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229

JOHNSON CONTROLS

SECTION 10 – MAINTENANCE

FORM 150.67-NM1

ISSUE DATE: 4/28/2017

NOTES

Main Page

Default Chapter5
- Table of Contents5
Section 1 – General Chiller Information and Safety15
- Responsibility for Safety16
- Pressure Systems17
FIGURE 1 - YCAL Air-Cooled Scroll Chillers19
Section 2 – Product Description19
- Condenser20
- Unit On/Off Switch21
  - Discharge Pressure Transducers and Readout Capability22
- Accessories and Options22
- FIGURE 2 - Unit Components Single System Units25
- Unit Components YCAL0019 - 003325
- Control - Power Panel Components YCAL0019-003326
- Unit Components - YCAL0043 - 006627
- Control / Power Panel Components - YCAL0043 - 006628
Section 3 - Handling and Storage35
- Delivery and Storage35
- Inspection35
- Moving the Chiller (YCAL0043 - 0066 Dual System Only)35
  - Lifting Weights35
- Moving the Chiller (YCAL0019 - 0033 Single Circuit Only)35
- Unit Rigging36
  - Lifting Weights36
FIGURE 7 - Unit Rigging/Lifting (YCAL0019 - 0033 Single Circuit Models Only)36
FIGURE 8 - Unit Rigging/Lifting (YCAL0043- 0066 Dual Circuit Models)37
Section 4 - Installation39
- Handling39
- Inspection39
- Installation Checklist39
- Location and Clearances39
  - Ground Level Locations39
  - Rooftop Locations40
  - Noise Sensitive Locations40
- Chilled Liquid Piping40
- Compressor Mounting40
- Remote Cooler Option40
- Spring Isolators (Optional)40
- Duct Work Connection41
  - Field Wiring41
  - FIGURE 9 - Chilled Liquid System41
  - General Requirements41
  - Wiring41
  - FIGURE 10 - Single-Point Supply Connection - Terminal Block, Non-Fused Disconnect Switch or Circuit Breaker44
  - Control Wiring45
- Pipework Arrangement41
- Alarm Status Contacts42
- Evaporator Pump Start Contacts42
- Flow Switch Input42
- Load Limit Input42
- Remote Emergency Cutoff42
- Remote Start/Stop Contacts42
- Remote Temp Reset Input42
- System Run Contacts42
- Compressor Heaters43
- High Pressure Cutout43
- Relief Valves43
- FIGURE 11 - Control Wiring45
- TABLE 1 - Temperatures and Flows47
- TABLE 2 - Voltage Limitations47
- Operational Limitations (SI)50
  - Voltage Limitations50
Section 5 - Technical Data47
- Operational Limitations (English)47
  - Voltage Limitations47
  - TABLE 5 - Ethylene and Propolyne Glycol Correction Factors50
  - TABLE 4 - Voltage Limitations50
  - TABLE 3 - Temperatures and Flows (Si)50
  - TABLE 6 - Physical Data (English)53
  - Electrical Data (English)54
  - TABLE 7 - Electrical Data (English)54
  - TABLE 8 - Micro Panel Power Supply58
  - TABLE 9 - Voltage Range58
  - Electrical Notes and Legend59
- Physical Data (English)53
- FIGURE 12 - Control Wiring Diagram, Single Circuit, Ipu II60
- FIGURE 13 - Control Wiring Diagram, Single Circuit, Ipu II63
- FIGURE 14 - Control Wiring Diagram, Dual Circuit, Ipu II64
- FIGURE 15 - Control Wiring Diagram, Dual Circuit, Ipu II66
- FIGURE 16 - Control Wiring Diagram, Details, Single Circuit68
- FIGURE 17 - Control Wiring Diagram, Details, Dual Circuit70
- FIGURE 18 - Power Wiring, Single Circuit72
- FIGURE 19 - Power Wiring, Single Circuit74
- FIGURE 20 - Power Wiring, Single Circuit76
- FIGURE 21 - Power Wiring, Single Circuit78
- FIGURE 22 - Power Wiring, Dual Circuit80
- FIGURE 23 - Power Wiring, Dual Circuit82
- FIGURE 24 - Connection Wiring, Single Circuit84
- FIGURE 25 - Connection Wiring, Single Circuit86
- FIGURE 26 - Connection Wiring, Single Circuit88
- FIGURE 27 - Connection Wiring, Single Circuit90
- FIGURE 28 - Connection Wiring, Dual Circuit92
- FIGURE 29 - Connection Wiring, Dual Circuit94
- FIGURE 30 - Unit Clearances - All Models132
- General133
- Weight Distribution and Isolator Mounting Positions YCAL0019 - 0033 (Without Pump Package Option)133
  - Isolator Selection134
  - General135
FIGURE 31 - One Inch Deflection Spring Isolator Cross-Reference136
FIGURE 32 - One Inch Deflection Spring Isolators Installation Instructions137
FIGURE 33 - Durulene Isolator Cross-Reference138
FIGURE 34 - Installation of Durulene Vibration Isolators139
FIGURE 35 - Two Inch Deflection Seismic Isolator Cross-Reference140
FIGURE 36 - Seismic Isolator Installation and Adjustment141
FIGURE 37 - One Inch Deflection Spring Isolator Cross-Reference (Cip-X)142
FIGURE 38 - Neoprene Isolator Cross-Reference144
FIGURE 39 - Two Inch Deflection, Seismic Spring Isolator Cross-Reference145
FIGURE 40 - Slrs Seismic Isolator Installation and Adjustment146
Section 6 - Commissioning147
- Commissioning147
- Preparation - Power off147
- Preparation - Power on148
- Equipment Start-Up Checklist149
- Checking Superheat and Subcooling150
- TABLE 10 - Setpoints Entry List150
- Leak Checking151
- Unit Operating Sequence152
Section 7 – Unit Controls153
- Unit Switch154
- Status Key155
- Display/Print Keys161
TABLE 16 - Unit Keys Options Programming Quick Reference List182
Section 8 – Unit Operation183
- FIGURE 42 - Setpoint Adjust184
- Leaving Chilled Liquid Control Override to Reduce Cycling184
- TABLE 20 - YCAL0019 - YCAL0033 Condenser Fan Control Using Discharge Pressure188
- TABLE 23 - YCAL0043 - YCAL0066 Condenser Fan Control Using Discharge Pressure Only189
- YCAL0019-0028 Low Ambient Fan Control Option190
FIGURE 58 - Inverter Wiring199
TABLE 28 - YCAL0043-0066 VFD Low Ambient Option - Condenser Fan Control Operation199
TABLE 29 - Compressor Operation -Load Limiting200
Section 9 – Service and Troubleshooting203
- Service Mode – Chiller Configuration204
- Control Inputs/Outputs205
- TABLE 31 - I/O Digital Outputs205
- TABLE 30 - I/O Digital Inputs205
TABLE 37 - Troubleshooting212
Section 10 – Maintenance215
- Overall Unit Inspection216
  - FIGURE 62 - Micro Panel Connections217
  - Yorktalk 2 Communications223
- Bacnet and Modbus Communications219

York YCAL0022 - Page 229

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