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

YLAA0180 - 0516 Style B 50 Hz Air-Cooled Scroll Chillers Brazed
AIR-COOLED SCROLL CHILLER
INSTALLATION, OPERATION, MAINTENANCE
Supersedes: 150.72-ICOM7 (414) Form 150.72-ICOM7 (614)
035-23573-100
YLAA0180 - YLAA0516
AIR-COOLED SCROLL CHILLERS
WITH BRAZED PLATE HEAT EXCHANGER
STYLE B (50 HZ) 4-8 FAN
50 - 150 TON
180 - 530 KW
R-410A
Products are produced at a
facility whose qualitymanagement systems are
ISO9001 certified.
Issue Date:
June 10, 2014
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus.
During installation, operation maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
materials under pressure, rotating components, and
both high and low voltage. Each of these items has the
potential, if misused or handled improperly, to cause
bodily injury or death. It is the obligation and 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 is intended for use by owner-authorized
operating/service personnel. It is expected that these
individuals possess 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 in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Identifies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollution if proper care is not taken or instructions and are not followed.
Indicates a potentially hazardous situation which will result in possible injuries
or damage to equipment if proper care is
not taken.
Highlights additional information useful
to the technician in completing the work
being performed properly.
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accordance with Johnson Controls’ published specifications and must be performed only by a qualified
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warning will void the manufacturer’s warranty and cause serious damage to property or personal injury.
2
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
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.
Johnson Controls makes no commitment to update or
provide current information automatically to the manual owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson Controls Service office or accessing the Johnson Controls QuickLIT
website at http://cgproducts.johnsoncontrols.com.
Operating/service personnel maintain responsibility for
the applicability of these documents to the equipment.
If there is any question regarding the applicability of
these documents, the technician should verify whether
the equipment has been modified and if current literature is available from the owner of the equipment prior
to performing any work on the chiller.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical information and any other changes in spelling, grammar
or formatting are not included.
ASSOCIATED LITERATURE
Manual Description
Form Number
Start-Up Checklist - Style A and B
150.72-CL1
Renewal Parts - YLAA0180 - YLAA0516 Style B 50 Hz
150.72-RP4
Limited Warranty Engineered Systems Equipment
50.05-NM2
JOHNSON CONTROLS
3
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
NOMENCLATURE
YLAA0180SE 50XCB
1 2 3 4
BASE PRODUCT TYPE
5 6 7 8
NOMINAL CAPACITY
9
UNIT DESIGNATOR
10
REFRIGERANT
11 12 13
VOLTAGE/STARTER
14 15
DESIGN/DEVELOPMENT LEVEL
: Design Series A, B, C
Y : YORK
0 # # #
S: Standard Efficiency E: R-410A
1
7 : 200 / 3/ 60 C
: Development Level A
: 230 / 3 / 60
L : Scroll
1 # # #
H
2
8
A
: High Efficiency
(Shell & Tube Evap)
: 380 / 3 / 60
A
4 0
: Air-Cooled 60 HZ Nominal Tons
4
6
B : Dev. Level B
: 460 / 3 / 60
: Americas
50 HZ Nominal kW
(Braze
Plate Evap)
5
8
Europe
: 575 / 3 / 60
5
0
A
: 380-415 / 3 / 50
X : Across the Line
4
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
TABLE OF CONTENTS
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY...................................................................... 11
Introduction...................................................................................................................................................... 11
Warranty.......................................................................................................................................................... 11
Handling.......................................................................................................................................................... 11
Safety And Quality........................................................................................................................................... 11
About This Manual.......................................................................................................................................... 12
Misuse Of Equipment...................................................................................................................................... 12
SECTION 2 – PRODUCT DESCRIPTION...............................................................................................................15
Introduction...................................................................................................................................................... 15
General System Description............................................................................................................................ 15
Communications.............................................................................................................................................. 17
Building Automation System Interface............................................................................................................. 17
Power Panel.................................................................................................................................................... 17
Accessories And Options................................................................................................................................ 17
SECTION 3 – HANDLING AND STORAGE............................................................................................................31
Delivery And Storage....................................................................................................................................... 31
Inspection........................................................................................................................................................ 31
Moving The Chiller.......................................................................................................................................... 31
Lifting Using Lugs............................................................................................................................................ 33
Lifting Using Shackles..................................................................................................................................... 33
Lifting Weights................................................................................................................................................. 34
SECTION 4 – INSTALLATION.................................................................................................................................35
Installation Checklist........................................................................................................................................ 35
Startup/Commissioning................................................................................................................................... 35
Location And Clearances................................................................................................................................ 35
Spring Isolators (Optional)............................................................................................................................... 36
Compressor Mounting..................................................................................................................................... 36
Remote Cooler Option..................................................................................................................................... 36
Chilled Liquid Piping........................................................................................................................................ 36
Pipework Arrangement.................................................................................................................................... 37
Wiring.............................................................................................................................................................. 37
Relief Valves.................................................................................................................................................... 38
High Pressure Cutout...................................................................................................................................... 38
Single-Point Supply Connection – Terminal Block, Non-Fused
Disconnect Switch Or Circuit Breaker............................................................................................................. 39
SECTION 5 – TECHNICAL DATA...........................................................................................................................43
Operational Limitations.................................................................................................................................... 43
Physical Data YLAA0180 – YLAA0516 50Hz.................................................................................................. 46
Electrical Data................................................................................................................................................. 48
Compressor Heaters....................................................................................................................................... 48
Electrical Notes............................................................................................................................................... 53
Weight Distribution And Isolator Mounting Positions....................................................................................... 82
Clearances...................................................................................................................................................... 83
Four Fan Isolator Locations............................................................................................................................. 84
Five And Six Fan Isolator Locations................................................................................................................ 84
Seven And Eight Fan Isolator Locations......................................................................................................... 85
Isolator Information.......................................................................................................................................... 86
JOHNSON CONTROLS
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FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
TABLE OF CONTENTS (CONT’D)
SECTION 6 – COMMISSIONING.............................................................................................................................93
Preparation – Power Off.................................................................................................................................. 93
Preparation – Power On.................................................................................................................................. 94
SECTION 7 – UNIT CONTROLS.............................................................................................................................99
Introduction...................................................................................................................................................... 99
IPU II And I/O Boards...................................................................................................................................... 99
Transformer .................................................................................................................................................. 100
Display........................................................................................................................................................... 100
Keypad.......................................................................................................................................................... 100
Unit Switch.................................................................................................................................................... 100
Battery Back-Up............................................................................................................................................ 100
Programming # Of Compressors................................................................................................................... 100
Status Key..................................................................................................................................................... 101
Display/Print Keys......................................................................................................................................... 107
Entry Keys..................................................................................................................................................... 115
Setpoints Keys.............................................................................................................................................. 116
Schedule/Advance Day Key.......................................................................................................................... 117
Program Key................................................................................................................................................. 119
Unit Keys ...................................................................................................................................................... 123
Bacnet, Modbus, N2 And Yorktalk 2 Communications.................................................................................. 129
SECTION 8 – UNIT OPERATION..........................................................................................................................141
Capacity Control............................................................................................................................................ 141
Suction Pressure Limit Controls.................................................................................................................... 142
Discharge Pressure Limit Controls................................................................................................................ 142
Leaving Chilled Liquid Control....................................................................................................................... 142
Leaving Chilled Liquid Control Override To Reduce Cycling......................................................................... 143
Leaving Chilled Liquid System Lead/Lag And Compressor Sequencing...................................................... 144
Return Chilled Liquid Control........................................................................................................................ 144
Return Chilled Liquid System Lead/Lag And Compressor Sequencing........................................................ 145
Anti-Recycle Timer........................................................................................................................................ 145
Anti-Coincidence Timer................................................................................................................................. 145
Evaporator Pump Control And York Hydro Kit Pump Control........................................................................ 146
Evaporator Heater Control............................................................................................................................ 146
Pumpdown Control........................................................................................................................................ 146
Standard Condenser Fan Control................................................................................................................. 146
Load Limiting................................................................................................................................................. 149
Compressor Run Status................................................................................................................................ 149
Alarm Status.................................................................................................................................................. 149
Remote BAS/EMS Temperature Reset Using A Voltage Or Current Signal.................................................. 150
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JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
TABLE OF CONTENTS (CONT’D)
SECTION 9 – SERVICE AND TROUBLESHOOTING...........................................................................................151
Clearing History Buffers................................................................................................................................ 151
Service Mode................................................................................................................................................ 151
Service Mode – Outputs................................................................................................................................ 151
Service Mode – Chiller Configuration............................................................................................................ 152
Service Mode – Analog And Digital Inputs.................................................................................................... 152
Control Inputs/Outputs.................................................................................................................................. 153
Checking Inputs And Outputs........................................................................................................................ 155
Optional Printer Installation........................................................................................................................... 158
Troubleshooting............................................................................................................................................. 160
SECTION 10 – MAINTENANCE............................................................................................................................163
Compressors................................................................................................................................................. 163
Condenser Fan Motors.................................................................................................................................. 163
Condenser MCHX Cleaning.......................................................................................................................... 163
Operating Parameters................................................................................................................................... 164
On-Board Battery Back-Up............................................................................................................................ 164
Brazed Plate Heat Exchanger (Evaporator) Heater......................................................................................164
Overall Unit Inspection.................................................................................................................................. 164
Temperature.................................................................................................................................................. 167
JOHNSON CONTROLS
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FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
LIST OF FIGURES
FIGURE 1 - Unit Components (Front)���������������������������������������������������������������������������������������������������������������������20
FIGURE 2 - Unit Components (Side)����������������������������������������������������������������������������������������������������������������������21
FIGURE 3 - Power Panel Components�������������������������������������������������������������������������������������������������������������������22
FIGURE 4 - Power Panel / Control Components����������������������������������������������������������������������������������������������������23
FIGURE 5 - Process And Instrumentation Diagram������������������������������������������������������������������������������������������������29
FIGURE 6 - Unit Rigging/Lifting �����������������������������������������������������������������������������������������������������������������������������32
FIGURE 7 - Warning�����������������������������������������������������������������������������������������������������������������������������������������������34
FIGURE 8 - Chilled Liquid System �������������������������������������������������������������������������������������������������������������������������37
FIGURE 9 - S
ingle-Point Supply Connection – Terminal Block, Non-Fused Disconnect Switch
Or Circuit Breaker Or Circuit Breaker��������������������������������������������������������������������������������������������������39
FIGURE 10 - Control Wiring Inputs�������������������������������������������������������������������������������������������������������������������������40
FIGURE 11 - Control Wiring Outputs����������������������������������������������������������������������������������������������������������������������41
FIGURE 12 - Elementary Wiring Diagram���������������������������������������������������������������������������������������������������������������58
FIGURE 13 - Elementary Wiring Diagram���������������������������������������������������������������������������������������������������������������60
FIGURE 14 - F
an Wiring, Standard Low Sound Or Ultra Quiet, YLAA0180 - YLAA0516��������������������������������������� 62
FIGURE 15 - Fan Wiring, High Air Flow������������������������������������������������������������������������������������������������������������������64
FIGURE 16 - Single And Dual Point Wiring Options�����������������������������������������������������������������������������������������������66
FIGURE 17 - Pump Wiring��������������������������������������������������������������������������������������������������������������������������������������67
FIGURE 18 - Compressor Wiring����������������������������������������������������������������������������������������������������������������������������68
FIGURE 19 - Power Options Connection Diagram�������������������������������������������������������������������������������������������������70
FIGURE 20 - Power Panel��������������������������������������������������������������������������������������������������������������������������������������72
FIGURE 21 - Micro Panel Connections�������������������������������������������������������������������������������������������������������������������74
FIGURE 22 - S
ample Printout Supplied In The Isolator Package And In The Chiller Panel Literature Packet������� 82
FIGURE 23 - Unit Clearances – All Models�������������������������������������������������������������������������������������������������������������83
FIGURE 24 - Status Key Messages Quick Reference List�����������������������������������������������������������������������������������106
FIGURE 25 - Operation Data�������������������������������������������������������������������������������������������������������������������������������� 110
FIGURE 26 - Setpoints Quick Reference List�������������������������������������������������������������������������������������������������������122
FIGURE 27 - Unit Keys Options Programming Quick Reference List�������������������������������������������������������������������128
FIGURE 28 - Micro Panel Connections�����������������������������������������������������������������������������������������������������������������130
FIGURE 29 - L
eaving Water Temperature Control Example���������������������������������������������������������������������������������142
FIGURE 30 - Setpoint Adjust���������������������������������������������������������������������������������������������������������������������������������143
FIGURE 31 - Condenser Fan Locations���������������������������������������������������������������������������������������������������������������146
FIGURE 32 - Microboard Layout���������������������������������������������������������������������������������������������������������������������������154
FIGURE 33 - I/O Board Relay Contact Architecture����������������������������������������������������������������������������������������������158
FIGURE 34 - Printer To Microboard Electrical Connections����������������������������������������������������������������������������������159
8
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
LIST OF TABLES
TABLE 1 - Complete Pin Number Description��������������������������������������������������������������������������������������������������������24
TABLE 2 - Temperatures And Flows�����������������������������������������������������������������������������������������������������������������������43
TABLE 3 - Ethylene And Propylene Glycol Correction Factors�������������������������������������������������������������������������������44
TABLE 4 - Physical Data (English)�������������������������������������������������������������������������������������������������������������������������46
TABLE 5 - Micropanel Power Supply����������������������������������������������������������������������������������������������������������������������48
TABLE 6 - Voltage Range���������������������������������������������������������������������������������������������������������������������������������������48
TABLE 7 - Pump Electrical Data (50 hz)�����������������������������������������������������������������������������������������������������������������49
TABLE 8 - Electrical Data Without Pumps��������������������������������������������������������������������������������������������������������������50
TABLE 9 - Transformer Load����������������������������������������������������������������������������������������������������������������������������������50
TABLE 10 - Wiring Lugs������������������������������������������������������������������������������������������������������������������������������������������52
TABLE 11 - Cooling Setpoint, Programmable Limits And Defaults����������������������������������������������������������������������� 118
TABLE 12 - Program Key Limits And Default��������������������������������������������������������������������������������������������������������120
TABLE 13 - Minimum, Maximum And Default Values�������������������������������������������������������������������������������������������130
TABLE 14 - Values Required For Bas Communication�����������������������������������������������������������������������������������������131
TABLE 15 - Real Time Error Numbers������������������������������������������������������������������������������������������������������������������132
TABLE 16 - Bacnet And Modbus Communications Data Map������������������������������������������������������������������������������133
TABLE 17 - Yorktalk 2 Communications Data Map�����������������������������������������������������������������������������������������������137
TABLE 18 - Sample Compressor Staging For Return Water Control������������������������������������������������������������������� 143
TABLE 19 - Return Chilled Liquid Control For 4 Compressors (6 Steps)������������������������������������������������������������� 143
TABLE 20 - Lead/Lag Return Chilled Liquid Control For 4 Compressors (6 Steps)��������������������������������������������� 144
TABLE 21 - YLAA Standard Condenser Fan Control Using Discharge Pressure Only
(2, 3, Or 4 Fans Per System)�������������������������������������������������������������������������������������������������������������147
TABLE 22 - YLAA Standard Condenser Fan Control Using Discharge Pressure Only
(5 Or 6 Fans Per System)������������������������������������������������������������������������������������������������������������������148
TABLE 23 - Compressor Operation Load Limiting������������������������������������������������������������������������������������������������149
TABLE 24 - I/O Digital Inputs��������������������������������������������������������������������������������������������������������������������������������153
TABLE 25 - I/O Digital Outputs�����������������������������������������������������������������������������������������������������������������������������153
TABLE 26 - I/O Analog Inputs�������������������������������������������������������������������������������������������������������������������������������153
TABLE 27 - I/O Analog Outputs����������������������������������������������������������������������������������������������������������������������������153
TABLE 28 - Outdoor Air Sensor Temperature/Voltage/Correlation�����������������������������������������������������������������������155
TABLE 29 - Entering/Leaving Chilled Liquid Temp. Sensor, Temperature/Voltage Correlation���������������������������� 156
TABLE 30 - Pressure Transducers�����������������������������������������������������������������������������������������������������������������������157
TABLE 31 - Troubleshooting���������������������������������������������������������������������������������������������������������������������������������160
TABLE 32 - SI Metric Conversion�������������������������������������������������������������������������������������������������������������������������167
JOHNSON CONTROLS
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FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
THIS PAGE INTENTIONALLY LEFT BLANK
10
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY
1
INTRODUCTION
YORK YLAA chillers are manufactured to the highest
design and construction standards to ensure high performance, reliability and adaptability to all types of air
conditioning installations.
Rigging and lifting should only be done by a professional rigger in accordance with a written rigging and
lifting plan. The most appropriate rigging and lifting
method will depend on job specific factors, such as the
rigging equipment available and site needs. Therefore
a professional rigger must determine the rigging and
lifting method to be used, and it is beyond the scope of
the manual to specify rigging and lifting details.
This manual contains all the information required for
correct installation and commissioning of the unit, together with operating and maintenance instructions.
The manuals 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 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.
serial number information is printed on the unit identification plate.
The unit warranty will be void if any modification to
the unit is carried out without prior written approval
from Johnson Controls.
For warranty purposes, the following conditions must
be satisfied:
• The initial start of the unit must be carried out by
trained personnel from an Authorized Johnson
Controls Service Center (see SECTION 6 – COMMISSIONING).
• Only genuine YORK approved spare parts, oils,
coolants, and refrigerants must be used.
• All the scheduled maintenance operations detailed
in this manual must be performed at the specified
times by suitably trained and qualified personnel
(see SECTION 10 – MAINTENANCE).
• Failure to satisfy any of these conditions will automatically void the warranty (see Warranty on page
11).
HANDLING
These units are shipped as completely assembled units
containing full operating charge, and care should be
taken to avoid damage due to rough handling.
WARRANTY
SAFETY AND QUALITY
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.
Standards for Safety and Quality
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
JOHNSON CONTROLS
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:
• ANSI/ASHRAE Standard 15 - Safety Code for
Mechanical Refrigeration.
• 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.
11
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 1 – GENERAL CHILLER INFORMATION and SAFETY
• ASHRAE 90.1 - Energy Efficiency compliance.
• Conform to Intertek Testing Services, formerly
ETL, for construction of chillers and provide
ETL/cETL listing label.
• Manufactured in facility registered to ISO 9002.
• OSHA – 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.
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
rigging, lifting, maintaining, operating or working on
any machinery is primarily responsible for:
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
• Personal safety, safety of other personnel, and the
machinery.
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.
• Correct utilization of the machinery in accordance
with the procedures detailed in the manuals.
The unit must not be operated outside the design parameters specified in this manual.
ABOUT THIS MANUAL
The following terms are used in this document to alert
the reader to areas of potential hazard.
A WARNING is given in this document
to identify a hazard, which could lead to
personal injury. Usually an instruction
will be given, together with a brief explanation and the possible result of ignoring
the instruction.
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.
A NOTE is used to highlight additional
information, which may be helpful to
you but where there are no special safety
implications.
12
The contents of this manual include suggested best
working practices and procedures. These are issued for
guidance only, and they do not take precedence over
the above stated individual responsibility and/or local
safety regulations.
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 is 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 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-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 1 – GENERAL CHILLER INFORMATION and SAFETY
Pressure Systems
Refrigerants and Oils
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.
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
is, 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.
Electrical
High Temperature and Pressure Cleaning
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.
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.
Rotating Parts
Fan guards must be fitted at all times and not removed
unless the power supply has been isolated. If ductwork
is to be fitted, requiring the wire fan guards to be removed, alternative safety measures must be taken to
protect against the risk of injury from rotating fans.
Emergency Shutdown
In case of emergency, the control panel is fitted with
a Unit Switch to stop the unit in an emergency. When
operated, it removes the low voltage 120VAC electrical supply from the unit controller, thus shutting down
the unit.
Sharp Edges
The fins on the air-cooled condenser coils have sharp
metal edges. Reasonable care should be taken when
working in contact with the coils to avoid the risk of
minor abrasions and lacerations. The use of gloves is
recommended.
Frame rails, brakes, and other components may also
have sharp edges. Reasonable care should be taken
when working in contact with any components to avoid
risk of minor abrasions and lacerations.
JOHNSON CONTROLS
13
1
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
THIS PAGE INTENTIONALLY LEFT BLANK
14
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
2
INTRODUCTION
GENERAL SYSTEM DESCRIPTION
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 rugged steel base.
Compressors
The units are completely assembled with all interconnecting refrigerant piping and internal wiring, ready
for field installation.
Brazed Plate Evaporator
Prior to delivery, the packaged unit is pressure-tested,
evacuated, and fully charged with Refrigerant R-410A
and oil. After assembly, a complete operational test is
performed with water flowing through the cooler to assure that the refrigeration circuit operates correctly.
The unit structure is 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 “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
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 compact, high efficiency Brazed Plate Heat Exchanger (BPHE) is constructed with 316L stainless
steel corrugated channel plates with a filler material
between each plate. It offers excellent heat transfer
performance with a compact size and low weight, reducing structural steel requirements on the job site.
The heat exchanger is manufactured in a precisely controlled vacuum-brazing process that allows the filler
material to form a brazed joint at every contact point
between the plates, creating complex channels. The arrangement is similar to older plate and frame technology, but without gaskets and frame parts.
Water inlet and outlet connections are grooved for
compatibility with field supplied ANSI/AWWA C-606
couplings.
15
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
The evaporator is equipped with a thermostat-controlled heater. The heater provides freeze protection
for the evaporator down to -20°F (-29°C) ambient. The
evaporator is covered with 3/4” flexible, closed-cell,
foam insulation (K=0.25).
A 1/16” (1.6mm) mesh wye-strainer is provided as
standard for installation upstream of the heat exchanger to prevent clogging from water system debris.
Condenser
Microchannel Condenser (MCHX)
MCHX Condensers are made of a single material to
avoid galvanic corrosion due to dissimilar metals.
MCHX and headers are brazed as one piece. Integral
sub cooling is included. The design working pressure
of the MCHX is 650 PSIG (45 bar). MCHX Condenser
is easily washable with clear water.
Fans
The condenser fans are composed of corrosion 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. All blades are statically and
dynamically balanced for vibration free operation.
Motors
The fan motors are Totally Enclosed Air-Over, and are
current protected. They feature ball bearings that are
double sealed and permanently lubricated.
Control Center
All controls are contained in a NEMA 3R/12 cabinet
with hinged outer door and includes a Liquid Crystal
Display with Light Emitting Diode backlighting for
outdoor viewing:
• Two display lines
• Twenty characters per line
Display/Print Keys
• Color coded 12-button non-tactile keypad with sections for display and print of typical information:
• Chilled liquid temperatures
• Ambient temperature
16
•
•
•
•
•
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-toprint button, is provided to permit the capability
of hard copy print-outs via a separate printer (by
others).
Entry Keys
This section is used to enter setpoints or modify system
values.
Setpoints Keys
Updating can be performed to:
•
•
•
•
•
•
•
•
•
•
•
Chilled liquid temperature setpoint and range
Remote reset temperature range
Set daily schedule/holiday for start/stop
Manual override for servicing
Low and high ambient cutouts
Number of compressors
Low liquid temperature cutout
Low suction pressure cutout
High discharge pressure cutout
Anti-recycle timer (compressor start cycle time)
Anti-coincident timer (delay compressor starts)
Unit Keys
This section is used to:
• Set time
• Set unit options
Oper Data Key
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
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
• Discharge pressure (optional)
• Liquid Temperature Reset via a Johnson Controls
ISN DDC or Building Automation System (by
others) via a 4 to 20 milliamp or 0 to10VDC input
• Anti-recycle timer status for each system
• Anti-coincident system start timer condition
• Compressor run status
• No cooling load condition
• Day, date and time
• Daily start/stop times
• Holiday status
• Automatic or manual system lead/lag control
• Lead system definition
• Compressor starts and operating hours
• (each compressor)
• Status of hot gas valves, evaporator heater
• and fan operation
• Run permissive status
• Number of compressors running
• Liquid solenoid valve status
• Load and unload timer status
• Water pump status
Provisions are included for: pumpdown at shutdown;
optional remote chilled water temperature reset and
two steps of demand load limiting from an external
building automation system. Unit alarm contacts are
standard.
The operating program is stored in non-volatile memory battery backed RAM to eliminate chiller failure due
to AC powered failure/battery discharge. Programmed
setpoints are retained in lithium battery-backed RTC
memory for 5 years minimum.
COMMUNICATIONS
• Native communication capability for BACnet
(MS/TP) and Modbus.
• Optional communication available for N2 and
LON via eLink Gateway option.
SECTION 2 – PRODUCT DESCRIPTION
BUILDING AUTOMATION SYSTEM
INTERFACE
The Microprocessor Board can accept a 4 to 20 milliamp, or 0 to10VDC 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 a
PWM 4 to 20 milliamp or 0 to 10VDC input signal or up to two stages of demand (load) limiting
depending on model.
• The standard control panel can be directly connected to a Johnson Controls Building Automated
System.
POWER PANEL
Each panel contains:
• Compressor power terminals
• Compressor motor starting contactors per I.E.C.**
• Control power terminals to accept incoming for
110-1-50 control power
• Fan contactors and overload current protection
The power wiring is routed through liquid-tight conduit to the compressors and fans.
ACCESSORIES AND OPTIONS
Power Options
Compressor Power Connections
Single-point terminal block connection(s) are provided as standard. The following power connections are
available as options. (See electrical data for specific
voltage and options availability.) (Factory-mounted)
Single-Point Supply Terminal Block
Includes enclosure, terminal-block and interconnecting
wiring to the compressors. Separate external protection
must be supplied, by others, in the incoming compressor-power wiring. (Do not include this option if either
the Single-Point Non-Fused Disconnect Switch or Single-Point Circuit Breaker options have been included.)
* Intensity of Protection European Standard
** International Electrotechnical Commission
JOHNSON CONTROLS
17
2
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
Single-Point Non-Fused Disconnect Switch
Compressor, Piping, Evaporator Options
Unit-mounted disconnect switch with external, lockable
handle (in compliance with Article 440-14 of N.E.C.),
can be supplied to isolate the unit power voltage for 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.
Low Temperature Glycol
Single-Point Circuit Breaker
A unit mounted circuit breaker with external, lockable
handle (in compliance with N.E.C. Article 440-14), can
be supplied to isolate the power voltage for servicing.
(This option includes the Single-Point Power connection.)
Control Transformer
Converts unit power voltage to 115-1-60 (2.0 or 3.0
KVA capacity). Factory mounting includes primary
and secondary wiring between the transformer and the
control panel. (Factory-mounted)
Control Options
Ambient Kit (Low)
Units will operate to 25°F (-3.9°C). This accessory includes all necessary components to permit chiller operation to 0°F (-18°C). (This option includes the Discharge
Pressure Transducer / Readout Capability option.) For
proper head pressure control in applications below 30°F
(-1°C) where wind gusts may exceed 5 mph, it is recommended that Optional Condenser Louvered Enclosure
Panels also be included. (Factory-mounted)
High Ambient Kit With Sunshield
Allows units to operate when the ambient temperature
is above 115°F (46°C). Includes sun shield panels and
discharge pressure transducers.
Language LCD and Keypad Display
Spanish, French, German, and Italian unit LCD controls and keypad display available. Standard language
is English.
18
Replaces standard Thermostatic Expansion Valves
with Electronic Expansion Valves to achieve leaving
glycol temperatures as low as 10°F (-12°C). Required
for any leaving liquid temperature below 30°F (-1°C).
Electronic Expansion Valves permit operation at both
low temperatures and comfort cooling applications
without a capacity loss or derate at either condition.
(Factory installed)
Chicago Code Relief Valves
Unit will be provided with relief valves to meet Chicago code requirements. (Factory-Mounted)
Service Suction Isolation Valve
Service suction (ball-type) isolation valves are added
to unit per system (discharge service ball-type isolation
valve is standard on each circuit). (Factory-Mounted)
Hot Gas By-Pass
Permits continuous, stable operation at capacities below
the minimum step of compressor unloading to as low
as 5% capacity (depending on both the unit and operating conditions) by introducing an artificial load on the
cooler. Hot gas by-pass is installed on only refrigerant
system #1 on two-circuited units. (Factory-Mounted)
Flanges (ANSI/AWWA C-606 couplings Type)
Consists of (2) Flange adapter for grooved end pipe (standard 150 psi [10.5 bar] cooler). (Not available on optional
DX cooler 300 PSIG DWP waterside.) (Field-mounted)
Flow Switch
A thermal dispersion type flow switch provides accurate, low maintenance flow proving and is included
standard. It is factory wired and installed in the extension pipe between evaporator outlet and edge of chiller. The extension pipe is secured to the chiller frame
for shipping to avoid risk of damage to evaporator
and is easily attached to the evaporator at startup using the supplied ANSI/AWWA C-606 connector. The
flow switch can be deleted if alternate or existing flow
switch is field supplied.
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
Heat Recovery Condenser
A partially condensing refrigerant to liquid condenser
recovers heat off both refrigerant circuits and rejects
into a single liquid circuit. Factory installed between
the compressor discharge and the condenser (air) coils
to capture the maximum amount of heat. Capable of
recovering up to 85% total heat of rejection (cooling
load plus work input); temperatures as high as 140°F
(60°C) are possible.
Hydro-Kit
Factory installed Hydro-Kit suitable for water and 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 balancing
valve, discharge check valve, discharge shutoff valve,
thermal dispersion flow switch, pressure ports, inlet
wye-strainer, bleed and drain valves and frost protection.
SECTION 2 – PRODUCT DESCRIPTION
• Wire Panels (Full Unit) - Consists of welded
wire-mesh guards mounted on the exterior of the
unit. Prevents unauthorized access, yet provides
free air flow. (Factory-Mounted)
• Wire/Louvered Panels - Consists of welded
wire-mesh panels on the bottom part of unit and
louvered panels on the condenser section of the
unit. (Factory-Mounted)
• Louvered Panels (MCHX Condenser Only)
- Louvered Panels are mounted on the sides and
ends of the MCHX condenser for protection.
(Factory-Mounted)
• Louvered Panels (Full Unit) - Louvered panels
surround the front, back, and sides of the unit.
They prevent unauthorized access and visually
screen unit components. Unrestricted air flow
is permitted through generously sized louvered
openings. This option is applicable for any outdoor design ambient temperature up to 115°F
(46°). (Factory-Mounted)
Service shut off valves, additional pressure ports and expansion tanks are optional within the hydro-kit option.
MCHX End Hail Guard
Louvered panel attached to exposed MCHX end. (Factory-Mounted)
Condenser and Cabinet Options
Sound Attenuation
MCHX Condenser protection against corrosive environments is available by choosing any of the following
options. For additional application recommendations,
refer to FORM 150.12-ES1. (Factory-Mounted)
Post-Coated Dipped MCHX Condenser
The unit MCHX is constructed with post dipped-epoxy
MCHX condenser. This is recommended for seashore
and other corrosive applications (with the exception of
strong alkalies, oxidizers and wet bromine, chlorine
and fluorine in concentrations greater than 100 ppm).
Enclosure Panels (Unit)
Tamperproof Enclosure Panels prevent unauthorized
access to units. Enclosure Panels can provide an aesthetically pleasing alternative to expensive fencing.
Additionally, for proper head pressure control, Johnson
Controls recommends the use of Condenser Louvered
Panels for winter applications where wind gusts may
exceed five miles per hour. The following types of enclosure panels are available:
JOHNSON CONTROLS
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 5/8” (15mm) thickness; one layer of antivibrating heavy material thickness of 1/8” (3mm).
Both are closed by two sheets of welded PVC,
reinforced for temperature and UV resistance.
(Factory-Mounted)
• Ultra Quiet Fans - Lower RPM, 8-pole fan motors are used with steeper-pitch fans. (FactoryMounted)
Vibration Isolators
Level adjusting, spring type 1” (25.4mm) or seismic
deflection or neoprene pad isolators for mounting under unit base rails. (Field-mounted)
19
2
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
1
2
3
POWER
PANEL
POWER
PANEL
5
6
4
ITEM
DESCRIPTION
1
Fan Assemblies
2
MCHX Condenser
3
Control Panel
4
Compressors
5
Receiver Included with Optional Heat
Recovery Condenser
6
Filter Driers
Figure 1 - UNIT COMPONENTS (FRONT)
20
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
2
2
1
3
4
8
5
6
7
ITEM
DESCRIPTION
1
Fan Deck
2
MCHX Condenser
3
Coil Headers
4
Control and Power Panels
5
Compressors
6
Brazed Plate Evaporator
7
Formed Steel Base Rails
8
Hydro-Kit Pumps And Motors (Optional)
Figure 2 - UNIT COMPONENTS (SIDE)
JOHNSON CONTROLS
21
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
1
2
3
4
7
5
6
LD13248
ITEM
DESCRIPTION
1
Fan Contactor
2
Fan Fuses
3
Fan Contactor
4
Disconnect Switch (Optional)
5
XTBF1
6
Compressor Contactors
7
Compressor Overloads
Figure 3 - POWER PANEL COMPONENTS
22
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
2
1
3
4
2
5
6
12
7
9
11
8
10
LD13248
ITEM
DESCRIPTION
1
Fan Contactor
2
Fan Fuses
3
Control Relay
4
Microcomputer Control Center
5
Display
6
Keypad
7
XTBC1
8
Microboard
9
XTCB2
10
XTBF2
11
Compressor Contactors
12
Compressor Overloads
Figure 4 - POWER PANEL / CONTROL COMPONENTS
JOHNSON CONTROLS
23
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
PRODUCT IDENTIFICATION NUMBER (PIN)
Table 1 - COMPLETE PIN NUMBER DESCRIPTION
FEATURE
FEATURE
DESCRIPTION
MODEL
Model (PIN 1-4)
CAPACITY
OPTION DESCRIPTION
YLAA
0180
0180
0195
0080
0210
0090
0220
0091
0221
0091
0240
0100
0241
0100
0260
0101
0261
0101
0285
0115
0286
0115
0300
0300
0320
0320
0350
0350
0360
0360
0390
0390
0400
0400
0435
0435
0441
0441
0456
0456
0485
0485
0516
0516
UNIT
Unit Designator
(PIN 9)
S
Standard Efficiency
H
High Efficiency
REF.
Refrigerant (PIN 10)
E
R-410A
17
200-208/3/60
28
230/3/60
40
380/3/60
46
460/3/60
50
380-415/3/50
58
575/3/60
X
Across the Line starter
T
Soft Start
A
Design Series A (MicroChannel) Copeland Compressor
B
Design Series C (MicroChannel CE/ETL Panel)
Copeland Compressor
C
Design Series D (MicroChannel) Bitzer Compressor
D
Design Series F (MicroChannel CE/ETL Panel) Bitzer Compressor
B
Development Level B
VOLTS
STARTER
DESIGN
DEV
24
Capacity
(PIN 5-8)
OPTION
Voltage
(PIN 11 & 12)
Starter
(PIN 13)
Design Series
(PIN 14)
Development Level
(PIN 15)
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
TABLE 1 - COMPLETE PIN NUMBER DESCRIPTION (CONT’D)
FEATURE
FEATURE
DESCRIPTION
POWER
Power Field
(PIN 16 &17)
Cntrl Transformer
(PIN 18)
TRANS
PFC
Power Factor Capacitor
(PIN 19)
AMB
BAS
LCD
Ambient Kits
(PIN 20)
Bas Reset/Offset
(PIN 21)
Language
(PIN 22)
RDOUT
Readout Kits
(PIN 23)
SAFETY
Safety Codes
(PIN 24)
SENSOR
PIN 25
PUMP
Motor Current Module
(PIN 26)
REMOTE
Remote Panel
(PIN 27)
SEQ
Sequence Kit
(PIN 28)
TEMP
Leaving Water Temp
(PIN 29,30)
JOHNSON CONTROLS
OPTION
OPTION DESCRIPTION
SX
SP Supply TB
SD
SP NF Disconnect Switch
BX
SP Circuit Breaker w/ Lockable Handle
X
No Control Transformer Required
T
Control Transformer Required
Q
Special Control Transformer Required
X
No Power Capacitor required
C
Power Capacitor required
Q
Special Power Capacitor required
H
High Ambient Kit Standard (factory)
A
Both Low/High Ambient Kit required (factory)
B
Both Low/High Ambient Kit w/Sunshield (factory)
S
High Ambient Kit w/Sunshield (factory)
Q
Special Ambient Kit required
X
BAS Reset/Offset required (standard)
L
LON E-Link Kit (factory)
Q
Special BAS Reset/Offset required
X
English
S
Spanish
C
Chinese (Simplified) (Not Applicable to eLogia)
E
English with Chinese Displayed Board
(Not Applicable to eLogia)
F
French
G
German
2
I
Italian
B
Both Discharge & Suction Pressure Transducer Readout required
Q
Special Pressure Readout required
C
European Saftey Code ( CE )
G
China Safety Code (GB) (Not Applicable to eLogia)
L
N American Safety Code (cUL/cETL)
X
X
Q
Special Quote
C
Motor Current Module
Q
Special Quote
X
No Remote Panel required
Q
Special Remote Panel required
X
No Sequence Kit required
Q
Special Sequence Kit required
NUM
Leaving Water Temp = Temp/Num Deg.
25
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
TABLE 1 - COMPLETE PIN NUMBER DESCRIPTION (CONT’D)
FEATURE
CHICAGO
VALVES
HGBP
Chicago Code Kit
(PIN 31)
Valves
(PIN 32)
Hot Gas Bypass
(PIN 33)
GAUGE
PIN 34
OVERLOAD
PIN 35
OPTION
OPTION DESCRIPTION
X
No Chicago Code Kit required
B
Both Chicago Code & Serv Isolation
C
Chicago Code Kit required
G
Both Suction Service Valve and Dual Relief Valve (Europe only)
R
Dual Relief Valves no Suction Service Valve (Europe only)
S
Service Isolation Valves
Q
Special Chicago Code Kit required
X
Standard Valves Req’d
E
Electronic Expansion Valve
Q
Special Optional Valves Req’d
X
No Hot Gas Bypass required
1
Hot Gas Bypass required - 1 circuit
Q
Special Hot Gas Bypass required
X
X
Q
Special Quote
X
X
Q
Special Quote
X
X
Q
Special Quote
PIN36
PIN 36
HTR
Crankcase Heater
(Pin 37)
H
Crankcase Heater Standard
Q
Special Crankcase Heater required
DWP
DWP
(PIN 38)
X
150psig DWP Waterside
Q
Special Quote
X
Standard Insulation
INS
Insulation
(PIN 39)
FLANGES
FLOW
VESSEL
26
FEATURE
DESCRIPTION
Flanges
(PIN 40)
Flow Switch
(PIN 41)
Vessel Codes
(PIN 42)
CLR
Cooler
(PIN 43)
PIN44
PIN 44
COILS
Coils
(PIN 45)
D
Double Thick Insulation
Q
Special Insulation required
X
No Flanges required
V
Victaulic Flanges required
Q
Special Flanges required
X
No Flow Switch required
S
One Flow Switch Required
Y
Flow Switch With Extension Kit
A
ASME Pressure Vessel Codes
E
PED Pressure Vessel Codes
G
GB Pressure Vessel Codes
Q
Special Quote
X
Standard Cooler required
Q
Special Cooler required
X
X
Q
Special Quote
X
Aluminum Coils
P
Post-Coated Dipped Coils
Q
Special Coils
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
TABLE 1 - COMPLETE PIN NUMBER DESCRIPTION (CONT’D)
FEATURE
FEATURE
DESCRIPTION
OPTION
Heat Recovery
(PIN 46)
X
No Option required
HEAT
H
Heat Recovery
Q
Special Quote
FANMOTORS
ENCL
ACOUSTIC
SRDOCS
PIN 51
FANS
PAINT
JOHNSON CONTROLS
Fan Motors
(PIN 47)
Enclosure Panels
(PIN 48)
Acoustic Blanket
(PIN 49)
SR Documents
(PIN 50)
PIN 51
Sound Fans
(PIN 52)
PIN 53
OPTION DESCRIPTION
X
TEAO Fan Motors
Q
Special Fan Motors required
X
No Enclosure required
1
Wire (Full Unit) Encl Panels (factory)
2
Wire (Full Unit) Encl Panels (field)
3
Wire/Louvered Encl Panels (factory)
4
Wire/Louvered Encl Panels (field)
5
Louvered (Cond only) Encl Panels (factory)
6
Louvered (Cond only) Encl Panels (field)
7
Louvered (Full Unit) Encl Panels (factory)
8
Louvered (Full Unit) Encl Panels (field)
9
End Louver (End Hail Guard) Encl Panels (factory)
A
End Louver (End Hail Guard) Encl Panels (field)
B
Aesthetic Panel Kit only (factory)
C
Aesthetic Panel Kit only (field)
D
Aesthetic Panel Kit plus Hail Guards (factory)
E
Aesthetic Panel Kit plus Hail Guards (field)
Q
Special Enclosure Panels
X
No Acoustic Blanket required
B
Acoustic Blanket Required
E
Acoustic Enclosure
Q
Special Acoustic Blanket required
X
No Documents Required
A
Base, Material & Witness Documents
B
Base Document
M
Base & Material Documents
W
Base & Witness Documents
Q
Special Quote
X
X
Q
Special Quote
X
Standard Low Sound Fans required
A
High Airflow Fans required (Vendor Specific)
E
Low Sound Fans required (Vendor Specific)
G
High AirFlow Fans required
L
Ultra Quiet Fans required
S
High Static Fans required (Vendor Specific)
U
Ultra Quiet Fans required (Vendor Specific)
2
Two Speed Fans required (Vendor Specific)
Q
Special Sound Fans required
X
X
Q
Special Quote
2
27
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
TABLE 1 - COMPLETE PIN NUMBER DESCRIPTION (CONT’D)
FEATURE
ISOL
FEATURE
DESCRIPTION
Vibration Isolators
(PIN 54)
PIN 55
PIN 55
PIN 56
PIN 56
SHIP
PIN 58
PKG
PKGOPT
Ship Instructions
(PIN 57)
OPTION
X
No Isolators required
1
1” Deflection Isolators required
N
Neoprene Isolators required
S
2” Deflection Isolators required
Q
Special Isolators required
Marketing Purposes Only!
Marketing Purposes Only!
X
No Containerization required with Shipping Bag
A
Buy American Act Compliance with Shipping Bag
B
Both Buy American Act Compliance and Container Shipped without Shipping Bag (Factory Prep)
C
Container Shipped without Shipping Bag (Factory Load)
D
Container Shipped with Shipping Bag (Factory Load US Port)
E
Container Shipped with Shipping Bag (Factory Load Mexico Port)
F
Container Shipped with Shipping Bag (Factory Prep)
G
Both Buy America Act Compliance and Container Shipped with
Shipping Bag (Factory Prep)
M
Container Shipped without Shipping Bag (Factory Load Mexico
Port)
N
No Containerization required without Shipping Bag
P
Container Shipped without Shipping Bag (Factory Prep)
U
Buy American Act Compliance without Shipping Bag
Q
Special quote
PIN 58
Pump Package
(PIN 59)
Pump Package Options
(PIN 60)
Marketing Purposes Only!
X
A -V
LOC
28
Pump Kit A to V required
Special quote
X
No option required
1
Single Pump, standard
2
Single Pump, full feature
3
Dual Pump, standard
4
Dual Pump, full feature
PIN 61
Mfg Location
No Pump required
Q
Q
PIN 61
OPTION DESCRIPTION
Special quote
Marketing Purposes Only!
GZ
Guangzhou, China
MTY
Monterrey, Mexico
SAT
San Antonio, Texas
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 2 – PRODUCT DESCRIPTION
Control Functions:
DV - Display Value
CHT - Chilled Liquid Temperature
HPC - High Pressure Cutout
LPC - Low Pressure Cutout
HPL - High Pressure Load Limiting
LTC - Low Temperature Cutout
Fans
Fans
2
Components:
Pressure Relief Valve
Service (Ball) Valve
Expansion Valve
Condenser
S
Solenoid Valve
Sight Glass
Sensor Pressure
or Temperature
585 PSIG
PS
DV
HPL
HPC
Service (Stop) Access Valve
P
PS
650 PSIG
ZCPR-3
ZCPR-2
Filter Drier
(Removable Core)
See P.R.V.
Options
ZCPR-1
Pressure Switch
Chilled
Liquid
450 PSIG
Evaporator
Compressors
DV
LPC
P
Ambient Air Sensor
DV
HTC
LTC
T
Chilled
Liquid
S
-YLLSV
T
DV
CHT
LTC
LD13139
Figure 5 - PROCESS AND INSTRUMENTATION DIAGRAM
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 at the compressor where pressure and superheat are increased. The
JOHNSON CONTROLS
high pressure vapor is 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 entering to the cooler.
29
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
THIS PAGE INTENTIONALLY LEFT BLANK
30
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 3 – HANDLING AND STORAGE
DELIVERY AND STORAGE
INSPECTION
To ensure consistent quality and maximum reliability,
all 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.
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 on the carrier’s freight bill
and a claim entered in accordance with the instructions
given on the advice note.
If the unit is to be put into storage, prior to installation,
the following precautions should be observed:
Major damage must be reported immediately to your
local Johnson Controls representative.
• The chiller must be “blocked” so that the base is
not permitted to sag or bow.
• Ensure that all openings, such as water connections, are securely capped.
• Do not store where exposed to ambient air temperatures 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
is minimal activity in order to limit the risk of accidental physical damage.
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 unit must only be lifted by the base
frame at the points provided. Never move
the unit on rollers, or lift the unit using a
forklift truck.
Care should be taken to avoid damaging the condenser
cooling fins when moving the unit.
• To prevent inadvertent operation of the pressure
relief devices the unit must not be steam cleaned.
• It is recommended that the unit is periodically inspected during storage.
JOHNSON CONTROLS
31
3
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 3 – HANDLING AND STORAGE
D
A
B
Control Panel
Y
C
X
LD18120
4 Fan Units
E
F
A
B
C
Control Panel
Y
D
X
LD18121
5 - 10 Fan Units
Figure 6 - UNIT RIGGING/LIFTING
32
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 3 – HANDLING AND STORAGE
LIFTING USING LUGS
LIFTING USING SHACKLES
Units are provided with lifting holes in the base frame
which accept the accessory lifting lug set as shown in
the figure below. The lugs (RH and LH) should be inserted into the respective holes in the base frame and
turned so that the spring loaded pin engages into the
hole and the flanges on the lug lock behind the hole.
The lugs should be attached to the cables/chains using
shackles or safety hooks.
The shackles should be inserted into the respective
holes in the base frame and secured from the inside.
CORRECT
LIFTING HOLE
IN BASE FRAME
LUG
INCORRECT
LUG
Use spreader bars to avoid lifting chains hitting the
chiller. Various methods of spreader bar arrangements
may be used, keeping in mind the intent is to keep the
unit stable and to keep the chains from hitting the chiller and causing damage.
Lifting Instructions are placed on a label on the chiller
and on the shipping bag.
FLANGE
FLANGE
LOCKING PIN
LIFTING HOLE
IN BASE FRAME
LOCKING PIN
LUG
LOCKING
PIN
FLANGE
JOHNSON CONTROLS
33
3
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 3 – HANDLING AND STORAGE
LD18119
Figure 7 - WARNING
Rigging and lifting should only be done by
a professional rigger in accordance with a
written rigging and lifting plan. The most
appropriate rigging and lifting method
will depend on job specific factors, such
as the rigging equipment available and
site needs. Therefore a professional rigger must determine the rigging and lifting
method to be used and it is beyond the
scope of the manual to specify rigging
and lifting details.
34
LIFTING WEIGHTS
Refer to the unit nameplate for unit shipping weight.
Note that weight may vary depending on unit configuration at the time of lifting. See page 46 for further
information regarding shipping and operating weights.
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 4 – INSTALLATION
To ensure warranty coverage, this equipment must be commissioned and serviced
by an authorized Johnson Controls
service mechanic or a qualified service
person experienced in chiller installation.
Installation must comply with all applicable codes, particularly in regard to electrical wiring and other safety elements
such as relief valves, HP cutout settings,
design working pressures, and ventilation
requirements consistent with the amount
and type of refrigerant charge.
Lethal voltages exist within the control
panels. Before servicing, open and tag
all disconnect switches.
INSTALLATION CHECKLIST
The following items, 1 through 6, 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
connections until piping is ready for attachment.
Check water piping to ensure cleanliness.
4. Pipe unit using good piping practice (see ASHRAE
handbook section 215 and 195).
5. Check to see that wiring is tight and meets NEC
and local codes.
6. Check to see that the unit is installed and operated
within limitations (Refer Operational Limitations
on page 43).
STARTUP/COMMISSIONING
The following pages outline detailed procedures to be
followed to install and start-up the chiller.
LOCATION AND CLEARANCES
Units are designed for outdoor installations on ground
level, rooftop, or beside a building. Location should
be selected for minimum sun exposure and to insure
adequate supply of fresh air for the condenser. The
units must be installed with sufficient clearances for air
entrance to the condenser coil, for air discharge away
from the condenser, and for servicing access.
JOHNSON CONTROLS
In installations where winter operation is intended and
snow accumulations are expected, additional height
must be provided to ensure normal condenser air flow.
Clearances are listed in Figure 23 on page 83.
Foundation
The unit should be mounted on a flat and level foundation, floor, or rooftop capable of supporting the entire
operating weight of the equipment. See Physical Data
YLAA0180 – YLAA0516 50Hz on page 46 for operating weight. If the unit is 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 building foundations as noise and vibration may
be transmitted. Mounting holes (5/8” dia.) are provided
in the steel channel for bolting the unit to its foundation
(see Dimensions on page 76).
For ground level installations, precautions should be
taken to protect the unit from tampering by or injury to
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 is a result of compressor and fan operation.
35
4
SECTION 4 – INSTALLATION
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SPRING ISOLATORS (OPTIONAL)
When ordered, isolators will be furnished. Identify the
isolator, locate at the proper mounting point, and adjust
per instructions.
COMPRESSOR MOUNTING
The compressors are mounted on four (4) rubber 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 compressor access when laying out water piping. Routing the water piping too close to
the unit could make compressor servicing/
replacement difficult.
Hand stop valves should be installed in all lines to 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.
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.
36
The piping to and from the cooler must be designed to
suit the individual installation. It is important that the
following considerations be observed:
1. The chilled liquid piping system should be laid out
so that the circulating pump discharges directly into
the cooler. The suction for this pump should be 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 on page 46 (Physical Data).
3. A 1/16” mesh strainer is provided at the cooler inlet
line just ahead of the cooler. This is important to
protect the cooler from entrance of large particles
which could cause damage to the evaporator.
4. All chilled liquid piping should be thoroughly
flushed to free it from foreign material before the
system is placed into operation. Use care not to
flush any foreign material into or through the cooler.
5. As an aid to servicing, thermometers and pressure
gauges should be installed in the inlet and outlet water lines.
6. The chilled water lines that are exposed to outdoor
ambients should be wrapped with supplemental
heater cable and insulated to protect against freezeup 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.
7. A chilled water flow switch, (either by Johnson
Controls or others) MUST be installed in the leaving water piping of the cooler. If the factory wired
flow switch and extension pipe kit is not selected,
the field installed flow switch must be installed so
that there is a straight horizontal run of at least 5 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 and 14 of XTBC1 located in the
control panel, as shown on the unit wiring diagram.
The Flow Switch MUST NOT be used
to start and stop the chiller (i.e. starting
and stopping the chilled water pump). It
is intended only as a safety switch.
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 4 – INSTALLATION
PIPEWORK ARRANGEMENT
The following are suggested pipework arrangements
for single unit installations, for multiple unit installations, each unit should be piped as shown.
Recommendations of the Building Services Research Association.
When ducting is to be fitted to the fan discharge it is
recommended that the duct should be the same crosssectional 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 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.
LD06596
ISOLATING VALVE - NORMALLY OPEN
ISOLATING VALVE - NORMALLY CLOSED
Units are supplied with outlet guards for safety and to
prevent damage to the fan blades. If these guards are
removed to fit duct work, adequate alternative precautions must be taken to ensure persons cannot be harmed
or put at risk from rotating fan blades.
FLOW REGULATING VALVE
FLOW MEASUREMENT DEVICE
WIRING
Liquid Chillers are shipped with all factory-mounted
controls wired for operation.
STRAINER
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 the Electrical Data tables.
PRESSURE TAPPING
FLOW SWITCH
FLANGED CONNECTION
LD06597A
Figure 8 - CHILLED LIQUID SYSTEM
Fan Discharge Ducting
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.
JOHNSON CONTROLS
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 recirculation of air when only one of the fans is running.
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 is used to supply power to the chiller, AL-CU
compression fittings should be used to transition from
37
4
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 4 – INSTALLATION
aluminum to copper. This transition should be done in
an external box separate to the power panel. Copper
conductors can then be run from the box to the chiller.
A 110-1-50, 15 amp source must be supplied for the
control panel through a fused disconnect when a control panel transformer (optional) is not provided (Refer
to Figure 9 on page 39).
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 SECTION 8 – UNIT OPERATION for a detailed description of operation concerning aforementioned contacts and inputs.
RELIEF VALVES
Relief valves are located on both the high and low
pressure side of the piping. High side relief valve pressure setting is 650 PSIG. Low side relief valve pressure
setting is 450 PSIG.
HIGH PRESSURE CUTOUT
A high pressure cutout is installed in the discharge piping of each system. The cutout opens at 585 PSIG plus
or minus 10 PSIG and closes at 440 PSIG plus or minus 25 PSIG.
Evaporator Pump Start Contacts
Terminal block XTBC2 – Terminals 23 (110VAC) to
24, are nor­mally- open contacts that can be used to
switch field supplied power to provide a start signal
to the evapo­rator pump contactor. The contacts will be
closed when any of the following conditions occur:
1. Low Leaving Chilled Liquid Fault
2. Any compressor is running
3. Daily schedule is not programmed OFF and the
Unit Switch is ON
The pump will not run if the micro panel has been
powered up for less than 30 seconds, or if the pump
has run in the last 30 seconds, to prevent pump motor
overheating. Refer to Figure 11 on page 41 and unit
wiring dia­gram.
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 XTBC2 – Terminals
27 to 28 for system 2. Refer to Figure 4 on page 23,
Figure 11 on page 41 and unit wiring diagram.
38
Alarm Status Contacts
Normally‑open contacts are available for each re­
frigerant 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 across terminals 13 and 51 on XTBC1. Refer
to Figure 4 on page 23, Figure 10 on page 40 and
unit wiring diagram.
Remote Emergency Cutoff
Immediate shutdown of the chiller can be 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 Figure 10 on page 40 and unit
wiring diagram.
Remote Temp Reset Input
The Remote Temp Reset input allows reset of the
chilled liquid set­point by supplying a voltage or current
signal field wiring should be connected to XTBC1 –
Terminals A+ to A-. A detailed explanation is provided
in SECTION 7 – UNIT CONTROLS. Refer to Figure 3
on page 22, Figure 4 on page 23 and unit wiring
diagram.
Load Limit Input
Load limiting is a feature that prevents the unit from
loading beyond a desired value. The unit can be “load
limited” either 33%, 40%, 50%, 66% or 80%, depending on the number of compressors on unit. The field
connections are wired to XTBC1 – Terminals 13 to 21,
and work in conjunction with the PWM inputs. A detailed explanation is provided in SECTION 7 – UNIT
CONTROLS. Refer to Figure 4 on page 23, Figure
10 on page 40 and unit wiring diagram.
When using the Load Limit feature, the
PWM feature will not function – SIMULTANEOUS OPERATION OF LOAD
LIMITING AND TEM­P ERATURE
RESET (PWM INPUT) CANNOT BE
DONE.
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 4 – INSTALLATION
SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED
DISCONNECT SWITCH OR CIRCUIT BREAKER
Power Panel
Control Panel
14
4
13 XTBC1
Terminal Block,
NF Disconnect SW
or Circuit Breaker
MICROPANEL
Flow Switch
GRD
1L1 1L2 1L3
L 2
XTBC2
See electrical note 9
Field
Provided
Unit Power
Supply
Field Provided 110-1-50
Micropanel Power Supply if
Control Transformer not supplied.
Field supplied control power wiring
must be run in separate grounded
conduit. Never run control wiring
in the same conduit with power LD13141
wiring.
LD13141
It is possible that multiple sources of
power can be supplying the unit power
panel. To prevent serious injury or death,
the technician should verify that NO
LETHAL VOLTAGES are present inside
the panel AFTER disconnecting power,
PRIOR to working on equipment.
The unit evaporator heater uses 110VAC.
Disconnecting 110VAC power from the
unit, at or below freezing temperatures,
can result in damage to the evaporator
and unit as a result of the chilled liquid
freezing.
Figure 9 - SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED DISCONNECT
SWITCH OR CIRCUIT BREAKER OR CIRCUIT BREAKER
JOHNSON CONTROLS
39
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 4 – INSTALLATION
USER CONTROL WIRING INPUTS
AA+
14
13
50
13
21
13
20
13
19
13
18
13
51
13
INTERNAL
REMOTE
TEMP.
RESET
BOARD
INTERNALWIRING
WIRINGTO
TOOPTIONAL
OPTIONAL
REMOTE
TEMP.
RESET
BOARD
FLOW SWITCH
REMOTE UNLOAD STEP 1
PWM REMOTE TEMP RESET
INTERNAL WIRING TO 2-KCR CONTROL RELAY
INTERNAL WIRING TO 1-KCR CONTROL RELAY
REMOTE START / STOP
XTBC1
LD13130
All externally supplied contacts must be
capable of switching 24VDC / 110 VAC.
Gold contacts are recommended. If supplied contacts are from a Relay / Contactor (Inductive Load), the coil of the Relay
/ Contactor must be suppressed. Typical
suppressor is P/N 031-00808-000.
The unit evaporator heater uses 110VAC.
Disconnecting 120VAC power from the
unit, at or below freezing temperatures,
can result in damage to the evaporator
and unit as a result of the chilled liquid
freezing.
It is possible that multiple sources of
power can be supplying the unit power
panel. To prevent serious injury or death,
the technician should verify that NO
LETHAL VOLTAGES are present inside
the panel AFTER disconnecting power,
PRIOR to working on equipment.
Figure 10 - CONTROL WIRING INPUTS
40
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 4 – INSTALLATION
USER CONTROL WIRING OUTPUTS
Normally jumpered.
Can be used as
EMERGENCY STOP
contacts from an
external source.
140
123
32
31
30
29
28
27
26
25
24
23
5
L
2
2
2
GND
INTERNAL WIRING TO EVAPORATOR HEATER
INTERNAL WIRING TO HOT GAS SOLENOID VALVE
SYSTEM 2 ALARM DRY CONTACTS (OPEN = ALARM)
SYSTEM 1 ALARM DRY CONTACTS (OPEN = ALARM)
SYSTEM 2 RUN DRY CONTACTS (CLOSE = RUN)
4
SYSTEM 1 RUN DRY CONTACTS (CLOSE = RUN)
EVAPORATOR PUMP DRY CONTACTS (CLOSE = RUN
BASED ON DAILY SCHEDULE)
INTERNAL 120 VAC WIRING TO F1 FUSE
INTERNAL 120 VAC WIRING (TYPICALLY FROM CONTROL TRANSFORMER)
INTERNAL NEUTRAL WIRING
INTERNAL NEUTRAL WIRING (TYPICALLY FROM CONTROL TRANSFORMER)
INTERNAL NEUTRAL WIRING
XTBC2
LD13242
All chiller supplied contacts are rated at
110VAC, 100VA, resistive load only, and
must be suppressed at the load by user
if powering an inductive load (Relay /
Contactor Coil). Typical suppressor P/N
is 031-00808-000.
It is possible that multiple sources of
power can be supplying the unit power
panel. To prevent serious injury or death,
the technician should verify that NO
LETHAL VOLTAGES are present inside
the panel AFTER disconnecting power,
PRIOR to working on equipment.
The unit evaporator heater uses 110VAC.
Disconnecting 120VAC power from the
unit, at or below freezing temperatures,
can result in damage to the evaporator
and unit as a result of the chilled liquid
freezing.
Figure 11 - CONTROL WIRING OUTPUTS
JOHNSON CONTROLS
41
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
THIS PAGE INTENTIONALLY LEFT BLANK
42
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
OPERATIONAL LIMITATIONS
Table 2 - TEMPERATURES AND FLOWS
NOMINAL EVAPORATOR WATER FLOW
TEMPERATURE (°C)
MODEL
WATER FLOW (I/S)
AIR ON CONDENSER (°C)
MIN1
MAX2
MIN
MAX
MIN3
MAX4
YLAA0180SE
4.4
12.8
5
12.6
-17.8
51.7
YLAA0210SE
4.4
12.8
5
12.6
-17.8
51.7
YLAA0240SE
4.4
12.8
5
12.6
-17.8
51.7
YLAA0241SE
4.4
12.8
5
12.6
-17.8
51.7
YLAA0285SE
4.4
12.8
6.3
22.4
-17.8
51.7
YLAA0286SE
4.4
12.8
6.3
22.4
-17.8
51.7
YLAA0320SE
4.4
12.8
6.3
24.3
-17.8
51.7
YLAA0360SE
4.4
12.8
6.3
24.3
-17.8
51.7
YLAA0400SE
4.4
12.8
7.6
39.4
-17.8
51.7
YLAA0435SE
4.4
12.8
7.6
39.4
-17.8
51.7
YLAA0485SE
4.4
12.8
9.5
39.4
-17.8
51.7
5
HIGH EFFICIENCY
YLAA0195HE
4.4
12.8
6.3
22.4
-17.8
51.7
YLAA0220HE
4.4
12.8
6.3
22.4
-17.8
51.7
YLAA0221HE
4.4
12.8
6.3
22.4
-17.8
51.7
YLAA0260HE
4.4
12.8
6.3
24.3
-17.8
51.7
YLAA0261HE
4.4
12.8
6.3
24.3
-17.8
51.7
YLAA0300HE
4.4
12.8
6.3
24.3
-17.8
51.7
YLAA0350HE
4.4
12.8
7.6
39.4
-17.8
51.7
YLAA0390HE
4.4
12.8
9.5
39.4
-17.8
51.7
YLAA0441HE
4.4
12.8
9.5
39.4
-17.8
51.7
YLAA0456HE
4.4
12.8
7.6
39.4
-17.8
51.7
YLAA0516HE
4.4
12.8
11.3
41.0
-17.8
51.7
NOTES:
1. For leaving liquid temperature below 40°F (4°C) (to 10°F [-12°C]) optional low temperature glycol kit required. Contact your nearest Johnson Controls Office for application requirements.
2. For leaving liquid temperature higher than 55°F (13°C), contact the nearest Johnson Controls Office for application guidelines.
3. The evaporator is protected against freezing to -20°F (-29°C) with an electric heater as standard.
4. For operation at temperatures above 115°F (46°C), the optional High Ambient Kit will need to be installed on the system.
Excessive flow will cause damage to the
cooler. Do not exceed maximum cooler
flow. Special care should be taken when
multiple chillers are fed by a single pump.
JOHNSON CONTROLS
43
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
HEAT EXCHANGER FLOW, GPM
YLAA Evaporator Pressure Drop (Metric Units)
Water Pressure Drop (kPa)
500
C
E
A
50
F
B
D
5
5
50
Water Flow Rate (m3/h)
EVAPORATOR
A
B
C
D
E
F
YLAA MODELS
180SE, 210SE, 240SE, 241SE
285SE, 286SE, 195HE, 220HE, 221HE
320SE, 360SE, 260HE, 261HE, 300HE
400SE, 435SE, 350HE, 456HE
485SE, 390HE, 441HE
516HE
Table 3 - ETHYLENE AND PROPYLENE GLYCOL CORRECTION FACTORS
ETHYLENE GLYCOL
%
TONS
WEIGHT
PROPYLENE GLYCOL
COMPR
KW
GPM F/
TON
PRESS
DROP
FREEZE
PT
%
WEIGHT
TONS
COMPR GPM F/
KW
TON
PRESS
DROP
FREEZE
PT
10.0
1.0
1.0
24.3
1.0
26.2
10.0
1.0
1.0
24.0
1.0
26.0
20.0
1.0
1.0
25.1
1.1
17.9
20.0
1.0
1.0
24.3
1.1
19.0
30.0
1.0
1.0
25.9
1.2
6.7
30.0
1.0
1.0
24.9
1.3
9.0
40.0
1.0
1.0
26.9
1.4
-8.1
40.0
1.0
1.0
25.6
1.4
-6.0
50.0
1.0
1.0
28.0
1.6
-28.9
50.0
0.9
1.0
26.6
1.7
-28.0
NOTE: Water Pressure Drop Curves may extend past the minimum and maximum water flow ranges.
44
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
THIS PAGE INTENTIONALLY LEFT BLANK
JOHNSON CONTROLS
45
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
PHYSICAL DATA YLAA0180 – YLAA0516 50HZ
Table 4 - PHYSICAL DATA (ENGLISH)
YLAA
STANDARD EFFICIENCY UNITS
GENERAL UNIT DATA 0180SE 0210SE 0240SE 0241SE 0285SE 0286SE 0320SE 0360SE 0400SE 0435SE 0485SE
NOMINAL TONS,
R-410A1
53.3
57.7
63.2
62.1
78.2
77.0
87.7
97.6
109.2
118.4
132.1
COP
2.95
2.44
2.7
2.8
2.70
2.61
2.55
2.65
2.55
2.69
2.56
IPLV
4.58
3.87
4.06
4.25
4.27
4.46
4.19
4.41
4.29
4.41
4.32
Length (mm)
2912
2912
2912
2912
2912
2912
2912
3614
3614
3614
3614
Width (mm)
2242
2242
2242
2242
2235
2235
2235
2242
2242
2242
2242
Height (mm)
2397
2397
2397
2397
2397
2397
2397
2397
2397
2397
2397
2
2
2
2
2
2
2
2
2
2
2
Refrigerant Charge,
Operating R-410A,
Ckt 1 / Ckt 2, kg
21/15
25/15
24/23
24/23
26/24
26/24
26/26
30/26
31/29
31/29
32/30
Oil Charge, Ckt 1 /
Ckt 2, Liters
9/6
11/6
10/10
9/9
12/10
9/11
11/11
16/9
16/11
16/14
16/16
Shipping Weight (kg)
1668
1702
1801
1768
1891
1831
1995
2781
2834
2604
2705
Operating Weight (kg)
1689
1723
1821
1789
1916
1857
2028
2814
2873
2642
2755
3/2
2/2
2/2
3/3
2/2
3/2
2/2
3/3
3/2
3/3
3/3
7.4
7.4
10.0
10.0
10.0
10.0
10.0
12.6
12.6
15.0
15.0
1
1
1
1
1
1
1
1
1
1
1
2/2
2/2
2/2
2/2
2/2
2/2
2/2
3/2
3/2
3/3
3/3
2
2
2
2
2
2
2
2
2
2
2
Fan RPM
950
950
950
950
950
950
950
950
950
950
950
Total Chiller M3/SEC
20
20
28
28
28
28
28
35
35
42
42
Water Volume, Liters
20.4
20.4
20.4
20.4
25.4
25.4
33.3
33.3
37.9
37.9
50.0
Maximum Water Side
Pressure, Bar
10.3
10.3
10.3
10.3
10.3
10.3
10.3
10.3
10.3
10.3
10.3
Maximum Refrigerant
Side Pressure, Bar
31
31
31
31
31
31
31
31
31
31
31
Water Connections
Size, Inch
3
3
3
3
3
3
3
3
3
3
3
Number Of Refrigerant
Circuits
COMPRESSORS, SCROLL TYPE
1Compressors Per
Circuit
CONDENSER
Total Face Area M2
Number Of Rows
CONDENSER FANS
Number Of Fans,
CKT 1/CKT 2
Fan HP
EVAPORATOR
NOTES:
1. kW = Compressor Input Power.
2. EER = Chiller EER (includes power from compressors, fans, and the control panels 0.8 kW).
3. Rated in accordance with AHRI Standard 550/590 at an air on condenser temperature of 95°F and a leaving chilled water temperature of 44°F.
4. Additional rating information can be provided by your local Johnson Controls Sales Office.
46
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
YLAA
HIGH EFFICIENCY UNITS
0195HE
0220HE
0221HE
0260HE
0261HE
0300HE
0350HE
0390HE
441HE
456HE
516HE
55.6
60.4
60.1
71.7
70.5
87.8
98.1
109.6
121.9
128.1
147.9
3.07
3.17
3.23
3.02
3.10
3.1
3.1
3.03
3.04
3.07
3.05
4.85
4.39
4.84
4.43
4.75
4.57
4.48
4.63
4.62
4.66
4.86
2912
2912
2912
2912
2912
3614
3614
3614
4807
4807
4807
2242
2242
2242
2242
2242
2235
2235
2242
2242
2242
2242
2397
2397
2397
2397
2397
2397
2397
2397
2393
2393
2393
2
2
2
2
2
2
2
2
2
2
2
24/17
25/23
25/23
25/25
25/25
28/24
29/29
33/28
38/28
37/36
40/40
9/6
10/8
9/6
10/10
9/9
12/10
11/11
16/9
16/11
16/14
16/16
1688
1750
1700
1854
1822
2137
2301
2458
3294
3444
3561
1714
1776
1725
1887
1855
2170
2339
2508
3344
3482
3615
3/2
2/2
3/2
2/2
3/3
2/2
2/2
3/3
3/2
3/3
3/3
7.4
7.4
7.4
10.0
10.0
10.0
10.0
12.6
17.6
20.1
20.1
1
1
1
1
1
1
1
1
1
1
1
2/2
2/2
2/2
2/2
2/2
2/2
2/2
4/2
4/3
4/4
4/4
2
2
2
2
2
2
2
2
2
2
2
950
950
950
950
950
950
950
950
950
950
950
20
20
20
28
28
35
42
42
49
56
56
25.4
25.4
25.4
33.3
33.3
33.3
37.9
50.0
50
37.9
54
10.3
10.3
10.3
10.3
10.3
10.3
10.3
10.3
10.3
10.3
10.3
31
31
31
31
31
31
31
31
31
31
31
3
3
3
3
3
3
3
3
3
3
3
JOHNSON CONTROLS
5
47
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
ELECTRICAL DATA
Table 5 - MICROPANEL POWER SUPPLY
UNIT VOLTAGE
MODELS W/O
CONTROL
TRANS
UNIT
VOLTAGE
MODELS W/
CONTROL
TRANS
CONTROL
POWER
MCA
NOTE A
115-1-60/50
OVER CURRENT PROTECTION,
SEE NOTE B
NF DISC SW
MIN
MAX
15A
10A
15A
30 A / 240V
-17
200-1-60
15A
10A
15A
30 A / 240V
-28
230-1-60
15A
10A
15A
30 A / 240V
-40
380-1-60
15A
10A
15A
30 A / 480V
-46
460-1-60
15A
10A
15A
30 A / 480V
-50
380/415-1-50
15A
10A
15A
30A / 415V
-58
575-1-60
15A
10A
15A
30 A / 600V
NOTE: A. Minimum #14 AWG, 75 °C, Copper Recommended.
B. Minimum and Maximum Over Current Protection, Dual Element Fuse or Circuit Breaker.
The unit evaporator heater uses 110VAC.
Disconnecting 120VAC power from the
unit, at or below freezing temperatures,
can result in damage to the evaporator
and unit as a result of the chilled liquid
freezing.
It is possible that multiple sources of
power can be supplying the unit power
panel. To prevent serious injury or death,
the technician should verify that NO
LETHAL VOLTAGES are present inside
the panel AFTER disconnecting power,
PRIOR to working on equipment.
Voltage Limitations
The following voltage limitations are absolute and
operation beyond these limitations may cause serious
damage to the compressor.
Table 6 - VOLTAGE RANGE
VOLTAGE CODE
-17
-28
-40
-46
-50
-58
VOLTAGE RANGE
UNIT POWER
MIN.
MAX.
200-208/3/60
230-3-60
380-3-60
460-3-60
380/415-3-50
575-3-60
180
207
342
414
342
517
220
253
440
506
440
633
COMPRESSOR HEATERS
Compressor heaters are standard. ZP180 compressors
utilize 70W heaters; ZP235, compressor use 120W
heaters and ZP285 and ZP385 utilize 150W heaters. If
power is OFF more than two hours, the crankcase heat-
48
ers must be energized for 18 – 24 hours prior to restarting a compressor. This will assure that liquid slugging
and oil dilution does not damage the compressors on
start.
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
Table 7 - PUMP ELECTRICAL DATA (50 HZ)
PUMP MODEL
HP
RPM
400V-3-50HZ
FLA
LRA
A, G, L
10
3600
13.7
85.8
B, H, N
15
3600
19.7
132.0
C
3.0
3600
4.4
31.4
D, I
N/A
3600
N/A
N/A
E, J
5.0
3600
6.8
47.6
F, K
7.5
3600
10.2
131.0
M
3
1800
4.5
31.4
O
20
3600
27.2
162.4
P
N/A
1800
N/A
N/A
5
JOHNSON CONTROLS
49
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
Table 8 - ELECTRICAL DATA WITHOUT PUMPS
CHILLER MODEL
VOLT
HZ
MCA
(DOES NOT
INCLUDE
XFR AMPS)
YLAA0180SE
YLAA0195HE
YLAA0210SE
YLAA0220HE
YLAA0221HE
YLAA0240SE
YLAA0241SE
YLAA0260HE
YLAA0261HE
YLAA0285SE
YLAA0286SE
YLAA0300HE
YLAA0320SE
YLAA0350HE
YLAA0360SE
YLAA0390HE
YLAA0400SE
YLAA0435SE
YLAA0485SE
YLAA0441HE
YLAA0456HE
YLAA0516HE
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
136
136
177
159
128
189
184
189
184
218
216
222
248
256
272
281
306
327
365
314
335
378
MIN N/F DISC SW
150
150
200
250
150
250
250
250
250
250
250
250
400
400
400
400
400
400
600
400
400
600
MIN ELEM FUSE & MAX DUAL ELEM
MIN CB
FUSE MAX CB
150
150
200
175
150
225
200
225
200
250
250
250
300
300
300
300
350
350
400
350
350
400
150
150
225
200
150
225
200
225
200
250
250
250
300
300
300
300
350
350
400
350
350
400
NOTE:
• Reference PIN 59 for Pump Model.
• Use this table along with Pump Electrical Data to determine electrical data of the unit plus the pump.
• Does not include control transformer.
Table 9 - TRANSFORMER LOAD
VOLT
400
50
KVA
2
3
5.0
7.5
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
COMPR 1
SYSTEM # 1
COMPR 2
COMPR 3
RLA
LRA
RLA
LRA
RLA
LRA
QTY
FLA
25.0
25.0
54.5
54.5
25.0
54.5
25.0
54.5
25.0
54.5
25.0
54.5
54.5
54.5
54.5
54.5
54.5
54.5
54.5
54.5
54.5
54.5
198
198
310
310
198
310
198
310
198
310
198
310
310
310
310
310
310
310
310
310
310
310
25.0
25.0
54.5
25.0
25.0
25.0
25.0
25.0
25.0
54.5
25.0
54.5
54.5
54.5
54.5
54.5
54.5
54.5
54.5
54.5
54.5
54.5
198
198
310
198
198
198
198
198
198
310
198
310
310
310
310
310
310
310
310
310
310
310
25.0
25.0
198
198
25.0
198
25.0
198
25.0
198
25.0
198
54.5
54.5
54.5
54.5
54.5
54.5
54.5
54.5
310
310
310
310
310
310
310
310
2
2
2
2
2
2
2
2
2
2
2
3
2
3
3
4
3
3
3
4
4
4
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
JOHNSON CONTROLS
COMPR 1
SYSTEM # 2
COMPR 2
COMPR 3
LRA
RLA LRA
RLA
LRA
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
21.8
21.8
21.8
21.8
21.8
25.0
25.0
54.5
25.0
54.5
54.5
54.5
54.5
54.5
25.0
54.5
54.5
41.9
54.5
54.5
41.9
54.5
21.8
21.8
21.8
25.0
25.0
25.0
25.0
25.0
25.0
25.0
54.5
25.0
54.5
54.5
25.0
25.0
54.5
41.9
54.5
54.5
41.9
54.5
140
140
140
198
198
198
198
198
198
198
310
198
310
310
198
198
310
272
310
310
272
310
FAN
140
140
140
198
198
310
198
310
198
310
310
310
310
310
198
310
310
272
310
310
272
310
RLA
LRA
25.0
198
25.0
198
25.0
198
41.9
54.5
272
310
41.9
54.5
272
310
FAN
QTY
FLA
LRA
2
2
2
2
2
2
2
2
2
2
2
2
2
3
2
2
2
3
3
3
4
4
1.4
1.4
1.4
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
3.4
3.4
3.4
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
19.0
51
5
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
Table 10 - WIRING LUGS
MODEL
VOLT HZ
YLAA
0180SE
400
50
0210SE
400
50
0240SE
400
50
0241SE
400
50
0285SE
400
50
0286SE
400
50
0320SE
400
50
0360SE
400
50
0400SE
400
50
0435SE
400
50
0485SE
400
50
0195HE
400
50
0220HE
400
50
0221HE
400
50
0260HE
400
50
0261HE
400
50
0300HE
400
50
0350HE
400
50
0390HE
400
50
0441HE
400
50
0456HE
400
50
0516HE
400
50
52
ETL TB
1XX
ETL NFDS
2XX
ETL CB
3XX
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(1) #6 500 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) 250 500 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(1) #6 AWG 350 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 500 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(1) #6 500 kCMIL
(2) #6 500 kCMIL
(2) #6 500 kCMIL
(2) #4 500 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) 250 500 kCMIL
(2) 250 500 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
LUGS
ETL BFDS
W/INDIVIDUAL
SYSTEM
CBS 4XX
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(2) #3/0 AWG 250 kCMIL
(1) 250 500 kCMIL
& (2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) 250 500 kCMIL
(2) 250 500 kCMIL
CE NFDS
W/MMS
CE NFDS
W/MMS
& SS
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(1) #6 AWG 350 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) #3/0 AWG 250 kCMIL
(2) 250 500 kCMIL
(2) 250 500 kCMIL
N/A
N/A
N/A
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
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: -50 = 380/415-350, add 1 amps.
2. The minimum recommended disconnect switch is
based on 115% of the rated load amps for all loads
included in the circuit, per N.E.C. Article 440.
3. Minimum fuse size is based upon 150% of the
rated load amps for the largest motor plus 100%
of the rated load amps for all other loads included
in the circuit to avoid nuisance trips at start‑up due
to lock rotor amps. It is not recommended in applications where brown outs, frequent starting and
stopping of the unit, and/or operation at ambienttemperatures in excess of 35ºC (95ºF) is anticipated.
4. Maximum fuse size is based upon 225% of the
rated load amps for the largest motor plus 100%
of the rated load amps for all other loads included
in the circuit, per N.E.C. Article 440-22.
5. Circuit breakers must be UL listed and CSA 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 HACR circuit
breaker rating is based on 225% of the rated load
amps for the largest motor plus 100% of the rated
load amps for all other loads included in the circuit.
6. The “INCOMING WIRE RANGE” is the minimum and maximum wire size that can be accommodated by the unit wiring lugs. The (2)
preceding the wire range indicates the number
of termination points available per phase of the
wire range 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.
7. 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.
8. 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.
9. Field Wiring by others which complies to the National Electrical Code & Local Codes.
LEGEND
ACR-LINE
ACROSS THE LINE START
C.B.
CIRCUIT BREAKER
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
JOHNSON CONTROLS
VOLTAGE CODE
-50 = 380/415-3-50
53
5
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
THIS PAGE INTENTIONALLY LEFT BLANK
54
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
ELECTRICAL NOTES AND LEGEND
DESIGNATION
DESCRIPTION
DESIGNATION
DESCRIPTION
ACCESSORY
- MF
MOTOR FAN
- ADIS
DISPLAY BOARD
- MP
MOTOR PUMP
- AMB
ACC
MICRO BOARD
NU
NOT USED
- BAMB
AMBIENT
PE
PROTECTIVE EARTH
- BDAT
DISCHARGE AIR TEMPERATURE
- BDP
DISCHARGE PRESSURE
- BECT
ENTRING CHILLED TEMPERATURE
- BLCT
LEAVING CHILLED TEMPERATURE
NOT FITTED ON REMOTE EVAP UNITS
-BMP
MOTOR PROTECTOR COMPRESSOR
- BSP
SUCTION PRESSURE
- CPF
CAPACITOR POWER FACTOR
- ECH
CRANKCASE HEATER
- EEH
EVAPORATOR HEATER
- EHRH
HEAT RECOVERY HEATER
- EPH
PUMP HEATER
- EXT
EXTERNAL TO CONTROL PANEL
-F
FUSE
PWM
PULSE WIDTH MODULATION TEMP RESET or REMOTE UNLOAD 2nd STEP
- QCB
CIRCUIT BREAKER
- QMMSC
MANUAL MOTOR STARTER
COMPRESSOR
- QMMSP
MANUAL MOTOR STARTER PUMP
- QSD
R
RED
SWITCH DISCONNECT
RESISTOR
RED
RP
RUN PERMISSIVE
RU
REMOTE UNLOAD 1st STEP
SCH
THERMOSTAT CRANKCASE HEATER
SCR
SCREEN
- SF
FLOW SWITCH
- SKP
KEYPAD
- SOA
SWITCH OFF AUTO
- SZT
ZONE THERMOSTAT
- FHP
HIGH PRESSURE CUTOUT
- FSC
FAN SPEED CONTROLLER
- FSI
FAN SPEED INHIBIT TWO SPEED
FAN OPTION ONLY
GND
GROUND
G/Y
GREEN / YELLOW
- UBR
BRIGDE RECFIFIER
PLUG BOARD CONNECTOR
- WHT
WHITE
J
-K
CIRCUIT BOARD RELAY
- KF
FAN CONTACTOR LINE
(INCLUDING COIL SUPPRESSOR)
- KFH
FAN CONTACTOR HIGH SPEED
(INCLUDING COIL SUPPRESSOR)
- KFL
FAN CONTACTOR LOW SPEED
(INCLUDING COIL SUPPRESSOR)
- KFOL
- TC
- XP
RELAY FAN SPEED
- KH
HEATER RELAY
- KM
COMPRESSOR CONTACTOR (INCLUDING COIL SUPPRESSOR)
CONTROL RELAY
- KP
PUMP CONTACTOR PART
(INCLUDING COIL SUPPRESSOR)
- KT
RELAY TIMER
-M
COMPRESSOR MOTOR
TRANSFORMER
TRANSFORMER CURRENT
PLUGS BETWEEN POW./MICROBOARD.
SECTION
- XTBC
TERMINAL BLOCK CUSTOMER
- XTBF
TERMINAL BLOCK FACTORY
- YESV
EVAPORATOR SOLENOID VALVE
- YHGSV
HOT GAS SOLENOID VALVE (INCLUDING
COIL SUPPRESSOR)
- YLLSV
LIQUID LINE SOLENOID VALVE FIELD
MOUNTED AND WIRED ON REMOTE
EVAP. UNITS
- ZCPR
COMPRESSOR
FAN OVERLOAD
- KFS
- KCR
-T
5
NB
NOTE WELL {SEE NOTE}
WIRING AND ITEMS SHOWN THUS ARE
STANDARD YORK ACCESSORIES
WIRING AND ITEMS SHOWN THUS ARE
NOT SUPPLIED BY YORK
ITEMS THUS ENCLOSED FORM A COMPONENTS OR SETS OF COMPONENTS
035-21966-101 REVG
JOHNSON CONTROLS
55
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
ELECTRICAL NOTES AND LEGEND (CONT’D)
035-21966-101 REV I
GENERAL
a.
This drawing is based on IEC symbols.
b.
Field wiring to be in accordance with the relevant electrical code as well as all other applicable codes and specifications.
c.
All sources of supply shown on this diagram to be taken from one main isolator, not shown or supplied by YORK.
d.
Green and yellow wire is used for earth, multi-colored cable used for low voltage. Red wire used for AC Control, blue
wire for neutral, black wire for AC and DC power. Orange wire should be used for interlock control wiring supplied by
external source.
e.
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.
f.
All wiring to control section voltage free contacts requires a supply provided by the customer maximum voltage 240
volts. The customer must take particular care when deriving 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.
h.
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.
Notes
1
Refer to installation commissioning operation and maintenance manual for customer connections and customer connection notes, non compliance to these instructions will invalidate unit warranty.
2
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 & 135. 2-BMP3 is replaced by a link across terminals 234 & 235.
3
FHP2 is only fitted on CE YLAA??? and above. When not fitted 1-FHP2 is replaced by a link across terminals 132
&139. 2-FHP2 is replaced by a link across terminals 232 & 239.
4
Fitted on units with hot gas bypass option.
5
EMS option is wired as shown.
6
This wiring must be used for old display 031-0110-000.
7
Network connection point.
8
Printer port.
9
Remote emergency stop can be wired between terminal l and 5 after removing link.
10
Power factor correction accessory. Power factor correction fitted to each compressor contactor.
11
Not fitted on compressors with internal motor protection. For system 1 terminals 132 & 133, 133 & 134 and 134 & 135
are linked. For system 2 terminals 232 & 233, 233 & 234 and 234 & 235 are linked.
12
Only fitted on systems with 3 or 4 fans.
13
Only fitted on systems with 4 fans.
14
Only fitted on systems with 5 fans.
15
Only fitted on systems with 6 fans.
16
Input switch disconnect (standard on CE units) or circuit breaker option replaces input terminal block.
17
Input switch disconnect & individual system circuit breaker option replaces input terminal block.
18
115V control circuit requires a 115V supply unless control circuit transformer -T2 & -F3 are fitted (standard on CE
units).
19
For optional hydro kit. Heater -EPH is fitted and wired as shown. On single pump -KP1, -QMMSP1 & -MP1 are fitted &
wired as shown. On two pump hydro kits -KP2, -QMMSP2 & -MP2 are also fitted and wired as shown.
20
Current measurement option wired as show.
21
Only fitted on systems with single speed fans.
22
Only fitted on systems with two speed fans.
23
Optional compressor manual motors starters (standard on CE units).
24
See sheet 3 of connection diagram for power input options.
56
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
ELECTRICAL NOTES AND LEGEND (CONT’D)
25
Alternate connections shown for different two speed motor types.
26
Only fitted on systems with a maximum of 4 fans.
27
220/230V units require a separate fuse for units w/4 or more fans per system.
28
Low ambient kit -FSC for fan -MF1 is only fitted on systems with less than 4 fans.
29
Only fitted on YLAA0091.
30
Only fitted on YLAA0090, 0091 & 0135.
31
Input dual point circuit breaker option replaces input terminal block.
32
Field installed on remote evaporator units.
33
Fitted on units with single phase motors only.
34
Fitted on units with low ambient option only.
35
Only fitted on units with an acoustic kit.
36
Only fitted on heat recovery units.
37
Only fitted on condensing units.
38
Omitted on condensing units.
39
Fitted on units with low ambient option using single phase motors (50hz only).
40
Fitted on units with high airflow fan option only.
41
Part of e-link kit option.
42
Part of temp. sensor kit (on condensing units only).
43
When the compressors motor protection (-bmp) includes phase reversal the extra -bmp terminals and three wires are
fitted as shown in the compressor terminal box as detailed for 1-zcpr1 (copeland).
44
When the compressors motor protection (-bmp) includes phase reversal the extra -bmp terminals and three wires are
fitted as shown in the compressor terminal box as detailed for bitzer.
JOHNSON CONTROLS
57
5
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
035-21583-101 REV I
WIRING DIAGRAMS
ELEMENTARY WIRING DIAGRAMS
1/2.1 What these numbers mean. Example:
1 = follow wire no.1
2. = is the DWG number on the bottom center of each page.
.1 = is the locator number across the top of the page.
At the top of the pages the numbers 1 to 11 go from left to right. Find drawing number 2 and in
column number 1 across the top of the page, locate wire number 1.
DWG. 1
Figure 12 - ELEMENTARY WIRING DIAGRAM
58
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
5
DWG. 1
FIGURE 11 - ELEMENTARY WIRING DIAGRAM (CONT’D)
JOHNSON CONTROLS
59
SECTION 5 – TECHNICAL DATA
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
035-21583-102 REV J
DWG. 2
1/2.1 What these numbers mean. Example:
1 = follow wire no.1
2. = is the DWG number on the bottom center of each page.
.1 = is the locator number across the top of the page.
At the top of the pages the numbers 1 to 11 go from left to right. Find drawing number 2 and in
column number 1 across the top of the page, locate wire number 1.
/'D
Figure 13 - ELEMENTARY WIRING DIAGRAM
60
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
5
DWG. 2
LD16751a
FIGURE 12 - ELEMENTARY WIRING DIAGRAM (CONT’D)
JOHNSON CONTROLS
61
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
035-21583-103 REV C
FAN WIRING
LD16765a
DWG. 3
Figure 14 - F
AN WIRING, STANDARD LOW SOUND OR ULTRA QUIET, YLAA0180 - YLAA0516
62
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
5
DWG. 3
LD16766a
FIGURE 13 - F
AN WIRING, STANDARD LOW SOUND OR ULTRA QUIET, YLAA0180 - YLAA0516 (CONT’D)
JOHNSON CONTROLS
63
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
FAN WIRING
035-21583-118 REV C
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.
DWG. 18
LD16769a
Figure 15 - FAN WIRING, HIGH AIR FLOW
64
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
Only fitted on systems with 3 or 4 fans.
Only fitted on systems with 4 fans.
Only fitted on systems with 5 fans.
5
DWG. 18
LD16770a
FIGURE 14 - FAN WIRING, HIGH AIR FLOW (CONT’D)
JOHNSON CONTROLS
65
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
SINGLE AND DUAL POINT WIRING OPTIONS
035-21583-116 REV A
SINGLE POINT WIRING OPTIONS
DUAL POINT WIRING OPTIONS
DWG. 16
Figure 16 - SINGLE AND DUAL POINT WIRING OPTIONS
66
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
PUMP WIRING
035-21583-105 REV D
5
DWG. 5
/'
Figure 17 - PUMP WIRING
JOHNSON CONTROLS
67
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
COMPRESSOR WIRING
035-21589-106 REV L
/'
Figure 18 - COMPRESSOR WIRING
68
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
5
/'
FIGURE 17 - COMPRESSOR WIRING (CONT’D)
JOHNSON CONTROLS
69
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
POWER OPTIONS CONNECTION DIAGRAM
035-21589-103 REV B
035-21589-103 REVB
LD13234A
Figure 19 - POWER OPTIONS CONNECTION DIAGRAM
70
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
5
LD13901
FIGURE 18 - POWER OPTIONS CONNECTION DIAGRAM (CONT’D)
JOHNSON CONTROLS
71
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
POWER PANEL
035-21589-101 REV E
/'
Figure 20 - POWER PANEL
72
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
5
/'
FIGURE 19 - POWER PANEL (CONT’D)
JOHNSON CONTROLS
73
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
MICRO PANEL CONNECTIONS
035-21589-102 REV J
/'
Figure 21 - MICRO PANEL CONNECTIONS
74
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
5
/'
FIGURE 20 - MICRO PANEL CONNECTIONS (CONT’D)
JOHNSON CONTROLS
75
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
DIMENSIONS
FOUR FAN UNITS
DIMENSIONS – YLAA0180SE, YLAA0195HE , YLAA0210SE,










     

Dimensions are in millimeters unless otherwise noted
LD18066
NOTE:
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable
operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow
patterns and possible diminished performance. Johnson Controls’s unit controls will optimize operation without nuisance high-pressure safety
cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m (6'); rear to wall – 2m (6’); control panel to end
wall – 1.2m (4'0''); top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher
than the unit.
76
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
DIMENSIONS – YLAA0240SE, 0285SE, 0320SE


5








     

LD18067
NOTE:
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable
operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow
patterns and possible diminished performance. Johnson Controls’s unit controls will optimize operation without nuisance high-pressure safety
cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m (6'); rear to wall – 2m (6’); control panel to end
wall – 1.2m (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
77
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
DIMENSIONS – YLAA0300HE, YLAA0360SE, YLAA0400SE
FIVE FAN UNITS








     
LD18068
NOTE:
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable
operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow
patterns and possible diminished performance. Johnson Controls’s unit controls will optimize operation without nuisance high-pressure safety
cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m (6'); rear to wall – 2m (6’); control panel to end
wall – 1.2m (4'0''); top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher
than the unit.
78
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
DIMENSIONS – YLAA0350HE, YLAA0390HE, YLAA0435SE, YLAA0485SE
SIX FAN UNITS

5







     
LD18069
NOTE:
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable
operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow
patterns and possible diminished performance. Johnson Controls’s unit controls will optimize operation without nuisance high-pressure safety
cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m (6'); rear to wall – 2m (6’); control panel to end
wall – 1.2m (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
79
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
DIMENSIONS – YLAA0441HE
SEVEN FAN UNITS
16 DIA.
2077
330 WIDE X 178 HIGH
1102
83
21
1753
1918
2393 - OVERALL HEIGHT
2251 - FRAME HEIGHT
194
100 INLET
589
2243 - FRAME WIDTH
2255 - OVERALL WIDTH
1473
1519
823
254
100 OUTLET
137
4731 - FRAME LENGTH
LD18070
NOTE:
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable
operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow
patterns and possible diminished performance. Johnson Controls’s unit controls will optimize operation without nuisance high-pressure safety
cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m (6'); rear to wall – 2m (6’); control panel to end
wall – 1.2m (4'0''); top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher
than the unit.
80
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
DIMENSIONS – YLAA0456HE, YLAA0516HE
EIGHT FAN UNITS
16 DIA.
2077
330 WIDE X 178 HIGH
1102
83
21
194
1753
1918
5
2393 - OVERALL HEIGHT
2251 - FRAME HEIGHT
100 INLET
589
2243 - FRAME WIDTH
2255 - OVERALL WIDTH
1473
1519
823
254
100 OUTLET
137
4731 - FRAME LENGTH
LD18071
NOTE:
Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable
operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow
patterns and possible diminished performance. Johnson Controls’s unit controls will optimize operation without nuisance high-pressure safety
cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m (6'); rear to wall – 2m (6’); control panel to end
wall – 1.2m (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
81
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
WEIGHT DISTRIBUTION AND ISOLATOR
MOUNTING POSITIONS
General
Weights of specific chiller models vary significantly as
options are added. As a result, total weights, weights at
individual isolator positions, and actual isolator selection at each position cannot be published due to the
vast number of possible combinations. This information will be available when the specific chiller/ option
selection is made from the local Johnson Controls sales
office. Be aware, weights will change with each option along with possible isolator changes. Weights and
isolators may need to be recalculated when the option
selections are changed.
Whenever the isolator option is ordered, the isolators
will be shipped loose with the chiller. Packed with
the isolators and also in the control panel information packet is a drawing and table specifically for each
chiller, based on the option selection. The drawing and
table will be similar to the two samples shown below
and on the following page. The drawing will show the
isolator locations along with the weight in pounds and
kilograms at the specific location, isolator position,
and location measurements for each isolator.
Sample Isolator Location Drawings
See Figure 22 below for sample printouts supplied in
the isolator package and in the chiller panel literature
packets.
UNIT SHIPPING
WEIGHT
(Display on unit data
nameplate)
LBS.
2032
4480
L2
Control Panel
L1
KG
0
0
R1
R2
Y
X
LOCATION
X DISTANCE
INCHES (MM)
R1
L1
Top View
Y DISTANCE
INCHES (MM)
VENDOR NUMBER
OPERATING WEIGHT
LBS (KG)
19.5 (495.3)
1.36 (34.5)
ND-D / Yellow
1092 (495.3)
19.5 (495.3)
86.86 (2206.2)
ND-D / Yellow
1406 (637.8)
R2
96.1 (2440.9)
1.36 (34.5)
ND-D / Yellow
1015 (460.4)
L2
96.1 (2440.9)
86.86 (2206.2)
ND-D / Yellow
1304 (591.5)
Figure 22 - S
AMPLE PRINTOUT SUPPLIED IN THE ISOLATOR PACKAGE AND IN THE CHILLER PANEL
LITERATURE PACKET
82
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
CLEARANCES
(2 m)
See Figure 23 below for minimum clearances for all
YLAA units.
5
(2 m)
(2 m)
(1.3 m)
NOTES:
1. No obstructions allowed above the unit.
2. Only one adjacent wall may be higher than the unit.
3. Adjacent units should be 10 feet (3 Meters) apart.
Figure 23 - UNIT CLEARANCES – ALL MODELS
JOHNSON CONTROLS
83
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
ISOLATOR LOCATIONS
FOUR FAN ISOLATOR LOCATIONS
1.4
[36.4]
1.4
[36.4]
LD17643
FIVE AND SIX FAN ISOLATOR LOCATIONS
1.4
[36.4]
1.4
[36.4]
7.7
[194.6]
NOTE: All Dimensions In Inches (Millimeters)
84
LD17644
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
SEVEN AND EIGHT FAN ISOLATOR LOCATIONS
1.4
[36.4]
85.4
[2169.2]
1.4
[36.4]
7.7
[194.6]
69.0
[1753.2]
75.5
[1917.9]
33.3
[845.6]
5
LD17645
NOTE: All Dimensions In Inches (Millimeters)
JOHNSON CONTROLS
85
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
ISOLATOR INFORMATION
One Inch Deflection Spring Isolator Cross-reference
CP
5/8"
Ø1/2"
H"
C"
T"
B"
L"
D"
W"
MOUNT
TYPE
86
LD13759A
DIMENSION DATA (INCHES)
W
D
L
B
C
T
H
CP1
3
5/8
7-3/4
6-1/2
4-3/4
1/2
5-5/8
CP2
3
5/8
10-1/2
9-1/4
7-3/4
9/16
6
MODEL NUMBER
RATED CAPACITY (LBS)
DEFLECTION RATED (IN)
COLOR CODE
CP1-1D-85
85
1.360
LT. PURPLE
CP1-1D-120
120
1.200
DK. YELLOW
CP1-1D-175
175
1.170
DK. BLUE
CP1-1D-250
250
1.400
YELLOW
CP1-1D-340
340
1.130
RED
CP1-1D-510
510
1.020
BLACK
CP1-1D-675
675
1.320
DK. PURPLE
CP1-1D-900
900
1.020
DK. GREEN
CP1-1D-1200
1200
0.900
GRAY
CP1-1D-1360
1360
0.770
WHITE
CP1-1D-1785N
1785
0.880
GRAY/RED
MODEL NUMBER
RATED CAPACITY (LBS)
DEFLECTION RATED (IN)
COLOR CODE
CP2-1D-1020
1020
1.020
BLACK
CP2-1D-1350
1350
1.320
DK. PURPLE
CP2-1D-1800
1800
1.020
DK. GREEN
CP2-1D-2400
2400
0.900
GRAY
CP2-1D-2720
2720
0.770
WHITE
CP2-1D-3570N
3570
0.880
GRAY / RED
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
ONE INCH DEFLECTION SPRING ISOLATORS
INSTALLATION INSTRUCTIONS
1. Read instructions in their entirety before beginning installation.
2. Isolators are shipped fully assembled and are to be
positioned in accordance with the submittal drawings or as otherwise recommended.
3. Set isolators on floor, housekeeping pad or subbase, ensuring that all isolators centerlines match
the equipment mounting holes. The VMC group
recommends that the isolator base (“B”) be installed on a level surface. Shim or grout as required, leveling all isolator bases to the same
elevation (1/4-inch maximum difference can be
tolerated).
6. The adjustment process can only begin after the
equipment or machine is 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 adjusting each isolator until a minimum
of 1/4” clearance is achieved between the lower
housing and upper housing. (See drawing below).
9. Fine adjust isolators to level equipment.
10. Installation is complete.
4. Bolt or anchor all isolators to supporting structure
utilizing base slotted holes (“C”).
5. Place equipment on top of isolators making sure
that mounting holes of the equipment line up with
isolator positioning pin (“H”).
5
LD13790
JOHNSON CONTROLS
87
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
2” DEFLECTION ISOLATOR CROSS-REFERENCE
Y2RS
1-1/8"
5"
5/8"
2-3/4"
2-3/4"
12"
3/8" GAP
5/8-11UNC
TYP. (4)
Ø3/4"
TYP.(4)
3/4"
7/8"
14"
1/2" LIMIT
STOP &
NUT
8-3/8"
OPER.
HEIGHT
12-1/4"
3-1/2"
3/8"
LD13761A
5"
NOTES:
1. ALL DIMENSIONS ARE IN INCHES, INTERPRET PER ANSI Y14.
2. STANDARD FINISH: HOUSING-POWDER COATED (COLOR:BLACK), SPRING-POWDER COATED (COLOR: SEE T
HARDWARE ZINC-ELECTROPLATE.
3. EQUIPMENT MUST BE BOLTED OR WELDED TO THE TOP PLATE TO MEET ALLOWABLE SEISMIC RATINGS.
4. ALL SPRINGS ARE DESIGNED FOR 50% OVERLOAD CAPACITY WITH EXCEPTION OF THE 2D-3280N & 2D-2870
5. REFER TO PAGE
FOR INSTALLATION INSTRUCTIONS.
6. CONSULT FACTORY FOR CONCRETE INSTALLATION.
1. All dimensions are in inches, interpret per ANSI
Y14.
4. All springs are designed for 50% overload capacity with exception of the 2D-3280N and 2D-2870.
2. Standard finish: housing-powder coated (color,
black), spring-powder coated (color, see table below) hardware - zinc-electroplate.
5. Refer to next page for installation instructions.
6. Consult factory for concrete installation.
3. Equipment must be bolted or welded to the top
plate to meet allowable seismic ratings.
MODEL Y2RSI-2D SEISMICALLY RESTRAINED VIBRATION ISOLATOR FOR 2” DEFLECTION
SEISMIC
MOUNT SIZE
RATED LOAD
(LBS)
RATED
DEFLECTION
(IN)
SPRING RATE
(LBS/IN)
SOLID LOAD
(LBS)
COLOR
CODE
ALLOWABLE
G RATING
HORIZONTAL
Y2RSI-2D-150
150
2.4
62
234
WHITE
34.7
Y2RSI-2D-320
320
2.3
140
490
YELLOW
16.3
Y2RSI-2D-460
460
2.3
200
688
GREEN
11.3
Y2RSI-2D-710
710
2.2
330
1072
DK BROWN
7.3
Y2RSI-2D-870
870
1.9
460
1312
RED
6
Y2RSI-2D-1200N
1200
1.9
638
1818
RED/BLACK
4.3
Y2RSI-2D-1450
1450
1.8
900
2450
TAN
3.6
Y2RSI-2D-1690
1690
1.7
1140
2892
PINK
3.1
Y2RSI-2D-2000N
2000
1.7
1318
3342
PINK/BLACK
2.6
Y2RSI-2D-2640N
2640
1.5
1854
4283
PINK/GRAY
2
Y2RSI-2D-2870N
3080
1.5
2004
4629
PINK/GRAY/
ORANGE
1.7
Y2RSI-2D-3280N
3740
1.8
2134
4930
PINK/GRAY/DK
BROWN
1.4
88
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
2” DEFLECTION ISOLATOR INSTALLATION AND ADJUSTMENT
equipment or bracket to the top plate (“A”) of isolator 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).
1. Read instructions in their entirety before beginning installation.
2. Isolators are shipped fully assembled and are to be
positioned in accordance with the submittal drawings or as otherwise recommended.
7. The adjustment process can only begin after the
equipment or machine is at its full operating
weight.
3. Set isolators on floor, housekeeping pad, or subbase, 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).
8. Back off each of the (4) limit stop lock nuts (“F”)
on isolators 1/2".
9. 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 (“F”)
periodically to ensure that clearance between the
washer and rubber grommet is maintained. Stop
adjustment of isolator only when the top plate
(“A”) has risen just above the shim (“E”).
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 conditions.
10. Remove all spacer shims (“E”).
5. Isolators are shipped to the job site with (2) removable spacer shims (“E”) between the top plate
and the housing. These shims must be in place
when the equipment is positioned over the isolators.
11. Fine adjust isolators to level equipment.
12. Adjust all limit stop lock nuts (“F”) per isolator,
maintaining a 1/4 to 3/8-inch gap. The limit stop
nuts must be kept at this gap to ensure uniform
bolt loading during uplift (as the case when equipment is drained).
6. With all shims (“E”) in place, position equipment
on top of plate (“A”) 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
("A")
("E")
CL
("G")
("E")
13. Installation is complete.
GROMMET
("A")
1/4 - 3/8 GAP
WASHER
CL
EQUIPMENT
("F")
("E")
("F")
("C")
("B")
("C")
LD13763B
JOHNSON CONTROLS
89
5
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
NEOPRENE ISOLATOR CROSS-REFERENCE
RD-Style
Isolators
DW
CD
MOLDED
DURULENE
HF
ø AD THRU
TYP 2 PLACES
BT
AL
W
L
LD13760A
1. All dimensions are inches, interpreted per ANSI
4. AL = Mounting hole center to center spacing.
Notes:
Y14.
1. All dimensions are inches, interpreted per ANSI Y14. 5. HF = Free height of mount, prior to loading. Op2. Refer to Page 98 for installation instructions.
3. Mount molded ininstructions.
weather resistant duralene compound as standard.
available incalculated
other materials by the free height less
2. Refer to next page for installation
eratingAlsoheight
such as natural rubber, extreme high temperature silicone, high-damped silicone, nitrile and EDPM.
4. AL = Mounting hole center to center spacing.
the static deflection under load. All dimensions
5. HFresistant
= Free height duralene
of mount, prior comto loading. Operating height calculated by the free height less the
3. Mount molded in weather
static deflection under load. All dimensions for reference only. for reference only.
pound as standard. Also6.available
in other materiHardware zinc-electroplated.
als such as natural rubber, extreme high tempera6. Hardware zinc-electroplated.
ture silicone, high-damped silicone, nitrile and
EDPM.
DIMENSION DATA (INCHES)
MOUNT
TYPE
L
W
HF
AL
AD
BT
CD
DW
RD1-WR
3.13
1.75
1.25
2.38
0.34
0.19
5/16-18 UNC X 3/4
1.25
RD2-WR
3.88
2.38
1.75
3.00
0.34
0.22
3/8-16 UNC X 1
1.75
RD3-WR
5.50
3.38
2.88
4.13
0.56
0.25
1/2-13 UNC X 1
2.50
RD4-WR
6.25
4.63
2.75
5.00
0.56
0.38
1/2-13 UNC X 1
3.00
MODEL
NUMBER
RATED
RATED
DURO
CAPACITY DEFLECTION
(± 5)
(IN)
(LBS)
MODEL
NUMBER
RATED
RATED
DURO
CAPACITY DEFLECTION
(± 5)
(IN)
(LBS)
RD2-LIGHT BLUE-WR
35
0.4
30
RD3-Brown-WR
250
0.5
40
RD2-BROWN-WR
45
0.4
40
RD3-Brick Red-WR
525
0.5
50
RD2-BRICK RED-WR
70
0.4
50
RD3-Lime-WR
750
0.5
60
RD 2-LIME-WR
120
0.4
60
RD3 Charcoal-WR
1100
0.5
70
MODEL
NUMBER
RATED
RATED
DURO
CAPACITY DEFLECTION
(± 5)
(IN)
(LBS)
MODEL
NUMBER
RATED
RATED
DURO
CAPACITY DEFLECTION
(± 5)
(IN)
(LBS)
RD2-LIGHT BLUE-WR
135
0.5
30
RD4-BROWN-WR
1500
0.5
40
RD2-BROWN-WR
170
0.5
40
RD4-BRICK RED-WR
2250
0.5
50
RD2-BRICK RED-WR
240
0.5
50
RD4-LIME-WR
3000
0.5
60
RD 2-LIME-WR
380
0.5
60
RD4 CHARCOAL-WR
4000
0.5
70
RD2 CHARCOAL-WR
550
0.5
70
90
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 5 – TECHNICAL DATA
INSTALLATION OF NEOPRENE VIBRATION ISOLATORS
1. Read instructions in their entirety before beginning installation.
4. Bolt or anchor all isolators to supporting structure
utilizing base thru holes (“B”).
2. Isolators are shipped fully assembled and are to be
positioned in accordance with the submittal drawings or as otherwise recommended.
5. Remove top bolt and top washer. Place equipment on top of isolators so that mounting holes
in equipment or base line up with threaded hole
(“C”).
3. Set isolators on floor, housekeeping pad, or subbase, ensuring that all isolator centerlines match
the equipment mounting holes. The VMC group
recommends that the isolator base (“A”) be installed on a level surface. Shim or grout as required, leveling all isolator bases to the same
elevation (1/32-inch maximum difference can be
tolerated).
6. Reinstall top bolt and washer and tighten down.
7. Installation is complete.
TOP BOLT
("B")
D
TOP WASHER
5
D
("C")
CL
("B")
CL
SECTION D-D
("A")
LD13762B
JOHNSON CONTROLS
91
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
THIS PAGE INTENTIONALLY LEFT BLANK
92
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 6 – COMMISSIONING
Commissioning of this unit should only
be carried out by Johnson Controls Authorized personnel.
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. Refer to Equipment Pre-Startup And Startup
Checklist (Form 150.72-CL1) as the commissioning
procedure is carried out.
PREPARATION – POWER OFF
The following basic checks should be made with the
customer power to the unit switched OFF.
Inspection
Inspect unit for installation damage. If found, take 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 SECTION 5 – TECHNICAL DATA.
Service and Oil Line Valves
Open each compressor suction, economizer, and discharge service valve. If valves are of the back-seat
type, open them fully (counterclockwise) then close
one turn of the stem to ensure operating pressure is fed
to pressure transducers. Open the liquid line service
valve and oil return line ball valve fully in each system.
JOHNSON CONTROLS
Compressor Oil
To add oil to a circuit – connect a Johnson Controls
hand oil pump (Part No. 470-10654-000) to the 1/4” oil
charging connection on the compressors with a length
of clean hose or copper line, but do not tighten the flare
nut. Using clean oil of the correct type (“V” oil), pump
oil until all air has been purged from the hose then
tighten the nut. Stroke the oil pump to add oil to the oil
system. Approximately 1.8 to 2.3 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 is 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 SECTION
5 – TECHNICAL DATA has not been exceeded.
Control Panel
Check the panel to see that it is free of foreign materials (wire, metal chips, etc.) and clean out if required.
Power Connections
Check that the customer power cables are connected
correctly to the terminal blocks or optional circuit
breaker. Ensure that connections of power cables 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.
93
6
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 6 – COMMISSIONING
Supply Voltage
Temperature Sensor(s)
Verify that the site voltage supply corresponds to the
unit requirement and is within the limits given in SECTION 5 – TECHNICAL DATA.
Ensure the leaving liquid temperature sensor is coated
with heat conductive compound (Part No. 013-00890000) 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.
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 extension pipe.
Flow rates and pressure drops must be within the limits
given in SECTION 5 – TECHNICAL DATA. Operation
outside of these limits is undesirable and could cause
damage.
If mains power must be switched OFF for extended
maintenance or an extended shutdown period, the 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 is
removed for more than 8 hours) for at least 8 hours (24
hours if ambient temperature is below 86 °F [30 °C])
before the unit is restarted.
Flow Switch
Verify a chilled water flow switch is correctly fitted in
the customer’s piping on the cooler outlet, and wired
into the control panel correctly using shielded cable.
There should be a straight run of at least 5 pipe diameters on either side of the flow switch. The flow switch
should be connected to terminals 13 and 14 of XTBC1
on the panel.
94
PREPARATION – POWER ON
Perform the commissioning using the
detailed checks outlined. Refer to Equipment Pre-Startup And Startup Checklist
(Form 150.72-CL1) as the commissioning
procedure is carried out.
Apply power to the chiller. Turn on the option panel
circuit breaker if supplied.
The machine is now live!
Switch Settings
Assure the chiller OFF/ON UNIT switch at the bottom
of the keypad is 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 is 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 is above 96 °F (36 °C) the compressor heaters must be on for at least 8 hours before startup to ensure all refrigerant liquid is driven out of the
compressor and the oil. If the ambient temperature is
below 86 °F (30 °C), allow 24 hours.
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 6 – COMMISSIONING
Supersedes: 150.72-CL1 (1112)
Form 150.72-CL1 (113)
MODEL - YLAA
INSTALLATION CHECKLIST AND REQUEST FOR AUTHORIZED STARTUP ENGINEER
CUSTOMER: ____________________________________
JOB NAME: ____________________________________
ADDRESS: _____________________________________
LOCATION: ____________________________________
PHONE: ________________________________________
CUSTOMER ORDER NO: _________________________
JCI TEL NO: _____________________
JCI ORDER NO: __________________
CHILLER MODEL NO: ____________________________
JCI CONTRACT NO: ______________
UNIT SERIAL NO: _______________________________
The work (as checked below) is in process and will be completed by:
_____________ / ____________ / ___________
Month
Day
Year
The following work must be completed in accordance with installation instructions:
A. PRE-STARTUP
Unit Checks (No Power)
The following basic checks should be made with the
customer power to the unit switched OFF.
1. Inspect the unit for shipping or installation
damage ...................................................................
2. Assure that all piping has been completed. ............
3. Visually check for refrigerant piping leaks ...............
4. Open suction line ball valve, discharge line ball
valve, and liquid line valve for each system ............
5. The compressor oil level should be maintained so
that an oil level is visible or splashing in the sight
glass when fully loaded. At shutdown, the oil level
should be between the bottom and middle of the oil
equalizing sight glass. .............................................
6. Assure water pumps are ON. Check and adjust water pump flow rate and pressure drop across the
cooler (see "Operational Limitations" (English)).
Verify flow switch operation.....................................
7. NOTE: Excessive flow may cause catastrophic damage to the heat exchanger (evaporator)
8. Check the control panel to ensure it is free of foreign material (wires, metal chips etc.) .....................
9. Visually inspect wiring (power and control) Wiring
MUST meet N.E.C. and local codes. .......................
10. Check tightness of power wiring inside the
power panel on both sides of the motor contactors
and overloads ..........................................................
11. Check for proper size fuses in main and control
circuits, and verify overload setting corresponds
with RLA and FLA values in electrical tables (see
Table 8 and Table) ...................................................
JOHNSON CONTROLS
12. Assure 120VAC (110VAC for 50Hz units)Control
Power to TB1 has 15 amp minimum capacity. .........
13. Be certain all water temp sensors are inserted completely in their respective wells and are coated with
heat conductive compound ......................................
14. Assure that evaporator TXV bulbs are strapped
onto the suction lines at 4 or 8 o'clock positions or
suction temp. sensors if EEVs are installed. ...........
6
B. COMPRESSOR HEATER
(Power On - 24 Hours Prior To Start)
Apply 120VAC and verifiy its value between Terminals
5 and 2 of XTBC2. The voltage should be 120VAC
(110VAC for 50Hz units) plus or minus 10% .................
NOTE: Power must be applied 24 hours prior
to start-up. Each heater should draw approximately 0.5 to 1A.
C. STARTUP
Panel checks (Power On - Both unit switch Off)
1. Apply 3-phase power and verify its value. Voltage
imbalance should be no more than 2% of the average voltage. ............................................................
2. Apply 120VAC (110VAC for 50Hz units) and verify
its value on the terminal block in the Power Panel.
Make the measurement between Terminals 5 and 2
of XTBC2. The voltage should be 120VAC plus or
minus 10% .................................................................
3. Program/verify the Cooling Setpoints, Program
Setpoints, and unit Options. Record the values in
the following table (see "SETPOINTS KEYS" and
"UNIT KEYS" in Section 7 of Form 150.72-ICOM6
for programming instruction). ....................................
95
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
FORM 150.72-CL1
SECTION
6 – COMMISSIONING
ISSUE DATE: 1/11/2013
SETPOINTS ENTRY LIST
OPTIONS
Display Language
Sys 1 Switch
Sys 2 Switch
Chilled Liquid
Ambient Control*
6. Turn system 1 OFF and system 2 ON (refer to "Option 2 – System Switches (two system units only)"
under "UNIT KEYS" for more information on system switches)).............................................................
Local/Remote Mode
Control Mode
Display Units
Lead/Lag Control*
Place the Unit Switch in the control panel to the ON
position.
NOTE: The chilled liquid setpoint may need to
be temporarily lowered to ensure all compressors cycle ON.
Fan Control*
Manual Override
Current Feedback
Soft Start**
Unit Type**
Refrigerant Type**
Expansion Valve Type**
COOLING SETPOINTS
Cooling Setpoint
EMS-PWM Max. Setpoint
PROGRAM
Discharge Pressure Cutout
Suct. Pressure Cutout
Low Amb. Temp. Cutout
Leaving Liquid Temp. Cutout
Anti-Recycle Time
Fan Control ON Pressure
Fan Differential OFF Pressure
Total # of Compressors
Number of Fans/System*
Unit/Sys Voltage*
Unit ID
**Viewable Only
4. Put the unit into Service Mode (see "SERVICE
MODE" in Section 9 of Form 150.72-ICOM6) and
cycle each condenser fan to ensure proper rotation...............................................................................
5. Prior to this step, turn system 2 OFF (if applicable –
refer to Option 2 under "UNIT KEYS" on page 2 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.
NOTE: The chilled liquid setpoint may need to
be temporarily lowered to ensure all compressors cycle ON.
2
96
As each compressor cycles ON, ensure that the
discharge pressure rises and the suction pressure
decreases. If this does not occur, the compressor
being tested is operating in the reverse direction and
must be corrected. After verifying proper co pressor
rotation, turn the Unit Switch to OFF.
D. CHECKING SUPERHEAT AND SUBCOOLING
Range
*Not on All Models
As each compressor cycles ON, ensure that the
discharge pressure rises and the suction pressure
decreases. If this does not occur, 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.”
NOTE: This unit uses scroll compressors which
can only operate in one direction. Failure to
observe this will lead to compressor failure.
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 temp. is converted from a temperature/pressure chart).
Example:
Liquid line pressure =
325 PSIG converted to temp.
minus liquid line temp.
Subcooling =
101 °F
- 83 °F
18 °F
The subcooling should be adjusted to 18 °F (-8 °C) at
design conditions.
1. Record the liquid line pressure and its corresponding temperature, liquid line temperature and
subcooling below: .......................................................
Liq Line Press =
Saturated Temp =
Liq Line Temp =
Subcooling =
SYS 1
_______
_______
_______
_______
SYS 2
_______PSIG
_______ °F
_______ °F
_______ °F
After the subcooling is verified, the suction superheatshould 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
temperature, and the unit is running in a fully loaded
condition. Correct superheat setting for a system is 10
°F to 15 °F (5.56 °C to 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 refrig-
JOHNSON CONTROLS
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 6 –FORM
COMMISSIONING
150.72-CL1
ISSUE DATE: 1/11/2013
erant 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 =
minus Suction Press
105 PSIG converted to Temp
Superheat =
46 °F
- 34 °F
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.
Assure that superheat is set at a minimum of 10 °F
(5.56 °C) with a single compressor running on each
circuit.
2. Record the suction temperature, suction pressure,
suction saturation temperature, and superheat of
each system below: ....................................................
SYS 1
SYS 2
Suction Temp =
_______
_______
°F
Suction Pressure =
_______
_______
PSIG
Saturation Temp =
_______
_______
°F
Superheat =
_______
_______
°F
E. Leak Checking
Leak check compressors, fittings, and piping to ensure no leaks. ..................................................................
If the unit is functioning satisfactorily during the 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.
Owner's operating personnel:
Name: ______________________________________________________
Phone Number: _____________________________________________
Name: ______________________________________________________
Phone Number: _____________________________________________
Name: ______________________________________________________
Phone Number: _____________________________________________
6
CONTRACTOR'S RESPONSIBILITIES AND INSTRUCTIONS TO USE FORM
This installation checklist provides a quick way to check if all necessary installation work was completed in accordance with
all applicable installation instructions in Form 150.72-ICOM6, and when completed, acts as a request for Johnson Controls to
furnish start-up supervision.
Complete this form as follows:
1. Fill out the top of the page.
2. Check off each item as required. Cross out (x) items that do not apply.
3. Enter names, initials, and date of the operating personnel who completed the checklist.
4. Bottom of Form: Enter the date that the Johnson Controls start-up technician should be at the job site and the name(s)
of the supervisor(s) to be contacted.
5. Retain one copy in files and send one copy to customer.
With reference to the terms of the above contract, we are requesting the presence of your JCI Authorized Representative at the job site on
______ / ______ / ______ to start the system and instruct operating personnel. Have the JCI representative contact: _________________________________
Month
Day
Name/Phone
Year
We understand that the services of the Johnson Controls Authorized Representative will be furnished in accordance with the contract for a period of time of not
more than _______ consecutive normal working hours, and we agree that a charge of _________ per diem plus travel expenses will be made to Johnson Controls if services are required for longer than ________ consecutive normal hours or if repeated calls are required, through no fault of Johnson Controls.
Customer/Contractor Signature: _______________________________________
Title: _______________________________________
Form Completed by: _______________________________________
JOHNSON CONTROLS
97
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
THIS PAGE INTENTIONALLY LEFT BLANK
98
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
LD13283
INTRODUCTION
IPU II AND I/O BOARDS
The YORK Control Center is a microprocessor based
control system designed to provide the entire control
for the liquid chiller. The control logic embedded in
the microprocessor based control system will provide
control for the chilled liquid temperatures, as well as
sequencing, system safeties, displaying status, and
daily schedules. The MicroComputer Control Center
consists of four basic components:
The IPU and I/O boards are assembled to function as
a single microprocessor controller. The IPU II board
contains a microprocessor and is the controller. The
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.
1. IPU II and I/O Boards
2. Transformer
3. Display
4. 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 activates or deactivates the
unit.
JOHNSON CONTROLS
The I/O board constantly scans inputs to monitor the
chiller operating conditions. The input values are transmitted 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 115VAC levels used
by motor contactors, fan contactors, solenoid valves,
etc. to control system operation. The low voltage side
of all relay coils on the I/O board 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.
The on-board power supply converts 24VAC from
75VA, 120/24VAC 50/60Hz UL listed class 2 power
transformer to +12V, +5V and +3.3V using switching
and linear voltage regulators located on the I/O and IPU
II boards. These voltages are used to operate integrated
circuitry on the board. The 40 character display and
unit sensors (transducers and temp sensors) are sup-
99
7
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
plied power for the micro board +5V supply. 24VAC
is rectified, but not regulated, to provide unregulated
+30VDC to supply all of the digital inputs.
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 to 20mA or 0 to
10VDC as the input type on the remote temperature
reset analog input.
TRANSFORMER
A 75VA, 120/240VAC, 50/60Hz transformer is 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.
DISPLAY
The 40 Character Display (2 lines of 20 characters) is
a liquid crystal display used for displaying system parameters and operator messages.
When a key is pressed, such as the OPER DATA key,
system parameters will be displayed and will remain
on the display until another key is pressed. The system
parameters can be scrolled with the use of the ↑ (UP)
and ↓ (DOWN) arrow keys. The display will update all
information at a rate of about 1 a second.
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 the use of the
keypad and display. This will allow the user to make full
use of the capabilities and diagnostic features available.
UNIT SWITCH
A unit ON/OFF switch is just underneath the keypad.
This switch allows the operator to turn the entire unit
OFF if desired. The switch must be placed in the ON
position for the chiller to operate.
BATTERY BACK-UP
The IPU II contains a Real Time Clock integrated 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.
PROGRAMMING # OF COMPRESSORS
The total number of compressors is programmable under the PROGRAM key. Dual (2) system chillers can
have 4, 5, or 6 compressors.
Display Messages may show characters indicating
“greater than” (>) or “less than” (<). These characters
indicate the actual values are greater than or less than
the limit values which are being displayed.
100
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
STATUS KEY
00066VIP
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.
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 is pressed. Following each displayed message is an explanation pertaining to that particular message.
General Status Messages
In the case of messages which apply to individual
systems, SYS 1 and SYS 2 messages will both be displayed and may be different. In the case of single system units, all SYS 2 messages will be blank.
UN I T SW I TCH OF F
S
H
U
T
D
O
W
N
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.
REMOT E CONTROL L ED
S
H
U
T
D
O
W
N
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
DA I LY SCHEDULE
S
H
U
T
D
O
W
N
The DAILY SCHEDULE SHUTDOWN message indicates that the daily/holiday schedule programmed is
keeping the unit from running.
REMOTE STOP
NO RUN PERM
REMOTE STOP NO RUN PERM shows that a remote
start/stop contact is open in series with the flow switch.
These contacts are connected to Terminals 51 and 13 of
XTBC1. A 3-second delay is built into the software to
prevent nuisance shutdowns due to erroneous signals
on the run permissive input.
FLOW SWITCH
OPEN
FLOW SWITCH OPEN indicates the flow switch contacts connected to Terminals 13 and 14 of XTBC1 are
open. A 3-second delay is built into software to prevent
nuisance shutdowns due to erroneous signals from the
flow switch.
SYS 1 SYS SWI TCH OFF
SYS 2 SYS SWI TCH OFF
SYS SWITCH OFF tells that the system switch under
OPTIONS is turned OFF. The system will not be allowed to run until the switch is turned back ON.
101
7
SECTION 7 – UNIT CONTROLS
SYS 1 NO COOL LOAD
SYS 2 NO COOL LOAD
This message informs the operator that the chilled liquid temperature is below the point (determined by the
setpoint and control range) that the microprocessor
will bring on a system or that the microprocessor has
not loaded the lead system far enough into the loading
sequence to be ready to bring the lag system ON. The
lag system will display this message until the loading
sequence is ready for the lag system to start.
SYS1COMPSRUNX
SYS2COMPSRUNX
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.
SYS1ARTIMERXXS
SYS2ARTIMERXXS
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.
SYS1ACTIMERXXS
SYS2ACTIMERXXS
The anti-coincidence timer is a software feature that
guards against 2 systems starting simultaneously. This
assures instantaneous starting current does not become
excessively high due to simultaneous starts. The microprocessor limits the time between compressor starts
to 1 minute regardless of demand or the anti-recycle
timer being timed out. The anti-coincidence timer is
only present on two system units.
SYS 1 DSCH L I M I T I NG
SYS 2 DSCH L I M I T I NG
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 is important to keep in mind that this control will not function unless the discharge transducer is
installed in the system.
102
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
The limiting pressure is a factory set limit to keep the
system from faulting on the high discharge pressure
cutout due to high load or pull down conditions. When
the unload point is reached, the microprocessor will
automatically unload the affected system by de 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.
SYS 1 SUCT L I M I T I NG
SYS 2 SUCT L I M I T I NG
When this message appears, suction pressure limiting
is in effect. The suction pressure limit is a control point
that limits the loading of a system when the suction
pressure drops to within 15% above the suction pressure cutout. On a standard system programmed for 44
PSIG/3.0 Bar suction pressure cutout, the microprocessor would inhibit loading of the affected system
with the suction pressure less than or equal to 1.15 *
44 PSIG/3.0 Bar = 50 PSIG/3.5 Bar. The system will
be allowed to load after 60 seconds and after the suction pressure rises above the suction pressure load limit
point.
SYS 1 LOAD L I M I T XX%
SYS 2 LOAD L I M I T XX%
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.
M
A
N
U
A
L
O
V
E
R
RI
D
E
If MANUAL OVERRIDE mode is selected, the STATUS display will display 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
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
OVERRIDE is to only be used in emergencies or for
servicing. Manual override mode automatically disables
itself after 30 minutes.
SYS 1 PUMP I NG DOWN
SYS 2 PUMP I NG DOWN
The PUMPING DOWN message indicates that a compressor in the respective system is 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. Following
are display messages and explanations.
System Safeties
System safeties are faults that cause individual systems
to be shut down if a safety threshold is exceeded for 3
seconds. They are auto reset faults in that the system
will be allowed to restart automatically after the fault
condition is no longer present. However, if 3 faults on
the same system occur within 90 minutes, that system
will be locked out on the last fault. This condition is
then a manual reset. The system switch (under OPTIONS key) must be turned OFF and then back on
to clear the lockout fault. Fault messages will be displayed whenever a system is locked out.
SYS1HIGHDSCHPRES
SYS2HIGHDSCHPRES
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
SYS 1 LOW SUCT PRESS
SYS 2 LOW SUCT PRESS
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 evaporator
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 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 MP / HPCO FAULT
SYS 2 MP / HPCO FAULT
SYS 1MP/HPCO INHIB
SYS 2MP/HPCO INHIB
The Motor Protector/Mechanical High Pressure Cutout
protect the compressor motor from overheating or the
system from experiencing dangerously high discharge
pressure.
This fault condition is present when CR1 (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 0VDC to be read on the
inputs to the microboard. The fault condition is cleared
when a 30VDC signal is restored to the input.
103
7
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
The internal motor protector opens at 185 °F to 248 °F
(85 °C to 120 °C) and auto resets. The mechanical HP
switch opens at 585 PSIG plus or minus 10 PSIG (27.92
barg plus or minus .69 barg) and closes at 330 PSIG
plus or minus 25 PSIG (22.75 barg plus or minus 1.72
barg).
This safety will shut down a system if either suction
temperature or suction pressure sensors read out of
range high or low. This condition must be present for 3
seconds to cause a system shutdown. The safety locks
out a system after the first fault and will not allow automatic restarting.
The compressor is also equipped with a discharge
temperature 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.
Unit Safeties
When the sensor senses a high temperature, it opens
the motor protector circuit in the compressor causing
the compressor to shut down.
During the first two faults an MP/HP INHIBIT message
will be displayed and the system will not be locked out.
Only after the third fault in 90 minutes will the MP/
HPCO FAULT message be displayed.
Whenever the motor protector or discharge sensor
shuts down a compressor and the system, the 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 is 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
will not try to restart the compressors in a system that
shuts down on this safety for a period of 30 minutes to
allow the internal compressor to time out.
During the 30 minute timeout, the MP/HPCO INHIB
message will be displayed. The MP/HPCO fault will
only be displayed after 3 shutdowns in 90 minutes,
indicating the system is locked out and will not
restart.
S Y S 1H I G H
S Y S 2 H I G H
M T R C U R R
M T R C U R R
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.
104
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.
UNITFAULT:
LOW AMBIENT TEMP
The Low Ambient Temp Cutout is a safety shutdown
designed to protect the chiller from operating in a low
ambient condition. If the outdoor ambient temperature
falls below the programmable cutout, the chiller will
shut down. Restart can occur when temperature rises 2
°F above the cutoff.
UNITFAULT:
LOW L I QU I D T EMP
The Low Leaving Chilled Liquid Temp Cutout protects
the chiller form an evaporator freeze-up should the
chilled liquid temperature drop below the freeze point.
This situation could occur under low flow conditions or
if the micro panel setpoint values are improperly 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.
U
NITF
A
U
L
T:
1 1 5 VAC UNDER VOL TAGE
The Under Voltage Safety assures that the system is
not operated at voltages where malfunction of the microprocessor could result in system damage. When the
115VAC to the micro panel drops below a certain level,
a unit fault is initiated to safely shut down the unit. Restart is allowed after the unit is fully powered again and
the anti-recycle timers have finished counting down.
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
U N I T
F A U L T :
H I G H
M T R
C U R R
When the CURRENT FEEDBACK ONE PER UNIT
option is selected under the OPTIONS key, the unit will
shut down when the voltage exceeds the programmed
trip voltage for 5 seconds.
The trip voltage is programmed at the factory according to compressor or unit RLA.
Restart will occur after the anti-recycle timer times out.
Unit Warning
The following messages are not unit safeties and will
not be logged to the history buffer. They are unit warnings and will not auto-restart. Operator intervention is
required to allow a restart of the chiller.
! ! LOW BATTERY ! !
CHECK PROG / SETP / OPTN
The Low Battery Warning can only occur at unit power-up. On micro panel power-up, the RTC battery is
checked. If a low battery is found, all programmed
SECTION 7 – UNIT CONTROLS
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 is pressed
the anti-recycle timers will be set to the programmed
anti-recycle time to allow the operator time to check
setpoints, and if necessary, reprogram programmable
values and options.
If a low battery 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 (031-02565000) is located at U5 on the microboard.
I N C O R R E C T
U N I T
T Y P E
This indicates the condensing unit jumper is installed
between J11-12 and J11-7. This jumper must be removed to operate the chiller.
7
JOHNSON CONTROLS
105
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
STATUS KEY MESSAGES
General Messages
Fault Messages
Unit Switch Off
Shutdown
System Safeties
Unit Safeties &
Warning Messages
Remote Controlled
Shutdown
System X High Disch Pressure
Low Ambient Temp
Daily Schedule
Shutdown
System X Low Suct Pressure
Low Liquid Temp
System X MP/HPCO Inhibit
115VAC Undervoltage
Rem Stop
No Run Permissive
Flow Switch
Open
System X MP/HPCO Fault
System X Switch Off
System X
No Cooling load
System X HIGH MTR CURR
(Optional)
Low Battery
Check Prog/Step/Optn
(Unit Warning Message)
Incorrect Unit Type
(Unit Warning Message)
System X Comps Run
System X AR Timer
High Motor Current
System X AC Timer
System X Disch Limiting
System X Suction Limiting
System X Percentage Load Limiting
Manual Overide Status
System X Pumping Down (on shutdown)
LD11297B
Figure 24 - STATUS KEY MESSAGES QUICK REFERENCE LIST
106
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
DISPLAY/PRINT KEYS
00067VIP
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 is pressed, system parameters will be displayed and
remain on the display until another key is pressed. After
pressing the OPER DATA key, the various operating
data screens can be scrolled through by using the ↑ (UP)
and ↓ (DOWN) arrow keys or the ENTER/ADV key
located under the “ENTRY” section.
System 2 information will only be displayed for 2 system units.
With the “UNIT TYPE” set as a liquid chiller (no
jumper from J11-7 to J11-12 on the I/O Board), the
following list of operating data screens are viewable
under the OPER DATA key in the order that they are
displayed. The ↓ (DOWN) arrow key scrolls through
the displays in the order they appear below:
The chiller MUST be set to be a liquid
chiller (no jumper from J11-7 to J11-12
on the I/O Board). DO NOT operate the
chiller if not properly set up.
LCHLT = 46.2°F
RCHL T = 5 7 . 4 ° F °
This display shows chilled leaving and return liquid
temperatures. The minimum limit on the display for
these parameters are 2.2 °F (-19 °C). The maximum
limit on the display is 140 °F (60 °C).
AMBIENT AIR TEMP
=8
7.5°
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 is 131.2 °F (55.1 °C).
JOHNSON CONTROLS
107
7
SECTION 7 – UNIT CONTROLS
SYSXSP=72.1PSIG
D
P=
2
2
7.0P
SI
G
These displays show suction and discharge pressures
for each system. The discharge pressure transducer is
optional on some models.
If the optional discharge transducer is not installed, the
discharge pressure would display 0 PSIG (0 barg).
The minimum limits for the display are:
• Suction Pressure: 0 PSIG (0 barg)
• Discharge Pressure: 0 PSIG (0 barg)
The maximum limits for the display are:
• Suction Pressure: 400 PSIG (27.58 barg)
• Discharge Pressure: 650 PSIG (44.82 barg)
SYS X HOURS 1=XXXXX
2= X X X X X, 3 = X X X X X
SYSXSTARTS1=XXXXX
2= X X X X X, 3 = X X X X X
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 displayed
for the actual number of systems and
compressors on the unit.
A total of 99,999 hours and starts can be logged before
the counter rolls over to “0”.
L O A D T I M E R
5 8 S E C
UNLOAD T I MER 0 SEC
This display of the load and unload timers indicate
the time in seconds until the unit can load or unload.
Whether the systems loads or unloads is determined by
how far the actual liquid temperature is from setpoint.
A detailed description of unit loading and unloading is
covered under the topic of Capacity Control.
108
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
COOL I NG DEMAND
2OF8STEPS
The display of COOLING DEMAND indicates the
current “step” in the capacity control scheme when in
Return Water Control Mode. The number of available
steps are determined by how many compressors are in
the unit. In the above display, the “2” does not mean
that two compressor are running but only indicates that
the capacity control scheme is on step 2 of 8. Capacity
Control is covered in more detail in this publication
which provides specific information on compressor
staging (for Return Water Control only).
T EMP ERROR XXX . X ° F
TEMP RATE XXX . X ° F / M
The COOLING DEMAND message will be replaced
with this message when Leaving Chilled liquid control
is selected. This message indicates the temperature error and the rate of change of the chilled liquid temperature.
LEAD SYSTEM I S
S Y S T EM NUMBER 2
This display indicates the current LEAD system. In
this example system 2 is the LEAD system, making
system 1 the LAG system. The LEAD system can be
manually selected or automatic. Refer to the programming under the Options Key on page 123. The Lead
System display will only appear on a two system unit.
A unit utilizing hot gas bypass should be
programmed for MANUAL with system
1 as the lead system. Failure to do so
will prevent hot gas operation if system
2 switches to the lead system when programmed for AUTOMATIC LEAD/LAG.
E VAPORATOR HEATER
ST
A
T
U
SIS=
X
X
X
This display indicates the status of the evaporator
heater. The evaporator heater is controlled by ambient
air temperature. When the ambient temperature drops
below 40 °F the heater is turned ON. When the temperature rises above 45 °F the heater is turned OFF. An
under voltage condition will keep the heater OFF until
full voltage is restored to the system.
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
EV
A
P
O
R
A
T
O
RW
A
T
E
R
PU
M
PS
T
A
T
U
S=
X
X
X
X
The evaporator pump dry contacts are energized when
any compressor is running, or the unit is not OFF on
the daily schedule and the unit switch is ON, or the unit
has shutdown on a Low Leaving Chilled Liquid fault.
However, even if one of above is true, the pump will
not run if the micro panel has been powered up for less
than 30 seconds or if the pump has run in the last 30
seconds to prevent pump motor overheating.
EVAP PUMP TOTAL RUN
H
O
U
R
S=
X
X
X
X
X
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.
ACT I VE REMOTE CTRL
N
O
N
E
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 active. Remote monitoring
may be via ISN.
LOAD LIM – Load limiting enabled using contact closure.
PWM TEMP – EMS temperature reset
SECTION 7 – UNIT CONTROLS
SYSXCOMPSTATUS
1=XXX 2=XXX 3=XXX
S Y S X R U N
T I M E
XX-XX-XX-XX D-H-M-S
SYSXLLSV ISON
HOTGASSOL ISOFF
S Y S X F A N
S T A G E
3
S Y S X A M P S = 3 6 . 0
V O L T S =
0 . 8
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 is not available for system 2, so
there is no message pertaining to the hot gas solenoid
when system 2 message is displayed.
The fourth message indicates the stage of condenser
fan operation that is active.
*Refer to Remote BAS/EMS Temperature Reset
Using A Voltage Or Current Signal on page 150.
See Standard Condenser Fan Control on page 146 for
more information.
If the microprocessor is programmed for CURRENT
FEEDBACK ONE PER UNIT under the OPTIONS
key, the display will show up as the first display prior
to the SYS 1 displays. Total chiller current is displayed
as shown below:
The fifth message displays current as sensed 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:
U N I T A M P S = 5 4 . 0
V O L T S =
1 . 2
If the microprocessor is programmed for CURRENT
FEEDBACK NONE, no current display will appear.
JOHNSON CONTROLS
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 is displayed.
109
7
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
Oper Data Quick Reference List
Print Key
The following table is a quick reference list for information available under the OPER DATA key.
The PRINT key allows the operator to obtain a printout
of real-time system operating data or a history printout of system data at the “instant of the fault” on the
last six faults which occurred on the unit. An optional
printer is required for the printout.
Oper Data Key
Operating Data Printout
Pressing the PRINT key and then OPER DATA key
allows the operator to obtain a printout of current system operating parameters. When the OPER DATA key
is pressed, a snapshot will be taken of system operating conditions and panel programming selections. This
data will be temporarily stored in memory and transmission of this data will begin to the printer. A sample
Operating Data printout is shown below. (Note: Not all
values are printed for all models.)
Leaving & Chilled Liquid Temps
Ambient Air Temperature
System 1 Discharge & Suction Pressure
*System X Accumulated Hours
*System X Accumulated Starts
Load and Unload Timers
Cooling Demand Steps
(Return Chilled Liquid Control Only)
Temp Rate & Temp Error
(Leaving Chilled Liquid Control Only)
Lead System Indicator
Evaporator Heater Status
Evaporator Water Pump Status
Active Remote Control
Current Feedback One Per Unit
*System X Compressors Status
*System X Run Time
* Sys X LLSV & HGSV Status
*System X Condenser Fan Stage
Current Feedback One Per System
* Block of information repeats for each system
Figure 25 - OPERATION DATA
110
LD12585
YORK INTERNATIONAL CORPORATION
MILLENNIUM LIQUID CHILLER
UNIT STATUS
2:04PM 01 OCT 07
SYS 1
NO COOLING LOAD
SYS 2
COMPRESSORS RUNNING 2
OPTIONS
CHILLED LIQUID
WATER
AMBIENT CONTROL
STANDARD
LOCAL/REMOTE MODE
REMOTE
CONTROL MODE
LEAVING LIQUID
LEAD/LAG CONTROL
AUTOMATIC
FAN CONTROL
AMB & DSCH PRESS
CURRENT FEEDBACK
NONE
POWER FAILURE RESTART AUTOMATIC
SOFT START
ENABLED
EXPANSION VALVE THERMOSTATIC
REMOTE TEMP RESET 4 TO 20 MA
PROGRAM VALUES
DSCH PRESS CUTOUT
570 PSIG
SUCT PRESS CUTOUT
80 PSIG
SUCT PRESS CUT COOLING 42 PSIG
SUCT PRESS CUT HEATING 31 PSIG
LOW AMBIENT CUTOUT
25.0 DEGF
LEAVING LIQUID CUTOUT 25.0 DEGF
ANTI RECYCLE TIME
600 SECS
FAN CONTROL ON PRESS
425 PSIG
FAN DIFF OFF PRESS
125 PSIG
NUMBER OF COMPRESSORS
6
NUMBER OF FANS PER SYSTEM
4
UNIT TRIP VOLTS
3.0
REFRIGERANT TYPE
R-22
DEFROST INIT TEMP
41.0 DEGF
DEFROST INITIATION TIME
60MIN
DEFROST TERMINATION TIME
3MIN
BIVALENT HEAT DELAY TIME 30 MIN
REMOTE UNIT ID PROGRAMMED
2
YORK HYDRO KIT PUMPS
1 (410a)
PUMP TOTAL RUN HOURS XXXXX (410a)
UNIT DATA
RETURN LIQUID TEMP
58.2 DEGF
LEAVING LIQUID TEMP
53.0 DEGF
DISCHARGE AIR TEMP
55.3 DEGF
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
COOLING RANGE 42.0 +/- 2.0 DEGF
HEATING RANGE 122.0 +/- 2.0 DEGF
SYS 1 SETPOINT
70 +/- 3 PSIG
SYS 2 SETPOINT
70 +/- 3 PSIG
REMOTE SETPOINT
44.0 DEGF
AMBIENT AIR TEMP
74.8 DEGF
LEAD SYSTEM
SYS 2
EVAPORATOR PUMP
ON
EVAPORATOR HEATER
OFF
ACTIVE REMOTE CONTROL
NONE
LAST DEFROST SYS X DURATION XXXS
TIME TO SYS X DEFROST
XX MIN
BIVALENT DELAY REMAINING XX MIN
UNIT XXX.X AMPS
X.X VOLTS
SOFTWARE VERSION
C.M02.13.00
SYSTEM 1 DATA
COMP STATUS 1=OFF 2=OFF 3=OFF
RUN TIME
0- 0- 0- 0 D-H-M-S
TIME YYYYYYY0- 0- 0- 0 D-H-M-S
LAST STATE
YYYYYYY
SUCTION PRESSURE
105 PSIG
DISCHARGE PRESSURE
315 PSIG
SUCTION TEMPERATURE 46.0 DEGF
SAT SUCTION TEMP
34.0 DEGF
SUCTION SUPERHEAT
12.0 DEGF
COOLER INLET REFRIG 31.6 DEGF
DEFROST TEMPERATURE 52.8 DEGF
LIQUID LINE SOLENOID
OFF
MODE SOLENOID
OFF
HOT GAS BYPASS VALVE
OFF
CONDENSER FAN STAGE
OFF
EEV OUTPUT
0.0 %
SYSTEM
XXX.X AMPS X.X VOLTS
SYSTEM 2 DATA
COMP STATUS 1=ON, 2=OFF, 3=ON
RUN TIME
0-0-1-46 D-H-M-S
TIME YYYYYYY
0-0-0-0 D-H-M-S
LAST STATE
YYYYYYY
SUCTION PRESSURE
110 PSIG
DISCHARGE PRESSURE
320 PSIG
SUCTION TEMPERATURE 49.3 DEGF
SAT SUCTION TEMP
36.0 DEGF
SUCTION SUPERHEAT
13.3 DEGF
COOLER INLET REFRIG 31.6 DEGF
DEFROST TEMPERATURE 52.8 DEGF
LIQUID LINE SOLENOID
ON
MODE SOLENOID
ON
CONDENSER FAN STAGE
3
EEV OUTPUT
63.2%
SYSTEM
XXX.X AMPS X.X VOLTS
DAILY SCHEDULE
S M T W T F S
*=HOLIDAY
SUN START=00:00AM STOP=00:00AM
MON START=00:00AM STOP=00:00AM
TUE START=00:00AM STOP=00:00AM
WED START=00:00AM STOP=00:00AM
THU START=00:00AM STOP=00:00AM
FRI START=00:00AM STOP=00:00AM
SAT START=00:00AM STOP=00:00AM
HOL START=00:00AM STOP=00:00AM
JOHNSON CONTROLS
SECTION 7 – UNIT CONTROLS
See Optional Printer Installation on page
158 for Printer Installation information.
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 lockout.
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
is very important when attempting to troubleshoot a
system problem. This data reflects the system conditions at the instant the fault occurred and often reveals
other system conditions which actually caused the
safety threshold to be exceeded.
The history printout is similar to the operational data
printout shown in the previous section. The differences
are in the header and the schedule information. The
daily schedule is not printed in a history print.
One example history buffer printout is shown following. The data part of the printout will be exactly the
same as the operational data print so it is not repeated
here. The difference is that the Daily Schedule is not
printed in the history print and the header will be as
follows.
YORK INTERNATIONAL CORPORATION
MILLENNIUM LIQUID CHILLER
SAFETY SHUTDOWN NUMBER 1
SHUTDOWN @ 3:56PM 29 SEP 07
SYS 1
HIGH DSCH PRESS SHUTDOWN
SYS 2
NO FAULTS
111
7
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
History Displays
The HISTORY key gives the user access to many unit
and system operating parameters at the time of a unit
or system safety shutdown. When the HISTORY key is
pressed the following message is displayed.
D I SPLAY SAFETY SHUT D OWN N O . 1 ( 1 TO 9 )
While this message is displayed, the ↑ (UP) arrow key
can be used to select any of the six history buffers. Buffer number 1 is the most recent, and buffer number 6 is
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
03:56 PM29JAN02
The ↑ (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:
UNITFAULT:
LOW L I QU I D T EMP
Displays the type of fault that occurred.
U
N
ITT
Y
P
E
LIQUID CHILLER
Displays the type of chiller; Liquid, Condensing Unit
or Heat Pump.
CHILLED LIQUID
X
X
X
X
X
Displays the chilled liquid type; Water or Glycol.
AMB I ENT CONTROL
XXXXXXXXXX
Displays the type of Ambient Control; Standard or
Low Ambient.
L O C A L / RE M O T E MO D E
XXXXXXXXX
CONTROL MODE
LEAVING LIQUID
Displays the type of chilled liquid control; Leaving or
Return.
L EAD / L AG CONTROL
XXXXXXXX
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
D I SCHARGE PRESSURE
Displays the type of fan control; Discharge Pressure or
Ambient and Discharge Pressure.
MANUAL OVERR I DE MODE
XXXXXXXXX
Displays whether Manual Override was Enabled or
Disabled.
C U R R E N T
F E E D B A C K
X X X X X X X X X X X X X X X X
Displays type of Current Feedback utilized.
S O F T S T A R T
X X X X X X X
Displays whether the optional European Soft Start was
installed and selected.
D I SCHARGE PRESSURE
CUTOUT = XXXX PS I G
Displays the programmed Discharge Pressure Cutout.
SUCT I ON PRESSURE
CUTOUT = XXXX PS I G
Displays the programmed Suction Pressure Cutout.
LOW AMBIENT TEMP
CUTOUT = XXX . X ° F
Displays the programmed Low Ambient Cutout.
Displays Local or Remote control selection.
112
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
L EAV I NG L I QU I D TEMP
CUTOUT = XXX . X ° F
Displays the Leaving Liquid Temp. Cutout programmed.
F AN CONTROL ON
PRESSURE = XXX PS I G
Displays the programmed Fan On Pressure.
F A N D I F F E R E N T I A LO F F
PRESSURE = PS I G
Displays the programmed Fan Off Differential.
S Y S 1
T R I P
= X . X
V O L T S
V O L T S
Displays the programmed High Current Trip Voltage.
S Y S 2 T R I P V O L T S
= X . X
V O L T S
Displays the programmed High Current Trip Voltage.
Y
O
R
KH
Y
D
R
O
KITP
U
M
P
S=
X
Indicates the Pump Control option is selected.
LCHLT = XXX . X ° F
RCHL T = XXX . X ° F
Displays the Leaving and Return chilled Liquid Temperature at the time of the fault.
SETPO I NT = XXX . X ° F
RANGE=+/-°F
Displays the programmed Setpoint and Range, if the
chiller is programmed for leaving chilled liquid control.
SETPO I NT = XXX . X ° F
RANGE=+XX.X°F
Displays the programmed Setpoint and Range, if the
chiller is programmed for return chilled liquid control.
AMBIENT AIR TEMP
=X
X
X.X°
F
LEAD SYSTEM I S
S Y S T EM NUMBER X
Displays which system is in the lead at the time of the
fault.
E VAPORATOR HEATER
ST
A
T
U
SISX
X
X
Displays status of the Evaporator Heater at the time of
the fault.
E VAPORA TOR WA T ER
PU
M
PS
T
A
T
U
SX
X
X
X
Displays status of Evaporator Water Pump at the time
of fault. Status may read ON, OFF or trip.
EVAPPUMPTOTALRUN
H
O
U
R
S=
X
X
X
X
Evap Pump total run hours at the time of fault.
ACT I VE REMOTE CTRL
X
X
X
X
Displays whether Remote Chiller Control was active
when the fault occurred.
UN I T ACTUAL AMPS
=
X
X
X.XA
M
P
S
7
This is only displayed when the Current Feedback Option is one per unit.
SYSXCOMPSTATUS
1=XXX 2=XXX 3=XXX
Displays which Compressors were running in the system when the fault occurred.
SYSXRUNTIME
XX-XX-XX-XX D-H-M-S
Displays the system run time when the fault occurred.
SYSXSP=XXXXPSIG
D
P=X
X
X
XP
SI
G
Displays the system Suction and Discharge Pressure of
the time of the fault.
Displays the Ambient Temp. at the time of the fault.
JOHNSON CONTROLS
113
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
SYSXSUCT=XXX.X°F
SATSUCT=XXX.X°F
Displays the System Suction Temp and Saturated Suction Temp when an EEV is installed.
SYSXLLSV ISXXX
HOTGASSOL ISXXX
Displays whether the System Liquid Line Solenoid or
Hot Gas Solenoid was energized at the time of the fault.
SYSXFANSTAGEXXX
Displays the number of Fan Stages in the system active
at the time of the fault.
SYSX A
CTUALAMPS
=
X
X
X.XA
M
P
S
Displays the system Amperage (calculated approximately) at the time of the fault.
For this message to appear, CURRENT FEEDBACK
ONE PER SYSTEM must be programmed under the
OPTIONS key. If the microprocessor is programmed
as one CURRENT FEEDBACK ONE PER UNIT un-
114
der the PROGRAM key, the display will be the first
display prior to the SYS 1 info. If the microprocessor is
programmed for CURRENT FEEDBACK NONE, no
current display will appear.
Displays for System 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.
D I SPLAY SAFETY SHUT DOWNNO.1 (1TO6)
After the ↓ (DOWN) arrow key is pressed again, the
software version will appear.
C ONTROL C.MXX.ZZ.Y Y
I/
OC.
M
X
X.
1
8.
Y
Y
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
ENTRY KEYS
00068VIP
7
The Entry Keys allows the user to view, change programmed values. The ENTRY keys consist of an ↑ (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 ↑ (UP) and
↓(DOWN) arrow keys allow the user to scroll through
the various data screens. Refer to Display/Print Keys
on page 107 for specific information on the displayed information and specific use of the ↑ (UP) and
↓ (DOWN) arrow keys.
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 is 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 ↑ (UP)
arrow key, and ↓ (DOWN) arrow, and ENTER/ADV
keys are covered in detail under the SETPOINTS, and
UNIT keys.
The ↑ (UP) arrow key, and ↓ (DOWN) arrow key are
also used for programming the control panel such as
changing numerical or text values when programming
cooling setpoints, setting the daily schedule, changing
safety setpoints, chiller options, and setting the clock.
JOHNSON CONTROLS
115
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
SETPOINTS KEYS
00069VIP
Programming of the cooling setpoints, daily schedule,
and safeties is accomplished by using the keys located
under the SETPOINTS section.
The three keys involved are labeled COOLING
SETPOINTS, SCHEDULE/ADVANCE DAY, and
PROGRAM.
Following 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.
Leaving Chilled Liquid Control
SETPOINT=45.0°F
RANGE = +/- 2 . 0 ° F
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 ↑
(UP) or ↓ (DOWN) arrow will change the setpoint in .5
°F increments. After using the ↑ (UP) or ↓ (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 ↑ (UP)
and ↓ (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 +/- X.X°
F. This indicates the SETPOINT to be in the center of
116
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
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.
When in leaving chilled liquid temperature control,
the microprocessor will attempt to control the leaving
water temperature within the temperature range of the
setpoint + or – the range. In the above example, control
will be in the range of 43 to 47 °F.
Return Chilled Liquid Control
SETPOINT=45.0 °F
R A N G E = + 1 0 . 0 ° F
In return chilled liquid 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 18 on page 143.
The SETPOINT and RANGE displays just described
were based on LOCAL control. If the unit was 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 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 Capacity Control on page 141.
Remote Setpoint Control
Pressing the COOLING SETPOINTS key a second
time will display the remote setpoint and cooling
range. This display automatically updates about every
2 seconds. Notice that these setpoints are not “locally”
programmable, but are controlled by a remote device
such as an ISN control, remote reset option board, or
remote PWM signal. These setpoints would only be
valid if the unit was operating in the REMOTE mode.
JOHNSON CONTROLS
SECTION 7 – UNIT CONTROLS
The following messages illustrate both leaving chilled
liquid control and return chilled liquid control respectively.
REMSETP = 44.0°F
RANGE=+/-2.0°F
(leaving chilled liquid control)
REMSETP = 44.0°F
R
A
N
G
E=
+ 1
0.0°
F
(return chilled liquid control)
The low limit, high limit, and default values for the
keys under “SETPOINTS” are listed in Table 18 on
page 143.
Pressing the COOLING SETPOINTS a third time will
bring up the display that allows the Maximum EMSPWM Temperature Reset to be programmed. This
message is shown below.
M A X E M S - P WM R E M O T E
T E M P R E S E T = + 2 0 ° F
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 or from the Temperature Reset Option Board. See Remote BAS/EMS Temperature Reset
Using A Voltage Or Current Signal on page 150 for a
detailed explanation of this feature.
As with the other setpoints, the ↑ (Up) arrow and ↓
(Down) arrow keys are used to change the Temp Reset
value. After using the ↑ (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/ADVANCE
DAY key. The display will immediately show the following display.
117
7
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
Table 11 - COOLING SETPOINT, PROGRAMMABLE LIMITS AND DEFAULTS
SETPOINT KEY
MODE
LOW LIMIT
HIGH LIMIT
DEFAULT
WATER COOLING
40.0°F
4.4°C
**70.0°F
21.1°C
44.0°F
6.7°C
GLYCOL COOLING*
10.0°F
-12.2°C
**70.0°F
21.1°C
44.0°F
6.7°C
—
1.5°F
0.8°C
2.5°F
1.4°C
2.0°F
1.1°C
WATER COOLING
40.0°F
4.4°C
70.0°F
21.1°C
44.0°F
6.7°C
GLYCOL COOLING*
10.0°F
-12.2°C
70.0°F
21.1°C
44.0°F
6.7°C
4.0°F
2.2°C
20.0°F
11.1°C
10.0°F
5.6°C
2°F
1.0°C
40°F
22.0°C
20°F
11.0°C
LEAVING CHILLED LIQUID SETPOINT
LEAVING CHILLED LIQUID CONTROL RANGE
RETURNED CHILLED LIQUID SETPOINT
RETURN CHILLED LIQUID CONTROL RANGE
MAX EMS-PWM REMOTE TEMPERATURE
RESET
—
—
* Refer to Engineering Guide for operation below 30°F (-1.1°C). Alternate thermal expansion valves must be used below 30°F (-1.1°C).
*When using glycol, Leaving Chilled Liquid Setpoint should not be set below 20°F (-6.7°C).
**Do not exceed 55°F (12.8°C) setpoint before contacting the nearest Johnson Controls Office for application guidelines.
M
ONSTART=00 : 00 AM
S
T
O
P=0
0:0
0A
M
The line under the 0 is the cursor. If the value is wrong,
it may be changed by using the ↑ (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 the schedule to the next day.
Whenever the daily schedule is changed
for Monday, all the other days will change
to the new Monday schedule. This means
if the Monday times are not applicable
for the whole week then the exceptional
days would need to be reprogrammed to
the desired schedule.
To page to a specific day, press the SCHEDULE/ADVANCE DAY key until the desired day appears. The
start and stop time of each day may be programmed
differently using the ↑ (UP) and ↓ (DOWN) arrow, and
ENTER/ADV keys.
118
After SUN (Sunday) schedule appears on the display
a subsequent press of the SCHEDULE/ADVANCE
DAY key will display the Holiday schedule. This is a
two part display. The first reads:
HOL START = 00 : 00 AM
S
T
O
P=0
0:0
0A
M
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 __ MTWTFS
HOLIDAYNOTEDBY *
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 is pressed. To set the Holiday,
the cursor is moved to the space following the day of
the week of the holiday and the ↑ (UP) arrow key is
pressed. An * will appear in the space signifying that
day as a holiday. The * can be removed by pressing the
↓ (DOWN) arrow key.
The Holiday schedule must be programmed weekly –
once the Holiday schedule runs, it will revert to the
normal daily schedule.
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
PROGRAM KEY
There are several operating parameters under the 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 ↑ (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 12 on page 120 shows
the programmable limits and default values for each
operating parameter.
Following are the displays for the programmable values in the order they appear:
d D I SCHARGE PRESSURE
CUTOUT = 3 9 5 PS I G
DISCHARGE PRESSURE CUTOUT is the discharge
pressure at which the system will shutdown as monitored by the optional discharge transducer. This is 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.
SUCT I ON PRESSURE
CUTOUT = 80. 0 PS I G
The SUCTION PRESSURE CUTOUT protects the
chiller from an evaporator freeze-up. If the suction
pressure drops below the cutout point, the system will
shut down. Typically, the cutout should be set to 80
PSIG (5.52 Bars) form water cooling.
There are some exceptions when the suction pressure is permitted to temporarily
drop below the cutout point. Details are
explained under the topic of SYSTEM
SAFETIES.
JOHNSON CONTROLS
SECTION 7 – UNIT CONTROLS
LOW AMBIENT TEMP
CUTOUT = 2 5 . 0 ° F
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.
L EAV I NG L I QU I D T EMP
CUTOUT = 3 6 . 0 ° F
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 12 on page 120.
ANT I RECYCLE T I MER
=6
0
0S
E
C
The programmable anti-recycle timer assures that
systems do not short cycle, and the compressor motors have sufficient time to dissipate heat after a start.
This timer is programmable under the PROGRAM key
between 300 and 600 seconds. Whenever possible,
to reduce cycling and motor heating, the anti-recycle
timer should be adjusted as high as possible. The programmable anti-recycle timer starts the timer when the
first compressor in a system starts. The timer begins to
count down. If all the compressors in the circuit cycle
OFF, a compressor within the circuit will not be 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, if currently programmed for less than 10
minutes.
F AN CONTROL ON
P R E S S U R E = X X X P S I G
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 Standard
Condenser Fan Control on page 146 in SECTION 7
– UNIT CONTROLS and Table 21 on page 147 and
Table 22 on page 148.
119
7
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
This MUST be programmed correctly to
assure proper chiller operation.
F AN D I FFERENT I AL OFF
PR E S S U R E = X X X P S I G
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 Standard Condenser Fan Control on page 146
in SECTION 8 – UNIT OPERATION and Table 21 on
page 147 and Table 22 on page 148.
NU
M
B
E
R
O
FF
A
N
S
PE
RS
Y
S
T
E
M=
X
The Number of Fans Per System must be programmed
as needed to match the number of fans on each system.
TOTAL NUMBER OF
COMPRESSORS = 6
S Y S
X T R I P V O L T S
= X. X V O L T S
The TOTAL NUMBER OF COMPRESSORS is the
total quantity of compressors in the chiller, and determines the stages of cooling available. Note in Table
12, the chiller may have single or dual systems. Single
system units can have 2 or 3 compressors, while dual
system units may have 4 or 6 compressors.
U N I T
T R I P
= X. X
V O L T S
V O L T S
Table 12 - PROGRAM KEY LIMITS AND DEFAULT
PROGRAM VALUE
MODE
DISCHARGE PRESSURE CUTOUT
—
WATER COOLING
SUCTION PRESSURE CUTOUT
GLYCOL COOLING
STANDARD AMBIENT
LOW AMBIENT TEMP. CUTOUT
LOW AMBIENT
LEAVING CHILLED LIQUID
TEMP. CUTOUT
WATER COOLING
GLYCOL COOLING
ANTI-RECYCLE TIMER
—
FAN CONTROL ON PRESSURE
—
FAN DIFFERENTIAL OFF PRESSURE
—
TOTAL NUMBER OF COMPRESSORS
SINGLE SYSTEM
LOW LIMIT
HIGH LIMIT
DEFAULT
325 PSIG
575 PSIG
570 PSIG
22.4 BARG
39.6 BARG
39.3 BARG
80.0 PSIG
120.0 PSIG
80.0 PSIG
5.52 BARG
8.27 BARG
5.52 BARG
42.0 PSIG
70.0 PSIG
44.0 PSIG
2.9 BARG
4.83 BARG
3.03 BARG
25.0 °F
60.0 °F
25.0 °F
-3.9 °C
15.6 °C
-3.9 °C
0 °F
60.0 °F
25.0 °F
-17.8 °C
15.6 °C
-3.9 °C
—
—
36 °F
2.2 °C
-1.0 °F
36.0 °F
36.0 °F
-18.3 °C
2.2 °C
2.2 °C
300 SEC.
600 SEC.
600 SEC.
360 PSIG
485 PSIG
385 PSIG
24.8 BARG
33.4 BARG
26.5 BARG
80 PSID
160 PSID*
125 PSID
5.51 BARD
11.03 BARD*
8.62 BARD
2
3
3
DUAL SYSTEM
4
6
6
NUMBER OF FANS PER SYSTEM
—
2
4
3
UNIT/SYSTEM TRIP VOLTS
CURRENT FEEDBACK
0.5 Volts
4.5 Volts
2.5 Volts
REMOTE UNIT ID
—
0
7
0
* T
he 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.
120
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
Depending on the option, the trip voltage for a
specific system or unit high current trip can be
programmed. It also calibrates the current readout under the OPER DATA key. The approximate
programmed value is calculated using the following
formulas.
SECTION 7 – UNIT CONTROLS
Unit Trip Volts
For total chiller high current trip programming on
460VAC chillers:
• Add the sum of all the compressors and fan RLA’s
in the chiller
System Trip Volts
• Multiply the sum by 1.25
For individual system high current trip programming
on chillers:
• Divide by 225A
• 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
625VA
x 1.25=
=2.8V
225A 225A
The programmed value will be 2.8V. A similar calculation and programming will be necessary for the other
system in a 2-system chiller.
• The resulting voltage is the value that should be
programmed
For example, if fan and compressor RLA’s total 180A:
5V x 180A
1125VA
x 1.25=
=5.0V
225A 225A
The programmed value will be 5.0V.
R
E M O T E U N I T
P R O G R A M M E D =
I D
X
When communications is required with a BAS or OptiView Panel, individual unit IDs are necessary for
communications with specific chillers on a single RS485 line. ID 0 - 7 is selectable.
7
JOHNSON CONTROLS
121
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
Quick Reference Programming Chart
Setpoints Section
Cooling Setpoints Key
(press key to adv.)
Schedule/
Advance Day Key
Program Mode
(press enter to adv.)
Local Leaving
Water Temp Control
(Display Only)
Mon. – Sun.
&
Holiday
Schedule
Discharge
Pressure
Cutout
Chilled Liquid
Setpoint
&
Range
Suction
Pressure
Cutout
Remote Setpoint
&
Range
(Display Only)
Low Ambient Temp.
Cutout
EMS - PWM
Remote Temp
Reset Setpoint
Table 12 provides a quick reference of the setpoints list for the Setpoints Keys.
Leaving Liquid
Temperature
Cutout
Anti-Recycle
Timer
Fan Control
On-Pressure
Fan Differential
Off-Pressure
Total Numbers
of
Compressors
Number of
Fans Per System
SYS / Unit
Trip Volts Option
Remote Unit ID
LD07404c
Figure 26 - SETPOINTS QUICK REFERENCE LIST
122
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
UNIT KEYS
OPTIONS
CLOCK
00070VIP
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
OPTIONS key. After the selected option has been displayed, the ↑ (UP) and ↓ (DOWN) arrow keys are then
used to change that particular option. After the option
is changed, the ENTER/ADV key must be pressed to
enter the data into memory.
Many of the OPTIONS displayed are
only programmable under the SERVICE
MODE and not under the OPTIONS key.
Options only programmable under the
SERVICE MODE are noted in the details
describing the option.
Figure 27 on page 128 shows the programmable options. Following are the displays in the order they appear:
Option 1 – Language
D I SP L AY L ANGUAGE
E
N
G
LIS
H
English, Spanish, French, German, and Italian can be
programmed.
Option 2 – System Switches (two system
units only)
(Single System Display is similar)
SYS1SWITCHON
SYS2SWITCHON
JOHNSON CONTROLS
This allows both systems to run.
or
SYS1SWITCHON
SYS2SWITCHOFF
This turns system 2 OFF.
SYS 1 SWI TCH OFF
SYS2SWITCHON
7
This turns system 1 OFF.
or
SYS 1 SWI TCH OFF
SYS2SWITCHOFF
This turns systems 1 and 2 OFF.
Turning a system OFF with its system
switch allows a pumpdown to be performed prior to shutdown.
Option 3 – Chilled Liquid Cooling Type
CHILLED LIQUID
W
A
T
E
R
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
123
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
CHILLED LIQUID
G L Y C O L
The chilled liquid is glycol. The Cooling Setpoint can be
programmed from 10 °F to 70 °F (-12.2 °C to 21.1 °C).
Option 4 – Ambient Control Type
A M B I E N T C O N T R O L
S T A N D A R D
The low ambient cutout is adjustable from 25 °F to 60 °F
(-3.9 °C to 15.6 °C).
or
AMB I ENT CONTROL
L
O
WA
M
BIE
N
T
The low ambient cutout is programmable down to 0 °F
(-17.8 °C). A low ambient kit MUST be installed for
this option to be chosen. If the kit is NOT installed,
and low ambient is selected, low pressure faults and
compressor damage may occur.
Option 5 – Local/Remote Control Type
LOCA L / REMOT E MODE L
L
O
C
A
L
When programmed for LOCAL, an ISN or RCC control can be used to monitor only. The micro panel will
operate on locally programmed values and ignore all
commands from remote devices, or through the RS485 inputs. The chiller will communicate and send data
to the remote monitoring devices.
or
LOCA L / REMOT E MODE
R
E
M
O
T
E
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 L I QU I D
124
Unit control is based on return chilled liquid temp.
Return Chilled Liquid Control can only be selected on
units that have 4 to 6 compressors (dual system units).
or
CONTROL MODE
LEAVING LIQUID
Option 7 – Display Units
D I SPLAY UN I TS
I
M
P
E
RIA
L
This mode displays system operating values in Imperial units of °F or PSIG.
or
D I SPLAY UN I TS
SI
This mode displays system operating values in Scientific International Units of °C or barg.
Option 8 – Lead/Lag Type (two system units
only)
L EAD / L AG 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
L EAD / L AG CONTROL
MANUAL SYS 2 LEAD
SYS 2 selected as lead compressor.
or
L EAD / L AG CONTROL
A
U
T
O
M
A
TIC
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 will then assign the
“lead” to the system with the shortest average run time.
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
Option 9 – Condenser Fan Control Mode
F AN CONTROL
D I SCHARGE PRESSURE
Condenser fans are controlled by discharge pressure
only. This mode must be chosen.
or
F AN CONTROL
AMB I ENT & DSCH PRESS
Do not select this option on R-410A chillers.
Option 10 – Manual Override Mode
MANUAL OVERR I DE MODE
DIS
A
B
L
E
D
This option allows overriding of the daily schedule
that is programmed. MANUAL OVERRIDE MODE –
DISABLED indicates that override mode has no effect.
or
MANUAL OVERR I DE MODE
E
N
A
B
L
E
D
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
C U R R E N T F E E D B A C K
N O N E
This mode should be selected when the panel is not
equipped with current sensing capability.
or
C U R R E N T F E E D B A C K
O N E P E R U N I T
This mode should be selected when an optional 2ACE
Module is installed to allow combined current monitoring of all systems by sensing current on the incoming line.
or
JOHNSON CONTROLS
C U R R E N T F E E D B A C K
O N E P E R S Y S T E M
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 I/O.
SYS 2 input is to J8 of the I/O.
Option 12 – Power Fail Restart
P OWER FA I L RESTART
A
U
T
O
M
A
TIC
Chiller auto restarts after a power failure.
P OWER FA I L RESTART
M
A
N
U
A
L
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
S O F T S T A R T
D I S A B L E D
SOFT START “DISABLED” MUST be selected on all
chillers.
This message may not be viewable on non-European
chillers.
Option 14 – Unit Type
U N I T T Y P E
L I Q U I D C H I L L E R
The UNIT TYPE message cannot be modified under
the unit keys.
“Liquid CHILLER” must be displayed, or
damage to compressors or other components will occur if operated in the HEAT
PUMP or CONDENSING UNIT modes.
If unit type needs to be changed to make the unit a
liquid chiller, remove power and then remove the
jumper between J11-7 and J11-12 on the I/O Board.
Reapply power to the micro panel and the microprocessor will store the change.
125
7
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
Option 15 – Refrigerant Type
R E F R I G E R A N T T Y P E
R – 41 0 A
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.
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.
FLASHCARDUPDATING
P LEASE WA I T . . .
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.
FLASHCARDUPDATE ER
R
O
R
XXXXX
Option 16 – Expansion Valve Type
X P A N S I O N
E
V A L V E
T Y P E
T H E R M O S T A T I C
Expansion valve type, thermostatic or electronic
may be selected under Service 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.
If the update resulted in an error, the original program
will still be active. When 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 is bad.
Option 18 – Remote Temperature Reset
R EMOTE TEMP RESET I
N
P
U
T
XXXXXXXXXXXXXX
Remote Temp Reset input selection is programmable
according to the type of input utilized. The following
options are available:
• DISABLED (default)
Also see the UNIT KEYS PROGRAMMING QUICK
REFERENCE LIST in Figure 27 on page 128.
• 0.0 – 10.0 (DC)
Option 17 – Flash Card Update
• 0.0 – 20.0 mA
FLASHCARDUPDATE DIS
A
B
L
E
D
A Flash Card is used to input the operating program
into the chiller IPU. A Flash Card is used instead of an
EPROM. Normally, a Flash Card update is not required
and the message above will be displayed.
If the operating software is to be updated, insert the
Flash Card into the Flash Card input port. Turn off the
unit switch and set the FLASH CARD UPDATE TO
“ENABLED” using the ↑ and ↓ keys.
FLASHCARDUPDATE E
N
A
B
L
E
D
126
• 2.0 – 10.0V (DC)
• 4.0 – 20.0 mA
The options display message for Remote
Temp Reset Input only appears if the
Temp Reset Option is enabled under Service Mode. The option must be enabled
under the Service Mode for the Remote
Temperature Reset to operate.
Option 19 – Pump Control
Pump Control is utilized to operate the optional 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:
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
Y
O
R
KH
Y
D
R
O
KITP
U
M
P
S=
1
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 is ON and Remote Stop is closed.
Even if one of the above conditions are
true, the pump will not run if 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.
E
X
T
E
R
N
A
L E
V
A
PP
U
M
P
EXTERNAL EVAP PUMP should be selected if an external pump is being controlled with the chiller pump
contacts. The operation will be the same as YORK
HDRO KIT PUMPS = 1
The following option should not be selected.
Y
O
R
KH
Y
D
R
O
KITP
U
M
P
S=
2
Option 20 – Pump Selection
SECTION 7 – UNIT CONTROLS
Clock
The CLOCK display shows the current day, time, and
date. Pressing the CLOCK key will show the current
day, time, and date.
It is important that the date and time be correct, 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:
T O D A Y I S FRI 08 : 51AM
25JAN02
The line under the F is 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
↑ (UP) or ↓ (DOWN) arrow keys until the desired day
is displayed and then press the ENTER/ADV key at
which time the day will be accepted and the cursor will
move under the first digit of the “2 digit hour”. In a
similar manner, the hour, minute, meridian, month, day,
and year may be programmed, whenever the cursor is
under the first letter/numeral of the item. Press the ↑
(UP) or ↓ (DOWN) arrow keys until the desired hour,
minute, meridian; day, month, and year are displayed.
Pressing the ENTER/ADV key will save the valve and
move the cursor on to the next programmable variable.
The displays for this PUMP SELECTION option
should only appear if “YORK HYDRO KIT PUMPS =
2” are selected under Option 19. Presently, this option
should not be used.
JOHNSON CONTROLS
127
7
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
Options Key
(press Options Key
to adv.)
Display Language
System Switches
on/off
Expansion Valve Type
(Thermoplastic or Electric)
(Programmed under Service
Mode, Viewable Only)
Must be programmed
for Thermostatic
Flash Card Update
Chilled Liquid Type
(water or glycol)
Ambient Control
(standard or low)
Local/Remote Mode
Remote Temp Reset
Pump Control
Pump Selection
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)
Figure 27 provides a quick reference list for the Unit key setpoints.
LD07405d
Figure 27 - UNIT KEYS OPTIONS PROGRAMMING QUICK REFERENCE LIST
128
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
BACNET, MODBUS, N2 AND YORKTALK 2
COMMUNICATIONS
• RS-485: connect to TB2 - Network (-1) to TB2
(-1); Network (+1) to TB2 (+1)
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.
• RS-232: connect to TB3 - Network (RX) to TB3
(TXD); Network (TX) to TB3 (RXD); Network
(GND) to TB3 (GND)
BACnet and YorkTalk 2 RS485 networks are wired to
the + and - terminals of TB1 for port 1 communications. Modbus network connection has the option of
RS232 or RS485 connection for port 2 communications. Modbus network is wired to either TB2 or TB3
as follows:
Refer to Figure 28 on page 130 for TB1, TB2 and TB3
locations.
In most cases, communication parameters will need to
be modified. Table 30 on page 131 lists setup parameters for the available protocols. Modification is 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
DE MODIFIER ADDRESS
XXXXXXXXXX
XXXXX
P2 MANUAL MAC
DE MODIFIER OFFSET
XX
ADDRESS
P2 BAUD RATE
P1 PROTOCOL
XXXXX
XXXXXX
P2 PARITY
P1 MANUAL MAC
ADDRESS
XXX
7
XXXXX
XXX
P2 STOP BITS
P1 BAUD RATE
X
XXXXX
P2 HW SELECT BIT
P1 PARITY
XXXXX
XXXXX
REAL TIME ERROR
P1 STOP BITS
X
##
RESET 1 = YES, 0 = NO 0
Note: See Table 15 on page 132 for error descriptions
JOHNSON CONTROLS
129
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
035-02550-xxx I/O Board
LD14318
Figure 28 - MICRO PANEL CONNECTIONS
The table below shows the minimum, maximum, and
default values.
Table 13 - MINIMUM, MAXIMUM AND DEFAULT VALUES
MINIMUM
MAXIMUM
DEFAULT
DE MODIFIER ADDRESS
DESCRIPTION
-1
41943
-1
DE MODIFIER OFFSET
-1
99
-1
1200
76800
4800
P1 BAUD RATE
1200, 4800, 9600, 19200, 38400, 76800, AUTO SELECTABLE
P2 BAUD RATE
1200
57600
1200
1200, 4800, 9600, 19200, 38400, 57600 SELECTABLE
P1, P2 MANUAL Mac ADDRESS
P1, P2 PARITY
-1
127
-1
NONE
IGNORE
NONE
NONE, EVEN, ODD, IGNORE SELECTABLE
P1 PROTOCOL
BACNET
API
BACNET
MODBUS CLIENT
API
BACNET, API SELECTABLE
P2 PROTOCOL
TERMINAL
TERMINAL, MODBUS IO, MODBUS SERVER, API, MODBUS CLIENT SELECTABLE
P1, P2 STOP BITS
RESET REAL TIME ERROR
130
1
2
1
NO
YES
NO
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
The table below shows set-up requirements for each
communication protocol.
Table 14 - VALUES REQUIRED FOR BAS COMMUNICATION
SETTING DESCRIPTION
DE MODIFIER ADDRESS
DE MODIFIER OFFSET
P1 PROTOCOL
P1 MANUAL MAC ADDRESS
P1 BAUD RATE
P1 PARITY
PROTOCOL
BACNET MS/TP
MODBUS RTU5
YORKTALK 2
0 to 419433
1
-1
0 to 419433
0 to 994
0
N/A
0 to 994
BACNET
N/A
N/A
9n2
0-127
N/A
N/A
0-1271
9600 To 76800 or
Auto Selectable1
N/A
N/A
9600
NONE
N/A
N/A
NONE
1
N/A
N/A
1
P1 STOP BITS
1
N26
P2 PROTOCOL
N/A
MODBUS SVR
N/A
N/A
P2 MANUAL MAC ADDRESS
N/A
0-1271
N/A
N/A
P2 BAUD RATE
N/A
19,2002
N/A
N/A
P2 PARITY
N/A
NONE
N/A
N/A
P2 STOP BITS
N/A
1
N/A
N/A
P2 HW SELECT BIT
N/A
RS-485 or
RS-2321
N/A
N/A
RESET REAL TIME ERROR
N/A
N/A
N/A
N/A
P1 HW SELECT BIT
N/A
N/A
N/A
N/A
CHILLER ID
N/A
N/A
0
N/A
2
1. As required by network. 2. Or other as required by network. 3. Number is multiplied by 100, set as required by network.
4. Number is added to de modifier address, set as required by network.
5. Unit operating software version C.Mmc.13.03 or later required for Modbus Protocol.
6. Unit operating software version 04 (C.MMC.13.04, C.MMC.14.04, or C.MMC.16.04) or higher required for N2 protocol functionality.
7
BACnet and Modbus Communications
Analog Read Only Points
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:
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 513 + AI #.
Analog Write Points
Binary Monitor Only 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 #.
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 #.
Binary Write Points
This data can be read and modified using a BACnet
or Modbus network connection. The Modbus Register
Address for these points is 1537 + BV #.
JOHNSON CONTROLS
Refer to Table 16 on page 133 for complete list of
BACnet and Modbus registers.
The latest data map information is listed
on the Johnson Controls Equipment Integration website.
131
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
Communications Data Map Notes
(See Table 16)
1. IPU II based units are configured for Native BACnet MS/TP and Modbus RTU communications.
E-Link Gateway not required for these two communication protocols.
2. BACnet Object Types:
0 = Analog In
5 = Binary Value
1 = Analog Out
8 = Device
2 = Analog Value
15 = Alarm Notification (0 through 127
are reserved ASHRAE
Objects).
3 = Binary In
4 = Binary Output
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.
Table 15 - REAL TIME ERROR NUMBERS
ERROR
NUMBER
(##)
DESCRIPTION
0
ALL OK
1
DATUM TYPE OK TEST FAILED
2
ENGLISH TEXT TOO LONG
3
FLOATING POINT EXCEPTION
4
GET PACKET FAILED
5
GET TYPE FAILED
6
INVALID UNIT CONVERSION
7
INVALID HARDWARE SELECTION
8
REAL TIME FAULT
9
SPANISH TEXT TOO LONG
10
THREAD EXITED
11
THREAD FAILED
12
THREAD STALLED
13
IO BOARD RESET
14
BRAM INVALID
15
BACNET SETUP FAILED
Reboot required (cycle power) after settings are changed.
4. Water Cooled Scroll units use the same firmware
as Air Cooled Scroll units, ignoring Fan Control.
The table below shows the real time error numbers that
may be encountered during communication setup and
a description of each.
132
JOHNSON CONTROLS
JOHNSON CONTROLS
1030
1031
AV_5
AV_6
AV_7
16
17
18
19
20
21
22
23
24
25
27
28
29
30
31
32
33
34
35
36
37
38
39
40
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
ANALOG READ ONLY POINTS
LCHLT
AI_1
RCHLT
AI_2
DAT
AI_3
S1_SUCT_TEMP
AI_4
OAT
AI_5
S1_SUCT_SHEAT
AI_6
S1_RUN_TIME
AI_7
S1_SUCT_PR
AI_8
S1_DSCH_PR
AI_9
S1_CIR_TEMP
AI_10
S1_DEF_TEMP
AI_11
S1_EEV_OUT
AI_12
S1_AR_TIMER
AI_13
AC_TIMER
AI_14
S2_SUCT_TEMP
AI_15
S2_RUN_TIME
AI_16
S2_SUCT_PR
AI_17
S2_DSCH_PR
AI_18
S2_CIR_TEMP
AI_19
S2_DEF_TEMP
AI_20
S2_SUCT_SH
AI_21
S2_AR_TIMER
AI_22
S2_EEV_OUT
AI_23
MM Native Bacnet_Modbus_N2
1540
SS_SYS2
15
1539
1538
1032
BV_3
BV_1
BV_2
SS_SYS1
12
BINARY WRITE POINTS
START_STOP
REM_SP_HEAT
HP_MODE
1026
1027
1028
1029
AV_1
AV_2
AV_3
AV_4
ANALOG WRITE POINTS
REM_SETP
SP_REM_SP_S1
LOAD_LIMIT
REM_CR
SP_REM_SP_S2
MODBUS
ADDRESS
BACnet
Object/Inst
ance
BACnet NAME
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10*
X10
X10
X10
X10
X10
X10
n/a
n/a
n/a
div10
div10
n/a
div10
div10
div10
n/a
SEE NOTE 7
MODBUS
Scaling
ADF 8
ADF 9
ADF 10
ADF 11
ADF 12
ADF 13
ADF 14
ADF 15
ADF 16
ADF 17
ADF 18
ADF 19
ADF 20
ADF 21
ADF 22
ADF 23
ADF 24
ADF 25
ADF 26
ADF 27
ADF 28
ADF 29
ADF 30
BD 3
BD 2
BD 1
ADF 1
ADF 2
ADF 3
ADF 4
ADF 5
ADF 6
ADF 7
N2 Metasys
CK Sum
Native
Comments
Board: 031-02630-xxx w/ 031-02550
R/W
R/W
R/W
R/W
R/W
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
F°
index
0, 1
0, 1
0, 1
F°
F°
F°
F°
F°
F°
seconds
PSIG
PSIG
F°
F°
F°
seconds
seconds
°F
seconds
PSIG
PSIG
F°
F°
F°
F°
seconds
Leaving Chilled Liquid Temp
Return Chilled Liquid Temp
Disch Air Temp ( Condensing Units Only
Sys 1 Suction Temp (EEV & Cond Units Only)
Ambient Air Temperature
Sys 1 Suction Superheat ( EEV Models Only)
Sys 1 Run Time (seconds)
Sys 1 Suction Pressure
Sys 1 Discharge Pressure
Sys 1 Cooler Inlet Refrigerant Temp (R-407c Models Only)
Sys 1 Defrost Temperature (HP Only)
System 1 EEV Output % ( EEV Models Only)
Sys 1 Anti-Recycle Timer
Anti-Coincident Timer
System 2 Suction Temp ( EEVModels Only)
Sys 2 Run Time (seconds)
Sys 2 Suction Pressure
Sys 2 Discharge Pressure
Sys 2 Cooler Inlet Refrigerant Temperature(R-407c Only)
Sys 2 Defrost Temperature (HP Only)
Sys 2 Suction SuperHeat (EEV Models Only)
Sys 2 Anti-Recycle Timer
Sys 2 Suction Superheat ( EEV Models Only)
Sys 2 Start/Stop ( Suction Pressure (SP) Control Only)
Sys 1 Start/Stop ( Suction Pressure (SP) Control Only)
Stop Start Command
Heating Setpoint (HP Only), 999 = Auto (95F - 122F)
Mode (HP Only) (0=Panel, 1=Cooling, 2=Heating)
Setpoint Cooling
Setpoint(HP Only), 99 = Auto; (40°F - 70°F)
Sys 1 Setpoint (Suction Pressure Control units only)
Load Limit Stage (0, 1, 2) ( see note 2 below)
Cooling Range (DAT Mode Only)
Sys 2 Setpoint (Suction Pressure Control)
R/W
R/W
R/W
R/W
R/W
F°
PSIG
index
F°
PSIG
POINT DESCRIPTION
SEE NOTE 1
READ
WRITE
SEE NOTE 5
ENG
UNITS
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
1
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
2
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
3
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
4
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
6
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
7
Page 1 of 3
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
5
8
9
10
S=Standard; O = Optional; N = Not Available
Point List Code
Basildon MMHP with Board: 031-02630-xxx w/ 031-02550
Standard Micro Board 031-02550-xxx . Fix native Modbus communications. Fix Café Metric functionality (SCR-766)
MMHP with Board: 031-02630-xxx w/ 031-02550Fix native Modbus communications. Fix Café Metric functionality (SCR-766)
Basildon MMHP with Board: 031-02630-xxx w/ 031-02550 Fix native Modbus communications. Fix Café Metric functionality (SCR
Add AI 54, 55, 56, 57
Add AI 54, 55, 56, 57
Add AI 54, 55, 56, 57
Modbus, BACnet MS/TP, N2 Data Maps
Property of JCI/York International. Subject to change without notice
Small Tonnage Scroll IPU II NATIVE BACnet _Modbus _N2 Data Maps_ Rev A_10b
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
01,03,05,15,06,
16
01,03,05,15,06,
16
01,03,05,15,06,
03,06,16
03,06,16
03,06,16
03,06,16
03,06,16
03,06,16
03,06,16
Type Supported
MODBUS Data
York PN
031-02755-004
031-02755-001
031-02755-003
031-02755-004
031-02755-001
031-02755-003
031-02755-004
Date
29-Nov-06
17-Oct-08
17-Oct-08
17-Oct-08
3-Mar-09
3-Mar-09
3-Mar-09
Version
C.MMC.16.00
C.MMC.13.02
C.MMC.14.02
C.MMC.16.02
C.MMC.13.03
C.MMC.14.03
C.MMC.16.03
13
14
10
11
4
5
6
7
8
9
1
3
ITEM REF
NUM
1
2
3
4
5
6
7
8
9
10
ITEM
YCAL/YCUL/YCWL/YLAA/YLUA IPU II
5/23/2012
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
Table 16 - BACNET AND MODBUS COMMUNICATIONS DATA MAP
133
7
134
1282
1283
1284
1285
1286
1287
1288
1289
1290
AR_TIME
LCHLT_CUT
LOW_AMB_CUT
SUCT_P_CO_HT
L_SUCT_P_CO
H_DSCH_P_CO
COOL_SETP
SP_SETP_S1
CONTROL_RG
SP_CTL_RG_S1
SP_SETP_S2
HEAT_SETP
SP_CTL_RG_S2
HEAT_RANGE
S1_DSCH_TEMP
S1_DSCH_SHEAT
S2_DSCH_TEMP
S2_DSCH_SH
LEAVING_HOT
BINARY MONITOR ONLY POINTS
S1_ALARM
BI_1
S2_ALARM
BI_2
EVAP_HTR
BI_3
EVAP_PUMP
BI_4
S1_C1_RUN
BI_5
S2_C1_RUN
BI_6
S1_LLSV
BI_7
S1_MODE_SV
BI_8
S1_HGBV
BI_9
MM Native Bacnet_Modbus_N2
S1_BHS
S1_C2_RUN
S2_C2_RUN
S2_LLSV
S2_MODE_SV
87
88
89
90
RETURN_HOT
R_COOL_SETP
R_SP_SETP_S1
R_SP_SETP_S2
R_HEAT_SETP
BI_11
BI_12
BI_13
BI_14
BI_10
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
AI_33
AI_34
AI_35
AI_36
AI_37
AI_38
AI_39
AI_40
AI_41
AI_42
AI_43
AI_44
AI_45
AI_46
AI_47
AI_48
AI_49
AI_50
AI_51
AI_52
AI_53
AI_54
AI_55
AI_56
AI_57
CONTROL_MODE
1292
1293
1294
1295
1291
546
537
538
539
540
541
542
543
544
545
NUM_COMPS
S1_OP_CODE
S1_FLT_CODE
S2_OP_CODE
S2_FLT_CODE
S1_DBG_CODE
S1_FAN_STAGE
S2_DBG_CODE
S2_FAN_STAGE
MODBUS
ADDRESS
BACnet
Object/Inst
ance
AI_24
AI_25
AI_26
AI_27
AI_28
AI_29
AI_30
AI_31
AI_32
BACnet NAME
86
76
77
78
79
80
81
82
83
84
85
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
41
42
43
44
45
46
47
48
49
ITEM REF
NUM
BD 14
BD 15
BD 16
BD 17
BD 13
BD 4
BD 5
BD 6
BD 7
BD 8
BD 9
BD 10
BD 11
BD 12
ADF 41
ADF 42
ADF 43
ADF 44
ADF 45
ADF 46
ADF 47
ADF 48
ADF 49
ADF 50
ADF 51
ADF 52
ADF 53
ADF 54
ADF 55
ADF 56
ADF 57
ADF 58
ADF 59
ADF 60
ADF 61
ADF 62
ADF 63
ADF 64
ADF 40
ADF 31
ADF 32
ADF 33
ADF 34
ADF 35
ADF 36
ADF 37
ADF 38
ADF 39
N2 Metasys
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
seconds
F°
F°
PSIG
PSIG
PSIG
F°
F°
F°
F°
F°
F°
F°
F°
F°
F°
F°
F°
F°
F°
F°
F°
F°
F°
count
count
index
index
index
index
index
count
index
count
ENG
UNITS
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
READ
WRITE
Sys 1 Alarm
Sys 2 Alarm
Evaporator Heater Status
Evaporator Pump Status
Sys 1 Comp 1 Run
Sys 2 Comp 1 Run
Sys 1 Liquid Line Solenoid Valve
Sys 1 Mode Solenoid Valve (HP Only)
Sys 1 Hot Gas Bypass Valve
Bivalent Heat Source (YLAE HP Only), Tray Heater (YLPA HP
only)
Sys 1 Comp 2 Run
Sys 2 Comp 2 Run
Sys 2 Liquid Line Solenoid Valve
Sys 2 Mode Solenoid Valve (HP Only)
S
S
S
S
S
S
S
S
S
S
S
S
S
S
N
N
N
N
Remote Setpoint
Remote Setpoint 1 (SP Control)
Remote Setpoint 2 (SP Control)
Remote Heating Setpoint (HP and YCWL HP)
S
1
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
Air, 3=Suction Press, 4=Cooling, 5=Heating)
Point List Code
S
S
S
S
S
S
S
S
S
S
S
S
S
S
N
N
N
N
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
2
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
N
N
N
N
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
3
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
N
N
N
N
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
4
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
6
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
7
S
S
S
S
S
S
S
S
S
Page 2 of 3
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
5
S
S
S
S
S
S
S
S
S
8
9
10
S=Standard; O = Optional; N = Not Available
Anti-Recycle Time (Programmed)
Leaving Chilled Liquid Temp Cutout
Low Ambient Temperature Cutout
Low Suction Pressure Cutout Heating (HP Only)
Low Suction Pressure Cutout (Cooling on HP units )
High Discharge Pressure Cutout
Setpoint
Setpoint 1 (SP Control)
Cooling Range
Cooling Range 1 (SP Control)
Setpoint 2 (SP Control)
Heating Setpoint (HP Only)
Cooling Range 2 (SP Control)
Heating Range (HP Only)
Sys 1 Discharge Temperature (EEV Only)
Sys 1 Discharge Superheat (EEV Only)
Sys 2 Discharge Temperature (EEV Only)
Sys 2 Discharge Superheat (EEV Only)
Leaving Liquid Hot Temp (R-410a)
Return Liquid Hot Temp (R-410a)
Number of Compressors
Sys 1 Operational Code (Definition in Table A)
Sys 1 Fault Code (Definition in Table B)
Sys 2 Operational Code (Definition in Table A)
Sys 2 Fault Code (Definition in Table B)
Sys 1 Debug Code
Sys 1 Condenser Fan Stage
Sys 2 Debug Code
Sys 2 Condenser Fan Stage
Unit Control Mode
(0=Leaving Water, 1=Return Water, 2=Discharge
POINT DESCRIPTION
Property of JCI/York International. Subject to change without notice
Small Tonnage Scroll IPU II NATIVE BACnet _Modbus _N2 Data Maps_ Rev A_10b
n/a
n/a
n/a
n/a
n/a
01,02,03
01,02,03
01,02,03
01,02,03
01,02,03
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
X10
X10
X10
X10
X10*
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X10
X1
X1
X1
X1
X1
X1
X1
X1
X1
X1
MODBUS
Scaling
01,02,03
01,02,03
01,02,03
01,02,03
01,02,03
01,02,03
01,02,03
01,02,03
01,02,03
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
03,04
Type Supported
MODBUS Data
5/23/2012
SECTION 7 – UNIT CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
TABLE 16 - BACNET AND MODBUS COMMUNICATIONS DATA MAP (CONT’D)
JOHNSON CONTROLS
JOHNSON CONTROLS
BACnet
Object/Inst
ance
BI_15
BI_16
BI_17
BI_18
BI_19
BI_20
BI_21
BI_22
BI_23
14
15
16
17
18
19
20
12
13
11
Code
0
1
2
3
4
5
6
7
8
9
10
1296
1297
1298
1299
1300
1301
1302
1303
1304
MODBUS
ADDRESS
BD 18
BD 19
BD 20
BD 21
BD 22
BD 23
BD 24
BD 25
BD 26
N2 Metasys
Fault Codes
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
MODBUS
Scaling
Low Motor Current / MP / HPCO
Motor Current Unbalanced
Low Differential Oil Pressure
Ground Fault
MP/HPCO Fault
Low Evaporator Temperature
Incorrect Refrigerant Programmed
High Discharge Temperature
Improper Phase Rotation
High Oil Temperature
No Fault
VAC Under Voltage
Low Ambient Temperature
High Ambient Temperature
Low Leaving Chilled Liquid Temp
High Discharge Pressure
High Differential Oil Pressure
Low Suction Pressure
High Motor Current
LLSV Not On
Low Battery Warning
01,02,03
01,02,03
01,02,03
01,02,03
01,02,03
01,02,03
01,02,03
01,02,03
01,02,03
Type Supported
MODBUS Data
R
R
R
R
R
R
R
R
R
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
35
36
37
38
39
40
41
33
34
32
TABLE B
Code
21
22
23
24
25
26
27
28
29
30
31
READ
WRITE
ENG
UNITS
Fault Codes
Power Failure, Manual Reset Required
Unit Motor Current
Low Superheat
Sensor Fault
Discharge Inhibit
MP/HPCO Inhibit
Pump Trip
Pump Fail Make Flow
High Ambient Temperature
Lead System (0 = Sys 1, 1 = Sys 2)
Sys 1 Comp 3 Run
Sys 2 Comp 3 Run
Chilled Liquid Type (0=Water, 1=Glycol)
Ambient Control Mode (0=Std Amb, 1=Low Amb)
Local/Remote Control Mode (0=Local, 1=Remote)
Units (0=Imperial, 1=SI)
Lead/Lag Control Mode (0=Manual, 1=Auto)
Sys 2 HotGas Bypass Valve
POINT DESCRIPTION
Point List Code
1
S
S
S
S
S
S
S
S
N
3
S
S
S
S
S
S
S
S
N
4
S
S
S
S
S
S
S
S
N
5
S
S
S
S
S
S
S
S
N
Note
Property of JCI/York International. Subject to change without notice
Small Tonnage Scroll IPU II NATIVE BACnet _Modbus _N2 Data Maps_ Rev A_10b
6
S
S
S
S
S
S
S
S
N
7
S
S
S
S
S
S
S
S
N
8
9
10
Shaded Codes may not be
available on all models. Please
check the Fault and
Operational codes against the
codes published in your
operators manual or confirm
Code is available through the
display of your unit. If the Code
appears in the display, you will
recieve that value through the
BAS.
2
S
S
S
S
S
S
S
S
N
S=Standard; O = Optional; N = Not Available
Page 3 of 3
IPU II ( PN 031-02550-xxx ) based equipment are configured for Native BACnet MS/TP and Modbus RTU communications. The Microgateway product is not required for these 2 interfaces
Load Limit Stage 0 = 100% full run ( all compressors ) , 1 = 50% Run ( 4 compressor sys), 1 = 66% Run ( 6 compressor sys), 2 = 0% Run ( 4 compressor sys), 2 = 33% Run ( 6 compressor sys)
BACnet Object Types: 0= Analog In, 1 = Analog Out, 2= Analog Value, 3= Binary In, 4 = Binary Output, 5= Binary Value, 8= Device, 15 = Alarm Notification ( 0 -127 are reserved ASHRAE Objects)
WC= Inches of water column; CFM = Cubic Feer per Minute; FPM = Feet per Minute: PSI = Lbs per square inch; Pa = Pascals; kPa = Kilopascals; PPM = Part Per Million; kJ/kg = Kilojoules per Kilogram
See the applicable Middle Market Chiller Operations Manual for more details
The YCWL uses the same firmware as a YCAL , it just ignores Fan Control
Modbus values are all of type signed. Scaling values in 10X BOLD indicate that scaling in Metric is X100. Scaling and signing may not be modified in the field.
Suction Limiting
Discharge Limiting
Current limiting
Load Limiting
Compressor(s) Running
Heat Pump Load Limiting
Anti-Recycle Timer Active
Manual Override
Anti-Coincidence Timer Active
TABLE A
Operational Codes
No Abnormal Condition
Unit Switch Off
System Switch Off
Lock-Out
Unit Fault
System Fault
Remote Shutdown
Daily Schedule Shutdown
No Run Permissive
No Cool Load
LEAD_SYS
S1_C3_RUN
S2_C3_RUN
CH_LIQ_TYPE
AMB_MODE
CNTL_MODE
DATA_UNIT
AUTO_LL
S2_HGBV
BACnet NAME
MM Native Bacnet_Modbus_N2
NOTES
1
2
3
4
5
6
7
8
9
10
14
15
16
17
18
19
20
12
13
11
Code
0
1
2
3
4
5
6
7
8
9
10
91
92
93
94
93
94
95
96
97
ITEM REF
NUM
5/23/2012
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
TABLE 16 - BACNET AND MODBUS COMMUNICATIONS DATA MAP (CONT’D)
135
7
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
Yorktalk 2 Communications
Transmitted Data
Received Data (Control Data)
After receiving a valid transmission from the E-Link
Gateway, the unit will transmit either operational data
or history buffer data depending on the “History Buffer
Request” on ENG PAGE 10. Data must be transmitted
for every page under feature 54. If there is no value to
be sent to a particular page, a zero will be sent. Table
17 on page 137 shows the data values and page listings for this unit.
The unit receives eight data values from the E-Link
Gateway. The first four are analog values and the last
four are digital values. These eight data values are used
as control parameters when in REMOTE mode. When
the unit is in LOCAL mode, these eight values are ignored. If the unit receives no valid YorkTalk 2 transmission for 5 minutes it will revert back to all local
control values. Table 17 on page 137 lists the control
parameters. These values are found under feature 54 in
the E-Link Gateway.
136
The latest point map information is
listed on the Johnson Controls Equipment Integration website http://
my.johnsoncontrols.com/portal/myportal/
cg/prod/na/chiller_in
JOHNSON CONTROLS
JOHNSON CONTROLS
ASCII
PAGE
REF
P01
P02
P03
P04
P05
P06
P07
P08
P09
P10
P11
P12
P13
P14
P15
P16
P17
P18
P19
P20
P21
P22
P23
P24
P25
P26
P27
P28
P29
P30
P31
P32
P33
P34
P35
P36
P37
P38
P39
P40
ENG
PAGE
REF
P03
P04
P05
P06
P07
P08
P09
P10
P11
P12
P13
P14
P15
P16
P17
P18
P19
P20
P21
P22
P23
P24
P25
P26
P27
P28
P29
P30
P31
P32
P33
P34
P35
P36
P37
P38
P39
P40
P41
P42
Date
YORK P N
031-02049-001
031-02049-001
031-02049-001
flash
flash
flash
Checksum
944D
964B
2226
xxxx
xxxx
xxxx
Middle Market w/ 2050, 2550
Baud
4800
4800
4800
4800
4800
4800
ELINK
York Talk
Point
Type
A. Control
A. Control
A. Control
A. Control
D. Control
D. Control
D. Control
D. Control
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_switch (95)
SNVT_switch (95)
SNVT_switch (95)
SNVT_switch (95)
SNVT_switch (95)
SNVT_switch (95)
SNVT_switch (95)
nvoYTS01p014
nvoYTS01p015
nvoYTS01p016
nvoYTS01p017
nvoYTS01p018
nvoYTS01p019
nvoYTS01p020
nvoYTS01p021
nvoYTS01p022
nvoYTS01p023
nvoYTS01p024
nvoYTS01p025
nvoYTS01p026
nvoYTS01p027
nvoYTS01p028
nvoYTS01p029
nvoYTS01p030
nvoYTS01p031
nvoYTS01p032
nvoYTS01p033
nvoYTS01p034
nvoYTS01p035
nvoYTS01p036
nvoYTS01p037
nvoYTS01p038
nvoYTS01p039
nvoYTS01p040
nvoYTS01p041
nvoYTS01p042
SNVT_switch (95)
nviYTS01p009
SNVT_count_f (51)
SNVT_switch (95)
nviYTS01p008
nvoYTS01p013
SNVT_switch (95)
nviYTS01p007
nvoYTS01p012
SNVT_count_f (51)
nviYTS01p006
SNVT_switch (95)
SNVT_count_f (51)
nviYTS01p005
SNVT_count_f (51)
SNVT_count_f (51)
nviYTS01p004
nvoYTS01p011
SNVT_count_f (51)
nviYTS01p003
nviYTS01p010
LON SNVT
Type
LON Profile
Name
137
ADF 1
ADF 2
ADF 3
ADF 4
BD 1
BD 2
BD 3
BD 4
ADF 5
ADF 6
ADF 7
ADF 8
ADF 9
ADF 10
ADF 11
ADF 12
ADF 13
ADF 14
ADF 15
ADF 16
ADF 17
ADF 18
ADF 19
ADF 20
ADF 21
ADF 22
ADF 23
ADF 24
ADF 25
ADF 26
ADF 27
ADF 28
ADF 29
BD 5
BD 6
BD 7
BD 8
BD 9
BD 10
BD 11
N2
Address
O
S
S
O
S
S
S
S
O
O
S
O
S
S
S
S
S
S
S
S
Sys 1 EEV Output % (EEV only)
Sys 1 Anti- Recycle Timer
Anti-Coincident Timer
Sys Suction Temp ( EEV only)
Sys 2 Run Time (seconds)
Sys 2 Suction Pressure
Sys 2 Discharge Pressure
Sys 2 Cooler Inlet Refrigerant Temperature (R-407c systems Only)
Sys 2 Defrost Temperature ( HP only)
Sys 2 Suction Superheat (EEV only)
Sys 2 Anti-Recycle Timer
Sys 2 EEV Output % (EEV only)
Number of Compressors
Sys 1 Alarm
Sys 2 Alarm
Evaporator Heater Status
Evaporator Pump Status
Sys 1 Compressor 1 Run
Sys 2 Compressor 1 Run
Sys 1 Liquid Line Solenoid Valve
O
S
S
O
S
S
S
S
O
O
S
O
S
S
S
S
S
S
S
S
S
S
S
O
S
O
S
O
S
S
S
S
O
S
S
O
S
S
S
S
O
O
S
O
S
S
S
S
S
S
S
S
S
S
S
O
S
O
S
O
S
S
S
S
O
S
S
O
S
S
S
S
O
O
S
O
S
S
S
S
S
S
S
S
S
S
S
O
S
O
S
O
S
S
S
S
O
S
S
O
S
S
S
S
O
O
S
O
S
S
S
S
S
S
S
S
S
S
S
O
S
O
S
O
S
S
S
S
Property of York International York, PA
S
S
S
O
S
O
S
O
S
S
S
S
N = NOT AVAILABLE
1 2 3 4 5 6 7 8 9 10
S S S S S
S S S S S
O O O O O
O O O O O
S S S S S
History Buffer Request
Leaving Chilled Liquid Temp
Return Chilled Liquid Temp
Leaving Hot Liquid Temp (R-410a) Heat Mode Only
Discharge Air Temp ( Cond Unit) Return Hot Liquid Temp (410a- Heat Mod
Leaving Liquid Temp Hot (R-410a)
Ambient Air Temperature
Sys 1 Suction Superheat ( EEV only)
Sys 1 Run Time (seconds)
Sys 1 Suction Pressure
Sys 1 Discharge Pressure
Sys 1 Cooler Inlet Refrigerant Temperature(R-407c Only)
POINT LIST CODE:
S = STANDARD
O = OPTIONAL
POINT LIST DESCRIPTION
Setpoint
Load Limit Stage (0, 1, 2)
Heating Setpoint (HP and YCWL HP)
Mode (HP and YCWL HP only) (0=Panel, 1= Cooling, 2 = Heating)
Start/Stop Command
Tab: YCAL-YCWL-YLAA-YLUA-YCRL 2550)
8 - 11
12 - 15
16 - 19
20 - 23
24 - 27
28 - 31
32 - 35
36 - 39
40 - 43
44 - 47
48 - 51
52 - 55
56 - 59
60 - 63
64 - 67
68 - 71
72 - 75
76 - 79
80 - 83
84 - 87
88 - 91
92 - 95
96 - 99
100 - 103
104 - 107
108
109
110
111
112
113
114
York Talk
Character
Position
Page: 1
ENG
PAGE
REF
P03
P04
P05
P06
P07
P08
P09
P10
P11
P12
P13
P14
P15
P16
P17
P18
P19
P20
P21
P22
P23
P24
P25
P26
P27
P28
P29
P30
P31
P32
P33
P34
P35
P36
P37
P38
P39
P40
P41
P42
Micro Board: 031-02050/02550
COMMENTS
YCAL Micro Board 031-02050-xxx
YCAL Micro Board 031-02050-xxx
YCAL Micro Board 031-02050-xxx
YCAL Micro Board 031-02550-xxx, IPU 2 board.
YCWL ( water cooled version) Micro Board 031-02550-xxx, IPU 2 board.
Micro Board 031-02550-xxx . Fix native Modbus communications (SCR . Fix Café Metric functionality (SCR-766)
York Talk 2
Use ASCII page column for interfaces utilizing an ASCII XL Translator or MicroGateway to communicate to a chiller LINC
Version
C.MMC.03.02
C.MMC.03.01
C.MMC.03.00
C.MMC.13.xx
C.MMC.13.xx
C.MMC.13.02
Table 17 - YORKTALK 2 COMMUNICATIONS DATA MAP
Revision: YCAL_YCWL_YCUL_YLAA_YLUA Small Tonnage Scroll (Rev K_03 )
Ref.
Item
1
2
3
4
5
6
7
8
9
10
YCAL/YCWL/YLAA/YLUA/YCRL
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
7
138
ASCII
PAGE
REF
P41
P42
P43
P44
P45
P46
P47
P48
P49
P50
P51
P52
P53
P54
P55
P56
P57
P58
P59
P60
P61
P62
P63
P64
P65
P66
P67
P68
P69
P70
P71
P72
P73
P74
P75
P76
P77
P78
P79
P80
P81
P82
York Talk
Point
Type
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
Code Monitor
Code Monitor
Code Monitor
Code Monitor
Code Monitor
Code Monitor
Code Monitor
Code Monitor
Code Monitor
Code Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
A. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
D. Monitor
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_count_f (51)
SNVT_switch (95)
SNVT_switch (95)
SNVT_switch (95)
SNVT_switch (95)
SNVT_switch (95)
nvoYTS01p062
nvoYTS01p063
nvoYTS01p064
nvoYTS01p065
nvoYTS01p066
nvoYTS01p067
nvoYTS01p068
nvoYTS01p069
nvoYTS01p070
nvoYTS01p071
nvoYTS01p072
nvoYTS01p073
nvoYTS01p074
nvoYTS01p075
nvoYTS01p076
nvoYTS01p077
nvoYTS01p078
nvoYTS01p079
nvoYTS01p080
nvoYTS01p081
nvoYTS01p082
nvoYTS01p083
nvoYTS01p084
SNVT_switch (95)
nvoYTS01p054
nvoYTS01p061
SNVT_switch (95)
nvoYTS01p053
SNVT_count_f (51)
SNVT_switch (95)
nvoYTS01p052
nvoYTS01p060
SNVT_switch (95)
nvoYTS01p051
SNVT_count_f (51)
SNVT_switch (95)
nvoYTS01p050
nvoYTS01p059
SNVT_switch (95)
nvoYTS01p049
SNVT_count_f (51)
SNVT_switch (95)
nvoYTS01p048
nvoYTS01p058
SNVT_switch (95)
nvoYTS01p047
nvoYTS01p057
SNVT_switch (95)
nvoYTS01p046
SNVT_switch (95)
SNVT_switch (95)
nvoYTS01p045
SNVT_count_f (51)
SNVT_switch (95)
nvoYTS01p044
nvoYTS01p056
SNVT_switch (95)
nvoYTS01p043
nvoYTS01p055
LON SNVT
Type
LON Profile
Name
BD 12
BD 13
BD 14
BD 15
BD 16
BD 17
BD 18
BD 19
BD 20
BD 21
BD 22
BD 23
BD 24
ADI 1
ADI 2
ADI 3
ADI 4
ADI 5
ADI 6
ADI 7
ADI 8
ADI 9
ADI 10
ADF 30
ADF 31
ADF 32
ADF 33
ADF 34
ADF 35
ADF 36
ADF 37
ADF 38
ADF 39
ADF 40
ADF 41
ADF 42
ADF 43
BD 25
BD 26
BD 27
BD 28
BD 29
N2
Address
S
S
S
S
S
S
S
S
S
O
O
O
O
O
O
S
S
S
S
S
S
S
S
S
O
O
O
O
O
O
S
S
S
S
S
S
S
S
S
O
O
O
O
O
O
JOHNSON CONTROLS
Property of York International York, PA
NOTE: The Appropriate Product Code Listing Summary Should Accompany Document
S
S
S
S
S
S
S
S
S
O
O
O
O
O
O
N = NOT AVAILABLE
1 2 3 4 5 6 7 8 9 10
S S S S S
S S S S S
S S S S S
S S S S S
S S S S S
S S S S S
S S S S S
S S S S S
S S S S N
S S S S S
S S S S S
S S S S S
S S S S S
S S S S S
S S S S S
S S S S S
S S S S S
S S S S S
S S S S S
S S S S S
S S S S S
Unit Control Mode (0=Lv Wtr, 1=Ret Wtr, 2=Dis Air, 3=SP, 4=Cool, 5=Heat) S
Anti-Recycle Time (Programmed)
S
Leaving Chilled Liquid Temp Cutout
S
Low Ambient Temperature Cutout
S
Low Suction Pressure Cutout (Heating HP Only)
S
Low Suction Pressure Cutout (Cooling HP only)
S
High Discharge Pressure Cutout
S
Remote Setpoint
S
Cooling Range
S
Remote Setpnt 2 ( SP Control), Remote Heatng Setpnt ( HP and YCWL HPO
Cool Range Setpoint 2 (SP Control), Heat Range (HP and YCWL HP only) O
Sys 1 Discharge Temp (EEV only)
O
Sys 1 Discharge Superheat (EEV only)
O
Sys 2 Discharge Temp (EEV only)
O
Sys 2 Discharge Superheat (EEV only)
O
Sys 2 Condenser Fan Stage
Sys 1 Condenser Fan Stage
POINT LIST CODE:
S = STANDARD
O = OPTIONAL
POINT LIST DESCRIPTION
Sys 1 Hot Gas Bypass Valve
Sys 1 Compressor 2 Run
Sys 2 Compressor 2 Run
Sys 2 Liquid Line Solenoid Valve
Lead System (0 = Sys 1, 1 = Sys 2)
Sys 1 Compressor 3 Run
Sys 2 Compressor 3 Run
Chilled Liquid Type (0=Water, 1=Glycol)
Ambient Control Mode (0=Std Amb, 1=Low Amb)
Local/Remote Control Mode (0=Local, 1=Remote)
Units (0=Imperial, 1=SI)
Lead/Lag Control Mode (0=Manual, 1=Auto)
Sys 2 Hot Gas Bypass Valve
*Sys 1 Operational Code
*Sys 1 Fault Code
*Sys 2 Operational Code
*Sys 2 Fault Code
Page: 2
ENG
PAGE
REF
P43
P44
P45
P46
P47
P48
P49
P50
P51
P52
P53
P54
P55
P56
P57
P58
P59
P60
P61
P62
P63
P64
P65
P66
P67
P68
P69
P70
P71
P72
P73
P74
P75
P76
P77
P78
P79
P80
P81
P82
P83
P84
TABLE 17 - YORKTALK 2 COMMUNICATIONS DATA MAP (CONT’D)
Tab: YCAL-YCWL-YLAA-YLUA-YCRL 2550)
York Talk
Character
Position
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138 - 141
142 - 145
146 - 149
150 - 153
154 - 157
158 - 161
162 - 165
166 - 169
170 - 173
174 - 177
178 - 181
182 - 185
186 - 189
190 - 193
194
195
196
197
198
Revision: YCAL_YCWL_YCUL_YLAA_YLUA Small Tonnage Scroll (Rev K_03 )
ENG
PAGE
REF
P43
P44
P45
P46
P47
P48
P49
P50
P51
P52
P53
P54
P55
P56
P57
P58
P59
P60
P61
P62
P63
P64
P65
P66
P67
P68
P69
P70
P71
P72
P73
P74
P75
P76
P77
P78
P79
P80
P81
P82
P83
P84
SECTION 7 – UNIT CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
ENG
PAGE
P56
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
ASCII
PAGE
P54
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
JOHNSON CONTROLS
Shaded Codes may not be available on all
models. Please check the Fault and
Operational codes against the codes
published in your operators manual or confirm
Code is available through the display of your
unit. If the Code appears in the display, you
will recieve that value through the BAS.
* Note
C_OPER.CODE
No Abnormal Condition
Unit Switch Off
System Switch Off
Lock-Out
Unit Fault
System Fault
Remote Shutdown
Daily Schedule Shutdown
No Run Permissive
No Cool Load
Anti-Coincidence Timer Active
Anti-Recycle Timer Active
Manual Override
Suction Limiting
Discharge Limiting
Current Limiting
Load Limiting
Compressor(s) Running
Heat Pump Load Limiting ( HP Only)
Operational Code
ENG
PAGE
P57
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
ASCII
PAGE
P55
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
C_FAULT.CODE
No Fault Code
VAC Undervoltage
Low Ambient Temperature
High Ambient Temperature
Low Leaving Chilled Liquid Temperature
High Discharge Pressure
High Differential Oil Pressure
Low Suction Pressure
High Motor Current
LLSV Not On
Low Battery Warning
High Oil Temperature
High Discharge Temperature
Improper Phase Rotation
Low Motor Current / MP / HPCO
Motor Current Inpomabalanced
Low Differntail Oil Pressure
Grpound Fault
MP / HPCO Fault
Low Evaporator Temperature
Incorrect Refrigernat Programmed
Power Failure, Manual Reset Required
Unit Motor Current
Low Superheat
Sensor Fault
Discharge Inhibit
MP/HPCO Inhibit
Pump Trip
Pump Fail Make Flow
High Ambient Temperature
Fault Code
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 7 – UNIT CONTROLS
TABLE 17 - YORKTALK 2 COMMUNICATIONS DATA MAP (CONT’D)
7
139
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
THIS PAGE INTENTIONALLY LEFT BLANK
140
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 8 – UNIT OPERATION
Unit Operating Sequence
The operating sequence described below relates to 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 1 minute.
1. For the chiller system to run, the Flow Switch
must be closed, any remote cycling contacts must
be closed, the Daily Schedule must not be scheduling the chiller OFF, and temperature demand
must be present.
2. When power is applied to the system, the microprocessor will start a 2 minute timer. This is the
same timer that prevents an instantaneous start after a power failure.
3. At the end of the 2 minute timer, the microprocessor 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 assignment is made whenever
all systems shut down.
4. Several seconds after the compressor starts, that
systems first condenser fan will be cycled ON
(outdoor air temperature more than 25 °F (-4 °C)
or discharge pressure). See Standard Condenser
Fan Control on page 146 for details concerning
condenser fan cycling.
5. After 1 minute of compressor run time, the next
compressor in 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 minutes. Refer to the section on Capacity Control for
a detailed explanation of system and compressor
staging.
JOHNSON CONTROLS
7. As the load decreases below setpoint, the compressors 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 Leaving Chilled Liquid Control on page 142 for a detailed explanation.
8. When the last compressor in a “system” (two or
three compressors per system), is to be cycled
OFF, the system will initiate a pump-down. Each
“system” has a pump-down feature upon shut-off.
On a non-safety, non-unit switch shutdown, the
LLSV will be turned OFF and the last compressor
will be allowed to run until the suction pressure
falls below the suction pressure cutout or for 180
seconds, whichever comes first.
CAPACITY CONTROL
To initiate the start sequence of the chiller, all run permissive inputs must be satisfied (flow/remote start/stop
switch), and no chiller or system faults exist.
The first phase of the start sequence is initiated by the
Daily Schedule Start or any Remote Cycling Device. If
the 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.
141
8
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 8 – UNIT OPERATION
SUCTION PRESSURE LIMIT CONTROLS
The anticipatory controls are intended to prevent the
unit from ever actually reaching a low-pressure cutout. Loading is prevented, if the suction pressure drops
below 1.15 x suction pressure cutout (15% below the
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 it reaches a safety limit due to high load or dirty
condenser coils. The microprocessor 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.
LEAVING CHILLED LIQUID CONTROL
The setpoint, when programmed for Leaving Chilled
Liquid Control, is the temperature the unit will control
to within plus or minus the (control) cooling range. The
Setpoint High Limit is the Setpoint plus the Cooling
Range. The Setpoint Low Limit is the Setpoint minus
the Cooling Range. Figure 30 below should be used to
aid in understanding the following description of Leaving Chilled Liquid Control.
30 sec.
unloading
LWT
Contol Range
(no compressor staging)
44.0 ºF
(6.7 ºC)
Low Limit
46.0 ºF
(7.8 ºC)
Setpoint
60 sec.
loading
48.0 ºF
(8.9 ºC)
High Limit
Leaving Water Temp. Control - Compressor Staging
Setpoint = 46.0 ºF (7.8 ºC) Range = +/-2 ºF (1.1 ºC)
LD14404
Figure 29 - LEAVING WATER TEMPERATURE
CONTROL EXAMPLE
If the leaving chilled liquid temperature is above the
Setpoint High Limit, the lead compressor on the lead
system will be energized along with the liquid line solenoid. Upon energizing any compressor, the 60 second Anti-Coincidence timer will be initiated to prevent
multiple compressors from turning ON.
142
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
once every 60 seconds if the chilled liquid temperature
remains above the Setpoint High Limit and the chilled
liquid temperature is dropping less than 3 °F/min. The
lag system will not be allowed to start a compressor
until the lead system has run for 5 minutes.
If the chilled liquid temperature falls below the Setpoint High Limit but is greater than the Setpoint Low
Limit, loading and unloading do not occur. This area of
control is called the control range.
If the chilled liquid temperature drops to between Setpoint Low Limit and 0.5 °F (0.28 °C) below the Setpoint Low Limit, unloading (a compressor turns OFF)
occurs at a rate of 1 every 30 seconds. If the chilled
liquid temperature falls to a value greater than 0.5 °F
(0.28 °C) below the Setpoint Low Limit but not greater
than 1.5 °F (0.83 °C) below the Setpoint Low Limit,
unloading occurs at a rate of 20 seconds. If the chilled
liquid temperature falls to a value greater than 1.5 °F
(0.83 °C) below the Setpoint Low Limit, unloading occurs at a rate of 10 seconds. If the chilled liquid temperature falls below 1 °F above the low chilled liquid
temperature cutout, unloading occurs at a rate of 10
seconds if it is greater than 10 seconds.
In water cooling mode on R-410A chillers, the minimum low limit of the control range will be 40.0ºF. For
leaving chilled liquid temperature setpoint and control
range combinations that result in the low limit of the
control range being below 40.0ºF, the low limit will be
reset to 40.0ºF and the difference will be added to the
high limit. This will result in a control range the same
size as programmed but not allow the unit to run below
40.0ºF. 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 LWT is less than SP. Hot gas is turned OFF
as temperature rises when LWT is more than SP plus
CR/2. If temperature remains below the setpoint low
limit on the lowest step of capacity, the microprocessor
will close the liquid line solenoid, after turning off hot
gas, and pump the system down before turning off the
last compressor in a system.
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 8 – UNIT OPERATION
Table 18 - SAMPLE COMPRESSOR STAGING FOR RETURN WATER CONTROL
COMPRESSOR STAGING FOR RETURN WATER CONTROL
4 COMPRESSOR
COOLING SETPOINT = 45 °F (7.2 °C) RANGE = 10 °F (5.6 °C)
# OF COMP ON
0
* 1+HG
1
2
3
4
RWT
45 °F
(7.2 °C)
46.25 °F
(7.9 °C)
47.5 °F
(8.6 °C)
50.0 °F
(10.0 °C)
52.5 °F
(11.4 °C)
55.0 °F
(12.8 °C)
*Unloading only
LEAVING CHILLED LIQUID CONTROL
OVERRIDE TO REDUCE CYCLING
To avoid compressor cycling the microprocessor will
adjust the setpoint upward temporarily. The last run
time of the system will be saved. If the last run time
was greater than 5 minutes, no action is to be taken.
If the last run time for the lead system was less than 5
minutes, the microprocessor will increase the setpoint
high limit according to the chart at right, with a maximum value allowed of 50 °F (see Figure 29 on page
152).
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.
SETPOINT ADJUST (DEG. F)
The leaving chilled liquid setpoint is 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 from plus or minus1.5 °F to plus or
minus2.5 °F (plus or minus.83 °C to 1.39 °C).leaving
chilled liquid control.
6
5
4
3
2
1
0
0
1
2
3
4
5
6
LAST RUN TIME OF LEAD SYSTEM (MINUTES)
LD11415
Figure 30 - SETPOINT ADJUST
Table 19 - RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS)
*STEP
COMPRESSOR
COMPRESSOR ON POINT
COMPRESSOR OFF POINT
0
0
SETPOINT
SETPOINT
1
1 W/HGB
SP + CR/8 (Note 1)
SETPOINT
2
1 NO HGB
SP + CR/4
SP + CR/8
3
2
SP + 2*CR/4 (Note 2)
SP + CR/4
4
2
SP + 2*CR/4
SP + CR/4 (Note 3)
5
3
SP + 3*CR/4
SP + 2*CR/4
6
4
SP + CR
SP + 3*CR/4
NOTES:
1. Step 1 is Hot Gas Bypass and is skipped when loading occurs. Hot Gas Bypass operation is inhibited during Pumpdown.
2. Step 3 is skipped when loading occurs.
3. Step 4 is skipped when unloading occurs.
* STEP can be viewed using the OPER DATA key and scrolling to COOLING DEMAND.
JOHNSON CONTROLS
143
8
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 8 – UNIT OPERATION
LEAVING CHILLED LIQUID SYSTEM LEAD/
LAG AND COMPRESSOR SEQUENCING
A Lead/Lag option may be selected to help equalize
average run hours between systems with 2 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 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 chillers, the microprocessor 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 system first.
RETURN CHILLED LIQUID CONTROL
(Can be used on Dual System 4, 5 and 6 Comp
Units Only)
Return chilled liquid control is based on staging the
compressors to match the cooling load. The chiller
will be fully loaded when the return water temperature
is equal to the Cooling Setpoint plus the Range. The
chiller will be totally unloaded (all compressors OFF)
when the return water temperature is equal to the Cooling Setpoint (See sample in Table 18 on page 143).
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 19 on page 143.
Return Chilled Liquid Control MUST
only be used when constant chilled liquid
flow is ensured.
The range MUST always be programmed
to equal the temperature drop across
the evaporator when the chiller is “fully
loaded”. Otherwise, chilled liquid 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.
Table 20 - LEAD/LAG RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS)
LEAD SYSTEM
LAG SYSTEM
STEP
COMP 1
COMP 2
-
COMP 1
COMP 2
-
0
OFF
OFF
-
OFF
OFF
-
1
ON + HG
OFF
-
OFF
OFF
-
2
ON
OFF
-
3
ON
OFF
-
4
ON
ON
-
5
ON
ON
6
ON
ON
SEE NOTE 1
OFF
OFF
-
ON
OFF
-
OFF
OFF
-
-
ON
OFF
-
-
ON
ON
-
SEE NOTE 2
SEE NOTE 3
NOTES:
1. Step is Hot Gas Bypass and is skipped when loading occurs. Hot Gas Bypass operation is inhibited during pumpdown. For Leaving Chilled Liquid Control the Hot Gas Bypass solenoid is energized only when the lead compressor is running and the LWT < SP, the Hot Gas Bypass
solenoid is turned off when the LWT more than SP + CR/2.
2. Step 3 is skipped when loading occurs.
3. Step 4 is skipped when unloading occurs.
144
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
The return chilled liquid setpoint is programmable
from 40 °F to 70 °F (4.4 °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).
As an example of compressor staging (refer to Table 19
on page 143), a chiller with six compressors using a
Cooling Setpoint programmed for 45 °F (7.20 °C) and
a Range Setpoint of 10 °F (5.56 °C). Using the formulas in Table 19 on page 143, the control range will be
split up into six (seven including hot gas) segments,
with the Control Range determining the separation 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
point 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 19 on page 143 not only provides
the formulas for the loading (ON POINT) and unloading (OFF POINT) of the system, the “STEP” is also
shown in the table. The “STEP” is the increment in the
sequence of the capacity control scheme that can be
viewed under the OPER DATA key. Refer to Display/
Print Keys on page 107 for specific information on
the OPER DATA key.
RETURN CHILLED LIQUID SYSTEM LEAD/
LAG AND COMPRESSOR SEQUENCING
A Lead/Lag option may be selected to help equalize
average run hours between systems with 2 refrigerant systems. This may be programmed under the OPTIONS key. Auto Lead/Lag of the 2 systems based on
JOHNSON CONTROLS
SECTION 8 – UNIT OPERATION
average run hours of the compressors in each system.
Manual Lead/Lag selects specifically the sequence
which the microprocessor starts the systems.
The microprocessor will sequence compressors load
and unload systems according to Table 20 on page
144. 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 2 times in
a row. The microprocessor will not attempt to equalize
run time on individual compressors within a system.
Each compressor in a system will be assigned an arbitrary number 1, or 2. The non-running compressor
within a system with the lowest priority number will
always be the next compressor to start. The running
compressor with priority number 1 will always be the
next compressor to shut OFF. Whenever a compressor
is shut OFF, the priority numbers of all compressors
in each system will be decreased by 1 with the wrap
around. This control scheme assures the same compressor does not repeatedly cycle ON and OFF.
ANTI-RECYCLE TIMER
The programmable anti-recycle timer assures that systems do not cycle. This timer is programmable under
the PROGRAM key between 300 and 600 seconds.
Whenever possible, to reduce cycling and motor heating, the anti-recycle timer should be adjusted to 600
seconds. The programmable anti-recycle timer starts
the timer when the first compressor in a system starts.
The timer begins to count down. If all of the 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
timing controls are present in 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 a minimum time between compressor starts within
a system.
145
8
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 8 – UNIT OPERATION
pressors but one in the system will be shut OFF. The
LLSV will also be turned OFF. The final compressor
will be allowed to run until the suction pressure falls
below the cutout, or for 180 seconds, whichever comes
first.
EVAPORATOR PUMP CONTROL AND YORK
HYDRO KIT PUMP CONTROL
The evaporator pump dry contacts (XTBC2 – Terminals 23 and 24) are energized when any of the following conditions are true:
1. Low Leaving Chilled Liquid Fault
STANDARD CONDENSER FAN CONTROL
2. Any compressor is running
Condenser fan operation must be programmed with
the OPTIONS key under “Fan Control.” Condenser
fan must be selected for Discharge Pressure only. Fan
control by discharge pressure will work according to
the tables on the following pages (see Table 21 on page
147 and Table 22 on page 148). 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. Daily Schedule is ON, Unit Switch is ON and Remote Stop is closed
The pump will not run if the microprocessor panel
has been powered up for less than 30 seconds or if the
pump has run in the last 30 seconds to prevent pump
motor overheating.
Whenever the option “YORK HYDRO KIT PUMPS =
1” is 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. If a dual pump option is installed, the
active pump is selected by the selector switch.
The delay between turning ON and OFF fan stages is
always fixed at 5 seconds.
When a fan stage is turned ON by pressure, the on
pressure for the next stage is increased 20 PSIG and
ramped back to the programmed on pressure over the
next 20 seconds. Typically, standard ambient control
on pressure should be programmed at 385 PSIG with a
differential of 125 PSIG.
EVAPORATOR HEATER CONTROL
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 above 45 °F (7.2 °C) the heater is turned
OFF. An under voltage condition will keep the heater
OFF until full voltage is restored to the system.
When a fan stage is turned OFF (programmed on pressure minus programmed differential), the off pressure
for the next stage is decreased 20 PSIG and ramped
back to the programmed off pressure minus the differential over the next 20 seconds.
PUMPDOWN CONTROL
Condenser fan locations are shown in Figure 31 on
page 146. Detailed Standard Fan Control operation
is shown in Table 21 on page 147 and Table 22 on
page 148.
Each system has a pump-down feature upon shut-off.
Manual pumpdown from the keypad is not possible.
On a non-safety, non-unit switch shutdown, all com-
YLAA0180SE, YLAA0195HE,
YLAA0210SE
YLAA0220HE, YLAA0240SE,
YLAA0260HE, YLAA0285SE,
YLAA0320SE
YLAA0390HE
YLAA0300HE, YLAA0360HE,
YLAA0400SE
YLAA0441HE
YLAA0350HE, YLAA0435SE,
YLAA0485SE
YLAA0456HE, YLAA0516SE
LD17081
Figure 31 - CONDENSER FAN LOCATIONS
146
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 8 – UNIT OPERATION
Table 21 - Y
LAA STANDARD CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONLY (2, 3,
OR 4 FANS PER SYSTEM)
FAN
STAGE
1
2
3
ON*
OFF**
IPUII I/O OUTPUT
FAN
CONTACTOR
FAN #
SYS 1
SYS 2
SYS 1
SYS 2
SYS 1
SYS 2
DP > PROGRAMMED
FAN CONTROL ON
PRESSURE
DP < PROGRAMMED
FAN CONTROL ON
PRESSURE MINUS
PROGRAMMED
DIFFERENTIAL
PRESSURE
7B7-8
TB10-8
1-KF1
2-KF1
1-MF1
2-MF2
DP > PROGRAMMED
FAN CONTROL ON
PRESSURE AND FAN
STAGE 1 IS
ENERGIZED
DP < PROGRAMMED
FAN CONTROL ON
PRESSURE MINUS
PROGRAMMED
DIFFERENTIAL
PRESSURE AND FAN
STAGE 1 IS
ENERGIZED
TB7-8
and
TB7-9
TB10-8
and
TB10-9
1-KF1
and
1-KF2
2-KF1
and
2-KF2
1-MF1
and
1-MF2
2-MF1
and
2-MF2
2-KF1
and
2-KF2
and
2-KF3
3 FAN:
1-MF1
and
1-MF2
and
1-MF3
4 FAN:
1-MF1
and
1-MF2
and
1-MF3
and
1-MF4
3 FAN:
2-MF1
and
2-MF2
and
2-MF3
4 FAN:
2-MF1
and
2-MF2
and
2-MF3
and
2-MF4
DP > PROGRAMMED
FAN CONTROL ON
PRESSURE AND FAN
STAGES 1 AND 2 ARE
ENERGIZED
DP < PROGRAMMED
FAN CONTROL ON
PRESSURE MINUS
PROGRAMMED
DIFFERENTIAL
PRESSURE AND FAN
STAGES 1 AND 2
ARE ENERGIZED
TB7-8
and
TB7-9
and
TB7-10
TB108 and
TB10-9
and
TB10-10
1-KF1
and
1-KF2
and
1-KF3
* 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) between
turning fan stages on and off is fixed at
5 seconds.
JOHNSON CONTROLS
147
8
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 8 – UNIT OPERATION
Table 22 - YLAA STANDARD CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONLY (5 OR 6
FANS PER SYSTEM)
FAN
STAGE
1
2
3
IPUII I/O OUTPUT
FAN CONTACTOR
SYS 1
SYS 2
SYS 1
SYS 2
SYS 1
SYS 2
DP >
PROGRAMMED
FAN CONTROL
ON PRESSURE
DP <
PROGRAMMED
FAN CONTROL
ON PRESSURE
MINUS
PROGRAMMED
DIFFERENTIAL
PRESSURE
TB7-8
TB10-8
1-KF1
2-KF1
1-MF1
2-MF1
DP >
PROGRAMMED
FAN CONTROL
ON PRESSURE
AND FAN STAGE
1 IS ENERGIZED
DP <
PROGRAMMED
FAN CONTROL
ON PRESSURE
MINUS
PROGRAMMED
DIFFERENTIAL
PRESSURE
AND FAN
STAGE 1 IS
ENERGIZED
TB7-8
and
TB7-9
TB10-8
and
TB10-9
1-KF1
and
1-KF2
2-KF1
and
2-KF2
1-MF1
and
1-MF2
and
1-MF3
2-MF1
and
2-MF2
and
2-MF3
2-KF1
and
2-KF2
and
2-KF3
5 FAN:
1-MF1
and
1-MF2
and
1-MF3
and
1-MF4
and
1-MF5
6 FAN:
1-MF1
and
1-MF2
and
1-MF3
and
1-MF4
and
1-MF5
and
1-MF6
5 FAN:
1-MF1
and
1-MF2
and
1-MF3
and
1-MF4
and
1-MF5
ON*
OFF**
DP <
PROGRAMMED
FAN CONTROL
DP >
ON PRESSURE
PROGRAMMED
MINUS
FAN CONTROL
PROGRAMMED
ON PRESSURE
DIFFERENTIAL
AND FAN
PRESSURE
STAGES 1 AND 2
AND FAN
ARE ENERGIZED
STAGES 1 AND
2 ARE
ENERGIZED
TB7-8
and
TB7-9
and
TB7-10
TB10-8
and
TB10-9
and
TB10-10
1-KF1
and
1-KF2
and
1-KF3
FAN #
* 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.
** W
hen 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) between
turning fan stages on and off is fixed at
5 seconds.
148
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
LOAD LIMITING
Load Limiting is a feature that prevents the unit from
loading beyond the desired value. 2 and 4 compressor units can be load limited to 50%. This would allow
only 1 compressor per system to run. 3 and 6 compressor units can be load limited to 33% or 66%. The 66%
limit would allow up to 2 compressors per system to
run, and the 33% limit would allow only 1 compressor
per system to run. Five-compressor units may be load
limited to 40% (1 compressor per system runs) or 80%
(up to 2 compressors per system) are permitted to run.
No other values of limiting are available.
There are two ways to load limit the unit. The first is
through remote communication via an ISN. Load limit
stages are sent through YORK Talk on pages 9 and 10
of feature 54. Page 9 is stage 1 load limit and page 10
is stage 2 load limit.
A second stage of load limiting the unit is accomplished by closing contacts connected to the Load Limit
(XTBC1 – terminals 13-21) and PWM inputs (XTBC1
– terminals 13-20). Stage 1 of load limiting involves
closing the Load Limit input. Stage 2 of load limiting
involves closing both the Load Limit and PWM inputs.
The first stage of limiting is either 80%, 66% or 50%,
depending on the number of compressors on the unit.
The second stage of limiting is either 40% or 33% and
is only available on 3, 5 and 6 compressor units. Table
23 on page 149 shows the load limiting permitted for
the various numbers of compressors.
JOHNSON CONTROLS
SECTION 8 – UNIT OPERATION
Table 23 - COMPRESSOR OPERATION LOAD
LIMITING
COMPRESSORS
IN UNIT
STAGE 1
2
50%
-
3
66%
33%
4
50%
-
5
80%
40%
6
66%
33%
STAGE 2
Simultaneous operation of Remote Load
Limiting and EMS-PWM Temperature
Reset (described on following pages)
cannot occur.
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 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.
149
8
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 8 – UNIT OPERATION
REMOTE BAS/EMS TEMPERATURE RESET
USING A VOLTAGE OR CURRENT SIGNAL
The Remote Reset Option allows the Control Center
of the unit to reset the chilled liquid setpoint using a
0 to 10VDC input, or a 4 to 20mA input connected
to XTBC1 Terminals A- and A+. 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 to 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 0VDC
and 10VDC use the following formula:
If a 4 to 20mA signal is supplied, it is applied to Terminals A+ and A‑ and jumper JP1 on the I/O board
must be installed between pin 1 and 2. To calculate the
chilled liquid setpoint for values between 4mA and 20
mA use the following formula:
Setpoint = Local Chilled Liquid Setpoint + °Reset
°Reset = (mA signal ‑ 4) x (*Max 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)
Setpoint = Local Chilled Liquid Setpoint + °Reset
°Reset = 8mA x 10 °F
°Reset = (DC voltage signal) x (*Max Reset Value)
Setpoint = 45 °F + 5 °F = 50 °F
10
16
= 5 °F Reset
Example:
(Metric)
Local Chilled Liquid Setpoint = 45 °F (7.22 °C)
°Reset = 8mA x 5.56 °C
*Max Reset Value = 20 °F (11.11 °C)
Input Signal = 6VDC
Setpoint = 7.22 °C + 2.78 °C = 10.0 °C
(English)
°Reset = 6VDC x 20 °F
10
= 12 °F Reset
16
= 2.78 °C Reset
A 240 to 24 Volt Ratio Transformer (T3)
is used to derive nominal 12 volt output
from the 120 volt supply.
New Setpoint = 45 °F + 12 °F = 57 °F
(Metric)
°Reset = 6VDC x 11. 11 °C
10
= 6.67 °C Reset
New Setpoint = 7.22 °C + 6.67 °C = 13.89 °C
* M
ax Reset Value is the “Max EMS‑PWM Remote Temp. Reset”
setpoint value described in “Remote Setpoint Control” on page
117 under “Cooling Setpoints”. Programmable values are from 2
°F to 40 °F (1.11 °C to 11.11 °C).
150
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 9 – SERVICE AND TROUBLESHOOTING
CLEARING HISTORY BUFFERS
The history buffers may be cleared by pressing the
HISTORY key and then repeatedly pressing the UP
arrow key until you scroll past the last history buffer
choice. The following message will be displayed:
I I N I T I AL I ZE H I STORY
E
N
T
E
R=Y
E
S
Pressing the ENTER/ADV key at this display will
cause the history buffers to be cleared. Pressing any
other key will cancel the operation.
DO NOT CLEAR BUFFERS. Important
information may be lost. Contact factory
service.
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 is accidentally left
in this mode. Otherwise, turning the unit switch ON
will take the panel out of Service Mode.
SERVICE MODE – OUTPUTS
After pressing the key sequence as described, the 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 is used to
advance through the outputs. Using the ↑ and ↓ (UP/
DOWN ) arrow keys will turn the respective digital output ON/OFF or modify the value.
JOHNSON CONTROLS
Following is the order of outputs that will appear as the
ENTER/ADV key is pressed:
SYS 1 COMP 1 STATUS TB7-2 IS:
SYS 1 LLSV STATUS TB7-3 IS:
SYS 1 COMP 2 STATUS TB7-4 IS:
SYS 1 COMP 3 STATUS TB7-5 IS:
SYS 1 HGBP STATUS TB7-7 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 TB10-5 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 TB10-10 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 TB5-1, 2 = XXX%
SYS 2 EEV OUTPUT TB6-1, 2 = XXX%
SYS 1 COND FAN SPEED J15-1,5 = XXX%
SYS 2 COND FAN SPEED J15-2,6 = XXX%
SPARE AO J15-3,7 = XXX%
SPARE AO J15-4,8 = XXX%
DATA LOGGING MODE 1 = ON, 0 = OFF
DATA LOGGING TIMER X SECS
SOFT START (disabled)
REFRIGERANT TYPE (R-410A only)
EXPANSION VALVE TYPE (Thermostatic Only)
REMOTE TEMP RESET OPTION =
REMOTE INPUT SERVICE TIME =
“NORTH AMERICAN FEATURE SET ENABLED”
HYDRO PUMP SELECTION
EVAP PUMP TOTAL RUN HOURS
SYS 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:
151
9
SECTION 9 – SERVICE AND TROUBLESHOOTING
SYS1LLSVSTATUS
T
B
10
-3ISO
F
F
This display indicates that the system 1 liquid line solenoid valve is OFF, and the output connection from the
microboard is coming from terminal block 10 – pin 3.
Pressing the ↑ (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 deenergizing 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
(R-410A), and Expansion Valve Type
(Thermostatic), and North American
Feature (Enabled) MUST be properly
programmed or damage to compressors
and other system components may result
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 ↑ (UP) and ↓ (Down)
arrow keys, but under normal circumstances would not
be required or advised. After the last start display, the
microprocessor will display the first programmable
value under the PROGRAM key.
152
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SERVICE MODE – ANALOG AND DIGITAL
INPUTS
After entering Service Mode (PROGRAM ↑↑ ↓↓),
all digital and analog inputs to the microboard can be
viewed by pressing the OPER DATA key. After pressing the OPER DATA key, the ↑ (UP) arrow and ↓
(DOWN) arrow keys are used to scroll through the
analog and digital inputs.
Following is the order of analog and digital inputs that
will appear when sequenced with the ↓ (Down) arrow
key:
(analog inputs)
SYS 1 SUCT PRESSURE
UNIT TYPE
SYS 1 *DISCH PRESSURE
SYS 1** SUCTION TEMP.
SYS 2** SUCTION TEMP.
AMBIENT AIR TEMP.
LEAVING LIQUID TEMP.
RETURN LIQUID TEMP.
SYS 2 SUCTION PRESSURE
SYS 2 SPARE
SYS 2 *DISCH PRESSURE
SYS 1 MTR VOLTS
SYS 2 MTR VOLTS
(digital inputs)
PWM TEMP RESET INPUT
LOAD LIMIT INPUT
FLOW SW / REM START
SPARE
SINGLE SYSTEM SELECT
SYS 1 MP / HPCO INPUT
SYS 2 MP / HPCO INPUT
* The discharge pressure transducer is optional on some models.
** The suction temp. sensor is on EEV units only.
The analog inputs will display the input connection,
the temperature or pressure, and corresponding input
voltage such as:
SYS1SUCTPRJ7-10
2.1VDC=81PSIG
This example indicates that the system 1 suction pressure input is connected to plug 7 – pin 10 (J7-10) on the
I/O board. It indicates that the voltage is 2.1VDC which
corresponds to 81 PSIG (5.6 bars) suction pressure.
The digital inputs will display the input connection and
ON/OFF status such as:
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
FLO
WSW/REMSTART
J
13
-5ISO
N
This indicates that the flow switch/remote start input is
connected to plug 13- pin 5 (J13-5) on the microboard,
and is ON (ON = +30VDC unregulated input, OFF =
0VDC input on digital inputs).
CONTROL INPUTS/OUTPUTS
Table 24 through Table 27 on page 153 are a quick
reference list providing the connection points and a
description of the inputs and outputs respectively. All
input and output connections pertain to the connections
at the microboard.
Table 24 - I/O DIGITAL INPUTS
J13-2
Unit ON/OFF Switch
J13-3
Load Limit Stage 2 on 3, 5 & 6 Comp. Units
J13-4
Load Limit Stage 1
J13-5
Flow Switch and Remote Start/Stop
J13-6
Spare
J13-7
Single System Select
(Jumper = Single Sys, No Jumper = Two Sys)
J13-8
CR1
(Sys 1 Motor Protector/High Pressure Cutout)
J13-10
CR2
(Sys 2 Motor Protector/High Pressure Cutout)
SECTION 9 – SERVICE AND TROUBLESHOOTING
Table 26 - I/O ANALOG INPUTS
J7-10
SYS 1 Suction Transducer
-orSYS 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)
J6-9
Ambient Air Temp. Sensor
J6-7
Leaving Chilled Liquid Temp. Sensor
J6-8
Return Chilled Liquid Temp. Sensor
J9-10
SYS 2 Suction Pressure Transducer
-orSYS 2 Low Pressure Switch
J9-11
SYS 2 Discharge Pressure Transducer
(Optional)
J7-12
Unit/SYS 1 Voltage
J9-12
SYS 2 Voltage
J11-11 Remote Temperature Reset
Table 27 - I/O ANALOG OUTPUTS
N/A
Not Applicable
Table 25 - I/O DIGITAL OUTPUTS
TB7-2
SYS 1 Compressor 1
TB7-3
SYS 1 Liquid Line Solenoid Valve
TB7-4
SYS 1 Compressor 2
TB7-5
SYS 1 Compressor 3
TB7-7
SYS 1 Hot Gas Bypass Valve
TB10-2
SYS 2 Compressor 1
TB10-3
SYS 2 Liquid Line Solenoid Valve
TB10-4
SYS 2 Compressor 2
TB10-5
SYS 2 Compressor 3
TB7-8
SYS 1 Condenser Fan Output 1
TB7-9
SYS 1 Condenser Fan Output 2
TB7-10
SYS 1 Condenser Fan Output 3
TB10-8
SYS 2 Condenser Fan Output 1
TB10-9
SYS 2 Condenser Fan Output 2
TB10-10
SYS 2 Condenser Fan Output 3
TB8-2
Evaporator Heater
TB8-3
SYS 1 Alarm
TB9-2
SYS 2 Alarm
9
TB8-6 & 7 Evaporator Pump Starter
TB10-7
SYS 2 Hot Gas Bypass Valve
JOHNSON CONTROLS
153
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 9 – SERVICE AND TROUBLESHOOTING
TB6
TB5
I/O BOARD
J15
TB1
TB7
J3
TB8
J5
IPU
BOARD
TB9
J6
J7
J8
TB10
J9
J10
J14
J13
J12
J11
JP1
LD12721
Figure 32 - MICROBOARD LAYOUT
154
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
CHECKING INPUTS AND OUTPUTS
Digital Inputs
SECTION 9 – SERVICE AND TROUBLESHOOTING
Table 28 - OUTDOOR AIR SENSOR TEMPERATURE/VOLTAGE/CORRELATION
Refer to the unit wiring diagram. All digital inputs are
connected to J13-1 of the I/O board. The term “digital”
refers to two states – either ON or OFF. As an example,
when the flow switch is closed, 30VDC will be applied
to J13, pin 5 (J13-5) of the I/O board. If the flow switch
is open, 0VDC will then be present at J13-5.
TEMP °F
VOLTAGE
(SIGNAL INPUT
TO RETURN)
TEMP °C
0
0.7
-18
Pin 1 of J13 is an unregulated 30VDC source used to
supply the DC voltage to the various user contacts,
unit switch, flow switch, etc. This DC source is factory
wired to XTBC1, 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, 0VDC would be applied to that particular digital
input.
Typically, voltages of 24 to 36VDC could be measured
for the DC voltage on the digital inputs. This voltage is
in reference to ground. The unit case should be 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 the unit case (ground). Following are the connections for the temperature sensing inputs.
5
0.8
-15
10
0.9
-12
15
1.0
-9
20
1.1
-7
25
1.2
-4
30
1.4
-1
35
1.5
2
40
1.7
4
45
1.8
7
50
2.0
10
55
2.2
13
60
2.3
16
65
2.5
18
70
2.6
21
75
2.8
24
80
2.9
27
85
3.1
29
90
3.2
32
95
3.4
35
100
3.5
38
105
3.6
41
110
3.7
43
115
3.8
46
120
3.9
49
125
4.0
52
130
4.1
54
Outside Air Sensor
J6-6 = +5VDC regulated supply to sensor.
9
J6-9 = VDC input signal to the microboard.
See Table 28 on page 155 for voltage readings
that correspond to specific outdoor temperatures.
J6-3 = drain (shield connection = 0VDC) return
JOHNSON CONTROLS
155
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 9 – SERVICE AND TROUBLESHOOTING
Table 29 - ENTERING/LEAVING CHILLED LIQUID TEMP. SENSOR, TEMPERATURE/
VOLTAGE CORRELATION
156
Liquid and Refrigerant Sensor Test Points
(See Table 29 on page 156)
Entering Chilled Liquid Sensor
TEMP °F
VOLTAGE
(SIGNAL INPUT
TO RETURN)
TEMP °C
10
1.33
-12
12
1.39
-11
14
1.46
-10
16
1.51
-9
18
1.58
-8
20
1.65
-7
22
1.71
-6
J6-4 = +5VDC regulated supply to sensor.
24
1.78
-4
26
1.85
-3
28
1.91
-2
30
1.98
-1
J6-7 = VDC input signal to the microboard. See Table
29 on page 156 for voltage readings that correspond to specific liquid temperatures.
32
2.05
0
34
2.12
1
36
2.19
2
38
2.26
3
40
2.33
4
42
2.40
6
44
2.47
7
46
2.53
8
48
2.60
9
50
2.65
10
52
2.73
11
54
2.80
12
56
2.86
13
58
2.92
14
60
2.98
16
62
3.05
17
64
3.11
18
66
3.17
19
68
3.23
20
70
3.29
21
72
3.34
22
74
3.39
23
76
3.45
24
78
3.5
26
80
3.54
27
J6-5 = +5VDC regulated supply to sensor.
J6-8 = VDC input signal to the I/O board. See Table
29 on page 156 for voltage readings that correspond to specific liquid temperatures.
J6-2 = drain (shield connection = 0VDC) Return
Leaving Chilled Liquid Temperature Sensor
J6-1 = drain (shield connection = 0VDC) return
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 suction pressure transducers have a
range of 0 to 400 PSIG. The output will be linear from
0.5VDC to 4.5VDC over the 400 PSIG (27.5 barg)
range.
The discharge transducers have a range from 0 to
650 PSIG. The output will be linear from 0.5VDC to
4.5VDC over the 600 PSIG (41.25 barg) range. Following is the formula that can be used to verify the
voltage output of the transducer. All voltage reading
are in reference to ground (unit case).
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 9 – SERVICE AND TROUBLESHOOTING
J9-7 = +5VDC return
Table 30 - PRESSURE TRANSDUCERS
0-600 PSIG DISCHARGE
PRESSURE
TRANSDUCER
0-400 PSIG SUCTION
PRESSURE
TRANSDUCER
PRESSURE
PSIG
VOLTAGE
VDC
PRESSURE
PSIG
VOLTAGE
VDC
J9-2 = drain (shield connection = 0VDC)
The suction transducers have a range from 0 to 400
PSIG (27.5 barg). The output will be linear from
0.5VDC to 4.5VDC over the 400 PSIG (27.5 barg)
range. Following is a formula that can be used to verify
the voltage output of the transducer. All voltage reading are in reference to ground (unit case).
0
0.5
0
0.5
50
1.0
75
1.0
100
1.5
150
1.5
150
2.0
225
2.0
200
2.5
300
2.5
250
3.0
375
3.0
300
3.5
450
3.5
350
4.0
525
4.0
where V = DC voltage input to microprocessor
400
4.5
600
4.5
Pressure = pressure sensed by transducer
RED WIRE = 5V, BLACK WIRE = 0V, WHITE/GREEN WIRE = SIGNAL
TEST POINTS:
Suction Pressure:
System 1: ...............................................Microboard J7-10 to J7-9
System 2: ...............................................Microboard J9-10 to J9-9
Discharge Pressure:
System 1: ...............................................Microboard J7-11 to J7-7
System 2: ...............................................Microboard J9-11 to J9-7
V = (Pressure in PSIG x .01) + .5
or
V = (Pressure in BARG x .145) + .5
V = (Pressure in PSIG x .02) + .5
or
V = (Pressure in barg x .29) + .5
Following are the I/O board connections for the Suction Transducer.
System 1 Suction Transducer
J7-5 = +5VDC regulated supply to transducer.
J7-10 = V
DC input signal to the microboard. See the
formula above for voltage readings that correspond to specific suction pressures.
J7-9 = +5VDC return.
J7-1 = drain (shield connection = 0VDC).
where V = DC voltage output
System 2 Suction Transducer
Pressure = pressure sensed by transducer
J9-5 = +5VDC regulated supply to transducer.
The I/O board connections for the Discharge
Transducers are as follows.
System 1 Discharge Transducer
J9-10 = V
DC input signal to the microboard. See the
formula above for voltage readings that correspond to specific suction pressures.
J7-6 = +5VDC regulated supply to transducer.
J7-9 = +5VDC return.
J7-11 = V
DC input signal to the microboard. See the
formula above for voltage readings that correspond to specific discharge pressures.
J7-11 = drain (shield connection = 0VDC).
J7-7 = +5VDC return
J7-2 = drain (shield connection = 0VDC)
System 2 Discharge Transducer
J9-6 = +5VDC regulated supply to transducer.
9
Digital Outputs
Refer to the unit wiring diagram and Figure 33 on page
158. The digital outputs are located on TB7, TB8, and
TB9 and TB-10 of the microboard. All outputs are
120VAC with the exception of TB8-6 to TB8-7 which
are the contacts that can be used for a remote evaporator pump start signal. The voltage applied to either of
these terminals would be determined by field wiring.
J9-11 = VDC input signal to the microboard. See the
formula above for voltage readings that correspond to
specific discharge pressures.
JOHNSON CONTROLS
157
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 9 – SERVICE AND TROUBLESHOOTING
Each output is controlled by the microprocessor by
switching 120VAC to the respective output connection
energizing contactors, evaporator heater, and solenoids
according to the operating sequence.
120VAC is supplied to the I/O board via connections
at TB7-1, TB7-6, TB10-1, TB10-6, TB8-1 and TB9-1.
Figure 34 illustrates the relay contact architecture on the
microboard.
TB7-2
SYS 1
COMP 1
TB7-3
LLSV 1
TB7
TB7-5
SYS 1
COMP 2
SYS 1
COMP 3
TB7-7
SYS 1
HGSV
TB7-4
TB7-8
TB7
TB7-9
SYS 1
FAN 2
SYS 1
FAN 1
SYS 2
TB10-4 COMPR 2 (5)
SYS 2
TB10-5 COMPR 3 (6)
SYS 2
TB10-7 HGSV
TB10-8
TB8
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 is P/N 950915576. The cable to
connect the printer can either be locally assembled
from the parts listed, or ordered directly from WEIGHTRONIX under part number 287-040018.
Parts
TB10-9 SYS 2
FAN 2
SYS 2
TB10-10 FAN 4
The following parts are required:
1. WEIGH-TRONIX model 1220 printer.
2. Desk top calculator paper, 2.25” (5.7cm) wide.
TB8-7
EVAP
PUMP
TB8-2
HEAT EXCH
HEATER
LD12722
Figure 33 - I/O BOARD RELAY CONTACT
ARCHITECTURE
The WEIGH-TRONIX printer can be obtained by contacting WEIGH-TRONIX for purchase information at:
Santa Rosa, CA 95402
TB10-3 LLSV 2
TB8-6
Johnson Controls recommends the field tested WEIGHTRONIX model 1220 printer (or former IMP 24). This
is a compact low cost printer that is ideal for service
work and data logging.
2320 Airport Blvd.
SYS 2
TB10-2 COMPR 1 (4)
TB10
The micro panel is capable of supplying a printout
of chiller conditions or fault shutdown information at
any given time. This allows operator and service personnel to obtain data and system status with the touch
of the keypad. In addition to manual print selection,
the micro panel will provide an automatic printout
whenever a fault occurs. Detailed explanation of the
print function is given under Print Key on page 110.
WEIGH-TRONIX
SYS 1
TB7-10 FAN 3
TB10
OPTIONAL PRINTER INSTALLATION
3. Twisted Pair Shielded Cable (minimum 3 conductor), #18 AWG stranded, 300V minimum insulation, 25 ft. (7.62m) maximum length.
4. One 25 pin Cannon connector and shell.
5. Cannon P/N DB-25P connector, or equivalent.
6. Cannon P/N DB-C2-J9 shell.
158
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 9 – SERVICE AND TROUBLESHOOTING
Assembly and Wiring
Obtaining a Printout
All components should be assembled and wired as
shown in Figure 34. Strip the outside insulation back
several inches and individual wires about 3/8” (9.5
mm) to connect the cable at the Microboard. Do not
connect the shield at the printer-end of the cable.
A printout is obtained by pressing the PRINT key on
the keypad and then pressing either the OPER DATA
key or HISTORY key.
Printer
Chiller Microboard
TB3
TB3-3 TXD
2 RD
TB3-2 CTS
5 CTS
TB3-5 GND
7 SG
Shield (connect shield to Pin 5
of the connector.
Do not connect shield
at printer end.
LD12723
Figure 34 - PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS
9
JOHNSON CONTROLS
159
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 9 – SERVICE AND TROUBLESHOOTING
TROUBLESHOOTING
Table 31 - TROUBLESHOOTING
PROBLEM
CAUSE
1. No 115VAC to 24VAC
Transformer.
SOLUTION
1a. Check wiring and fuse 1FU.
1b. Check wiring emergency stop contacts 5 to
L of XTBC2 Terminal Block.
1c. Replace Control Transformer.
NO DISPLAY ON PANEL. UNIT
WILL NOT OPERATE
2. No 24VAC to Microboard.
2. Check wiring Control Transformer to
Microboard.
3. Control Transformer defective,
no 24VAC output.
3. Replace Control Transformer.
4. Short in wire to temp. sensors or
pressure transducers.
4. Unplug connections at IPU II & I/O Board to
isolate.
5. Defective IPU II & I/O Board or
the Display Board.
5. Replace IPU II & I/O Board or the Display
Board.
Contact Johnson Controls
Service before replacing circuit Boards!
FLOW SWITCH/REM STOP NO
RUN PERMISSIVE
LOW SUCTION PRESSURE
FAULT
HIGH DISCHARGE PRESSURE
FAULT
160
1. No chilled liquid flow.
1. Check chilled liquid flow.
2. Flow switch improperly installed.
2. Check that the flow switch is installed
according to manufacturer’s instructions.
3. Defective flow switch.
3. Replace flow switch.
4. Remote cycling device open.
4. Check cycling devices connected to
terminals 13 and 14 of the XTBC1 Terminal
Block.
1. Improper suction pressure
cutouts adjustments.
1. Adjust per recommended settings.
2. Low refrigerant charge.
2. Repair leak if necessary and add refrigerant.
3. Fouled filter dryer.
3. Change dryer/core.
4. TXV defective.
4. Replace TXV.
5. Reduced flow of chilled liquid
through the cooler.
5. Check GPM (See Operational Limitations on
page 43). Check operation of pump, clean
pump strainer, purge chilled liquid system of
air.
6. Defective suction pressure
transducer/low pressure switch
or wiring.
6. Replace transducer/low pressure switch or
faulty switch or wiring. Refer to SECTION 9
– SERVICE AND TROUBLESHOOTING for
pressure/voltage formula.
7. LLSV defective
7. Replace LLSV
1. Condenser fans not operating or
operating backwards.
1. Check fan motor, and contactors. Assure fan
blows air upward.
2. Too much refrigerant.
2. Remove refrigerant.
3. Air in refrigerant system.
3. Evacuate and recharge system.
4. Defective discharge pressure
transducer.
4. Replace discharge pressure transducer.
Refer to SECTION 9 – SERVICE AND
TROUBLESHOOTING for pressure/voltage
formula.
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 9 – SERVICE AND TROUBLESHOOTING
TABLE 31 - TROUBLESHOOTING (CONT’D)
PROBLEM
LOW LIQUID TEMP FAULT
MP / HPCO FAULT
COMPRESSOR(S) WON’T START
LACK OF COOLING EFFECT
CAUSE
SOLUTION
1. Improperly adjusted leaving
chilled liquid temp. cutout (glycol
only).
1. Re-program the leaving chilled liquid temp.
cutout.
2. Micro panel setpoint/range
values improperly programmed.
2. Re-adjust setpoint/range.
3. Chilled liquid flow too low.
3. Increase chilled liquid flow. Refer to
Operational Limitations on page 43).
4. 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).
4. Compare sensor against a known good
Temperature sensing device. Refer to Table
29 on page 156
1. Compressor internal motor
protector (MP) open.
1. Verify refrigerant charge is not low. Verify
superheat setting of 10 °F to 15 °F (5.6 °C to
8.3 °C). Verify correct compressor rotation.
Verify compressor is not overloaded.
2. External overload tripped.
2. Determine cause and reset.
3. HPCO switch open.
3. See High Press. Disch. Fault.
4. Defective HPCO switch.
4. Replace HPCO switch.
5. Defective CR relay.
5. Replace relay.
1. Demand not great enough.
1. No problem. Consult Installation Manual to
aid in understanding compressor operation
and capacity control.
2. Defective water temperature
sensor.
2. Compare the display with a thermometer.
Should be within plus or minus 2 degrees.
Refer to Table 29 on page 156 for RWT/
LWT temp./voltage table.
3. Contactor/Overload failure.
3. Replace defective part.
4. Compressor failure.
4. Diagnose cause of failure and replace.
1. Fouled evaporator surface.
Low suction pressure will be
observed.
1. Contact the local Johnson Controls service
representative.
2. Improper flow through the
evaporator.
2. Reduce flow to within chiller design specs.
See Operational Limitations on page 43).
3. Low refrigerant charge. Low
suction pressure will be
observed.
3. Check subcooling and add charge as
needed.
9
JOHNSON CONTROLS
161
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
THIS PAGE INTENTIONALLY LEFT BLANK
162
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 10 – MAINTENANCE
It is the responsibility of the equipment owner to perform maintenance on the system.
Important
CONDENSER FAN MOTORS
Condenser fan motors are permanently lubricated and
require no maintenance.
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.
Condenser MCHX
COMPRESSORS
CONDENSER MCHX CLEANING
Oil Level check
The cleaning procedure for the condenser MCHX is
significantly different than tube and fin type MCHX.
Care must be taken to understand the differences to
avoid damage to the MCHX. These differences require
a number of DO NOT’s that must be observed:
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, it is acceptable if the oil
level falls to the bottom limit of the oil sight glass.
Use YORK “V” oil when adding oil.
Oil Analysis
The oil used in these compressors is pale yellow in
color (POE oil). If the oil color darkens or exhibits a
change in color, this may be an indication of 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 vacuum. Doing so will cause internal arcing
of the compressor motor which will result
in failure of compressor.
JOHNSON CONTROLS
Dirt should not be allowed to accumulate on the
MCHX condenser surfaces. Cleaning should be as
often as necessary to keep coils clean.
Exercise care when cleaning the MCHX
so that the fins are not damaged.
• DO NOT use coil cleaners or any chemical on
a MCHX. This can cause severe damage to the
coils.
• DO NOT use a pressure washer to clean the
MCHX. While it is possible to clean a the MCHX
with a pressure washer, it’s also possible to destroy it.
• DO NOT contact the MCHX with a hard surface
such as a hose nozzle or metal vacuum nozzle or
any other tool.
Follow the three steps below for cleaning the MCHX:
1. Remove surface debris such as dirt, leaves, insects,
fibers, etc. with a vacuum cleaner having a soft attachment rather than a metal tube. Compressed air
blown from the inside out can also be used. When
brushing debris off the face of the MCHX a soft
bristle (not wire) brush can be used. Do not scrape
the MCHX with the vacuum nozzle, air nozzle, or
any other tool.
163
10
SECTION 10 – MAINTENANCE
2. Rinse the MCHX with tap water. Do not use
MCHX cleaners. Rinse the coil from the inside
out, running water through every passage in the
heat exchanger surface until it is clean. Use a 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.
3. Because of the fin geometry, the condenser
MCHX retain water more than tube and fin style.
It is generally recommended to blow or vacuum
out the rinse water from the MCHX to speed drying and prevent water pooling.
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 SECTION 8 – UNIT
OPERATION, SECTION 6 – COMMISSIONING, and
SECTION 4 – INSTALLATION of this manual.
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
BRAZED PLATE HEAT EXCHANGER
(EVAPORATOR) HEATER
The internal power supply to the Evaporator Heater is 120VAC. Disconnecting
120VAC power from the unit, at or below
freezing temperatures, can result in damage to the evaporator and unit as a result
of the chilled liquid freezing.
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.
ON-BOARD BATTERY BACK-UP
The Real Time Clock chip (U5) located on the 03102630 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 JP1 installed when the 128K bram
is installed.
Do not confuse JP1 on the IPU II (03102630) board with JP1 on the I/O (03102550) board.
164
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 10 – MAINTENANCE
TEMPERATURE
TEMPERATURE CONVERSION
CONVERSION CHART
CHART
Temperature Conversion Chart Actual Temperatures
°F
0
4
8
12
16
20
24
28
32
36
40
44
48
52
56
60
64
68
72
76
80
84
88
92
96
100
104
108
112
116
120
124
128
132
136
140
144
148
152
156
160
164
168
172
176
180
184
188
192
196
200
204
208
212
216
220
224
228
232
236
240
244
=
JOHNSON CONTROLS
°C
-17.8
-15.6
-13.3
-11.1
-8.9
-6.7
-4.4
-2.2
0.0
2.2
4.4
6.7
8.9
11.1
13.3
15.6
17.8
20.0
22.2
24.4
26.7
28.9
31.1
33.3
35.6
37.8
40.0
42.2
44.4
46.7
48.9
51.1
53.3
55.6
57.8
60.0
62.2
64.4
66.7
68.9
71.1
73.3
75.6
77.8
80.0
82.2
84.4
86.7
88.9
91.1
93.3
95.6
97.8
100.0
102.2
104.4
106.7
108.9
111.1
113.3
115.6
117.8
°C
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
=
Temperature Conversion Chart Differential Temperatures
°F
-0.4
3.2
6.8
10.4
14
17.6
21.2
24.8
28.4
32
35.6
39.2
42.8
46.4
50
53.6
57.2
60.8
64.4
68
71.6
75.2
78.8
82.4
86
89.6
93.2
96.8
100.4
104
107.6
111.2
114.8
118.4
122
125.6
129.2
132.8
136.4
140
143.6
147.2
150.8
154.4
158
161.6
165.2
168.8
172.4
176
179.6
183.2
186.8
190.4
194
197.6
201.2
204.8
208.4
212
215.6
219.2
°F
0
4
8
12
16
20
24
28
32
36
40
44
48
52
56
60
=
°C
0
2.2
4.4
6.7
8.9
11.1
13.3
15.6
17.8
20
22.2
24.4
26.7
28.9
31.1
33.3
°C
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
=
°F
0
3.6
7.2
10.8
14.4
18
21.6
25.2
28.8
32.4
36
39.6
43.2
46.8
50.4
54
=
PSI
21.8
29
36.3
43.5
50.8
58
65.3
72.5
79.8
87
94.3
101.5
108.8
116
123.3
130.5
137.8
145
152.3
159.5
166.8
174
181.3
188.5
195.8
203
210.3
217.5
224.8
232
239.3
246.5
253.8
261
268.3
275.5
282.8
290
297.3
Pressure Conversion Chart Gauge or Differential
PSI
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
370
380
390
400
=
BAR
1.38
2.07
2.76
3.45
4.14
4.83
5.52
6.21
6.9
7.59
8.28
8.97
9.66
10.34
11.03
11.72
12.41
13.1
13.79
14.48
15.17
15.86
16.55
17.24
17.93
18.62
19.31
20
20.69
21.38
22.07
22.76
23.45
24.14
24.83
25.52
26.21
26.9
27.59
BAR
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
7.5
8
8.5
9
9.5
10
10.5
11
11.5
12
12.5
13
13.5
14
14.5
15
15.5
16
16.5
17
17.5
18
18.5
19
19.5
20
20.5
165
10
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
SECTION 10 – MAINTENANCE
R-410A PRESSURE TEMPERATURE CHART
166
PSIG
TEMP ˚F
PSIG
TEMP ˚F
0
-60
78
20
2
-58
80
21
4
-54
85
24
6
-50
90
26
8
-46
95
29
10
-42
100
32
12
-39
105
34
14
-36
110
36
16
-33
115
39
18
-30
120
41
20
-28
125
43
22
-26
130
45
24
-24
135
47
26
-20
140
49
28
-18
145
51
30
-16
150
53
32
-14
160
57
34
-12
170
60
36
-10
180
64
38
-8
190
67
40
-6
200
70
42
-4
210
73
44
-3
220
76
46
-2
225
78
48
0
235
80
50
1
245
83
52
3
255
85
54
4
265
88
56
6
275
90
58
7
285
92
60
8
295
95
62
10
305
97
64
11
325
101
66
13
355
108
68
14
375
112
70
15
405
118
72
16
500
134
74
17
600
149
76
19
700
159
JOHNSON CONTROLS
FORM 150.72-ICOM7 (614)
ISSUE DATE 6/10/2014
The following factors can be used to convert from
English to the most common SI Metric values.
Table 32 - SI METRIC CONVERSION
MEASUREMENT
MULTIPLY ENGLISH UNIT
BY FACTOR
TO OBTAIN METRIC UNIT
Capacity
Tons Refrigerant Effect (ton)
3.516
Kilowatts (kW)
Power
Horsepower
0.7457
Kilowatts (kW)
Flow Rate
Gallons / Minute (gpm)
0.0631
Liters / Second (l/s)
Feet (ft)
0.3048
Meters (m)
Inches (in)
25.4
Millimeters (mm)
Weight
Pounds (lbs)
0.4538
Kilograms (kg)
Velocity
Feet / Second (fps)
0.3048
Meters / Second (m/s)
Feet of Water (ft)
2.989
Kilopascals (kPa)
Pounds / Square Inch (psi)
6.895
Kilopascals (kPa)
Length
Pressure Drop
TEMPERATURE
To convert degrees Fahrenheit (°F) to degrees Celsius
(°C), subtract 32° and multiply by 5/9 or 0.5556.
To convert a temperature range (i.e., a range of 10°F)
from Fahrenheit to Celsius, multiply by 5/9 or 0.5556.
Example: (45.0°F - 32°) x 0.5556 = 27.2°C
Example: 10.0°F range x 0.5556 = 5.6 °C range
JOHNSON CONTROLS
167
P.O. Box 1592, York, Pennsylvania USA 17405-1592
Copyright © by Johnson Controls 2014
Form 150.72-ICOM7 (614)
Issue Date: June 10, 2014
Supersedes: 150.72-ICOM7 (414)
Tele. 800-861-1001
www.johnsoncontrols.com
Subject to change without notice. Printed in USA
ALL RIGHTS RESERVED
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