Johnson Controls York YCRL0096 Chiller Manuals

Manuals and User Guides for Johnson Controls York YCRL0096 Chiller. We have 1 Johnson Controls York YCRL0096 Chiller manual available for free PDF download: Installation Operation & Maintenance

Johnson Controls York YCRL0096 Installation Operation & Maintenance (162 pages)

WATER-COOLED LIQUID CHILLERS HERMETIC SCROLL

Brand: Johnson Controls | Category: Chiller | Size: 7 MB

Table of Contents
6
FIGURE 1 - YCRL Water Cooled Liquid Chiller

17
Chiller Options
21
- Final Paint Overspray
  21
- Service Isolation Valve
  21
- Hot Gas By-Pass
  21
- Compressor Acoustic Sound Blanket
  21
- Vibration Isolation
  21
  - Neoprene Isolation
    21
  - One Inch Spring Isolators
    21
  - Two Inch Seismic Isolators
    21
Control / Power Panel Components
22
Unit Components
24
FIGURE 6 - Refrigerant Flow Diagram (European)

30
Section 3 - Transportation, Handling and Storage

31
- Delivery and Storage
  31
- Inspection
  31
- Moving the Unit
  31
  - Lifting by Crane / Hoist
    31
- Lifting Weights
  32
FIGURE 7 - Chiller Rigging and Lifting Weights

32
Section 4 - Installation

33
FIGURE 13 - Control Wiring

45
TABLE 6 - Temperatures and Flows

47
TABLE 7 - Voltage Limitations

47
Section 5 - Technical Data

47
Section 6 - Commissioning

93
- General
  93
- Preparation - Power off
  93
  - Inspection
    93
  - Refrigerant Charge
    93
  - Service and Oil Line Valves
    93
  - Compressor Oil
    93
  - Isolation / Protection
    93
  - Control Panel
    93
  - Power Connections
    93
  - Grounding
    94
  - Supply Voltage
    94
- Preparation - Power on
  94
  - Switch Settings
    94
  - Compressor Heaters
    94
  - Water System
    94
  - Flow Switch
    94
  - Temperature Sensor(S)
    94
- Equipment Pre Start-Up and Start-Up Checklist
  95
  - Pre Start-Up
    95
    
    Checking the System Prior to Initial Start (no Power)
    95
    
    Compressor Heaters (Power on - 24 Hours Prior to Start)
    95
    
    Unit Checks
    95
  - Start-Up
    95
    
    Panel Checks (Power on - Unit Switch Off)
    95
- TABLE 13 - Setpoints Entry List
  
  96
- Checking Superheat and Subcooling
  97
- Leak Checking
  97
- Unit Operating Sequence
  98
Section 7 - Unit Controls

99
- Introduction
  99
  - IPU II and I/O Boards
    99
  - Unit Switch
    100
  - Display
    100
  - Keypad
    100
  - Battery Back-Up
    100
  - Transformer
    100
  - Programming # of Compressors
    100
- Status Key
  101
  - General Status Messages
    101
  - Unit Status
    101
  - Fault Safety Status Messages
    103
    
    System Safeties
    103
    
    Unit Safeties
    104
  - Unit Warning
    105
  - FIGURE 31 - Status Key Messages Quick Reference List
    
    106
  - Status Key Messages
    106
    
    FIGURE 32 - Operation Data
    110
    
    TABLE 14 - Cooling Setpoints, Programmable Limits and Defaults
    118
    
    Program Key
    119
    
    System Trip Volts
    120
    
    Unit Trip Volts
    121
  - Entry Keys
    115
    
    Enter/Adv Key
    115
    
    Up and down Arrow Keys
    115
  - Setpoints Keys
    116
    
    Cooling Setpoints
    116
    
    Leaving Chilled Liquid Control
    116
    
    Remote Setpoint Control
    117
    
    Return Chilled Liquid Control
    117
    
    Schedule/Advance Day Key
    117
- Display/Print Keys
  107
  - Oper Data Key
    107
    
    Oper Data Quick Reference List
    110
  - Print Key
    111
    
    Operating Data Printout
    111
    
    History Printout
    112
  - History Displays
    112
    
    Software Version
    114
  - TABLE 15 - Program Key Limits and Default
    
    121
  - FIGURE 33 - Setpoints Quick Reference List
    
    122
  - FIGURE 34 - Unit Keys Options Programming Quick Reference List
    
    128
  - Capacity Control
    129
  - Discharge Pressure Limit Controls
    129
- Unit Keys
  123
  - Options Key
    123
    
    Option 1 - Language
    123
    
    Option 2 - System Switches
    123
    
    Option 3 - Chilled Liquid Cooling Type
    123
    
    Option 4 - Ambient Control Type
    124
    
    Option 5 - Local/Remote Control Type
    124
    
    Option 6 - Unit Control Mode
    124
    
    Option 7 - Display Units
    124
    
    Option 8 - Lead/Lag Type (Two System Units Only)
    124
    
    Option 9 - Condenser Fan Control Mode
    124
    
    Option 10 - Manual Override Mode
    125
    
    Option 11 - Current Feedback Options Installed
    125
    
    Option 12 - Power Fail Restart
    125
    
    Option 13 - Soft Start Enable/Disable
    125
    
    Option 14 - Unit Type
    125
    
    Option 15 - Refrigerant Type
    126
    
    Option 16 - Expansion Valve Type
    126
    
    Option 17 - Flash Card Update
    126
    
    Option 18 - Remote Temperature Reset
    126
    
    Option 19 - Pump Control
    127
    
    Option 20 - Pump Selection
    127
  - Clock
    127
Section 8 - Unit Operation

129
Section 9 - Service and Troubleshooting

137
- Clearing History Buffers
  137
- Service Mode
  137
- Service Mode - Outputs
  137
- Service Mode - Analog and Digital Inputs
  138
- Service Mode - Chiller Configuration
  138
- Control Inputs/Outputs
  139
  - TABLE 22 - I/O Analog Inputs
    
    139
    
    FIGURE 37 - Microboard Layout
    140
    
    TABLE 24 - Entering/Leaving Chilled Liquid Temperature Sensor, Temperature/Voltage Correlation
    141
    
    Analog Inputs - Pressure
    142
    
    TABLE 25 - Pressure Transducers
    142
    
    Digital Outputs
    143
    
    FIGURE 38 - I/O Board Relay Contact Architecture
    143
    
    Assembly and Wiring
    144
    
    Obtaining a Printout
    144
    
    Optional Printer Installation
    144
    
    Parts
    144
  - TABLE 23 - I/O Analog Outputs
    
    139
  - Checking Inputs and Outputs
    141
    
    Analog Inputs - Temperature
    141
    
    Digital Inputs
    141
    
    Liquid and Refrigerant Sensor Test Points
    141
  - FIGURE 39 - Printer to Microboard Electrical Connections
    
    144
  - TABLE 26 - Troubleshooting
    
    145
  - Troubleshooting
    145
- TABLE 21 - I/O Digital Outputs
  
  139
- TABLE 20 - I/O Digital Inputs
  
  139
- Microboard Layout
  140
Section 10 - Maintenance

147
- Compressors
  147
  - Oil Level Check
    147
  - Oil Analysis
    147
- Important
  147
- On-Board Battery Back-Up
  147
- Operating Parameters
  147
- Overall Unit Inspection
  147
- Bacnet, Modbus and Yorktalk 2 Communications
  148
  - TABLE 27 - Minimum, Maximum and Default Values
    
    149
    
    FIGURE 40 - Micro Panel Connections
    149
    
    TABLE 28 - Values Required for Bas Communication
    150
    
    TABLE 29 - Real Time Error Numbers
    150
    
    TABLE 30 - Bacnet and Modbus Communications Data Map
    152
    
    TABLE 31 - Yorktalk 2 Communications Data Map
    156
    
    Temperature Conversion Chart
    159
    
    R410-A Pressure Temperature Chart
    160
    
    TABLE 32 - si Metric Conversion
    161
    
    Temperature
    161
  - Yorktalk 2 Communications
    155
    
    Received Data (Control Data)
    155
    
    Transmitted Data
    155
- Bacnet and Modbus Communications
  151
  - Analog Write Points
    151
  - Binary Write Points
    151
  - Analog Read Only Points
    151
  - Binary Monitor Only Points
    151
- Communications Data Map Notes
  151

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Johnson Controls York YCRL0096 Chiller Manuals

Johnson Controls York YCRL0096 Installation Operation & Maintenance (162 pages)

Table of Contents

FIGURE 1 - YCRL Water Cooled Liquid Chiller

FIGURE 2 - Control/Panel Components

FIGURE 6 - Refrigerant Flow Diagram (European)

Section 3 - Transportation, Handling and Storage

FIGURE 7 - Chiller Rigging and Lifting Weights

Section 4 - Installation

FIGURE 8 - Victaulic - Adapter Flanges

FIGURE 10 - Pipework Arrangements Legend

FIGURE 9 - Chilled Liquid System

TABLE 4 - YCRL Connection Line Sizes

TABLE 5 - YCRL Chiller Charges

TABLE 1 - Condenser / Cooler Connections

FIGURE 13 - Control Wiring

TABLE 6 - Temperatures and Flows

TABLE 7 - Voltage Limitations

Section 5 - Technical Data

FIGURE 14 - Evaporator Water Pressure Drop Curves (English and SI)

TABLE 8 - Ethylene and Propolyne Glycol Correction Factors

TABLE 9 - Recommended Glycol Solution Strengths

FIGURE 19 - Standard Power, Single Point and Multiple Point Control Panel Wiring, 6 Compressor Unit

FIGURE 20 - Standard Power and Single Point Power Circuit, 4 Compressor Unit

FIGURE 21 - Multiple Point Power Circuit, 4 Compressor Unit

FIGURE 22 - Standard Power and Single Point Power Circuit, 6 Compressor Unit

FIGURE 23 - Multiple Point Power Circuit, 6 Compressor Unit

FIGURE 24 - Standard Power and Single Point Connection Wiring Diagram, 4 Compressor Unit

FIGURE 25 - Multiple Point Power Connection Wiring Diagram, 4 Compressor Unit

FIGURE 26 - Standard Power and Single Point Connection Wiring Diagram, 6 Compressor Unit

FIGURE 27 - Multiple Point Connection Wiring Diagram, 6 Compressor Unit

FIGURE 28 - Standard Power, Single Point and Multiple Point Elementary Wiring Diagram Details

FIGURE 29 - Standard Power, Single Point and Multiple Point Elementary Wiring Diagram Details

FIGURE 30 - EEV Controller Wiring

Section 6 - Commissioning

TABLE 13 - Setpoints Entry List

Section 7 - Unit Controls

FIGURE 31 - Status Key Messages Quick Reference List

TABLE 15 - Program Key Limits and Default

FIGURE 33 - Setpoints Quick Reference List

FIGURE 34 - Unit Keys Options Programming Quick Reference List

Section 8 - Unit Operation

FIGURE 35 - Leaving Water Temperature Control Example

FIGURE 36 - Setpoint Adjust

TABLE 17 - Return Chilled Liquid Control for 4 Compressors (6 Steps)

TABLE 16 - Sample Compressor Staging for Return Water Control

Section 9 - Service and Troubleshooting

TABLE 22 - I/O Analog Inputs

TABLE 23 - I/O Analog Outputs

FIGURE 39 - Printer to Microboard Electrical Connections

TABLE 26 - Troubleshooting

TABLE 21 - I/O Digital Outputs

TABLE 20 - I/O Digital Inputs

Section 10 - Maintenance

TABLE 27 - Minimum, Maximum and Default Values

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