Johnson Controls YORK YCAL0041EC Manuals

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Johnson Controls YORK YCAL0041EC Installation Operation & Maintenance (168 pages)

AIR-COOLED LIQUID CHILLERS HERMETIC SCROLL

Brand: Johnson Controls | Category: Chiller | Size: 4 MB

General Safety Guidelines
2
Table of Contents
4
List of Figures
9
List of Tables
10
Section 1 - General Chiller Information & Safety
13
Introduction
13
Warranty
13
Safety
13
Standards for Safety
13
Responsibility for Safety
14
About this Manual
14
Misuse of Equipment
14
Suitability for Application
14
Structural Support
14
Mechanical Strength
15
General Access
15
Pressure Systems
15
Electrical
15
Rotating Parts
15
Sharp Edges
15
Refrigerants and Oils
15
High Temperature and Pressure Cleaning
15
Emergency Shutdown
15
Section 2 - Product Description
16
Introduction
16
General System Description
16
Compressors
16
Cooler
16
Condenser
17
Millennium Control Center
17
Power Panel
18
Accessories and Options
19
Power Options
19
Control Options
19
Compressor, Piping, Evaporator Options
20
Condenser and Cabinet Options
20
Sound Reduction Options
21
Unit Components
22
Control / Power Panel Components
23
Product Identification Number (Pin)
24
Unit Nomenclature
24
Basic Unit Nomenclature
24
Refrigerant Flow Diagram
29
Fig. 1 - 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
Section 4 - Installation
32
Installation Checklist
32
Handling
32
Inspection
32
Location and Clearances
32
Foundation
33
Ground Level Locations
33
Rooftop Locations
33
Noise Sensitive Locations
33
Spring Isolators (Optional)
33
Compressor Mounting
33
Remote Cooler Option
33
Chilled Liquid Piping
33
Duct Work Connection
34
Wiring
34
Evaporator Pump Start Contacts
35
System Run Contacts
35
Alarm Status Contacts
35
Remote Start/Stop Contacts
35
Remote Emergency Cutoff
35
PWM Input
35
Load Limit Input
35
Flow Switch Input
35
Compressor Heaters
35
Single-Point Supply Connection - Terminal Block, Non-Fused Disconnect Switch or Circuit Breaker (0041 - 0071)
36
Single-Point Supply Connection
36
Fig. 2 - Single-Point Supply Connection - Terminal Block, Non-Fused
36
Disconnect Switch or Circuit Breaker (0041 - 0071)
36
Control Wiring
37
Fig. 3 - Control Wiring
37
Section 5 - Commissioning
38
Preparation - Power off
38
Inspection
38
Refrigerant Charge
38
Service and Oil Line Valves
38
Compressor Oil
38
Fans
38
Isolation / Protection
38
Control Panel
38
Power Connections
38
Grounding
39
Supply Voltage
39
Preparation - Power on
39
Switch Settings
39
Compressor Heaters
39
Water System
39
Flow Switch
39
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
Setpoints Entry List
41
Table 1 - Setpoints Entry List
41
Checking Superheat and Subcooling
42
Leak Checking
42
Unit Operating Sequence
43
Section 6 - Technical Data
44
Operational Limitations (English)
44
Temperatures and Flows
44
Voltage Limitations
44
Table 2 - Temperatures and Flows
44
Table 3 - Voltage Limitations
44
Ethylene Glycol Correction Factors
45
Table 4 - Ethylene Glycol Correction Factors
45
Operational Limitations (Si)
46
Temperatures and Flows
46
Voltage Limitations
46
Table 5 - Temperatures and Flows (Si)
46
Table 6 - Voltage Limitations
46
Ethylene Glycol Correction Factors
47
Table 7 - Ethylene Glycol Correction Factors
47
Physical Data (English)
48
Table 8 - Physical Data (English)
48
Sound Data (English)
50
Table 9 - Sound Data (English)
50
Elctrical Data (English)
52
Table 10 - Electrical Data (English)
52
Table 11 - Micro Panel Power Supply
54
Table 12 - Voltage Range
54
Electrical Notes and Legend
55
Wiring Diagrams
56
Fig. 4 - Control Circuit, Dual
56
Fig. 5 - Control Circuit, Dual
58
Fig. 6 - Power Circuit, Dual
60
Fig. 7 - Power Circuit, Dual
61
Fig. 8 - Wiring Details
62
Connection Diagrams
63
Fig. 9 - Connection Diagram
63
Fig. 10 - Connection Diagram
64
Fig. 11 - Connection Diagram Microboard (Partial)
65
Dimensions - (English)
66
Dimensions - (Si)
80
Technical Data - Clearances
94
Fig. 12 - Unit Clearances
94
Isolators
95
Section 7 - Unit Controls
101
Introduction
101
Microprocessor Board
101
Unit Switch
102
Display
102
Keypad
102
Battery Back-Up
102
Transformer
102
Single System Select Andprogramming # of Compressors
102
Status" Key
103
Unit Status
103
General Status Messages
103
Fault Safety Status Messages
105
System Safeties
105
Unit Safeties
107
Unit Warning
107
Status Key Messages Quick Reference List
108
Table 13 - Status Key Messages Quick Reference List
108
Display/Print Keys
109
Oper Data Key
109
Operation Data Quick Reference List
112
Table 14 - Operation Data
112
Print Key
113
Operating Data Printout
113
History Printout
114
History Displays
114
Software Version
116
Table 15 - Cooling Setpoints, Programmable Limits and Defaults
120
Table 16 - Program Key Limits and Defaults
124
Table 17 - Setpoints Quick Reference List
125
Table 18 - Unit Keys Programming Quick Reference List
131
Fig. 13 - Leaving Water Temperature Control Example
133
Fig. 14 - Setpoint Adjust
133
Table 19 - Compressor Staging for Return Water Control
134
Table 20 - Return Chilled Liquid Control for 4 Compressors (6 Steps)
135
Table 21 - Return Chilled Liquid Control for 4 Compressors (6 Steps)
136
Fig. 15 - Ycal0041 - Ycal0071 Fan Location (Typical)
137
Table 22 - Ycal0041 - Ycal0071 Condenser Fan Control Using Outdoor
137
Discharge Pressure
137
Table 23 - Ycal0041 - Ycal0071 Condenser Fan Control Using Discharge
137
Pressure Only
137
Fig. 16 - Typical Inverter Location
138
Fig. 17 - Inverter Enclosure
138
Fig. 18 - Potentiometer Settings
139
Fig. 19 - Inverter Power Wiring Schematic
140
Fig. 20 - Inverter Wiring
140
Table 24 - Inverter Option Condenser Fan Control Operation
141
Table 25 - Compressor Operation - Load Limiting
142
Fig. 21 - Field and Factory Electrical Connections Optional Remote
144
Temperature Reset Board
144
Table 26 - Microboard Digital Inputs
147
Table 27 - Microboard Digital Outputs
147
Table 28 - Microboard Analog Inputs
147
Table 29 - Microboard Analog Outputs
147
Fig. 22 - Ipu II & I/O Layout
148
Correlation
149
Temperature Sensor, and Suction Temperature Sensor: Temperature/Voltage Correlation
150
Fig. 23 - Microboard Relay Contact Architecture
152
Fig. 24 - Printer to Microboard Electrical Connections
153
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

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Johnson Controls YORK YCAL0041EC Installation Operation & Maintenance (168 pages)

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