Johnson Controls York YCAL0014E Series Installation, Operation & Maintenance Instructions Manual
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Johnson Controls York YCAL0014E Series Installation, Operation & Maintenance Instructions Manual

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INSTALLATION, OPERATION, MAINTENANCE
New Release
YCAL0014E_ - YCAL0124E_
R-22 & HFC-407C
STYLE C
(60 Hz)
YCAL0014 – YCAL0080 EPROM (031-02050-001 MICRObOARD)
031-02049-001
YCAL0090 – YCAL0124 EPROM
031-02423-001
Standard, Glycol & Metric Models, Combined
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Form 150.62-NM6 (103)
035-19329-000
29224(R)A
200-3-60
230-3-60
380-3-60
460-3-60
575-3-60
MODELS ONLY

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  • Page 1 AIR-COOLED LIQUID CHILLERS HERMETIC SCROLL New Release Form 150.62-NM6 (103) INSTALLATION, OPERATION, MAINTENANCE 035-19329-000 YCAL0014E_ - YCAL0124E_ R-22 & HFC-407C STYLE C (60 Hz) 29224(R)A YCAL0014 – YCAL0080 EPROM (031-02050-001 MICRObOARD) 031-02049-001 YCAL0090 – YCAL0124 EPROM 200-3-60 230-3-60 031-02423-001 380-3-60 460-3-60 575-3-60 MODELS ONLY...
  • Page 2 The following symbols are used in this document to alert the reader to areas of potential hazard: DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. JOHNSON CONTROLS...
  • Page 3 If there is any question in the mind of operating/service personnel as to the applicability of these documents, then prior to working on the equipment, they should verify with the owner whether the equip- ment has been modified and if current literature is available. JOHNSON CONTROLS...

  • Page 4: Table Of Contents

    (YCAL0090E_ - YCAL0124E_) ............26 – 27 SINGLE-POINT POWER SUPPLY CONNECTIONS W/ INDIVIDUAL CIRCUIT bREAKERS (YCAL0090E_ - YCAL0124E_) 28 – 29 TEMPERATURES AND FLOWS (ENGLISH) ........... 30 VOLTAGE LIMITATIONS ................30 COOLER PRESSURE DROP CURVES (ENGLISH) ....... 31 JOHNSON CONTROLS...
  • Page 5 OUTDOOR AIR SENSOR TEMP./VOLT./RESISTANCE .......119 ENTERING & LEAVING CHILLED LIqUID TEMPERATURE SENSOR, COOLER INLET TEMP. & SUCTION TEMP......120 KEYPAD PIN ASSIGNMENT MATRIx ...........123 TROUbLESHOOTING CHARTS ............125 ISN RECEIVED DATA ................129 ISN TRANSMITTED DATA ..............129 ISN OPERATIONAL & FAULT CODES ..........131 JOHNSON CONTROLS...
  • Page 6 ELEMENTARY DIAGRAM, DETAIL A & b (YCAL0114E_ - YCAL0124E_) .....159 CONNECTION DIAGRAM (YCAL0114E_ - YCAL0124E_) ........160 - 161 ISOLATORS, TYPE CP 1 ....................164 ISOLATORS, TYPE CP 2 ....................164 R SPRING SEISMIC ISOLATOR ..................165 TYPE CP MOUNTING ....................166 “AEqM” SPRING-FLEx MOUNTING ................167 JOHNSON CONTROLS...

  • Page 7: Product Identification Number

    PIN Level : Condensing 60 HZ Nominal Tons : 460 / 3 / 60 Unit Odd Number: : 380-415 / 3 / 50 : Scroll 50 HZ Nominal kW : 575 / 3 / 60 : Across the Line JOHNSON CONTROLS...
  • Page 8 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 JOHNSON CONTROLS...

  • Page 9: Refrigerant Flow Diagram

    LOW PRESSURE SWITCH OR RETURN WATER SUCTION PRESSURE TRANSDUCER TEMP. SENSOR LEAVING ENTERING CHILLED WATER CHILLED WATER LEAVING CHILLED WATER TEMP. SENSOR OIL EQUALIZING LINE 2 OR 3 COMPRESSORS PER SYSTEM LD07613 FIG. 1 – REFRIGERANT FLOW DIAGRAM JOHNSON CONTROLS...
  • Page 10 These units are shipped as completely assembled units flow. containing full operating charge, and care should be taken to avoid damage due to rough handling. Clearances are listed under “Notes” in the “DIMEN- JOHNSON CONTROLS...
  • Page 11 Con- compressor servicing/replacement siderations should be made utilizing noise levels pub- lished in the YORK Engineering Guide for the specific difficult. chiller model. Sound blankets for the compressors and low sound fans are available. JOHNSON CONTROLS...
  • Page 12 PWM input, and load limit input. Refer to section on UNIT OPERATION for a detailed description of operation 5. As an aid to servicing, thermometers and pressure concerning aforementioned contacts and inputs. gauges should be installed in the inlet and outlet water lines. JOHNSON CONTROLS...
  • Page 13 18 - 24 hours prior to restarting a compressor. This will assure that liquid slugging and oil dilution does REMOTE EMERGENCY CUTOFF not damage the compressors on start. Immediate shutdown of the chiller can be accomplished by opening a field-installed dry contact to break the elec- JOHNSON CONTROLS...

  • Page 14: Single-Point Supply Connection

    FIG. 2 – SINGLE-POINT SUPPLY CONNECTION – TERMINAL bLOCK, NON-FUSED DISCONNECT SWITCH OR CIRCUIT bREAKER (0014 - 0080) JOHNSON CONTROLS...
  • Page 15 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 – MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL bLOCK (0040 - 0080) JOHNSON CONTROLS...

  • Page 16: Multiple Point Power Supply Connection

    FIG. 4 – MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL bLOCK, NON-FUSED DISCONNECT SWITCHES OR CIRCUIT bREAKERS (0090 - 0124) JOHNSON CONTROLS...

  • Page 17: Single-Point Supply Connection

    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. 5 – OPTIONAL SINGLE-POINT POWER WIRING JOHNSON CONTROLS...

  • Page 18: 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. 6 – CONTROL WIRING JOHNSON CONTROLS...
  • Page 19 -58 = 575-3-60 MAxIMUM MINIMUM CIRCUIT AMPACITY MINIMUM LEGEND: MIN NF MINIMUM NON FUSED Field Wiring RATED LOAD AMPS Factory Wiring S.P. WIRE SINGLE-POINT WIRING UNIT MOUNTED SERVICE (NON-FUSED UNIT MTD SERV SW DISCONNECT SWITCH) LOCKED ROTOR AMPS JOHNSON CONTROLS...

  • Page 20: Electrical Data

    AFTER disconnecting power, PRIOR to working on equipment. 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. JOHNSON CONTROLS...
  • Page 21 # 10 - 1/0 # 10 - 1/0 19.9 19.9 167 19.9 167 # 10 - # 1 # 10 - 1/0 # 10 - 1/0 16.0 16.0 125 16.0 125 See Notes and Legend on page 19 JOHNSON CONTROLS...
  • Page 22 # 10 - 3/0 47.8 47.8 47.8 # 10 - # 1 28.7 28.7 28.7 0080 # 10 - # 1 23.9 23.9 23.9 # 10 - # 1 19.1 19.1 19.1 See Notes and Legend on page 19. JOHNSON CONTROLS...
  • Page 23 # 10 - 3/0 47.8 47.8 47.8 # 10 - 3/0 47.8 47.8 47.8 # 10 - # 1 28.7 28.7 28.7 # 10 - # 1 23.9 23.9 23.9 # 10 - # 1 19.1 19.1 19.1 JOHNSON CONTROLS...
  • Page 24 250-500 # 10 - 300 # 6 - 350 # 4 - 300 0080 # 10 - 3/0 # 6 - 350 # 4 - 300 # 10 - 3/0 # 2 - 4/0 # 2 - 4/0 JOHNSON CONTROLS...
  • Page 25 19.9 19.9 19.1 19.1 19.1 16.0 16.0 16.0 47.8 47.8 47.8 47.8 47.8 47.8 47.8 47.8 47.8 47.8 47.8 47.8 28.7 28.7 28.7 28.7 28.7 28.7 23.9 23.9 23.9 23.9 23.9 23.9 19.1 19.1 19.1 19.1 19.1 19.1 JOHNSON CONTROLS...
  • Page 26 (1) # 6 - 350 (1) # 6 - 350 0124 # 14 - 2/0 (1) # 6 - 350 (1) # 6 - 350 # 14 - 2/0 (1) # 6 - 350 (1) # 3 - 3/0 JOHNSON CONTROLS...
  • Page 27 44.2 44.2 — — 35.4 35.4 — — 73.9 73.9 73.9 68.5 68.5 68.5 39.5 39.5 39.5 32.6 32.6 32.6 26.1 26.1 26.1 73.9 73.9 73.9 68.5 68.5 68.5 39.5 39.5 39.5 32.6 32.6 32.6 26.1 26.1 26.1 JOHNSON CONTROLS...
  • Page 28 (2) # 4 - 500 (1 or 2) 3/0 - 500 0124 # 6 - 400 (1 or 2) 3/0 - 500 # 6 - 400 (1) # 6 - 350 See Notes and Legend on page 19. JOHNSON CONTROLS...
  • Page 29 32.6 32.6 26.1 26.1 26.1 26.1 26.1 26.1 100.2 100.2 100.2 73.9 73.9 73.9 92.8 92.8 92.8 68.5 68.5 68.5 53.5 53.5 53.5 39.5 39.5 39.5 44.2 44.2 44.2 32.6 32.6 32.6 35.4 35.4 35.4 26.1 26.1 26.1 JOHNSON CONTROLS...

  • Page 30: Operational Limitations

    4. For operation at temperatures below 25°F (-3.9°C), the optional Low Ambient Kit will need to be installed on the system (for YCAL0014-0080 models only). 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 31 1.172 0090E_, 0094E_ 0104E_, 0114E_, 0124E PROPYLENE GLYCOL TONS PRESS COMPR F/TON % WEIGHT FREEZE PT ° DROP 0.983 0.996 24.2 1.048 0.974 0.995 24.4 1.086 0.961 0.990 25.1 1.134 0.946 0.98 26.0 1.186 0.928 0.984 27.2 1.247 JOHNSON CONTROLS...

  • Page 32: Voltage Limitations

    4. For operation at temperatures below 25°F (-3.9°C), the optional Low Ambient Kit will need to be installed on the system (for YCAL0014-0080 models only). 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 33 1.172 0090E_, 0094E_ 0104E_, 0114E_, 0124E PROPYLENE GLYCOL TONS PRESS COMPR F/TON % WEIGHT FREEZE PT ° DROP 0.983 0.996 24.2 1.048 0.974 0.995 24.4 1.086 0.961 0.990 25.1 1.134 0.946 0.98 26.0 1.186 0.928 0.984 27.2 1.247 JOHNSON CONTROLS...

  • Page 34: Physical Data

    8”x7’ 10”x8’ 10”x8’ 10”x8’ Water Volume, gallons 10.0 12.3 12.3 29.1 29.1 29.1 Maximum Water Side Pressure, PSIG Maximum Refrigerant Side Pressure, PSIG Minimum Chiller Water Flow Rate, gpm Maximum Chiller Water Flow Rate, gpm Water Connections, inches JOHNSON CONTROLS...
  • Page 35 1140 1140 1140 1140 1140 47360 46080 55253 55253 54550 53760 79800 79800 85800 106400 106400 10”x8’ 10”x8’ 12”x8’ 12”x8’ 12”x8’ 12”x8’ 14”x8’ 14”x8’ 15”x8’ 15”x8’ 15”x8’ 29.1 29.1 41.2 41.2 41.2 39.9 53.0 53.0 58.9 58.9 58.9 JOHNSON CONTROLS...

  • Page 36: Physical Data (Metric)

    34.9 34.9 37.7 46.7 46.7 110.3 110.3 110.3 Maximum Water Side Pressure, bar Maximum Refrigerant Side Pressure, bar Minimum Chiller Water Flow Rate, l/s Maximum Chiller Water Flow Rate, l/s 10.7 10.7 18.9 18.9 18.9 Water Connections, inches JOHNSON CONTROLS...
  • Page 37 39784 50214 50214 248x2438 248x2438 309x2438 309x2438 309x2438 315x2438 356x2438 356x2438 381x2438 381x2438 381x2438 110.3 110.3 156.1 156.1 156.1 151.1 200.6 200.6 222.9 222.9 222.9 10.4 11.4 18.9 18.9 22.1 22.1 22.1 24.3 33.1 33.1 39.4 39.4 39.4 JOHNSON CONTROLS...
  • Page 38 Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'0"; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 39 62" 14 11/16" 80 7/16" 105 1/8" SIDE VIEW LD07736 ALUMINUM COPPER Center of Gravity (in.) Center of Gravity (in.) YCAL YCAL 0014 44.8 24.1 28.3 0014 45.4 24.2 28.8 0020 45.4 24.2 28.8 0020 44.8 24.1 28.3 JOHNSON CONTROLS...
  • Page 40 Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'0''; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 41 ** Refers to Model YCAL0030 and YCAL0034 ALUMINUM COPPER Center of Gravity (in.) Center of Gravity (in.) YCAL YCAL 0024 45.0 24.4 35.3 0024 45.8 24.5 36.2 0030 45.0 24.4 34.9 0030 45.8 24.5 35.8 0034 45.0 25.5 33.8 0034 45.7 25.5 34.7 JOHNSON CONTROLS...
  • Page 42 Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'0''; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 43 40.2 41.2 0040 58.3 40.2 40.3 0042 58.3 40.4 39.7 0042 58.4 40.4 40.1 0044 58.4 40.2 39.5 0044 58.5 40.2 39.9 0050 58.4 40.4 39.5 0050 58.5 40.4 39.9 0060 58.5 40.2 39.4 0060 58.6 40.2 39.8 JOHNSON CONTROLS...
  • Page 44 Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'0"; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 45 Center of Gravity (in.) YCAL YCAL 0064 56.5 45.8 39.4 0064 56.7 45.7 40.0 0070 56.6 45.4 39.4 0070 56.8 45.5 40.0 0074 56.6 45.7 39.5 0074 56.8 45.7 40.1 0080 56.6 45.4 39.0 0080 56.8 45.5 39.6 JOHNSON CONTROLS...
  • Page 46 Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'0"; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 47 19 1/4" 83" 17 1/8" 106 3/4" 141" 148" LD08702 ALUMINUM COPPER Center of Gravity (in.) Center of Gravity (in.) YCAL YCAL 0090 63.4 44.3 42.1 0090 64.1 44.3 44.5 0094 64.3 44.4 41.9 0094 64.8 44.4 44.2 JOHNSON CONTROLS...
  • Page 48 Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'0"; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 49 (2) 3" X 3" RIGGING HOLES (EACH SIDE) 14 1/4" 83" 17 1/8" 124 3/4" 159" 166" LD08703 ALUMINUM COPPER Center of Gravity (in.) Center of Gravity (in.) YCAL YCAL 0104 70.3 45.7 40.8 0104 71.3 45.5 42.7 JOHNSON CONTROLS...
  • Page 50 Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'0"; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 51 7 7/8" 67 1/4" 67 1/4" 7 7/8" 183" 190" LD08705 COPPER ALUMINUM Center of Gravity (in.) Center of Gravity (in.) YCAL YCAL 0114 80.9 44.9 43.5 0114 79.4 45.0 41.4 0124 80.9 44.9 43.5 0124 79.4 45.0 41.5 JOHNSON CONTROLS...
  • Page 52 Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 53 (2) 76 X 76 RIGGING 3" HOLES (EACH SIDE) 3" WATER OUTLET WATER INLET 1575 2043 2670 SIDE VIEW LD07738 ALUMINUM COPPER Center of Gravity (mm) Center of Gravity (mm) YCAL YCAL 0014 1138 0014 1153 0020 1138 0020 1153 JOHNSON CONTROLS...
  • Page 54 Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 55 SIDE VIEW LD07734 * Refers to Model YCAL0024 ** Refers to Model YCAL0030 and YCAL0034 ALUMINUM COPPER Center of Gravity (mm) Center of Gravity (mm) YCAL YCAL 0024 1142 0024 1162 0030 1144 0030 1163 0034 1142 0034 1160 JOHNSON CONTROLS...
  • Page 56 Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 57 1021 1047 0040 1482 1021 1023 0042 1481 1026 1009 0042 1483 1026 1018 0044 1483 1021 1004 0044 1485 1021 1013 0050 1484 1025 1003 0050 1486 1025 1012 0060 1485 1021 1001 0060 1487 1021 1010 JOHNSON CONTROLS...
  • Page 58 Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 59 Center of Gravity (mm) Center of Gravity (mm) YCAL YCAL 0064 1435 1162 1001 0064 1440 1162 1016 0070 1437 1154 1002 0070 1442 1154 1017 0074 1438 1161 1003 0074 1443 1160 1018 0080 1437 1154 0080 1442 1154 1006 JOHNSON CONTROLS...
  • Page 60 Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 61 WATER INLET RIGGING HOLES (EACH SIDE) 2108 2711 3581 3759 LD08708 ALUMINUM COPPER Center of Gravity (mm) Center of Gravity (mm) YCAL YCAL 0090 1610 1125 1069 0090 1628 1125 1130 0094 1633 1128 1064 0094 1646 1127 1124 JOHNSON CONTROLS...
  • Page 62 Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 63 8" WATER OUTLET WATER INLET (2) 76 X 76 RIGGING HOLES (EACH SIDE) 2108 3169 4038 4216 LD08709 ALUMINUM COPPER Center of Gravity (mm) Center of Gravity (mm) YCAL YCAL 0104 1786 1160 1035 0104 1811 1155 1084 JOHNSON CONTROLS...
  • Page 64 Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. JOHNSON CONTROLS...
  • Page 65 RIGGING HOLES (EACH SIDE) 2108 1708 1708 4848 4826 LD08711 ALUMINUM COPPER Center of Gravity (mm) Center of Gravity (mm) YCAL YCAL 0114 2017 1144 1053 0114 2055 1140 1105 0124 2017 1144 1053 0124 2054 1140 1105 JOHNSON CONTROLS...

  • Page 66: Pre-Startup Checklist

     3. Program/verify the Cooling Setpoints, Program Setpoints, and unit Options. Record the values  7. Check the control panel to ensure it is free of below (see sections on Setpoints and Unit Keys foreign material (wires, metal chips, etc.). for programming instruction). JOHNSON CONTROLS...

  • Page 67: Initial Startup

    ON position. As each compressor cycles on, will clear and there should be a solid column of ensure that the discharge pressure rises and liquid when the TxV stabilizes. JOHNSON CONTROLS...
  • Page 68 The superheat should be checked cycle to control water temperature to setpoint, the chiller only after steady state operation of the chiller has been is ready to be placed into operation. JOHNSON CONTROLS...

  • Page 69: Unit Operating Sequence

    4. Several seconds after the compressor starts, that to run until the suction pressure falls below the suc- systems first condenser fan will be cycled on (out- tion pressure cutout or for 180 seconds, whichever comes first. JOHNSON CONTROLS...
  • Page 70 A Master ON/Off switch is available to activate or deac- +30VDC to supply the flow switch, PWM remote tem- tivate the unit. perature reset, and demand limit circuitry which is avail- able to be used with field supplied contacts. JOHNSON CONTROLS...
  • Page 71 “greater than” (>) or “less than” (<). These characters Status messages fall into the categories of General indicate the actual values are greater than or less than Status and Fault Status. the limit values which are being displayed. JOHNSON CONTROLS...
  • Page 72 13 and 14 of Terminal block CTb1. A 3-second delay is built into the software to prevent nuisance shutdowns due to erroneous signals on the run permissive input. JOHNSON CONTROLS...
  • Page 73 This message is displayed when the system is unable drops to 85% of the unload pressure and 10 minutes to start due the anti-recycle timer being active. have elapsed. JOHNSON CONTROLS...
  • Page 74 If at any time during this 3 minutes the suction pres- the suction pressure decreases to the suction pressure sure falls below the ramped cutout point, the system cutout setpoint or runs for 180 seconds, whichever will stop. comes first, the compressor will cycle off. JOHNSON CONTROLS...
  • Page 75 Ad- ditionally, the system will be locked out. safety is only active when EEV is selected as the ex- pansion valve in SERVICE Mode. This safety is ignored for the first 15 seconds of system runtime. JOHNSON CONTROLS...
  • Page 76 Restart can occur when chilled liquid tem- lost and the unit will be prevented from running on the perature rises 2°F above the cutout. next power interruption. The RTC/battery is located at U17 on the microboard. JOHNSON CONTROLS...

  • Page 77: Status Key

    System X AR Timer System X Sensor Failure (Optional EEV only) System X AC Timer System X Disch Limiting System X Suction Limiting System X Percentage Load Limiting Manual Overide Status LD07380 System X Pumping Down (on shutdown) JOHNSON CONTROLS...

  • Page 78: Display/Print Keys

    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). With the “UNIT TYPE” set as a liquid chiller (via no jumper between J4-11 and J4-6 on the microboard), JOHNSON CONTROLS...
  • Page 79 . x ° F / M The COOLING DEMAND message will be replaced with this message when Leaving Chilled liquid control is selected. This message indicates the temperature error and the rate of change of the chilled liquid tem- perature. JOHNSON CONTROLS...
  • Page 80 NONE – no remote control active. Remote monitoring is no message pertaining to the hot gas solenoid when may be via ISN. system 2 message is displayed. ISN – York Talk via ISN allows remote load limiting and temperature reset through an ISN system. JOHNSON CONTROLS...
  • Page 81 Individual displays will be present for each system, if CURRENT FEEDbACK ONE PER SYSTEM is pro- See the section on Condenser Fan Control in the UNIT grammed under the OPTIONS Key. Combined com- OPERATION section for more information. pressor current for each system is displayed. JOHNSON CONTROLS...
  • Page 82 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 83 NUMBER OF COMPRESSORS NUMBER OF FANS PER SYSTEM UNIT TRIP VOLTS See Service And Troubleshooting section REFRIGERANT TYPE R-22 REMOTE UNIT ID PROGRAMMED for Printer Installation information. UNIT DATA RETURN LIQUID TEMP 58.2 DEGF LEAVING LIQUID TEMP 53.0 DEGF JOHNSON CONTROLS...
  • Page 84 Daily Schedule is not printed in the C . M M C . 0 4 . 0 1 YORK INTERNATIONAL CORPORATION MILLENNIUM LIQUID CHILLER SAFETY SHUTDOWN NUMBER 1 SHUTDOWN @ 3:56PM 29 JAN 02 SYS 1 HIGH DSCH PRESS SHUTDOWN SYS 2 NO FAULTS JOHNSON CONTROLS...
  • Page 85 P R E S S U R E P R E S S U R E = P S I G Displays the type of fan control; Discharge Pressure or Ambient and Discharge Pressure. This message will not be displayed on YCAL0090 – YCAL0124. JOHNSON CONTROLS...
  • Page 86 Hot Gas Solenoid was energized at the time of the fault. A C T I v E R E M O T E C T R L x x x x Displays whether Remote Chiller Control was active when the fault occurred. JOHNSON CONTROLS...
  • Page 87 COMPS RUNNING x through SYS x AMPS = xxx.x VOLTS = X.X will be displayed first, followed by displays for System 2. Further explanation of the above displays is covered un- der the STATUS, OPER DATA, COOLING SETPOINTS, PROGRAM, and OPTIONS keys. JOHNSON CONTROLS...

  • Page 88: "Entry" Keys

    Programming and a description on the use of the UP The UP and DOWN arrow keys are also used for pro- and DOWN arrow and ENTER/ADV keys are covered gramming the control panel such as changing numerical in detail under the SETPOINTS, and UNIT keys. JOHNSON CONTROLS...

  • Page 89: "Setpoints" Keys

    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 90 + / - 2 . 0 ° F it may be changed by using the UP and DOWN arrow keys until correct. Pressing the ENTER/ADV key will (leaving chilled liquid control) enter the times and then move the cursor to the minute JOHNSON CONTROLS...
  • Page 91 ENTER/ADV key to enter Program Mode. Continuing S T O P 0 0 : 0 0 to press the ENTER/ADV key will display each oper- ating parameter. While a particular parameter is being displayed, the UP and DOWN arrow keys can be used JOHNSON CONTROLS...
  • Page 92 Restart will be permitted when below 160 PSIG. This assures discharge the leaving chilled liquid temperature rises 2°F (1.11°C) pressure does not drop too low. above the cutout setpoint. JOHNSON CONTROLS...
  • Page 93 (See page line. ID 0-7 is selectable. 86) can be programmed. It also calibrates the current readout under the OPER DATA key. The approximate programmed value is calculated using the following formulas: JOHNSON CONTROLS...
  • Page 94 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 95 Reset Setpoint Anti-Recycle Timer Fan Control On-Pressure Fan Differential Off-Pressure Total Numbers Compressors Number of Fans Per System YCAL0090 - 0124 ONLY SYS / Unit Trip Volts Option Remote Unit ID SYS 1 & 2 Superheat Setpoints LD07404 JOHNSON CONTROLS...
  • Page 96 The chilled liquid is glycol. The Cooling Setpoint can be programmed from 10°F to 70°F (-12.2°C to 21.1°C). S Y S S w I T C H S Y S S w I T C H O F F This turns system 2 off JOHNSON CONTROLS...
  • Page 97 L E A v I N G L I Q U I D cannot be reprogrammed. Unit control is based on leaving chilled liquid temp. Refer to section on Capacity Control for details on load- ing and unloading sequences. JOHNSON CONTROLS...
  • Page 98 YCAL0064-0080 YCAL0114-0124 Option 12 – Soft Start Enable/Disable: x = Compressors with soft start S O F T S T A R T E N A b L E D Control Panel End JOHNSON CONTROLS...
  • Page 99 T H E R M O S T A T I C Expansion valve type, thermostatic or electronic may be selected under Service Mode. Expansion valve type is displayed under the Options key, but is only pro- grammable in Service Mode. Incorrect programming may cause damage to compressors. JOHNSON CONTROLS...

  • Page 100: Unit Keys

    Table 23 provides a quick reference list for the Unit key setpoints. TAbLE 23 – 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 JOHNSON CONTROLS...

  • Page 101: Unit Operation

    10°F to 70°F (-12.2°C to 21.1°C) in glycol chilling This control is only applicable if optional discharge pres- mode. In both modes, the cooling range can be from sure transducers are installed. +/-1.5°F to +/-2.5°F (+/-.83°C to 1.39°C). JOHNSON CONTROLS...

  • Page 102: Setpoint Adjust

    Return Chilled Liquid Control MUST and from 10°F to 70°F (-12.2°C to 21.1°C) in glycol chilling mode. In both modes, the cooling range can be only be used when constant chilled from 4°F to 20°F (2.2° to 11.1°C). liquid flow is ensured. JOHNSON CONTROLS...

  • Page 103: Compressor Staging For Return Water Control

    NOTES: 1. Step 1 is Hot Gas bypass and is skipped when loading occurs. Hot Gas bypass operation is inhibited during Pumpdown. 2. Step 3 is skipped when loading occurs. 3. Step 4 is skipped when unloading occurs. JOHNSON CONTROLS...
  • Page 104 If Soft Start is enabled on European models with this option, compressor lead/lag will function as outlined in The evaporator pump dry contacts (CTb2 – terminals Option 12 under the Options key. 23 - 24) are energized when any of the following con- ditions are true: JOHNSON CONTROLS...
  • Page 105 As the superheat gets smaller, the proportional gain gets smaller. The output of the PI controller may be viewed on the JOHNSON CONTROLS...
  • Page 106 Table 28. The fan control on-pressure and programming does not match installed fan differential off-pressure are programmable under hardware. the PROGRAM key. CONDENSER FAN CONTROL (YCAL0090 – YCAL0124) YCAL0090 - YCAL0124 fan control will be by discharge pressure only. See Tables 30 - 31. JOHNSON CONTROLS...

  • Page 107: Ycal0014 - Ycal0080 Condenser Fan Control Using

    * NOTE: STEP 2 is not active in the “Standard Ambient” mode. When changing to “Low Ambient” control, fan power wiring also changes. Fan #4 Fan #3 Fan #1 LD07403 Fan #2 FIG. 9 – YCAL0014 – YCAL0080 FAN LOCATION (TYPICAL) JOHNSON CONTROLS...

  • Page 108: Ycal0014 - Ycal0080 Low Ambient Condenser Fan Control

    1 & 3 2 & 4 2 FANS FWD 40 PSIG (2.76 Bars) [Diff. Press. + 40 PSIG (2.76 Bars)] NOTE: When low ambient control of the fans is selected, fan control will be by discharge pressure only. JOHNSON CONTROLS...

  • Page 109: Ycal0090 - Ycal0094 Condenser Fan Control

    [(Diff. Press.) + 40 PSIG (2.76 Bars)] & 9M & 13M & 5 & 9 & 5 & 6 FAN #5 FAN #3 FAN #6 FAN #1 LD07828 FAN #2 FAN #4 FIG. 10 – YCAL0104 – YCAL0104 FAN LOCATION JOHNSON CONTROLS...

  • Page 110: Ycal0114 - Ycal0124 Condenser Fan Control

    [(Diff. Press.) + 60 PSIG (4.14 Bars)] 9M, 10M 13M, 14M & 5 & 9 5, 7 6, 8 FAN #7 FAN #5 FAN #3 FAN #1 FAN #8 FAN #2 FAN #6 FAN #4 LD07829 FIG. 11 – YCAL0114 – YCAL0124 FAN LOCATION JOHNSON CONTROLS...
  • Page 111 FORM 150.62-NM6 (103) This page intentionally left blank . JOHNSON CONTROLS...

  • Page 112: Compressor Operation - Load Limiting

    40% or 33% and is only available on 3, 5 & 6 compressor units. Table 32 shows the load limiting per- mitted for the various number of compressors. TAbLE 32 – COMPRESSOR OPERATION – LOAD LIMITING COMPRESSORS IN UNIT STAGE 1 STAGE 2 – – JOHNSON CONTROLS...
  • Page 113 = 7.22°C + 6.67°C = 13.89°C * Max Reset Value is the “Max EMS-PWM Remote Temp. Reset” setpoint value described in the programming section under COOLING SETPOINTS. Programmable values are from 2°F to 40°F (1.11°C to 22.22°C). JOHNSON CONTROLS...

  • Page 114: Optional Remote Temperature Reset Board

    Use YORK PN031­00808­000 suppres sor. * 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 115 Pressing the UP Arrow key will energize the liquid line solenoid valve and OFF will change to ON in the display After pressing the key sequence as described, the as the LLSV is energized. control will enter Service Mode permitting the outputs (except compressors), operating hours, refrigerant JOHNSON CONTROLS...

  • Page 116: Service Mode - Chiller Configuration

    All input and output connections SYS 1**** SUCTION TEMP. pertain to the connections at the microboard. SYS 2**** SUCTION TEMP. AMBIENT AIR TEMP. Figure 13 illustrates the physical connections on the microboard. LEAVING LIQUID TEMP. JOHNSON CONTROLS...

  • Page 117: Microboard Digital Inputs

    SYS 2 DISCHARGE PRESSURE TRANSDUCER (optional) J8-5 UNIT/SYS 1 VOLTAGE J8-6 SYS 2 VOLTAGE The 30 dc unregulated supply is not an input. This voltage originates on the microboard and is used to supply the contacts for the digital inputs. JOHNSON CONTROLS...

  • Page 118: Microboard Layout

    Service and Troubleshooting FORM 150.62-NM6 (103) REAL TIME CLOCK/ bATTERY CLK ON/OFF JUMPER 00770VIP FIG. 13 – MICRObOARD LAYOUT JOHNSON CONTROLS...
  • Page 119 Outside Air Sensor J6-4 = +5VDC regulated supply to sensor. J6-7 = VDC input signal to the microboard. See Table 37 for voltage readings that correspond to specific outdoor temperatures. J6-1 = drain (shield connection = 0VDC) JOHNSON CONTROLS...
  • Page 120 3.27 7017 3.33 6647 3.39 6298 3.45 5970 3.51 5661 3.56 5370 3.61 5096 3.67 4837 3.72 4593 3.76 4363 3.81 4145 3.86 3941 3.90 3747 3.94 3564 3.98 3392 4.02 3228 4.06 3074 4.10 2928 4.13 2790 JOHNSON CONTROLS...
  • Page 121 400 PSIG (27.5 bARG) range. Following is the J7-9 = drain (shield connection = 0VDC) formula that can be used to verify the voltage output of the transducer. All voltage reading are in reference to ground (unit case). JOHNSON CONTROLS...

  • Page 122: Microboard Relay Contact Architecture

    J7-5 = +5VDC regulated supply to LP switch. J7-10 = input signal to the microboard. 0VDC = open switch / +5VDC = closed switch. FIG. 14 – MICRObOARD RELAY CONTACT J7-2 = drain (shield connection = 0VDC) ARCHITECTURE JOHNSON CONTROLS...

  • Page 123: Keypad Pin Assignment Matrix

    “button” being checked is pressed and a reading of zero ohms should be observed. After releasing the “button,” the resistance value should be infinite (open circuit). Pin 1 is usually identified by a stripe on the ribbon cable. JOHNSON CONTROLS...

  • Page 124: Optional Printer Installation

    “OPER DATA” listed, or ordered directly from WEIGH-TRONIx under part number 287-040018. key or “HISTORY” key. LD03843 FIG. 15 – PRINTER TO MICRObOARD ELECTRICAL CONNECTIONS JOHNSON CONTROLS...
  • Page 125 13 and 14 of the CTB1 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 filter dryer. 3. Change dryer/core. CONT’D JOHNSON CONTROLS...
  • Page 126 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 127 2. Improper flow through the 2. Reduce flow 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 128 CONDENSER FAN MOTORS to ensure proper equipment operation. Items such as loose hardware, component operation, refrigerant leaks, Condenser fan motors are permanently lubricated and unusual noises, etc. should be investigated and cor- require no maintenance. rected immediately. JOHNSON CONTROLS...

  • Page 129: Isn Control

    SYS 1 Hot Gas bypass Valve Digital SYS 1 Comp 2 Run Digital SYS 2 Comp 2 Run Digital SYS 2 Liquid Line Solenoid Valve or EEV Pilot Solenoid Digital Lead System (0=SYS 1, 1=SYS 2) Digital SYS 1 Comp 3 Run JOHNSON CONTROLS...
  • Page 130 Coded SYS 1 Condenser Fan Stage Digital –– Coded –– Digital –– Coded SYS 2 Condenser Fan Stage Digital –– Coded –– Digital –– Coded Unit Control Mode (0=Leaving Water, 1=Return Water, 2=Discharge Air, 3=Suction Press., 4=Cooling, 5=Heating) JOHNSON CONTROLS...
  • Page 131 The operational and fault codes sent to pages 56 through 59 are defined in Table 43. Note that this table of fault and operational codes is for all Dx products. The codes that are grayed out are not used on all units. JOHNSON CONTROLS...
  • Page 132 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0014E_ – YCAL0030E_ LD08850 FIG. 16 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0014E_ - YCAL0030E_ JOHNSON CONTROLS...
  • Page 133 FORM 150.62-NM6 (103) LD08851 JOHNSON CONTROLS...
  • Page 134 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0014E_ – YCAL0030E_ LD08852 FIG. 17 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0014E_ - YCAL0030E_ JOHNSON CONTROLS...
  • Page 135 FORM 150.62-NM6 (103) This page intentionally left blank. JOHNSON CONTROLS...
  • Page 136 Diagrams FORM 150.62-NM6 (103) CONNECTION DIAGRAM YCAL0014E_ AND YCAL0030E_ LD08854 FIG. 18 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0014E_ - YCAL0030E_ JOHNSON CONTROLS...
  • Page 137 FORM 150.62-NM6 (103) LD08855 JOHNSON CONTROLS...
  • Page 138 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0014E_ AND YCAL0030E_ LD08856 FIG. 19 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0014E_ - YCAL0030E_ JOHNSON CONTROLS...
  • Page 139 FORM 150.62-NM6 (103) This page intentionally left blank. JOHNSON CONTROLS...
  • Page 140 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0034E_ LD08857 FIG. 20 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0034E_ JOHNSON CONTROLS...
  • Page 141 FORM 150.62-NM6 (103) LD08858 JOHNSON CONTROLS...
  • Page 142 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0034E_ LD08859 FIG. 21 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0034E_ JOHNSON CONTROLS...
  • Page 143 FORM 150.62-NM6 (103) This page intentionally left blank. JOHNSON CONTROLS...
  • Page 144 Diagrams FORM 150.62-NM6 (103) CONNECTION DIAGRAM YCAL0034E_ LD08861 FIG. 22 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0034E_ JOHNSON CONTROLS...
  • Page 145 FORM 150.62-NM6 (103) LD08862 JOHNSON CONTROLS...
  • Page 146 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0034E_ LD08863 FIG. 23 – ELEMENTARY DIAGRAM, MIDLLE MARKET – YCAL0034E_ JOHNSON CONTROLS...
  • Page 147 FORM 150.62-NM6 (103) This page intentionally left blank. JOHNSON CONTROLS...
  • Page 148 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0040E_ – YCAL0060E_ LD08864 FIG. 24 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0040E_ - YCAL0060E_ JOHNSON CONTROLS...
  • Page 149 FORM 150.62-NM6 (103) LD08865 JOHNSON CONTROLS...
  • Page 150 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0040E_ – YCAL0060E_ LD08866 FIG. 25 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0040E_ - YCAL0060E_ JOHNSON CONTROLS...
  • Page 151 FORM 150.62-NM6 (103) LD08867 JOHNSON CONTROLS...
  • Page 152 Diagrams FORM 150.62-NM6 (103) CONNECTION DIAGRAM YCAL0040E_ – YCAL0060E_ LD08868 FIG. 26 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0040E_ - YCAL0060E_ JOHNSON CONTROLS...
  • Page 153 FORM 150.62-NM6 (103) LD08869 JOHNSON CONTROLS...
  • Page 154 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0040E_ – YCAL0060E_ LD08870 FIG. 27 – ELEMENTARY DIAGRAM, MIDLLE MARKET – YCAL0040E_ - YCAL0060E_ JOHNSON CONTROLS...
  • Page 155 FORM 150.62-NM6 (103) This page intentionally left blank. JOHNSON CONTROLS...
  • Page 156 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0064E_ – YCAL0080E_ LD08871 FIG. 28 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0064E_ - YCAL0080E_ JOHNSON CONTROLS...
  • Page 157 FORM 150.62-NM6 (103) LD08872 JOHNSON CONTROLS...
  • Page 158 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0064E_ – YCAL0080E_ LD08876 FIG. 29 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0064E_ - YCAL0080E_ JOHNSON CONTROLS...
  • Page 159 FORM 150.62-NM6 (103) LD08877 JOHNSON CONTROLS...
  • Page 160 Diagrams FORM 150.62-NM6 (103) CONNECTION DIAGRAM YCAL0064E_ – YCAL0080E_ LD08873 FIG. 30 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0064E_ - YCAL0080E_ JOHNSON CONTROLS...
  • Page 161 FORM 150.62-NM6 (103) LD08874 JOHNSON CONTROLS...
  • Page 162 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0064E_ – YCAL0080E_ LD08875 FIG. 31 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0064E_ - YCAL0080E_ JOHNSON CONTROLS...
  • Page 163 FORM 150.62-NM6 (103) This page intentionally left blank. JOHNSON CONTROLS...
  • Page 164 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0090E_ – YCAL0094E_ LD08829 FIG. 32 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0090E_ - YCAL0094E_ JOHNSON CONTROLS...
  • Page 165 FORM 150.62-NM6 (103) LD08830 JOHNSON CONTROLS...
  • Page 166 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0090E_ – YCAL0094E_ LD08832 FIG. 33 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0090E_ - YCAL0094E_ JOHNSON CONTROLS...
  • Page 167 FORM 150.62-NM6 (103) LD08833 JOHNSON CONTROLS...

  • Page 168: Connection Diagram (Ycal0090E_ - Ycal0094E_)

    Diagrams FORM 150.62-NM6 (103) CONNECTION DIAGRAM YCAL0090E_ – YCAL0094E_ LD08834 FIG. 34 – CONNECTION DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE – YCAL0090E_ - YCAL0094E_ JOHNSON CONTROLS...
  • Page 169 FORM 150.62-NM6 (103) LD08835 JOHNSON CONTROLS...
  • Page 170 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0090E_ – YCAL0094E_ LD08831 FIG. 35 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0090E_ - YCAL0094E_ JOHNSON CONTROLS...
  • Page 171 FORM 150.62-NM6 (103) This page intentionally left blank. JOHNSON CONTROLS...
  • Page 172 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0104E_ LD08836 FIG. 37 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0104E_ JOHNSON CONTROLS...
  • Page 173 FORM 150.62-NM6 (103) LD08837 JOHNSON CONTROLS...
  • Page 174 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0104E_ LD08839 FIG. 38 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0104E_ JOHNSON CONTROLS...
  • Page 175 FORM 150.62-NM6 (103) LD08840 JOHNSON CONTROLS...

  • Page 176: Connection Diagram (Ycal0104E_)

    Diagrams FORM 150.62-NM6 (103) CONNECTION DIAGRAM YCAL0104E_ LD08841 FIG. 39 – CONNECTION DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE – YCAL0104E_ JOHNSON CONTROLS...
  • Page 177 FORM 150.62-NM6 (103) LD08842 JOHNSON CONTROLS...
  • Page 178 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0104E_ LD08838 FIG. 40 – ELEMENTARY DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE– YCAL0104E_ JOHNSON CONTROLS...
  • Page 179 FORM 150.62-NM6 (103) This page intentionally left blank. JOHNSON CONTROLS...
  • Page 180 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0114E_ – YCAL0124E_ LD08843 FIG. 41 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0114E_ - YCAL0124E_ JOHNSON CONTROLS...
  • Page 181 FORM 150.62-NM6 (103) LD08844 JOHNSON CONTROLS...
  • Page 182 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0114E_ – YCAL0124E_ LD08846 FIG. 42 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0114E_ - YCAL0124E_ JOHNSON CONTROLS...
  • Page 183 FORM 150.62-NM6 (103) LD08847 JOHNSON CONTROLS...
  • Page 184 Diagrams FORM 150.62-NM6 (103) CONNECTION DIAGRAM YCAL0114E_ – YCAL0124E_ LD08848 FIG. 43 – CONNECTION DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE – YCAL0114E_ - YCAL0124E_ JOHNSON CONTROLS...
  • Page 185 FORM 150.62-NM6 (103) LD08849 JOHNSON CONTROLS...
  • Page 186 Diagrams FORM 150.62-NM6 (103) ELEMENTARY DIAGRAM YCAL0114E_ – YCAL0124E_ LD08845 FIG. 44 – ELEMENTARY DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE – YCAL0114E_ - YCAL0124E_ JOHNSON CONTROLS...
  • Page 187 FORM 150.62-NM6 (103) This page intentionally left blank. JOHNSON CONTROLS...
  • Page 188 AEqM-1300 AEqM-1600 AEqM-1300 AEqM-1300 0094 AEqM-1600 AEqM-1600 AEqM-1300 AEqM-1600 AEqM-1300 AEqM-1300 0104 AEqM-1600 AEqM-1300 AEqM-1000 AEqM-1000 AEqM-1600 AEqM-1300 AEqM-1000 AEqM-1000 0114 AEqM-1625 AEqM-1600 AEqM-1300 AEqM-1000 AEqM-1625 AEqM-1600 AEqM-1300 AEqM-1000 0124 AEqM-1625 AEqM-1600 AEqM-1300 AEqM-1000 AEqM-1625 AEqM-1600 AEqM-1300 AEqM-1000 JOHNSON CONTROLS...
  • Page 189 -3 Gray -3 Grn 0114 -4 Red -4 blk -3 Gray -3 Gray -4 Red -4 blk -3 Gray -3 Gray 0124 -4 Red -4 blk -3 Gray -3 Gray -4 Red -4 blk -3 Gray -3 Gray JOHNSON CONTROLS...
  • Page 190 —- —- 0094 AEqM-1600 AEqM-1600 AEqM-1600 AEqM-1600 AEqM-1600 AEqM-1600 —- —- 0104 AEqM-1625 AEqM-1600 AEqM-1300 AEqM-1000 AEqM-1600 AEqM-1300 AEqM-1300 AEqM-1000 0114 AEqM-1625 AEqM-1625 AEqM-1600 AEqM-1300 AEqM-1625 AEqM-1600 AEqM-1300 AEqM-1000 0124 AEqM-1625 AEqM-1625 AEqM-1600 AEqM-1300 AEqM-1625 AEqM-1600 AEqM-1300 AEqM-1000 JOHNSON CONTROLS...
  • Page 191 -3 Gray -3 Gray 0114 -4 Red -4 blk -4 blk -3 Gray -4 Red -4 blk -4 blk -3 Gray 0124 -4 Red -4 blk -4 blk -3 Gray -4 Red -4 blk -4 blk -3 Gray JOHNSON CONTROLS...
  • Page 192 GREEN AEQM-97 301055-97 WHITE CP-1-31 308439-31 GRAY AEQM-98 301055-98 GRAY CP-2-25 308439-25 AEQM-1000 30106-1000 GREEN CP-2-26 308692-26 PURPLE AEQM-1300 30106-1300 YELLOW CP-2-27 308962-27 ORANGE AEQM-1600 301060-1600 GRAY CP-2-28 308692-28 GREEN AEQM-1625 301060-1625 CP-2-31 308692-31 GRAY AEQM-1628 301060-1628 GRAY/GREEN JOHNSON CONTROLS...
  • Page 193 AEQM-99 5-1/2 4-1/2 2-1/2 7-1/4 AEQM-1000 8-1/2 6-1/2 4-1/2 8-3/8 AEQM-1300 8-1/2 6-1/2 4-1/2 8-3/8 AEQM-1600 8-1/2 6-1/2 4-1/2 8-3/8 AEQM-1625 8-1/2 6-1/2 4-1/2 8-3/8 AEQM-1628 8-1/2 6-1/2 4-1/2 8-3/8 LD04045 FIG. 36 – R SPRING SEISMIC ISOLATOR JOHNSON CONTROLS...

  • Page 194: Type Cp Mounting

    This completes adjustment. 4. Set the machine or base on the mountings. The weight of the machine will cause the upper housing LD03837 FIG. 37 – TYPE CP MOUNTING JOHNSON CONTROLS...

  • Page 195: Aeqm" Spring-Flex Mounting

    “A”. A 1/4" maximum difference in ele- vation can be tolerated. 10. Tighten cap screw “C”. Adjustment is complete. Anchor all isolators to floor or subbase as required. For installing on concrete VMC recommends HILTI LD03838 FIG. 38 – “AEqM” SPRING-FLEx MOUNTING JOHNSON CONTROLS...
  • Page 196 P.O. box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA Copyright © by Johnson Controls, Inc. www.johnsoncontrols.com ALL RIGHTS RESERVED Form 150.62-NM6 (103) New Release...

  • Page 197: Single-Point Power Supply Connections

    Form Number: 150.62-NM6 (LS01) Supercedes: None LITERATURE SUPPLEMENT File with: 150.62-NM6 (103) Subject: Added YCAL0134 Model, Updated Electrical Data, Physical Data, and Isolator Selection For YCAL0134 model wiring diagrams, refer to 150.62-NM6. Diagrams for YCAL0014- YCAL0124 are also valid for YCAL0134. SINGLE-POINT POWER SUPPLY CONNECTIONS –...
  • Page 198 FORM 150.62-NM6 (LS1) ELECTRICAL DATA – DUAL POINT POWER SUPPLY CONNECTIONS – YCAL0040E_ - YCAL0080E_ (Two Field Provided Power Supply Circuits to the chiller. Field connections to Factory Provided Terminal Blocks per system) TABLE 3 – DUAL POINT POWER SUPPLY CONNECTIONS SYSTEM #1 FIELD SUPPLIED WIRING INCOMING (LUGS) WIRE RANGE SYSTEM #1 COMPRESSOR &...
  • Page 199 FORM 150.62-NM6 (LS1) SYSTEM #2 FIELD SUPPLIED WIRING INCOMING (LUGS) WIRE RANGE SYSTEM #2 COMPRESSOR & FAN COMPR. #1 COMPR. #2 COMPR. #3 FANS D.E. FUSE CKT. BKR. TERMINAL NF DISC. CIRCUIT DISC BLOCK SWITCH BREAKER LRA RLA LRA QTY FLA(EA) (std) (opt) (opt)
  • Page 200 FORM 150.62-NM6 (LS1) ELECTRICAL DATA – SINGLE POINT POWER SUPPLY CONNECTIONS – YCAL0040E_ - YCAL0080E_ (One Field Provided Power Supply Circuit to the chiller. Field connections to Factory Provided Terminal Block (optional), Non-Fused Discon- nect Switch (optional) or Circuit Breaker (optional).) TABLE 4 –...
  • Page 201 FORM 150.62-NM6 (LS1) SYSTEM #1 COMPRESSOR & FAN SYSTEM #2 FIELD SUPPLIED WIRING COMPR. #1 COMPR. #2 COMPR. #3 FANS COMPR. #1 COMPR. #2 COMPR. #3 FANS FLA(EA) FLA(EA) 37.4 37.4 — — 37.4 37.4 — — 34.6 34.6 — —...
  • Page 202 FORM 150.62-NM6 (LS1) ELECTRICAL DATA – MULTIPLE POINT POWER SUPPLY CONNECTIONS – YCAL0090E_ - YCAL0134E_ Two Field Provided Power Supply Circuits to the chiller. Field connections to Factory Provided Terminal Blocks (standard), Non-Fused Discon- nect Switches (optional), or Individual System Circuit Breakers (optional) per electrical system TABLE 5 –...
  • Page 203 FORM 150.62-NM6 (LS1) SYSTEM #1 COMPRESSOR & FAN COMPR. #1 COMPR. #2 COMPR. #3 FANS FLA(EA) 87.2 87.2 — — 80.8 80.8 — — 46.6 46.6 — — 38.5 38.5 — — 30.8 30.8 — — 87.2 87.2 — — 80.8 80.8 —...
  • Page 204 FORM 150.62-NM6 (LS1) ELECTRICAL DATA – SINGLE POINT POWER SUPPLY CONNECTIONS WITH INDIVIDUAL SYSTEM CIRCUIT BREAKERS – YCAL0090E_ - YCAL0134E_ One Field Provided Power Supply Circuit to the chiller. Field connections to Factory Provided Terminal Block (optional) or Non-Fused Discon- nect Switch (optional).
  • Page 205 FORM 150.62-NM6 (LS1) SYSTEM #1 COMPRESSOR & FAN SYSTEM #2 FIELD SUPPLIED WIRING COMPR. #1 COMPR. #2 COMPR. #3 FANS COMPR. #1 COMPR. #2 COMPR. #3 FANS FLA(EA) FLA(EA) 87.2 87.2 — — 69.4 69.4 — — 80.8 80.8 — —...
  • Page 206 FORM 150.62-NM6 (LS1) PHYSICAL DATA (ENGLISH) YCAL0014E_ - YCAL0134E_ TABLE 15 – PHYSICAL DATA (ENGLISH) Model Number YCAL 0014 0020 0024 0030 0034 0040 0042 0044 General Unit Data Nominal Tons, R-22 13.2 18.0 22.4 28.3 34.0 38.7 42.9 47.1 Nominal Tons, R-407C 12.7 17.4...

  • Page 207: Physical Data (English)

    FORM 150.62-NM6 (LS1) PHYSICAL DATA (ENGLISH) YCAL0014E_ - YCAL0134E_ Model Number YCAL 0050 0060 0064 0070 0074 0080 0090 0094 0104 0114 0124 0134 51.1 56.2 63.1 70.2 76.0 82.2 83.2 89.9 99.6 111.1 121.0 130.3 48.1 53.3 58.9 65.7 71.6 78.0 79.6...
  • Page 208 FORM 150.62-NM6 (LS1) PHYSICAL DATA (METRIC) YCAL0014E_ - YCAL0134E_ Model Number YCAL 0014 0020 0024 0030 0034 0040 0042 0044 General Unit Data Nominal kW, R-22 46.4 63.3 78.8 99.5 119.6 136.1 150.9 165.7 Nominal kW, R-407C 44.7 61.2 76.3 93.9 111.5 127.7...
  • Page 209 FORM 150.62-NM6 (LS1) PHYSICAL DATA (METRIC) YCAL0014E_ - YCAL0124E_ Model Number YCAL 0050 0060 0064 0070 0074 0080 0090 0094 0104 0114 0124 0134 179.7 197.7 221.9 246.9 267.3 289.1 292.6 316.2 350.3 390.7 425.6 457.9 169.2 187.5 207.2 231.1 251.8 274.3 280.0...
  • Page 210 FORM 150.62-NM6 (LS1) APPENDIX 1 – ISOLATOR SELECTIONS ALUMINUM FIN COILS 1” DEFLECTION ISOLATOR SELECTION - VMC TYPE YCAL 0014 CP-1-27 CP-1-26 CP-1-28 CP-1-27 0020 CP-1-27 CP-1-26 CP-1-28 CP-1-27 0024 CP-1-28 CP-1-27 CP-1-28 CP-1-28 0030 CP-1-28 CP-1-27 CP-1-28 CP-1-28 0034 CP-1-28 CP-1-28 CP-1-31...
  • Page 211 FORM 150.62-NM6 (LS1) APPENDIX 1 – ISOLATOR SELECTIONS ALUMINUM FIN COILS - CON'D NEOPRENE ISOLATOR SELECTION - VMC TYPE RD YCAL 0014 -3 Grn -2 Gray -3 Gray -3 Grn 0020 -3 Grn -2 Gray -3 Gray -3 Grn 0024 -3 Gray -3 Grn -3 Gray...
  • Page 212 FORM 150.62-NM6 (LS1) APPENDIX 1 – ISOLATOR SELECTIONS COPPER FIN COILS 1" DEFLECTION ISOLATOR SELECTION - VMC TYPE Model YCAL 0014 CP-1-27 CP-1-27 CP-1-27 CP-1-27 —- —- —- —- 0020 CP-1-27 CP-1-27 CP-1-27 CP-1-27 —- —- —- —- 0024 CP-1-27 CP-1-27 CP-1-27 CP-1-27...
  • Page 213 FORM 150.62-NM6 (LS1) APPENDIX 1 – ISOLATOR SELECTIONS COPPER FIN COILS - CON'D NEOPRENE ISOLATOR SELECTION - VMC TYPE Copper Fin, Neoprene Mount Selections VMC Type RD YCAL 0014 -3 Grn -3 Grn -3 Gray -3 Grn 0020 -3 Grn -3 Grn -3 Gray -3 Grn...
  • Page 214 FORM 150.62-NM6 (LS1) DIMENSIONS - YCAL0114 - YCAL0134 (ENGLISH) 3/4" DIA. MOUNTING HOLES (TYP.) 1 1/4 19 1/8" POWER PANEL POWER PANEL 88 1/4" CONTROL PANEL CONTROL PANEL 50" * 1 1/4 * 63" for -17 and -28 voltage panels ORIGIN 22 3/4"...
  • Page 215 FORM 150.62-NM6 (LS1) DIMENSIONS - YCAL0114 - YCAL0134 (METRIC) 3/4" DIA. MOUNTING HOLES (TYP.) POWER PANEL 2241 CONTROL PANEL 1270 * * 1600 for -17 and -28 voltage panels ORIGIN 22 3/4" 1499 1499 VIEW D-D 2323 2438 8" 8" WATER OUTLET WATER INLET (4) 76 X 76...
  • Page 216 P.O. Box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA Copyright © by York International Corporation 2003 www.york.com ALL RIGHTS RESERVED Form 150.62-NM6 (LS1) New Release...

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