be load limited to 33 or 66 The 66 limit would allow up to two compressors per system to run and the 33 limit would allow only one compressor per system to run Five compressor units may be load limited to 40 one compressor per system runs or 80 up to 2 compressors per system No other values of limiting are available There are two ways to load limit the unit The first is through remote communica
122. HILLED LIQUID 1 5 F CONTROL RANGE 0 8 C 44 C 21 1 6 7 10 0 F 270 0 44 0 F 12 2 C 21 1 6 7 2 5 2 0 F 1 4 1 1 40 0 F 70 0 F 44 0 F WATER COOLING RETURNED CHILLED LIQUID SETPOINT GLYCOL COOLING RETURN CHILLED LIQUID CONTROL RANGE 44 C 10 0 F 12 2 C 4 0 F 2 21 1 C 6 7 C 70 0 F 44 0 F 21 1 C 6 7 C 20 0 F 10 0 F 11 1 C 5 6 C MAX EMS REMOTE 40 F 20 F TEMPERATURE RESET 1 22 0 C 11 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 XX guidelines The line under the 0 15 the cursor If the value is wrong it may be changed by using the 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 necessary 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 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
123. HOOTING OPTIONAL PRINTER INSTALLATION The micropanel is capable of supplying a printout of chiller conditions or fault shutdown information at any given time This allows operator and service personnel to obtain data and system status with the touch of the keypad In addition to manual print selection the micropanel will provide an automatic printout whenever a fault occurs Detailed explanation of the print function is given under Print Key located in the Keypad and Display section of this IOM Johnson Controls recommends the field tested WEIGH TRONIX model 1220 printer or former IMP 24 This is a compact low cost printer that 15 ideal for service work and data logging The WEIGH TRONIX printer can be obtained by contacting 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 specifically for YORK 15 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 Chiller Microboard TB3 TB3 3 TXD TB3 2 CTS TB3 5 GND Shield connect shield to Pin 5 of the connector Parts The following parts are required 1 One WEIGH TRONIX model 1220 printer 2 2 25 5 7cm wide desk top calculator paper 3 25 ft 7 62m maximum len
124. IONS POWER OPTIONS COMPRESSOR POWER CONNECTIONS Single point terminal block connection s are provided as standard The following power connections are avail able as options See electrical data for specific voltage and options availability Factory mounted SINGLE POINT SUPPLY TERMINAL BLOCK Includes enclosure terminal block and intercon necting wiring to the compressors Separate external protection must be supplied by others the incom ing compressor power wiring Do not include this option if either the Single Point Non Fused Discon nect Switch or Single Point Circuit Breaker options have been included SINGLE POINT NON FUSED DISCONNECT SWITCH Unit mounted disconnect switch es with external lockable handle in compliance with Article 440 14 of N E C can be supplied to isolate the unit power voltage for servicing Separate external fusing must be supplied by others in the power wiring which must comply with the National Electrical Code and or local codes SINGLE POINT NON FUSED DISCONNECT SWITCH WITH INDIVIDUAL SYSTEM BREAKERS Includes unit mounted disconnect switch with ex ternal lockable handles in compliance with Article 440 14 of N E C to isolate unit power voltage for servicing Factory interconnecting wiring 15 provided from the disconnect switch to factory supplied system circuit breakers SINGLE POINT CIRCUIT BREAKER A unit mounted circuit breaker with external lock able handle in comp
125. LE POINT SUPPLY CONNECTION TERMINAL BLOCK NON FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER Power Panel Control Panel Terminal Block NF Disconnect SW or Circuit Breaker Field Provided 120 1 60 Micropanel Power Supply if Control Transformer not supplied Field Field supplied control power wiring pp uM 22212 Provided must be run in separate grounded Unit Power conduit Never run control wiring See electrical note 9 Supply in the same conduit with power wiring 1013141 Electrical Notes and Legend located page 53 FIG 9 SINGLE POINT SUPPLY CONNECTION TERMINAL BLOCK NON FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER It is possible that multiple sources The unit evaporator heater uses of power can be supplying the unit 120VAC Disconnecting 120 power panel To prevent serious power from the unit at or below freez injury or death the technician ing temperatures can result in dam Should verify that NO LETHAL age to the evaporator and unit as a VOLTAGES are present inside the result of the chilled liquid freezing panel AFTER disconnecting power PRIOR to working on equipment 42 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 4 INSTALLATION USER CONTROL WIRING INPUTS s s s uma s s uma s s s s 1 113130 FIG 10 CONTROL WIRING INP
126. MENTARY WIRING DIAGRAM YLAA0195 SHT 1 56 FIG 13 ELEMENTARY WIRING DIAGRAM 0195 SHT 2 58 FIG 14 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 3 60 15 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 4 62 FIG 16 ELEMENTARY WIRING DIAGRAM 0195 SHT 5 64 FIG 17 ELEMENTARY WIRING DIAGRAM 0195 SHT 6 66 FIG 18 ELEMENTARY WIRING DIAGRAM YLAA0195 8 7 2 68 FIG 19 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 8 70 FIG 20 ELEMENTARY WIRING DIAGRAM YLAA0195 SHT 9 72 FIG 21 CONNECTION WIRING DIAGRAM YLAA0195 SHT 1 74 FIG 22 CONNECTION WIRING DIAGRAM YLAA0195 SHT 2 76 FIG 23 CONNECTION WIRING DIAGRAM YLAA0195 SHT 78 FIG 24 CONNECTION WIRING DIAGRAM YLAA0195 SHT 4
127. NTROLS FORM 150 72 811 ISSUE DATE 8 15 2011 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 of the control panel The three keys involved are labeled COOLING SETPOINTS SCHEDULE ADVANCE DAY and PROGRAM The following are instructions for programming the respective 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 setpoint display entry screen will appear 154 00069 Leaving Chilled Liquid Control SETPOINT RANGE The above message shows the current chilled water temperature SETPOINT at 45 0 F 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 UP DOWN arrow 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
128. NTROLS 23 FORM 150 72 3 811 SECTION 2 PRODUCT DESCRIPTION ISSUE DATE 8 15 2011 UNIT COMPONENTS CONT FAN ASSEMBLIES CONDENSER CONDENSER COILS COILS EVAPORATOR RECEIVERS LD13426 FIG 2 UNIT COMPONENTS SIDE 24 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 2 PRODUCT DESCRIPTION CONTROL POWER PANEL COMPONENTS DISCONNECT SWITCH FAN FUSES FAN CONTACTORS FAN CONTACTOR COMPRESSOR OVERLOADS COMPRESSOR CONTACTORS 1013247 FIG 3 POWER PANEL COMPONENTS JOHNSON CONTROLS 25 FORM 150 72 3 811 SECTION 2 PRODUCT DESCRIPTION ISSUE DATE 8 15 2011 CONTROL POWER PANEL COMPONENTS CONT FAN FUSES MICROCOMPUTER FAN CONTACTORS CONTROL CONTROL RELAY CENTER MICROPANEL DISPLAY COMPRESSOR OVERLOADS MICROBOARD COMPRESSOR CONTACTORS 2 LD13248 FIG 4 POWER PANEL CONTROL COMPONENTS 26 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 2 PRODUCT DESCRIPTION PRODUCT IDENTIFICATION NUMBER PIN BASIC UNIT NOMENCLATURE YLAA03605E S0XCA 8 9 14 15 NOMINAL UNIT DESIGN DEVELOPMENT CAPACITY DESIGNATOR I L Y L A Air Cooled Development Level Condensing Unit C Design Series A B C A Americas X Across the Line E Europe 50 380 415 3 50 E R 410A Four Digit Unit Number S Standard Efficiency H High Efficiency Z
129. OPTIONS is turned OFF The system will not be allowed to run until the switch 15 turned back on 139 SECTION 7 UNIT CONTROLS SYS 1 NO COOL COOL LOAD LOAD SYS 2 This message informs the operator that the chilled liquid temperature 15 below the point determined by the setpoint and control range that the microprocessor board will bring on a system or that the microprocessor board 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 COMPS RUN X RUN X SYS 2 The COMPS RUNNING message indicates that the respective system is running due to demand The X will be replaced with the number of compressors in that system that are running SYS 1 AR TIMER XX S TIMER XX S SYS 2 AR 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 TIMER XX S TIMER XX S SYS 2 AC The anti coincidence timer is a software feature that guards against two systems starting simultaneously This assures Instantaneous starting current does not become excessively high due to simultaneous starts The microprocessor board limits the time between compressor starts to on
130. OTE 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 FIG 48 DIMENSIONS ENGLISH YLAA0455HE 118 safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit 15 no higher than on spring isolators Recommended minimum clearances Side to wall 6 rear to wall 6 control panel to end wall 4 0 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA DIMENSIONS YLAA0515HE ENGLISH POWER ENTRY 8712 WIDE 178 HIGH 14012 VIEW BOTTOM OF PANEL la lt 2242 BASE WIDTH 774 gt TO CLR CONN NOTE 2261 FRONT VIEW 2077
131. RAM KEY There are several operating parameters under the PROGRAM 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 display 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 enter the data into memory Table 11 shows the programmable limits and default values for each operating parameter The following are the displays for the programmable values in the order they appear DISCHARGE PRESSURE 570 PSIG CUTOUT DISCHARGE PRESSURE CUTOUT is the discharge pressure at which the system will shutdown as monitored by the optional discharge transducer This 15 a software shutdown that acts as a backup for the mechanical high pressure switch located in the refrigerant circuit The system can restart when the discharge pressure drops 40 PSIG 2 76 barg below the cutout point If the optional discharge pressure transducer is not installed 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 PRESSURE PSIG CUTOUT 80 0 The SUCTION PRESSURE CUTOUT
132. REQUIRED ONE DIFFERENTIAL PRESSURE SWITCH REQUIRED TWO DIFFERENTIAL PRESSURE SWITCHES REQUIRED THREE DIFFERENTIAL PRESSURE SWITCHES REQUIRED SPECIAL FLOW SWITCH REQUIRED ASME PRESSURE VESSEL CODES PED PRESSURE VESSEL CODES SPECIAL QUOTE gt lt FLANGES PIN 40 FLOW SWITCH PIN 41 VESSEL CODES PIN 42 m JOHNSON CONTROLS 29 SECTION 2 PRODUCT DESCRIPTION FEATURE CLR FEATURE PIN44 COILS HEAT FANMOTORS ENCL ACOUSTIC SRDOCS 30 FORM 150 72 3 811 ISSUE DATE 8 15 2011 PRODUCT IDENTIFICATION NUMBER PIN CON T COOLER PIN 43 FEATURE DESCRIPTION PIN 44 COILS PIN 45 HEAT RECOVERY PIN 46 FAN MOTORS PIN 47 ENCLOSURE PANELS PIN 48 ACOUSTIC BLANKET PIN 49 SR DOCUMENTS PIN 50 OPTION X OPTION DESCRIPTION STANDARD COOLER REQUIRED REMOTE COOLER REQUIRED SPECIAL COOLER REQUIRED OPTION OPTION DESCRIPTION X SPECIAL QUOTE ALUMINUM COILS COPPER FIN COILS PRE COATED FIN COILS POST COATED DIPPED COILS SPECIAL COILS NO OPTION REQUIRED HEAT RECOVERY SPECIAL QUOTE TEAO FAN MOTORS SPECIAL FAN MOTORS REQUIRED NO ENCLOSURE REQUIRED WIRE FULL UNIT ENCL PANELS FACTORY WIRE FULL UNIT ENCL PANELS FIELD WIRE LOUVERED ENCL PANELS FACTORY WIRE LOUVERED ENCL PANELS FIELD LOUVERED COND ONLY ENCL PANELS FACTORY LOUVERED COND ONLY ENCL PANELS FIELD LOUVERED FULL UNIT ENCL PANELS FACTORY LOUVERED FULL UNIT ENCL PANELS FIELD
133. S ENTER Pressing the ENTER ADV key at this display will cause the history buffers to be cleared Pressing any other key will cancel the operation DO NOT CLEAR BUFFERS Impor tant information may be lost Contact factory 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 UP ARROW UP ARROW DOWN ARROW DOWN ARROW ENTER Service Mode will time out after 30 minutes and return to normal control mode if the panel ts 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 control 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 15 used to advance through the outputs Using the 7 and UP DOWN arrow keys will turn the respective digital output on off or modify the value The following is the order of outputs that will appear as the ENTER ADV key is pressed SYS 1 COMP 1 STATUS 7 2 IS SYS I LLSV STATUS TB7 3 IS SYS 1 COMP 2 STATUS 7 4 IS JOHNSON
134. SELECTABLE P1 P2 MANUAL MAC p 1 T NONEEVENODD IGNORESELECTALE OO BAONELAPISELECTARE _ MODBUS 10 MODBUS SERVER API MODBUS CLIENT SELECTABLE 192 JOHNSON CONTROLS FORM 150 72 811 ISSUE DATE 8 15 2011 SECTION 10 MAINTENANCE The table below shows set up requirements for each communication protocol TABLE 29 VALUES REQUIRED FOR BAS COMMUNICATION PROTOCOL BACNET MS TP MODBUS RTU YORKTALK 2 SETTING DESCRIPTION 0 419439 0 99 0 127 a o4 NA Na SELECTABLE NA NA ML NA _ DE MODIFIER ADDRESS DE MODIFIER OFFSET P1 PROTOCOL P1 MANUAL MAC ADDRESS P1 BAUD RATE P1 PARITY P1 STOP BITS P2 PROTOCOL P2 MANUAL MAC ADDRESS P2 BAUD RATE NONE MODBUS SVR RS 485 OR 232 P2 HW SELECT BIT RESET REAL TIME ERROR AS REQUIRED BY NETWORK OTHER AS REQUIRED BY NETWORK IS MULTIPLIED BY 100 SET AS REQUIRED BY NETWORK NUMBER IS ADDED TO DE MODIFIER ADDRESS SET AS REQUIRED BY NETWORK UNIT OPERATING SOFTWARE VERSION C MMC 13 03 OR LATER REQUIRED FOR MODBUS PROTOCOL 1 NOTE REBOOT REQUIRED CYCLE POWER AFTER SETTINGS ARE CHANGED The table below shows the real time error numbers that may be encounter
135. SON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 1 11 12 11 1L3 1 1 DUAL PUMP WIRING m SECTION 5 TECHNICAL DATA 5 4 Ha or 43 43 QMMSP1 QMMSP2 ut Wii a 1 14 PL XTBC2 023 XTBF 1499 1 1 GND KP1 A2 KP2 A2 2 2 2 12 1 2 1 2 4 3 1 MEE 11 10 11 12 1 _ 1013237 FIG 38 DUAL PUMP WIRING JOHNSON CONTROLS 107 FORM 150 72 NM3 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 WIRING 1 12 95 2 KFOL1 2 KFOL2 96 2 KFOL3 o6 13 1 CN 71 5 2 KFS1 2 2 2 2 KFS1 10 22 10 12 10 6 21 21 2 2 KFL3 2 22 5 22 LO oo 1 1 z2 KFL1 A2 z2 KFH1 A2 z2 KFL2 A2 z2 KFL3 A2 z2 KFH3 A2 2 12 2 32 1474 14 eras 714136 244 139 4 132 1132 134 134 136 135 2132 AMET st 136 ste 135 3 T u Bw Bw Bw Bw 212 212222 217 217 217 217 14 2 6 AES 1013238 FIG 39 WIRING 108 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA 95 2 KFOL4 96 2 KFOL5 96 13 6 O O 21 2 KFS1 10 22 Oo o 21 2 KFH4 22 1 2 KFL4 A2 29
136. Standard Efficiency round tube Y High Efficiency round tube FEATURE FEATURE DESCRIPTION OPTION OPTION DESCRIPTION CONTRACT CONTRACT NUMBER CONTRACT NUMBER CONTRACT NUM ORDER ORDER QUANTITY ORDER QUANTITY ORDER QTY USA ORIGIN NOT REQUIRED USA ORIGIN USA ORIGIN REQUIRED CRANE RIGGING SHIPPING WEIGHT LBS SHIPWT SHIPPING WEIGHT CRANE RIGGING SHIPPING WEIGHT KG STOCK STOCK UNIT CONV STOCK CONVERSION UNIT BEING BUILT FOR SOLD ORDER 0195 0220 0260 0285 0300 0320 MODEL MODEL PIN 1 4 2 0360 0390 0400 0435 0440 0455 0485 0515 UNIT BEING BUILT FOR STOCK UNIT NOT A CONVERSION ORDER BEING CONVERTED FROM STOCK 0195 0220 0260 0285 0300 0320 0350 0360 0390 0400 0435 0440 0455 0485 So ST EFFICIENCY EFFICIENCY HIGH EFFICIENCY HIGH EFFICIENCY ROUND TUBE STANDARD EFFICIENCY ROUND TUBE R 410A UNIT DESIGNATOR PIN 9 2 m H REFRIGERANT PIN 10 JOHNSON CONTROLS x I FORM 150 72 3 811 SECTION 2 PRODUCT DESCRIPTION ISSUE DATE 8 15 2011 PRODUCT IDENTIFICATION NUMBER PIN FEATURE FEATURE DESCRIPTION OPTION VOLTS VOLTAGE PIN 11 amp 12 STARTER STARTER PIN 13 DESIGN OPTION DESCRIPTION 380 415 3 50 ACROSS THE LINE STARTER SOFT START DESIGN SERIES A MICROCHANNEL DESIGN SERIES B TUBE AND FIN DESIGN SERIES C MICROCHANNEL CE ETL PANEL DEVELOPMENT LEVELA MP SUPPL
137. TION ISOLATORS REQUIRED NEOPRENE ISOLATORS REQUIRED SEISMIC ISOLATORS REQUIRED SPECIAL ISOLATORS REQUIRED MARKETING PURPOSES ONLY MARKETING PURPOSES ONLY NO CONTAINERIZATION REQUIRED WITH SHIPPING BAG BUY AMERICAN ACT COMPLIANCE WITH SHIPPING BAG BOTH BUY AMERICAN ACT COMPLIANCE AND CONTAINER SHIPPED WITHOUT SHIPPING BAG FACTORY PREP CONTAINER SHIPPED WITHOUT SHIPPING BAG FACTORY LOAD NO CONTAINERIZATION REQUIRED WITHOUT SHIPPING BAG CONTAINER SHIPPED WITHOUT SHIPPING BAG FACTORY PREP BUY AMERICAN ACT COMPLIANCE WITHOUT SHIPPING BAG SPECIAL QUOTE MARKETING PURPOSES ONLY OPTION DESCRIPTION X FORM 150 72 3 811 SECTION 2 PRODUCT DESCRIPTION ISSUE DATE 8 15 2011 PRODUCT IDENTIFICATION NUMBER PIN CON T X NO PUMP REQUIRED A PUMP KIT A REQUIRED PUMP KIT B REQUIRED PUMP KIT C REQUIRED PUMP KIT D REQUIRED PUMP KIT E REQUIRED PUMP KIT F REQUIRED PUMP KIT G REQUIRED PUMP KIT H REQUIRED PUMP KIT REQUIRED PUMP KIT J REQUIRED PUMP KIT K REQUIRED PUMP KIT L REQUIRED PUMP KIT M REQUIRED PUMP KIT N REQUIRED PUMP KIT O REQUIRED PUMP KIT P REQUIRED PUMP KIT R REQUIRED SPECIAL QUOTE NO OPTION REQUIRED SPECIAL QUOTE PLANT OF MANUFACTURE MONTERREY PLANT OF MANUFACTURE SABADELL CURITIBA BRAZIL MEXICO ES MONTERREY BE SAN ANTONIO TEXAS YORKWORKS CONFIGURATION VERSION YW CV YORKWORKS UPLOAD VERSION YW UV SPECIAL QUOTE PKG PUMP PACKAGE PIN 59 PUMP PACK
138. TIONS key After the selected option has been displayed 7 UP and DOWN arrow keys are then used to change that particular option After the option is changed the ENTER ADV key must be pressed to enter the data into memory Many of the OPTIONS displayed are only programmable under the SERVICE MODE and not under the OPTIONS key Options only program mable under the SERVICE MODE are noted in the details describing the option NOTE Table 13 shows the programmable options Following are the displays In the order they appear 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 is similar 5 5 1 SWITCH ON SWITCH ON SYS 2 JOHNSON CONTROLS 00070VIP This allows both systems to run or SWITCH SWITCH SYS 1 SYS 2 ON OFF This turns system 2 off SYS 1 SWITCH SYS 2 SWITCH OFF ON This turns system 1 off or SYS 1 SWITCH SWITCH OFF OFF SYS 2 This turns systems 1 amp 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 WATER LIQUID The chilled liquid is water The Cooling Setpoint can be programmed from 40 F to 70 F 4 4 C to 21 1 C or CHILLED LIQUID GLYCOL The chilled liquid is
139. Terminal Block 10 pin 3 177 SECTION 9 SERVICE AND TROUBLESHOOTING Pressing the 1 UP arrow key will energize the liquid line solenoid valve and OFF will change to ON in the display as the LLSV is energized Energizing and de energizing outputs may be useful during troubleshooting 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 configuration Soft start disabled Refrigerant Type R410A and Expansion Valve Type Thermostatic and North American Feature Enabled MUST be properly programmed or damage to compres sors and other system components may result The following is a list of chiller configuration selections in order of appearance 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 accumulated run and start timers for each system All values can also be changed using the 1 UP and Down arrow keys but under normal circumstances would not be required or advised After the last s
140. UT i e 120 is wire and 14 3 refers to SHT 14 column 3 NOTES Refer to installation commissioning operation and maintenance manual for customer connections and customer connection 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 __ 0 Power factor correction accessory Power factor correction fitted to sach compressor contactor 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 Only fitted on systems with 3 or 4 fans Only fitted on systems with 4 fans Only fitted on systems with 5 fans Only fitted on systems with 6 fans Input switch disconnect standard on CE units or circuit breaker option replaces input terminal block Input switch disconnect amp individual system circuit breaker option replaces input terminal block 115V control circuit requires a 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 14 15 16 17
141. UTS be capable of switching 24 VDC 115 120VAC Disconnecting 120VAC VAC Gold contacts are recommended power from the unit at or below freez If supplied contacts are from a Relay ing temperatures can result in damage Contactor Inductive Load the coil evaporator and unit as a of the Relay Contactor must sup of the chilled liquid freezing pressed Typical suppressor is P N 03 1 00808 000 II 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 dis connecting power PRIOR to working on equipment All externally supplied contacts must A The unit evaporator heater uses JOHNSON CONTROLS 43 SECTION 4 INSTALLATION FORM 150 72 811 ISSUE DATE 8 15 2011 USER CONTROL WIRING OUTPUTS Normally jumpered Can be used as EMERGENCY STOP contacts from an external source XTBC2 FIG 11 CONTROL WIRING OUTPUTS All chiller supplied contacts are rated at 115 VAC 100 VA resistive load only and must be suppressed at the load by user if powering an inductive load Relay Contactor Coil Typical sup pressor P N is 031 00808 000 The unit evaporator heater uses 120VAC Disconnecting 120VAC power from the unit at or below freez ing temperatures can result in damage to the evaporator and unit as a result of the chilled l
142. Y TB SP SUPPLY TB SP NF DISCONNECT SWITCH SP CIRCUIT BREAKER W LOCKABLE HANDLE SP NF DISC SWITCH W IND SYS CB MP SUPPLY W IND SYS CB amp L EXT HANDLES MP NF DISC SWITCHES NO CONTROL TRANSFORMER REQUIRED CONTROL TRANSFORMER REQUIRED SPECIAL CONTROL TRANSFORMER REQUIRED NO POWER CAPACITOR REQUIRED POWER CAPACITOR REQUIRED SPECIAL POWER CAPACITOR REQUIRED HIGH AMBIENT KIT STANDARD FACTORY BOTH LOW HIGH AMBIENT KIT REQUIRED FACTORY SPECIAL AMBIENT KIT REQUIRED BAS RESET OFFSET REQUIRED SPECIAL BAS RESET OFFSET REQUIRED ENGLISH SPANISH FRENCH GERMAN ITALIAN BOTH DISCHARGE amp SUCTION PRESSURE TRANSDUCER READOUT REQUIRED SPECIAL PRESSURE READOUT REQUIRED N AMERICAN SAFETY CODE CUL CETL EUROPEAN SAFTEY CODE CE X SPECIAL QUOTE MOTOR CURRENT MODULE SPECIAL QUOTE NO REMOTE PANEL REQUIRED SPECIAL REMOTE PANEL REQUIRED OPTION DESCRIPTION NO SEQUENCE KIT REQUIRED SPECIAL SEQUENCE KIT REQUIRED 50 X T A DESIGN SERIES PIN 14 O DEV DEVELOPMENT LEVEL PIN 15 A XX SX SD POWER POWER FIELD PIN 16 amp 17 BX MB MD gt lt TRANS CNTRL TRANSFORMER PIN 18 gt lt PFC POWER FACTOR CAPACITOR 19 O H AMB AMBIENT KITS PIN 20 BAS BAS RESET OFFSET PIN 21 LCD LANGUAGE PIN 22 RDOUT SAFETY SAFETY CODES PIN 24 SENSOR PIN 25 MOTOR CURRENT MODULE PIN 26 REMOTE REMOTE PANEL PIN 27 FEATURE FEATURE DESCRIPTION OPTION X READOUT KITS PIN 23 L C
143. above 45 F 7 2 C the heater is turned off An under voltage condition will keep the heater off until full voltage 15 restored to the system EVAPORATOR WATER P UMP STATUS X X XX The evaporator pump dry contacts are energized when any compressor 15 running or the unit is not OFF on the daily schedule and the unit switch 15 on or the unit has shutdown on a Low Leaving Chilled Liquid fault However even if one of above 15 true the pump will not run if the micropanel 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 E VAP PUMP TOTAL RUN XXXXX HOURS The Evaporator Pump Total Run Hours display indicates the total pump run hours Total hours continually increments similar to Compressor Run Hours If dual pumps are fitted run hours indicates total hours on both pumps ACTIVE REMOTE CTRL NONE There are several types of remote systems that can be used to control or monitor the unit The following messages indicate the type of remote control mode active NONE no remote control is active Remote monitoring may be via ISN ISN YORK Talk via ISN allows remote load limiting and temperature reset through an ISN system LOAD LIM Load limiting enabled using contact closure PWM TEMP EMS temperature reset JOHNSON CONTROLS SECTION 7 UNIT CONTROLS Refer to the section on OPERATING CONTROLS If
144. ake II VI I 10 11 12 13 equipment or bracket to the top plate A of isola tor with a minimum of 3 8 fillet welds 2 long 3 on center for a minimum total weld of 10 All sides of equipment or bracket resting on top plate A must be welded The adjustment process can only begin after the equipment or machine 15 at its full operating weight Back off each of the 4 limit stop lock nuts F on isolators 1 2 Adjust each isolator in sequence by turning spring adjusting nuts G one full clockwise turn at a time Repeat this procedure on all isolators one at a time Check the limit stop lock nuts periodi cally 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 the shim E Remove all spacer shims E Fine adjust isolators to level equipment Adjust all limit stop lock nuts per isolator maintaining 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 equipment is drained Installation 1s complete 3 K X X X 4 TX KKK EQUIPMENT LD13763B FIG 55 SEISMIC ISOLATOR INSTALLATION AND ADJUSTMENT INSTRUCTIONS JOHNSON CONTROLS 127 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15
145. al Electrical Code amp Local Codes LEGEND ACR LINE ACROSS THE LINE START VOLTAGE CODE C B CIRCUIT BREAKER 50 2 380 415 3 50 D E DUAL ELEMENT FUSE DISC SW DISCONNECT SWITCH FACT MOUNT CB FACTORY MOUNTED CIRCUIT BREAKER FLA FULL LOAD AMPS HZ HERTZ MAX MAXIMUM MCA MINIMUM CIRCUIT AMPACITY MIN MINIMUM MIN NF MINIMUM NON FUSED RLA RATED LOAD AMPS S P WIRE SINGLE POINT WIRING UNIT MTD SERV SW UNIT MOUNTED SERVICE NON FUSED DISCONNECT SWITCH LRA LOCKED ROTOR AMPS 50 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA ELECTRICAL DATA Sinde Pontia Dual Point Data System 1 System 2 VOLT CHILLER MODEL MINIMUM AE MAX DUAL MINIMUM MIN DUAL MINIMUM DER MIN N F ELEM MIN N F MIN N F ELEM CIRCUIT ELEM FUSE ELEM CIRCUIT AMPS DISC SW FUSE amp DISC SW amp MINCB FUSE amp AMPS DISC SW FUSE amp MIN CB MAX CB Electrical Data COMPR 1 COMPR2 2 COMPR3 3 COMPR1 1 COMPR2 2 COMPR3 3 CONDFANS FANS COND FANS CHILLER VOLT MODEL YLAA0285SE 545 545 545 251 198 Em 19 ote s VLM 86 40 50 sas 35 45 24 mr mim 9 2 4 vuaanaoose 40 S 545 55 55 ms S 2 4 6 JOHNSON CONTROLS 51 SECTION 5 TECHNICAL DATA WIRING LUGS Lugs
146. al Requirements The following duct work recommendations are intended to ensure satisfactory operation of the unit Failure to follow these recommendations could cause damage to the unit or loss of performance and may invalidate the warranty When ducting 15 to be fitted to the fan discharge it 1s 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 hangers to prevent noise and vibration being transmitted to the structure A flexible joint is also recommended between the duct attached to the fan and the next section for the same reason Flexible connectors should not be allowed to concertina The unit s 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 condenser 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 fitted in the individual fan ducts This will prevent re circulation of air when only one of the fans 15 running Units are supplied with outlet guards for safety and to prevent damage to the fan blades If these gua
147. al YORK ul AIR COOLED SCROLL CHILLER BY JOHNSON CONTROLS Supersedes 150 72 NM3 909 Form 150 72 NM3 811 035 21911 001 YLAA0195 YLAA0515 AIR COOLED SCROLL CHILLERS WITH MICROCHANNEL CONDENSER COILS STYLE A 50 HZ 57 142 TON R 410A A LIBS CERTIFIED www ahridirectory org Air Cooled Chillers Issue Date C AHRI Standard 550 590 Listed August 15 2011 FORM 150 72 811 ISSUE DATE 8 15 2011 IMPORTANT READ BEFORE PROCEEDING GENERAL SAFETY GUIDELINES This equipment 15 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 oils 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 responsibility 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 15 intended for use by owner authorized operating service personnel It is expected that this individual p
148. aporator 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 189 SECTION 10 MAINTENANCE MICROCHANNEL COIL CLEANING The coil cleaning procedure for microchannel coils is significantly different than tube and fin type coils As such care must be taken to understand the differences to avoid damage to the microchannel coil These differences require a number of DO NOT s that must be observed 190 DO NOT use coil cleaners or any chemical on a microchannel coil This can cause severe damage to the coils DO NOT use a pressure washer to clean the coils While it is possible to clean a coil with a pressure washer it s also possible to destroy it DO NOT contact the coil with a hard surface such as a hose nozzle or metal vacuum nozzle or any other tool FORM 150 72 811 ISSUE DATE 8 15 2011 Follow the three steps below for cleaning the coils 1 Remove surface debris such as dirt leaves sects fibers etc with a vacuum cleaner having a soft attachment rather than a metal tube Com pressed air blown from the inside out can also be used When brushing debris off the face of the co
149. arg The minimum limits for the display are Suction Pressure 0 PSIG 0 barg Discharge Pressure 0 PSIG 0 barg The maximum limits for the display are Suction Pressure 400 PSIG 27 58 barg Discharge Pressure 650 PSIG 44 82 barg SYS STARTS 2 The above two messages will appear sequentially for each system The first display shows accumulated running 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 dis played for the actual number of sys tems and compressors on the unit A total of 99 999 hours and starts can be logged before the counter rolls over to 0 LOAD TIMER 5 8 TIMER 0 SEC SEC UNLOAD 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 15 from setpoint A detailed description of unit loading and unloading is covered under the Capacity Control topic 146 FORM 150 72 3 811 ISSUE DATE 8 15 2011 COOLING DEMAND STEPS 2 OF 8 The display 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
150. at particular message General Status Messages In the case of messages which apply to individual systems SYS 1 and SYS 2 messages will both be displayed and may be different In the case of single system units all SYS 2 messages will be blank UNIT SWITCH SHUTDOWN OFF This message informs the operator that the UNIT switch on the control panel is in the OFF position which will not allow the unit to run REMOTE CONTROLLED SHUTDOWN The REMOTE CONTROLLED SHUTDOWN message indicates that either an ISN system or RCC has turned the unit OFF not allowing it to run JOHNSON CONTROLS 00066VIC DAILY SCHEDULE SHUTDOWN The DAILY SCHEDULE SHUTDOWN message indicates that the daily holiday schedule program is preventing the unit from running REMOTE STOP 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 amp 13 of 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 contacts connected to Terminals 13 and 14 of XTBCI are open A 3 second delay is built into software to prevent nuisance shutdowns due to erroneous signals from the flow switch OFF OFF SYS 1 SYS SYS SWITCH SWITCH SYS 2 SYS SWITCH OFF indicates that the system switch under
151. ator freeze up should the chilled liquid temperature drop below the freeze point This situation could occur under low flow conditions or if the micropanel setpoint values are improperly programmed Anytime the leaving chilled liquid temperature water or 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 15 not operated at voltages where malfunction of the microprocessor could result in system damage When the 115VAC to the micropanel drops below a certain level a unit fault is initiated to safely shut down the unit Restart is allowed after the unit is fully powered again and the anti recycle timers have finished counting down JOHNSON CONTROLS SECTION 7 UNIT CONTROLS UNIT MTR FAULT CURR HIGH 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 1s programmed at the factory according to compressor or unit Running load Amps 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 warnings and will not auto restart Operator intervention is required to allow a restart of t
152. ature and the unit is running in a fully loaded condition The correct superheat setting for a system is 10 F 15 F 5 56 C 8 33 C 18 46 cm from the heat exchanger Superheat should typically be set for no less than 10 F with only a single compressor running on a circuit The superheat is calculated as the difference between the actual temperature of the returned refrigerant gas in the suction line entering the compressor and the temperature corresponding to the suction pressure as shown in a standard pressure temperature chart Example Suction Temp 46 F minus Suction Press 105 PSIG converted to Temp 34 F Superheat 12 F 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 15 minutes between adjustments for the system and the thermal expansion valve to respond and stabilize JOHNSON CONTROLS SECTION 6 COMMISSIONING Assure that superheat is set at a minimum of 10 F 5 56 C with a single compressor running on each circuit 12 Record the suction temperature suction pressure suction saturation temperature and superheat of each system below SYS1 5 52 Suction Temp F Suction Pressure PSIG Saturation Temp F Superheat LEAK CHECKING 11 Leak check compressors fittings and piping to ensure no leaks If the unit is functioning satisfactorily during the
153. bber isolators 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 final position the unit water piping may be connected Normal installation precautions should be observed in order to receive maximum operating efficiencies Piping 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 All piping must be supported independent of the chiller Consideration should be given to com pressor access when laying out water piping Routing the water piping too close to the unit could make compres sor servicing replacement difficult NOTE Hand stop valves should be installed in all lines to facilitate 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 vibration 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 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 4 INSTALLATION The Flow Sw
154. be performed by suitably trained and qualified personnel The manufacturer will not be liable for any injury or damage caused by incorrect installation commissioning operation or maintenance resulting from a failure to follow the procedures and instructions detailed in the manuals WARRANTY Johnson Controls warrants all equipment and materials 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 All 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 All warranty claims must specify the unit model serial number order number and run hours starts Model and serial number information is printed on the unit identification plate The unit warranty will be void if any modification to the unit 1 carried out without prior written approval from Johnson Controls 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
155. 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 For ground level installations precautions should be taken to protect the unit from tampering by or injury to unauthorized 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 minimize 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 1s a result of compressor and fan operation 38 FORM 150 72 811 ISSUE DATE 8 15 2011 SPRING ISOLATORS OPTIONAL When ordered four 4 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 ru
156. 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 is reset during a loss of power the contacts will remain open until power is reapplied and no fault conditions exist 175 SECTION 8 UNIT OPERATION 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 10VDC input or a 4 20mA input connected to terminals A and 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 If a 0 10VDC signal is supplied it is applied to terminals A and A 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 0V DC and 1OVDC use the following formula Setpoint Local Chilled Liquid Setpoint Reset Reset DC voltage signal Reset Value 10 Example Local Chilled Liquid Setpoint 45 F 7 22 C Max Reset Value 20 F 11 11 C Input Signal 6VDC English Reset 6V DC x 20 F 12 F Reset 10 New Setpoint 45 F 12 F 57 F Metric Reset 6VDC x 11 11 C 6 67
157. chillers When communications is required with a BAS or 5 Add the SUm of all the compressor and fan RLA s OptiView Panel individual unit IDs are necessary for in the chiller communications with specific chillers on a single RS Multiply the sum by 1 25 485 line Remote Unit ID 0 7 are selectable Divide by 225A e The resulting voltage is the value that should be programmed For example if fan and compressor RLA s total 180A SV x 180A _ 1125 555 125 SA 5 0V The programmed value will be 5 0V TABLE 11 PROGRAM KEY LIMITS AND DEFAULT PROGRAM VALUE MODE LOW LIMIT HIGH LIMIT DEFAULT DISCHARGE PRESSURE CUTOUT 325 PSIG 575 PSIG 570 PSIG 22 4 BARG 39 6 BARG 39 3 BARG SERE IE 80 0 PSIG 120 0 PSIG 80 0 PSIG 5 52 552 8 27 BARG 5 52 BARG P 42 0 70 0 PSIG 44 0 PSIG 2 9 BARG 4 83 BARG 3 03 BARG 25 0 F 60 0 F 25 0 F STANDARD AMBIENT 3c LOW AMBIENT 60 0 F 25 0 F 378 156 C LEAVING CHILLED LIQUID TEMP CUTOUT 36 0 F 36 0 F 18 3 C ANTI RECYCLE TIMER ___ 800 SEC 600 SEC 600 SEC EAN CONTROL ON PRESSURE 360 PSIG 485 PSIG 385 PSIG 24 8 BARG 33 4 BARG 26 5 BARG SUCTION PRESSURE CUTOUT LOW AMBIENT TEMP CUTOUT 80 PSID 160 PSID 125 PSID peas BARD 11 D 22 BARD SINGLE SYSTEM TOTAM MAER eee DUALSYSTEM UNIT SYSTEM TRIP VOLTS CURRENT FEEDBACK 0 5 Volts 4 5 Volts 2 5 Volts REMOTE UNIT ID
158. ctly 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 diameters on either side of the flow switch The flow switch should be connected to terminals 13 and 14 of on the panel 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 inserted in the water outlet sensor well JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 6 COMMISSIONING EQUIPMENT PRE STARTUP amp STARTUP CHECKLIST JOB NAME SALES ORDER LOCATION SOLD BY INSTALLING CONTRACTOR START UP TECHNICIAN COMPANY START UP DATE CHILLER MODEL SERIAL PRE STARTUP CHECKING THE SYSTEM PRIOR TO INITIAL START NO POWER Unit Checks 1 LI 2 LI 3 LI 4 LI 5 LI 6 Inspect the unit for shipping or installation dam age Assure that all piping has been completed Visually check for refrigerant piping leaks Open suction line ball valve discharge line ball 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 shutdow
159. d 555050685 2 545 953 84 sd 5 5 6 94 64 99d 55555 S S 82 994 Sod 55555 seo SAS pead 140 2 994 vSd 900 I ezag 92 ON _ 24 94 5 1 1 0 sun 208 81 mowa 664 2d 1 001 0 SPON 1 1008 0 sd 7 PIS 0 euuv 0208 ech OW osa IooMO L 8108 10 uny 1108 00 OW da CSAS SAS 0 ord 545 V Sed zib ow q a uny 2 eb de 98 uo q
160. d This message is shown below REMOTE 2 0 F MA X EMS PWM TEMP RESET The Temp Reset value is the maximum allowable remote reset of the temperature setpoint The setpoint can be reset upwards by the use of an Energy Management System See page 164 amp 176 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 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 is a seven day daily schedule that allows one start stop time per day The schedule can be programmed Monday through Sunday with an alternate 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 programmed when the times in the schedule are all zeros 00 00 AM To set the schedule press the SCHEDULE AD VANCE DAY key The display will immediately show the following display SECTION 7 UNIT CONTROLS FORM 150 72 811 ISSUE DATE 8 15 2011 TABLE 10 COOLING SETPOINTS PROGRAMMABLE LIMITS AND DEFAULTS SETPOINT KEY LOW LIMIT HIGH LIMIT DEFAULT 40 0 F 44 0 F WATER COOLING LEAVING CHILLED LIQUID SETPOINT GLYCOL COOLING LEAVING C
161. ds The IPU II and I O boards are assembled to function as a single microprocessor controller requiring no additional hardware The IPU II board contains a coldfire microprocessor and is the controller and decision maker in the control panel The I O 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 contains a processor capable of reading the inputs and controlling the outputs It communicates through the transition header with the IPU II microprocessor The I O board circuitry multiplexes the analog inputs digitizes them and constantly scans them to keep watch on the chiller operating conditions The input values are transmitted serially to the IPU II microprocessor board From this information 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 react to safety conditions The I O board converts logic signals to operate relay outputs to 115 VAC 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 are powered by 12V Keypad commands are actuated upon by the microprocessor to change setpoints cutouts scheduling operating requirements and to provide displays The keypad and display are connected to the I O board 137
162. e 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 2 3 gallons is present in the each refrigerant system Oil levels in the oil equalizing 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 Temperature 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 splashing in the sight glass 15 normal Fans Check that all fans are free to rotate and are not damaged Ensure blades are at the same height when rotated 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 the Technical Data section of ths IOM have not been exceeded Control Panel Check the panel to see that it 1s free of foreign materials wire metal chips etc and clean out if required Power Connections Check that the c
163. e cutout Loading may reoccur after suction pressure rises above the unload point and a period of one minute 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 1t reaches a safety limit due to high load or dirty condenser coils The microprocessor board monitors discharge 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 pressure and 10 minutes have elapsed This control is only applicable if optional discharge pressure transducers are installed JOHNSON CONTROLS LEAVING CHILLED LIQUID CONTROL The setpoint when programmed for Leaving Chilled Liquid Control is the temperature the unit will control to within p us 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 Fig 58 should be utilized to aid in understanding the following description of Leaving Chilled Liquid Control 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 solenoid Upon energizing any compressor the 60 second
164. e minute regardless of demand or the anti recycle timer being timed out The coincidence timer is only present on two system units SYS 1 DSCH DS CH LIMITING LIMITING SYS 2 When this message appears discharge pressure limiting is in effect The Discharge Pressure Limiting feature is integral to the standard software control however the discharge transducer is optional on some models Therefore it 15 important to keep in mind that this control will not function unless the discharge transducer is installed in the system 140 FORM 150 72 811 ISSUE DATE 8 15 2011 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 1s reached the microprocessor board will automatically unload the affected system by de energizing one compressor The discharge pressure unload will occur when the discharge pressure gets within 10 PSIG 0 69 barg of the programmed discharge pressure 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 occur when the discharge pressure drops to 85 of the unload pressure and 10 minutes have elapsed LIMITING LIMITING SYS 1 SUCT SUCT SYS 2 When this message appears suction pressure limiting 15
165. e selected to help equalize average run hours between systems with 2 refrigerant systems This may be programmed under the OPTIONS 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 selects specifically the sequence which the microprocessor board 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 compressors 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 arbitrary priority number 1 2 or 1 2 3 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 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 repeatedly cycle on and off Once the second system starts a compressor on a 2 system chiller the microprocessor board will attempt to equally load each system as long as the system is not limiting or pumping down Once this occurs loading and unloading will alternate between systems loading the lead system first or unloading the lag
166. ear the lockout fault Fault messages will be displayed whenever a system is locked out PRES PRES SYS 1 H I GH H I GH DSCH DSCH SYS 2 The Discharge Pressure Cutout is a software cutout in the microprocessor and is backed up by a mechanical high pressure cutout switch located in the refrigerant circuit It assures that the system pressure does not exceed 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 PRESS PRESS LOW SUCT SUCT LOW The Suction Pressure Cutout is a 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 suction pressure fault will cause evapo rator freeze up Whenever a system locks out on this safety or any safety immediate steps should be taken to identify the cause At system start the cutout Is 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
167. ed 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 15 not possible On non safety non unit switch shutdown all compressors 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 The fan control on pressure and fan differential off pressure are programmable under the PROGRAM key Standard fan control operates down to a temperature of 25 F 3 9 The delay between turning on and off fan stages 15 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 should be programmed at 385 PSIG with a differential of 125 PSIG When a fan stage is turned off programmed on pressure minus programmed differential the off pressure for the next stage 1s decreased 20 PSIG and ra
168. ed during communication setup and a description of each TABLE 30 REAL TIME ERROR NUMBERS a DESCRIPTION 7 1 2 4 JOHNSON CONTROLS 193 SECTION 10 MAINTENANCE BACnet and Modbus Communications Chiller data that can be read and modified using specific 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 is 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 ANALOG READ ONLY POINTS This data can be read using a BACnet or Modbus network connection and can NOT be modified using this connection The Modbus Register Address for these points 15 513 Al BINARY MONITOR ONLY POINTS This data can be read using a BACnet or Modbus network connection and can NOT be modified using this connection The Modbus Register Address for these points is 1281 BI Refer to Table 31 for complete list of BACnet and Modbus registers The latest data map information is listed on the Johnson Controls Equip ment Integration website NOTE 194 FORM 150 72 811 ISSUE DATE 8 15 2011 Communications Data Map Notes See Table 31 1 IPU II based units are confi
169. emperature sensor for the purpose of sensing internal scroll temperature This sensor protects the scrolls from overheating due to inadequate cooling that may occur when refrigerant charge is low or superheat is too high When the sensor indicates 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 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 internal 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 15 open While this message is displayed the compressors will not be permitted to start After 30 minutes the contacts will close and the system will be permitted to restart The microprocessor board 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 142 FORM 150 72 811 ISSUE DATE 8 15 2011 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 mi
170. en an error occurs assure the correct Flash Card was utilized Incorrect chiller software 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 15 bad Option 18 Remote Temperature Reset TEMP REMOTE RESET INPUT XXXXXXXXXXXXXX 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 2 0 10 0V DC 0 0 20 0 mA 4 0 20 0mA The options display message for Re mote Temp Reset Input only appears if the Temp Reset Option is enabled un der Service Mode The option must be enabled under the Service Mode for the Remote Temperature Reset to oper ate JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 Option 19 Pump Control Pump Control is utilized to operate the optional onboard 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 YORK HYDRO PUMPS When YORK HYDRO KIT PUMPS 1 the controls will be closed to run the pumps whenever any one of the following conditions are true Low Leaving Chilled Liquid Fault Any compressor is running Daily Schedule 15 ON and Remote Stop 15 closed Even if one of the above conditions are true the pump will not run i
171. ending on the number of compressors on unit The field connections are wired to XTBC1 Terminals 13 to 21 and work conjunction with the PWM inputs A detailed explanation 15 provided in the Unit Controls section of this IOM Refer to Fig 4 10 and unit wiring diagram When using the Load Limit feature the PWM feature will not function SIMULTANEOUS OPERATION OF LOAD LIMITING AND TEM PERATURE RESET PWM INPUT CANNOT BE DONE NOTE Flow Switch Input The flow switch is field wired to Terminals 13 14 See Fig 4 and unit wiring diagram COMPRESSOR HEATERS Compressor heaters are standard ZP103 ZP120 amp ZP137 compressors utilize 90W heaters ZP180 compressors utilize 70W heaters ZP235 compressors utilize 120W heaters If power is OFF more than two hours the crankcase heaters must be energized for 18 24 hours prior to restarting a compressor This will assure that liquid slugging and oil dilution does not damage the compressors on s art RELIEF VALVES Relief valves are located on both the high and low pressure side of the piping High side relief valve pressure setting 1s 650 PSIG Low side relief valve pressure setting 1s 450 PSIG HIGH PRESSURE CUTOUT A high pressure cutout 1s installed in the discharge piping of each system The cutout opens at 585 PSIG 10 PSIG and closes at 440 PSIG 25 PSIG 41 FORM 150 72 3 811 SECTION 4 INSTALLATION ISSUE DATE 8 15 2011 SING
172. ensed by the optional 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 each system if CURRENT FEEDBACK ONE PER SYSTEM is programmed under the OPTIONS key Combined compressor current for each system 15 displayed Oper Data Quick Reference List The following table is a quick reference list for information available under the OPER DATA key 148 FORM 150 72 3 811 ISSUE DATE 8 15 2011 TABLE 9 OPERATION DATA Oper Data Key Leaving amp Chilled Liquid Temps Ambient Air Temperature System 1 Discharge amp Suction Pressure Return Chilled Liquid Control Only Leaving Chilled Liquid Control Only Active Remote Control Current Feedback One Per Unit System X Compressors Status Block of information repeats for each system LD12585 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 7 UNIT CONTROLS Print Key The PRINT key allows the operator to obtain a printout UNIT DATA f t Io dal hist RETURN LIQUID TEMP 58 2 of real time system operating data or a history printou LEAVING LIQUID TEMP 53 0 of system data at the Instant of the fault on the last six DISCHARGE AIR TEMP 55 3 DEGF faults which occurred on the unit An optional printer is COOLING RANGE 42 0 2 0 red ton Bapa HE
173. epted 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 value and move the cursor on to the next programmable variable 165 SECTION 7 UNIT CONTROLS TABLE 13 UNIT KEYS OPTIONS PROGRAMMING QUICK REFERENCE LIST Options Key press Options Key to adv Display Language System Switches on off Chilled Liquid Type water or glycol Ambient Control standard or low 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 Only Table 13 provides a quick reference list for the Unit key setpoints 166 Expansion Valve Type Thermoplastic or Electric Programmed under Service Mode Viewable Only Must be programmed for Thermostatic FORM 150 72 3 811 ISSUE DATE 8 15 2011 10074050 JOHNSON CONTROLS FORM 150 72
174. er external static pressure 6 Protection against corrosive environments 15 avail able by supplying the units with either copper fin cured phenolic or epoxy coating on the condenser coils The phenolic or epoxy coils should be offered with any units being installed at the seashore or where salt spray may hit the unit In installations where winter operation 15 intended and snow accumulations are expected additional height must be provided to ensure normal condenser air flow Recommended clearances for units are listed under Notes in the Dimensions section of this IOM When the available space 1s less the unit s must be equipped with the discharge pressure transducer option to permit high pressure unloading in the event that air recirculation were to occur 37 SECTION 4 INSTALLATION Foundation The unit should be mounted on a flat and level foundation floor or rooftop capable of supporting the entire operating weight of the equipment See PHYSICAL DATA for operating weights If the unit 1s elevated beyond the normal reach of service personnel a suitable catwalk must be capable of supporting service personnel their equipment and the compressors Ground Level Locations It is 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 recommended Additionally the slab should not be tied to the main
175. ergized 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 S YS X ACTUAL AMPS XXX X AMPS Displays the system amperage calculated approximately at the time of the fawult For this message to appear CURRENT FEEDBACK ONE PER SYSTEM must be programmed under the options key If the microprocessor board 1s programmed as one CURRENT FEEDBACK ONE PER UNIT under the program key the display will be the first display prior to the SYS 1 info If the microprocessor board 15 programmed for CURRENT FEEDBACK NONE no current display will appear Displays for System 1 starting with SYS X NUMBER OF COMPS RUNNING X through SYS X AMPS XXX X VOLTS X X will be displayed first followed by displays for System 2 Further explanation of the above displays is covered 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 history buffer choice DISPLAY SAFETY SHUT DOWN NO 1 1T06 After the DOWN arrow key is pressed again the software version will appear C MXX ZZ Y Y C M X X 1 8 Y Y JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 7 UNIT CONTROLS ENTRY KEYS The ENTRY keys allows the user to v
176. ernal 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 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 Verify refrigerant charge is not low Verify superheat setting of 10 15 F 5 6 8 3 C Verify correct com pressor rotation Verify compressor is not over loaded Determine cause and reset See High Press Disch Fault Replace HPCO switch Replace relay No problem Consult Installation Manual to aid in understanding compres sor operation and capacity control Compare the display with a thermometer Should be within 2 degrees Refer to Service section for RWT LWT temp voltage table Replace defective part Diagnose cause of failure and replace Contact the local Johnson Controls service representative Reduce flow to within chiller design specs See Limita tions in Installation section Check subcooling and add charge as needed JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 10 MAINTENANCE Itis the responsibility ofthe equipment owner to provide
177. f the chiller has been powered up for less than 30 seconds or if the pump has run in the last 30 seconds to prevent pump overheating NOTE EXTERNAL PUMP E VAP EXTERNAL EVAP PUMP should be selected if an external pump 15 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 YORK HYDRO PUMPS JOHNSON CONTROLS SECTION 7 UNIT CONTROLS 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 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 otherwise 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 15 the cursor If the day is correct press the ENTER ADV key The cursor will move under the 0 In 08 hours If the day is incorrect press the 1 UP or DOWN arrow keys until the desired day 1s displayed and then press the ENTER ADV key at which time the day will be acc
178. gt X 2 5 EXT 2 BSP WHT 1 5 EXT 1 BSP BLK 1 BSP RED 1 WHT 2 232 D 2 231A lt 2 EXT 2 BDP RED lt 2 WHT BLCT BLK Ops 69 kapan 2AQ FORM 150 72 NM3 811 ISSUE DATE 8 15 2011 BLCT 5 9 CV FIG 25 CONNECTION WIRING DIAGRAM YLAA0195 SHT 5 82 e JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA _ EHRHI EXT ae 2 EHRH2 ip E BAMB BLK Oe RED 1 YLLSV 2 EXT 120A D 2 2 _ 1 YLLSV O ND 2 YLLSV gt lt Sa Se 202 lt 82 amp 1 1 9 22 ETXVH at GND 1 5 OR 144 2 NB28 28207 BLK Ope RED 202 E 1 BDPO F1 FHP m 1 FBDP 2 2 L 2 GND 1 EXT lt 1 BLK 1 BLK 1 RED JOHNSON CONTROLS 83 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 CONNECTION WIRING DIAGRAMS YLAA019
179. gth of Twisted Pair Shielded Cable minimum 3 conductor 18 AWG stranded 300V minimum insulation 4 25 pin Cannon connector and shell Connector Cannon P N DB 25P or equivalent Shell Cannon P N DB C2 J9 Assembly and Wiring All components should be assembled and wired as shown in Fig 63 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 Obtaining a Printout A printout is obtained by pressing the PRINT key on the keypad and then pressing either the OPER DATA key or HISTORY key Printer Do not connect shield at printer end LD12723 FIG 63 PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS JOHNSON CONTROLS 185 FORM 150 72 811 SECTION 9 SERVICE TROUBLESHOOTING ISSUE DATE 8 15 2011 TROUBLESHOOTING TABLE 27 TROUBLESHOOTING PROBLEM CAUSE SOLUTION No display on panel 115VAC to 24 VAC 1a Check wiring and fuse Unit will not operate Transformer 1FU b Check wiring emergency stop contacts 5 to Lof XTBC2 Terminal Block Replace Control Transformer 24VAC to Microboard Check wiring Control Transformer to Microboard Control Transformer defective no Replace Control Transformer 24VAC output Short in wire to temp sensors Unplug connections IPU II or pressure transducers amp Board
180. gured for Native BACnet MS TP and Modbus RTU communications Microgateway or E Link not required for these two communication protocols 2 BACnet Object Types 0 Analog In 1 Analog Out 2 Analog Value 3 Bina ry In 4 Binary Output 5 Binary Value 8 Device 15 Alarm Notification 0 127 are reserved ASHRAE Objects 3 WC Inches of water column CFM Cubic Feet per Minute FPM Feet per Minute PSI Lbs per square inch Pa Pascals kPa Kilopascals PPM Part per Million kJ kg Kilojoules per Kilogram 4 Water Cooled Scroll units use the same firmware as Air Cooled Scroll units ignoring Fan Control JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 10 MAINTENANCE TABLE 31 BACNET AND MODBUS COMMUNICATIONS DATA MAP sK 90 19V V II IPPIN o j2e qng Jo Aujedoug A33 199 990 6 2 55 spuoos poso 99 iv 0 ajkoou nuy 4 2090 ses ZS iuo sI poN 256 4 voso ves kiv HS tons co dH 4 poso ees 25 22 iuo 220 elu 9000 2 S S 2060 zes WL ozs
181. he chiller LOW BATTERY 10 PROG SETP OPTN CHECK The Low Battery Warning can only occur at unit power up On micropanel power up the RTC battery is checked If a low battery is found all programmed setpoints program values options time schedule and history buffers will be lost These values will all be reset 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 PROGRAM key is pressed Once PROGRAM 15 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 is 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 03 1 02565 000 is located at 05 on the microboard INCORRECT UNIT TYPE This indicates the condensing unit jumper is installed between 11 12 and 11 7 This jumper must be removed to operate the chiller 143 FORM 150 72 811 SECTION 7 UNIT CONTROLS ISSUE DATE 8 15 2011 STATUS KEY MESSAGES TABLE 8 STATUS KEY MESSAGES QUICK REFERENCE LIST STATUS KEY MESSAGES General Messages Fault Messages System Safeties Unit Safeties amp Warning Messages System X High Disch Pressure Low Ambient Temp Sy
182. ies and diagnostic features available Battery Back up The IPU II contains a Real Time Clock integrated circuit 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 during a power failure regardless of the time involved in a power cut or shutdown period Transformer 75 120 24VAC 50 60Hz transformer 15 provided to supply power to the Microprocessor Board which in turn rectifies filters and regulates as necessary to supply power to the display sensors and transducers Programming of Compressors The total number of compressors is programmable under the Program Key Dual two system chillers can have 4 5 or 6 compressors JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 7 UNIT CONTROLS STATUS KEY Unit Status Pressing the STATUS key will enable the operator to determine current chiller operating status The messages displayed will include running status cooling demand fault status external cycling device status The display will be a single message relating to the highest priority message as determined by the microprocessor board Status messages fall into the categories of General Status and Fault Status The following General Safety and Warning messages are displayed when the STATUS key 1s pressed Following each displayed message is an explanation pertaining to th
183. iew change programmed 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 arrow keys allow the user to scroll through the various data screens Refer to the section on DISPLAY PRINT keys for specific information on the displayed information and specific use of the 1 UP and DOWN arrow keys The 1 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 00068 Enter ADV Key The ENTER ADV key must be pushed after any change is 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 ENTER ADV key 15 not pressed after a value is changed the changes will not be entered and the original values will be used to control the chiller Programming and a description on the use of the 1 UP arrow key and DOWN arrow and ENTER ADV keys are covered in detail under the SETPOINTS and UNIT keys 153 SECTION 7 UNIT CO
184. il a soft bristle not wire brush can be used Do not scrape the coil with the vacuum nozzle air nozzle or any other tool Rinse coil with tap water Do not use coil cleaners Rinse the coil from the inside out run ning water through every passage in the heat exchanger surface until it is clean Use a gentle 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 Because of the fin geometry microchannel coils retain water more than tube and fin style It is generally recommended to blow or vacuum out the rinse water from the coils to speed drying and prevent water pooling JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 10 MAINTENANCE BACNET MODBUS 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 communications 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 TB1 for port I communications Modbus network connection has the option of RS232 or RS485 connection for port 2 communications Modbus network 15 wired to either TB2 or TB3 as follows RS 485 connect to TB2 Network 1 to 2 1 Network 1 to TB2 1 DE MODIFIER A
185. initial operating period no safeties trip and the compressors cycle to control water temperature to setpoint the chiller is ready to be placed into operation 135 SECTION 6 COMMISSIONING FORM 150 72 811 ISSUE DATE 8 15 2011 UNIT OPERATING SEQUENCE The operating sequence described below relates to operation on a hot water start after power has been applied such as start up commissioning When a compressor starts internal timers limit the minimum time before another compressor can start to one minute 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 scheduling the chiller off and temperature demand must be present 2 When power 15 applied to the system the micro processor will start a two minute timer This 15 the same timer that prevents an instantaneous start after a power failure 3 At the end of the two minute timer the microproces 136 sor will check for cooling demand If all conditions allow for start a compressor on the lead system will start and the liquid line solenoid will open Coincident with the start the anti coincident timer will be set and begin counting downward 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 system A new lead lag assignmen
186. inutes JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SYS 1 PUMPING PUMPING DOWN DOWN SYS 2 The PUMPING DOWN message indicates that a compressor in the respective system 15 presently in the process 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 system to be shut down Unit safeties are faults that cause all running compressors to be shut down The 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 These 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 requires a manual reset The system switch under the OPTIONS key must be turned off and then back on to cl
187. ion is listed on the Johnson Controls Equip ment Integration website NOTE JOHNSON CONTROLS SECTION 10 MAINTENANCE FORM 150 72 3 811 ISSUE DATE 8 15 2011 TABLE 32 YORKTALK 2 COMMUNICATIONS DATA MAP ed 555505065 45 vil Ord Wd 555655 uny 2545 Ord 555650685 uny 40ssejduo 5 5 608 JomowG 864 0 550505065 smejsdungjoeldej mowa 884 550505065 501918 208 964 860 sd 5 5 5 77 7 4 909 OW q Sd 44 984 5 5 sag OW TE sed 550506505 6 4 20 70 owy 99 ved 8234 801 00 mowy 424 66 96 ON ltd 660 92340 96 26 OW Oed __ 16 88 _ 609 __ mowy 2545 ezaav t8 08 won ainssald 4885 2040 6 9 mowy 824 und 2 545 7 mowy 184 OcJQv 11 89
188. iquid freezing 44 INTERNAL WIRING EVAPORATOR HEATER INTERNAL WIRING TO HOT GAS SOLENOID VALVE _ SYSTEM 2 ALARM DRY CONTACTS OPEN ALARM _ SYSTEM 1 ALARM DRY CONTACTS OPEN ALARM SYSTEM 2 RUN DRY CONTACTS CLOSE RUN SYSTEM 1 RUN DRY CONTACTS CLOSE RUN EVAPORATOR PUMP DRY CONTACTS CLOSE RUN BASED ON DAILY SCHEDULE INTERNAL 120 VAC WIRING F1 FUSE INTERNAL 120 VAC WIRING TYPICALLY FROM CONTROL TRA I INTERNAL NEUTRAL WIRING INTERNAL NEUTRAL WIRING TYPICALLY FROM CONTROL TF INTERNAL NEUTRAL WIRING LD13242 II 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 dis connecting power PRIOR to working on equipment JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA OPERATIONAL LIMITATIONS ENGLISH TABLE 1 TEMPERATURES AND FLOWS Nominal Evaporator Water Flow Unit Designation MM MAX MM MAX 0285 40 5 125 YLAAO3208SE 50 55 125 YyuawsosE 5 t 35 0o 95 YLAAD40SE 0590 5 10 65 0 15 YLAAD435SE _ 40 5 10 65 15 VLM048556 4 5 1
189. ischarge Pressure Transducer J9 11 Optional J7 12 Unit SYS 1 Voltage J9 12 SYS 2 Voltage J11 11 Remote Temperature Reset TABLE 23 ANALOG OUTPUTS N A Not Applicable 179 SECTION 9 SERVICE AND TROUBLESHOOTING TB6 TBS iF TB8 Erw 411 UT J13 FIG 61 MICROBOARD LAYOUT 180 FORM 150 72 3 811 ISSUE DATE 8 15 2011 BOARD J15 E ZI BT A ae ee _ E ha mm J5 aid CEN E LL E 11111311 ET i nd d s ur LIN sm TOL 142 J11 1012721 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 9 SERVICE AND TROUBLESHOOTING CHECKING INPUTS AND OUTPUTS TABLE 24 OUTDOOR AIR SENSOR TEMPERATURE VOLTAGE Digital Inputs CORRELATION Refer to the unit wiring diagram digital inputs are VOLTAGE connected to J13 1 of the I O board The term digital TEMP Signal Input TEMP C refers to two states either on or off As an example to Return when the flow switch is closed 30VDC will be applied to J13 pin 5 J13 5 of the I O board If the flow switch is open OVDC will then be present at J13 5 10 Pin 1 of J13 is an unregulated 30VDC source used to 15 supply the DC voltage to the various user contacts
190. itch MUST NOT be used to start and stop the chiller i e start ing and stopping the chilled water pump It is intended only as a safety switch A small valve or valves should be installed at the highest point or points in the chilled water piping to allow any trapped air to be purged Vent and drain connections should be extended beyond the insulation to make them accessible CAUTION i The piping to and from the cooler must be designed to PIPEWORK ARRANGEMENT suit the individual installation It is important that the l The followi ted pi k ts f following considerations be observed single unit installations for multiple unit installations f each unit should be piped as shown 1 The chilled liquid piping system should be laid out so that the circulating pump discharges directly Recommendations of the Building Services into the cooler The suction for this pump should Research Association q x be taken from the piping system return line and not the cooler This piping scheme is recommended but is not mandatory 2 The inlet and outlet cooler connection sizes are provided in Table 4 Physical Data 3 A strainer preferably 40 mesh must be installed in 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 150 m LD06596 4 All chilled liquid piping should be thoroughly
191. ized louvered openings This option is applicable for any outdoor design ambient temperature up to 46 115 F Factory mounted COIL END HAIL GUARD Louvered panel attached to exposed coil end Factory mounted FORM 150 72 811 ISSUE DATE 8 15 2011 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 acoustic sound blanket The sound blankets are made with one layer of acoustical absorbent textile fiber of 15mm 5 8 thickness one layer of anti vibrating heavy material thickness of 3 mm 1 8 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 motors are used with steeper pitch fans Factory mounted VIBRATION ISOLATORS Level adjusting spring type 25 4mm 1 or seismic deflection or neoprene pad isolators for mounting under unit base rails Field mounted JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 2 PRODUCT DESCRIPTION UNIT COMPONENTS FAN DECK POWER PANEL CONTROL PANEL MICROCHANNEL COILS LIQUID TIGHT CONDUIT COMPRESSORS FILTER DRIERS FORMED BASE RAIL SIGHT SN GLASS TXV VALVES EVAPORATOR LD14317 FIG 1 UNIT COMPONENTS FRONT JOHNSON CO
192. justing each isolator until a minimum of 1 4 clearance is achieved between the lower hous ing and upper housing See drawing below 9 Fine adjust isolators to level equipment 10 Installation is complete EQUIPMENT POSITIONING PIN BASE H 1 4 MIN 1 2 I NON SKID C ELASTOMERIC P 2 x 1 11 LD13790 FIG 53 ONE INCH DEFLECTION SPRING ISOLATORS INSTALLATION INSTRUCTIONS JOHNSON CONTROLS 125 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 SEISMIC ISOLATOR CROSS REFERENCE Y2RS 5 5 8 3 8 SS TYP 4 5 8 11UNC TYP 4 3 4 7 8 2 3 4 1 2 LIMIT STOP amp NUT 8 3 8 OPER HEIGHT 12 1 4 14 NOTES 1 ALL DIMENSIONS ARE IN INCHES INTERPRET PER ANSI Y14 2 STANDARD FINISH HOUSING POWDER COATED SPRING POWDER COATED COLOR SEE T HARDWARE ZINC ELECTROPLATE EQUIPMENT MUST BE BOLTED OR WELDED TO THE TOP PLATE TO MEET ALLOWABLE SEISMIC RATINGS ALL SPRINGS ARE DESIGNED FOR 50 OVERLOAD CAPACITY WITH EXCEPTION OF THE 2D 3280N amp 2D 2870 REFER TO NEXT PAGE FOR INSTALLATION INSTRUCTIONS CONSULT FACTORY FOR CONCRETE INSTALLATION LD13761A VMC PART NUMBER WEIGHT RANGE KGS FIG 54 SEISMIC ISOLATOR CROSS REFERENCE 126 JOHNSON CONTROLS FORM
193. l 6 rear to wall 6 control panel to end wall 4 0 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit 119 FORM 150 72 811 SECTION 5 TECHNICAL DATA ISSUE DATE 8 15 2011 TECHNICAL DATA CLEARANCES LD13243 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 FIG 50 UNIT CLEARANCES ALL MODELS 120 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS GENERAL Whenever the isolator option 15 ordered the isolators isolator location select the appropriate isolator from the will be shipped loose with the chiller Use the drawings isolators packaged with the chiller The isolator capacity that follow to select the appropriate chiller model and ranges are provided in the information that follows based weight by isolator location Based on the weight by on type of isolator being installed L1 L2 L3 X R1 R2 R3 6 Y YLAAO195HE Isolator Weights kg if selected 0195 Isolator Locations 3 __ 2 L N A L 495 2207 2641 2207 N A R N A R 495 36 2461 36 N A YLAA0220HE Isolator Weights kg if selected YLAA0220HE Isolator Locations mm 3 __ 2 L N A L 495 2207
194. level surface of free of obstructions safety cutouts however the system designer must including snow for winter operation or air circulation consider potential performance degradation Access to ensures rated performance reliable operation and ease the unit control center assumes the unit 1s no higher than of maintenance Site restrictions may compromise on spring isolators Recommended minimum clearances minimum clearances indicated below resulting in Side to wall 6 rear to wall 6 control panel to end unpredictable airflow patterns and possible diminished wall 4 0 top no obstructions allowed distance performance Johnson Controls s unit controls will between adjacent units 10 No more than one adjacent optimize operation without nuisance high pressure wall may be higher than the unit FIG 45 DIMENSIONS ENGLISH YLAA0350HE ENGLISH JOHNSON CONTROLS 115 SECTION 5 TECHNICAL DATA FORM 150 72 3 811 ISSUE DATE 8 15 2011 DIMENSIONS YLAA0390HE YLAA0485SE ENGLISH 525 POWER ENTRY 14012 L 8712 WIDE X 178 HIGH VIEW B B BOTOM OF PANEL TO CLR CONN 2242 BASE WIDTH 2261 FRONT VIEW POWER SINGLE POINT SUPPLY WITH TERMINAL BLOCK 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 indica
195. liance with N E C Article 440 14 can be supplied to isolate the power voltage for servicing This option includes the Single Point Power connection CONTROL TRANSFORMER Converts unit power voltage to 115 1 60 0 5 or 1 0 KVA capacity Factory mounting includes primary and secondary wiring between the transformer and the control panel Factory mounted 20 POWER FACTOR CORRECTION CAPACITORS Will correct unit compressor power factors to a 0 90 0 95 Factory mounted CONTROL OPTIONS AMBIENT KIT LOW Units will operate to 1 C 30 0 F This accessory in cludes all necessary components to permit chiller opera tion to 18 C 0 F This option includes the Discharge Pressure Transducer Readout Capability option For proper head pressure control in applications below 1 C 30 F where wind gusts may exceed 8 kph 5 mph it is recommended that Optional Condenser Louvered Enclosure Panels also be included Factory mounted AMBIENT KIT HIGH Required if units are to operate when the ambient temperature is above 46 C 115 F Includes 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 COMPRESSOR PIPING EVAPORATOR OPTIONS LOW TEMPERATURE BRINE Required for brine chilling below 1 C 30 F leaving brine temperature Option includes resized thermal expansion valve Factory mounted
196. meo toso SLNIOd SO TVNV 1466 062 ds Gases 256 10 SLNIOd SLIMM ASIVNIS x C lt 6LII00 0 440 wa 919060 260 AV 0 vr wi vr mm 4242 4096 666 440 919050 0 9 6 IonuoO voyons uodas 2 546 95 9 9050 060 28 48 as 8 EN iuo poW 1 Bujooo 1 990600 620 4 m peoa 990600 820 eaw 9 MI 9 0 591 uonons 00 5 545 95 919080 IS dS WaYdS S SLNIOd 3IIHAASOTVNV 8 _ pO E CCR 7 6 V 5 2 9 lt ong P295 odis ssauqav curssfqo SNEGOW snaaow 19 V9 N 46400440 pjepueis s 99 426 Aieuoroung XL suonporunututuo2 XLI 06 00 160 06900 160 700 66 50 150 80 50 11 209VONWO 1 99 426 IMAN XL suogeorunumuoo
197. mped back to the programmed off pressure minus the differential over the next 20 seconds Condenser fan locations are shown in Fig 60 Detailed Standard Fan Control operation is shown in Table 17 and 18 171 _ FORM 150 72 3 811 SECTION 8 UNIT OPERATION ISSUE DATE 8 15 2011 YLAAOO80SE YLAAOO91HE YLAAOO9OSE YLAAO100SE YLAAO101HE YLAAOT115SE 1205 YLAAO125HE YLAA0135SE YLAA0141HE YLAA0150SE YLAA0155SE CONTROL PANEL CONTROL PANEL CONTROL PANEL CONTROL PANEL CONTROL PANEL CONTROL PANEL YLAA0175HE YLAA0156HE LD13244 CONTROL PANEL CONTROL PANEL FIG 60 CONDENSER FAN LOCATIONS WIRING DIAGRAMS 172 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 8 UNIT OPERATION TABLE 17 YLAA STANDARD CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONLY 2 3 OR 4 FANS PER SYSTEM FAN OUTPUT CONTACTOR FAN DP lt PROGRAMMED p gt procraamen PAN ON FAN CONTROL ON PROGRAMMED 787 8 TB10 8 1 KF1 2 KF1 1 MF1 2 MF2 DIFFERENTIAL PRESSURE DP lt PROGRAMMED gt procraamn PAN CONTROL ON FAN NTROL ON amp PROGRAMMED TB7 8 amp TB10 8 amp 1 KF1 amp 2 KF1 amp 1 amp 2 MF1 amp FAN STAGE 1 18 DIFFERENTIAL 7 9 10 9 1 2 2 2 1 2 2 2 PRESSURE 8 ENERGIZED FAN STAGE 1 ENERGIZED DP lt PROGRAMMED FAN CONTROL ON PE PRESSURE MINUS F
198. n the oil level should be between the bottom and middle of the oil equalizing sight glass Assure water pumps are on Check and adjust water pump flow rate and pressure drop across the cooler see OPERATIONAL LIMITATIONS Verify flow switch operation Excessive flow may cause catastrophic damage to the heat exchanger evapo rator NOTE JOHNSON CONTROLS 17 Check the control panel to ensure it is free of foreign material wires metal chips etc 18 Visually inspect wiring power and control Wir ing MUST meet N E C and local codes 19 Check tightness of power wiring inside the power panel on both sides of the motor contactors and overloads 110 Check for proper size fuses in main and control circuits and verify overload setting corresponds with RLA and FLA values in electrical tables 011 Assure 120VAC Control Power to has 15 amp minimum capacity 112 Be certain all water temp sensors are inserted completely in their respective wells and are coated with heat conductive compound 113 Assure that evaporator TXV bulbs are strapped onto the suction lines at 4 or 8 o clock positions or suction temperature sensors if EEVs are in stalled COMPRESSOR HEATERS 6 POWER ON 24 HOURS PRIOR TO START 11 Apply 120VAC and verify its value between ter minals 5 and 2 of XTBC2 The voltage should be 120VAC 10 Power must be applied 24 hours prior to Start up Each heater should draw ap
199. n 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 1s no higher than on spring isolators Recommended minimum clearances Side to wall 6 rear to wall 6 control panel to end wall 4 0 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit FIG 44 DIMENSIONS ENGLISH YLAA0435SE ENGLISH 114 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA DIMENSIONS YLAA0350HE ENGLISH 5 8 DIA MOUNTING HOLES TYP 525 POWER ENTRY 14012 M 8712 WIDE X 178 HIGH 2077 VIEW BOTOM OF PANEL ORIGIN 193 2977 TOP VIEW 2393 TT INLET M i X 4 h TO CLR CONN 2242 BASE WIDTH EACH SIDE 3613 2261 FRONT VIEW RIGHT VIEW 2 RIGGING HOLES POWER SINGLE POINT SUPPLY WITH TERMINAL BLOCK NOTE Placement on a
200. ng controls are present software to assure compressors within a circuit or between systems do not start simultaneously The anti coincidence timer assures there is at least a one minute delay between system starts on 2 circuit systems This timer is NOT programmable The load timers further assure that there is minimum time between compressor starts within a system EVAPORATOR PUMP CONTROL amp YORK HYDRO KIT PUMP CONTROL The evaporator pump dry contacts XTBC2 terminals 23 24 are energized when any of the following conditions are true 1 Low Leaving Chilled Liquid Fault 2 compressor 15 running 3 Daily Schedule is ON Unit Switch is ON and Remote Stop is closed The pump will not run if the micropanel 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 YORK HYDRO KIT PUMPS 1 15 selected under the OPTIONS key the pump control will be as described above DO NOT SELECT the option YORK HYDRO KIT PUMPS 2 under the OPTIONS key Ifa dual pump option is installed the active pump is selected by the selector switch JOHNSON CONTROLS SECTION 8 UNIT OPERATION EVAPORATOR HEATER CONTROL The evaporator heater is controlled by ambient air temperature When the ambient temperature drops below 40 F 4 4 the heater 15 turned When the temperature rises above 45 F 7 2 C the heater is turn
201. nted POST COATED DIPPED CONDENSER COILS The unit is built with dipped cured condenser coils This is the choice for corrosive applications with the exception of strong alkalis 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 aesthetically pleasing alternative to expensive fenc ing 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 enclosure panels are available WIRE PANELS FULL UNIT Consists of welded wire mesh guards mounted on the exterior of the unit Prevents unauthor ized access yet provides free air flow Factory mounted WIRE LOUVERED PANELS Consists of welded wiremesh panels on the bottom part of unit and louvered panels on the condenser section of the unit Factory mounted 21 SECTION 2 PRODUCT DESCRIPTION 22 LOUVERED PANELS CONDENSER COIL ONLY Louvered panels are mounted on the sides and ends of the condenser coils 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 s
202. nutes indicating the system is locked out and will not restart SYS 1 HIGH MTR CURR 2 HIGH MTR CURR SYS When the System Current Feedback option is installed and selected Option 11 under OPTIONS Key Current Feedback 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 This safety will shut down a system 1f 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 automatic restarting JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 Unit Safeties Unit safeties are faults that cause all running compressors 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 TEMP LOW AMBIENT 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 LIQUID TEMP L OW The Low Leaving Chilled Liquid Temp Cutout protects the chiller from an evapor
203. oint to 46 7 F 8 2 C the hot gas bypass would shut off still leaving one compressor running As the load increased the compressors would stage on every 1 7 F 94 C Also note that Table 15 not only provides the formulas for the loading ON POINT and unloading OFF POINT of the system the STEP is also shown in the tables The STEP is the increment in the sequence of the capacity control scheme that can be viewed under the OPER DATA key Refer to the section in this on DISPLAY PRINT keys for specific information on the OPER DATA key TABLE 14 SAMPLE COMPRESSOR STAGING FOR RETURN WATER CONTROL Compressor Staging for Return Water Control 4 Compressor Cooling Setpoint 45 F 7 2 C Range 10 F 5 6 C ofCompON 0 4 2 4 46 25 F 7 9 C 45 F 7 2 C Unloading only JOHNSON CONTROLS 47 5 F 8 6 C 52 5 F 11 4 C 55 0 F 12 8 C 50 0 F 10 0 C 169 SECTION 8 UNIT OPERATION FORM 150 72 811 ISSUE DATE 8 15 2011 TABLE 15 RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS 6 STEPS COMPRESSOR COMPRESSOR ON POINT COMPRESSOR OFF POINT SP CR 4 Note 3 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 occur
204. ossesses independent training that will enable them to perform their assigned tasks properly and safely It is essential that prior to performing any task on this equipment this individual shall have read and understood this document and any referenced materials This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task 1n question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to areas of potential hazard DANGER WARNING indicates a potentially hazardous situation which if not avoided could result in death or se DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious CAUTION identifies a hazard which N could lead to damage to the machine damage to other equipment and or environmental pollution Usually an instruction will be given together with a brief explanation NOTE is used to highlight additional information which may be helpful to you NOTE External wiring unless specified as an optional connection in the manufacturer s product line is NOT to be connected inside the micropanel cabinet Devices such as relays switches transducers and controls may NOT be installed inside the panel NO external wiring is al WARNING rious injury WARNING Jury lowed to be run through the micropanel All wiring must be in accordance with John
205. otating fans JOHNSON CONTROLS SECTION 1 GENERAL CHILLER INFORMATION AND SAFETY 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 1s 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 Refrigerants and Oils Refrigerants and oils used in the unit are generally nontoxic non flammable and non corrosive and pose no special safety hazards Use of gloves and safety glasses 1s however recommended when working on the unit The build up of refrigerant vapor from a leak for example 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 120 VAC electrical supply from the inverter sy
206. ould be made with the customer power to the unit switched OFF Inspection Inspect unit for installation damage If found take action and or repair as appropriate Refrigerant Charge Packaged units are normally shipped as standard with a full refrigerant operating charge Check that refrigerant 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 the Technical Data section of ths IOM Service and Oil Line Valves Open each compressor suction economizer and discharge service valve If valves are the back seat type open them fully counterclockwise then close one turn of the stem to ensure operating pressure 15 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 YORK hand oil pump Part No 470 10654 000 to the 1 4 oil charging connection on th
207. ow resulting in unpredictable airflow patterns and possible diminished performance Johnson Controls s unit controls will optimize operation without nuisance high pressure FIG 47 DIMENSIONS ENGLISH YLAA0440HE JOHNSON CONTROLS 5 8 DIA MOUNTING HOLES TYP WATER OUTLET a _ m p s ELE L r4 i Er lt E LI PET HI as B H ao 3 RIGGING HOLES EACH SIDE 1473 RIGHT VIEW safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 6 rear to wall 6 control panel to end wall 4 0 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit 117 SECTION 5 TECHNICAL DATA FORM 150 72 3 811 ISSUE DATE 8 15 2011 DIMENSIONS YLAA0455HE ENGLISH 525 POWER ENTRY 8712 WIDE X 178 HIGH 2077 VIEW B B BOTTOM OF PANEL ORIGIN 193 774 498 588 2242 VIEW 5 8 DIA MOUNTING HOLES TYP 28 TYP 4 1918 VIEW 3 RIGGING HOLES 2124 EACH SIDE 1473 1675 4731 FRONT VIEW POWER SINGLE POINT SUPPLY WITH TERMINAL BLOCK N
208. programmed for REMOTE control under the OPTIONS key the above programmed setpoints would have no effect When in return chilled liquid temperature control the microprocessor board will turn all compressors off at setpoint 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 temperature 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 loads and unloads according to return chilled liquid temperature Both LEAVING and RETURN control are described in detail under the Capacity Control section of this IOM Remote Setpoints 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 return chilled liquid control The low limit high limit and default values for the keys under SETPOINTS are listed in Table 10 Pressing the COOLING SETPOINTS a third time will bring up the display that allows the Maximum EMS PWM Temperature Reset to be programme
209. proximately 0 5 1A STARTUP PANEL CHECKS POWER ON BOTH UNIT SWITCH OFF 1 Apply 3 phase power and verify its value Volt age imbalance should be no more than 2 of the average voltage 12 Apply 120VAC and verify its value on the ter minal block the Power Panel Make the mea surement between terminals 5 and 2 of XTBC2 The voltage should be 120VAC 10 13 Program verify the Cooling Setpoints Program Setpoints and unit Options Record the values in Table 7 see sections on Setpoints and Unit Keys located in this for additional pro gramming instruction 133 SECTION 6 COMMISSIONING TABLE 7 SETPOINTS ENTRY LIST o o Dispaylanpag 1 2 F Ambient Contro _ CowoMode 1 0 Display Units ___ Current Feedback Jj sosen S _ __ ___ RefigerantType Expansion COOLING SETPOINTS ___ 12 22 Rage EMS WMMaxSepon PROGRAMS Discharge Pressure Cutout Suct Pressure SSS Low Amb Temp Cutout Leaving Liquid Temp Cutout AmiReodeTme Fan Control On Pressure Fan Differential Off Pressure Total Compressors Number of Fans System 1
210. ption 9 Condenser Fan Control Mode FAN CONTROL PRESSURE DISCHARGE Condenser fans are controlled by discharge pressure only This mode must be chosen Or CONTROL AMBIENT amp DSCH F AN PRESS Do not select this option on R 410A chillers Option 10 Manual Override Mode MANUAL OVERRIDE MODE DISABLED 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 ENABLED MODE 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 automatically 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 15 installed to allow combined current monitoring of all systems by sensing current on the incoming 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 monitoring of each system SYS 1 input is to J7 of the SYS 2 input is to J of the I O Option 12 Power Fail Restart
211. r AC Control blue wire for neutral O 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 1 FHP2 refers to high pressure cutout no 2 on system no 1 All wiring to control section voltage free contacts requires a supply provided by the customer maximum voltage 120 volts The customer must take particular care when deriving the 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 G 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 connected 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 120 14 3 Signal IN O
212. r enne oot nenne coo sanae eo onere u naue ene ua aa s 192 JOHNSON CONTROLS 11 FORM 150 72 811 ISSUE DATE 8 15 2011 LIST OF TABLES TABLE 1 TEMPERATURES AND FLOWS lu ce ona xE Hue rne 45 TABLE 2 VOLTAGE LIMITATIONS l luu su hasa 45 TABLE ETHYLENE amp PROPYLENE GLYCOL CORRECTION FACTORS 46 TABLE 4 PHYSICAL DATA ENGLISH u uu u u pennae ie oin saaaaassaasaadassasaa assaka sasa 47 TABLE 4A PHYSICAL DATA ENGLISH I U U U u uu u 48 TABLE 5 MICROPANEL POWER SUPPLYu 49 TABLE 0 VOLTAGE RANGE is 0 15 mu a a m uuu wu ma u 49 TABLE 7 5 5 a tec co nues uw cuu s 134 TABLE 8 STATUS KEY MESSAGES QUICK REFERENCE 144 TABLE 9 OPERATION 148 TABLE 10 COOLING SETPOINTS PROGRAMMABLE LIMITS AND DEFAULT S 156 TABLE 11 PROGRAM KEY LIMITS AND DEFAULLI U u u 159 TABLE 12 SETPOINTS QUICK REFERENCE 160 TABLE 13 UNIT KEYS OPTIONS PROGRAMMING QUICK REFERENCE LIST 166 TABLE 14 SAMPLE COMPRESSOR STAGING FOR RETURN WATER CONTROL
213. rds are removed to fit duct work adequate alternative precautions must be taken to ensure persons cannot be harmed or put 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 circuit ampacity and maximum dual element fuse size are given in Tables 6 40 FORM 150 72 811 ISSUE DATE 8 15 2011 Copper power wiring only should be used for supplying power to the chiller This is recommended to avoid safety and reliability issues resulting from connection failure at the power connections to the chiller Aluminum wiring is not recommended due to thermal characteristics that may cause loose terminations resulting 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 15 used to supply power to the chiller AL CU compression fittings should be used to transition from 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 120 1 60 15 amp source must be supplied for the control panel through a fused disconnect when a control panel transformer optional
214. rgest motor plus 100 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 certified and maximum size is based on 225 of the rated load amps for the largest motor plus 100 of the rated load amps for all other loads included in the circuit Otherwise HACR type circuit breakers must be used Maximum circuit breaker rating is based on 225 of the rated load amps for the largest motor plus 100 of the rated load amps for all other loads included in the circuit The INCOMING WIRE RANGE is the minimum and maximum wire size that can be accommodated by the unit wiring lugs The 2 preceding the wire range indicates the number of termination points available per phase of the wire range specified Actual wire size and number of wires per phase must be determined based on the National Electrical Code using copper connectors only Field wiring must also comply with local codes A ground lug is provided for each compressor system to accommodate a field grounding conductor per N E C Table 250 95 A control circuit grounding lug is also supplied The supplied disconnect is a Disconnecting Means as defined in the N E C 100 and is intended for isolating the unit for the available power supply to perform maintenance and troubleshooting This disconnect is not intended to be a Load Break Device Field Wiring by others which complies to the Nation
215. rmines the stages of cooling available Note in Table 12 the chiller may have single or dual systems Dual system units may have 4 5 or 6 compressors This MUST be programmed correctly to assure proper chiller operation NOTE 158 FORM 150 72 3 811 ISSUE DATE 8 15 2011 FANS NUMBER OF PER SYSTEM The Number of Fans Per System must be programmed as needed to match the number of fans on each system SYS X TRIP VOLTS X X VOLTS TRIP VOLTS VOLTS UNIT Depending on the option the trip voltage for a specific system or unit high current trip can be programmed It also calibrates the current readout 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 the value that should be programmed For example if fan and compressor RLA s total 100A 5V x 100A 025 _ 225A 1525 225 2 8 The programmed value will be 2 8V A similar calculation and programming will be necessary for the other system in a 2 system chiller JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 7 UNIT CONTROLS Unit Trip Volts REMOTE UNIT ID For total chiller high current trip programming on PROGRAMMED 460VAC
216. rotection European Standard International Electrotechnical Commission JOHNSON CONTROLS SECTION 2 PRODUCT DESCRIPTION The operating program is stored in non volatile memory EPROM 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 HIGH AMBIENT KIT Allows units to operate when the ambient temperature is above 46 C 115 F Includes discharge pressure transducers BUILDING AUTOMATION SYSTEM INTERFACE The Microprocessor Board can accept a 4 20 milliamp 0 10VDC input to reset the leaving chiller liquid temperature from a Building Automation System The standard unit capabilities include remote start stop remote water temperature reset via 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 via the standard on board RS232 com munication port POWER PANEL Each panel contains Compressor power terminals Compressor motor starting contactors per Control power terminals to accept incoming for 115 1 60 control power Fan contactors amp overload current protection The power wiring 1s routed through liquid tight conduit to the compressors and fans 19 SECTION 2 PRODUCT DESCRIPTION FORM 150 72 811 ISSUE DATE 8 15 2011 ACCESSORIES AND OPT
217. s STEP can be viewed using the OPER DATA key and scrolling to COOLING DEMAND RETURN CHILLLED LIQUID SYSTEM LEAD LAG AND COMPRESSOR SEQUENCING A lead lag option may be selected to help equalize average run hours between systems with two refrigerant systems This may be programmed under the OPTIONS key Auto Lead Lag of the two systems based on average run hours of the compressors in each system Manual Lead Lag specifically selects the sequence in which the microprocessor board starts the systems The microprocessor board will sequence compressors load and unload systems according to Table 16 The microprocessor will lead lag compressors within each circuit to maximize individual compressor run time for the purpose of lubrication It will also prevent the same compressor from starting two times in a row The microprocessor board will not attempt to equalize run time on individual compressors within a system Each compressor in a system will be assigned an arbitrary number 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 each system will be decreased by 1 with the wrap around This control scheme assures the same compressor does not repeatedly cycle on and off TABLE 16 R
218. s of the chilled liquid freezing connecting power PRIOR to working on equipment TABLE 6 VOLTAGE RANGE VOLTAGE RANGE VOLTAGE CODE UNIT POWER 200 3 60 230 3 60 207 380 415 3 60 E 342 506 380 415 3 50 52 4 575 3 60 JOHNSON CONTROLS 49 SECTION 5 TECHNICAL DATA FORM 150 72 811 ISSUE DATE 8 15 2011 ELECTRICAL NOTES NOTES 1 Minimum Circuit Ampacity MCA is based on 125 of the rated load amps for the largest motor plus 100 of the rated load amps for all other loads included in the circuit per N E C Article 430 24 If the optional Factory Mounted Control Transformer is provided add the following MCA values to the electrical tables for the system providing power to the transformer 17 add 2 5 amps 28 add 2 3 amps 40 add 1 5 amps 46 add 1 3 amps 58 add 1 amps 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 applications where brown outs frequent starting and stopping of the unit and or operation at ambient temperatures in excess of 95 F 35 C is anticipated Maximum fuse size is based upon 225 of the rated load amps for the la
219. s to 81 PSIG 5 6 bars suction pressure JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 The digital inputs will display the input connection and ON OFF status such as FLOW SW REM START 13 5 This indicates that the flow switch remote start input 15 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 Tables 20 through 23 are a quick reference list providing the connection points and a description of the inputs and outputs respectively All input and output connections pertain to the connections at the microboard TABLE 20 I O DIGITAL INPUTS J13 7 Single System Select Jumper Single Sys No Jumper Two Sys J13 8 Sys 1 Motor Protector High Pressure Cutout J13 10 Sys 2 Motor Protector High Pressure Cutout JOHNSON CONTROLS SECTION 9 SERVICE AND TROUBLESHOOTING TABLE 21 DIGITAL OUTPUTS TABLE 22 ANALOG INPUTS SYS 1 Suction Transducer J7 10 or SYS 1 Low Pressure Switch Unit Type Chiller NO Jumper J11 12 to 24 VDC J11 12 YCUL Condensing Unit Jumper J11 12 to 24 VDC Do NOT Use J7 11 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 J9 10 or SYS 2 Low Pressure Switch SYS 2 D
220. scharge Transducer J9 6 5VDC regulated supply to transducer J9 11 VDC input signal to the microboard See the formula above for voltage readings that correspond to specific discharge pressures J9 7 5V DC return J9 2 drain shield connection 0VDC 183 SECTION 9 SERVICE AND TROUBLESHOOTING 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 The following is a formula that can be used to verify the voltage output of the transducer All voltage reading are in reference to ground unit case V Pressure in PSIG x 02 5 or V Pressure in barg x 29 5 where V dc voltage input to microprocessor board Pressure pressure sensed by transducer The f ollowing are the I O board connections for the Suction Transducer System Suction Transducer J7 5 5VDC regulated supply to transducer J7 10 VDC input signal to the microboard See the formula above for voltage readings that cor respond to specific suction pressures J7 9 5VDC return J7 1 drain shield connection System 2 Suction Transducer J9 5 5VDC regulated supply to transducer J9 10 VDC input signal to the microboard See the formula above for voltage readings that cor respond to specific suction pressures J7 9 5VDC return J7 11 drain shield connection 184 TB10 TB10 FORM 150 72
221. scharge pressure rises and the suction pressure decreases If this does not oc cur the compressor being tested is operating in the reverse direction and must be corrected After verifying proper compressor rotation turn the Unit Switch to OFF The chilled liquid setpoint may need to be temporarily lowered to ensure all compressors cycle ON NOTE JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 CHECKING SUPERHEAT AND SUBCOOLING The subcooling temperature of each system can be calculated by recording the temperature of the liquid line at the outlet of the condenser and subtracting it from the liquid line saturation temperature at the liquid stop valve liquid line saturation temperature is converted from a temperature pressure chart Example Liquid line pressure 325 PSIG converted to temp 101 F minus liquid line temp 83 F Subcooling 18 F The subcooling should be adjusted to 18 F at design conditions 1 Record the liquid line pressure and its correspond ing temperature liquid line temperature and subcooling below 5751 SYS2 Liq Line Press PSIG Saturated Temp F Liq Line Temp Subcooling F After the subcooling is verified the suction superheat should be checked The superheat should be checked only after steady state operation of the chiller has been established the leaving water temperature has been pulled down to the required leaving water temper
222. section to Set time Set unit options JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 UNIT ON OFF switch The microprocessor control center is capable of displaying 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 Discharge pressure optional Liquid Temperature Reset via a Johnson Controls ISN DDC or Building Automation System by others via a pulse width modulated PWM input as standard Anti recycle timer status for each system Anti coincident system start timer condition Compressor run status Nocooling load condition Day date and time Daily start stop times Holiday status Automatic or manual system lead lag control ead system definition Compressor starts amp operating hours each compressor Status of hot gas valves evaporator heater and fan operation e Run permissive status Number of compressors running Liquid solenoid valve status Load amp 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 Intensity of P
223. son Controls published specifications and must be performed ONLY by qualified Johnson Controls personnel Johnson Controls will not be responsible for damages problems resulting from improper connections to the controls or application of improper control signals Failure to follow this will void the manufacturer s warranty and cause serious damage to property or injury to persons N JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls policy for continuous product improvement the information contained in this document is subject to change without notice While Johnson Controls makes no commitment to update or provide current information automatically to the manual owner that information if applicable can be obtained by contacting the nearest Johnson Controls Service office JOHNSON CONTROLS It is the responsibility of operating service personnel to verify the applicability of these documents to the equipment in question If there is any question in the mind of operating service personnel as to the applicability of these documents then prior to working on the equipment they should verify with the owner whether the equipment has been modified and if current literature is available WARRANTY Responsibility for Safety ABOUT THIS MANUAL MISUSE OF EQUIPMENT Suitability for Application Structural Support Mechanical Strength General Access
224. stem thus shutting down the unit 15 FORM 150 72 811 SECTION 1 GENERAL CHILLER INFORMATION AND SAFETY ISSUE DATE 8 15 2011 THIS PAGE INTENTIONALLY LEFT BLANK 16 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 2 PRODUCT DESCRIPTION INTRODUCTION YORK YLAA Air Cooled Scroll Chillers provide chilled water for all air conditioning applications using central station air handling or terminal units They are completely self contained and are designed for outdoor 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 R 410A and a weather resistant microprocessor control center all mounted on a pressed steel base The units are completely assembled with all interconnecting refrigerant piping and internal wiring ready for field installation Prior to delivery the packaged unit is pressure tested evacuated and fully charged with a zero ozone depletion Refrigerant R410A and oil After assembly a complete operational test is performed with water flowing through the cooler to assure that the refrigeration circuit operates correctly The unit structure 15 heavy gauge galvanized steel This galvanized steel is coated with baked on powder paint which when subjected to ASTM B117 1000 hour salt spray testing yields a minimum ASTM 1654 rating of
225. stem X Low Suct Pressure Low Liquid Temp System X MP HPCO Inhibit 115VAC 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 System X MP HPCO Fault System X Switch Off System X system X HIGH MTR CURR 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 LD11297B Manual Overide Status System X Pumping Down on shutdown 144 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 7 UNIT CONTROLS DISPLAY PRINT KEYS Display Print Entry OPER DATA MN HISTORY The DISPLAY PRINT keys allow the user to retrieve system and unit information that is useful for monitoring chiller operation diagnosing potential problems troubleshooting 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 15 pressed system parameters will be displayed and remain on the display until another key is
226. suction pressure transducers have a range of 0 to 400 PSIG The output will be linear from 0 5 VDC to 4 5VDC over 400 PSIG 27 5 barg range The discharge transducers have a range from 0 to 650 PSIG The output will be linear from 0 5 VDC to 4 5 over the 600 PSIG 41 25 barg range The following is the formula that can be used to verify the voltage output ofthe transducer All voltage reading are in reference to ground unit case TABLE 26 PRESSURE TRANSDUCERS 0 400 PSIG SUCTION 0 600 PSIG DISCHARGE PRESSURE PRESSURE TRANSDUCER TRANSDUCER PRESSURE PRESSURE E dm PSIG RED WIRE 5V BLACK WIRE OV WHITE GREEN WIRE SIGNAL JOHNSON CONTROLS SECTION 9 SERVICE AND TROUBLESHOOTING TEST POINTS Suction Pressure System 1 Me Microboard J7 10 to J7 9 SU Stef Microboard J9 10 to J9 9 Discharge Pressure iube Microboard 17 11 to J7 7 System usa Microboard J9 11 to J9 7 V Pressure in PSIG x 01 5 or V Pressure in BARG x 145 5 where V dc voltage output Pressure pressure sensed by transducer The I O board connections for the Discharge Transducers System 1 Discharge Transducer J7 6 5VDC regulated supply to transducer J7 11 VDC input signal to the microboard See the formula above for voltage readings that correspond to specific discharge pressures 7 7 5VDC return J7 2 drain shield connection 0VDC System 2 Di
227. system These normally open contacts close when the system is functioning normally The respective contacts will open when the unit is shut down on a unit fault or locked out on a system fault Field connections 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 in series with the flow switch and Terminals 13 to 14 Refer to Fig 4 10 and unit wiring diagram Remote Emergency Cutoff Immediate shutdown of the chiller can be accomplished by opening a field installed dry contact to break the electrical circuit between Terminals 5 to L on Terminal Block XTBC2 The unit is shipped with a factory jumper installed between Terminals 5 to L which must be removed if emergency shutdown contacts are installed Refer to Fig 10 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 Terminals A to A A detailed explanation is provided in the Unit Controls section of this Refer to Fig s 3 4 and unit wiring diagram JOHNSON CONTROLS SECTION 4 INSTALLATION Load Limit Input Load limiting 1s a feature that prevents the unit from loading beyond a desired value The unit can be load limited either 33 40 50 66 or 80 dep
228. system first FIG 58 LEAVING WATER TEMPERATURE CONTROL EXAMPLE 168 JOHNSON CONTROLS Unit Operation RETURN CHILLED LIQUID CONTROL Can be used on Dual System 4 5 amp 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 Cooling Setpoint See sample in Table 14 At return water temperatures between the Cooling Setpoint and Cooling Setpoint plus Range compressor loading and unloading will be determined by the formulas in Table 15 Return Chilled Liquid Control MUST only be used when constant chilled liquid flow is ensured The RANGE MUST always be pro grammed to equal the temperature drop across the evaporator when the chiller is fully loaded Otherwise chilled liquid temperature will over or under shoot Variable flow must never be used in return chilled liquid mode Normal loading will occur at intervals of 60 seconds according to the temperatures determined by the formulas Unloading will occur at a rate of 30 seconds according to the temperatures determined in the formulas used to calculate the on and off points for each step of capacity The return chilled liquid setpoint is programmable from 40 F to 70 F 4 4
229. t Temp at the time of the fault SYSTEM 5 NUMBER X LEAD SYSTEM Displays which system is in the lead at the time of the fault 151 SECTION 7 UNIT CONTROLS EVAPORATOR 5 5 15 X X X FORM 150 72 NM3 811 ISSUE DATE 8 15 2011 X X X X X X SYS X HOT GAS 1 SV SOL 15 15 Displays status of the Evaporator Heater at time of the fault EVAPORATOR WATER PUMP STATUS X X X X Displays status of Evaporator Water Pump at the time of fault Status may read on off or trip E VAP HOURS PUMP TOTAL RUN X X X X Evap Pump total run hours at the time of fault ACTIVE REMOTE X X X X CTRL Displays whether Remote Chiller Control was active when the fault occurred ACTUAL XXX X AMP 5 UNIT This 15 only displayed when the Current Feedback Option is one per unit COMP 2 X X X STATUS 3 X X X SYS X 1 X X X Displays which Compressors were running in the system when the fault occurred SYS X RUN XX XX XX X X TIME 5 Displays system run time when fault occurred S YS X SP XXXX DP XXXX Displays the system Suction and Discharge Pressure of the time of the fault SUCT SUCT 5 YS X SAT Displays the System Suction Temp and Saturated Suction Temp when an EEV is installed 152 Displays whether the System Liquid Line Solenoid or Hot Gas Solenoid was en
230. t after a start This timer is programmable under the PROGRAM key between 300 600 seconds Whenever possible to reduce cycling and motor heating the anti recycle timer should be adjusted as high as possible The programmable anti recycle timer starts 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 permitted to start until the anti recycle timer has timed out If the lead system has run for less than 5 minutes three times In a row the anti recycle timer will be extended to 10 minutes if currently programmed for les than 10 minutes FAN CONTROL ON XXX PSIG PRESSURE The Fan Control On Pressure is the programmed pressure value that is used to stage the condenser fans on in relation to discharge pressure Refer to Condenser Fan Control in the Unit Operation section of this IOM and Tables 19 20 21 and 22 157 SECTION 7 UNIT CONTROLS DIFFERENTIAL OFF XXX PSIG F AN PRESSURE The Fan Differential Off Pressure is the programmed differential pressure value that is used to stage the condenser fans off in relation to discharge pressure Refer to Condenser Fan Control in the Unit Operation section of this IOM and Tables 19 20 21 and 22 TOTAL NUMBER OF COMPRESSORS 6 The TOTAL NUMBER OF COMPRESSORS is the total quantity of compressors in the chiller and dete
231. t is made whenever all systems shutdown 4 Several seconds after the compressor starts the systems first condenser fan will be cycled on outdoor air temperature greater than 25 F 4 C or discharge pressure See the Operating Controls section of this IOM for details concern ing condenser fan cycling 5 After one minute of compressor run time the next compressor in sequence will start when a system 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 Capacity Control section of this IOM for a detailed explanation of system and compressor staging 7 Asthe load decreases below setpoint the compres sors 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 setpoint and control mode See the Capacity Control section of this IOM for a detailed explanation 8 When the last compressor in a system two or three compressors per system 1s 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
232. tart display the microprocessor board will display the first programmable value under the PROGRAM key 178 FORM 150 72 811 ISSUE DATE 8 15 2011 SERVICE MODE ANALOG amp DIGITAL INPUTS After entering Service Mode PROGRAM 44 all digital and analog inputs to the microboard can be viewed by pressing the OPER DATA key After pressing the OPER DATA key the 1 UP arrow and DOWN arrow keys are used to scroll through the analog and digital inputs Following 15 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 VOLTS SYS 2 MTR VOLTS digital inputs PWM TEMP RESET INPUT LOAD LIMIT INPUT FLOW SW REM START SPARE SINGLE SYSTEM SELECT SYS 1 INPUT SYS 2 INPUT The discharge pressure transducer is optional 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 This example indicates that the system 1 suction pressure input 18 connected to plug 7 pin 10 77 10 on the I O board It indicates that the voltage is 2 1 VDC which correspond
233. ted below resulting in unpredictable airflow patterns and possible diminished performance Johnson Controls s unit controls will optimize operation without nuisance high pressure 2077 5 8 DIA MOUNTING HOLES TYP 28 TYP 193 2977 TOP VIEW 5 M 2 RIGGING HOLES EACH SIDE 3613 RIGHT VIEW safety cutouts however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances Side to wall 6 rear to wall 6 control panel to end wall 4 0 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be higher than the unit FIG 46 DIMENSIONS ENGLISH YLAA0390HE YLAA0485SE 116 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 SECTION 5 TECHNICAL DATA DIMENSIONS YLAA0440HE ENGLISH 525 POWER ENTRY _ 14012 L 8712 WIDE X 178 HIGH VIEW B B BOTTOM OF PANEL 749 TO CLR CONN 2242 BASE WIDTH 2261 FRONT VIEW POWER SINGLE POINT SUPPLY WITH TERMINAL BLOCK 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 bel
234. the microprocessor board 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 displayed as shown below If the microprocessor board is programmed for CURRENT FEEDBACK NONE no current display will appear SYS X X X COMP 2 STATUS 3 X X X TIME 5 YS X RUN XX XX XX SYS X LL SV IG ON HOT GAS SOL S OFF SYS X FAN STAGE The preceding five messages will appear sequentially first for system 1 then for system 2 The first message indicates the system and the associated 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 15 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 147 SECTION 7 UNIT CONTROLS See the Condenser Fan Control section in the Unit Operation section of this IOM for more information The fifth message displays current as s
235. ther 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 a history print The following is one example of a history buffer printout The data part of the printout will be exactly the same as the operational data print so it 1s not repeated here The difference is that the Daily Schedule 15 not printed in the history print and the header will be as follows YORK INTERNATIONAL CORPORATION MILLENNIUM LIQUID CHILLER SAFETY SHUTDOWN NUMBER 1 SHUTDOWN 3 56PM 01 AUG 09 41 5 5 2 HIGH DSCH PRESS SHUTDOWN NO FAULTS 150 FORM 150 72 811 ISSUE DATE 8 15 2011 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 SAFETY SHUT 1 DOWN NO 1 While this message 15 displayed 1 UP arrow key can be used to select any of the six history buffers Buffer number 1 15 the most recent and buffer number 6 15 the oldest safety shutdown that was saved After selecting the shutdown number pressing the ENTER key displays the following message which shows when the shutdown occurred SHUTDOWN OCCURRED 03
236. tion via an ISN Load limit stages are sent through YORK Talk on pages 9 and 10 of feature 54 Page 9 is stage load limit and page 10 is stage 2 load limit A second stage of load limiting the unit is accomplished by closing contacts connected to the Load Limit XTBC1 terminals 13 21 and PWM inputs 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 15 either 80 66 or 50 depending on the number of compressors on the unit The second stage of limiting 1s either 40 or 33 and is only available on 3 5 amp 6 compressor units Table 19 shows the load limiting permitted for the various numbers of compressors TABLE 19 COMPRESSOR OPERATION LOAD LIMITING IN UNIT 2 806 gt _ 5 ____6 6 33 _ JOHNSON CONTROLS SECTION 8 UNIT OPERATION Simultaneous operation of Remote Load Limiting and EMS PWM Tem perature Reset described on following ages cannot occur NOTE pag COMPRESSOR RUN STATUS Compressor run status is indicated by closure of contacts 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 experiences a loss of power to the
237. to LIMITATIONS The following pages outline detailed procedures to be followed to install and start up the chiller HANDLING These units are shipped as completely assembled units containing full operating charge and care should be taken to avoid damage due to rough handling JOHNSON CONTROLS INSPECTION Immediately upon receiving the unit it should be inspected for possible damage which may have occurred during transit If damage is evident it should be noted in the carrier s freight bill A written request for inspection by the carrier s agent should be made at once See Instruction manual Form 50 15 NM for more information and details LOCATION AND CLEARANCES The YLAA chillers are designed for outdoor installation When selecting a site for installation be guided by the following conditions 1 For outdoor locations of the unit select a place having an adequate supply of fresh air for the con denser 2 Avoid locations beneath windows or between structures where normal operating sounds may be objectionable 3 Installation sites may be either on a roof or at ground level See Foundation within this section of the IOM 4 The condenser fans are the propeller type and are not recommended for use with duct work in the condenser air stream 5 When it 1s desirable to surround the unit s it 1s recommended that the screening be able to pass the required chiller l s CFM without exceeding 0 1 of wat
238. to isolate Defective IPU amp I O Board 5 Replace IPU II Board or the Display Board or the Display Board Contact Johnson Controls Service before replacing circuit boards FLOW SWITCH REM No chilled liquid flow Check chilled liquid flow STOP NO RUN PERMISSIVE Flow switch improperly Check that the flow switch installed is installed according to manufacturer s instructions Defective flow switch Replace flow switch Remote cycling device open Check cycling devices connected to terminals 13 and 14 of the XTBC1 Terminal Block LOW SUCTION PRESSURE Improper suction pressure Adjust per recommended FAULT cutouts adjustments settings Low refrigerant charge Repair leak if necessary and add refrigerant Fouled filter dryer Change dryer core CONT D 186 JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 TROUBLESHOOTING CONT D SECTION 9 SERVICE AND TROUBLESHOOTING PROBLEM CAUSE SOLUTION LOW SUCTION PRESSURE FAULT CONT D HIGH DISCHARGE PRESSURE FAULT LOW LIQUID TEMP FAULT JOHNSON CONTROLS 4 5 TXV defective Reduced flow of chilled Defective suction pressure transducer low pressure switch or wiring LLSV defective Condenser fans not operating or operating backwards Too much refrigerant Air in refrigerant system Defective discharge pressure transducer
239. trols representative JOHNSON CONTROLS MOVING THE CHILLER Prior to moving the unit ensure that the installation site is suitable for installing the unit and is easily capable of supporting the weight of the unit and all associated services The units are designed to be lifted using cables A spreader bar or frame should be used in order to prevent damage to the unit from the lifting chains Units are provided with lifting eyes in the sides of the base frame which can be attached to directly using shackles or safety hooks The unit must only be lifted by the base frame at the points provided Never move the unit on rollers or lift the unit J klift truck using a forklift truc Care should be taken to avoid damaging the condenser cooling fins when moving the unit Lifting Weights For details of weights and weight distribution refer to the data shipped in the chiller information packet and unit nameplate The unit should be lifted by inserting hooks through the holes provided in unit base rails Spreader bars should be used to avoid crushing the unit frame rails with the lifting chains See below 35 SECTION 3 HANDLING AND STORAGE FORM 150 72 3 811 ISSUE DATE 8 15 2011 RIGGING INSTRUCTIONS Typical Lifting Arrangement 8 Fan Models LD13137 Typical Lifting Arrangement 4 Fan Models FIG 7 UNIT RIGGING LIFTING 36 LD13140 Use spreader bars to avoid lifting chains hitting the
240. two compressor are running but only indicates that the capacity control scheme is on step 2 of 8 Capacity Control is covered more detail in this publication which provides specific information on compressor staging for Return Water Control only TEMP ERROR RATE X F XXX X F M TEMP The COOLING DEMAND message will be replaced with this message when Leaving Chilled liquid control is selected This message indicates the temperature error and the rate of change of the chilled liquid temperature LEAD SYSTEM I S NUMBER 2 SYSTEM This display indicates the current LEAD system In this example system 2 is the LEAD system making system the LAG system The LEAD system be manually selected or automatic Refer to the programming under the OPTIONS key The Lead System display will only appear on a two system unit A unit utilizing hot gas bypass should be programmed for MANUAL with system I as the lead system Failure to do so will prevent hot gas operation if system 2 switches to the lead system when programmed for AUTOMATIC LEAD LAG JOHNSON CONTROLS FORM 150 72 3 811 ISSUE DATE 8 15 2011 HEATER X X X STATUS I S 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 4 4 C the heater is turned on When the temperature rises
241. unit switch flow switch etc This DC source 15 factory wired to terminal 13 Any switch or contact used as a digital input would be connected to this terminal 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 particular digital input Any time a switch or contact is open OVDC would be applied to that particular digital input Typically voltages of 24 36VDC could be measured for the DC voltage on the digital inputs This voltage is in reference to ground The unit case should be sufficient as a reference point when measuring digital input voltages Analog Inputs Temperature Refer to the unit wiring diagram Temperature inputs are connected to the microboard on plug J6 These analog inputs represent varying DC signals corresponding to varying temperatures All voltages are in reference to 110 the unit case ground Following are the connections for the temperature sensing inputs _ 130 Outside Air Sensor 08 os J6 6 5VDC regulated supply to sensor J6 9 VDC input signal to the microboard See Table 24 for voltage readings that corre spond to specific outdoor temperatures 6 3 drain shield connection 0VDC Return JOHNSON CONTROLS 181 SECTION 9 SERVICE AND TROUBLESHOOTING TABLE 25 ENTERING LEAVING CHILLED LIQUID TEMP SENSOR TEMPERATURE VOLTAGE CORRELATION VOLT
242. ure bar Water Connections Size inch JOHNSON CONTROLS STANDARD EFFICIENCY UNITS 0285 030 0360 040 0435 _ xe so 3e 48 _ LJ 4 gt gt 272 37 3 5 5 6 4 4d 1 4 36 26 s 325 3 14 15 286 8 6 es 6 6 s 60 0485 466 3690 2242 2393 32 33 3042 3290 3 3 6 15 0 3 3 950 39 250 10 3 31 47 SECTION 5 TECHNICAL DATA FORM 150 72 811 ISSUE DATE 8 15 2011 PHYSICAL DATA ENGLISH HIGH EFFICIENCY YLAA0195 YLAA0515 50Hz TABLE 4A PHYSICAL DATA ENGLISH Refrigerant R 410A General Unit Data YLAA Nominal Kw R 410A Length mm Width mm Height mm Number of Refrigerant Circuits Refrigerant Charge Operating R 410A ckt2 KG Oil Charge ckt1 ckt2 LITERS Shipping Weight Operating Weight Compressors scroll type Compressors per circuit Compressors per unit Condenser Total Face Area Number of Rows Condenser Fans Low Sound Number of Fans ckt1 ckt2 Fan hp Fan RPM Total Chiller Evaporator Water Volume liters Maximum Water Side Pressure bar Maximum Refrigerant Side Pressure bar Water Connections Size inch 48 HIGH EFFICIENCY UNITS gt 020 0260 0310 0350 0299 05
243. ure 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 minimum low limit of the control range will be 40 0 F 4 4 C 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 4 4 C the low limit will be reset to 40 0 F 4 4 C and the difference will 167 SECTION 8 UNIT OPERATION 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 4 4 C 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 running and Leaving Water Temperature is less than setpoint Hot gas is turned off as temperature rises when Leaving Water Temperature is more than setpoint plus the control range divided by two If temperature remains below the setpoint low limit on the lowest step of capacity the microprocessor board 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 The leaving chilled liquid setpoint 1s programmable from 40 F to 70 F 4 4 C to 21 1 C in water chilling mode and from 10 F to 70 F 12 2 C to 21 1 C in glycol chilling mode In both modes the cooling range can be
244. ustomer power cables are connected correctly to the terminal blocks or optional circuit breaker Ensure that connections of power cables within 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 a suitable grounding point Ensure that all unit internal ground connections are tight 131 SECTION 6 COMMISSIONING Supply Voltage Verify that the site voltage supply corresponds to the unit requirement and is within the limits given in the Technical Data section of ths IOM PREPARATION POWER ON as the commissioning procedure is CAUTION carried out Perform the commissioning using the detailed checks outlined in the EQUIP MENT START UP CHECK SHEET Apply power to the chiller Turn ON the option panel circuit breaker 1f supplied The machine is now live WARNING Switch Settings Assure the chiller OFF ON UNIT switch at the bottom of the keypad 15 OFF Place the optional circuit breaker handle on the panel door to ON The customer s disconnection devices can now be set to ON Verify the control panel display 15 illuminated Assure the system switches under the SYSTEM SWITCHES Key are in the OFF position Compressor Heaters Verify the compressor heaters are energized If the ambient temperature 1s above 96 F 36 C the compressor heaters must be on for at least 8 hours before start up to ensure
245. vac uum Doing so will cause internal arcing of the compressor motor which will re CAUTION sult in failure of compressor CONDENSER FAN MOTORS Condenser fan motors are permanently lubricated and require no maintenance JOHNSON CONTROLS CONDENSER COILS Dirt should not be allowed to accumulate on the condenser coil surfaces Cleaning should be as often as necessary to keep coils clean Exercise care when cleaning the coil so that the coil fins are not damaged NOTE OPERATING PARAMETERS Regular checks of the system 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 the Unit Operation Commissioning and Installation sections of this manual ON BOARD BATTERY BACK UP 05 15 the Real Time Clock chip 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 is installed Do not confuse JPI on the PU II 03 1 02630 board with JPI the 031 02550 board NOTE PLATE AND FRAME HEAT EXCHANGER EVAPORATOR HEATER The Plate and Frame Heat Exchanger evaporator heater is 120VAC Dis connecting 120VAC power from the unit at or below freezing tempera CAUTION tures can result in damage to the ev
246. 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 expansion valves Incorrect programming may cause damage to compressors CAUTION Also see the UNIT KEYS PROGRAMMING QUICK REFERENCE LIST in Table 15 Option 17 Flash Card Update FLASH 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 15 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 and keys FORM 150 72 3 811 ISSUE DATE 8 15 2011 CARD UPDATE ENABLED 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 update is completed F 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 XXXXX E RROR If the update resulted in an error the original program will still be active Wh

5 - Johnson Controls

Contents

Download Pdf Manuals

Related Search

Related Contents