Johnson Controls YORK YCAL0041EC Installation Operation & Maintenance
  1. Manuals
  2. Brands
  3. Johnson Controls Manuals
  4. Chiller
  5. YORK YCAL0041EC
  6. Installation operation & maintenance

Johnson Controls YORK YCAL0041EC Installation Operation & Maintenance

Air-cooled liquid chillers hermetic scroll
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Supersedes 150.66-NM1 (1005)
Form 150.66-NM1 (708)
INSTALLATION, OPERATION, MAINTENANCE
035-20895-000
YCAL0041EC - YCAL0071EC
AIR-COOLED
SCROLL CHILLERS
STYLE D
WITH IPU II & I/O BOARDS
(60 Hz)
35-60 TON
LD10950
R-22

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the YORK YCAL0041EC and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Johnson Controls YORK YCAL0041EC

Summary of Contents for Johnson Controls YORK YCAL0041EC

  • Page 1 AIR-COOLED LIQUID CHILLERS HERMETIC SCROLL Supersedes 150.66-NM1 (1005) Form 150.66-NM1 (708) INSTALLATION, OPERATION, MAINTENANCE 035-20895-000 YCAL0041EC - YCAL0071EC AIR-COOLED SCROLL CHILLERS STYLE D WITH IPU II & I/O BOARDS (60 Hz) 35-60 TON LD10950 R-22...

  • Page 2: General Safety Guidelines

    Failure to fol low this will void the man u fac tur er’s warranty and cause serious dam age to property or injury to per sons. JOHNSON CONTROLS...
  • Page 3 If there is any question in the mind of operating/service personnel as to the applicability of these doc u ments, then prior to work ing on the equipment, they should verify with the owner whether the equip ment has been modifi ed and if current literature is available. JOHNSON CONTROLS...

  • Page 4: Table Of Contents

    PRODUCT IDENTIFICATION NUMBER (PIN) ....................24 UNIT NOMENCLATURE ..........................24 BASIC UNIT NOMENCLATURE .........................24 REFRIGERANT FLOW DIAGRAM ......................29 SECTION 3 - HANDLING AND STORAGE ..................30 DELIVERY AND STORAGE ........................30 INSPECTION ...............................30 MOVING THE CHILLER ..........................30 Lifting Weights .............................30 UNIT RIGGING ............................31 JOHNSON CONTROLS...
  • Page 5 Temperature Sensor(s) ........................39 EQUIPMENT STARTUP CHECKLIST ......................40 Checking the System Prior To Initial Start (No Power) ..............40 Compressor Heaters (Power ON – 24 Hours Prior To Start) ............40 Panel Checks (Power ON – Both Unit Switches OFF) ..............40 JOHNSON CONTROLS...
  • Page 6 STATUS KEY MESSAGES QUICK REFERENCE LIST ................108 DISPLAY/PRINT KEYS ..........................109 Oper Data Key ............................109 Operation Data Quick Reference List ....................112 Print Key ............................. 113 Operating Data Printout ........................113 History Printout ..........................114 History Displays ..........................114 Software Version ..........................116 JOHNSON CONTROLS...
  • Page 7 LOW AMBIENT FAN CONTROL OPTION ....................138 General ...............................138 Confi guration (Jumpers and Potentiometers) ................139 Wiring ..............................140 PROGRAMMING ............................141 LOAD LIMITING ............................141 COMPRESSOR RUN STATUS .........................142 ALARM STATUS ............................142 EMS-PWM REMOTE TEMPERATURE RESET ..................142 BAS/EMS TEMPERATURE RESET OPTION ...................143 JOHNSON CONTROLS...
  • Page 8 CONDENSER COILS ..........................157 OPERATING PARAMETERS ........................157 ON-BOARD BATTERY BACK-UP ......................157 PLATE AND FRAME HEAT EXCHANGER (EVAPORATOR) HEATER ...........157 OVERALL UNIT INSPECTION .........................158 ISN CONTROL ............................159 Received Data (Control Data) ......................159 Transmitted Data ..........................159 BACNET AND MODBUS DATA COMMUNICATION ................162 JOHNSON CONTROLS...

  • Page 9: List Of Figures

    FIG. 21 – FIELD AND FACTORY ELECTRICAL CONNECTIONS OPTIONAL REMOTE TEMPERATURE RESET BOARD ...................144 FIG. 22 – IPU II & I/O LAYOUT ......................148 FIG. 23 – MICROBOARD RELAY CONTACT ARCHITECTURE ............152 FIG. 24 – PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS ........153 JOHNSON CONTROLS...

  • Page 10: List Of Tables

    TABLE 29 – MICROBOARD ANALOG OUTPUTS .................147 TABLE 30 – OUTDOOR AIR SENSOR TEMPERATURE/VOLTAGE/ RESISTANCE CORRELATION ......................149 TABLE 31 – ENTERING/LEAVING CHILLED LIQUID TEMP. SENSOR, COOLER INLET TEMPERATURE SENSOR, AND SUCTION TEMPERATURE SENSOR: TEMPERATURE/VOLTAGE CORRELATION ............150 TABLE 32 – TROUBLESHOOTING ....................154 JOHNSON CONTROLS...
  • Page 11 TABLE 33 – ISN RECEIVED DATA ....................159 TABLE 34 – ISN TRANSMITTED DATA ..................159 TABLE 35 – ISN OPERATIONAL AND FAULT CODES ..............161 TABLE 36 – MINIMUM, MAXIMUM AND DEFAULT VALUES ............163 TABLE 37 – REAL TIME ERROR NUMBERS ................163 JOHNSON CONTROLS...
  • Page 12 FORM 150.66-NM1 (708) THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 13: Section 1 - General Chiller Information & Safety

    Laboratories (U.L.) for construction of chillers and unit identifi cation plate. provide U.L./cU.L. Listing Label. The unit warranty will be void if any modifi cation to the unit is carried out without prior written approval from YORK International. JOHNSON CONTROLS...

  • Page 14: Responsibility For Safety

    Usually an instruction proper support may result in injury to the operator, or will be given, together with a brief explanation and damage to the equipment and/or building. the possible result of ignoring the instruction. JOHNSON CONTROLS...

  • Page 15: Mechanical Strength

    In case of emergency, the control panel is fi tted with a Unit Switch to stop the unit in an emergency. When operated, it removes the low voltage 120 VAC electrical supply from the inverter system, thus shutting down the unit. JOHNSON CONTROLS...

  • Page 16: Section 2 - Product Description

    -20°F (- restrict unauthorized access to internal components. 29°C) ambient. The cooler is covered with 3/4” (19mm) Units are designed in accordance with NFPA 70 fl exible, closed-cell, foam insulation (K~0.25). JOHNSON CONTROLS...

  • Page 17: Condenser

    • Low ambient temperature cutout setting • Two display lines • Outdoor air temperature • Twenty characters per line • English or Metric data Color coded 12-button non-tactile key pad with sections • Suction pressure cutout setting for: • Each system suction pressure JOHNSON CONTROLS...

  • Page 18: Power Panel

    (EPROM) to eliminate chiller failure due to AC powered failure/battery discharge. Programmed setpoints are re tained in lithium battery-backed RTC memory for 5 years minimum. * Intensity of Protection European Standard ** International Electrotechnical Commission JOHNSON CONTROLS...

  • Page 19: Accessories And Options

    fi ve mph, it is recommended that Optional liquid temperature (interconnecting wiring by others). Condenser Louvered Enclosure Panels also be included (Only one of following options can be offered on a unit (Factory-Mounted). at a time: BAS, Remote Control Panel or Multi-unit Sequence Control) (Factory-Mounted). JOHNSON CONTROLS...

  • Page 20: Compressor, Piping, Evaporator Options

    DIFFERENTIAL PRESSURE SWITCH – Alterna- tive to an above mentioned fl ow switch. Pretempco model DPS300AP40PF-82582-5 (300 psi max. working pressure), SPDT 5 amp 125/250VAC switch, Range 0 - 40 PSID, deadband 0.5 - 0.8 psi, with 1/4” NPTE Pressure Connections. JOHNSON CONTROLS...

  • Page 21: Sound Reduction Options

    ULTRA QUIET FANS – Lower RPM, 8-pole fan motors are used with steeper-pitch fans (Factory- Mounted). VIBRATION ISOLATORS – Level adjusting, spring type 1” (25.4mm) or seismic defl ection or neoprene pad isolators for mounting under unit base rails (Field- Mounted). JOHNSON CONTROLS...

  • Page 22: Unit Components

    Product Description FORM 150.66-NM1 (708) UNIT COMPONENTS JOHNSON CONTROLS...

  • Page 23: Control / Power Panel Components

    FORM 150.66-NM1 (708) CONTROL / POWER PANEL COMPONENTS TERMINAL BLOCK FAN FUSES CR1 / CR2 LD11459 LD11460 LD11461 LD11458 LD11462 LD11463 COMPRESSOR CONTACTS TB1 / CTB1 JOHNSON CONTROLS...

  • Page 24: Product Identification Number (Pin)

    Unit Designator (PIN 9) High Effi ciency Refrigerant (PIN 10) R-22 200/3/60 230/3/60 VOLTS Voltage (PIN 11 & 12) 380/3/60 460/3/60 575/3/60 STARTER Starter (PIN 13) Across The Line Starter DESIGN Design Series (PIN 14) Design Series D JOHNSON CONTROLS...
  • Page 25 (PIN 26) Motor Current Readout Special Quote No Remote Panel Required REMOTE Remote Panel (PIN 27) OptiView Remote Panel Required Special Remote Panel Required No Sequence Kit Required Sequence Kit (PIN 28) Sequence Kit Required= {SEQ/S} Special Sequence Required JOHNSON CONTROLS...
  • Page 26 No Flow Switch Required One Flow Switch Required Two Flow Switches Required Three Flow Switches Required One Differential Pressure Switch FLOW Flow Switch (PIN 41) Required Two Differential Pressure Switches Required Three Differential Pressure Switches Required Special Flow Switch Required JOHNSON CONTROLS...
  • Page 27 Ultra Low Sound Fans Required Special Sound Fans Required No Option Required PAINT (PIN 53) Special Quote No Isolators Required 1” Defl ection Isolators Required ISOL Vibration Isolators (PIN 54) Neoprene Isolators Required Seismic Isolators Required Special Isolators Required JOHNSON CONTROLS...
  • Page 28 PIN 59 (PIN 59) Special Quote No Option Required PIN 60 (PIN 60) Special Quote Plant of Mfg. (PIN 61) Plant of Manufacture-Monterrey Mexico Mfg. Location San Antonio YorkWorks Version YorkWorks ConVersion YorkWorks Version Special Quote Special Quote JOHNSON CONTROLS...

  • Page 29: Refrigerant Flow Diagram

    AIR COOLED CONDENSERS AIR COOLED CONDENSERS HOT DISCHARGE GAS LINE “OPTIONAL” “OPTIONAL” DISCHARGE LINE DISCHARGE LINE DISCHARGE LINE BALL VALVE BALL VALVE BALL VALVE “OPTIONAL” “OPTIONAL” “OPTIONAL” SERVICE VALVE “OPTIONAL” “OPTIONAL” “OPTIONAL” LD11417 FIG. 1 – REFRIGERANT FLOW DIAGRAM JOHNSON CONTROLS...

  • Page 30: Section 3 - Handling And Storage

    If any damage is evident, it should be noted on the carrier’s freight bill and a claim entered in accordance with the instructions given on the advice note. Major damage must be reported immediately to your local YORK representative. JOHNSON CONTROLS...

  • Page 31: Unit Rigging

    Use spreader bars to avoid lifting chains hitting the chiller. Never lift the chiller using a forklift or by hooking to the top rails. Use only the lifting holes provided. Lifting Instructions are placed on a label on the chiller and on the shipping bag. LD10951 JOHNSON CONTROLS...

  • Page 32: Section 4 - Installation

    In installations where winter operation is intended and taken to avoid damage due to rough handling. snow accumulations are expected, additional height must be provided to ensure normal condenser air fl ow. Clearances are listed under “Notes” in the “DIMENSIONS” section. JOHNSON CONTROLS...

  • Page 33: Foundation

    YORK Engineering Guide for vibration. The necessary components must be obtained the specific chiller model. Sound blankets for the in the fi eld. compressors and low sound fans are available. JOHNSON CONTROLS...

  • Page 34: Duct Work Connection

    The switch is to be wired to terminals 13 with N.E.C. or local code requirements. Minimum - 14 of CTB1 located in the control panel, as shown on the unit wiring diagram. circuit ampacity and maximum dual element fuse size are given in Table 10. JOHNSON CONTROLS...

  • Page 35: Evaporator Pump Start Contacts

    fl ow switch and CTB1 - termi- damage the compressors on start. nals 13 to 14. Refer to Fig. 3 and unit wiring diagram. JOHNSON CONTROLS...

  • Page 36: Single-Point Supply Connection - Terminal Block, Non-Fused Disconnect Switch Or Circuit Breaker (0041 - 0071)

    FIG. 2 – SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER (0041 - 0071) JOHNSON CONTROLS...

  • Page 37: Control Wiring

    The unit evaporator heater uses 120VAC. Disconnecting 120VAC power from the unit, at or below freezing temperatures, can result in damage to the evaporator and unit as a result of the chilled liquid freezing. FIG. 3 – CONTROL WIRING JOHNSON CONTROLS...

  • Page 38: Section 5 - Commissioning

    (counterclockwise) then close one turn of the stem to ensure operating pressure is fed to pressure transducers. Open the liquid line service valve and oil return line ball valve fully in each system. JOHNSON CONTROLS...

  • Page 39: Grounding

    96°F (36°C) the compressor heaters must be on for at least 8 hours before start-up to ensure all refrigerant liquid is driven out of the compressor and the oil. If the ambient temperature is below 86°F (30°C), allow 24 hours. JOHNSON CONTROLS...

  • Page 40: Equipment Startup Checklist

    120VAC +/- 10%. 3. Program/verify the Cooling Setpoints, Program Excessive fl ow may cause catastrophic Setpoints, and unit Options. Record the values damage to the evaporator. below (see sections on Setpoints and Unit Keys for programming instruction) in TABLE 1. JOHNSON CONTROLS...

  • Page 41: Setpoints Entry List

    If this does not oc- cur, the compressor being tested is operating in the reverse direction and must be corrected. After verifying proper compressor rotation, turn the Unit Switch to “OFF.” JOHNSON CONTROLS...

  • Page 42: Checking Superheat And Subcooling

    When adjusting the expansion valve (TXV only), the adjusting screw should be turned not more than one turn at a time, allowing suffi cient time (approximately 15 minutes) between adjustments for the system and the thermal expansion valve to respond and stabilize. JOHNSON CONTROLS...

  • Page 43: Unit Operating Sequence

    EEV will close (EEV equipped chillers only), and the last compressor will be allowed to run until the suction pressure falls below the suction pressure cutout or for 180 seconds, whichever comes fi rst. JOHNSON CONTROLS...

  • Page 44: Section 6 - Technical Data

    4. For operation at temperatures below 25°F (-3.9°C), the optional Low Ambient Kit will need to be installed on the system. 5. For operation at temperatures above 115°F (46.1°C), the optional High Ambient Kit will need to be installed on the system. JOHNSON CONTROLS...

  • Page 45: Ethylene Glycol Correction Factors

    TABLE 4 – ETHYLENE GLYCOL CORRECTION FACTORS % WT FACTORS FREEZE ETHYLENE POINT COMPR. DELTA GPM/°F/ GLYCOL TONS (°F) .994 .997 1.03 24.1 .986 .993 1.06 24.9 .979 .990 1.09 25.9 .970 .985 1.13 27.3 .959 .980 1.16 29.0 JOHNSON CONTROLS...

  • Page 46: Operational Limitations (Si)

    4. For operation at temperatures below 25°F (-3.9°C), the optional Low Ambient Kit will need to be installed on the system. 5. For operation at temperatures above 115°F (46.1°C), the optional High Ambient Kit will need to be installed on the system. JOHNSON CONTROLS...

  • Page 47: Ethylene Glycol Correction Factors

    TABLE 7 – ETHYLENE GLYCOL CORRECTION FACTORS % WT FACTORS FREEZE ETHYLENE POINT COMPR. DELTA GPM/°F/ GLYCOL TONS (°F) .994 .997 1.03 24.1 .986 .993 1.06 24.9 .979 .990 1.09 25.9 .970 .985 1.13 27.3 .959 .980 1.16 29.0 JOHNSON CONTROLS...

  • Page 48: Physical Data (English)

    90.6 62.6 56.0 65/55 2.2/2.2 3863 4436 3908 4481 – – 0061 153.6 90.6 62.6 61.0 65/60 2.2/2.2 4097 4703 4142 4748 – – 0065 153.6 90.6 62.6 65.0 65/70 2.2/2.2 4257 5047 4302 5092 – – 0071 JOHNSON CONTROLS...
  • Page 49 PSIG PSIG Inches 87.0 1140 47400 838 47400 87.0 1140 47400 838 47400 87.0 1140 47400 838 47400 116.0 1140 52000 838 52000 116.0 1140 52000 838 52000 128.0 1140 52000 838 52000 128.0 1140 52000 838 52000 JOHNSON CONTROLS...

  • Page 50: Sound Data (English)

    4000 8000 YCAL0041 YCAL0045 YCAL0051 YCAL0055 YCAL0061 YCAL0065 YCAL0071 DATA NOT AVAILABLE 60Hz Line Frequency ULTRA QUIET FAN WITH COMPRESSOR SOUND BLANKETS INSTALLED R-22 1000 2000 4000 8000 YCAL0041 YCAL0045 YCAL0051 YCAL0055 YCAL0061 YCAL0065 YCAL0071 DATA NOT AVAILABLE JOHNSON CONTROLS...
  • Page 51 4000 8000 YCAL0041 YCAL0045 YCAL0051 YCAL0055 YCAL0061 YCAL0065 YCAL0071 DATA NOT AVAILABLE 60Hz Line Frequency ULTRA QUIET FAN WITH COMPRESSOR SOUND BLANKETS INSTALLED R-22 1000 2000 4000 8000 YCAL0041 YCAL0045 YCAL0051 YCAL0055 YCAL0061 YCAL0065 YCAL0071 DATA NOT AVAILABLE JOHNSON CONTROLS...

  • Page 52: Elctrical Data (English)

    0065 6awg - 500MCM 6awg - 350MCM 6awg - 350MCM 6awg - 500MCM 6awg - 350MCM 6awg - 350MCM 6awg - 500MCM 6awg - 350MCM 6awg - 350MCM 0071 * - Chiller not available at time of publication. JOHNSON CONTROLS...
  • Page 53 23.7 23.7 17.5 21.0 24.1 24.1 19.0 19.0 15.3 68.3 53.8 68.3 68.3 44.0 22.8 63.3 49.8 63.3 63.3 17.5 22.8 36.5 28.7 36.5 36.5 23.0 12.7 30.1 23.7 30.1 30.1 17.5 21.0 24.1 19.0 24.1 24.1 15.3 JOHNSON CONTROLS...

  • Page 54: Table 11 - Micro Panel Power Supply

    TABLE 12 – VOLTAGE RANGE VOLTAGE RANGE VOLTAGE CODE UNIT POWER MIN. MAX. 200-3-60 230-3-60 380/415-3-60 460-3-60 380/415-3-50 575-3-60 JOHNSON CONTROLS...

  • Page 55: Electrical Notes And Legend

    -58 = 575-3-60 HERTZ MAXIMUM MINIMUM CIRCUIT AMPACITY LEGEND: MINIMUM MIN NF MINIMUM NON-FUSED Field Wiring RATED LOAD AMPS Factory Wiring S.P. WIRE SINGLE POINT WIRING UNIT MTD SERV SW UNIT MOUNTED SERVICE (NON-FUSED DISCONNECT SWITCH) LOCKED ROTOR AMPS JOHNSON CONTROLS...

  • Page 56: Wiring Diagrams

    Technical Data FORM 150.66-NM1 (708) ELEMENTARY DIAGRAM 0041 - 0071 STANDARD LOW SOUND AND 460V ULTRA LOW SOUND LD13247 FIG. 4 – CONTROL CIRCUIT, DUAL JOHNSON CONTROLS...
  • Page 57 FORM 150.66-NM1 (708) ELEMENTARY DIAGRAM (CON’T) LD13248 FIG. 4 (CON’T) - CONTROL CIRCUIT, DUAL JOHNSON CONTROLS...

  • Page 58: Fig. 5 - Control Circuit, Dual

    Technical Data FORM 150.66-NM1 (708) ELEMENTARY DIAGRAM 0041 - 0071 ULTRA LOW SOUND, 200V, 230V, 380V & 575V LD13259 FIG. 5 – CONTROL CIRCUIT, DUAL JOHNSON CONTROLS...
  • Page 59 FORM 150.66-NM1 (708) ELEMENTARY DIAGRAM (CON’T) LD13260 FIG. 5 (CON’T) - CONTROL CIRCUIT, DUAL JOHNSON CONTROLS...

  • Page 60: Fig. 6 - Power Circuit, Dual

    Technical Data FORM 150.66-NM1 (708) ELEMENTARY DIAGRAM 0041 - 0071 STANDARD LOW SOUND AND 460V ULTRA LOW SOUND LD13249 FIG. 6 – POWER CIRCUIT, DUAL JOHNSON CONTROLS...

  • Page 61: Fig. 7 - Power Circuit, Dual

    FORM 150.66-NM1 (708) ELEMENTARY DIAGRAM 0041 - 0071 ULTRA LOW SOUND, 200V, 230V, 380V & 575V LD13261 FIG. 7 – POWER CIRCUIT, DUAL JOHNSON CONTROLS...

  • Page 62: Fig. 8 - Wiring Details

    Technical Data FORM 150.66-NM1 (708) ELEMENTARY DIAGRAM 0041 - 0071 ULTRA LOW SOUND, ALL VOLTAGES LD10958 FIG. 8 – WIRING DETAILS JOHNSON CONTROLS...

  • Page 63: Connection Diagrams

    FORM 150.66-NM1 (708) CONNECTION DIAGRAM 0041 - 0071 STANDARD LOW SOUND AND 460V ULTRA LOW SOUND LD13250 FIG. 9 – CONNECTION DIAGRAM JOHNSON CONTROLS...

  • Page 64: Fig. 10 - Connection Diagram

    Technical Data FORM 150.66-NM1 (708) CONNECTION DIAGRAM 0041 - 0071 ULTRA LOW SOUND, 200V, 230V, 380V & 575V LD13262 FIG. 10 – CONNECTION DIAGRAM JOHNSON CONTROLS...

  • Page 65: Fig. 11 - Connection Diagram Microboard (Partial)

    FORM 150.66-NM1 (708) CONNECTION DIAGRAM CONNECTION DIAGRAM ALL MODELS BACNET MICROGATEYWAY OPTION LD10960A FIG. 11 – CONNECTION DIAGRAM MICROBOARD (PARTIAL) JOHNSON CONTROLS...

  • Page 66: Dimensions - (English)

    – 6'; rear to wall – 6'; cooler end to wall – 4'0"; coil end to wall - 6'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 6". JOHNSON CONTROLS...
  • Page 67 END CAP WIDTH 45 5/16" 1 1/16" 9 13/16" 9 13/16" ORIGIN 21 13/16" TOP VIEW 5 5/16" 38" CONTROL PANEL 25 3/8" 13 5/8" LD10962 TWO LIFTING HOLES BOTH SIDES 13 15/16" 15 1/16" 144 13/16" FRONT VIEW JOHNSON CONTROLS...
  • Page 68 – 6'; rear to wall – 6'; cooler end to wall – 4'0"; coil end to wall - 6'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 6". JOHNSON CONTROLS...
  • Page 69 END CAP WIDTH 45 5/16" 1 1/16" 9 13/16" 9 13/16" ORIGIN 20 1/16" TOP VIEW 5 5/16" 38" CONTROL PANEL 25 3/8" 13 5/8" LD10964 TWO LIFTING HOLES BOTH SIDES 13 15/16" 15 1/16" 144 13/16" FRONT VIEW JOHNSON CONTROLS...
  • Page 70 – 6'; rear to wall – 6'; cooler end to wall – 4'0"; coil end to wall - 6'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 6". JOHNSON CONTROLS...
  • Page 71 END CAP WIDTH 45 5/16" 1 1/16" 9 13/16" 9 13/16" ORIGIN 20 1/16" TOP VIEW 5 5/16" 38" CONTROL PANEL 25 3/8" 13 5/8" TWO LIFTING HOLES BOTH SIDES 13 15/16" LD10966 15 1/16" 144 13/16" FRONT VIEW JOHNSON CONTROLS...
  • Page 72 – 6'; rear to wall – 6'; cooler end to wall – 4'0"; coil end to wall - 6'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 6". JOHNSON CONTROLS...
  • Page 73 END CAP WIDTH 45 5/16" 1 1/16" 9 13/16" 9 13/16" ORIGIN TOP VIEW 18 7/16" 5 3/16" 38" CONTROL PANEL 25 3/8" 28 9/16" TWO LIFTING HOLES BOTH SIDES 14" 15 1/16" LD10968 144 13/16" FRONT VIEW JOHNSON CONTROLS...
  • Page 74 – 6'; rear to wall – 6'; cooler end to wall – 4'0"; coil end to wall - 6'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 6". JOHNSON CONTROLS...
  • Page 75 END CAP WIDTH 43 5/16" 1 1/16" 9 13/16" 9 13/16" ORIGIN 16 11/16" TOP VIEW 5 3/16" 38" CONTROL PANEL 25 3/8" 28 9/16" TWO LIFTING HOLES BOTH SIDES 14" LD10970 15 1/16" 144 13/16" FRONT VIEW JOHNSON CONTROLS...
  • Page 76 – 6'; rear to wall – 6'; cooler end to wall – 4'0"; coil end to wall - 6'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 6". JOHNSON CONTROLS...
  • Page 77 90 9/16" END CAP WIDTH 43 5/16" 1 1/16 ORIGIN 9 13/16" 9 13/16 TOP VIEW 16 11/16" 5 3/16" 38" CONTROL PANEL 25 3/8" 28 9/16" LD10972 TWO LIFTING HOLES BOTH SIDES 16" 15 1/16" 153 5/8" JOHNSON CONTROLS...
  • Page 78 – 6'; rear to wall – 6'; cooler end to wall – 4'0"; coil end to wall - 6'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 6". JOHNSON CONTROLS...
  • Page 79 END CAP WIDTH 43 5/16" 1 1/16" ORIGIN 9 13/16" 9 13/16" TOP VIEW 16 11/16" 5 3/16" 38" CONTROL PANEL 25 3/8" 28 9/16" TWO LIFTING HOLES BOTH SIDES 16" 15 1/16" 153 5/8" FRONT VIEW LD13252 JOHNSON CONTROLS...

  • Page 80: Dimensions - (Si)

    – 2m; cooler end to wall – 1.2m; coil end to wall - 2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 152mm. JOHNSON CONTROLS...
  • Page 81 FORM 150.66-NM1 (708) DIMENSIONS - YCAL0041 (SI) (CON’T) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1150 ORIGIN ORIGIN TOP VIEW CONTROL PANEL TWO LIFTING HOLES BOTH SIDES LD10974 3678 FRONT VIEW JOHNSON CONTROLS...
  • Page 82 – 2m; cooler end to wall – 1.2m; coil end to wall - 2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 152mm. JOHNSON CONTROLS...
  • Page 83 FORM 150.66-NM1 (708) DIMENSIONS - YCAL0045 (SI) (CON’T) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1150 ORIGIN TOP VIEW CONTROL PANEL TWO LIFTING HOLES BOTH SIDES LD10976 3678 FRONT VIEW JOHNSON CONTROLS...
  • Page 84 – 2m; cooler end to wall – 1.2m; coil end to wall - 2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 152mm. JOHNSON CONTROLS...
  • Page 85 FORM 150.66-NM1 (708) DIMENSIONS - YCAL0051 (SI) (CON’T) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1150 ORIGIN TOP VIEW CONTROL PANEL LD10978 TWO LIFTING HOLES BOTH SIDES 3678 FRONT VIEW JOHNSON CONTROLS...
  • Page 86 – 2m; cooler end to wall – 1.2m; coil end to wall - 2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 152mm. JOHNSON CONTROLS...
  • Page 87 FORM 150.66-NM1 (708) DIMENSIONS - YCAL0055 (SI) (CON’T) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1151 ORIGIN TOP VIEW CONTROL PANEL TWO LIFTING HOLES BOTH SIDES LD10980 3678 FRONT VIEW JOHNSON CONTROLS...
  • Page 88 – 2m; cooler end to wall – 1.2m; coil end to wall - 2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 152mm. JOHNSON CONTROLS...
  • Page 89 FORM 150.66-NM1 (708) DIMENSIONS - YCAL0061 (SI) (CON’T) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1100 ORIGIN TOP VIEW CONTROL PANEL TWO LIFTING HOLES BOTH SIDES LD10982 3678 FRONT VIEW JOHNSON CONTROLS...
  • Page 90 – 2m; cooler end to wall – 1.2m; coil end to wall - 2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 152mm. JOHNSON CONTROLS...
  • Page 91 FORM 150.66-NM1 (708) DIMENSIONS - YCAL0065 (SI) (CON’T) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1100 ORIGIN TOP VIEW CONTROL PANEL TWO LIFTING HOLES BOTH SIDES LD10984 3902 FRONT VIEW JOHNSON CONTROLS...
  • Page 92 – 2m; cooler end to wall – 1.2m; coil end to wall - 2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. 1" nominal defl ection isolators (not shown) will increase overall unit height by 152mm. JOHNSON CONTROLS...
  • Page 93 FORM 150.66-NM1 (708) DIMENSIONS - YCAL0071 (SI) (CON’T) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1100 ORIGIN TOP VIEW CONTROL PANEL TWO LIFTING HOLES BOTH SIDES 3902 FRONT VIEW JOHNSON CONTROLS...

  • Page 94: Technical Data - Clearances

    (2 m) (1.3 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. FIG. 12 – UNIT CLEARANCES JOHNSON CONTROLS...

  • Page 95: Isolators

    CIP- B-1650 / Black 1113 (504.9) 135.01 (3429.3) 89.16 (2264.7) CIP-B-1000 / Blue 648 (293.9) 9.79 (248.7) 89.16 (2264.7) CIP-B- 1250 / Gray 993 (450.4) SAMPLE PRINTOUT SUPPLIED IN THE ISOLATOR PACKAGE AND IN THE CHILLER PANEL LITERATURE PACKET. JOHNSON CONTROLS...
  • Page 96 Yellow w/ 1786 to 2028 lbs 910 to 920 kg CIP-C- 029-24583-011 Green 2028 to 2254 lbs 920 to 1022 kg CIP-C- Red w/ Red 029-24583-012 2254 to 2936 lbs 1022 to 1332 kg CIP-C- Red w/ Green 029-24583-013 JOHNSON CONTROLS...
  • Page 97 10mm (1/4”) shim between the upper load plate and vertical uprights. Lower the equipment on the 10. Installation is now complete. blocking or shimmed isolators. JOHNSON CONTROLS...
  • Page 98 Weight Range Weight Range Model Number Color (lbs) (kg) Up to 751 lbs Up to 341 kg ND-C Yellow 751 to 1651 lbs 341 to 749 kg ND-D Yellow 1651 to 3226 lbs 749 to 1463 kg ND-E Yellow JOHNSON CONTROLS...
  • Page 99 679 to 933 kg SLRS-2-C2- Silver 029-24585-012 2058 to 2619 lbs 933 to 1188 kg SLRS-2-C2- Gray w/ red 029-24585-013 2619 to 3180 lbs 1188 to 1442 kg SLRS-2-C2- Silver w/ red 029-24585-014 *Value is de-rated by 15% JOHNSON CONTROLS...
  • Page 100 Bolt Diameter LOWER Rubber RESTRAINING Snubbing BOLTS Collar 1/4" Adjustment Bolt Non-Skid Neoprene Pad- Internal Lower Pad can be removed if Enclosed Neoprene SHIPPED & INSTALLED AFTER ADJUSTMENT Restraining mounts are welded Steel Acoustical into position. Housing LD10568 JOHNSON CONTROLS...

  • Page 101: Section 7 - Unit Controls

    120VAC is supplied to the optimal T3 Transformer, which supplies 12VAC to the bridge diode module. The Bridge Diode Module rectifi es the voltage to -12V unreg. The +12V unreg voltage supplies power to the Remote Temp. Reset Circuit Board. JOHNSON CONTROLS...

  • Page 102: Unit Switch

    It is essential the user become familiar with the use of the keypad and display. This will allow the user to make full use of the capabilities and diagnostic features available. JOHNSON CONTROLS...

  • Page 103: Status" Key

    OFF position which will SYS SWITCH OFF tells that the system switch under not allow the unit to run. OPTIONS is turned “OFF”. The system will not be allowed to run until the switch is turned back on. JOHNSON CONTROLS...
  • Page 104 STATUS messages when in the MANUAL control will not function unless the discharge transducer OVERRIDE mode. MANUAL OVERRIDE is to only is installed in the system. be used in emergencies or for servicing. Manual override mode automatically disables itself after 30 minutes. JOHNSON CONTROLS...

  • Page 105: Fault Safety Status Messages

    PSIG below the cutout. Discharge transducers must be contacts to open causing 0VDC to be read on the inputs installed for this function to operate. to the microboard. The fault condition is cleared when a 30VDC signal is restored to the input. JOHNSON CONTROLS...
  • Page 106 This safety is only active when seconds, the system will shutdown. EEV is selected as the expansion valve type in SERVICE Mode. This safety is ignored for the fi rst 15 seconds of system runtime. JOHNSON CONTROLS...

  • Page 107: Unit Safeties

    fi nished counting down. This indicates the condensing unit jumper is installed between J4-11 and J4-6, on a liquid chiller. This jumper must be removed to operate the chiller. JOHNSON CONTROLS...

  • Page 108: Status Key Messages Quick Reference List

    System X Low Superheat System X AC Timer (Optional EEV only) System X Disch Limiting System X Sensor Failure (Optional EEV only) System X Suction Limiting System X Percentage Load Limiting LD11297 Manual Overide Status System X Pumping Down (on shutdown) JOHNSON CONTROLS...

  • Page 109: Display/Print Keys

    A I R T E M P 8 7 . 5 ° F This display shows the ambient air temperature. The minimum limit on the display is 0.4°F (-17.6°C). The maximum limit on the display is 131.2°F (55.1°C). JOHNSON CONTROLS...
  • Page 110 “OPTIONS” key. The Lead System display will only system. The second message shows the number of starts appear on a two system unit. for each compressor on each system. JOHNSON CONTROLS...
  • Page 111 1 and 3 will be actually used to cycle the condenser fans. * R e f e r t o t h e s e c t i o n o n O P E R AT I N G CONTROLS. JOHNSON CONTROLS...

  • Page 112: Operation Data Quick Reference List

    Current Feedback One Per Unit *System X Compressors Status *System X Run Time Sys X LLSV & HGSV Status *System X Condenser Fan Stage Current Feedback One Per System * Block of information repeats for each system LD07381 JOHNSON CONTROLS...

  • Page 113: Print Key

    FAN DIFF OFF PRESS 80 PSIG NUMBER OF COMPRESSORS NUMBER OF FANS PER SYSTEM See Service And Troubleshooting section UNIT TRIP VOLTS for Printer Installation information. REFRIGERANT TYPE R-22 REMOTE UNIT ID PROGRAMMED UNIT DATA RETURN LIQUID TEMP 58.2 DEGF JOHNSON CONTROLS...

  • Page 114: History Printout

    SYS 1 HIGH DSCH PRESS SHUTDOWN Displays the type of chiller; Liquid, Condensing Unit SYS 2 NO FAULTS or Heat Pump. C H I L L E D L I Q U I D X X X X X JOHNSON CONTROLS...
  • Page 115 S U C T I O N P R E S S U R E S Y S T E M N U M B E R C U T O U T X X X X P S I G JOHNSON CONTROLS...

  • Page 116: Software Version

    L L S V X X X H O T G A S S O L X X X Displays whether the System Liquid Line Solenoid or Hot Gas Solenoid was energized at the time of the fault. JOHNSON CONTROLS...
  • Page 117 The ↑ (UP) arrow key, and ↓ (DOWN) arrow key are also used for programming the control panel such as changing numerical or text values when programming cooling setpoints, setting the daily schedule, changing safety setpoints, chiller options, and setting the clock. JOHNSON CONTROLS...
  • Page 118 Notice that the RANGE was programmed for +/- X.X° F. This indicates the SETPOINT to be in the center of the control range. If the control mode has been programmed for RETURN LIQUID control, the message below would be displayed in place of the previous message. JOHNSON CONTROLS...
  • Page 119 The following messages illustrate both leaving M O N S T A R T 0 0 : 0 0 chilled liquid control and return chilled liquid control S T O P 0 0 : 0 0 respectively. JOHNSON CONTROLS...

  • Page 120: Table 15 - Cooling Setpoints, Programmable Limits And Defaults

    ↑ (UP) and ↓ (DOWN) arrow, and ENTER/ADV keys. After SUN (Sunday) schedule appears on the display a subsequent press of the SCHEDULE/ADVANCE DAY key will display the Holiday schedule. This is a two part display. The fi rst reads: JOHNSON CONTROLS...
  • Page 121 Details are explained under the topic on, in relation to discharge pressure. Refer to Condenser of SYSTEM SAFETIES. Fan Control in the UNIT OPERATION section and Tables 22, 23, and 24. JOHNSON CONTROLS...
  • Page 122 2-system chiller. The jumper is only checked by the micro at unit power-up. If the jumper is removed, power must be removed and re-applied to register the change in memory. JOHNSON CONTROLS...
  • Page 123 P R O G R A M M E D When communications is required with a BAS or OptiView Panel, individual unit IDs are necessary for communications with specifi c chillers on a single RS- 485 line. ID 0-7 is selectable. JOHNSON CONTROLS...

  • Page 124: Table 16 - Program Key Limits And Defaults

    SYSTEM 2 SUPERHEAT SETPOINT 5.5°C 8.3°C 6.6°C The minimum discharge pressure allowed is 160 PSIG. The fan differential Off Pressure will be lowered to prevent going below 160 PSIG based on where the fan control On Pressure is programmed. JOHNSON CONTROLS...

  • Page 125: Table 17 - Setpoints Quick Reference List

    Table 17 provides a quick reference of the setpoints list for the Setpoints Keys. Fan Control On-Pressure Fan Differential Off-Pressure Total Numbers Compressors Number of Fans Per System YCAL0041 - 0071 ONLY SYS / Unit Trip Volts Option Remote Unit ID SYS 1 & 2 Superheat Setpoints LD07404A JOHNSON CONTROLS...
  • Page 126 S W I T C H The chilled liquid is glycol. The Cooling Setpoint can be S Y S S W I T C H O F F programmed from 10°F to 70°F (-12.2°C to 21.1°C). This turns system 2 off JOHNSON CONTROLS...
  • Page 127 Condenser fans are controlled by discharge pressure only. This mode may only be chosen when discharge C O N T R O L M O D E pressure transducers are installed. L E A V I N G L I Q U I D JOHNSON CONTROLS...
  • Page 128 Service Mode. Refrigerant type is displayed under the monitoring of each system. SYS 1 input is to J8-5 of the Options Key, but is only programmable in Service micro. SYS 2 input is to J8-6 of the micro. Mode. JOHNSON CONTROLS...
  • Page 129 Temp reset Option is enabled under “ENABLED” using the ↑ and ↓ keys. Service Mode. F L A S H C A R D U P D A T E E N A B L E D JOHNSON CONTROLS...
  • Page 130 N O 1 the ENTER/ADV Key will save the valve and move the cursor on to the next programmable variable. Selecting Manual Pump 1 allows pump 1 to operate as the duty pump without automatic change over to pump 2. JOHNSON CONTROLS...

  • Page 131: Table 18 - Unit Keys Programming Quick Reference List

    TABLE 18 – UNIT KEYS PROGRAMMING QUICK REFERENCE LIST Unit Type ("Chiller" MUST be Selected Via No Jumper Installed) (Viewable Only) (Programmed under Service Mode) (Viewable Only) (Programmed under Service Mode) (Viewable Only) LD07405 Table 18 provides a quick reference list for the Unit key setpoints. JOHNSON CONTROLS...
  • Page 132 LWT<SP. Hot gas is turned off as temperature rises The setpoint, when programmed for Leaving Chilled when LWT>SP + CR/2. If temperature remains below Liquid Control, is the temperature the unit will control JOHNSON CONTROLS...

  • Page 133: Fig. 13 - Leaving Water Temperature Control Example

    (Can be used on Dual System 4, 5 & 6 Comp Each compressor in a system will be assigned an Units Only) arbitrary priority number 1, 2, or 1, 2, 3. The non-running compressor within a system with the lowest priority JOHNSON CONTROLS...

  • Page 134: Table 19 - Compressor Staging For Return Water Control

    TABLE 19 – COMPRESSOR STAGING FOR RETURN WATER CONTROL Compressor Staging for Return Water Control 4 Compressor Cooling Setpoint = 45°F (7.2°C) Range = 10°F(5.6°C) # of Comp * 1+HG 45°F 46.25°F 47.5°F 50.0°F 52.5°F 55.0°F (7.2°C) (7.9°C) (8.6°C) (10.0°C) (11.4°C) (12.8°C) *Unloading only JOHNSON CONTROLS...

  • Page 135: Table 20 - Return Chilled Liquid Control For 4 Compressors (6 Steps)

    An under voltage condition will keep the heater off until full voltage is restored to the system. has timed out. If the lead system has run for less than 5 minutes, 3 times in a row, the anti-recycle timer will be extended to 10 minutes. JOHNSON CONTROLS...

  • Page 136: Table 21 - Return Chilled Liquid Control For 4 Compressors (6 Steps)

    PROGRAM key. A low ambient kit MUST be installed when “AMBIENT CONTROL LOW AMBIENT” is selected under the OP- TIONS key. Compressor damage could occur if programming does not match installed hardware. JOHNSON CONTROLS...

  • Page 137: Fig. 15 - Ycal0041 - Ycal0071 Fan Location (Typical)

    Press - ((Diff. Press.) & & & & & & 40 PSIG (2.76 Bars) + 40 PSIG TB7-10 TB10-10 (2.76 Bars)) FAN #3 FAN #2 FAN #4 FAN #1 LD11419 FIG. 15 – YCAL0041 – YCAL0071 FAN LOCATION (TYPICAL) JOHNSON CONTROLS...

  • Page 138: Fig. 16 - Typical Inverter Location

    The pressures indicated in this section describing the VFD control will vary from VFD to VFD. Expect tolerances for the entire pressure range of con- trol to potentially shift -0 PSIG/+24 LD11299 PSIG. FIG. 17 – INVERTER ENCLOSURE JOHNSON CONTROLS...

  • Page 139: Fig. 18 - Potentiometer Settings

    This is the range of pressure where the VSD modulates the fan speed from 0 RPM to full speed. Remove The range is subtracted from the setpoint to calculate the 0 RPM pressure. IN for 60Hz Remove for 50Hz JOHNSON CONTROLS...

  • Page 140: Fig. 19 - Inverter Power Wiring Schematic

    TO MICROBOARD (P7) TO PANEL 10 M TO PANEL 10 M TO FAN #2 (EXIS TING HARNESS) TO FAN #2 (EXIS TING HARNESS) LD11302 NOTE: Fans must run in the forward direction (AIR ↑) FIG. 20 – INVERTER WIRING JOHNSON CONTROLS...

  • Page 141: Table 24 - Inverter Option Condenser Fan Control Operation

    (PRESSURE IS SPEED UNDER < FAN TB7-3 TB10-3 INVERTER CONTROL ON CONTROL ON & & & & & & CONTROL AND PRESSURE PRESSURE TB7-10 TB10-10 2ND FAN FULL MINUS FAN SPEED UNDER DIFFERENTIAL CONTACTOR PRESSURE CONTROL) =170 PSIG) JOHNSON CONTROLS...

  • Page 142: Table 25 - Compressor Operation - Load Limiting

    Setpoints key twice. The new value will be displayed as “REM SETP = 10.0°C.” Max Reset Value is the “Max EMS-PWM Remote Temp. Reset” setpoint value described in the program ming section under Cooling Setpoints. Programmable values are from 2°F to 40°F (1.11°C to 11.11°C). JOHNSON CONTROLS...
  • Page 143 Use YORK Max Reset Value is the “Max EMS-PWM Remote Temp. Reset” setpoint PN 031-00808-000 suppressor. value described in the programming section under Cooling Setpoints. Programmable values are from 2°F to 40°F (1.11°C to 11.11°C). JOHNSON CONTROLS...

  • Page 144: Fig. 21 - Field And Factory Electrical Connections Optional Remote

    Unit Operation FORM 150.66-NM1 (708) – 035-15961-000 LD03875A FIG. 21 – FIELD AND FACTORY ELECTRICAL CONNECTIONS OPTIONAL REMOTE TEMPERATURE RESET BOARD JOHNSON CONTROLS...
  • Page 145 Using the ↑ and ↓ (UP/DOWN ) ar- counters. Data logging, soft start, refrigerant type, and row keys will turn the respective digital output on/off expansion valve type all must be programmed to match or modify the value. actual chiller confi guration. JOHNSON CONTROLS...
  • Page 146 SYS 1*** COOLER INLET REFRIG. TEMP. SYS 2*** COOLER INLET REFRIG. TEMP. SYS 1**** SUCTION TEMP. SYS 2**** SUCTION TEMP. AMBIENT AIR TEMP. LEAVING LIQUID TEMP. RETURN LIQUID TEMP. SYS 2 *SUCTION PRESSURE SYS 2 SPARE SYS 2 **DISCH PRESSURE JOHNSON CONTROLS...

  • Page 147: Table 26 - Microboard Digital Inputs

    TB9-2 Sys 2 Alarm J15-2&6 Sys 2 Condenser Fan Speed TB8-6 & 7 Evaporator Pump Starter TB10-7 Sys 2 Hot Gas Bypass Valve TB8-4 Evaporator Pump Starter 2 TB8-5 Spare TB8-9 Spare TB9-4 Bivalent Heat Step (HP only) JOHNSON CONTROLS...

  • Page 148: Fig. 22 - Ipu Ii & I/O Layout

    Service and Troubleshooting FORM 150.66-NM1 (708) I/O BOARD BOARD TB10 LD12721 LD12721 FIG. 22 – IPU II & I/O LAYOUT JOHNSON CONTROLS...

  • Page 149: Correlation

    Outside Air Sensor J6-6 = +5VDC regulated supply to sensor. J6-9 = VDC input signal to the microboard. See Table 30 for voltage readings that corre spond to specifi c outdoor temperatures. J6-3 = drain (shield connection = 0VDC) Return JOHNSON CONTROLS...

  • Page 150: Temperature Sensor, And Suction Temperature Sensor: Temperature/Voltage Correlation

    J6-1 = drain (shield connection = 0VDC) Return 1.65 1.71 1.78 1.85 1.91 1.98 2.05 2.12 2.19 2.26 2.33 2.40 2.47 2.53 2.60 2.65 2.73 2.80 2.86 2.92 2.98 3.05 3.11 3.17 3.23 3.29 3.34 3.39 3.45 3.54 JOHNSON CONTROLS...
  • Page 151 All voltage reading are in reference to pressures. ground (unit case). J9-7 = +5VDC return J9-2 = drain (shield connection = 0VDC) JOHNSON CONTROLS...

  • Page 152: Fig. 23 - Microboard Relay Contact Architecture

    SYS 2 TB10-5 COMPR 3 (6) SYS 2 TB10-7 HGSV TB10-8 TB10 SYS 2 TB10-9 FAN 2 SYS 2 TB10-10 FAN 4 TB8-6 EVAP PUMP TB8-7 HEAT EXCH TB8-2 HEATER LD12722A FIG. 23 – MICROBOARD RELAY CONTACT ARCHITECTURE JOHNSON CONTROLS...

  • Page 153: Fig. 24 - Printer To Microboard Electrical Connections

    Printer TB3-3 TXD 2 RD 5 CTS TB3-2 CTS TB3-5 GND 7 SG Shield (connect shield to Do not connect shield Pin 5 of the connector) at printer end. LD13278 FIG. 24 – PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS JOHNSON CONTROLS...
  • Page 154 Terminal Block. “LOW SUCTION PRESSURE” 1. Improper suction pressure 1. Adjust per recommended FAULT cutouts adjustments. settings. 2. Low refrigerant charge. 2. Repair leak if necessary and add refrigerant. 3. Fouled fi lter dryer. 3. Change dryer/core. CONT’D JOHNSON CONTROLS...
  • Page 155 4. Compare sensor against a (assure the sensor is properly known good temperature installed in the bottom of the well sensing device. Refer to with a generous amount of heat) Service section for temp./ conductive compound). voltage table. CONT’D JOHNSON CONTROLS...
  • Page 156 2. Improper fl ow through the 2. Reduce fl ow to within chiller evaporator. design specs. See Limita- tions in Installation section. 3. Low refrigerant charge. 3. Check subcooling and add Low suction pressure will charge as needed. be observed. JOHNSON CONTROLS...
  • Page 157 CONDENSER FAN MOTORS peratures, can result in damage to the evaporator and unit as a result of the Condenser fan motors are permanently lubricated and chilled liquid freezing. require no maintenance. JOHNSON CONTROLS...
  • Page 158 In addition to the checks listed on this page, periodic overall inspections of the unit should be accomplished to ensure proper equipment operation. Items such as loose hardware, component operation, refrigerant leaks, unusual noises, etc. should be investigated and corrected immediately. JOHNSON CONTROLS...

  • Page 159: Table 33 - Isn Received Data

    (EEV Only) tions protocol type utilized. The latest SYS 2 96-99 Analog point map information is listed on the Anti-Recycle Timer Johnson Controls Group Equipment SYS 2 EEV 100-103 Analog Output % Integration website. (EEV Only) 104-107...
  • Page 160 Operational Code * SYS 2 Coded Fault Code The operational and fault codes sent to pages 56 through 59 are defi ned in Table 35. Note that this table of fault and operational codes is for all DX products. JOHNSON CONTROLS...

  • Page 161: Table 35 - Isn Operational And Fault Codes

    COMPRESSOR(S) RUNNING GROUND FAULT HEAT PUMP LOAD LIMITING MP /HPCO LOW EVAPORATOR TEMPERATURE INCORRECT REFRIGERANT PROGRAMMED POWER FAILURE, MANUAL RESET REQUIRED UNIT MOTOR CURRENT LOW SUPERHEAT SENSOR FAIL DISCHARGE INHIBIT MP/HPCO INHIBIT PUMP TRIP PUMP FAIL MAKE FLOW JOHNSON CONTROLS...
  • Page 162 P2 BAUD RATE P1 PROTOCOL XXXXX XXXXXX P2 PARITY P1 MANUAL MAC ADDRESS XXXXX P2 STOP BITS P1 BAUD RATE XXXXX P1 PARITY REAL TIME ERROR RESET 1 = YES, 0 = NO 0 XXXXX P1 STOP BITS JOHNSON CONTROLS...

  • Page 163: Table 36 - Minimum, Maximum And Default Values

    ENGLISH TEXT TOO LONG FLOATING POINT EXCEPTION GET PACKET FAILED GET TYPE FAILED INVALID UNIT CONVERSION INVALID HARDWARE SELECTION REAL TIME FAULT SPANISH TEXT TOO LONG THREAD EXITED THREAD FAILED THREAD STALLED IO BOARD RESET BRAM INVALID BACNET SETUP FAILED JOHNSON CONTROLS...
  • Page 164 SYS 1 RUN TIME (SECONDS) S1_SUCT_PR SYS 1 SUCTION PRESSURE S1_DSCH_PR SYS 1 DISCHARGE PRESSURE S1_SUCT TEMP SYS 1 SUCTION TEMPERATURE S1_CIR_TEMP SYS 1 COOLER INLET REFRIGERANT TEMPERATURE (R-407C ONLY) S1_DEF_TEMP SYS 1 DEFROST TEMPERATURE (HP ONLY) Continued on next page JOHNSON CONTROLS...
  • Page 165 COOLING RANGE 2 (SP CONTROL) HEAT_RANGE HEATING RANGE (HP ONLY) S1_DSCH_TEMP SYS 1 DISCHARGE TEMPERATURE (EEV ONLY) S1_DSCH_SH SYS 1 DISCHARGE SUPERHEAT (EEV ONLY) S2_DSCH_TEMP SYS 2 DISCHARGE TEMPERATURE (EEV ONLY) S2_DSCH_SH SYS 2 DISCHARGE SUPERHEAT (EEV ONLY) JOHNSON CONTROLS...
  • Page 166 LOCAL / REMOTE CONTROL MODE (0 = LOCAL, 1 = REMOTE) DATA_UNIT UNITS (0 = IMPERIAL, 1 = SI) AUTO_LL LEAD / LAG CONTROL MODE (0 = MANUAL, 1 = AUTO) S2_HGBV SYS 2 HOT GAS BYPASS VALVE JOHNSON CONTROLS...
  • Page 167 FORM 150.66-NM1 (708) NOTES JOHNSON CONTROLS...
  • Page 168 ©2008 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53203 Printed in USA 150.66-NM1 (708) www.johnsoncontrols.com Supersedes 150.66-NM1 (1005)

This manual is also suitable for:

York ycal0071ec

Table of Contents