Johnson Controls York VERSECON YSWD Series Owner's manual

035-21989-000
INSTALLATION, OPERATION & MAINTENANCE
VERSECON AIR CONDITIONING UNIT
Supersedes 145.05-NOM1 (1107) Form 145.05-NOM1(708)
MODEL YSWD & YSWU

JOHNSON CONTROLS
2
FORM 145.05-NOM1 (708)
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, materials under pressure, rotating components,
and both high and low voltage. Each of these items
has the potential, if misused or handled improperly, to
cause bodily injury or death. It is the obligation and
responsibility of operating/service personnel to identify
and recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to
comply with any of these requirements could result in
serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
individual possesses independent training that will
enable them to perform their assigned tasks properly
and safely. It is essential that, prior to performing any
task on this equipment, this individual will have read
and understood this document and any referenced
materials. This individual will also be familiar with and
comply with all applicable governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
CAUTION identifies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instruction will be given, together with
a brief explanation.
NOTE is used to highlight additional
information which may be helpful to
you.
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 se-
rious injury.
External wiring, unless specified as an optional connection in the manufacturer’s product
line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the micro panel. NO external wiring
is allowed to be run through the micro panel. All wiring must be in accordance with YORK’s
published specifications and must be performed ONLY by qualified YORK personnel. YORK
will not be responsible for damages/problems resulting from improper connections to the
controls or application of improper control signals. Failure to follow this will void the
manufacturer’s warranty and cause serious damage to property or injury to persons.

3
JOHNSON CONTROLS
FORM 145.05-NOM1 (708)
CHANGEABILITY OF THIS DOCUMENT
In complying with YORK’s policy for continuous
product improvement, the information contained in this
document is subject to change without notice. While
YORK makes no commitment to update or provide
current information automatically to the manual owner,
that information, if applicable, can be obtained by
contacting the nearest YORK Applied Systems office.
It is the responsibility of operating/service personnel
to verify the applicability of these documents to the
equipment in question. 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 equipment has been modified and if current
literature is available.

JOHNSON CONTROLS
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FORM 145.05-NOM1 (708)
CHANGEABILITY OF THIS DOCUMENT ...........................................................................................................3
TABLE OF CONTENTS .......................................................................................................................................4
LIST OF TABLES .................................................................................................................................................9
LIST OF FIGURES .............................................................................................................................................10
SECTION 1 – INTRODUCTION .........................................................................................................................11
ABOUT THIS MANUAL ..............................................................................................................................11
DESCRIPTION OF UNIT .............................................................................................................................11
NOMENCLATURE .......................................................................................................................................11
SECTION 2 – INSTALLATION ...........................................................................................................................13
APPROVALS ...............................................................................................................................................13
LIMITATIONS ...............................................................................................................................................13
UNIT INSPECTION ......................................................................................................................................13
LOCATION AND CLEARANCES ................................................................................................................14
RIGGING AND UNIT HANDLING ...............................................................................................................14
FACTORY-SUPPLIED PLENUM .................................................................................................................17
VIBRATION ISOLATORS ............................................................................................................................17
SEGMENTED UNIT ASSEMBLY ................................................................................................................17
REMOVE SHIPPING RESTRAINTS ...........................................................................................................18
ELECTRICAL DATA ....................................................................................................................................27
Field Power Wiring ..............................................................................................................................27
Disconnect ...........................................................................................................................................27
Electrical Service Sizing .....................................................................................................................27
MCA ................................................................................................................................................27
MOP ................................................................................................................................................27
Field Control Wiring ............................................................................................................................28
Pump Start .....................................................................................................................................28
Fan Start ........................................................................................................................................29
VAV Box Full Open ........................................................................................................................29
PHASE MONITOR .......................................................................................................................................29
DUCTING ....................................................................................................................................................29
Supply Air .............................................................................................................................................29
Return Air .............................................................................................................................................29
Ducted Return ...............................................................................................................................29
Free Return ....................................................................................................................................29
WATER PIPING ...........................................................................................................................................30
General .................................................................................................................................................30
Condenser Connections .....................................................................................................................30
Cooling Towers .............................................................................................................................31
Waterside Piping Arrangements ..................................................................................................31
Water Temperature Requirements ...............................................................................................31
Condensate Drain Connections .........................................................................................................31
TABLE OF CONTENTS

5
JOHNSON CONTROLS
FORM 145.05-NOM1 (708)
STATIC PRESSURE TRANSDUCER INSTALLATION (VAV UNITS ONLY) ..............................................31
Mounting Instructions .........................................................................................................................32
STATIC PRESSURE TRANSDUCER INSTALLATION (FLEXSYS UNITS ONLY) ....................................32
Installation Instructions ......................................................................................................................32
RETURN, OUTDOOR, SUPPLY AIR, AND MIXED AIR SENSORS ...........................................................33
Return Air Sensor ................................................................................................................................33
Supply Air Sensor ...............................................................................................................................33
Mixed Air Sensor .................................................................................................................................33
Outdoor Air Sensor .............................................................................................................................33
STEAM HEAT ..............................................................................................................................................33
Specification ........................................................................................................................................33
Steam Piping ........................................................................................................................................33
HOT WATER HEAT .....................................................................................................................................33
Specification ........................................................................................................................................33
Hot Water Piping ..................................................................................................................................34
ELECTRIC HEAT ........................................................................................................................................34
FILTERS ......................................................................................................................................................34
SECTION 3 – START-UP ...................................................................................................................................35
CRANKCASE HEATERS ............................................................................................................................35
PRE-STARTUP REQUIREMENTS ..............................................................................................................35
UNIT CHECKS – POWER APPLIED ..........................................................................................................36
Verifying Compressor Rotation ..........................................................................................................36
INITIAL START-UP ......................................................................................................................................36
Refrigerant Charge ..............................................................................................................................37
Subcooling ...........................................................................................................................................37
Superheat (R-22) ..................................................................................................................................37
Leak Checking .....................................................................................................................................37
SECTION 4 – MAINTENANCE ..........................................................................................................................39
GENERAL ...................................................................................................................................................39
PERIODIC MAINTENANCE – MONTHLY ...................................................................................................39
Filters ....................................................................................................................................................39
Linkages ...............................................................................................................................................39
Compressors .......................................................................................................................................39
Oil Analysis ..........................................................................................................................................39
Fan Bearing Lubrication .....................................................................................................................39
Recommended Lubricant for Fan Bearings ......................................................................................39
PERIODIC MAINTENANCE – THREE TO SIX MONTHS .............................................................................................40
Motor Bearing Lubrication ..................................................................................................................40
Belt Tension .........................................................................................................................................40
TABLE OF CONTENTS

JOHNSON CONTROLS
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FORM 145.05-NOM1 (708)
PERIODIC MAINTENANCE – YEARLY ......................................................................................................40
Entire Unit Inspection .........................................................................................................................40
Sheave Alignment ...............................................................................................................................40
Belts ......................................................................................................................................................41
Belt Replacement ................................................................................................................................41
Belt Tensioning: ...................................................................................................................................41
Filter Drier Replacement .....................................................................................................................41
Supply Fan ...........................................................................................................................................41
Fan Motor .............................................................................................................................................42
Fan Shaft Bearings ..............................................................................................................................42
Mounting Details ...........................................................................................................................42
Bearing Locking Devices .............................................................................................................43
Condenser Coil Cleaning ....................................................................................................................43
WATER PRESSURE DROP TABLES .........................................................................................................44
SECTION 5 – SEQUENCE OF OPERATION ....................................................................................................47
ON / OFF .....................................................................................................................................................47
SUPPLY FAN OPERATION .........................................................................................................................47
Constant Volume Fan Operation ........................................................................................................47
VAV Fan Operation ..............................................................................................................................48
Communicated VFD Speed Input .......................................................................................................48
FLEXSYS DEW POINT CONTROL ............................................................................................................49
Sequence of Operation .......................................................................................................................49
ECONOMIZER OPERATION ......................................................................................................................49
Sequence of Operation .......................................................................................................................50
Waterside Economizer ..................................................................................................................50
Outdoor Air Economizer ...............................................................................................................50
CONDENSER WATER VALVE OPERATION ..............................................................................................51
Sequence of Operation .......................................................................................................................51
CONDENSER WATER BYPASS .................................................................................................................51
Sequence of Operation .......................................................................................................................51
MECHANICAL COOLING OPERATION .....................................................................................................51
Sequence of Operation .......................................................................................................................52
Supply Air Temperature Control ..................................................................................................52
Return Air Temperature Control ..................................................................................................52
Dew Point Temperature Control (FlexSys Units) .......................................................................52
Coil Leaving Temperature Control (FlexSys Units) ...................................................................52
Compressor Analog Output .........................................................................................................52
Compressor Staging .....................................................................................................................53
Lead Lag Operation .............................................................................................................................54
Two Compressor Units .................................................................................................................54
Four Compressor Units ................................................................................................................54
TABLE OF CONTENTS

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JOHNSON CONTROLS
FORM 145.05-NOM1 (708)
FLEXSYS BYPASS DAMPER CONTROL ..................................................................................................54
Sequence of Operation .......................................................................................................................54
COMPRESSOR SAFETY CONTROL OPERATION ...................................................................................54
Compressor High Pressure (Fault / Alarm) .......................................................................................54
Compressor Low Pressure (Fault / Alarm) ........................................................................................55
Compressor Low Suction Pressure Control .....................................................................................55
High Pressure Switch ..........................................................................................................................55
Compressor Motor Protector .............................................................................................................55
HEATING OPERATION ...............................................................................................................................55
Sequence of Operation .......................................................................................................................55
Supply Air Temperature Control ..................................................................................................55
Return Air Temperature Control ..................................................................................................56
Staged Heat Operation .................................................................................................................56
Tristate Modulated Heat ...............................................................................................................57
SECTION 6 – USER INTERFACE CONTROL CENTER ...................................................................................59
KEYPAD ......................................................................................................................................................59
POWER UP BANNER SCREEN .................................................................................................................59
RUN STATUS SCREEN ..............................................................................................................................59
ALARM SCREEN ........................................................................................................................................60
FAULT SCREEN ..........................................................................................................................................60
INPUT ..........................................................................................................................................................61
Analog In ..............................................................................................................................................61
Digital In ...............................................................................................................................................61
OUTPUTS ....................................................................................................................................................61
Analog Out ...........................................................................................................................................61
PID Loop Out ........................................................................................................................................61
Digital Out ............................................................................................................................................61
SETPOINTS .................................................................................................................................................62
FORCED OUTPUTS ....................................................................................................................................64
SETTING DATE AND TIME .........................................................................................................................65
DAILY SCHEDULE ......................................................................................................................................67
HOLIDAY SCHEDULE ................................................................................................................................68
OVERRIDE SCHEDULE .............................................................................................................................68
COMMUNICATIONS ...................................................................................................................................69
Communication Wiring .......................................................................................................................69
Network Baud Rate ..............................................................................................................................69
Device Object Instance (DE) ...............................................................................................................70
TABLE OF CONTENTS

JOHNSON CONTROLS
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FORM 145.05-NOM1 (708)
SECTION 7 – PARAMETER DESCRIPTIONS AND OPTIONS ......................................................................107
SECTION 8 – SERVICE ...................................................................................................................................113
ANALOG INPUTS .....................................................................................................................................113
Temperature Sensors ........................................................................................................................113
Duct Pressure Transducer ................................................................................................................113
Coil Pressure Drop (FlexSys Units Only) ........................................................................................114
Discharge Pressure Transducer ......................................................................................................114
Suction Pressure Transducer ...........................................................................................................114
Humidity Sensor (FlexSys Units Only) ............................................................................................114
FAULTS AND ALARMS ............................................................................................................................115
Compressor High Pressure (Fault / Alarm) .....................................................................................115
Compressor Low Pressure (Fault / Alarm) ......................................................................................115
Dirty Filter (Alarm) .............................................................................................................................116
Duct High Static (Fault / Alarm) ........................................................................................................116
External Safety ...................................................................................................................................116
Fan Failure (Alarm) ............................................................................................................................116
Freeze (Fault / Alarm) ........................................................................................................................117
CONTROL BOARD CONFIGURATION ....................................................................................................118
Main Control Board ...........................................................................................................................118
Auxiliary Control Board ....................................................................................................................119
WIRING DIAGRAMS .................................................................................................................................124
Constant Volume, Variable Air Volume ............................................................................................124
CV, VAV, FlexSys ................................................................................................................................125
CV, VAV, FlexSys ................................................................................................................................126
FlexSys ...............................................................................................................................................127
TABLE OF CONTENTS

9
JOHNSON CONTROLS
FORM 145.05-NOM1 (708)
LIST OF TABLES
TABLE 1 – ACRONYM CHART .........................................................................................................................11
TABLE 2 – VOLTAGE LIMITATIONS ................................................................................................................13
TABLE 3 – OPERATING LIMITATIONS ............................................................................................................13
TABLE 4 – ACCESS REQUIREMENTS ............................................................................................................14
TABLE 5 – WEIGHTS ........................................................................................................................................15
TABLE 6 – DATA TABLE ...................................................................................................................................19
TABLE 7 – REFRIGERANT CHARGE DATA ....................................................................................................23
TABLE 8 – FAN MOTOR DATA .........................................................................................................................28
TABLE 9 – COMPRESSOR MOTOR DATA ......................................................................................................28
TABLE 10 – SETSCREW TORQUES ................................................................................................................35
TABLE 11 – TEMPERATURE/PRESSURE CHART – REFRIGERANT R-22 ...................................................38
TABLE 12 – FAN BEARING – LUBRICATION INTERVALS ............................................................................39
TABLE 13 – BELT TENSION DATA ..................................................................................................................40
TABLE 14 – WINDOW OF OPERATION, COMPRESSOR STAGING ..............................................................52
TABLE 16 – SETPOINT SCREEN PARAMETERS ...........................................................................................63
TABLE 17 – FORCED ON PARAMETERS .......................................................................................................64
TABLE 18 – BACnet MS/TP points ..................................................................................................................70
TABLE 19 – N2 POINTS LIST .........................................................................................................................102
TABLE 20 – DEFINITIONS ..............................................................................................................................107
TABLE 21 – TEMPERATURE SENSOR RESISTANCE ..................................................................................113
TABLE 22 – VAV DUCT STATIC PRESSURE TRANSDUCER ......................................................................113
TABLE 23 – FLEXSYS DUCT STATIC PRESSURE TRANSDUCER .............................................................113
TABLE 24 – COIL PRESSURE DROP (FLEXSYS) ........................................................................................114
TABLE 25 – REFRIGERANT PRESSURE TRANSDUCERS .........................................................................114
TABLE 26 – HUMIDITY SENSOR OUTPUT ...................................................................................................115
TABLE 27 – CONSTANT VOLUME / VARIABLE AIR VOLUME MAIN CONTROL BOARD * .......................120
TABLE 28 – CONSTANT VOLUME / VARIABLE AIR VOLUME EXPANSION CONTROL BOARD * ...........121
TABLE 29 – FLEXSYS MAIN CONTROL BOARD * .......................................................................................122
TABLE 30 – FLEXSYS EXPANSION CONTROL BOARD * ...........................................................................123

JOHNSON CONTROLS
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FORM 145.05-NOM1 (708)
LIST OF FIGURES
FIG. 1 – RECOMMENDED SERVICE AND MAINTENANCE CLEARANCE ....................................................14
FIG. 2 – SHIPPING RESTRAINT LOCATIONS .................................................................................................18
FIG. 3 – SHEAVE ALIGNMENT .........................................................................................................................40
FIG. 4 – BELT TENSIONING GAUGE ...............................................................................................................41
FIG. 5 – KEYPAD / DISPLAY .............................................................................................................................59
FIG. 6 – COMMUNICATION WIRING ................................................................................................................69
FIG. 7 – MAIN CONTROL BOARD PIN POSITIONS ......................................................................................118
FIG. 8 – AUXILIARY CONTROL BOARD PIN POSITIONS ............................................................................119
FIG. 9 – MAIN CONTROL BOARD .................................................................................................................119
FIG. 10 – AUXILIARY CONTROL BOARD ......................................................................................................119
FIG. 11 – ELEMENTARY CONTROL WIRING DIAGRAM, YWSU- ALL OPTIONS .......................................124
FIG. 12 – ELEMENTARY CONTROL WIRING DIAGRAM, YSWU .................................................................125
FIG. 13 – ELEMENTARY POWER WIRING DIAGRAM, YSWU .....................................................................126
FIG. 14 – ELEMENTARY CONTROL WIRING DIAGRAM, YSWU DOWNFLOW ..........................................127