Ycav
Ycav
LIQUID CHILLERS
INSTALLATION, OPERATION, MAINTENANCE Supersedes 201.21-NM1 (315) Form 201.21-NM1 (616)
035-20552-000
YCAV STYLE A
MODELS YCAV0157-0267, 60 HZ
(150-260 TONS)
E/V HIGH EFFICIENCY AND S/P STANDARD EFFICIENCY
LD10477
R134a
Issue Date:
June 30, 2016
FORM 201.21-NM1 (616)
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or
During rigging, installation, operation, maintenance, death to themselves and people at the site.
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to: This document is intended for use by owner-authorized
heavy objects, refrigerants, materials under pressure, rigging, installation, and operating/service personnel. It
rotating components, and both high and low voltage. is expected that these individuals possess independent
Each of these items has the potential, if misused or training that will enable them to perform their assigned
handled improperly, to cause bodily injury or death. It tasks properly and safely. It is essential that, prior to
is the obligation and responsibility of rigging, instal- performing any task on this equipment, this individual
lation, and operating/service personnel to identify and shall have read and understood the on-product labels,
recognize these inherent hazards, protect themselves, this document and any referenced materials. This in-
and proceed safely in completing their tasks. Failure dividual shall also be familiar with and comply with
to comply with any of these requirements could result all applicable industry and governmental standards and
in serious damage to the equipment and the property in regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
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 accor-
dance 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 warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.
2 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
JOHNSON CONTROLS 3
FORM 201.21-NM1 (616)
The DC Voltage on the VSD DC Bus will take 5 minutes to bleed off, after AC
power is removed. Always check the DC Bus Voltage with a Voltmeter to assure
the capacitor charge has bled off before working on the system.
• NEVER place loose tools, debris, or any objects inside the Control Panel/VSD
Cabinet.
• NEVER allow the Control Panel VSD Cabinet doors to remain open if there is
a potential for rain to enter the panel. Keep doors closed and assure all latches
are engaged on each door unless the unit is being serviced.
4 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
TABLE OF CONTENTS
SECTION 1 - GENERAL CHILLER SECTION 3 - RIGGING, HANDLING & STORAGE
INFORMATION & SAFETY
DELIVERY AND STORAGE....................................26
INTRODUCTION.......................................................9 INSPECTION.............................................................26
WARRANTY...............................................................9 MOVING THE CHILLER.........................................26
SAFETY.......................................................................9 Lifting Weights.......................................................26
Standards for Safety................................................9 UNIT RIGGING.........................................................27
RESPONSIBILITY FOR SAFETY...........................10
ABOUT THIS MANUAL..........................................10 SECTION 4 - INSTALLATION
MISUSE OF EQUIPMENT.......................................10
Suitability for Application.....................................10 LOCATION REQUIREMENTS.................................29
Structural Support..................................................10 OUTDOOR INSTALLATION....................................29
Mechanical Strength..............................................10 INDOOR INSTALLATION........................................29
General Access......................................................10 LOCATION CLEARANCES.....................................30
Pressure Systems................................................... 11 VIBRATION ISOLATORS........................................30
Electrical................................................................ 11 Installation..............................................................30
Rotating Parts........................................................ 11 SHIPPING BRACES..................................................30
Sharp Edges........................................................... 11 CHILLED LIQUID PIPING.......................................30
Refrigerant & Oils................................................. 11 General Requirements............................................30
High Temperature & Pressure Cleaning................ 11 WATER TREATMENT...............................................32
Emergency Shutdown............................................ 11 CONNECTION TYPES & SIZES..............................32
COOLER CONNECTIONS.......................................32
SECTION 2 - PRODUCT DESCRIPTION Option Flanges........................................................32
REFRIGERANT RELIEF VALVE PIPING...............33
INTRODUCTION.....................................................12 DUCTWORK CONNECTION..................................33
General System Description..................................12 General Requirements............................................33
Compressor............................................................13 ELECTRICAL CONNECTION.................................33
Evaporator.............................................................14 POWER WIRING.......................................................34
Condensor..............................................................14 115 VAC CONTROL SUPPLY TRANSFORMER....34
Flash Tank Feed / Drain Valve...............................15 CONTROL PANEL WIRING.....................................34
Oil Separator / Oil System.....................................15 VOLTS FREE CONTACTS.......................................35
Relief Valves..........................................................15 Chilled Liquid Pump Starter...................................35
Oil Cooling............................................................16 Run Contact............................................................35
Capacity Controls..................................................16 Alarm Contact........................................................35
Power and Control Panel.......................................16 SYSTEM INPUTS......................................................35
Microprocessor & VSD Controls..........................16 Flow Switch............................................................35
Display...................................................................17 Remote Run/Stop....................................................35
Keypad...................................................................17 Optional Remote Setpoint Offset Temp.................35
Unit Switch............................................................17 Optional Remote Setpoint Offset Sound Limit......35
Variable Speed Drive (VSD).................................18
ACCESSORIES & OPTIONS...................................19 SECTION 5 - COMMISSIONING
Single Point Circuit Breaker..................................19
Building Automation System (BAS) Interface......19 PREPARATION..........................................................36
Condensor Coil Protection....................................19 PREPARATION - POWER OFF................................36
DX COOLER OPTIONS...........................................20 Inspection...............................................................36
SERVICE VALVE OPTION......................................20 Refrigerant Charge.................................................36
UNIT ENCLOSURES...............................................20 Service and Oil Line Valves...................................36
FANS..........................................................................20 Compressor Oil.......................................................36
SOUND REDUCTION OPTIONS............................20 Fans.........................................................................36
VIBRATION ISOLATION........................................20 Isolation / Protection...............................................36
UNIT NOMENCLATURE........................................21 Control Panel..........................................................36
PRODUCT IDENTIFICATION NUMBER..............22 Power Connections.................................................37
JOHNSON CONTROLS 5
FORM 201.21-NM1 (616)
TABLE OF CONTENTS (CONT’D)
Grounding..............................................................37 CHILLER ELECTRONIC COMPONENTS...........158
Water System.........................................................37 Keypad.................................................................158
Flow Switch...........................................................37 Display.................................................................159
Temperature Sensor(s)...........................................37 Chiller Control Board..........................................160
Programmed Options.............................................38 Relay Output Boards...........................................161
Programmed Settings.............................................38 VSD (Variable Speed Drive)...............................161
Date & Time..........................................................38 AC to DC Rectifier..............................................161
Start / Stop.............................................................38 SCR Trigger Board..............................................162
Setpoint & Remote Offset.....................................38 DC Link Filter.....................................................162
FIRST TIME STARTUP............................................38 1L Line Inductor..................................................163
Interlocks...............................................................38 AC to DC Inverter...............................................163
Unit Switch............................................................38 Laminated Bus Structure.....................................163
Start-Up.................................................................38 VSD Logic Board................................................164
Oil Pressure...........................................................38 Control Panel to VSD Communications..............164
Refrigerant Flow....................................................39 IBGT Gate Driver Boards....................................165
Loading..................................................................39 Current Transformers...........................................165
Condensor & Fan Rotation....................................39 DV/DT Output Suppression Network.................166
Suction Super Heat................................................39 Flash Tank Feed/Drain Valve Controller.............166
Sub-Cooling...........................................................39 DC Bus Voltage Isolation Board..........................167
General Operation.................................................39 Chiller Circuit Breaker........................................167
Autotransformer..................................................167
SECTION 6 - TECHNICAL DATA CHILLER CONFIGURATION JUMPERS.............168
Number of Compressors Configuration Jumpers.. 168
WATER PRESSURE DROP CHARTS.....................40
VSD LOGIC TO CHILLER MICROPROCESSOR
GLYCOL CORRECTION FACTORS.......................41
BOARD RS-485 COMMUNICATION
WATER TEMP. AND FLOWS..................................42
CONFIGURATION JUMPERS..............................168
PHYSICAL DATA.....................................................44
OPERATING LIMITATIONS AND SOUND POWER..... 48 MAX VSD FREQUENCY......................................169
ELECTRICAL DATA................................................49
ELECTRICAL NOTES.............................................54 SECTION 7 - OPERATION
ELEMENTARY WIRING DIAGRAM.....................56
CONNECTION DIAGRAM.....................................60 OPERATING CONTROLS.....................................170
LOCATION LABEL..................................................64 BASIC OPERATING SEQUENCE.........................172
DIMENSIONS...........................................................66 NUMBER OF COMPRESSORS TO START.........173
TECHNICAL DATA (CLEARANCES)..................122 General................................................................173
WEIGHT DIST. & ISOLATOR MOUNTING........124 Standard IPLV.....................................................173
ISOLATOR MOUNTING POSITIONS..................125 Optional Optimized IPLV....................................173
SEISMIC ISOLATOR INSTALLATION................128 MINIMUM VSD COMPRESSOR
NEOPRENE ISOLATOR POSITION.....................130 START/RUN FREQUENCY...............................174
1" DEFLECTION ISOLATOR INSTALLATION...131 Minimum VSD Start Frequency..........................174
REFRIGERANT FLOW DIAGRAM......................133 Minimum VSD Run Frequency...........................174
PROCESS & INSTRUMENTATION DIAGRAM.... 134 ACCELERATION/DECELERATION RATE
COMPONENT LOCATIONS.................................135 WHEN STARTING & STOPPING
EQUIPMENT START-UP CHECK SHEET...........152 COMPRESSORS.....................................................175
Unit Checks (NO power).....................................152 VSD Acceleration/ Deceleration Rates...............175
Panel Checks STANDARD IPLV CAPACITY CONTROL.........176
(Power ON-both system switches OFF)..............154 Fuzzy Logic Control............................................177
Programmed Values.............................................155 Hot Water Starts...................................................178
Chilled Liquid Setpoint............................................155 Lag Compressor Operation in Load Limiting.....178
Date/Time, Daily Schedule, & Clock Jumper.....156 OPTIONAL IPLV CAPACITY CONTROL............179
Initial Start-Up.....................................................156 Fuzzy Logic.........................................................180
Check Subcooling & Superheat...........................156 Hot Water Starts...................................................181
Leak Checking.....................................................157 LOAD LIMITING CONTROL...............................182
6 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
TABLE OF CONTENTS (CONT’D)
FLASH TANK DRAIN/FEED VALVE UNIT SETUP MODE..............................................272
CONTROLLER.......................................................185 DEFAULT PROGRAMMABLE VALUES.............274
Valve Controller & Control Algorithm ...............185 SERIAL PORT CONNECTIONS............................275
ECONOMIZER CONTROL....................................188 ANALOG INPUT CONNECTIONS.......................276
CONDENSER FAN CONTROL.............................189 DIGITAL INPUT CONNECTIONS........................278
VSD TEMPERATURE CONTROL/FAN ANALOG OUTPUT CONNECTIONS...................280
CONTROL OPERATION........................................191 DIGITAL OUTPUT CONNECTIONS....................282
REMOTE TEMPERATURE RESET CONTROL...192 ISN COMMUNICATIONS & TRANSMITTED DATA 284
Local Current Limit Control...............................193
Pulldown Current Limit Setpoint........................193 SECTION 9 - MAINTENANCE
REMOTE CURRENT LIMIT RESET ...................194
Sound Limit Controls..........................................196 R-134A CONVERSION TABLES..........................291
MAINTENANCE....................................................291
SECTION 8 - MICROPANEL General Requirements.........................................291
MAINTENANCE REQUIREMENTS....................292
VSD OPERATION & CONTROLS........................198 TROUBLESHOOTING GUIDE.............................294
VSD Cooling and Cooling Loop.........................200 EVACUATING A SYSTEM....................................296
VSD SAFETIES......................................................204 WARRANTY POLICY............................................297
IBGT Gate Driver (Hardware) Fault...................207 New Equipment...................................................297
Power Supply (Hardware) Fault..........................209 Reconditioned or Replacement Materials...........297
UNIT WARNINGS..................................................212 All Warranties are VIOD if..................................297
UNIT SAFETIES.....................................................216 CHILLED LIQUID & SUCTION TEMP
SYSTEM SAFETIES..............................................218 SENSOR INPUT VOLTAGE TABLE.....................298
STATUS KEY..........................................................224 OUTSIDE AIR TEMP SENSOR INPUT
UNIT DATA KEY....................................................228 VOLTAGE TABLE..................................................299
SYSTEM DATA KEY..............................................230 PRESSURE TRANSDUCER OUTPUT
VSD DATA KEY.....................................................234 VOLTAGE TABLE..................................................300
OPERATING HOURS & START KEYS................236 MOTOR TEMPERATURE SENSOR
HISTORY KEY........................................................237 RESISTANCE TABLE............................................301
Unit Data.............................................................239
COMPRESSOR MOTOR OVERLOAD SETTINGS
VSD Data.............................................................239
& MAXIMUM VSD FREQUENCY.......................302
System Data.........................................................240
Compressor Operating Hours & Starts................242 PRINTER WIRING.................................................303
Chilled Liquid & Cooling Setpoints...................242 Okidata 184.........................................................304
Options................................................................242 Weigh-Tronix IMP Model 2600..........................304
Program Values....................................................243 Seiko....................................................................304
SETPOINTS KEY...................................................245 OPERATING LOG..................................................305
PROGRAM KEY.....................................................247 Site and Chiller Info............................................305
OPTIONS KEY........................................................250 Programmed Values.............................................305
DATE/TIME & SCHEDULE KEY.........................254 Unit Operating Temperature, Pressures,
Date/Time Key.....................................................254 & Currents...........................................................306
Schedule Key.......................................................255 System Operating Conditions..............................307
Unit Operating Schedule.....................................256 Water System Conditions....................................308
Sound Limit Schedule.........................................257 Condensor Conditions.........................................308
MANUAL OVERRIDE KEY..................................258 RECOMMENDED SPARE PARTS........................309
PRINT KEY.............................................................259
Operating Data Printout.......................................260
History Data Printout...........................................261
SERVICE KEY........................................................262
SYSTEM SWITCHES KEY....................................268
SERIAL NUMBER PROGRAMMING..................269
ENABLING OPTIMIZED HIGH IPLV MODE.....271
JOHNSON CONTROLS 7
General Chiller Information & Safety
FORM 201.21-NM1 (616)
Rigging and lifting should only be done by a profes- • The initial start of the unit must be carried out by
sional rigger in accordance with a written rigging and trained personnel from an Authorized YORK Ser-
lifting plan. The most appropriate rigging and lifting vice Center. See Commissioning (Page 36).
method will depend on job specific factors, such as the • Only genuine YORK approved spare parts, oils,
rigging equipment available and site needs. Therefore, coolants, and refrigerants must be used. Recom-
a professional rigger must determine the rigging and mendations on spare parts stocking can be found
lifting method to be used, and it is beyond the scope of on Page 307.
this manual to specify rigging and lifting details.
• All the scheduled maintenance operations detailed
This manual contains all the information required for in this manual must be performed at the specified
correct installation and commissioning of the unit, to- times by suitably trained and qualified personnel.
gether with operating and maintenance instructions. The See Maintenance Section, Page 288-307.
manuals should be read thoroughly before attempting • Failure to satisfy any of these conditions will auto-
to operate or service the unit. matically void the warranty. See Warranty Policy
(Page 295).
All procedures detailed in the manuals, including in-
stallation, commissioning and maintenance tasks must
SAFETY
only be performed by suitably trained and qualified
personnel. Standards for Safety
YCAV chillers are designed and built within an ISO
The manufacturer will not be liable for any injury or
9002 accredited design and manufacturing organization.
damage caused by incorrect installation, commission-
The chillers comply with the applicable sections of the
ing, operation or maintenance resulting from a failure
following Standards and Codes:
to follow the procedures and instructions detailed in
the manuals. • ANSI/ASHRAE Standard 15, Safety Code for Me-
chanical Refrigeration.
WARRANTY
• ANSI/NFPA Standard 70, National Electrical Code
(N.E.C.).
YORK International warrants all equipment and materi-
als against defects in workmanship and materials for a • ASME Boiler and Pressure Vessel Code, Section
period of eighteen months from date of shipment, unless VIII Division 1.
labor or extended warranty has been purchased as part • ARI Standard 550/590-98, Water Chilling Packages
of the contract. Using the Vapor Compression Cycle.
The warranty is limited to parts only replacement and • ASHRAE 90.1 Energy Standard for Building Except
shipping of any faulty part, or sub-assembly, which has Low-Rise Residential Buildings.
failed due to poor quality or manufacturing errors. All • ARI 370 Sound Rating of Large Outdoor Refrigera-
claims must be supported by evidence that the failure tion and Air Conditioning Equipment.
has occurred within the warranty period, and that the In addition, the chillers conform to Underwriters Labo-
unit has been operated within the designed parameters ratories (U.L.) for construction of chillers and provide
specified. U.L./cU.L. Listing Label.
JOHNSON CONTROLS 9
PRODUCT DESCRIPTION
FORM 201.21-NM1 (616)
RESPONSIBILITY FOR SAFETY The contents of this manual include suggested best
working practices and procedures. These are issued for
Every care has been taken in the design and manufac- guidance only, and they do not take precedence over
ture of the unit to ensure compliance with the safety the above stated individual responsibility and/or local
requirements listed above. However, the individual safety regulations.
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 YORK which reserves all rights.
They may not be reproduced, in whole or in part, without
• Personal safety, safety of other personnel, and prior written authorization from an authorized YORK
the machinery. representative.
• Correct utilization of the machinery in ac-
cordance with the procedures detailed in the
MISUSE OF EQUIPMENT
manuals.
Mechanical Strength
The unit contains refrigerant vapor and liquid under Refrigerants and oils used in the unit are generally non-
pressure, release of which can be a danger and cause toxic, non-flammable and non-corrosive, and pose no
injury. The user should ensure that care is taken during special safety hazards. Use of gloves and safety glasses
2
installation, operation and maintenance to avoid dam- is, however, recommended when working on the unit.
age to the pressure system. No attempt should be made The build up of refrigerant vapor, from a leak for ex-
to gain access to the component parts of the pressure ample, does pose a risk of asphyxiation in confined or
system other than by suitably trained and qualified enclosed spaces and attention should be given to good
personnel. ventilation.
Fan guards must be fitted at all times and not removed Emergency Shutdown
unless the power supply has been isolated. If ductwork is
In case of emergency, the control panel is fitted with
to be fitted, requiring the wire fan guards to be removed,
a Unit Switch to stop the unit in an emergency. When
alternative safety measures must be taken to protect
operated, it removes the low voltage 120 VAC electri-
against the risk of injury from rotating fans.
cal supply from the inverter system, thus shutting down
the unit.
Sharp Edges
JOHNSON CONTROLS 11
Product Description
FORM 201.21-NM1 (616)
PRODUCT DESCRIPTION
LD10477
YORK YCAV R134a chillers are designed for water The Latitude (YCAV) Air Cooled Chiller line combines
or glycol cooling. All units are designed to be located the best of modern screw compressor design with the
outside on the roof of a building or at ground level. latest technology in variable speed drives. The result is
superior control and efficiency in real world conditions.
The units are completely assembled with all intercon- The VSD enables slowing the speed of the compressor to
necting refrigerant piping and internal wiring, ready for match the load on the system resulting in precise chilled
field installation. liquid control, minimized sound, maximum energy ef-
ficiency, and reduced cost of ownership. The VSD also
Prior to delivery, the unit is pressure tested, evacuated, provides soft starts with no electrical inrush. The lack
and fully charged with refrigerant and oil in each of the of heat build-up on start also enables required off time
two independent refrigerant circuits. After assembly, between starts to be reduced to a period of 2 minutes.
an operational test is performed with water flowing
through the cooler to ensure that each refrigerant circuit The YCAV Air-Cooled Screw Chiller utilizes many
operates correctly. components, which are the same or nearly the same as
a standard screw chiller of a similar size. This includes
The unit structure is manufactured from heavy gauge, modular frame rails, condenser, fans, compressors and
galvanized steel. Many external structural parts are evaporator.
coated with “Champagne” baked-on enamel powder
paint. This provides a finish which, when subjected to The chiller consists of 2 screw compressors in a corre-
ASTM B117, 1000 hour, 5% salt spray conditions, shows sponding number of separate refrigerant circuits, a single
breakdown of less than 1/8” either side of a scribed line shell and tube DX evaporator, an air-cooled condenser,
(equivalent to ASTM D1654 rating of “6”). flash tanks, drain/feed valves, oil separators, and com-
pressor mufflers. Oil separators utilize no moving parts
All exposed power wiring is routed through liquid-tight, and are rated for a 405 PSIG design working pressure.
non-metallic conduit. Oil cooling is accomplished by routing oil from the oil
separator through several rows of tubes in the air cooled
condenser.
12 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
An integral liquid cooled, transistorized, PWM, Variable Refrigerant gas is injected into the void created by the
Speed Drive (VSD) is controlled by the chiller micro- un-meshing of the five lobed male and seven lobed fe-
processor control panel to start/stop, select compressors male rotor. Further meshing of the rotors closes the rotor
to run, and select compressor speed. Power Factor is threads to the suction port and progressively compresses
95% at part or full load. the gas in an axial direction to the discharge port. The
2
gas is compressed in volume and increased in pressure
The chiller microprocessor communicates with the VSD before exiting at a designed volume at the discharge end
Logic Board via a 3-wire RS-485 opto coupled data link. of the rotor casing. Since the intake and discharge cycles
The VSD Logic Board runs the number of compressors overlap, a resulting smooth flow of gas is maintained.
required to meet the load and the compressors to the The rotors are housed in a cast iron compressor hous-
speed requested by the chiller microprocessor. ing precision machined to provide optimal clearances
for the rotors. Contact between the male and female
The basic system control architecture is shown in the rotor is primarily rolling on a contact band on each of
diagram below: the rotor’s pitch circle. This results in virtually no rotor
CHILLER CONTROL SYSTEM wear and increased reliability, a trademark of the screw
compressor.
INPUTS OUTPUTS
(Relay Output
Pressure Transducers
Temperature Sensors
Board) The MTS compressor incorporates a complete anti-
Level Sensor
Switches
Solenoids
Contactors
friction bearing design for reduced power input and
Liquid Flow CONTROL
High Pressure
PANEL
Alarm
Pump
increased reliability. Separated, cylindrical, roller bear-
Start/Stop
Customer Supplied
(Chiller Control
Board)
Compressor Heater
Run Status ings handle radial loads. Angular-contact ball bearings
Contacts
Evap Heater
handle axial loads. Together they maintain accurate rotor
Microprocessor
User Interface positioning at all pressure ratios, thereby minimizing
leakage and maintaining efficiency.
Display
&
COMMUNICATIONS
Keypad VSD
VSD Logic Board
Building Automation
SCR Trigger Board
Printer
Power Components
Modem
PWM (Speed Control)
MOTOR
LD10478
Compressor
LD10482
JOHNSON CONTROLS 13
Product Description
FORM 201.21-NM1 (616)
Motor cooling is provided by suction gas from the The water nozzles are provided with grooves for
evaporator flowing across the motor. Redundant over- mechanical couplings and should be insulated by the
load protection is provided using both internal thermistor contractor after pipe installation.
and current overload protection on all three phases.
A 300 PSIG (20.7 bar) waterside design working pres-
The MTS compressor is lubricated by removing oil from sure option is available.
the refrigerant using an external oil separator. The pres-
surized oil is then cooled in the condenser coils and piped 2 compressor chillers utilize a typical 2-pass “E” type
back to the compressor through a removable 0.005” evaporator with liquid inlets and suction outlets at the
mesh screen oil filter to provide compressor lubrication. same end. Entering chilled liquid enters the refrigerant
The cast iron compressor housing design working pres- liquid inlet end of the cooler and leaving chilled liquid
sure is 450 PSIG (31 bar). Each chiller receives a 300 exits at the opposite end.
PSIG (21 bar) low side and a 450 PSIG (31 bar) high side
factory test. A 350 Watt (115-1-60 Hz) cartridge heater 3 and 4 compressor chillers utilize a single pass “J”
is located in the compressor. The heater is temperature type evaporator with liquid inlets at one end and suction
activated to prevent refrigerant condensation. outlets at the opposite end. Entering chilled liquid is
split and half flow enters at each end of the evaporator
The following items are also included: with leaving chilled liquid exiting in the center of the
evaporator. “J” type evaporators have fewer, longer
• Acoustically tuned, external discharge muffler to tubes than a comparable “E” type. This results in a
minimize noise, while optimizing flow for maxi- smaller diameter, longer shell. Water flow rate internally
mum performance. in the evaporator is ½ of the total loop flow rate since
the flow is split between two inlets. This results in a
• Discharge shutoff valve.
low evaporator water pressure drop.
• Rain-tight terminal box.
• Suction gas screen within the compressor hous- Condenser
ing.
The fin and tube condenser coils are manufactured
Evaporator from seamless, internally enhanced, high-condensing
coefficient, corrosion-resistant copper tubes arranged
The system uses a high-efficiency Shell and Tube type in staggered rows and mechanically expanded into cor-
Direct Expansion Evaporator. Each of the two (2) refrig- rosion resistant aluminum alloy fins with full height fin
erant circuits consists of two (2) passes with the chilled collars. The condensor has a design working pressure
liquid circulating back and forth across the tubes from of 450 PSIG (31 bar).
one end to the other.
Multiple, standard low sound, high efficiency, TEAO
The design working pressure of the cooler on the shell motor driven fans move air through the coils. They are
side is 150 PSIG (10 bar), and 235 PSIG (16 bar) for dynamically and statically balanced, direct drive with
the tube (refrigerant) side. The evaporator is constructed corrosion-resistant glass fiber reinforced composite
and tested in accordance with applicable sections of the blades molded into low-noise, full airfoil cross sec-
ASME Pressure Vessel Code, Section VII, Division (1). tions, providing vertical air discharge from extended
Waterside exempt per paragraph U-1, c, (6). orifices for efficiency and low sound. Fans or pairs of
fans are located in a separate compartments separated
The water baffles are fabricated from galvanized steel by "V" panels to prevent cross flow during fan cycling.
to resist corrosion. Removable heads are provided for Guards of heavy-gauge, PVC-coated galvanized steel
access to internally enhanced, seamless, copper tubes. are provided.
Water vent and drain connections are included.
The standard fan motors are high-efficiency, direct drive,
The cooler is equipped with a thermostatically con- 6-pole, 3-phase, Class- “F,” current overload protected,
trolled heater for protection to -20°F (-29°C) ambient totally enclosed (TEAO) type with double-sealed, per-
and insulated with 3/4” (19 mm) flexible closed-cell manently lubricated ball bearings.
insulation.
14 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
A Flash Tank is fitted to both refrigerant circuits. The The external oil separators, with no moving parts and
Flash Tank is a shell type refrigerant reservoir designed designed for minimum oil carry-over, are mounted in
to sustain 2 phase refrigerant. The purpose of the Flash the discharge line of the compressor. The high pressure
2
Tank is to increase the efficiency of the system. A discharge gas is forced around a 90 degree bend. Oil is
portion of the liquid fed into the Flash Tank gases off, forced to the outside of the separator through centrifugal
cooling the remaining liquid in the tank another 25-35°F. action and captured on wire mesh where it drains to the
Both liquid and gas exist in the flash tank. The refriger- bottom of the oil separator and is then forced into the
ant gas in the flash tank is fed to the economizer port on condensor.
the compressor at a point on the rotors approximately
1.7X suction when the economizer solenoid is activated. The oil (YORK “L” oil – a POE oil used for all refriger-
The liquid in the tank is fed to the evaporator. ant applications), flows from the oil separator, through
the condenser where it is cooled, and back into the com-
The vapor feed to the economizer port of the compres- pressor through a replaceable 0.5 micron oil filter at high
sor is at an intermediate pressure between discharge pressure. This high pressure “oil injection” forces the oil
and suction (1.7 x suction) and therefore little energy into the compressor, where it is fed to the bearings and
is required to pump it back through the compressor to rotors for lubrication. After lubricating the bearings, it is
condenser pressure. This results in a very small loss to injected through orifices on a closed thread near the suc-
system efficiency. tion end of the rotors. The oil is automatically injected
because of the pressure difference between the discharge
The design working pressure of the flash tank is 450 pressure and the reduced pressure at the suction end of
PSIG (31 bar). The Drain and Feed Valves on the flash the rotors. This lubricates the rotors as well as provides
tank are activated on start-up. The Feed Valve on the an oil seal against leakage around the rotors to ensure
Flash Tank acts like a liquid line solenoid, but also func- refrigerant compression efficiency.
tions to control the liquid level in the flash tank. The
Drain Valve functions similar to an electronic expan- The oil also provides cooling by transferring much of
sion valve (EEV). The Drain Valve controls refriger- the heat of compression from the gas to the oil, keeping
ant flow to the evaporator based on suction superheat. discharge temperatures down and reducing the chance
Both valves are stepper motor valves. An economizer for oil breakdown. Oil injected into the rotor cage
solenoid is placed between the flashtank and the econo- flows into the rotors at a point about 1.2x suction. This
mizer port of the compressor. The economizer solenoid ensures that a required minimum differential of at least
valve is generally activated at speeds above 90-120 Hz, 30 PSID exists between discharge and 1.2x suction, to
depending upon a number of other factors. force oil into the rotor case. A minimum of 10 PSID
(0.6 bar) is all that is required to ensure protection of
Both valves are controlled by 2 phase drive signals from the compressor. The oil pressure safety is monitored as
a stand-alone controller in the Control Cabinet. Signals the difference between suction pressure and the pressure
from sensors such as suction pressure and temperature of the oil entering the rotor case.
are sent to the Chiller Control Board, which in turn sends
control signals to the Drain and Feed Valve Controller. Maximum working pressure of the oil separator is 450
The control algorithm in the Chiller Control Board will PSIG (31 bar). Oil level should be above the midpoint
attempt to control the liquid level in the flash tank to of the “lower” oil sight glass when the compressor is
35% on the level sensor and the system will fault if the running. Oil level should not be above the top of the
flash tank level exceeds 87.5%. “upper” sight glass.
During operation, it will be noted the flash tank level Relief Valves
will typically remain between 30-40% level when the
economizer solenoid is ON. The economizer solenoid Two relief valves are installed in each refrigerant circuit.
valve will typically be on most of the time. When the A 325 PSIG relief valve is located on each Flash Tank
economizer solenoid is OFF, the liquid level will vary and a 250 PSIG relief valve is located on the suction
greatly as the Drain and Feed Valves directly affect the line of the compressor near the evaporator.
level as they open and close.
JOHNSON CONTROLS 15
Product Description
FORM 201.21-NM1 (616)
The chiller is available with Standard IPLV or High IPLV The standard controls include: brine chilling, thermal
software (EPROM). High IPLV software optimizes the storage, run signal contacts, unit alarm contacts, chilled
performance of the chiller capacity and fan controls. liquid pump control, automatic reset after power fail-
High IPLV chillers also require additional factory ure, automatic system optimization to match operating
programming. conditions.
Power and Control Panel Remote cycling, optional current limiting, optional
temperature setpoint reset, and optional remote sound
All controls and the VSD are factory-wired and function limit can be accomplished by connecting user-supplied
tested. The panel enclosures are designed to NEMA 3R signals to the microprocessor.
(IP65) rating and are manufactured from powder-painted
steel with hinged, latched, and gasket sealed outer doors Unit operating software is stored in non-volatile
with wind struts for safer servicing. memory. Field programmed setpoints are retained in
lithium battery backed real time clock (RTC) memory
The Power and Micro Control Panels are combined into for 10 years.
a single control/power cabinet and include Compressor
VSD Controls, Chiller Microprocessor Controls, Fan
Controls, and all other chiller controls.
Display Keypad
The display consists of a liquid crystal 2 line by 40 An operator keypad allows complete control of the
characters per line display, with backlighting for outdoor system from a central location. The keypad utilizes
viewing of operating parameters and program points. an overlay to allow use in 5 languages. The keypad is 2
a color-coded, 36 button, sealed keypad with keys for
Parameters are displayed in 5 languages in either Eng- Display, Entry, Setpoints, Clock, Print, Program, Unit
lish (°F and PSIG) or Metric (°C and Bars) units, and for ON/OFF and other functions. Details on a few of the
each circuit, the following items can be displayed: keys follow.
• Entering and leaving chilled liquid, and ambient Status – Allows viewing present unit or system status
temperature. displayed by the microprocessor.
• Day, date and time. Daily start/stop times. Holiday Entry – Numeric keypad and supporting keys used to
and Manual Override status. confirm Setpoint changes, cancel inputs, advance day,
and change AM/PM.
• Compressor operating hours and starts. Automatic or
manual lead/lag. Lead compressor identification. Setpoints – For setting chilled liquid temperature,
chilled liquid range, remote reset temperature range.
• Run permissive status. Compressor run status.
Date/Time – Used to set time, daily or holiday start/stop
• Anti-recycle timers. schedule, manual override for servicing, and sound
limiting schedule.
• System suction (and suction superheat), discharge
(and discharge superheat), and oil pressures and Print – Used to display or print operating data or sys-
temperatures. tem fault shutdown history for last ten faults. Printouts
are generated through an RS-232 port via a separate
• Percent full load compressor motor current and printer.
average motor current. Compressor motor speed
(frequency). Program – For setting low leaving liquid temperature
cutout, average motor current limit, and pulldown de-
• Cutout status and setpoints for: supply chilled liquid mand limit.
temperature, low suction pressure, high discharge
pressure and temperature, high oil temperature, low Displays are also provided for programming low am-
ambient, and low leaving liquid temperature. bient cutout, low suction pressure cutout, superheat
setpoint, etc., under the PROGRAM key.
• Unloading limit setpoints for high discharge pres-
sure and compressor motor current. Unit Switch
• Status of: evaporator heater, condenser fans, load/ A master unit switch allows activation or de-activation
unload timers, and chilled water pump. of the chiller system. Separate system switches for con-
trolling each system are provided as part of the chiller
• “Out of range” message. control panel keypad.
JOHNSON CONTROLS 17
PRODUCT DESCRIPTION
FORM 201.21-NM1 (616)
Variable Speed Drive (VSD) The power section of the drive is composed of four
major blocks consisting of an AC to DC rectifier section
The VSD (variable speed drive) is a liquid cooled, tran- with accompanying pre-charge circuit, a DC link filter
sistorized, PWM inverter, which provides speed control section, a three phase DC to AC inverter section, and
to vary the speed of 2, 3 or 4 compressor motors. The an output suppression network.
VSD changes the duration of the voltage pulses supplied
to the motor to enable control of compressor speed to The AC to DC rectifier utilizes a semi-converter formed
match the system load. A PWM generator, on the VSD by the connection of three SCR/diode modules (1SCR-
Logic Board, with a switching frequency of 3125 Hz 3SCR) in a three phase bridge configuration. The mod-
modulates the voltage signal to provide a relatively ules are mounted on a liquid cooled heatsink. Use of the
pulses constant V/F ratio. In some cases, the V/F ratio semi-converter configuration permits implementation
is slightly modified to provide additional torque to the of a separate pre-charge circuit to limit the flow of cur-
motor. Sample 3 phase current waveforms are shown rent into the DC link filter capacitors when the drive is
in FIG. 1 to show the sinusoidal characteristics of the switched on and it also provides a fast disconnect from
current drawn by the compressor motors. the power mains when the drive is switched off. When
the drive is turned off, the SCRs in the semiconverter
remain in a non-conducting mode and the DC link filter
capacitors remain uncharged. When the drive is com-
manded to run, the DC link filter capacitors are slowly
charged via the semi-converter. The SCR’s are then
gated fully on.
18 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
Gate Bipolar Transistor (IGBT) modules mounted to a ing high voltage to the VSD Logic Board. A Current
liquid cooled heatsink, and a IGBT Gate Driver Board, Transformer is included on each output phase assembly
which provides the On and Off gating pulses to the to provide motor current information to the VSD logic
IGBT’s as determined by the VSD Logic board. In board.
order to minimize the parasitic inductance between the
2
IGBT’s and the capacitor banks, copper plates, which
electrically connect the capacitors to one another and to ACCESSORIES AND OPTIONS
the IGBT’s are connected together using a “laminated
bus” structure. Single Point Circuit Breaker
This “laminated bus” structure is a actually composed of A single-point supply circuit with factory provided
a pair of copper bus plates with a thin sheet of insulating circuit breaker protection with lockable external handle
material acting as the separator/insulator. The “lami- located in the panel.
nated bus” structure forms a parasitic capacitor, which
acts as a small valued capacitor, effectively canceling Building Automation System (BAS) Interface
the parasitic inductance of the bus bars themselves. To
further cancel the parasitic inductances, a series of small Provides a means to reset the leaving chilled liquid
film capacitors are connected between the positive and temperature or percent full load amps (current limiting)
negative plates of the DC link. from a BAS Interface.
The VSD output suppression network is composed of The chiller microprocessor board will accept a 4 to
a series of capacitors and resistors connected in a three 20mA or 0 to 10VDC input from an ISN or BAS.
phase delta configuration. The parameters of the sup-
pression network components are chosen to work in The chiller is also capable of accepting an RS-485 com-
unison with the parasitic inductance of the DC to AC munications link through the Microgateway.
inverter sections in order to simultaneously limit both the
rate of change of voltage and the peak voltage applied to Condenser Coil Protection
the motor windings. By limiting the peak voltage to the
motor windings, as well as the rate-of-change of motor The standard condenser coils have aluminum fins, cop-
voltage, we can avoid problems commonly associated per tubes, and galvanized steel supports for generally
with PWM motor drives, such as stator-winding end-turn adequate corrosion resistance. However, these materials
failures and electrical fluting of motor bearings. are not adequate for all environments.
The VSD is cooled by a propylene glycol cooling The following options provide added protection:
loop. The loop utilizes a glycol pump, which pumps
glycol through the VSD heatsinks to cool the power Black fin condenser coils – Condenser coils con-
components. The glycol is then circulated through the structed using black epoxy-coated aluminum fin stock
condenser to reject the heat from the VSD. The cooled for corrosion-resistance for typical seashore locations
glycol is then circulated back through the loop. (not directly exposed to salt spray).
Various ancillary sensors and boards are used to send Copper fin condenser coils – Coils constructed with
information back to the VSD Logic board. Each IGBT corrosion-resistant copper fins. Not recommended in
Power Module within the DC to AC inverter section con- areas where units may be exposed to acid rain.
tains a thermistor heatsink temperature sensor to provide
temperature information to the VSD logic board. The Epoxy Coated Condenser Coils – Completed
Bus Isolator board utilizes three resistors on the board condenser coil assemblies are covered with a cured
to provide a “safe” impedance (resistance) between the epoxy coating. Probably the most suitable selection
DC link filter capacitors located on the output phase for seashore locations where salt spray may come into
bank assemblies and the VSD logic board. It provides contact with the fins, and other corrosive applications
the means to sense the positive, midpoint and negative except: strong alkalis, oxidizers, and wet bromine,
connection points of the VSD’s DC link without apply- chlorine, and fluorine in concentrations greater than
100 PPM.
JOHNSON CONTROLS 19
PRODUCT DESCRIPTION
FORM 201.21-NM1 (616)
1-1/2” (38 mm) Insulation – Double-thickness insulation High Static Fans: Fans and motors suitable for High
provided for enhanced efficiency. External Static conditions to 100 Pa.
VIBRATION ISOLATION
SERVICE VALVE OPTION
Neoprene Pad Isolation – Recommended for normal
Suction Service Valve – Provides a suction and econo-
installations (Field-mounted).
mizer service valve on each refrigerant circuit.
1” (25 mm) Spring Isolators – Level adjustable,
UNIT ENCLOSURES spring and cage type isolators for mounting under the
unit base rails (Field-mounted).
Wire Enclosure – Heavy-gauge welded wire mesh
guards mounted on the exterior of the unit (Factory- or 2” (51 mm) Seismic Spring Isolators – Restrained
field-mounted). Spring-Flex Mountings incorporate welded steel hous-
ing with vertical and horizontal limit stops. Housings
Louvered Panels and Wired Guards – Louvered pan- designed to withstand a minimum 1.0 g accelerated
els mounted over the exterior condenser coil faces, and force in all directions to 2” (51 mm). Level adjustable,
heavy-gauge welded wire mesh guards mounted around deflection may vary slightly by application (Field-
the bottom of the unit (Factory- or field-mounted). mounted).
20 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
NOMENCLATURE 2
The model number denotes the following characteristics of the unit.
Y C A V - 0267 - S - A - 46 - V A A
YORK DEVELOPMENT CODE
DESIGN SERIES
CHILLER
STARTER - VSD
AIR COOLED
VOLTAGE CODE
VSD DRIVEN
SCREW COMPRESSOR REFRIGERANT - R134a
MODEL NUMBER UNIT DESIGNATOR
JOHNSON CONTROLS 21
PRODUCT DESCRIPTION
FORM 201.21-NM1 (616)
JOHNSON CONTROLS 25
HANDLING AND STORAGE
FORM 201.21-NM1 (616)
LD19197
Rigging and lifting should only be done by a professional rigger in accordance with a written rig-
ging 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 this manual
to specify rigging and lifting details.
26 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
LUG
LIFTING HOLE
Care should be taken to avoid damaging the condenser LUG
IN BASE FRAME FLANGE
cooling fins when moving the unit. FLANGE
1. Place a clevis pin into the holes provided at the LIFTING HOLE
end of each base rail on the unit. Attach chains LOCKING PIN IN BASE FRAME
or nylon straps through the clevis pins and hook
onto a suitable lift truck for pulling the unit out of LUG
the container.
2. Slowly place tension on the chains or straps until
the unit begins to move and then slowly pull the LOCKING
unit from the container. Be sure to pull straight so PIN
LD19197a
JOHNSON CONTROLS 27
INSTALLATION
FORM 201.21-NM1 (616)
UNIT RIGGING
#4
#3
#2
#1
LD10496
NOTE: Weights and approximate center of gravity location shown for base unit. Any options selected
may add weight to the unit and affect the center of gravity. Locate the center of gravity through
trial lifts to account for possible variations in unit configuration. Contact your nearest Johnson
Controls Sales Office for weight data.
28 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
INSTALLATION
LOCATION REQUIREMENTS Any ductwork or attenuators fitted to the unit must
not have a total static pressure resistance, at full unit
To achieve optimum performance and trouble-free airflow, exceeding the capability of the fans installed
service, it is essential that the proposed installation site in the unit.
meets the location and space requirements for the model
being installed. For dimensions, refer to the Dimensions
Section. INDOOR INSTALLATIONS
It is important to ensure that the minimum service ac- The unit can be installed in an enclosed plant room, pro-
4
cess space is maintained for cleaning and maintenance vided the floor is level and of suitable strength to support
purposes. the full operating weight of the unit. It is essential that
there is adequate clearance for airflow to the unit. The
discharge air from the top of the unit must be ducted
OUTDOOR INSTALLATIONS away to prevent re-circulation of air within the plant
room. If common ducts are used for fans, non-return
The units can be installed at ground level on a suitable dampers must be fitted to the outlet from each fan.
flat level foundation easily capable of supporting the
weight of the unit, or on a suitable rooftop location. In The discharge ducting must be properly sized with a
both cases an adequate supply of air is required. Avoid total static pressure loss, together with any intake static
locations where the sound output and air discharge from pressure loss, less than the available static pressure
the unit may be objectionable. capability for the type of fan fitted.
The location should be selected for minimum sun ex- The discharge air duct usually rejects outside the build-
posure and away from boiler flues and other sources of ing through a louver. The outlet must be positioned to
airborne chemicals that could attack the condenser coils prevent the air being drawn directly back into the air
and steel parts of the unit. intake for the condenser coils, as such re-circulation
will affect unit performance.
If located in an area accessible to unauthorized persons,
steps must be taken to prevent access to the unit by
means of a protective fence. This will help to prevent
the possibility of vandalism, accidental damage, or
possible harm caused by unauthorized removal of pro-
tective guards or opening panels to expose rotating or
high voltage components.
Adequate clearances around the unit(s) are required for Place each mount in its correct position and lower the
the unrestricted airflow for the air-cooled condenser coils unit carefully onto the mounts ensuring the mount en-
and to prevent re-circulation of warm discharge air back gages in the mounting holes in the unit base frame.
onto the coils. If clearances given are not maintained,
airflow restriction or re-circulation will cause a loss of On adjustable mounts, transfer the unit weight evenly to
unit performance, an increase in power consumption, the springs by turning the mount adjusting nuts (located
and may cause the unit to malfunction. Consideration just below the top plate of the mount) counterclockwise
should also be given to the possibility of down drafts, to raise and clockwise to lower. This should be done
caused by adjacent buildings, which may cause re-cir- two turns at a time until the top plates of all mounts are
culation or uneven unit airflow. between 1/4” and 1/2” (6 and 12 mm) clear of top of
their housing and the unit base is level.
For locations where significant cross winds are expected,
such as exposed roof tops, an enclosure of solid or lou- A more detailed installation instruction
ver type is recommended to prevent wind turbulence is provided on Pages 128-132.
interfering with the unit airflow.
INSTALLATION OF VIBRATION ISOLATORS The liquid must enter the cooler at the
inlet connection. The inlet connection
Optional sets of vibration isolators can be supplied loose for the cooler is at the control panel
with each unit.
end of the cooler.
Using the Isolator tables shipped with the unit in the
information pack, refer to the Dimension Section (Pages
66-121), Weight Distribution and Isolator Mounting
Position Section (Pages 124-127) and Isolator types
(Pages 128-132). Identify each mount and its correct
location on the unit.
30 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
A flow switch must be installed in the customer pip- Thermometer and pressure gauge connections should
ing at the outlet of the cooler and wired back to the be provided on the inlet and outlet connections of each
control panel using shielded cable. cooler. Gauges and thermometers are not provided
with the unit.
There should be a straight run of piping of at least 5
pipe diameters on either side. The flow switch should be Drain and air vent connections should be provided at all
wired to Terminals 2 and 13 on the 1TB terminal block low and high points in the piping to permit drainage of
(See FIG. 17, Page 141). A flow switch is required to the system and to vent any air in the pipes.
prevent damage to the cooler caused by the unit operat-
ing without adequate liquid flow. Liquid system lines at risk of freezing, due to low ambi- 4
ent temperatures should be protected using insulation
The flow switch used must have gold plated contacts for and heater tape and/or a suitable glycol solution. The
low voltage/current operation. Paddle type flow switches liquid pump(s) may also be used to ensure liquid is
suitable for 150 PSIG (10 bar) working pressure and hav- circulated when the ambient temperature approaches
ing a 1” N.P.T. connection can be obtained from YORK freezing point.
as an accessory for the unit. Alternatively, a differential
pressure switch fitted across an orifice plate may be used, Insulation should also be installed around the cooler
preferably of the high/low limit type. nozzles. Heater tape of 21 watts per meter under the
insulation is recommended, supplied independently and
The chilled liquid pump(s) installed in the piping controlled by an ambient temperature thermostat set
system(s) should discharge directly into the unit cooler to switch on at approximately 4°F, above the freezing
section of the system. The pump(s) may be controlled temperature of the chilled liquid.
by the chiller controls or external to the unit. For de-
tails, refer to “Electrical Elementary and Connection Evaporator heater mats are installed under the insula-
Diagrams.” tion, and are powered from the chiller's control panel.
In sub-freezing conditions, unless the evaporator has
Pipework and fittings must be separately supported to been drained or an appropriate water-to-glycol con-
prevent any loading on the cooler. Flexible connections centration is maintained, high voltage power to the
are recommended which will also minimize transmis- chiller must be kept on to ensure the heater mats assist
sion of vibrations to the building. Flexible connections in evaporator freeze protection. If there is a potential
must be used if the unit is mounted on anti-vibration for power loss, Johnson Controls recommends that the
mounts, as some movement of the unit can be expected evaporator is drained or that water in the chilled water
in normal operation. circuit be replaced with an appropriate water-to-glycol
concentration.
Piping and fittings immediately next to the cooler should
be readily de-mountable to enable cleaning before opera-
tion, and to facilitate visual inspection of the exchanger Any debris left in the water piping
nozzles. between the strainer and cooler could
cause serious damage to the tubes in
The cooler must be protected by a strainer, prefer- the cooler and must be avoided. Be
ably of 40 mesh, fitted as close as possible to the sure the piping is clean before connect-
liquid inlet connection, and provided with a means ing it to the evaporator. Keep evapo-
of local isolation.
rator nozzles and chilled liquid piping
capped prior to installation to assure
The cooler must not be exposed to flushing velocities or
debris released during flushing. It is recommended that a construction debris is not allowed to
suitably sized bypass and valve arrangement is installed enter.
to allow flushing of the piping system. The bypass can
be used during maintenance to isolate the heat exchanger The installer/user must also ensure that
without disrupting flow to other units. the quality of the water in circulation is
adequate, without any dissolved gases,
which can cause oxidation of steel
parts within the cooler.
JOHNSON CONTROLS 31
INSTALLATION
FORM 201.21-NM1 (616)
The unit performance provided in the Design Guide For connection sizes relevant to individual models refer
is based on a fouling factor of 0.0001 ft2hr°F/Btu to the Technical Data Section.
(0.018m2/hr °C/kW). Dirt, scale, grease and certain
types of water treatment will adversely affect the heat
exchanger surfaces and therefore the unit performance. COOLER CONNECTIONS
Foreign matter in the water system(s) can increase the
heat exchanger pressure drop, reducing the flow rate and Standard chilled liquid connections on all coolers are of
causing potential damage to the heat exchanger tubes. the Victaulic Groove type (See FIG. 4).
PIPEWORK ARRANGEMENT
-Flanged Connection
-Pipework
WELD FLANGE VICTAULIC ADAPTER
32 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
REFRIGERANT RELIEF VALVE PIPING When ducting is to be fitted to the fan discharge it is
recommended that the duct should be the same cross-
The evaporator is protected against internal refrigerant sectional area as the fan outlet and straight for at least
overpressure by refrigerant relief valves. A pressure three feet (1 meter) to obtain static regain from the fan.
relief valve is mounted on each of the main refrigerant Ductwork should be suspended with flexible hangers
lines connecting the cooler to the compressors. to prevent noise and vibration being transmitted to the
structure. A flexible joint is also recommended between
A piece of pipe is fitted to each valve and directed so that the duct attached to the fan and the next section for the
when the valve is activated the release of high pressure same reason. Flexible connectors should not be allowed
gas and liquid cannot be a danger or cause injury. For to concertina. 4
indoor installations, pressure relief valves should be
piped to the exterior of the building. The unit is not designed to take structural loading. No
significant amount of weight should be allowed to rest
The size of any piping attached to a relief valve must on the fan outlet flange, deck assemblies or condenser
be of sufficient diameter so as not to cause resistance to coil module. No more than 3 feet (1 meter) of light
the operation of the valve. Unless otherwise specified construction ductwork should be supported by the unit.
by local regulations. Internal diameter depends on the Where cross winds may occur, any ductwork must be
length of pipe required and is given by the following supported to prevent side loading on the unit.
formula:
If the ducts from two or more fans are to be combined
D 5
= 1.447 x L into a common duct, back-flow dampers should be fitted
in the individual fan ducts. This will prevent re-circula-
Where: tion of air when only one of the fans is running.
D = minimum pipe internal diameter in cm
L = length of pipe in meters Units are supplied with outlet guards for safety and to
prevent damage to the fan blades. If these guards are
If relief piping is common to more than one valve, its removed to fit ductwork, adequate alternative precau-
cross-sectional area must be at least the total required tions must be taken to ensure persons cannot be harmed
by each valve. Valve types should not be mixed on a or put at risk from rotating fan blades.
common pipe. Precautions should be taken to ensure the
outlets of relief valves or relief valve vent pipes remain
clear of obstructions at all times. ELECTRICAL CONNECTION
JOHNSON CONTROLS 33
INSTALLATION
FORM 201.21-NM1 (616)
Voltage free contacts are rated at 115VAC, 100VA re- A Remote Run/Stop input is available for each pair of
sistive load only. Inductive loads must be suppressed systems (1/3 & 2/4). These inputs require a dry contact
across the coil. to start and stop the system. System 1/3 remote dry
contacts are connected between Terminals 2 and 15 of
Chilled Liquid Pump Starter 1TB (FIG. 17, Page 141) and System 2/4 dry contacts
are connected between Terminals 2 and 16 of 1TB (FIG.
Terminals 23 and 24 on 1TB close to start the chilled 17, Page 141). If remote start/stop is not utilized, a
liquid pump. This contact can be used as a master start/ jumper must be paced across the terminals to allow the 4
stop for the pump in conjunction with the daily start/ system to run. The remote run/stop circuitry is a 115VAC
stop schedule. Cycle the pumps from the unit panel if circuit. Contacts must be rated for low current (10ma).
the unit will be operational or shut-down during sub- Gold contacts should be used.
freezing conditions. Refer to the Evaporator Pump
Control on Page 170 for more information on testing Remote Print
the pumps.
Closure of suitable contacts connected to Terminals 2
and 14 of 1TB (FIG. 17, Page 141) will cause a hard
Run Contact copy printout of Operating Data/Fault History to be
made if an optional printer is connected to the RS-232
Terminals 21 and 22 on 1TB (FIG. 17, Page 141) close port. The remote print circuitry is a 115VAC circuit.
to indicate that a system is running. Contacts must be rated for low current (10ma). Gold
contacts should be used.
Alarm Contacts
JOHNSON CONTROLS 35
COMMISSIONING
FORM 201.21-NM1 (616)
COMMISSIONING
PREPARATION Service and Oil Line Valves
Commissioning of this unit should only Open each compressor suction, economizer, and dis-
be carried out by YORK Authorized charge service valve. If valves are of the back-seat type,
personnel. 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.
Commissioning personnel should be thoroughly familiar
Compressor Oil
with the information contained in this literature, in ad-
dition to this section.
To add oil to a circuit - connect a YORK hand oil pump
(Part No. 470-10654-000) to the 1/4” oil charging valve
Perform the commissioning using the detailed checks
on the oil separator piping with a length of clean hose
outlined in the EQUIPMENT START-UP CHECK
or copper line, but do not tighten the flare nut. Using
SHEET on Page 152 as the commissioning procedure
clean oil of the correct type (“L” oil), pump oil until
is carried out.
all air has been purged from the hose then tighten the
nut. Stroke the oil pump to add oil to the oil system.
PREPARATION – GENERAL
The oil level should be between the middle of the lower
The following basic checks should be made with the and middle of the upper sight glasses of the oil separa-
customer power to the unit switched OFF. tor. Approximately 4-5 gallons is present in the each
refrigerant system, with typically 1-2 gallons in each oil
separator. Oil levels in the oil separators above the top
Proper electrical lock out and tag pro-
sight glass in either oil separator should be avoided and
cedures must be followed. 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
Inspection and subsequent damage to the compressor.
Do not liquid charge with static water in the cooler. Check the panel to see that it is free of foreign materials
Care must also be taken to liquid charge slowly to avoid (wire, metal chips, etc.) and clean out if required.
excessive thermal stress at the charging point. Once the
vacuum is broken, charge into the condenser coils with
the full operating charge as given in the Technical Data
Section.
36 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
Verify a chilled water flow switch is correctly fitted in FIRST TIME START-UP
the customer’s piping on the cooler outlet, and wired
into the control panel correctly using shielded cable. During the commissioning period there
should be sufficient heat load to run the
There should be a straight run of at least 5 pipe diam-
unit under stable full load operation
eters on either side of the flow switch. The flow switch
should be connected to terminals 2 and 13 in the panel. to enable the unit controls, and system
operation to be set up correctly, and a
Temperature Sensor(s) commissioning log taken. Be sure that
the chiller is properly programmed and
Ensure the leaving liquid temperature sensor is coated the System Start-up Checklist (Page 152)
with heat conductive compound (Part No. 013-00890- is completed.
000) and is inserted to the bottom of the water outlet
sensor well in the evaporator. This sensor is part of the
JOHNSON CONTROLS 37
COMMISSIONING
FORM 201.21-NM1 (616)
38 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
General Operation
JOHNSON CONTROLS 39
TECHNICAL DATA
FORM 201.21-NM1 (616)
50
A
40
Pressure Drop (ft H2O)
30
D
20
10
0
0 100 200 300 400 500 600 700 800 900 1000
Water Flow Rate (GPM) LD10497
180
B
160
140
C
Pressure Drop (kPa)
120
A
100
D
80
60
40
20
0
0 5 10 15 20 25 30 35 40 45 50
Water Flow Rate (l/s)
40 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
JOHNSON CONTROLS 41
TECHNICAL DATA
FORM 201.21-NM1 (616)
NOTES:
1. For leaving brine temperature below 40°F (4.4°C), contact your nearest YORK office for application requirements.
2. For leaving water temperature higher than 60°F (15.6°C), contact the nearest YORK office for application guidelines.
NOTES:
1. For leaving brine temperature below 40°F (4.4°C), contact your nearest YORK office for application requirements.
2. For leaving water temperature higher than 60°F (15.6°C), contact the nearest YORK office for application guidelines.
42 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
JOHNSON CONTROLS 43
TECHNICAL DATA
FORM 201.21-NM1 (616)
HIGH EFFICIENCY
Refrigerant R-134a Model Number (YCAV_____E/V)
General Unit Data YCAV0157 YCAV0177 YCAV0187 YCAV0197 YCAV0207 YCAV0227 YCAV0247
Number of Independent Refrigerant Circuits 2 2 2 2 2 2 2
Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, lbs 170/170 185/170 185/185 192/192 225/192 225/225 230/230
Oil Charge, Ckt.-1/Ckt.-2, gal. 4.5/4.5 4.5/4.5 5/5 5/5 5/5 5/5 5/5
Compressors, Semihermetic Screw Qty per Chiller 2 2 2 2 2 2 2
Condensers, High Efficiency Fin/Tube with Integral Subcooler
Total Chiller Coil Face Area, ft2 235 264 293 293 323 352 352
Number of Rows 3 3 3 3 3 3 3
Fins per Inch 17 17 17 17 17 17 17
Condenser Fans
Number, Ckt.-1/Ckt.-2 4/4 5/4 5/5 5/5 6/5 6/6 6/6
Low Sound Fans
Fan Motor, HP 2 2 2 2 2 2 2
Fan & Motor Speed, revs./min. 1140 1140 1140 1140 1140 1140 1140
Fan Diameter, inches 35.4 35.4 35.4 35.4 35.4 35.4 35.4
Fan Tip Speed, ft./min. 10575 10575 10575 10575 10575 10575 10575
Total Chiller Airflow, cfm 104000 117000 130000 130000 143000 156000 156000
Ultra Quiet Fans
Fan Motor, HP 2 2 2 2 2 2 2
Fan & Motor Speed, revs./min. 838 838 838 838 838 838 838
Fan Diameter, inches 35.4 35.4 35.4 35.4 35.4 35.4 35.4
Fan Tip Speed, ft./min. 7774 7774 7774 7774 7774 7774 7774
Total Chiller Airflow, cfm 104000 117000 130000 130000 143000 156000 156000
Evaporator, Direct Expansion
Water Volume, gals. 95.0 95.0 95.0 110.0 110.0 110.0 140.0
Maximum Water Side Pressure, PSIG1 150 150 150 150 150 150 150
Maximum Refrigerant Side Pressure, PSIG 235 235 235 235 235 235 235
Minimum Chilled Water Flow Rate, gpm 150 150 150 180 180 180 180
Maximum Chilled Water Flow Rate, gpm 750 750 750 750 750 750 800
Water Connections, inches 10 10 10 10 10 10 10
1
Optional 300 PSIG Waterside available
44 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
HIGH EFFICIENCY
Refrigerant R-134a
Model Number (YCAV_____E/V)
General Unit Data YCAV0157 YCAV0177 YCAV0187 YCAV0197 YCAV0207 YCAV0227 YCAV0247
Number of Independent Refrigerant Circuits 2 2 2 2 2 2 2
Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, kg. 77/77 84/77 84/84 87/87 102/87 102/102 105/105
Oil Charge, Ckt.-1/Ckt.-2, liters 17/17 17/17 19/19 19/19 19/19 19/19 19/19
Compressors, Semihermetic Screw Qty per Chiller 2 2 2 2 2 2 2
Condensers, High Efficiency Fin/Tube with Integral Subcooler
Total Chiller Coil Face Area, m2 21.8 24.5 27.2 27.2 30.0 32.7 32.7
Number of Rows 3 3 3 3 3 3 3
6
Fins per meter 669 669 669 669 669 669 669
Condenser Fans
Number, Ckt.-1/Ckt.-2 4/4 5/4 5/5 5/5 6/5 6/6 6/6
Standard Fans
Fan Motor, HP 2 2 2 2 2 2 2
Fan & Motor Speed, revs./sec. 19.0 19.0 19.0 19.0 19.0 19.0 19.0
Fan Diameter, mm 899 899 899 899 899 899 899
Fan Tip Speed, m/sec. 53.7 53.7 53.7 53.7 53.7 53.7 53.7
Total Chiller Airflow, l/sec. 49082 55218 61353 61353 67488 73624 73624
Low Noise Fans
Fan Motor, HP 2 2 2 2 2 2 2
Fan & Motor Speed, revs./sec. 14.0 14.0 14.0 14.0 14.0 14.0 14.0
Fan Diameter, mm 899 899 899 899 899 899 899
Fan Tip Speed, m/sec. 39 39 39 39 39 39 39
Total Chiller Airflow, l/sec. 49082 55218 61353 61353 67488 73624 73624
Evaporator, Direct Expansion
Water Volume, liters 359.6 359.6 359.6 416.4 416.4 416.4 529.9
Maximum Water Side Pressure, Bar1 10 10 10 10 10 10 10
Maximum Refrigerant Side Pressure, Bar 16 16 16 16 16 16 16
Minimum Chilled Water Flow Rate, l/sec. 9.5 9.5 9.5 11.4 11.4 11.4 11.4
Maximum Chilled Water Flow Rate, l/sec. 47.3 47.3 47.3 47.3 47.3 47.3 50.5
Water Connections, inches 10 10 10 10 10 10 10
1
Optional 21 Bar Waterside available
JOHNSON CONTROLS 45
TECHNICAL DATA
FORM 201.21-NM1 (616)
STANDARD EFFICIENCY
Refrigerant R-134a
Model Number (YCAV_____S/P)
General Unit Data YCAV0157 YCAV0177 YCAV0187 YCAV0207 YCAV0227 YCAV0247 YCAV0267
Number of Independent Refrigerant Circuits 2 2 2 2 2 2 2
Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, lbs 162/162 170/170 185/170 192/175 192/192 230/195 230/230
Oil Charge, Ckt.-1/Ckt.-2, gal. 4.5/4.5 4.5/4.5 5/5 5/5 5/5 5/5 5/5
Compressors, Semi-hermetic Screw Qty per Chiller 2 2 2 2 2 2 2
Condensers, High Efficiency Fin/Tube with Integral Subcooler
Total Chiller Coil Face Area, ft2 235 235 264 264 293 323 352
Number of Rows 3 3 3 3 3 3 3
Fins per Inch 17 17 17 17 17 17 17
Condenser Fans
Number, Ckt.-1/Ckt.-2 4/4 4/4 5/4 5/4 5/5 6/5 6/6
Low Sound Fans
Fan Motor, HP 2 2 2 2 2 2 2
Fan & Motor Speed, revs./min. 1140 1140 1140 1140 1140 1140 1140
Fan Diameter, inches 35.4 35.4 35.4 35.4 35.4 35.4 35.4
Fan Tip Speed, ft./min. 10575 10575 10575 10575 10575 10575 10575
Total Chiller Airflow, cfm 104000 104000 117000 117000 130000 143000 156000
Ultra Quiet Fans
Fan Motor, HP 2 2 2 2 2 2 2
Fan & Motor Speed, revs./min. 838 838 838 838 838 838 838
Fan Diameter, inches 35.4 35.4 35.4 35.4 35.4 35.4 35.4
Fan Tip Speed, ft./min. 7774 7774 7774 7774 7774 7774 7774
Total Chiller Airflow, cfm 104000 104000 117000 117000 130000 143000 156000
Evaporator, Direct Expansion
Water Volume, gals. 67.0 95.0 95.0 110.0 110.0 140.0 140.0
Maximum Water Side Pressure, PSIG1 150 150 150 150 150 150 150
Maximum Refrigerant Side Pressure, PSIG 235 235 235 235 235 235 235
Minimum Chilled Water Flow Rate, gpm 140 150 150 180 180 180 180
Maximum Chilled Water Flow Rate, gpm 675 750 750 750 750 800 800
Water Connections, inches 8 10 10 10 10 10 10
1
Optional 21 Bar Waterside available
46 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
STANDARD EFFICIENCY
Refrigerant R-134a
Model Number (YCAV_____S/P)
General Unit Data YCAV0157 YCAV0177 YCAV0187 YCAV0207 YCAV0227 YCAV0247 YCAV0267
Number of Independent Refrigerant Circuits 2 2 2 2 2 2 2
Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, kg. 74/74 77/77 84/77 87/80 87/87 105/89 105/105
Oil Charge, Ckt.-1/Ckt.-2, liters 17/17 17/17 19/19 19/19 19/19 19/19 19/19
Compressors, Semihermetic Screw Qty per Chiller 2 2 2 2 2 2 2
Condensers, High Efficiency Fin/Tube with Integral Subcooler
Total Chiller Coil Face Area, m2 21.8 21.8 24.5 24.5 27.2 30.0 32.7
Number of Rows 3 3 3 3 3 3 3 6
Fins per meter 669 669 669 669 669 669 669
Condenser Fans
Number, Ckt.-1/Ckt.-2 4/4 4/4 5/4 5/4 5/5 6/5 6/6
Low Sound Fans
Fan Motor, HP 2 2 2 2 2 2 2
Fan & Motor Speed, revs./sec. 19.0 19.0 19.0 19.0 19.0 19.0 19.0
Fan Diameter, mm 899 899 899 899 899 899 899
Fan Tip Speed, m/sec. 53.7 53.7 53.7 53.7 53.7 53.7 53.7
Total Chiller Airflow, l/sec. 49082 49082 55218 55218 61353 67488 73624
Ultra Quiet Fans
Fan Motor, HP 2 2 2 2 2 2 2
Fan & Motor Speed, revs./sec. 14.0 14.0 14.0 14.0 14.0 14.0 14.0
Fan Diameter, mm 899 899 899 899 899 899 899
Fan Tip Speed, m/sec. 39 39 39 39 39 39 39
Total Chiller Airflow, l/sec. 49082 49082 55218 55218 61353 67488 73624
Evaporator, Direct Expansion
Water Volume, liters 253.6 359.6 359.6 416.4 416.4 529.9 529.9
Maximum Water Side Pressure, Bar 1
10 10 10 10 10 10 10
Maximum Refrigerant Side Pressure, Bar 16 16 16 16 16 16 16
Minimum Chilled Water Flow Rate, l/sec. 8.8 9.5 9.5 11.4 11.4 11.4 11.4
Maximum Chilled Water Flow Rate, l/sec. 42.6 47.3 47.3 47.3 47.3 50.5 50.5
Water Connections, inches 8 10 10 10 10 10 10
1
Optional 21 Bar Waterside available
JOHNSON CONTROLS 47
TECHNICAL DATA
FORM 201.21-NM1 (616)
48 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
ELECTRICAL DATA
2 COMPRESSOR POWER WIRING CONNECTIONS
UNIT CONTROLS
STANDARD
CONTROL EVAPORATOR HEATER
TRANSFORMERS
VSD SYSTEM
FAN
CONTACTORS
TERMINAL 6
BLOCK
LD10598a
FIG. 6 - SINGLE-POINT POWER SUPPLY CONNECTION WITH FIELD SUPPLIED CIRCUIT PROTECTION
VSD CONTROL PANEL
UNIT CONTROLS
STANDARD
CONTROL EVAPORATOR HEATER
TRANSFORMERS
VSD SYSTEM
FAN
CONTACTORS
CIRCUIT
BREAKER
LD10599a
FIG. 7 - SINGLE-POINT POWER SUPPLY CONNECTION WITH OPTIONAL FACTORY CIRCUIT BREAKER
JOHNSON CONTROLS 49
TECHNICAL DATA
FORM 201.21-NM1 (616)
50 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
JOHNSON CONTROLS 51
TECHNICAL DATA
FORM 201.21-NM1 (616)
52 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
Field Wiring & Protection Field Wiring Lugs Field Wiring Lugs
STD Terminal Block OPT Circuit Breaker
Minimum Max.
YCAV Ckt. Recommended Inverse Max Dual Lugs/ Lugs/
Ampacity Fuse/Ckt. Breaker Time Element Phase1 Lug Wire Range Phase1 Lug Wire Range
(MCA)4 Rating5 Ckt. Brkr. Fuse Size3
Rating2
677 800 1600 1200 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
587 700 1600 1000 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
0157 370 450 1000 600 3 2AWG - 600 kcmil 3 3/0AWG - 400 kcmil
293 350 700 500 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil 6
234 300 600 400 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
755 1000 2000 1200 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
654 800 1600 1200 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
0177 413 500 1000 700 3 2AWG - 600 kcmil 3 3/0AWG - 400 kcmil
326 400 800 600 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
261 300 600 450 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
805 1000 2000 1600 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
698 800 1600 1200 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
0187 440 500 1000 700 3 2AWG - 600 kcmil 3 3/0AWG - 400 kcmil
348 400 800 600 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
279 350 700 450 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
857 1000 2000 1600 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
742 1000 2000 1200 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
0207 468 600 1200 800 3 2AWG - 600 kcmil 3 3/0AWG - 400 kcmil
370 450 1000 600 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
296 350 700 500 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
908 1200 2000 1600 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
786 1000 2000 1600 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
0227 496 600 1200 800 3 2AWG - 600 kcmil 3 3/0AWG - 400 kcmil
392 450 1000 700 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
314 350 800 500 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
1002 1200 2000 1600 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
868 1000 2000 1600 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
0247 547 700 1600 1000 3 2AWG - 600 kcmil 3 3/0AWG - 400 kcmil
432 500 1000 700 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
347 400 800 600 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
1076 1200 2000 2000 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
932 1200 2000 1600 4 2AWG - 600 kcmil 4 4/0AWG - 500 kcmil
0267 588 700 1600 1000 3 2AWG - 600 kcmil 3 3/0AWG - 400 kcmil
464 600 1200 800 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
372 450 1000 600 2 2AWG - 600 kcmil 2 2/0AWG - 500 kcmil
JOHNSON CONTROLS 53
TECHNICAL DATA
FORM 201.21-NM1 (616)
ELECTRICAL NOTES
1. As standard, all units have single point power connection. Contact factory for information regarding dual point power units.
2. Maximum Inverse Time Circuit Breaker - 250% of the rated input current of the drive per NEC 430.52 (C1).
3. Maximum Dual Element (Time Delay) Fuse - 225% of the rated input current of the drive per NEC 430.52 (C1).
4. MCA - Minimum Circuit Ampacity - 125% of the largest compressor RLA plus 100% of the remaining compressor RLA’s plus the sum of all
condenser fan FLA’s per NEC 440.33
5. Recommended time delay or dual element fuse size - 150%of the largest compressor RLA plus 100% of the remaining compressor RLA’s
plus the sum of all condenser fan FLA’s.
9. System inrush current is less than RLA due to the use of YORK Variable Speed Drive technology. Typical Compressor Starting Current
( .rst four seconds of startup):
Rated Voltage Typical Starting Current per Compressor
200/60/3 53A
230/60/3 46A
380/60/3 29A
460/60/3 23A
575/60/3 18A
12. Condenser fan FLA applies to both low sound and ultra quiet fans.
LEGEND:
C.B. CIRCUIT BREAKER
D.E. DUAL ELEMENT FUSE
DISC SW DISCONNECT SWITCH
FACT 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
NOTES:
1. U.L. Label is provided on 60 Hz units for these electrical wiring congurations.
2. –– –– –– –– –– –– Dashed Line = Field Provided Wiring.
3. The above recommendations are based on the National Electric Code and using copper conductors only. Field wiring must also comply with local codes.
Group Rated breaker must be HACR type for cUL machines.
54 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
JOHNSON CONTROLS 55
TECHNICAL DATA
FORM 201.21-NM1 (616)
ELECTRICAL WIRING
ELEMENTARY CONTROL WIRING DIAGRAM
LD12518
56 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
LD12519
JOHNSON CONTROLS 57
TECHNICAL DATA
FORM 201.21-NM1 (616)
T (115VAC)
T
RUN
RUN
LD12516
58 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
LD12517
JOHNSON CONTROLS 59
TECHNICAL DATA
FORM 201.21-NM1 (616)
LD12514
60 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
LD12515
JOHNSON CONTROLS 61
TECHNICAL DATA
FORM 201.21-NM1 (616)
LD12512
62 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
LD12513
JOHNSON CONTROLS 63
TECHNICAL DATA
FORM 201.21-NM1 (616)
LOCATION LABEL
LD10519
64 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
JOHNSON CONTROLS 65
TECHNICAL DATA
FORM 201.21-NM1 (616)
POWER ENTRY
4" 10" WIDE X 13" HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL
1 3/4"
12"
VIEW C-C
B B
C
17 9/16"
4 3/4" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
VIEW A-A
LD10520A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; top
– no obstructions allowed; distance between adjacent units - 10’. No more than one adjacent wall may be higher than the unit.
66 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
5/8" MOUNTING
HOLES (TYP.)
1,055
SYS. 2 SYS. 1
6
APPROX. OPERATING WEIGHT
CONTROL PANEL
68"
DISTRIBUTION (LB)
60"
88 1/8"
VIEW D-D
X CG
D D
40"
96"
87 3/8"
6"
8"
8" WATER INLET
A
WATER OUTLET LD10521A
90" 110 1/4"
11 1/2"
100 7/8" 85 7/16"
230 3/8"
X CG
JOHNSON CONTROLS 67
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL
1 3/4"
12"
VIEW C-C
B B
C
19 1/4"
3 3/4" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
VIEW A-A
LD10522A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; top
– no obstructions allowed; distance between adjacent units - 10’. No more than one adjacent wall may be higher than the unit.
68 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
5/8" MOUNTING
HOLES (TYP.)
1,140
SYS. 2 SYS. 1
CONTROL PANEL
6
APPROX. OPERATING WEIGHT 68"
DISTRIBUTION (LB)
60"
88 1/8"
D D
40"
96"
87 3/8"
6"
10"
10" WATER INLET
A
WATER OUTLET
84 1/2" 113"
230 3/8"
X CG
JOHNSON CONTROLS 69
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL
1 3/4"
12"
VIEW C-C
B B
C
19 1/4"
3 3/4" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
LD10524A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; top
– no obstructions allowed; distance between adjacent units - 10’. No more than one adjacent wall may be higher than the unit.
70 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
5/8" MOUNTING
HOLES (TYP.)
1,145
SYS. 2 SYS. 1
CONTROL PANEL
6
APPROX. OPERATING WEIGHT 68"
DISTRIBUTION (LB)
60"
88 1/8"
VIEW D-D
X
CG
D D
40"
96"
87 3/8"
6"
10"
10" WATER INLET
WATER OUTLET A
84 1/2" 113"
230 3/8"
X
POWER: SINGLE POINT WITH TERMINAL BLOCK CG
JOHNSON CONTROLS 71
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 1 3/4"
12"
VIEW C-C
B B
C
19 1/4"
7 3/4" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
LD10526A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; top
– no obstructions allowed; distance between adjacent units - 10’. No more than one adjacent wall may be higher than the unit.
72 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
MOUNTING
HOLES (TYP.)
1" L5 L4 L3 L2 14 1/16"
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
60" 6
88 1/8"
1" R5 R4 R3 R2
10"
ORIGIN R1
3 3/4"
67 1/2" 85" 64" 48-1/2"
VIEW D-D
D D
40"
96"
87 3/8"
6"
10"
WATER INLET
(3) RIGGING HOLES 10"
A
WATER OUTLET
(EACH SIDE) 84 1/2" 112 7/8"
274 3/8"
LD10527
JOHNSON CONTROLS 73
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 1 3/4"
12"
VIEW C-C
B B
C
19 1/4"
7 3/4" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
LD10528A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; top
– no obstructions allowed; distance between adjacent units - 10’. No more than one adjacent wall may be higher than the unit.
74 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
MOUNTING
HOLES (TYP.)
1" L5 L4 L3 L2 14 1/16"
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
60" 6
88 1/8"
1" R5 R4 R3 R2
10"
ORIGIN R1
3 3/4"
67 1/2" 85" 64" 48-1/2"
VIEW D-D
D D
40"
96"
87 3/8"
6"
10"
WATER INLET
(3) RIGGING HOLES 10"
A
WATER OUTLET
(EACH SIDE) 84 1/2" 112 7/8"
274 3/8"
LD10529
JOHNSON CONTROLS 75
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 1 3/4"
12"
VIEW C-C
B B
C
19 1/4"
7 3/4" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
LD10530A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; 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 201.21-NM1 (616)
MOUNTING
HOLES (TYP.)
1" L5 L4 L3 L2 14 1/16"
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
60" 6
88 1/8"
1" R5 R4 R3 R2
10"
ORIGIN R1
3 3/4"
67 1/2" 85" 64" 48-1/2"
VIEW D-D
D D
40"
96"
87 3/8"
6"
10"
10" WATER INLET
(3) RIGGING HOLES A
WATER OUTLET
(EACH SIDE) 84 1/2" 112 7/8"
274 3/8"
LD10531
JOHNSON CONTROLS 77
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 1 3/4"
12"
VIEW C-C
B B
C
20 5/8"
7 7/8" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
LD10532A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; 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 201.21-NM1 (616)
MOUNTING
HOLES (TYP.)
1" L5 L4 L3 L2 14 1/16"
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
60" 6
88 1/8"
1" R5 R4 R3 R2
10"
ORIGIN R1
3 3/4"
67 1/2" 85" 64" 48-1/2"
VIEW D-D
D D
40"
96"
87 3/8"
6"
10"
WATER INLET
(3) RIGGING HOLES 10"
A
WATER OUTLET
(EACH SIDE) 85 5/8" 112 1/4"
274 3/8"
LD10533
JOHNSON CONTROLS 79
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 1 3/4"
12"
VIEW C-C
B B
C
21 1/4"
6 5/16" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
LD10534A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; 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 201.21-NM1 (616)
MOUNTING
HOLES (TYP.)
1" L5 L4 L3 L2 14 1/16"
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
60" 6
88 1/8"
1" R5 R4 R3 R2
10"
ORIGIN R1
3 3/4"
70 1/2" 80 5/8" 65 3/8" 48-1/2"
VIEW D-D
D D
40"
96"
87 3/8"
6"
10"
WATER INLET
(3) RIGGING HOLES 10"
A
WATER OUTLET
(EACH SIDE) 79 3/16" 114 5/8"
274 3/8"
LD10535
JOHNSON CONTROLS 81
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 1 3/4"
12"
VIEW C-C
B B
C
20 5/8"
7 7/8" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
LD10536A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; top
– no obstructions allowed; distance between adjacent units - 10’. No more than one adjacent wall may be higher than the unit.
82 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
MOUNTING
HOLES (TYP.)
1" L6 L5 L4 L3 L2 14 1/16"
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
60"
88 1/8"
6
1" R6 R5 R4 R3 R2 R1
10"
ORIGIN
3 3/4"
56 5/8" 54 7/8" 85" 64" 48-1/2"
VIEW D-D
D D
40"
96"
87 3/8"
6"
10" 10"
WATER OUTLET WATER INLET
(4) RIGGING HOLES A
85 5/8" 112 1/4"
(EACH SIDE)
88" 79 11/16" 85 7/16" 11 1/2"
318 3/8"
LD10537
JOHNSON CONTROLS 83
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 1 3/4"
12"
VIEW C-C
B B
C
21 1/4"
6 5/16" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
LD10538A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; top
– no obstructions allowed; distance between adjacent units - 10’. No more than one adjacent wall may be higher than the unit.
84 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
MOUNTING
HOLES (TYP.)
1" L5 L4 L3 L2 14 1/16"
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
60"
6
88 1/8"
1" R5 R4 R3 R2
10"
ORIGIN R1
3 3/4"
70 1/2" 80 5/8" 65 3/8" 48-1/2"
VIEW D-D
D D
40"
96"
87 3/8"
6"
10"
10" WATER INLET
(3) RIGGING HOLES A
WATER OUTLET
(EACH SIDE) 79 3/16" 114 5/8"
274 3/8"
LD10539
JOHNSON CONTROLS 85
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 1 3/4"
12"
VIEW C-C
B B
C
21 1/4"
6 5/16" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
VIEW A-A
LD10540A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; top
– no obstructions allowed; distance between adjacent units - 10’. No more than one adjacent wall may be higher than the unit.
86 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
MOUNTING
HOLES (TYP.)
1" L6 L5 L4 L3 L2 14 1/16"
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
60"
88 1/8"
6
1" R6 R5 R4 R3 R2 R1
10"
ORIGIN
3 3/4"
56 5/8" 57 7/8" 80 5/8" 65 3/8" 48-1/2"
VIEW D-D
D D
40"
96"
87 3/8"
6"
10" 10"
WATER OUTLET WATER INLET
(4) RIGGING HOLES A
79 3/16" 114 5/8"
(EACH SIDE)
88" 79 11/16" 84 7/16" 12 1/2"
318 3/8"
LD10541
JOHNSON CONTROLS 87
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 1 3/4"
12"
VIEW C-C
B B
C
21 1/4"
6 5/16" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
LD10542A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; top
– no obstructions allowed; distance between adjacent units - 10’. No more than one adjacent wall may be higher than the unit.
88 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
MOUNTING
HOLES (TYP.)
1" L6 L5 L4 L3 L2 14 1/16"
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
6
60"
88 1/8"
1" R6 R5 R4 R3 R2 R1
10"
ORIGIN
3 3/4"
56 5/8" 57 7/8" 80 5/8" 65 3/8" 48-1/2"
VIEW D-D
D D
40"
96"
87 3/8"
6"
10" 10"
WATER OUTLET WATER INLET
(4) RIGGING HOLES A
79 3/16" 114 5/8"
(EACH SIDE)
88" 79 11/16" 84 7/16" 12 1/2"
318 3/8"
LD10543
JOHNSON CONTROLS 89
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 1 3/4"
12"
VIEW C-C
B B
C
21 1/4"
6 5/16"(EDGE OF
UNIT TO COOLER
CONNECTION )
88 1/8"
LD10544
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; top
– no obstructions allowed; distance between adjacent units - 10’. No more than one adjacent wall may be higher than the unit.
90 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
MOUNTING
HOLES (TYP.)
1" L6 L5 L4 L3 L2 14 1/16"
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
6
60"
88 1/8"
1" R6 R5 R4 R3 R2 R1
10"
ORIGIN
3 3/4"
56 5/8" 57 7/8" 80 5/8" 65 3/8" 48-1/2"
VIEW D-D
D D
40"
96"
87 3/8"
6"
10" 10"
WATER OUTLET WATER INLET
(4) RIGGING HOLES A
79 3/16" 114 5/8"
(EACH SIDE)
88" 79 11/16" 85 7/16" 12 1/2"
318 3/8"
LD10545
JOHNSON CONTROLS 91
TECHNICAL DATA
FORM 201.21-NM1 (616)
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 1 3/4"
12"
VIEW C-C
B B
C
21 1/4"
6 5/16" (EDGE OF
UNIT TO COOLER
CONNECTION)
88 1/8"
LD10546A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reli-
able operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable
air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit
is no higher than on spring isolators. Recommended minimum clearances: side to wall - 6’ ; rear to wall - 6’; control panel end to wall - 4’; top
– no obstructions allowed; distance between adjacent units - 10’. No more than one adjacent wall may be higher than the unit.
92 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
MOUNTING
HOLES (TYP.)
1" L6 L5 L4 L3 L2 14 1/16"
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
6
60"
88 1/8"
1" R6 R5 R4 R3 R2 R1
10"
ORIGIN
3 3/4"
56 5/8" 57 7/8" 80 5/8" 65 3/8" 48-1/2"
VIEW D-D
D D
40"
96"
87 3/8"
6"
10" 10"
WATER OUTLET WATER INLET
(4) RIGGING HOLES A
79 3/16" 114 5/8"
(EACH SIDE)
88" 79 11/16" 84 7/16" 12 1/2"
318 3/8"
LD10547
JOHNSON CONTROLS 93
TECHNICAL DATA
FORM 201.21-NM1 (616)
CONTROL ENTRY
38 76 WIDE X 343 HIGH
POWER ENTRY
102 254 WIDE X 330 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL
44
305
VIEW C-C
B B
C
446
121 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10548A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
94 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
16 MOUNTING
HOLES (TYP.)
1,055
SYS. 2 SYS. 1
6
APPROX. OPERATING WEIGHT 1727
CONTROL PANEL
DISTRIBUTION (KG)
1524
2239
VIEW D-D
X CG
D D
1016
2438
2219
152
8"
8" WATER INLET
WATER OUTLET A
2286 2800
5852
LD10549A
(3) RIGGING HOLES Z
EACH SIDE (114 X 51)
POWER: SINGLE POINT WITH TERMINAL BLOCK
X
CG
JOHNSON CONTROLS 95
TECHNICAL DATA
FORM 201.21-NM1 (616)
38 CONTROL ENTRY
76 WIDE X 343 HIGH
POWER ENTRY
102 254 WIDE X 330 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL
44
305
VIEW C-C
B B
C
489
95 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10550A
VIEW A-A
POWER: SINGLE POINT WITH TERMINAL BLOCK
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
96 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
16 MOUNTING
HOLES (TYP.)
SYS. 2 SYS. 1
CONTROL PANEL
APPROX. OPERATING WEIGHT 1727
DISTRIBUTION (KG)
1524
2239
VIEW D-D
X CG
D D
1016
2438
2219
152
10"
10" WATER INLET
WATER OUTLET A
2146 2870
JOHNSON CONTROLS 97
FORM 201.21-NM1 (616)
38 CONTROL ENTRY
76 WIDE X 343 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 44
305
VIEW C-C
B B
C
489
197 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10552A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
98 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
MOUNTING
HOLES (TYP.)
26 L5 L4 L3 L2 357
L1
SYS. 2 SYS. 1
ONTROL P NEL
68
1524
2239
26 R5 R4 R3 R2
254
ORIGIN R1
95
1714 2160 1626 1232
IE
1016
2438
2219
152
10
10 TER INLET
(3) RIGGING HOLES
TER OUTLE T
(E H SI E) 2146 2867
6970
LD10555
JOHNSON CONTROLS 99
TECHNICAL DATA
FORM 201.21-NM1 (616)
38 CONTROL ENTRY
76 WIDE X 343 HIGH
POWER ENTRY
102 254 WIDE X 330 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL
44
305
VIEW C-C
B B
C
489
95 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10552A
VIEW A-A
POWER: SINGLE POINT WITH TERMINAL BLOCK
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
16 MOUNTING
HOLES (TYP.)
SYS. 2 SYS. 1
CONTROL PANEL
6
APPROX. OPERATING WEIGHT 1727
DISTRIBUTION (KG)
1524
2239
95
2756 1626 1232
Y
VIEW D-D
X CG
D D
1016
2438
2219
152
10"
10" WATER INLET
WATER OUTLET A
2146 2870
292
2562 2169
5852
LD10553A
(3) RIGGING HOLES Z
EACH SIDE (114 X 51)
POWER: SINGLE POINT WITH TERMINAL BLOCK X
X CG
38 CONTROL ENTRY
76 WIDE X 343 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 44
305
VIEW C-C
B B
C
489
197 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10554A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
MOUNTING
HOLES (TYP.)
26 L5 L4 L3 L2 357
L1
SYS. 2 SYS. 1
ONTROL P NEL
68
1524 6
2239
26 R5 R4 R3 R2
254
ORIGIN R1
95
1714 2160 1626 1232
IE
1016
2438
2219
152
10
10 TER INLET
(3) RIGGING HOLES
TER OUTLE T
(E H SI E) 2146 2867
6970
LD10555
38 CONTROL ENTRY
76 WIDE X 343 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 44
305
VIEW C-C
B B
C
489
197 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10556A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
MOUNTING
HOLES (TYP.)
26 L5 L4 L3 L2 357
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
1524 6
2239
26 R5 R4 R3 R2
254
ORIGIN R1
95
1714 2160 1626 1232
VIEW D-D
D D
1016
2438
2219
152
10"
10" WATER INLET
(3) RIGGING HOLES A
WATER OUTLET
(EACH SIDE) 2146 2867
6970
LD10557
38 CONTROL ENTRY
76 WIDE X 343 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 44
305
VIEW C-C
B B
C
524
200 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10558A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
MOUNTING
HOLES (TYP.)
26 L5 L4 L3 L2 357
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
1524 6
2239
26 R5 R4 R3 R2
254
ORIGIN R1
95
1714 2160 1626 1232
VIEW D-D
D D
1016
2438
2219
152
10"
WATER INLET
(3) RIGGING HOLES 10"
A
WATER OUTLET
(EACH SIDE) 2174 2851
6970
LD10559
38 CONTROL ENTRY
76 WIDE X 343 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 44
305
VIEW C-C
B B
C
540
161 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10560A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
MOUNTING
HOLES (TYP.)
26 L5 L4 L3 L2 357
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
1524 6
2239
26 R5 R4 R3 R2
254
ORIGIN R1
95
1791 2048 1661 1232
VIEW D-D
D D
1016
2438
2219
152
10"
WATER INLET
(3) RIGGING HOLES 10"
WATER OUTLET A
(EACH SIDE) 2011 2912
6970
LD10561
38 CONTROL ENTRY
76 WIDE X 343 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 44
305
VIEW C-C
B B
C
524
200 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10562A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
MOUNTING
HOLES (TYP.)
26 L6 L5 L4 L3 L2 357
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
1524
2239
6
26 R6 R5 R4 R3 R2 R1
254
ORIGIN
95
1438 1393 2160 1626 1232
VIEW D-D
D D
1016
2438
2219
152
10" 10"
WATER OUTLET WATER INLET
(4) RIGGING HOLES A
2174 2851
(EACH SIDE)
2235 2024 2169 292
8087
LD10563
38 CONTROL ENTRY
76 WIDE X 343 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 44
305
VIEW C-C
B B
C
540
161 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10564A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
MOUNTING
HOLES (TYP.)
26 L5 L4 L3 L2 357
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
1524 6
2239
26 R5 R4 R3 R2
254
ORIGIN R1
95
1791 2048 1661 1232
VIEW D-D
D D
1016
2438
2219
152
10"
10" WATER INLET
(3) RIGGING HOLES A
WATER OUTLET
(EACH SIDE) 2011 2912
6970
LD10565
38 CONTROL ENTRY
76 WIDE X 343 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 44
305
VIEW C-C
B B
C
524
200 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10566A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
MOUNTING
HOLES (TYP.)
26 L6 L5 L4 L3 L2 357
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
1524
6
2239
26 R6 R5 R4 R3 R2 R1
254
ORIGIN
95
1438 1393 2160 1626 1232
VIEW D-D
D D
1016
2438
2219
152
10" 10"
WATER OUTLET WATER INLET
(4) RIGGING HOLES A
2174 2851
(EACH SIDE)
2235 2024 2169 292
8087
LD10567
38 CONTROL ENTRY
76 WIDE X 343 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 44
305
VIEW C-C
B B
C
540
161 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
VIEW A-A
LD10575A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
MOUNTING
HOLES (TYP.)
26 L6 L5 L4 L3 L2 357
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
1524
2239
6
26 R6 R5 R4 R3 R2 R1
254
ORIGIN
95
1438 1470 2048 1661 1232
VIEW D-D
D D
1016
2438
2219
152
10" 10"
WATER OUTLET WATER INLET
(4) RIGGING HOLES A
2011 2912
(EACH SIDE)
2235 2024 2144 318
8087
LD10574
38 CONTROL ENTRY
76 WIDE X 343 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 44
305
VIEW C-C
B B
C
540
161 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10570A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
MOUNTING
HOLES (TYP.)
26 L6 L5 L4 L3 L2 357
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
1524
2239
6
26 R6 R5 R4 R3 R2 R1
254
ORIGIN
95
1438 1470 2048 1661 1232
VIEW D-D
D D
1016
2438
2219
152
10" 10"
WATER OUTLET WATER INLET
(4) RIGGING HOLES A
2011 2912
(EACH SIDE)
2235 2024 2169 318
8087
LD10571
38 CONTROL ENTRY
76 WIDE X 343 HIGH
VIEW B-B
POWER ENTRY IS ON BOTTOM OF PANEL 44
305
VIEW C-C
B B
C
540
161 (EDGE OF
UNIT TO COOLER
CONNECTION)
2239
LD10572A
VIEW A-A
Notes:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance, reliable
operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air
flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety
cutout; 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; rear to wall - 2m; control panel end to wall - 1.2m;
top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be higher than the unit.
MOUNTING
HOLES (TYP.)
26 L6 L5 L4 L3 L2 357
L1
SYS. 2 SYS. 1
CONTROL PANEL
68
6
1524
2239
26 R6 R5 R4 R3 R2 R1
254
ORIGIN
95
1438 1470 2048 1661 1232
VIEW D-D
D D
1016
2438
2219
152
10" 10"
WATER OUTLET WATER INLET
(4) RIGGING HOLES A
2011 2912
(EACH SIDE)
2235 2024 2144 318
8087
LD10573
(2 m)
(1.3 m) (2 m)
(2 m)
LD10506
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.
Weights of specific chiller models vary significantly as Whenever the isolator option is ordered, the isolators
options are added. As a result, total weights, weights at will be shipped loose with the chiller. Packed with
individual isolator positions, and actual isolator selection the isolators and also in the control panel information
at each position cannot be published due to the thou- packet is a drawing and table specifically for each
sands of possible combinations. This information will chiller, based on the option selection. The drawing and
be available when the specific chiller/option selection table will be similar to Figure 8 below. The drawing
is made from the local YORK sales office. Be aware, will show the isolator locations along with weight in
weights will change with each option along with pos- pounds and kilograms at the specific location, isolator
sible isolator changes. Weights and isolators may need position, and location measurements for each isolator.
to be recalculated when option selections are changed.
X
0
Y L1 L2 L3 L4 L5 L6
0
CONTROL PANEL
R1 R2 R3 R4 R5 R6
LD10499
FIG. 8 - SAMPLE PRINTOUT SUPPLIED IN THE ISOLATOR PACKAGE AND IN THE CHILLER PANEL
LITERATURE PACKET
L1 L2 L3 L4
Control
Panel
6
R1 R2 R3 R4
(3.75", 95mm) (48.5", 1231.9mm) (112.5", 2857.5mm) (224.75", 5708.7mm)
L1 L2 L3 L4
L5
Control
Panel
R1 R2 R3 R4 R5
(3.75", 95mm) (48.5", 1231.9mm) (112.5", 2857.5mm) (197.53", 5017.3mm) (265", 6731mm)
NOTE: Distances indicated are from the end of the chiller designated as X in FIG.8.
L1 L2 L3 L4 L5
Control
Panel
R1 R2 R3 R4 R5
(3.75", 95mm) (48.5", 1231.9mm) (113.875", 2892.4mm) (194.5", 4940mm) (265", 6731mm)
L1 L2 L3 L4 L5 L6
Control
Panel
R1 R2 R3 R4 R5 R6
(3.75", 95mm) (48.5", 1231.9mm) (112.5", 2857.5mm) (197.53", 5017.3mm) (252.38", 6410.5mm) (309", 7848.6mm)
L1 L2 L3 L4 L5 L6
Control
Panel
6
R1 R2 R3 R4 R5 R6
(3.75", 95mm) (48.5", 1231.9mm) (113.875", 2892.4mm) (194.5", 4940mm) (252.375", 6410.3mm) (309", 7848.6mm)
HCL Adjustment
HCW L Bolt
W
NOTES: Illustration above shows a SLRS-4-C2(4 Springs). SLRS-8-2 & C2 have one spring, and SLRS-2-C2 has two springs.
SLRS-6-C2 has six springs and SLRS-9-C2 has nine springs.
PIN 54 = S
*Weight Range (lbs) *Weight Range (kg) Vendor P/N COLOR YORK P/N
Adjustment
Bolt
LD10568
BC
H L
LD10569
W
T
ENGLISH
SIZE D H L T W BC CS MBD
ND-C 2-9/16 2-3/4 5-1/2 1/4 2-5/16 4-1/8 1/2-13x1" 1/2"
ND-D 3-3/8 2-3/4 6-1/4 5/16 4 5 1/2-13x1" 1/2"
ND-DS 3-3/8 2-3/4 6-1/4 5/16 4 5 1/2-13x1" 1/2"
SI
ND-C 65.1 69.9 139.7 6.4 58.7 101.9 1/2-13x1" 13
ND-D 85.7 69.9 158.8 7.9 101.6 127.0 1/2-13x1" 13
ND-DS 85.7 69.9 158.8 7.9 101.6 127.0 1/2-13x1" 13
PIN 54 = N
**Weight Range (lbs) **Weight Range (kg) COLOR YORK P/N YORK P/N
It is not neccesary to bolt the mountings to a concrete pad in most cases. Mountings should always be bolted to the
chiller rails. When mountings and the chiller are installed on steel framing above the ground, the mountings should
be bolted to the steel framework. Lower the chiller on to the mountings evenly to avoid placing excessive weight
on individual isolators.
6
LD10576
For Units With All Load Points Less than 1404 LBS (637 KG)
For Units With Any Load Point Above 1404 LBS (637 KG)
UP TO 851 LBS Up to 386 kg CIP-C-1000 Black 029-24583-007
NON-SKID NEOPRENE
ACOUSTICAL ISOLATION PAD L
(Bolting to floor is not necessary for
indoor applications)
T
W
SBC
HCL
MAX BOLT
DIA. - MBD
Slot Width - SW
All springs have additional
HCW
travel to solid equal to 50%
of the rated deflection.
3. Lubricate the threads of adjusting bolt. Loosen the 8. Turn the leveling bolt of all mountings in either
hold down bolts to allow for isolator adjustment. direction in order to level the installation.
4. Block the equipment 10mm (1/4”) higher than the 9. Tighten the nuts on hold down bolts to permit a
specified free height of the isolator. To use the iso- clearance of 2mm (1/8”) between resilient washer
lator as blocking for the equipment, insert a 10mm and underside of channel cap plate.
(1/4”) shim between the upper load plate and vertical
uprights. Lower the equipment on the blocking or
10. Installation is now complete.
shimmed isolators.
132 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
C R C
C R C
C R R R R
R R
RC2
C
R 22 R C
LD10505
CONDENSOR COIL
T
DV
S
AIR HTC
FLOW
LTC OS
SMV
PS
T P
FT DV
DV DIF
SMV
LPC P
COMP P DV
M HPC
HPL
HTR DPF
EVAPORATOR HTR
DV T T
CHT
LTC FS
DV
CHILLER WATER
FLOW
PLUG LD10589
COMPONENT LOCATIONS
KEYPAD/DISPLAY
PANEL CONDENSOR
DOOR COIL
6
LD10477
COMPRESSOR
FILTER
GLYCOL OIL DRIER
PUMP SEPARATORS
LD10578
CHILLER
MICROGATEWAY CONTROL
(OPTIONAL) BOARD RELAY BOARD #1
LD10579
OPTIONAL
CIRCUIT BREAKER RELAY BOARD #2
(Standard Unit will have terminal blocks.
Input power to the chiller will
be connected here (see FIG.-17)).
MICROGATEWAY CHILLER
CONTROL
(OPTIONAL) RELAY BOARD #1
BOARD
mA
▼ ▼
• • •
▲ ▲
V
JUMPER POSITION
VSD
LOGIC BOARD
LD10582
R86
(COMPR 4
Over Load Adjust)
R42
(COMPR 3
Over Load Adjust)
R64
(COMPR 2
Over Load Adjust)
R19
(COMPR 1
Over Load Adjust)
YORK
MADE IN THE USA
LD10590
LD10583
4-9FU FUSES &
10T INCOMING POWER 14-16FU FUSES
GROUND LUGS TRANSIENT
TRANSFORMER 17-21 FU SUPPRESSOR
1TB FUSES
TERMINAL INPUT POWER TO
BLOCK THE CHILLER CONNECTS
HERE 1L AC LINE
INDUCTOR
FAN CONTACTORS
4CR-9CR
LD10584
3T TRANSFORMER
(24VAC to SCR Gate Driver Board
and VSD Logic Board)
LD10585
BUS
ISOLATOR
BOARD
(Feeds VSD
Logic Board)
CURRENT
TRANSFORMERS SCR
TRIGGER
BOARD
IGBT GATE
SNUBBER DRIVER
CAPS BOARDS
(C7-C12)
IGBT
MODULES
SCR/DIODE
MODULES
LD10586
1L LINE BUS FILTER
INDUCTOR CAPACITORS
(Behind Panel) HEATSINK 1RES & 2RES
(Water Cooled) BUS CAPACITOR
BANK EQUALIZING/
BLEEDER
FIG. 20 - VSD COMPONENTS RESISTORS
CABINET CURRENT
COOLING TRANSFORMERS
COIL C13-C17
COOLING
FAN
FANS
RELAYS
TRANSIENT
SUPPRESSOR
BOARD
W/ 11FU, 12FU,
& 13 FU FUSES
(3 Phase Input)
10CR FAN
PUMP
CONTROL
RELAY
LD10587
1L LINE
INDUCTOR
SCR/DIODE
MODULES
SCR/DIODE
MODULE
LD10591
1RES & 2RES BUS CAPACITORS BANK
EQUALIZING/BLEEDER RESISTORS
LAMINATED
BUS
STRUCTURE
IGBT GATE
DRIVER
IGBT GATE BOARD #1
DRIVER
BOARD #2
LD10592
IGBT'S IGBT'S
LD10593
FIG. 24 - INVERTER POWER COMPONENTS
IGBT'S IGBT'S
SCR/DIODE
MODULES
SCR/DIODE
MODULES
LD10594
1RES & 2RES BUS CAPACITORS BANK
EQUALIZING/BLEEDER RESISTORS
REAR
OF
VSD PANEL
SEE
DETAIL "B"
SEE
DETAIL "C"
SEE
DETAIL "B"
SEE
6
REAR DETAIL "C"
OF
VSD PANEL
SEE
DETAIL "B"
SEE
SEE DETAIL "C"
SEE
DETAIL "A"
DETAIL "B"
SEE
DETAIL "C"
SEE
DETAIL "A"
SEE
DETAIL "A"
SEE
DETAIL "A"
GLYCOL
PUMP DETAIL "B"
TYPICAL 4 PLACES
GLYCOL
FILL
TUBE
DETAIL "B"
TYPICAL 4 PLACES
DETAIL "A"
DETAIL "C"
DETAIL "A"
DETAIL "C"
GLYCOL
FILL
TUBE
LD10597
JOHNSON CONTROLS
MOTOR/ROTOR
HOUSING
MOTOR
TERMINALS
COMPRESSOR COMPONENTS
BEARINGS
OIL
FILTER
FEMALE
ROTOR SHIMS
BEARINGS SHIMS
DISCHARGE
LD10596
HOUSING
FORM 201.21-NM1 (616)
151
6
TECHNICAL DATA
FORM 201.21-NM1 (616)
INSTALLING
CONTRACTOR: _________________________
Check the system 24 hours prior to initial start:
START-UP
TECHNICIAN/
COMPANY: _____________________________ 1. Inspect the unit for shipping or installation
damage.
START-UP DATE: ________________________ 2. Ensure that all piping has been completed.
3. Assure the unit is properly charged and there are no
CHILLER MODEL #: ______________________ piping leaks.
4. Open each system suction service valve, discharge
SERIAL #: ______________________________
service valve, economizer service valve, liquid line
stop valve, and oil line ball valve.
COMPRESSOR #1
MODEL#: ______________________________ 5. The oil separator oil level(s) should be maintained
so that an oil level is visible in either of the oil
SERIAL #: ______________________________ separator sight glasses when a compressor is running
at high speeds for 10 to 15 minutes. An oil level
COMPRESSOR #2 may not be visible in the sight glasses when the
MODEL#: ______________________________ compressor is off and it may be necessary to run the
compressor to obtain a level. In shutdown situations
SERIAL #: ______________________________ and at some load points, much of the oil may be in
the condenser and the level in the separators may
COMPRESSOR #3 fall below the bottom sight glass.
MODEL#: ______________________________
On systems with dual oil separators per compressor,
SERIAL #: ______________________________ one separator may show a lower level or no level,
while the other separator shows a level between the
COMPRESSOR #4 2 sight glasses. This is normal and a level is only
MODEL#: ______________________________ required in one separator. Do not add oil to raise
the level in the other oil separator.
SERIAL #: ______________________________
Oil levels in single separator systems should not go
above the top of the upper sight glass. Dual separa-
tor systems should also not show oil levels above the
top of one of the sight glasses. In the rare situation
where oil levels are high, drain enough oil to lower
the level to the bottom of the top sight glass.
LD10608
LD10609
DC LINK FILTER
LD10611
LD10613
IGBT'S IGBT'S
LD10612 6
1L LINE INDUCTOR LAMINATED BUS STRUCTURE
The 5% impedance 1L Line Inductor has multiple The Laminated Bus Structure is a group of copper plates
functions. 1L forms a low pass LC filter that filters the sandwiched together that connects the SCR/Diode Mod-
pulsating DC from the AC to DC converter, to smooth ules, Bus Filter Capacitors, and IGBT’s. The purpose of
DC voltage. The inductance eliminates notches on the the Laminated Bus Structure is to reduce the inductance
incoming AC line. The inductance also helps protect the that would be present in wiring or bus bars often used to
SCR’s from high voltage incoming line transients, which connect high voltage components in VSD’s. Removing
could damage them. 1L slows down the rate of rise of inductance in the circuit reduces the voltage spike that
current if an internal short circuit occurs, reducing the occurs when the IGBT’s turn off. These voltage spikes
potential damage caused by the short. 1L also reduces can potentially damage the IGBT’s.
the input current total harmonic distortion.
LAMINATED BUS
STRUCTURE
DC TO AC INVERTER
LD10614
LD10613
LD10619
LD10620
LD10624
LD10623
OPERATING CONTROLS
Anti-recycle Timer and off together. An under voltage condition will keep
the heater off until full voltage is restored to the system.
A typical 5 or 10 minute anti-recycle timer is not
necessary to allow compressor motor cooling, due to Pumpdown Control
the VSD’s ability to provide a low current inrush start.
The system does utilize a fixed 120 second anti-recycle The VSD assures a smooth slow compressor start.
timer to prevent short cycling of systems and to allow As a result of this, neither pumpdown on start-up or
positioning the Feed and Drain Valves to a zero (closed) pumpdown on shutdown is required. The Drain and
position by the Flash Tank Drain and Feed Valve Con- Feed Valves will close when a compressor stops. This
troller in the event of a power failure. is a similar to a liquid line solenoid valve closing on a
conventional chiller.
On power-up of the control panel, the anti-recycle timer
for each system will be set to 120 seconds and must time Compressor Heater Control
out before a compressor is allowed to start.
Each compressor has its own heater. The purpose of the
Whenever a system starts, the anti-recycle timer for all heater is to assure refrigerant does not condense in the
systems will be set to 120 seconds and will count down compressor. There is no oil sump, but refrigerant could
from the time the motor starts. The timer must time out possibly condense in the rotors or the motor housing.
before another compressor is allowed to start. The heater will be off whenever the respective compres-
sor is running. As soon as the compressor shuts off,
Whenever a system shuts down, the anti-recycle timer the heater will turn on as long as all motor temperature
for that system will be set to 120 seconds. The timer sensors in the compressor read <158°F. The heater will
must time out before the system is allowed to restart. turn off, if any internal compressor motor temperature
sensor reads >160°F.
Evaporator Pump Control
Alarms
The evaporator pump dry contacts are energized when
any of the following conditions are true: Each system has its own alarm. The Alarm output is
ON (dry contact closed) when no fault condition is
· If a Low Leaving Chilled Liquid Fault occurs. present and OFF (dry contact open) to indicate an alarm
situation. The Alarm should be activated (contact open),
if any of the following are true.
· Whenever a compressor is running.
· A System is faulted or inhibited from starting for
· The Daily Schedule is ON and the Unit Switch is more than 5 seconds.
ON.
Even if one of above is true, the pump will not run if · The Unit is faulted or inhibited from starting for
the panel has been powered up for less than 30 seconds more than 5 seconds.
or if the pump has run in the last 30 seconds to prevent
pump motor overheating. · A System is locked out.
LD10605
UNIT
SWITCH
A double pole single throw ON/OFF rocker switch on
the front of the control panel is used to turn the entire
chiller on and off. When the switch is placed in the OFF
position, the entire unit shuts down immediately. One
pole of the UNIT Switch contacts is wired to the Sys
1/3 and the other to Sys 2/4 VSD Run Signal input and
the Chiller Control Board “Unit Switch X” digital input
(X = System 1 or 2). Separate System Fuses are also
wired in series with each set of UNIT Switch contacts.
If either fuse is pulled or blown, only the system with
the good fuse (Input is high) will run. When both inputs
are high, the entire chiller will be enabled to run. When
both inputs are low, the chiller will be disabled as a Unit
Switch OFF Shutdown.
· At least one System Switch is ON When a compressor starts, the Feed and Drain Valves on
the system will immediately begin to control superheat
· Run permissive inputs (Remote Cycling Contacts) and the liquid level in the Flash Tank and the Chiller
must be closed. Control Board micro will begin to regulate the speed
on the VSD to bring the chilled liquid temperature to
within the Control Range (CR). The micro will regu-
· No unit faults exist. late the speed of the compressor(s) primarily based on
temperature offset as the loading timer permits.
· No unit start inhibits exist.
The Setpoint is the Leaving Chilled Liquid Temperature
· At least one system not faulted or inhibited. midpoint of the Control (Cooling) Range. The Setpoint
High Limit is the Setpoint plus the Control Range. The
Setpoint Low Limit is the Setpoint minus the Control
· The Daily Schedule is calling for the chiller to
Range. The chiller will attempt to control within the
run.
temperature range programmed by the Setpoint +/-
CR.
· The Flow Switch is closed.
Starting and stopping of compressors will be handled by
· Leaving Chilled Liquid Setpoint is above the the Standard or High IPLV Capacity Control Routine.
Setpoint + CR (Setpoint High Limit). Loading and unloading will be controlled by temperature
offset and rate by the Fuzzy Logic Control Routine.
48˚F --------------------------------------------------
40˚F --------------------------------------------------
38˚F --------------------------------------------------
LD10625
The number of compressors to start control logic varies On optimized IPLV chillers, the Number of
between the standard and optional high IPLV chillers. Compressors to Start Logic will be used to determine
Standard IPLV chiller control utilizes sequential logic how many compressors should be run when the unit
that requires the micro to start 1 compressor at a time starts from the all compressors stopped state. This
and only add a compressor when all running compres- routine will try to run all the compressors unless it is
sors reaches maximum speed. Optional High IPLV determined that less will be needed due to light load.
chillers have control algorithms that provide “smart”
anticipatory control to determine how many The first step in the sequence is for the micro to set the
compressors need to be started to satisfy the current number of compressors to start equal to the number of
load. The “smart” logic is capable of reducing short compressors in the chiller. The micro will look at two
cycling, and reducing loading time on a hot water start, prior conditions relating to the compressor operating
and starting all compressors at the same time. time the previous time it ran and how long the last
compressor has been off along with two indicators 7
of chilled liquid load requirements (rate of change of
STANDARD IPLV chilled liquid temperature and deviation from setpoint.).
Temperature deviation is the amount of error compared
The standard IPLV control always starts a single to the setpoint high limit (Setpoint + CR). Based on this
compressor under all circumstances as the first step information, the micro will then determine the number
of loading. The Chiller Control Board does not make of compressors to start. The flowchart in FIG. - 29
decisions on the number of compressors to start based describes the compressor starting decision process.
on chilled liquid temperatures and prior compressor
operation when starting the chiller. An additional It is desirable to run as many compressors as possible for
compressor is only started when the lead compressor increased efficiency. Optimized logic will keep as many
has reached maximum speed and cooling requirements compressors on line and reduce speed in an effort to
are not satisfied. optimize the use of the entire evaporator tube surface.
NUMBER OF COMPS
TO START LOGIC NUMBER OF COMPS TO
START
REDUCTION TABLE
NO NO
LCHLT RATE
LAST RUN TIME OFF TIME
< 3 °F/MIN AND
< 5 MIN ? < 5 MIN ?
LCHLT < CR+5°F?
CONTINUE
LD10626
· If the ambient temperature is 25°F or less, the · If the ambient temperature is <110°F, the Minimum
Minimum VSD Start Frequency will be VSD Run Frequency will be 50 Hz.
70 Hz.
· If the ambient temperature is 26-40 °F, the · If the ambient is 110-125°F, the Minimum VSD
Minimum VSD Start Frequency is 60 HZ. Run Frequency is scaled according to the following
· If the ambient temperature is 41-110 °F, the formula:
Minimum VSD Start Frequency will be (3X Ambient Temperature)-280°F.
50 Hz. The formula is also represented by the graph in FIG.
· If the ambient is 110-125 °F, the Minimum VSD 31.
Start Frequency is scaled according to the
following formula:
(3X Ambient Temperature)-280°F. 100
95
The formula is also represented by the graph in FIG.
Minimum VSD Frequency (Hz)
90
30. 85
80
75
100 70
95 65
Minimum VSD Frequency (Hz)
90 60
85 55
80 50
75 45
70 40
65 105 110 115 120 125 130
60 Ambient Temperature (°F)
55
50 NOTE: The graph above also illustrates the scaled frequency:
45
40 LD10628
NOTE: The graph above also illustrates the scaled frequency: · If the ambient temperature is >125°F, the Minimum
LD10627
VSD Run Frequency will be 95 Hz.
· A b o v e 1 2 5 ° F, t h e m i n i m u m V S D S t a r t
Frequency is 95 Hz.
When a compressor starts, the load and unload timers For example: Current VSD Freq = max freq of the chiller = 200 Hz.
Number of compressors enabled = 2 = Original
will be set to 30 seconds. During the first 30 seconds of compressor running, plus the compressor to be added.
operation after a compressor reaches the start frequency,
loading/unloading is inhibited. In this example, assume a single compressor had
been running at the max frequency of 200 Hz without
After 30 seconds, the control logic looks at the LCHLT satisfying cooling demand. (2) compressors are now
temp, compares it to the Setpoint plus CR, and makes enabled when the second compressor is activated. Plac-
decisions to load or unload. ing these values in the formula, the START Frequency
= 200 Hz x (2-1)/2 = 100 Hz. The compressors will be
For precise capacity control, the Chiller Control Board accelerated to a start frequency of 100 Hz. Load and
microprocessor loads and unloads compressors quickly, unload timers will be set to 30 seconds. The anti-recycle
as fast as every 2 seconds, in increments of 0.1-1 Hz each timer will be set to 120 seconds.
time a load or unload change is required. Fixed load and
unload timers of 2 sec. are set, after a speed change of If additional cooling is required, after the initial 30 sec-
0.1-1 Hz, to minimize undershoot and overshoot. onds of operation, loading will occur at the rate of 0.1 -1
Hz every 2 seconds, unless load limiting occurs.
As additional cooling is required (LCHLT > Setpoint
+ CR), the Chiller Control Board microprocessor will If the cooling capacity exceeds the demand and tem-
increase the speed of the compressor at the rate of 0.1-1 perature continues to drop while in the CONTROL
Hz every 2 seconds until the load is satisfied. Loading RANGE (CR) with multiple compressors operating,
will continue to occur as long as leaving chilled liquid the Chiller Control Board microprocessor will decrease
temperature is above the Setpoint + CR. the speed of the compressor(s) at the rate of 0.1-1 Hz
every 2 seconds until the LCHLT stabilizes within the
If the temperature falls very near or within the control CONTROL RANGE. If frequency (speed) drops below
range, the Chiller Control Board microprocessor will the LESS COMP FREQ – 20 Hz or the minimum VSD
make decisions regarding speed changes under condi- frequency, whichever is higher, the compressors will
tions where the “error” and “rate” conflict. Under these be decelerated to a speed of 5 Hz, the last compressor
conditions, loading/unloading follows the guidelines disabled, and the remaining compressor(s) restarted
described in the Fuzzy Logic Control Section (Page minus one lag compressor. The LESS COMP FREQ
177). is designated as:
If the compressor speed exceeds the maximum LESS COMP FREQ = Max VSD Freq x (Number of compressor enabled -1)
1 hertz for a period of 3 minutes without bringing the For example: 200 Hz = max freq of the chiller.
leaving chilled liquid temperature to within Setpoint + Number of compressors enabled before shutdown = 2
On 3 and 4 compressor chillers, if frequency (speed) In cases where temperature is dropping too fast when
drops below the LESS COMP FREQ – 20 Hz or temperature is within the desired CONTROL RANGE,
the minimum VSD frequency, whichever is higher, the micro will be required to make decisions regarding
another lag compressor will be shut down using the speed changes under conditions where the “error” and
same guidelines. “rate” conflict. For example, the micro may elect to
decrease the speed of the compressor(s) if the error is
When the system is only operating a single (lead) “0” (temperature is at Setpoint), while the rate of change
compressor, if temperature continues to stay below the of chilled liquid temperature is falling (negative). The
control range (Setpoint – CR) or continues to drop while Chiller Control Board microprocessor may also elect to
in the CONTROL RANGE, the Chiller Control Board hold the speed when error is “positive” (temperature is
microprocessor will unload the compressor at the rate of above Setpoint, but not above Setpoint + CR) because
0.1-1 Hz every 2 seconds. This will continue until the the rate of change of chilled liquid is “negative” (falling).
frequency drops below the Minimum VSD Frequency TABLE 4 illustrates these conditions.
determined by the ambient temperature. At this point,
the lead compressor will be shut down, if temperature
is below the Setpoint - CR.
Motor current load limiting helps prevent the system TABLE 7 - DISCHARGE PRESSURE
from tripping on the motor overload safety. The motor LOAD LIMITING/UNLOADING
“Current Limit Setpoint” is based on %FLA motor cur-
rent and is programmable under the Program key or may UN-
DISCHARGE PRESSURE
be set by a remote device. Motor current load limiting LOADING
prevents the system from loading even though increased Discharge Pressure Cutout- 20 PSIG 0 Hz
loading may be required when the current is between the
&
“Current Limit Setpoint – 2%” and the “Current Limit
setpoint”. Between the “Current Limit Setpoint” and the Discharge Pressure Cutout- 15 PSIG
“Current Limit Setpoint + 5%”, the system will unload Discharge Pressure Cutout- 13.5 PSIG 1 Hz
every 2 seconds according to the amount current is ex- Discharge Pressure Cutout- 12 PSIG 2 Hz
ceeding the “Current Limit Setpoint”. At the “Current
Discharge Pressure Cutout- 10.5 PSIG 3 Hz
limit Setpoint”, 0 Hz reduction in speed will take place
and at the “Current Limit Setpoint + 5%”, a 10 Hz speed Discharge Pressure Cutout- 9 PSIG 4 Hz
reduction will take place. Between the “Current Limit Discharge Pressure Cutout- 7.5 PSIG 5 Hz
Setpoint” and “Current Limit Setpoint + 5%”, unloading Discharge Pressure Cutout- 6 PSIG 6 Hz
will occur according to the TABLE 6 : Discharge Pressure Cutout- 4.5 PSIG 7 Hz
Discharge Pressure Cutout- 3 PSIG 8 Hz
Discharge Pressure Cutout- 1.5 PSIG 9 Hz
Discharge Pressure Cutout- 0 PSIG 10 Hz
LD10619
VALVE CONTROLLER AND CONTROL level in the Flash Tank is maintained at a proper level.
ALGORITHM OPERATION The Level Sensor is a rod inserted into the reservoir
connected to the side of the Flash Tank. The sensing rod
The Flash Tank Feed and Drain Valve PI Controller(s) has an active range of about 12”. The control algorithm
plays a dual role of supplying drive signals to control looks at feedback from the Level Sensor and compares
the opening and closing of both the Flash Tank Feed and it to the fixed level setpoint in the control algorithm.
Drain Valves. These valves control the liquid level in the This control strategy attempts to keep the level in the
Flash Tank and the suction superheat of the compressor. Flash Tank to approx 35% of the usable portion of the
The Flash Tank Feed and Drain Valve Controller receives sensing rod. In reality, this is approximately a 50%
analog signals from the Chiller Control Board to position level in the Flash Tank. As the level in the Flash Tank
the Feed and Drain Valves. The Chiller Control Board fluctuates, the control algorithm varies the voltage to
PI (Proportional plus Integral) control algorithm in the the Controller, which in turn sends a 2 phase stepped
Chiller Control Board software determines the open % drive signal to open or close the Feed Valve as needed.
for the Drain and Feed valves. A D/A converter on the As the Flash Tank level varies farther from the setpoint,
Chiller Control Board converts the 0-110.0% signal to the gain of the control algorithm increases for faster
an output voltage between 0 VDC and 10.28 VDC and response. In some cases, the Feed Valve will fully open
sends it to the Drain and Feed Controller. This voltage or fully close if the levels become too low or too high.
is then converted to a valve position by the Drain and When properly charged, the condenser subcooling will
Feed Valve Controller and a 2 phase (4 wire), signal be approx. 5-7°F at design conditions as the Feed Valve
drives the Feed Valve open or closed. Power for the controls refrigerant flow into the Flash Tank.
Valve Controller comes from a 30VDC supply from the
Chiller Control Board. The Drain Valve is also a stepper motor valve. Like
the Feed Valve, the controller receives a 0 - 10.28 VDC
The Feed Valve is a stepper motor valve that controls signal from the Chiller Control Board. The controller
the liquid flow from the condenser to assure the liquid then converts the signal to a valve position and a 2 phase
signal drives the Drain valve open or closed.
JOHNSON CONTROLS 185
OPERATION
FORM 201.21-NM1 (616)
The Drain Valve, Controller, and Chiller Control Board After the first minute of operation, the MOP Setpoint is
Algorithm combination functions as an Electronic ramped from the current calculated value to 68°F over
Expansion Valve (EEV). The controller receives an the next minute. At this point, normal superheat control
analog 0-10.28VDC signal sent from the Chiller Control based on the programmed setpoint resumes.
Board, which is based on system suction pressure and
suction temperature. These operating parameters are Low Ambient MOP Setpoint Control
used to compute and control suction superheat accord-
ing to the Setpoint programmed into the panel under In low ambient start-ups, suction pressure is erratic and
the PROGRAM Key. After computing the superheat, pressure differentials across the compressor may be
the signal to the controller is adjusted and the controller low, resulting in low oil differential faults. The Low
subsequently positions the Drain Valve to control the Ambient MOP setpoint control assures adequate
superheat. The gain of the control algorithm is adjusted differential is developed between discharge and
to aid in correcting for superheat error. suction to push oil through the oil cooling system and
the compressor.
The Chiller Control Board Algorithm assures the level
in the flash tank does not become too high. The level For the first 5 minutes of system run time, the MOP
setpoint for control is 35%. Levels normally run 30-40% Setpoint is set to the saturated suction temperature equal
with the economizer solenoid energized (open). With to 15PSIG below discharge pressure, which overrides
the solenoid closed, levels may vary significantly from superheat control. The control algorithm will not allow
the 30-40% level. If the level exceeds 85% of the full suction pressure control below the cutout. The low
level, the system will shut down on a fault. limit of the suction pressure is the low suction pressure
cutout. After 5 minutes of system run time, the MOP
The Feed and Drain Valves in a system open and begin Setpoint is set at 68°F and superheat control based on
to control as soon as a compressor starts. When the the programmed setpoint resumes.
compressor shuts down, the valves are driven to their
closed position. Actual MOP Setpoint
MOP Setpoint Control For Hot Water Starts The actual MOP Setpoint used by the controller is the
minimum of three calculations; the fixed MOP Setpoint,
Maximum Operating Pressure control overrides super- the moderate to high ambient setpoint, and the low
heat control of the Drain Valve when the MOP Setpoint ambient setpoint.
is exceeded on hot water starts. The fixed setpoint is
68°F Saturated Suction Temp (SST). When this value Valve Controller LED’s
is exceeded, the Drain Valve switches superheat control
to suction pressure control equal to 68°F SST. The Drain and Feed Valve stepper motor controller is
equipped with a pair of LED’s on the left side of the mod-
Moderate To High Ambient MOP ule and 10 LED’s in the center of the module (FIG. 32).
Setpoint Control. These LED’s may be useful during troubleshooting.
A pair of LED’s on the left side of the module when the valves are being pulsed. In most cases other
(FIG. 33) indicate when the module is powered. The than start-up, they may appear to not light at all. The
Power LED should be lit at all times. valves that are controlled by the outputs associated with
the LED’s are decoded using the table below:
The Open and Close LED’s on each system indicate Careless use of manual control could
when the Feed and Drain valves are being driven open cause liquid damage to the compressor
or closed in an effort to control Flash Tank level and
when it is started.
suction superheat.These valves will light“momentarily”
JOHNSON CONTROLS 187
OPERATION
FORM 201.21-NM1 (616)
ECONOMIZER CONTROL
ECONOMIZER CONTROL If a motor temperature sensor exceeds 240 °F, the Econo-
mizer Solenoid will de-energize to avoid overheating the
The Economizer Solenoid controls a vapor feed to the hot motor. When the economizer solenoid is de-ener-
economizer port on the compressor from the top of the gized, the compressor unload timer is set to 30 seconds
Flash Tank. When the valve is open, refrigerant gases and the economizer solenoid timer is set to 60 seconds.
off in the Flash Tank providing additional subcooling to All other economizer timers for other systems are set to
the liquid in the tank. The subcooled liquid is then fed 30 seconds, if they are already < 30 seconds.
to the evaporator resulting in additional system capacity
and efficiency. The Economizer Solenoid timer prevents the solenoid
from cycling too often.
In normal operation, the Economizer Solenoid on a
compressor will be turned on whenever the VSD fre-
Whenever a compressor is to be turned off, all system
quency is > 120 Hz, the flash tank level is <75%, motor
current < 80%FLA, motor temperature sensors are all Economizer Solenoids will be de-energized when
less than <150°F, and the economizer timer is timed out. the compressor(s) ramp down. The solenoids on the
Whenever the Economizer Solenoid is turned on, the compressors that will be ramped back up, if any, will
compressor load timer is set to 35 seconds and econo- remain off for 30 seconds before the Chiller Control
mizer timers for every system are set to 30 seconds, Board allows the solenoids to re-energize. Once on, the
unless they are already above 30 seconds. economizer solenoid(s) must remain on for 30 seconds as
determined by the economizer timer for each system.
In low ambient temperatures <40°F, run time on the re-
spective compressor is < 5 minutes, and the Flash Tank
level is <75%, the system Economizer Solenoid is turned
on. Under these conditions, the VSD frequency and the
motor temp sensor readings are not factors that could
overload the compressor. Energizing the Economizer
Solenoid also helps start a system in low ambients and
prevents low suction pressure and low oil differential
faults by increasing the load.
Condenser Fan control on each system is based on dis- The fan control algorithm in the Chiller Control Board 7
charge pressure. There are up to five possible stages of software will not skip steps as fan stages are staged up
fan control utilizing 3 outputs per system. Depending and down. The delay between turning on or off fan
upon the chiller model, there will be 4,5, or 6 fans per stages as discharge pressure rises and falls is 5 seconds.
system. The fan nearest the discharge liquid header The controller increments or decrements the fan stage
will always be the first fan on a system to start. As fan by one stage based on discharge pressure and fan delay
stages increment or decrement, a single fan or pair of time.
fans contained within a pair of fan baffles will be turned
on or off. The diagram above shows the location of TABLE 11 shows the fan staging and the outputs for each
the fan baffles. These baffles will not change location fan stage on 4, 5, and 6 fan systems. The microproces-
regardless of the number of fans on a chiller. sor fan outputs and the fan contactors will be the same
regardless of the number of fans. The fan wiring will
change to permit operation of 4,5, or 6 fans.
LD10634
180
170
160
150 High VSD Cabinet Ambient Temperature
Fan On Press
140
130 ` Fan Off Press Fan Operation
120
110
100 All condenser fans on all systems will run when the
90
75 85 95 105 115 125
chiller is off and enabled to run, if the VSD internal
Ambient Air Temp (°F) ambient temperature is higher than 5°F below the VSD
Cabinet Ambient Temperature Cutout of 158°F (158°F
LD10633
- 5°F = 153 °F). When the fans turn on in this situa-
tion, the fan outputs will cycle one at a time with a 100
FIG. 35 - STANDARD IPLV FAN CONTROL ms delay between fan starts. When the VSD internal
ambient falls below the “Restart Temperature” (158°F
Cutout - 10°F = 148 °F), the fans will all be turned off
without a delay.
· Pre-charge Enable 1 from the Chiller Logic Board · Glycol Pump and Cabinet Cooling Fans will also
is ON. run in the Service Mode if the Fan/Pump Run Bit
is Set.
A 0 VDC signal produces a 0°F reset. A 10 VDC signal A 0 mA signal produces a 0°F reset. A 20 mA signal
produces the maximum remote temp reset (program- produces the maximum remote temp reset (program-
mable under the SETPOINTS key). The setpoint reset mable under the SETPOINTS key). The setpoint reset is
is ramped linearly between these limits as the input ramped linearly between these limits as the input varies
varies between 0 VDC and 10 VDC. In order for this between 0 mA and 20 mA. In order for this input to
input to work properly, the Remote Temperature Reset work properly, the Remote Temperature Reset must be
must be programmed for 0 – 10 VDC input (OPTIONS programmed for 0 – 20 mA input (OPTIONS key) and
key) and Chiller Control Board jumper JP4 placed in Chiller Control Board jumper JP4 placed in the “mA”
the “V” position. position.
A 0 - 2 VDC signal produces a 0°F reset. A 10 VDC A 0 - 4 mA signal produces a 0°F reset. A 20 mA signal 7
signal produces the maximum remote temp reset (pro- produces the maximum remote temp reset (program-
grammable under the SETPOINTS key). The setpoint mable under the SETPOINTS key). The setpoint reset is
reset is ramped linearly between these limits as the input ramped linearly between these limits as the input varies
varies between 2 VDC and 10 VDC. In order for this between 4 mA and 20 mA. In order for this input to
input to work properly, the Remote Temperature Reset work properly, the Remote Temperature Reset must be
must be programmed for 2 – 10 VDC input (OPTIONS programmed for 4 – 20 mA input (OPTIONS key) and
key) and Chiller Control Board jumper JP4 placed in Chiller Control Board jumper JP4 placed in the “mA”
the “V” position. position.
Local Current Limit Control is used to set the actual Cur- The Pulldown Current Limit Setpoint can be set under
rent Limit Setpoint. This is accomplished by changing the PROGRAM key. This current limit setpoint is only
the Local Current Limit Setpoint under the PROGRAM active on startup for the time defined by the Pulldown
key. This is the value at which the unit will begin to Current Limit Time under the PROGRAM key. After
current limit and override capacity control if remote the run time has exceeded this time, the Pulldown Cur-
reset is not actively overriding this control. If any other rent Limit Setpoint is ignored.
current limit methods are active, the lowest value will
be used. This control is useful in limiting current pulldown de-
mand during peak usage periods where electric costs
Keep in mind that limiting current may interfere with are highest.
capacity control, pulling down chilled liquid tempera-
tures on hot water starts, and maintaining chilled liquid Keep in mind that limiting current may interfere with
setpoints. capacity control, pulling down chilled liquid tempera-
tures on hot water starts, and maintaining chilled liquid
setpoints.
The ISN Current Limit Setpoint can be set via the ISN Control board jumper JP5 must be positioned correctly
comms. The control panel will only accept a Current to receive either a voltage (0-10VDC or 2-10VDC) or
Limit Setpoint from the ISN if the control panel is in Re- current (0-20mA or 4-20mA) signal. Place the jumper
mote Control Mode (under the OPTIONS KEY). If the in the “V” position for a voltage signal or mA for a
control panel is in Local Control Mode, the ISN setpoint current signal (See FIG. 14, P136). The software must
will be ignored. The minimum and maximum allowable be configured under the OPTIONS key for the type of
values will be the same as the minimum and maximum input signal to be used.
allowable reset values for the Current Limit Setpoint
under the PROGRAM key. If these values are exceeded, The minimum current limit setpoint is achieved at either
the minimum or maximum value will be used. 10 VDC or 20 mA. Sending the minimum signal (0
VDC, 2 VDC, 0 mA, or 4 mA based on the OPTIONS
Contact a local YORK ISN Representative for details key setting) causes the current limit to revert back to its
on ISN controls and capabilities. maximum value.
0 – 20 mA Reset Input
4 – 20 mA Reset Input
0 – 20 mA Reset Input
4 – 20 mA Reset Input
VSD % Modulation
LD10636
When cooling is required (LCWT>SPHL), leaving In order to initiate a system run, two conditions must
chilled liquid temp is greater than the setpoint high be met. At least 1 of the 2 systems run signals from the
limit), the chiller Control Board will send a Pre-Charge control panel must be present and at least 1 of the 4
Enable (2 enables on a 4 comp unit) via comms to the possible Compressor RUN bits must be set in the serial
VSD Logic Board. The VSD’s DC bus voltage(s) across communications link between the VSD Logic Board
the Bus Filter Capacitors will slowly be increased to and the Chiller Control Board. Following successful
the proper level (>500VDC) through firing of the SCR completion of pre-charge and receipt of the system run
Trigger Board(s) and the associated pre-charge enable signals, the motor output voltage (% modulation) and
control signal(s). The pre-charge time interval is fixed output frequency commands will be determined by the
at 20 seconds. The purpose of the precharge is to limit VSD microprocessor located on the VSD Logic Board.
current when charging an uncharged capacitor bank. These two parameters will be sent to the PWM generator
When uncharged, the capacitor bank looks like an located on the VSD Logic Board for waveform process-
electrical short. The bus is brought up slowly by only ing at a rate of once every 10 msec.
turning on the SCR’s during the trailing half of the +
and – portion of the incoming AC sine wave. Follow- The voltage and frequency commands issued by the
ing is the status message displayed while the precharge VSD microprocessor are determined by the operating
is taking place. frequency command received on the communications
link from the Chiller Control Board and by the present
S YS X VSD DC BUS PRECHARGE operating frequency of the drive. Upon receipt of a legiti-
mate run command communication, the VSD’s output
frequency will be increased from 0 Hz to the operating
Following successful completion of the pre-charge frequency command from the communications link.
interval, the SCR’s on the AC to DC semi-converter
(SCR/Diode Modules) will be gated fully on by the DC Bus Voltage Sensing and Scaling
SCR Trigger Board and the DC bus will be brought up
to its full potential. After pre-charge has been success- Full DC Bus voltage and ½ DC Bus voltages are sensed
fully completed, the SCR’s will stay fully on until the for up to 2 DC Buses. 2 and 3 compressor chillers share
Chiller Control Board turns off the Pre-Charge Enable a common DC Bus, while 4 compressor chillers utilize 2
via comms. DC Buses (1/3 and 2/4). The DC Bus is wired to the DC
Bus Isolation Board, the voltage is divided down through
There will be a Unit Pre-charge Enable for 2 and 3 com- a resistance voltage divider, and the reduced voltage is
pressor units and separate System Pre-charge Enables fed to the VSD Logic Board for safety monitoring.
for 4 compressor units.
The pre-charge will only take place when all of the fol-
lowing conditions are true, otherwise it is disabled:
Individual current transformers on each leg sense three VSD operating parameters will be transmitted to the
phases of output current on each compressor. These sig- Chiller Control Board over the RS-485 communica-
nals are buffered, divided by 2, and filtered by an RMS tions link between the 2 boards. These values will be
to DC converter. The highest of the currents in the three displayed on the control panel display. The data and
phases of each compressor leaving the RMS converters display format are outlined in the TABLE 12 below:
is then sent to an A-D converter scaled, monitored by
the VSD Logic Board overload and high current protec-
tion circuitry, and sent to the Chiller Control Board for
display as the compressor current.
DATA DISPLAY
FORMAT
Highest Phase of Compressor XXX Amps
Motor Current in Amperes RMS
(per Compressor)
VSD Output Frequency XXX.X Hz
Motor Overload Setting XXX Amps
(105% FLA potentiometer setting)
in amperes RMS
(per Compressor)
DC Bus Voltage in DC Volts XXX Volts
(maximum of 2)
VSD Internal Ambient Temperature XXX.XºF
(or ºC)
IBGT Power Assembly Power Module XXX.XºF
Highest Baseplate Temperature (or ºC)
(maximum of 2)
Pre-Charge Enable Signal On or OFF
(maximum of 2)
VSD cooling Fan/Pump On or OFF
Compressor Run Status On or OFF
(maximum of 4)
VSD operating conditions are monitored by both soft- micro to capture fault data if the Fault relay fails. Both
ware algorithms and hardware circuitry. Both types the system and VSD fault data are then stored in the
exist as a result of the need for both extremely fast Chiller Control Board history buffers. Any additional
protection requirements such as a short circuit condition faults that may occur during shutdown on the first fault
or a slow reacting trip such as a slow rising overload or between the first fault and the next comms will also
condition. To eliminate nuisance unit trips, the sensor be stored and transmitted to the Chiller Control Board
inputs for the VSD’s operating parameters are averaged along with the original fault data. This data will be
four times before “Software” generated unit/system fault stored as “ALL FAULT” data.
trips from the VSD Logic Board are initiated. These
faults cause single compressor or total unit controlled When the control panel acknowledges a fault (via the
“ramped” shutdown. Other parameters that are not fed fault acknowledge bit in comms) the fault relay will be
to the VSD Logic Board microprocessor are protected reset (closed) by the VSD Logic Board and the fault
by “Hardware” generated fault trips. Hardware trips indication flag (in comms) will be reset.
involve electronic circuitry that measures voltages or
currents and activate level sensitive comparators con- The fault relay will not open when a non-running fault
nected to programmable gate arrays on the VSD Logic occurs. In this case, the system will be inhibited from
Board FPGA (Field Programmable Gate Array). These running until the fault condition is corrected. An inhibit
safeties operate extremely fast and provide “immediate” message will be displayed on the panel display indicat-
shutdown, because they are not dependent upon software ing the system is not allowed to run. Examples of this
program loops that operate in seconds or fractions of a type of fault would be the High Internal Ambient fault
second. Outputs from the gate arrays provide a digital and the VSD CT Plug Fault. When the chiller receives
signal to indicate whether a safety threshold has been the transmitted fault data via comms, it will save a snap-
reached. shot of system data in the history buffer even though the
chiller is not running.
Immediate Fault shutdowns are often accompanied by
audible motor backspin due to equalizing of the differen- Some faults will be unit faults; other faults will be system
tial between discharge and suction when the compressor (specific compressor or compressor pairs) faults, de-
is turned off while rotating at high speeds. This should pending upon the number of compressors in the chiller.
not cause concern and will not damage the chiller. Most faults will shut down the unit/ system and allow
restart once the fault clears and the 120 sec anti-recycle
Each fault outlined in the descriptions that follow will timer times out. These faults will allow up to 3 faults in
indicate whether it is a hardware or software generated 90 minutes before locking out the unit/system. Other
fault. faults lock out the unit/system after only a single fault.
Details on individual faults are provided in the follow-
It will be noted the “ramped” shutdown results in ing explanations.
minimal compressor backspin and noise associated with
backspin. “Immediate” shutdowns will result in com- A start inhibit will take place if a VSD fault condition
pressor backspin and a higher noise level based upon the exists and a compressor that is not running is called to
differential pressure between discharge and suction. start. The start inhibit will be cleared when the fault
condition goes away and the compressor will be per-
When a VSD fault occurs, the VSD Logic Board cap- mitted to start.
tures VSD data in the onboard battery backed RAM.
At the same time, the VSD Board “Fault Relay” will
open, signaling the Chiller Control Board microproces-
sor to save a snapshot of system data. The VSD Logic
Board then transmits the fault data to the Chiller Control
Board microprocessor on the next comms between the
two boards. If the Chiller Control Board receives the
comms fault indication before the Fault Relay signal, it
will immediately save a snapshot of system data when
the comms fault is recognized. This also enables the
204 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
Pre-charge Low DC Bus Voltage (Software) Fault pressor units. Two key presses of the STATUS key are
required to show the fault on both systems. The Status
The DC bus voltage must reach at least 50 VDC within display fault message is displayed below:
four seconds and 500 VDC within 19 seconds after the X indicates the system and YYYYYYY indicates the
pre-charge signal has been asserted. If not, the unit/sys-
tem will shut down on a fault. SYS X YYYYYYYY PRECHARGE-BUS VOLT IMBAL
The 1/2 DC bus voltage magnitude must remain within SYS X YYYYYYYY HIGH DC BUS VOLTAGE
+/- 100VDC of the total DC bus voltage divided by two
during the pre-charge interval. If not, the unit/system
shall shut down on a fault. X indicates the system and YYYYYYY indicates the
system is in a “FAULT” condition and will restart when
This safety will lock out on the 1st fault. The fault will the fault clears or “LOCKOUT” and will not restart until
be a unit fault for 2 or 3 compressor units. The Status the operator clears the fault using the keypad.
display fault message is shown below:
The fault will be a system 1/3 or 2/4 fault for 4 com-
UNIT YYYYYYYY
PRECHARGE - DC BUS VOLTAGE IMBALANCE
DC Bus Voltage Imbalance (Software) Fault This fault is an auto-restart safety that will lock out
system on the 3rd fault in 90 minutes. The fault will
The 1/2 DC bus voltage magnitude must remain within be an individual system/compressor fault for all units.
+/- 100 VDC of the total DC bus voltage divided by two. Following is a sample Status display fault message:
If the 1/2 DC bus magnitude exceeds the +/- 100 VDC
tolerances, the unit/system will fault and immediately SYS X YYYYYYYY HIGH MOTOR CURRENT
shut down.
X indicates the system and YYYYYYY indicates the
This safety will lock out on the 1st fault. The fault will system is in a “FAULT” condition and will restart or
be a unit fault for 2 or 3 compressor units. Below is the “LOCKOUT” and will not restart until the operator
Status display fault message: clears the fault using the keypad.
UNIT YYYYYYYY
DC BUS VOLTAGE IMBALANCE
The Motor Current Overload will compare the highest The unit’s phase bank assembly(s) contains one IGBT
of the 3 phases of motor current per compressor to the gate driver control board per compressor. These boards
compressor’s 105 % FLA ADJUST (overload) potenti- monitor the saturation voltage drop across each of the
ometer setting on the VSD Logic Board. If the current six IGBT’s while gated on. If the IGBT’s saturation
exceeds the setting continuously for 20 seconds, the voltage exceeds the prescribed limit, the gate driver will
compressor will trip. make the determination that a short circuit is present.
This in turn will cause the system to trip. During normal
This safety will lock out a system on the 1st fault and operation, the voltage drop across a saturated IGBT is
shut down with a controlled ramped shutdown. The low. When a short or shoot occurs, the extremely high
fault will be an individual system/compressor fault for current causes the voltage across the device to increase.
all systems. A sample Status display fault is shown When the electronic hardware on the IGBT Gate Driver
below: Board senses the current rise, it immediately turns off
all IGBT’s in the module and the system will shut down
SYS X YYYYYYYY MOTOR CURRENT OVERLOAD immediately.
UNIT YYYYYYYY Each phase bank assembly contains one liquid cooled
MOTOR CURRENT OVERLOAD heatsink to cool both the inverter power modules and
the converter SCR/Diode modules. Each compressor’s
YYYYYYYY indicates the unit is in a "Lockout" con- inverter power module (6 IGBT’s & Gate Driver Board)
dition and will not restart until the operator clears the contains an internal temperature sensor (5K ohm at 25
fault using the keypad. Deg. °C) to monitor the baseplate temperature.
3 compressor chillers operate at higher This safety will not cause a lockout. The fault will be a
baseplate temperature compared to 2 or unit fault for all units. Following is the Status display
4 compressor chillers. fault message.
UNIT YYYYYYYY
HIGH VSD INTERNAL AMBIENT TEMP
On 4 compressor chillers, the baseplate temperatures on
compressors 1 and 3 are OR’d together and the highest The unit will be allowed to restart when the internal
of the two temperatures compared in software to a limit ambient temperature drops 10°F below the cutout.
of 218°F. The baseplate temperatures on compressors
2 and 4 are OR’d together and the highest of the two YYYYYYYY indicates the unit is in a "Fault" condition
temperatures compared in software to a limit of 218°F. and will restart when the condition clears.
If the limit is exceeded by either of the 2 inputs, the
unit will fault and shut down with a controlled ramped Single Phase Input (Hardware) Fault
shutdown.
The VSD’s SCR Trigger Control board contains circuitry
This is an auto-restart safety that will lock out on the 3rd that checks the three phase mains for the presence of
fault in 90 minutes. The fault will be a system fault for all three-line voltages. If any of the line voltages are
all units. Below are the Status display fault messages not present, the system will immediately shut down on
for all systems. a fault.
SYS X YYYYYYYY HIGH VSD BASEPLATE TEMP This fault will not cause a lockout. The fault will be
a unit fault for 2 or 3 compressor units. Below is the
Status display fault message.
X indicates the system and YYYYYYY indicates the
system is in a “FAULT” condition and will restart when UNIT YYYYYYYY
the fault clears or “LOCKOUT” and will not restart until SINGLE PHASE INPUT VOLTAGE
the operator clears the fault using the keypad.
The fault will be a system fault 1/3 or 2/4 for 4 com-
After a fault, the fan(s) and water pump will remain pressor units. Two key presses of the STATUS key are
energized until the inverter power module base plate required to show the fault on both systems. Below is
temperature(s) falls below 165°F. The system will be the fault message for all systems.
allowed to restart when the inverter power module base
plate temperatures drop below this value.
SYS X YYYYYYYY SINGLE PHASE INPUT VOLTS
It is possible for an internal sensor to fail and not sense
temperature without causing a high baseplate sensor X indicates the system and YYYYYYY indicates the
fault. system is “FAULT” and will restart when the single
phase condition clears.
Various DC power supplies which power the VSD Logic Upon receipt of the voltage and frequency commands,
Board are monitored via hardware located on the logic the PWM generator will acknowledge receipt of the
board. If any of these power supplies fall outside their command. If the system microprocessor does not re-
allowable limits, the unit will immediately shut down ceive the handshake within 1.5 seconds of issuing the
on a fault. command, the unit will trip. This safety is only active
during precharge and during running of a compressor.
This is an auto-restart safety that will restart after the It is not active when all the compressors are shut down
fault clears and lock out on the 3rd fault in 90 minutes. and the precharge is disabled. If the VSD Logic Board
The fault will be a unit fault for all units. Below is the Fault occurs while the chiller is running, all systems will
Status display fault message. immediately shut down on a fault. On 4 compressor
chillers, with two VSD Logic Boards, only the systems
UNIT YYYYYYYY connected to the respective VSD Logic Board will the
VSD LOGIC BOARD POWER SUPPLY fault will be shut down.
YYYYYYY indicates the system is in a “FAULT” con- This is an auto-restart safety that will auto restart after
dition and will restart when the fault clears or “LOCK- the 120 second anti-recycle timer times out and lock out 8
OUT” and will not restart until the operator clears the on the 3rd fault in 90 minutes. The fault is a unit fault
fault using the keypad. for all units. Following is the fault message.
UNIT YYYYYYYY
Run Relay (Software) Fault
VSD LOGIC BOARD FAILURE
When a fault has occurred, the VSD Logic Board will Control of the Fault Relay is from the VSD Logic Board.
capture fault data. This data will be stored in the on- The Fault Relay on the VSD will be closed during a
board battery backed RAM for safekeeping and trans- non-fault condition.
ferred to the panel via the communications link as soon
as possible. When a running or pre-charge fault occurs on the VSD,
the fault relay will immediately open. The relay will
A fault code will be set for the fault that initiated the not open for non-running faults that occur.
system shutdown. This fault will appear as a specific
fault in the Status message. When the Chiller Control Board sees the VSD fault relay
open, it will immediately take a snapshot of system data
Any faults that occur after the initial fault, which occur and save it to the history buffer.
within the comms transmission time frame following the
inception of the first fault, will be stored and transmitted A fault acknowledge bit from the Chiller Control Board
to the Micro Logic Board together with the first fault is sent to the VSD via comms after receiving valid fault
data. These faults will appear in the "All Fault" display data from the VSD. When the VSD Logic Board re-
in the History. ceives the fault acknowledge via comms from the panel
it will reset (close) the Fault Relay. The fault acknowl-
A snapshot of the operating parameters of the VSD is edge is reset by the Chiller Control Board after the Fault
continuously updated in battery-backed memory once Relay is closed by the VSD Logic Board.
every program loop. Upon receipt of a first fault, the
snapshot of the operating parameters will be stored in VSD Fault Compressor Start Inhibit
memory and are transmitted to the panel as the fault
data. If a VSD fault condition exists while the compressor is
not running or pre-charging, the Chiller Control Board
will not try to start the faulted compressor(s). The start
inhibit will be automatically cleared when the fault
condition goes away.
UNIT WARNINGS
Unit Warning Operation If a low battery is detected, it should be replaced as
soon as possible. The programmed values will all be
Unit warnings are caused when a condition is pres- lost and the unit will be prevented from running on the
ent requiring operator intervention to restart the unit. next power interruption. The RTC/Battery is located on
All setpoints, program values, and options should be the Chiller Logic Board on page 213.
checked before operating the unit. Warnings are not
logged to the history buffer. If a unit warning is in effect, MICROBOARD (331-03478-XXX)
the message will be displayed to the operator when the The 331-03478-xxx microboard was developed as a direct
Status key is pressed. replacement for the 031-02478-xxx line of microboards.
STATUS No adapter harness is required when replacing a 02478
KEY with the new 03478. The 03478 uses the IPUII processor
card and provides some new features for the chillers that
the 02478 did not have. The 03478 program resides in
flash memory instead of EPROM. Program updates are
accomplished by loading the new program from an SD
card inserted into the SD card reader/writer. This same
SD card reader/writer also allows the user to datalog the
operating parameters to an SD card every 5 seconds. This
information is invaluable when troubleshooting unit and
system problems since it allows the service technician to
view operating parameters prior to a unit fault. Details
on the new datalogging capability are explained in the
OPTIONS Key area of this manual. A Real Time Clock/
BRAM keeps time and setpoints during power outtages.
LD10605
The 03478 has LEDs to indicate various states of opera-
tion of the microboard.
Low Battery Warning
STATUS – Flashes every ½ second to indicate that the
The LOW BATTERY WARNING can only occur at unit base board processor is running its program.
power-up. On micropanel power-up, the RTC battery is POWER – On solid indicates that the base board +12V
checked to see if it is still operational. If it is, normal unit and +5V power supplies are operational.
operation is allowed. If the battery voltage is determined
to be low, the following warning message is displayed TX1 – Red LED flashes when transmitting data out
indefinitely. Port 1 TB3 (Future native communications BAS port)
RX1 – Green LED flashes when receiving data in Port 1
UNIT WARNING: !! LOW BATTERY !! TB3 (Future native communications BAS port)
CHECK SETPOINTS/PROGRAM/OPTIONS/TIME
TX2 – Red LED that flashes when transmitting data
out Port 2 (E-Link TB2 or printer TB1)
If a low battery condition exists, all programmed
setpoints, program values, time, schedule, and history RX2 – Green LED that flashes when receiving data in
buffers will have been lost. These values will all be reset Port 2 (E-Link TB2 or printer TB1)
to their default values, which may not be the desired
VSD_TX – Red LED that flashes when transmitting
operating values. Once a bad battery is detected, the
data out Port 3 to the VSD Logic board
unit will be prevented from running until the MANUAL
OVERRIDE key is pressed. Once the MANUAL OVER- VSD_RX – Green LED that flashes when receiving
RIDE key is pressed, the anti recycle timers will be set data in Port 3 from the VSD Logic board
to the programmed default anti recycle time to allow 24VAC power is applied to the 331-03478-xxx mi-
the operator sufficient time to check setpoints, program croboard connector J12 and is then used to create the
values, etc. various DC power sources required by the microboard
circuitry.
212 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
Port 1
Future
Native
BAS
TP3
+5V
U26 Port 1
TP2 RS-485 Driver
+3.3V
U18 VSD
SD RS-485 Driver
Card VSD RX
VSD TX
RS-232 8
to Printer
Port 2
RX2
TX2
If the chiller control is malfunctioning, the power sup- JP5 Remote Current Limit jumper position Pins 1 to 2
ply test points should be measured to determine the sta- (left) = 4-20 mA, Pins 2 to 3 (right) = 0-10 VDC
tus of the microboard.
JP6 Remote Sound Limit jumper position (Pins 1 to 2
POWER SUPPLY TEST POINTS (left) = 4-20 mA, Pins 2 to 3 (right) = 0-10 VDC
TP1 GND (Measure TP2, TP3, TP4 and TP5 in refer- COMMUNICATION PORTS
ence to this Test Point)
TB3 Port 1 Native BAS RS-485.
TP2 +3.3V [3.2 to 3.4VDC] provides power to the pro-
cessors SW1 RS-485 Biasing Switch for Port. Set to ON if Chill-
er is in an End Of Line position on the network.
TP3 +5V [4.8 to 5.2VDC] power communiaction ports
2,3 and 4 and analog sensors U26 is the Port 1 RS-485 Driver Chip. It is socketed to
allow field replacement. RX1 and TX1 LEDs illuminate
TP4 +12V [11.64 to 12.36VDC] powers the display to indicate Port 1 communications activity.
and backlight and is regulated to become the +5V
E-LINK
TP5 +15V [11.3 to 16.6VDC] powers the analog out-
puts to the EEV valves SW2 RS-485 Biasing Switch for E-link Port 2, should be
in the OFF position.
CONFIGURATION JUMPERS
TB2 is the Port 2 RS-485 E-Link Communications Port.
The same configuration jumpers that existed on the RX2 and TX2 LEDs illuminate to indicate the Port
02478 are provided on the 03478. 2 communications activity. U23 is the Port 2 RS-485
Driver Chip. It is socketed to allow field replacement.
JP4 Remote Temp Reset jumper position Pins 1 to 2 J16 provides +12VDC to power the E-Link.
(left) = 4-20 mA, Pins 2 to 3 (right) = 0-10 VDC
JOHNSON CONTROLS 213
MICRO PANEL
FORM 201.21-NM1 (616)
9. If an error occurs during the update, an error mes- Once the SD card is inserted and the unit is powered up,
sage will be displayed where XXXX is the Error press the OPTIONS key. Then press the Down Arrow
Code key to advance to the DATA LOG TO FLASHCARD
selection. Next press the Right Arrow key to select ON
214 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
DATA LOGGING
SYS 1 SYS 1 SYS SYS 1 1SYS SYS 1 SYS 1 1SYS
SAT SYS 1 SAT SYS 1 SYS SYS 1 SYS 1 SYS SYS 1
MTR
SUCT DSCH 1 OIL SUCT SUCT DSCH DSCH DSCH 1 OIL COMP ECON 1 FAN MOTOR
HOUR MIN SEC PRESS PRESS PRESS TEMP SUCT SHEAT CURR TEMP TEMP SHEAT TEMP STATUS STAGE TEMP1
TEMP FLA
PSIG PSIG PSIG <?>F <?>F <?>F AMPS <?>F <?>F <?>F <?>F <?>F
0 0 10 82.6 84.4 84.4 93 77.5 15.5 0 83 78.6 4.4 82 OFF OFF 0 107.9
11 0 15 82.6 84.4 84.4 93 77.5 15.5 0 83 78.6 4.4 82 OFF OFF 0 107.9
11 22 20 82.6 84.4 84.4 93 77.5 15.5 0 83 78.6 4.4 82 OFF OFF 0 107.9
11 22 25 82.6 84.4 84.4 93 77.5 15.5 0 83 78.6 4.4 82 OFF OFF 0 107.9
11 22 30 82.6 84.4 84.4 93 77.5 15.5 0 83 78.6 4.4 82 OFF OFF 0 107.9
11 22 35 82.5 84.4 84.4 93 77.4 15.6 0 83 78.6 4.4 82 OFF OFF 0 107.9
then press the ENTER key to start the Data Log. A 2GB Invalid Serial Number Warning
SD card will hold about 8 months worth of data. A small- If the INVALID SERIAL NUMBER message appears,
er card may be used that will hold less data but should be immediately contact YORK Product Technical Sup-
tested for compatibility. The controller operating system port. The appearance of this message may mean the
does not support SD cards larger than 2GB. When the chiller has lost important factory programmed infor-
SD card becomes full, the oldest date file is automatically mation. The serial number can be entered using the
deleted and a new day log file is written in its place. To Service Key.
stop the data logging and retrieve the SD card, press the
OPTION key and then the Down Arrow key to display UNIT WARNING: INVALID SERIAL NUMBER
the DATA LOG TO FLASHCARD option and then ENTER UNIT SERIAL NUMBER
use the Right Arrow key to select OFF then press the Additionally, when this appears, an Optimized IPLV 8
ENTER key. Again, follow the JCI Safety Directives to chiller will only run in Standard IPLV control mode.
stop the chiller, power off the unit and open the con- Optimized IPLV cannot be enabled unless the serial
trol cabiner door to retrieve the SD card. Once inside number is programmed into the unit using the special
the control cabinet, lightly press in on the SD card and password supplied by YORK Product Technical Sup-
then release the pressure. The SD card should pop out port. Once the password is entered, a second password
slightly to allow removal. You may then copy the files will be needed to activate the optimized IPLV control
to a PC for analysis or email the file to someone. The (see Page 269).
files are saved as a CSV format which can be read by
Excel. Below is a sample of some of the data imported This status message can be bypassed to view additional
from a YCIV Chiller. Once the file is read in to Excel, messages under the STATUS key by pressing the STA-
you can hide unrelated columns or plot desired param- TUS key repeatedly to scroll through as many as three
eters to analyze the data. STATUS messages that could possibly be displayed at
any time.
Invalid Number of Compressors Warning
Optimized Efficiency Disabled
The INVALID NUMBER OF COMPRESSORS SE-
LECTED Warning will occur after the VSD has been If the OPTIMIZED EFFICIENCY DISABLED mes-
initialized, if no ”Number of Compressors Select” sage appears, immediately contact YORK Product
jumpers are installed or if more than 1 jumper is in- Technical Support or YORK ES Commercial. The ap-
stalled. The following warning message will be dis- pearance of this message means an optimized chiller is
played indefinitely. programmed for standard control.
To clear this warning, both the control panel and VSD Optimized IPLV cannot be enabled unless a special
control voltage must be turned off and the jumpers password is entered. Once the password is entered and
properly installed in the VSD wiring harness. See Page the option is enabled using the Service Key, the mes-
168 for more details on jumper installation. sage will disappear (see Page 262).
These jumpers are factory installed in the
This status message can be bypassed to view additional
wire harness plug and should not require
messages under the STATUS key by pressing the STA-
changes.
TUS key repeatedly to scroll through as many as three
STATUS messages that could possibly be displayed at
any time.
JOHNSON CONTROLS 215
MICRO PANEL
FORM 201.21-NM1 (616)
UNIT SAFETIES
Unit Safety Operation If a “VSD” fault occurs during the fault rampdown or
while the systems are shut down, the VSD fault will be
Unit faults are safeties that cause all running compres- registered as a new fault. The reason for this is the belief
sors to be shut down, if a safety threshold is exceeded any VSD fault should be registered with a full account
for 3 seconds. Unit faults are recorded in the history of the systems data at the time of the fault.
buffer along with all data on the unit and system operat-
ing conditions. Unit faults are auto reset faults where High Ambient Temp Fault
the unit will be allowed to restart automatically after the
fault condition is no longer present. The only exception If the ambient temperature rises above 130 F, the chiller
is any of the VSD related unit faults. If any 3 VSD unit will shut down with a controlled ramped shutdown. Re-
faults occur within 90 minutes, the unit will be locked start will automatically occur, if demand allows, when
out on the last fault. A VSD lockout condition requires temperature falls 2°F below the cutout (128°F). This
a manual reset using the system switches. Both system fault cannot cause a lockout. The fault display message
switches must be cycled off and on to clear a VSD unit will be present only during the time when the ambient
lockout fault. If a unit safety is in effect, the message temperature is causing a fault condition. A sample dis-
will be displayed to the operator when the Status key play is shown below:
is pressed.
STATUS
UNIT YYYYYYYY
KEY
HIGH AMBIENT TEMP
UNIT YYYYYYYY
LOW LEAVING CHILLED LIQUID TEMP
8
The unit is inhibited from starting any time the chilled
liquid temperature is below the cutout + 4°F.
LD10605
The mechanical High Pressure Cutout protects the The cutout pressure during operating periods of 30
system from experiencing dangerously high discharge seconds to 210 seconds is ramped and can be calculated
pressure. A system will fault and shut down immediately by:
when the mechanical high pressure cutout contacts open.
The fault will occur immediately and not wait 3 seconds, Cutout = (Programmed Cutout x Run Time)–1.2 PSIG
which is typical of most system faults. The HPCO is 200
wired in series with the VSD Run Signal and will only be
checked by the Chiller Control Board when the system is After the first 3 minutes and 30 seconds of run time, if
running. The mechanical cutout opens at 297+/-8 PSIG the suction pressure falls below the cutout as a result
and closes at 230 +/-10 PSIG. The Status display fault of a transient in the system, a transient timer is set at
message for this system is shown below: 30 seconds and a linearly ramped cutout is set starting
at 10% of the programmed cutout. If over the next 30
seconds, the suction pressure does not stay above the
SYS X YYYYYYYY HPCO FAULT ramped cutout, which ramps between 10% of the cutout
and the programmed cutout over the 30 second period, 8
the system will fault on low suction pressure.
X indicates the system and YYYYYYY indicates the
system is in a “FAULT” condition and will restart when Low Motor Current Cutout Fault
the 120 second anti-recylce timer times out or “LOCK-
OUT” and will not restart until the operator clears the The Motor Current Cutout shuts the system down with
fault using the keypad. a controlled ramped shutdown when the microprocessor
detects the absence of motor current (<10%FLA), usu-
Low Suction Pressure Cutout (Software) Fault ally indicating that a compressor is not running. This
safety is ignored for the first 10 seconds of operation.
The programmable Low Suction Pressure Cutout is
a secondary back-up for the flow switch and protects The status display fault message for this safety is shown
against operation with low refrigerant charge, which below:
helps protect the chiller from an evaporator freeze-up,
should the system attempt to run with a low refrigerant
SYS X YYYYYYYY LOW MOTOR CURRENT
charge. The Status display fault message for this cut-out
is shown below:
X indicates the system and YYYYYYY indicates the
system is in a “FAULT” condition and will restart when
SYS X YYYYYYYY LOW SUCTION PRESSURE
the 120 second anti-recycle timer times out or “LOCK-
OUT” and will not restart until the operator clears the
fault using the keypad.
X indicates the system and YYYYYYY indicates the
system is in a “FAULT” condition and will restart
when the the 120 second anti-recycle timer times out
or “LOCKOUT” and will not restart until the operator
clears the fault using the keypad. Typically, the cutout
will be set at 24 PSIG for chilled water applications.
SYS X YYYYYYYY HIGH DIFF OIL PRESSURE A 30 second safety bypass below 50 Hertz is employed
during rampdown. The bypass is primarily needed under
conditions where another compressor is being brought
on and the running compressor is being ramped down
X indicates the system and YYYYYYY indicates the
to 5 Hertz to add the additional compressor due to load
system is in a “FAULT” condition and will restart when
requirements. Under these conditions, the slow speed
the 120 second anti-recycle timer times out or “LOCK-
of the running compressor(s) causes the oil differential
OUT” and will not restart until the operator clears the
to become very low, especially if the water temperature
fault using the keypad.
is high and the suction pressure is high. The bypass as-
sures the compressor(s) will not trip on a nuisance low
Low Differential Oil Pressure Cutout Fault oil differential fault.
The Low Differential Oil Pressure Cutout protects the High Discharge Temperature Cutout Fault
compressor from low oil flow and insufficient lubrica-
tion. A system will fault and shut down with a controlled The High Discharge Temperature Cutout protects the
ramped shutdown when it’s differential between oil motor and compressor from overheating. A system will
and suction pressure falls below the cutout. This safety fault and shut down with a controlled ramped shutdown
assures that the compressor is pumping sufficiently to when its Discharge Temperature rises above 250°F. A
push oil through the oil cooling circuit and through the system will also be inhibited from starting if the dis-
internal compressor lubrication system. The Status charge temperature is above 200°F. The Status display
display fault message for this safety is shown below: fault message for this safety is shown below:
SYS X YYYYYYYY LOW DIFF OIL PRESSURE SYS X YYYYYYYY HIGH DSCHARGE TEMP
X indicates the system and YYYYYYY indicates the X indicates the system and YYYYYYY indicates the
system is in a “FAULT” condition and will restart when system is in a “FAULT” condition and will restart when
the 120 second anti-recycle timer times out or “LOCK- the 120 second anti-recycle timer times out or “LOCK-
OUT” and will not restart until the operator clears the OUT” and will not restart until the operator clears the
fault using the keypad. fault using the keypad.
X indicates the system and YYYYYYY indicates the The Low Discharge Superheat Cutout helps protect the
system is in a “FAULT” condition and will restart when compressor primarily from liquid floodback through
the fault clears or “LOCKOUT” and will not restart until the economizer line due to a high flash tank level. It
the operator clears the fault using the keypad. also provides protection from liquid floodback through
the suction line in conjunction with the low superheat 8
safety. This safety is ignored for the first 5 minutes of
Low Suction Superheat Cutout Fault
compressor operation.
The Low Suction Superheat Cutout helps protect the
After the first 5 minutes of run time, if the discharge
compressor from liquid floodback due to low suction
superheat falls below 10.0°F for 5 minutes, the system
superheat. This safety is ignored for the first 30 seconds
will fault and shut down with a controlled ramped
of compressor operation. Low suction superheat will
shutdown.
fault a system when any one of the following condi-
tions occur:
The Status display fault message for this safety is shown
below:
· After the first 30 seconds of run time, if the suction
superheat falls below 2.0°F, the discharge superheat
SYS X YYYYYYYY LOW DISCHARGE SUPERHEAT
is < 15°F, and the run time is <5 minutes, the super-
heat safety will be ignored for the next 30 seconds
followed by setting the superheat cutout to 0°F and X indicates the system and YYYYYYY indicates the
linearly ramping it up to 2.0°F over the next 60 system is in a “FAULT” condition and will restart when
seconds. If at any time during these 60 seconds the the 120 second anti-recycle timer times out or “LOCK-
suction superheat falls below the ramped cutout, the OUT” and will not restart until the operator clears the
system will fault and shut down with a controlled fault using the keypad.
ramped shutdown.
· If the suction superheat < 2°F, the discharge super-
heat < 15°F for 10 seconds, and the run time is =
or >5 minutes, the system will fault and shutdown
with a controlled ramped shutdown.
· If the suction superheat < 0.5°F and discharge
superheat is > 15°F for 60 seconds and run time =
or > 5 minutes, the system will fault and shutdown
with a controlled ramped shutdown.
· If suction superheat < 5°F for 10 minutes, the system
will fault and shutdown with a controlled ramped
shutdown.
STATUS KEY
STATUS
KEY
LD10605
STATUS Key Operation Unit status messages occupy 2 lines of the Status mes-
sage display. If no unit status message applies, indi-
The STATUS Key displays the current chiller or system vidual status messages for each system will be displayed.
operational status. The messages displayed include On 3 and 4 compressor units, the STATUS key must be
running status, cooling demand, system faults, unit pressed twice to display the status of all systems.
faults, VSD faults, unit warnings, external device status,
load limiting, anti-recycle timer, status of unit/system Any time the STATUS key is pressed or after the
switches, and a number of other messages. Pressing EPROM message disappears at power-up, a status dis-
the STATUS key will enable the operator to view the play indicating chiller or system status will appear.
current status of the chiller. The display will show one
message relating to the “highest priority” information
as determined by the microprocessor. The STATUS
key must be pressed twice to view both system 1/2 and
system 3/4 data. There are three types of status data,
which may appear on the display: General Status mes-
sages, Unit Safeties, and System Safeties.
UNIT STATUS This message indicates the system is not running because
DAILY SCHEDULE SHUTDOWN the chilled liquid is below the setpoint or the micro has
not loaded the lead system far enough into the loading
This message indicates that either the daily or holiday sequence to bring the lag system on. This message will
schedule programmed is keeping the chiller from run- be displayed on the lag system until the loading sequence
ning. is ready for the lag system to start.
UNIT STATUS
FLOW SWITCH SHUTDOWN SYS X COMPRESSOR RUNNING
STATUS KEY
The compressor shutting down message indicates the The ISN Current Limiting message indicates the motor
respective system is ramping down in speed prior to current load limit or motor current unloading is in effect
shutting off. This message is displayed after the software through the use of the YORKTalk setpoint.
run signal is disabled until the VSD notifies the Chiller
Control Board the compressor is no longer running.
SYS X REMOTE MOTOR CURRENT LIMITING
LD10605
GENERAL
The UNIT DATA Key provides the user with displays UNIT LOAD TIMER = XXX SEC
of unit temperatures, and unit related data. Displays UNLOAD TIMER = XXX SEC
can be selected by repeatedly pressing the UNIT DATA
key or the▲ or ▼ Arrow Keys. The next key press displays the error in temperature
between the actual leaving chilled liquid temperature
and the setpoint temperature. The display also shows
UNIT DATA Key Operation
the rate of change of the chilled liquid temperature.
The first key press displays Evaporator Leaving and
UNIT TEMP ERROR = XXX.X °F
Return Chilled Liquid Temps.
RATE = XXX.X °F/M
UNIT CHILLED LIQUID LEAVING = XXX.X °F
ENTERING = XXX.X °F
The next key press displays the system designated as the
lead system and the Flow Switch status (ON or OFF).
The next key press of the UNIT DATA key or the ▼
(ARROW) key displays the ambient air temperature.
UNIT LEAD SYSTEM NUMBER = X
FLOW SWITCH = XXX
UNIT
OUTSIDE AMBIENT AIR TEMP = XXX.X °F
The next key press displays the sound limit values as set
under the PROGRAM Key by the Local, ISN, and the
Remote Sound Limit Inputs. Any sound limits that are
inactive will display XXX instead of a numeric value.
SYSTEM 1
DATA KEY
SYSTEM 2
DATA KEY
SYSTEM 3
DATA KEY
SYSTEM 4
DATA KEY
LD10605
GENERAL The second key press of the SYSTEM DATA Key or the
▼ (DOWN ARROW) key displays all of the measured
The data keys provide the user with many displays of system temperatures (oil, suction, and discharge).
individual system temperatures, pressures, and other op-
erating data. These keys have multiple displays, which SYS 1 TEMPERATURES OIL = XXX.X °F
can be seen by repeatedly pressing the SYSTEM DATA SUCTION = XXX.X DISCHARGE = XXX.X °F
or the ▲ or ▼ (ARROW) keys. An explanation of each
key and its messages is provided below. The next key press displays the suction temperature
and all of the calculated suction temperatures (saturated
SYSTEM 1 DATA Key operation suction and system superheat).
The SYSTEM 1 DATA key provides the user with access SYS 1 SUCTION TEMP = XXX.X °F
to system 1 operating parameters. The following is a list SUPERHEAT = XXX.X SAT TEMP = XXX.X °F
of the data in the order in which it appears.
The next key press displays the discharge temperature
The first key press of the SYSTEM X DATA key displays
and all of the calculated discharge temperatures (satu-
all of the measured system pressures (oil, suction, and
rated discharge and discharge superheat).
discharge).
SYS 1 DISCHARGE TEMP = XXX.X °F
SYS 1 PRESSURES OIL = XXXX PSIG SUPERHEAT = XXX.X SAT TEMP = XXX.X °F
SUCTION = XXXX DISCHARGE = XXXX PSIG
The next key press displays the system 1 motor thermis-
tor temperatures.
SYS 1 MOTOR TEMPS T1 = XXX.X °F
T2 = XXX.X °F T3 = XXX.X °F
The next key press indicates the % of compressor load- On a 2 compressor system, the SYSTEM 3 and SYS-
ing and status of the economizer solenoid as determined TEM 4 data keys will display the following messages:
by the operating frequency.
SYS 3 DATA NOT AVAILABLE
SYS 1 COMPRESSOR SPEED = XXX.X %
ECONOMIZER SOLENOID = XXX
The next key press displays the liquid level in the flash
tank and an indicator of the % the Flash Tank Feed 8
Valve is open.
The next key press displays the system fan stage and the
status of the compressor heater.
The next key press displays the system run time in days,
hours, minutes, and seconds.
SYS 1 RUN TIME
XX DAYS XX HOURS XX MINUTES XX SECONDS
Sensor Displays
VSD
DATA KEY
LD10605
GENERAL
The VSD DATA Key provides the user with displays of VSD COMP 1 = XXX AMPS = XXX %FLA
VSD temperatures, voltages, currents, and other operat- COMP 2 = XXX AMPS = XXX %FLA
ing data. This key has multiple displays, which can be
seen by repeatedly pressing the VSD DATA or the ▲ For 3 and 4 compressor units only, the second key press
or ▼ (ARROW) keys. An explanation of each message will display the following message for systems 1 and
is provided below. 3:
The next key press displays the current limit values set The next key press displays the setting of the VSD’s
locally on the panel under the PROGRAM key, remotely 105% FLA overload potentiometer for Compressor #1
by an ISN, and remotely by the Current Limit input. and 2. The settings are determined by the adjustment of
Any current limits that are inactive will display “XXX” the overload potentiometers on the VSD Logic Board.
instead of a numeric value. These pots are factory set and should not require chang-
ing unless the circuit board is replaced. See TABLE 34
VSD CURRENT LIMIT LOCAL = XXX %FLA for factory settings.
ISN = XXX REMOTE = XXX %FLA
VSD COMP 1 MOTOR OVERLOAD = XXX AMPS
The next key press displays DC bus voltage for 2 and 3 COMP 2 MOTOR OVERLOAD = XXX AMPS
compressor units.. On 4 compressor units, the 2nd mes-
sage will apply, since two DC bus voltages are present
The next key press displays the setting of the VSD’s
(Systems 1/3 and 2/4).
105% FLA potentiometer for Compressor #3 and #4 (3
and 4 compressor units only). The second line will be
VSD DC BUS VOLTAGE = XXX VDC blanked out on 3 compressor units.
OPERATING HOURS/
START COUNTER
KEY
LD10605
HISTORY KEY
HISTORY
KEY
8
LD10605
The HISTORY key provides the user access to many If the NORMAL SHUTDOWNS History is selected,
unit and system operating parameters captured at the the following screen will be displayed:
instant a unit or system safety (fault) shutdown occurs.
The history buffer will also capture system data at the NORM HIST XX 18-JUN-20004 10:34:58 AM
time of normal shutdowns such as cycling shutdowns. YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY
When the HISTORY key is pressed the following screen
is displayed: XX is the normal shutdown number. The display will
provide date and time of the shutdown and the reason
HISTORY CHOOSE HISTORY TYPE for the cycling shutdown (YYY….).
◄ ► XXXXXXXXXXXXXXXXXXXXXXXXXXXX
The operator can view any of the stored 20 single display
The ◄ and ► (ARROW) keys allow choosing between normal shutdown history buffers. History buffer number
NORMAL SHUTDOWNS and FAULT SHUT- 1 provides the most recent shutdown information and
DOWNS. “Fault” shutdowns provide information on buffer number 20 is the oldest safety shutdown informa-
safety shutdowns, while “Normal” shutdowns provide tion saved. The ◄ and ► (ARROW) keys allow scrolling
chiller cycling information on temperature (demand), between each of the history buffers. The ► (ARROW)
cycling, remote, system switch, etc., shutdowns that key scrolls to the next normal history shutdown and the
are non-safety related shutdowns. Once the selection ◄ (ARROW) key scrolls to the previous normal history
is made, the (ENTER) key must be pressed to enter shutdown.
the selection.
The following display will typically be displayed on a
normal shutdown due to shutdown on lack of cooling
demand.
HISTORY KEY
Fault Shutdowns History Status Fault Type
FAULT HIST XX 18-JUN-20004 10:34:58 AM This message indicates the type of system fault. This
YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY screen is skipped if a UNIT Fault caused the shut-
down.
XX is the FAULT HISTORY shutdown number. The
display will provide the date, time, and a description of Unit Fault Type
the specific type of fault that occurred (YYY….).
UNIT FAULT
The operator can view any of the stored 10 fault history LOW AMBIENT TEMP
buffers. History buffer number 1 provides the most
recent safety shutdown information and buffer number This message indicates the type of unit fault. This screen
10 is the oldest safety shutdown information saved. The is skipped if a SYSTEM Fault caused the shutdown.
◄ and ► arrow keys allow scrolling between each of
the FAULT HIST buffers 1-10. The ▲ (UP) and ▼
All Fault Data
(DOWN) arrow keys can be used to scroll forwards and
backwards through the data in a specific history buffer, FAULT HIST XX ALL FAULTS ZZ OF WW
once it is displayed.
YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY
There is a large amount of data provided under each The ALL FAULT display indicates whether a fault
history. Rather than scroll sequentially through the data occurred while the unit is shutting down on another
in a history, which is possible using the ▼ arrow key, fault.
the use of a combination of the ◄, ►, ▲‚ and ▼ arrow
keys allows fast scrolling to specific data the user desires If a control panel fault occurred while the unit is shutting
to view. To use this feature, the user needs to be aware down on a VSD fault before it is reset, the control panel
the ◄ and ► arrow keys allow scrolling to the top of fault is an ALL FAULT of the VSD fault.
the data subgroups. Once a specific history is selected,
the history data is divided under the subgroups of Unit If another VSD fault occurs while the unit is shutting
Data, VSD Data, System Data, Hours/Starts, Setpoints, down on a VSD fault, the next VSD fault will be regis-
Options, and Program data. The ◄ and ► arrow keys tered as an ALL FAULT of the VSD fault.
allow moving to the first display under the next or pre-
vious subgroup at any time. Once the first display of a If a VSD fault occurs during the ramp down shutdown
subgroup is displayed, the ▲‚ and ▼ arrow keys allow of a control panel fault, the VSD fault is registered as a
scrolling though the data in the subgroup. The ▼ arrow new fault, not an ALL FAULT
key allows scrolling though the data from first to last.
When the last piece of data is displayed, the next press XX is the history number, YYY is the ALL FAULT
of the ▼ arrow key scrolls to the first piece of data in description, ZZ is the ALL FAULT number and WW
the next subgroup. The ▲ arrow key allows going to is the total number of All Faults for the current his-
the previous display. tory. Sometimes, multiple faults may occur during the
shutdown and multiple displays will be observed when
Listed below is a description of the fault data displays scrolling through the data using the ▼ arrow. In most
and their meaning. Data will be displayed in a specific cases, the ALL FAULT display will indicate NONE.
order starting with the Status Display (System Faults The ALL FAULT display will only indicate the cause
only), Fault Display, All Fault Display, Unit Data, VSD of the fault. No additional chiller information will be
Data, System Data, Operating Hours/Starts, Setpoints, displayed under the ALL FAULT, since a snapshot of all
Options, and Program Values at the time of the fault. chiller data was taken at the time of the first fault.
Evaporator Leaving and Return Chilled Liquid This message indicates the status of the evaporator pump
Temps UNIT EVAP PUMP RUN = XXX
EVAP HEATER = XXX
UNIT CHILLED LIQUID LEAVING = XXX.X °F
ENTERING = XXX.X °F and the evaporator heater at the time of the fault. XXX
indicates ON or OFF.
This message indicates the leaving and entering chilled
liquid temperatures at the time of the fault. Active Remote Control Status
COMP 1 = XXX AMPS = XXX %FLA Precharge Signal Status and VSD Cooling
COMP 3 = XXX AMPS = XXX %FLA Status
VSD DC BUS VOLTAGE = XXX VDC Compressor #3 and #4, 105% FLA Current
Setting
DC BUS VOLTAGES BUS 1 = XXX VDC
BUS 2 = XXX VDC COMP 3 MOTOR OVERLOAD = XXX AMPS
COMP 4 MOTOR OVERLOAD = XXX AMPS
This message displays the DC bus voltage at the time
of the fault. On 4 compressor units, the 2nd message This message displays the setting of the
will apply since two DC bus voltages are present (1/3 VSD’s 100% FLA potentiometer for Compressor #3 and
and 2/4) at the time of the fault. #4 at the time of the fault.
IGBT Baseplate Temperature This message displays all of the measured system pres-
sures (oil, suction, and discharge) at the time of the
VSD IGBT BASEPLATE TEMPS T1 = XXX °F fault.
T2 = XXX °F
This message displays all of the calculated suction This message displays the system suction superheat and
temperatures (saturated suction and system superheat) indicates the % the Flash Tank Drain Valve is open at 8
at the time of the fault as well as measured suction the time of the fault.
temperature.
System #1 Fan Stage and Compressor
System #1 Calculated Discharge Heater Status
Temperatures
SYS 1 CONDENSER FANS ON = XXX
SYS 1 DISCHARGE TEMP = XXX.X °F COMPRESSOR HEATER = XXX
SUPERHEAT = XXX.X SAT REMP = XXX.X °F
This message displays the actual # of system fans on,
This message displays all of the calculated discharge and the status of the compressor heater at the time of
temperatures (saturated discharge and discharge su- the fault. The fan display will show the number of fans
perheat) at the time of the fault as well as measured operating while the compressor heater status will indi-
discharge temperature. cate either ON or OFF.
This message displays the system 1 motor thermistor This message displays the system run time since the
temperatures at the time of the fault. last start in days, hours, minutes, and seconds at the
time of the fault.
System #1 Compressor Speed and
Economizer Solenoid Status System #1 Run Signals
Data for the remaining systems 2 – 4 at the time of the Display Language
fault is displayed in the same sequence as the system
#1 data. OPTIONS DISPLAY LANGUAGE
◄ ► XXXXXXXXXXXXXXXXXXXX
COMPRESSOR OPERATING HOURS AND This message displays the language selected at the time
STARTS of the fault.
This message displays the programmed control range When Remote Control Mode is selected, control of the
at the time of the fault. Chilled Liquid Setpoint is from a remote device such
as an ISN/BAS controller.
Remote Setpoint And Range OPTIONS DISPLAY UNITS
◄ ► XXXXXXXXXXXXXXXXXXXX
SETPOINTS REMOTE SETPOINT = XXX.X °F
REMOTE CONTROL RANGE = +/- X.X °F Display Units Mode
This message displays the remote setpoint and control This message indicates whether SI (°C, barg) or Imperial
range at the time of the fault. units (°F, PSIG) was selected at the time of the fault.
This message displays the maximum remote reset pro- This message indicates the type of lead lag control se-
grammed at the time of the fault. lected at the time of the fault. 5 choices are available:
Automatic, Sys 1 Lead, Sys 2 Lead, Sys 3 Lead, and Sys
4 Lead. The default mode will be AUTOMATIC.
OPTIONS REMOTE TEMP RESET INPUT This message indicates the he suction pressure cutout
◄ ► 0.0 TO 10.0 VOLTS DC programmed at the time of the fault.
PROGRAM
OPTIONS REMOTE TEMP RESET INPUT
SUCTION PRESSURE CUTOUT = XXX.X PSIG
◄ ► 2.0 TO 10.0 VOLTS DC
PROGRAM
PULLDOWN CURRENT LIMIT = XXX %FLA
PROGRAM
PULLDOWN CURRENT LIMIT TIME = XXX MIN
PROGRAM
SUCTION SUPERHEAT SETPOINT = XXX.X °F
Unit ID Number
PROGRAM
REMOTE UNIT ID NUMBER =X
PROGRAM
SOUND LIMIT SETPOINT = XXX %
SETPOINTS KEY
SETPOINTS
KEY
LD10605
SETPOINTS Key Operation Pressing the SETPOINTS key a second time or the ▼
(ARROW) key will display the leaving chilled liquid
Cooling setpoints and ranges may be programmed by control range, default, and low/high limits.
pressing the SETPOINTS key. The first setpoint entry
screen will be displayed as shown below. The first SETPOINTS ◄DEF XXXXX LO XXXXX HI XXXXX
line of the display will show the chiller default (DEF), LOCAL CONTROL RANGE = +/- X.X °F
minimum acceptable value (LO) and maximum ac-
ceptable value (HI). The second line shows the actual Pressing the SETPOINTS key or the ▼ (ARROW)
programmed value. TABLE 16 also shows the allowable key a third time will display the remote setpoint and
ranges for the cooling setpoints and control ranges. Note cooling range. This display automatically updates
that the Imperial units are exact values while the Metric about every 2 seconds. This remote setpoint message
units are only approximate. is show below:
PROGRAM KEY
PROGRAM
KEY
LD10605
PROGRAM KEY OPERATION Pressing the (ENTER) key again will display the first
programmable selection.
Various operating parameters are programmable by the
user. These are modified by pressing the PROGRAM Suction Pressure Cutout
key and then the (ENTER) key to enter Program
Mode. A listing of the limits of the programmable values PROGRAM ◄DEF XXXXX LO XXXXX HI XXXXX
is found below. Note that the Imperial units are exact SUCTION PRESSURE CUTOUT = XXX.X PSIG
values, while Metric units are only approximate.
The suction pressure cutout is protects the chiller from
The ▲ and ▼ (ARROW) keys are used to scroll through a low refrigerant condition. It also helps protect from a
the user programmable values. A value may be changed freeze-up due to low or no chilled liquid flow. However,
by keying in the new value and pressing the (ENTER) it is only a back-up for a flow switch and cannot protect
key to store the new value in memory. The cursor will be against an evaporator freeze under many conditions.
displayed on the screen when a number key is pressed. This cutout is programmable and should generally be
The first line of each message will indicate the chiller programmed for 24PSIG (1.65 Barg) for chilled water
default (DEF) value), lowest acceptable programmable cooling.
value (LO), and highest acceptable programmable value
(HI). The user programmable value is programmed on The cutout is programmable between 24.0 – 36.0 PSIG
in the second line of the message. (1.65 – 2.48 Barg) in the Water Cooling mode and 5.0
– 36.0 (0.34 – 2.28 Barg) in the Glycol Cooling mode.
When the PROGRAM Key is first pressed, the fol- The default value for both modes will be 24.0 (1.65
lowing display will appear indicating the user is in the Barg) PSIG.
program mode:
PROGRAM ◄DEF XXXXX LO XXXXX HI XXXXX PROGRAM ◄DEF XXXXX LO XXXXX HI XXXXX
LOW AMBIENT TEMP CUTOUT = XXX.X °F PULLDOWN CURRENT LIMIT TIME = XXX MIN
The low ambient temp cutout allows programming the The pulldown current limit time is programmable. This
outdoor temperature at which it is desired to shut down allows the micro to limit a system on pulldown limiting
the chiller to utilize other methods of cooling. for a defined period of time for the purpose of peak time
energy savings. The pulldown limit point is program-
The cutout is programmable between –2.0°F (-18.9°C) mable from 0 – 255 with a default of 0 Min.
and 50°F (10.0 C) with a 25°F (-3.9°C) default.
Suction Superheat Setpoint
Low Leaving Liquid Temp Cutout
PROGRAM ◄DEF XXXXX LO XXXXX HI XXXXX
PROGRAM ◄DEF XXXXX LO XXXXX HI XXXXX SUCTION SUPERHEAT SETPOINT = XXX.X °F
LEAVING LIQUID TEMP CUTOUT = XXX.X °F
The suction superheat setpoint is programmable from
The leaving chilled liquid temp cutout is programmed 8.0 – 12.0°F (4.4 – 8.3°C) with a 10.0°F (5.6°C) default.
to avoid freezing the evaporator due to excessively low Typically the superheat control will be programmed
chilled liquid temperatures. The cutout is automati- for 10.0 °F. Higher superheats of 10-12°F will reduce
cally set at 36°F (2.2 °C) in the Water Cooling mode the risk of liquid carry over and are preferred by some
and is programmable in the Glycol Cooling mode. In users.
the Glycol Cooling Mode, the cutout is programmable
from 11.0°F – 36.0°F (-11.7 – 2.2°C) with a default of
Unit ID Number
36.0°F (2.2°C).
PROGRAM ◄DEF XXXXX LO XXXXX HI XXXXX
REMOTE UNIT ID NUMBER = X
Motor Current Limit
OPTIONS KEY
OPTIONS
KEY
LD10605
The OPTIONS key provides the user with a display The Chilled liquid cooling mode can be selected for
of unit configuration and the capability to modify the Water Cooling or low temperature Glycol Cooling.
configuration. These options can only be viewed under
the OPTIONS key. To view the current options settings, OPTIONS CHILLED LIQUID COOLING MODE
press the OPTIONS key. Each press of the OPTIONS ◄ ► XXXXXXXXXXXXXXXXXX
key or press of the ▲ or ▼ (ARROW) keys will scroll to
the next option setting. The ◄ and ► (ARROW) keys When Water Cooling is chosen, the chilled liquid tem-
allow changing the option choices. The (ENTER) perature setpoint can only be programmed from 40°F
key must be pressed after a selection is made to save to 70°F
the change in memory.
OPTIONS CHILLED LIQUID COOLING MODE
An explanation of each option message is provided ◄ ► WATER COOLING
below.
When Glycol Cooling is chosen, the chilled liquid
Display Language Selection temperature setpoint can be programmed from 10°F
to 70°F.
The display language can be selected for English, Dutch,
German, Italian, and Chinese OPTIONS CHILLED LIQUID COOLING MODE
◄ ► GLYCOL COOLING
OPTIONS DISPLAY LANGUAGE
The default Chilled Liquid Mode will be WATER.
◄ ► XXXXXXXXXXXXXXXXXX
Local or Remote Control Mode allows the user to select The operator may select the type of lead/lag control
the chilled liquid temperature control mode. desired.
OPTIONS LOCAL / REMOTE CONTROL MODE OPTIONS LEAD / LAG CONTROL MODE
◄► XXXXXXXXXXXXXXXXXX ◄ ► XXXXXXXXXXXXXXXXXX
When LOCAL CONTROL mode is selected, chilled In most cases, automatic lead/lag will be selected. When
liquid control is from the keypad of the chiller. In local automatic lead/lag is selected, the micro will attempt
mode, a remote device can read system data, but not to balance run time by switching the lead compressor
reset operating parameters. whenever all compressors are shut off. If a compres-
sor is not able to run when the micro attempts a start,
OPTIONS LOCAL / REMOTE CONTROL MODE
the micro will select another compressor in an effort to
◄► LOCAL CONTROL
control chilled liquid temperature. Manual lead/lag al-
lows selecting a specific compressor to be the lead. If
When REMOTE CONTROL mode is selected, control #2 is selected as the lead in a 3 compressor chiller, the
of the chilled liquid setpoint is from a remote device
such as an ISN/BAS controller.
sequence will be 2, 3, and 1. 8
OPTIONS LEAD / LAG CONTROL MODE
OPTIONS LOCAL / REMOTE CONTROL MODE
◄ ► AUTOMATIC
◄► REMOTE CONTROL
The default mode will be AUTOMATIC.
The default mode will be LOCAL.
Lag selections of individual systems will appear as:
Display Units Selection
OPTIONS LEAD / LAG CONTROL MODE
Imperial or SI display units may be selected for data ◄ ► MANUAL SYS 1 LEAD
display.
OPTIONS LEAD / LAG CONTROL MODE
OPTIONS DISPLAY UNITS ◄ ► MANUAL SYS 2 LEAD
◄ ► XXXXXXXXXXXXXXXXXX
OPTIONS LEAD / LAG CONTROL MODE
The user may select system operating temperatures ◄ ► MANUAL SYS 3 LEAD
and pressures to be displayed in either SI (°C, Barg) or
Imperial units (°F, PSIG). SYSTEM 3 LEAD may be selected only on 3 and 4
compressor units.
OPTIONS DISPLAY UNITS
◄ ► IMPERIAL OPTIONS LEAD / LAG CONTROL MODE
◄ ► MANUAL SYS 4 LEAD
OPTIONS DISPLAY UNITS
◄ ► SI SYSTEM 4 LEAD may be selected only on 4 compres-
sor units.
The default mode is IMPERIAL.
Selections may be made for DISABLED (no signal), Low Ambient Cutout Enable/Disable
0-10VDC, 2-10VDC, 0-20ma, and 4-20ma.
The low ambient cutout may be enabled or disabled.
OPTIONS REMOTE CURRENT LIMIT INPUT When enabled, the chiller will cut off when the low
◄ ► DISABLED ambient cutout is reached. When disabled, the chiller
will run at any temperature.
OPTIONS REMOTE CURRENT LIMIT INPUT
◄ ► 0.0 TO 10.0 VOLTS DC OPTIONS LOW AMBIENT TEMPERATURE CUTOUT
◄► ENABLED
OPTIONS REMOTE CURRENT LIMIT INPUT
◄ ► 2.0 TO 10 VOLTS DC OPTIONS LOW AMBIENT TEMPERATURE CUTOUT
◄► DISABLED
OPTIONS REMOTE CURRENT LIMIT INPUT The default setting for the low ambient cutout will be
◄ ► 0.0 TO 20.0 MILLIAMPS ENABLED.
252 JOHNSON CONTROLS
FORM 201.21-NM1 (616)
DATE/ TIME
KEY
SCHEDULE
KEY
LD10605
CLOCK FRI 18-JUN-2005 10:15:33 AM The Daily Schedule must be programmed for the unit
HOUR = XX start and stop times. To set the schedule, press the
SCHEDULE key. The display will provide a message
The hour can be selected by keying in the numerical allowing access to 2 types of schedule information:
value for the hour. After the hour is selected, the
(ENTER) key must be pressed to store the data. SCHEDULE CHOOSE SCHEDULE TYPE
◄ ► XXXXXXXXXXXXXXXXXXXXXXXXX
One or two “0’s” must be keyed in for
hours 00-09. The schedule types are:
SOUND LIMIT SCHEDULE Once the schedule for a specific day is programmed and
entered, the schedule for the next day will appear. The
The SOUND LIMIT SCHEDULE allows setting the schedule for each day may be programmed the same or
day and time when the user desires using the “SILENT differently.
NIGHT” factory programmed option to limit chiller
loading and fan operation for reduced audible noise in To view the schedule without changing it, simply press
the surrounding area. If the SOUND LIMIT SCHED- the SCHEDULE key or the ▼ (DOWN ARROW) key
ULE is selected under the CHOOSE SCHEDULE until the desired day is displayed. The ▲ (UP ARROW)
display, the following message will appear: key will scroll backwards to the previous screen.
MANUAL OVERRIDE
KEY
LD10605
MANUAL OVERRIDE
PRINT KEY
PRINT
KEY
LD10605
8
(This section is printed only if the sound limit 2:04:14 PM 18 JUN 04
schedule is enabled) SYS 1 YYYYYYY
MON START=00:00AM STOP=00:00AM HIGH DSCH PRESS SHUTDOWN
TUE START=00:00AM STOP=00:00AM
WED START=00:00AM STOP=00:00AM STATUS AT TIME OF SHUTDOWN
THU START=00:00AM STOP=00:00AM SYS 1 XXXXXXXXXXXXXXXXXXXXXXXXXX
FRI START=00:00AM STOP=00:00AM SYS 2 XXXXXXXXXXXXXXXXXXXXXXXXXX
SAT START=00:00AM STOP=00:00AM
HOL START=00:00AM STOP=00:00AM ALL FAULTS
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
SERVICE KEY
SERVICE
KEY
LD10605
SERVICE Key Operation Pressing the (ENTER) key allows “view only” Service
Mode operation. All control board I/O will be view-
able in this mode. No outputs can be changed. For
The Service Key allows viewing data related to the in- troubleshooting or start-up commissioning purposes,
ternal function of the chiller system electronics. Data the Chiller Micro Board and some VSD outputs can be
such as circuit board output status as controlled by the toggled or changed by turning off the UNIT SWITCH,
Chiller Control software while operating can be viewed pressing the SERVICE Key, entering password 9675,
and compared to actual chiller operation in the event and pressing the (ENTER) key. Once the password
servicing is required. The Service Key allows control- is entered, the Digital Outputs (DO) can be toggled by
ling of analog and digital outputs for troubleshooting pressing the (ENTER) key. The Analog Outputs can
purposes when the unit is not running. The Unit Serial be programmed to output a specific value using the key-
Number and Optimized IPLV Control mode are also pad and programming in the desired value, which will
entered using the Service Key. usually be noted as a % or VDC. If the UNIT SWITCH
is turned back on, the chiller will revert to normal view-
The ▲▼ (ARROW) keys allow scrolling through the able only control.
displays. The ▼ (ARROW) key scrolls through the
displays in the forward direction. Displays can be viewed by pressing the ▲and ▼ (AR-
ROW) keys. The ▼ (ARROW) key scrolls through the
When the SERVICE key is pressed, the following mes- displays in the forward direction.
sage will appear:
The ◄ and ► (ARROW) keys allow jumping from data
SERVICE MODE XXXX section to data section to avoid scrolling sequentially
PRESS ENTER KEY TO CONTINUE through all the data. Once in a data section, the ▲and ▼
(ARROW) keys allow scrolling through the data under
XXXX will display a password, if a numerical password the section. Pressing the ◄ and ► (ARROW) keys at
is entered. any time moves to the top of the next data section.
SERVICE AI J21-3 SYS1 OIL TEMP SERVICE AI J23-13 SYS3 SUCTION TEMP
X.X VDC = XXX.X °F X.X VDC = XXX.X °F
SERVICE AI J21-6 SYS1 FL TANK LEVEL SERVICE AI J23-16 SYS3 DISCHARGE TEMP
X.X VDC = XXX.X % X.X VDC = XXX.X °F
SERVICE AI J21-13 SYS1 SUCTION TEMP SERVICE AI J23-20 SYS3 SUCTION PRESS
X.X VDC = XXX.X °F X.X VDC = XXX.X PSIG
SERVICE AI J21-16 SYS1 DISCHARGE TEMP SERVICE AI J23-22 SYS3 OIL PRESS
X.X VDC = XXX.X °F X.X VDC = XXX.X PSIG
SERVICE AI J21-20 SYS1 SUCTION PRESS SERVICE AI J23-24 SYS3 DISCHARGE PRESS
X.X VDC = XXX.X PSIG X.X VDC = XXX.X PSIG
SERVICE AI J22-6 SYS2 FL TANK LEVEL SERVICE AI J24-16 SYS4 DISCHARGE TEMP
X.X VDC = XXX.X % X.X VDC = XXX.X °F
SERVICE AI J22-13 SYS2 SUCTION TEMP SERVICE AI J24-20 SYS4 SUCTION PRESS
X.X VDC = XXX.X °F X.X VDC = XXX.X PSIG
SERVICE AI J22-16 SYS2 DISCHARGE TEMP SERVICE AI J24-22 SYS4 OIL PRESS
X.X VDC = XXX.X °F X.X VDC = XXX.X PSIG
SERVICE AI J22-20 SYS2 SUCTION PRESS SERVICE AI J24-24 SYS4 DISCHARGE PRESS
X.X VDC = XXX.X PSIG X.X VDC = XXX.X PSIG
SERVICE DI J4-6 VSD FAULT RELAY SERVICE DO J9-2 SYS 1/3 VSD RUN
STATUS = XXX RB1 TB1-18 STATUS = XXX
SERVICE DI J6-4 SYS 1/3 RUN PERM SERVICE DO J9-10 SYS 1 COND FAN OUT 3
STATUS = XXX RB1 TB1-4 STATUS = XXX
SERVICE DI J6-5 SYS 2/4 RUN PERM SERVICE DO J9-11 SYS 1 COMP HEATER
STATUS = XXX RB1 TB1-3 STATUS = XXX
SERVICE DI J6-6 SPARE DIGITAL INPUT 1 SERVICE DO J9-10 SYS 1 ECON SOL VALVE
STATUS = XXX RB1 TB1-2 STATUS = XXX
SERVICE DO J10-2 SYS 2/4 VSD RUN SERVICE DO J11-7 SYS 3 SPARE
RB1 TB1-18 STATUS = XXX RB1 TB1-8 STATUS = XXX
SERVICE DO J10-3 SYS 2/4 ALARM SERVICE DO J11-8 SYS 3 COND FAN OUT 1
RB1 TB1-16 STATUS = XXX RB1 TB1-6 STATUS = XXX
SERVICE DO J10-4 CHILLER RUN SERVICE DO J11-9 SYS 3 COND FAN OUT 2
RB1 TB1-14 STATUS = XXX RB1 TB1-5 STATUS = XXX
SERVICE DO J10-5 SYS 2 SPARE SERVICE DO J11-10 SYS 3 COND FAN OUT 3
RB1 TB1-12 STATUS = XXX RB1 TB1-4 STATUS = XXX
SERVICE DO J11-2 SYS 4 COND FAN OUT 2 SERVICE AO J15-1 SYS 1 FEED VALVE OUT
RB1 TB1-18 STATUS = XXX XXX.X % = XX.X VDC
SERVICE DO J11-3 SYS 4 COND FAN OUT 3 SERVICE AO J15-3 SYS 1 DRAIN VALVE OUT
RB1 TB1-16 STATUS = XXX XXX.X % = XX.X VDC
SERVICE DO J11-4 SYS 4 COMP HEATER SERVICE AO J15-5 SYS 2 FEED VALVE OUT
RB1 TB1-14 STATUS = XXX XXX.X % = XX.X VDC
SERVICE DO J11-5 SYS 4 ECON SOL VALVE SERVICE AO J15-7 SYS 2 DRAIN VALVE OUT
RB1 TB1-12 STATUS = XXX XXX.X % = XX.X VDC
SYSTEM
SWITCHES
KEY
LD10605
SYSTEM SWITCHES Key Operation The ◄ (LEFT ARROW) or ► (RIGHT ARROW) keys
allow scrolling through the choices of:
The SYSTEM SWITCHES key allows the operator to
turn individual systems ON and OFF. Safety lockouts · SYSTEM OFF (default)
are also reset by selecting the respective system switch
· SYSTEM ON
RESET. When the System Switches Key is pressed, the
following message will appear: · RESET (LOCKOUT)
SYSTEM SWITCHES SYS 1 ON / OFF / RESET The switch selection is accepted into memory by press-
◄ ► =XXXXXXXXXXXXXXX ing the (ENTER) key.
The display indicates the respective system and it’s When the “RESET” selection is made and accepted, it
on/off /reset switch status. The ▲▼ (ARROW) keys will not change the position of the switch (either ON
allow scrolling to the next and previous system switch or OFF).
(System 1, 2, 3, or 4).
Whenever possible, except in emergen-
SYSTEM SWITCHES SYS 2 ON / OFF / RESET cies, always use the associated system
◄ ► =XXXXXXXXXXXXXXX switch to turn off a compressor, which
allows the compressors to go through
SYSTEM SWITCHES SYS 3 ON / OFF / RESET a controlled shutdown. Avoid using
◄ ► =XXXXXXXXXXXXXXX the "UNIT" switch to turn off the
compressors.
SYSTEM SWITCHES SYS 4 ON / OFF / RESET
◄ ► =XXXXXXXXXXXXXXX
At this point, the letters entered for the YYYY and XXX
inputs should now appear in the top line of the display
and should match the first 7 characters of the serial
number on the unit Data Plate. The next three digits of
the serial number should now be keyed in. Press the
(ENTER) key to store the input. The full serial number
should now be displayed across the top of the display
and the cursor should disappear.
Unit Setup Mode will allow the programming all of the This mode may be entered by pressing the PROGRAM
programmable values that the user should never change. key, entering the password 4245, and pressing the
These will either be programmed at the factory or by (ENTER) key. TABLE 19 lists the values that can be
service personnel on the job. programmed in this mode. Details relating to the actual
message follow the table.
The following messages will be displayed for the Unit SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX
Setup Mode in the order they appear. The first group COMP 1 OPERATING HOURS = XXXXX
of displays relates to setup parameters that relate to unit
configuration and factory setpoints. SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX
COMP 2 OPERATING HOURS = XXXXX
SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX
SYS 1 NUMBER OF COND FANS =X SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX
COMP 3 OPERATING HOURS = XXXXX
SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX
SYS 2 NUMBER OF COND FANS =X SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX
COMP 4 OPERATING HOURS = XXXXX
SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX
SYS 3 NUMBER OF COND FANS =X
SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX SETUP MODE SYS 1 MOTOR SENSOR TO IGNORE
COMP 1 STARTS = XXXXX ◄ ► XXXXXXXXXXXXXXXXXXXXXXXXX
SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX SETUP MODE SYS 2 MOTOR SENSOR TO IGNORE
COMP 2 STARTS = XXXXX ◄ ► XXXXXXXXXXXXXXXXXXXXXXXXX
SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX SETUP MODE SYS 3 MOTOR SENSOR TO IGNORE
COMP 3 STARTS = XXXXX ◄ ► XXXXXXXXXXXXXXXXXXXXXXXXX
SETUP MODE ◄ DEF XXXXX LO XXXXX HI XXXXX SETUP MODE SYS 4 MOTOR SENSOR TO IGNORE
COMP 4 STARTS = XXXXX ◄ ► XXXXXXXXXXXXXXXXXXXXXXXXX
The following setup display is selectable as YES or NO If a motor temperature sensor fails, a single sensor may
using the ◄ and ► (ARROW) keys. be ignored by making a program change in the Unit
Setup Mode. The default setting is “NONE”, indicating
SETUP MODE CLEAR HISTORY BUFFERS? all sensors are being monitored.
◄ ► XXXXXXXXXXXXXXXXXXXXXXXX
8
The following (3) setup OPTION displays are select-
able as ENABLED or DISABLED using the ◄ and ►
(ARROW) keys according to the options installed on
the chiller:
· NONE (default)
· TEMP SENSOR 1
· TEMP SENSOR 2
· TEMP SENSOR 3
TABLE 21 lists the Analog inputs and the circuit board J12-3 can also be used as common, as well as chassis
they are located on. Not all of the sensors are installed in ground, or the common terminal point on the Chiller
every unit, as some of them are optional. The software Control Board. See the wiring diagrams. The +DC Bus,
must read the optional sensors if installed. The Analog -DC Bus and ½ DC Bus voltages are measured in refer-
input signals are typically referenced to the common ence to one of the other DC Bus points. For example:
(return, ground) in the system. +DC Bus measured to ½ DC Bus.
ISN COMMUNICATIONS
GENERAL Received Data (Control Data)
The Chiller Control Board contains a dual UART for RS- The chiller control panel receives 8 data values from
485 and RS-232 communications. UART1 is dedicated the ISN. The first 4 are analog values and the last 4 are
to RCC and ISN communications over an RS-485 link. digital values. These 8 data values are used as control
UART2 is dedicated to internal communications within parameters when in REMOTE mode. When the unit is
the chiller. The RS-485 port is configured for 4800 in LOCAL mode, these 8 values are ignored. If the unit
baud, 1 start bit, 8 data bits, odd parity, and 1 stop bit. receives no valid ISN transmission for 5 minutes it will
Connections for ISN communications are on the Chiller revert back to all local control values. TABLE 25 lists
Control Board on TB1/TB2. TB2 on the MicroGateway the 8 control parameters. These values are found under
is utilized for ISN comms connection. P3 is RS485+, Feature 54 on the ISN.
P2 is RS485-, and USHL is the shield.
ISN PAGE CHARACTER TYPE DXST CHILLER DATA (UNIT, Sys , Sys 2)
P11 8-11 Analog Leaving Chilled Liquid Temp.
P12 12-15 Analog Return Chilled Liquid Temp.
P13 16-19 Analog VSD Internal Ambient Temp.
P14 20-23 Analog Sys 1 Suction Temp.
P15 24-27 Analog Sys 1 Discharge Temp.
P16 28-31 Analog Outside Ambient Air Temp.
P17 32-35 Analog Sys 1 Oil Temp.
P18 36-39 Analog Sys 1 Oil Pressure
8
P19 40-43 Analog Sys 1 Suction Pressure
P20 44-47 Analog Sys 1 Discharge Pressure
P21 48-51 Analog Sys 1 Compressor % Full Load Amps
P22 52-55 Analog Sys 1 Total Run Hours
P23 56-59 Analog Sys 1 Total Number of Starts
P24 60-63 Analog Sys 1 Highest Motor Temp.
P25 64-67 Analog Sys 2 Highest Motor Temp
P26 68-71 Analog Sys 2 Oil Temp.
P27 72-75 Analog Sys 2 Oil Pressure
P28 76-79 Analog Sys 2 Suction Pressure
P29 80-83 Analog Sys 2 Discharge Pressure
P30 84-87 Analog Sys 2 Compressor % Full Load Amps
P31 88-91 Analog Sys 2 Total Run Hours
P32 92-95 Analog Sys 2 Total Number of Starts
P33 96-99 Analog VSD Output Frequency
P34 100-103 Analog Sys 1 Flash Tank Feed Valve % Open
P35 104-107 Analog Sys 2 Flash Tank Feed Valve % Open
P36 108 Digital Chiller Run
P37 109 Digital Chiller Alarm
P38 110 Digital Evaporator Heater Staus
P39 111 Digital Evaporator Pump Status
P40 112 Digital Sys 1 Compressor Run Status
P41 113 Digital Sys 2 Compressor Run Status
P42 114 Digital Sys 1 Economizer Solenoid Valve Status
P43 115 Digital Sys 2 Economizer Solenoid Valve Status
P44 116 Digital -
P45 117 Digital -
P46 118 Digital -
ISN PAGE CHARACTER TYPE DXST CHILLER DATA (UNIT, Sys , Sys 2)
P47 119 Digital -
P48 120 Digital -
P49 121 Digital -
P50 122 Digital Cooling Type: 0=Water, 1=Glycol
P51 123 Digital Local / Remote Control Mode: 0=Local, 1=Remote
P52 124 Digital Display Units Mode: 0=Imperial, 1=SI
P53 125 Digital -
P54 126 Digital -
P55 127 Digital -
P56 128 Coded *Sys 1 Operational Code
P57 129 Coded *Sys 1 Fault Code
P58 130 Coded *Sys 2 Operational Code
P59 131 Coded * Sys 2 Fault Code
P60 132 Coded Sys 1 Flash Tank Level (%)
P61 133 Coded Sys 1 Condensor Fan Stage (0-6)
P62 134 Coded Sys 2 Flash Tank Level (%)
P63 135 Coded Sys 2 Condensor Fan Stage (0-6)
P64 136 Coded Lead System Number
P65 137 Coded Sys 1 & 2 Debug Code
P66 138-141 Analog Local Leaving Chilled Liquid Setpoint
P67 142-145 Analog Low Leaving Chilled Liquid Temp. Cutout
P68 146-149 Analog Sys 1 Flash Tank Drain Valve % Open
P69 150-153 Analog Sys 2 Flash Tank Drain Valve % Open
P70 154-157 Analog Low Suction Pressure Cutout
P71 158-161 Analog VSD DC Bus Voltage
P72 162-165 Analog Remote Leaving Chilled Liquid Setpoint
P73 166-169 Analog Sys 1 Discharge Superheat
P74 170-173 Analog Cooling Range
P75 174-177 Analog Sys 1 Discharge Superheat
P76 178-181 Analog Sys 2 Suction Temp
P77 182-185 Analog Sys 2 Discharge Temp.
P78 186-189 Analog Sys 2 Suction Superheat
P79 190-193 Analog Sys 2 Discharge Superheat
P80 194 Digital -
P81 195 Digital -
P82 196 Digital -
P83 197 Digital -
P84 198 Digital -
* The operational and fault codes are defined in Tables 27 and 28 (Pages 285-287).
The following table can be used for converting R-134A pressures to their equivalent saturated temperatures.
MAINTENANCE
GENERAL REQUIREMENTS Refrigerant Leaks
The units have been designed to operate continuously, Visually check the heat exchangers, compressors and
provided they are regularly maintained and operated pipework for damage and gas leaks.
within the limitations given in this manual. Each unit
should be included in a routine schedule of daily main- Operating Conditions
tenance checks by the operator/customer, backed up by
regular service inspection and maintenance visits by a Read the operating pressures and temperatures at the
suitably qualified Service Engineer. control panel using the display keys and check that
these are within the operating limitations given in the
It is entirely the responsibility of the owner to provide for manual.
these regular maintenance requirements and/or enter into
a maintenance agreement with a YORK International Compressor Oil Level
service organization to protect the operation of the unit.
If damage or a system failure occurs due to improper Check the compressor oil level after the compressor has
maintenance during the warranty period, YORK shall been operating on ‘FULL LOAD’ for approximately half
not be liable for costs incurred to return the unit to sat- an hour. The oil level should be between the upper and
isfactory condition. lower sight glasses on the oil separators.
MAINTENANCE REQUIREMENTS
FOR YCAV CHILLERS
**Check Condensor
Subcooling X
**Leak check the
Chiller X
**Sample
Compressor Oil,
check for Acid, X
and replace if
necessary
MAINTENANCE REQUIREMENTS
FOR YCAV CHILLERS (CON'T)
9
* Reserved for customer use for any special site requirements.
**This procedure must be performed at the specific time by an industry certified technician who has been
trained and qualified to work on this type of equipment. A record of this procedure be successfuly carried out should
be maintained on file by the equipment owner should proof of adequate maintenance be required at a later date for
warranty purposes.
TROUBLESHOOTING GUIDE
(Always remove power to the chiller and assure the DC bus voltage has bled off)
EVACUATING A SYSTEM
If a system or a portion of a system needs to be evacuat-
ed, it should be evacuated to a minimum of 500 microns.
The system should then be able to hold the vacuum for
10 minutes with a maximum rise of 50 microns. If the
system is not able to hold a vacuum, recheck the system
for leaks.
LIMITED WARRANTY
1. Labor to remove or reinstall any equipment, mate- 4. Equipment is not installed, operated, maintained and
rials, or components. serviced in accordance with instructions issued by
YORK.
2. Shipping, handling, or transportation charges.
5. Equipment is damaged due to dirt, air, moisture, or
3. Cost of refrigerants. other foreign matter entering the refrigerant sys-
tem.
No warranty repairs or replacements will be made until 9
payment for all equipment, materials, or components 6. Equipment is not properly stored, protected or in-
has been received by YORK. spected by the customer during the period from date
of shipment to date of initial start.
WARRANTY ON RECONDITIONED OR 7. Equipment is damaged due to acts of GOD, abuse,
REPLACEMENT MATERIALS neglect, sabotage, or acts of terrorism.
Except for reciprocating compressors, which YORK
warrants for a period of one year from date of shipment,
YORK warrants reconditioned or replacement materials,
or start-up services performed by YORK in connection
therewith, against defects in workmanship or material
for a period of ninety (90) days from date of shipment. THIS WARRANTY IS IN LIEU OF ALL OTHER
Subject to the exclusions listed below, YORK, at its WARRANTIES AND LIABILITIES, EXPRESS OR
option, will repair or replace, FOB point of shipment, IMPLIED IN LAW OR IN FACT, INCLUDING THE
such materials or parts as YORK finds defective. How- WARRANTIES OF MERCHANTABILITY AND
ever, where reconditioned or replacement materials or FITNESS FOR A PARTICULAR PURPOSE. THE
parts are placed on equipment still under the original WARRANTIES CONTAINED HEREIN SET FORTH
new equipment warranty, then such reconditioned or BUYER’S SOLE AND EXCLUSIVE REMEDY IN
replacement parts are warranted only until the expiration THE EVENT OF A DEFECT IN WORKMANSHIP
of such original new equipment warranty. OR MATERIALS. IN NO EVENT SHALL YORK’S
LIABILITY FOR DIRECT OR COMPENSATORY
Exclusions: Unless specifically agreed to in the contract DAMAGES EXCEED THE PAYMENTS RECEIVED
documents, this warranty does not include the following BY YORK FROM BUYER FOR THE MATERIALS
costs and expenses: OR EQUIPMENT INVOLVED. NOR SHALL YORK
BE LIABLE FOR ANY SPECIAL, INCIDENTAL, OR
1. Labor to remove or reinstall any equipment, mate- CONSEQUENTIAL DAMAGES. THESE LIMITA-
rials, or components. TIONS ON LIABILITY AND DAMAGES SHALL
APPLY UNDER ALL THEORIES OF LIABILITY
2. Shipping, handling, or transportation charges. OR CAUSES OF ACTION, INCLUDING, BUT NOT
LIMITED TO, CONTRACT, WARRANTY, TORT
3. Cost of refrigerant. (INCLUDING NEGLIGENCE) OR STRICT LIABIL-
ITY. THE ABOVE LIMITATIONS SHALL INURE
No warranty repairs or replacements will be made until TO THE BENEFIT OF YORK’S SUPPLIERS AND
payment for all equipment, materials, or components SUBCONTRACTORS.
has been received by YORK.
JOHNSON CONTROLS 297
MAINTENANCE
FORM 201.21-NM1 (616)
2 COMP CHILLER MODELS WITH STANDARD (PIN 52 = X) AND ULTRA QUIET (PIN 52 = L) FANS
CHILLER MODEL CHILLER NAME- COMPRESSOR 1 COMPRESSOR 2
MAXIMUM VSD
(2 COMP) PLATE VOLTAGE OVERLOAD SETTING OVERLOAD SETTING
FREQUENCY (HZ)
W/ STD & UQ FANS (VAC) (AMPS) (AMPS)
YCAV0157EA/VA 200,230,380,460,575 192 192 186
YCAV0157SA/PA 200,230,380,460,575 196 196 200
YCAV0177EA/VA 200,230,380,460,575 184 197 200
YCAV0177SA/PA 200,230,380,460,575 270 191 182
YCAV0187EA/VA 200,230,380,460,575 250 183 192
YCAV0187SA/PA 200,230,380,460,575 254 198 200
YCAV0197EA/VA 200,230,380,460,575 244 244 182
YCAV0207EA/VA 200,230,380,460,575 234 250 192
YCAV0207SA/PA 200,230,380,460,575 247 273 186
YCAV0227EA/VA 200,230,380,460,575 238 238 200
YCAV0227SA/PA 200,230,380,460,575 255 255 200
YCAV0247EA/VA 200,230,380,460,575 289 238 200
YCAV0247SA/PA 200,230,380,460,575 289 254 200
YCAV0267SA/PA 200,230,380,460,575 289 289 200
PRINTER WIRING
A “serial” printer may be connected to the TB1 connec- Data from the chiller is transmitted at 1200 baud. Wir-
tor on the Chiller Logic Board for the purposes of log- ing diagrams for cables are shown below:
ging data and troubleshooting. Weightronix Imp-2600,
Seiko DPU-414, and Okidata Microline 184 printers or
equivalents may be used.
RD TXD TB1-3
3
7
GND GND TB1-5
9
SEIKO DPU-414
9 pin RS-232 (DB-9) TB1 Chiller Control Board
RD TXD TB1-3
3
RD TXD TB1-3
2
PRINTER WIRING
Printer Cables
SW1 – off: (-) Low when busy
Printer cables should be shielded coaxial, #18AWG, 2 – off: 1200 baud
stranded wire cables, not to exceed 50’ in length. On 3 – off: 1200 baud
long cable runs or whenever permanent installation is 4 – on: 1200 baud
required, the shield of the coax should be tied to the 5 – not used
chassis ground at the chiller only, not at the printer. 6 – off: no parity
7 – off: Pin 20 & pin 11 act as busy line
Printer Setup
The following information may be useful for quick set up WEIGH-TRONIX IMP 24 MODEL 2600:
of a printer. Specific printer manuals should be utilized,
if problems occur, since functions often change as new SW1 – off: 1200 baud
versions of printers are introduced with enhancements 2 – on: 1200 baud
requiring control code, signal programming, and wiring
changes.
SEIKO:
OKIDATA 184:
DipSW1-1 – off: Input -Serial
Control Board Switch settings: 1-2 – on: Printing speed high
1-3 – on: Auto loading - on
SW1 – on: Unslashed 0 1-4 – off: Auto LF - off
2 – off: Unslashed 0 1-5 – on: Setting Command - Enable
3 – off: Unslashed 0 1-6 – off: Printing density - 100%
4 – off: Form Length 11 in. 1-7 – on: Printing density - 100%
5 – on: Form Length 11 in. 1-8 – on: Printing density - 100%
6 – off: Auto Line feed off
7 – on: 8 bit data DipSW2-1 – on: Printing Columns - 40
8 – off: Enable front panel 2-2 – on: User Font Back-up - on
2-3 – on: Character Select - normal
With SUPER SPEED Serial Board: 2-4 – off: Zero - slash
2-5 – on: International character set-
SW1-1 – on: Odd or even parity American
1-2 – on: No parity 2-6 – on: International character set -
1-3 – on: 8 bit data American
1-4 – on: Protocol ready/busy 2-7 – on: International character set -
1-5 – on: Test select American
1-6 – on: Print mode 2-8 – off: International character set –
1-7 – off: SDD(-) pin 11 American
1-8 – on: SDD(-) pin 11
2-1 – on: 1200 baud DipSW3-1 – on: Data length - bits
2-2 – on: 1200 baud 3-2 – on: Parity Setting - no
2-3 – off: 1200 baud 3-3 – on: Parity condition - odd
2-4 – off: DSR active 3-4 – on: Busy control – H/W busy
2-5 – on: Buffer threshold 32 bytes 3-5 – on: Baud rate select - 1200
2-6 – on: Busy signal 200ms 3-6 – off: Baud rate select - 1200
2-7 – on: DTR space after power on 3-7 – on: Baud rate select - 1200
2-8 – not used 3-8 – off: Baud rate select - 1200
COMPRESSOR # 2 - MODEL #:
SALES ORDER #:
COMPRESSOR # 3 - MODEL #:
TECHNICIAN NAME:
COMPRESSOR # 4 - MODEL #:
CHILLER MODEL #:
9
SERIAL #:
SERIAL #:
PROGRAMMED VALUES
CHILLED LIQUID SETPOINT PROGRAMMED CUTOUTS
Display Units =
Lead/Lag Control =
Actual = ON OFF
T1 = ºF(ºC)
T2 = ºF(ºC)
System 2
System 3
System 4
EVAPORATOR FLOW
CONDENSOR CONDITIONS
AIR TEMPERATURE
NOTES