Johnson Controls YORK YCAL0043E Series Owner's manual

YCAL0043E_ - YCAL0377E_
R-22 & HFC-407C
STYLE C
(50 Hz)
WITH IPU II AND I/O BOARDS
Standard, Glycol & Metric Models, Combined
380/415-3-50
MODELS ONLY
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
New Release Form 150.62-NM9 (709)
29224(R)A
035-22321-000

JOHNSON CONTROLS
2
FORM 150.62-NM9 (709)
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 underpressure, rotatingcomponents, 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 respon-
sibility 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
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
individual possesses independent training that will en-
able 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 thisdocumentandanyreferenced materials.
This individual will also be familiar with and comply
with all applicable governmental standards and regula-
tions 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:

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    
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
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
   
    
      -

   
    
-


not
notno
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only 
-




JOHNSON CONTROLS 3
FORM 150.62-NM9 (709)
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for continu-
ous product improvement, the information contained
in this document is subject to change without notice.
While Johnson Controls 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 Johnson Controls
Service ofce.
It is the responsibility of operating/service personnel to
verify the applicability of these documents to the equip-
ment 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 equip-
ment, they should verify with the owner whether the
equipment has been modied and if current literature
is available.
TABLE OF CONTENTS
PRODUCT IDENTIFICATION NUMBER (PIN)....................................................................................7
REFRIGERANT FLOW DIAGRAM......................................................................................................9
SECTION 1 - INSTALLATION ...........................................................................................................10
ELECTRICAL DATA....................................................................................................................................20
OPERATIONAL LIMITATIONS (ENGLISH) ................................................................................................26
PHYSICAL DATA (ENGLISH) .....................................................................................................................30
DIMENSIONS AND CLEARANCES............................................................................................................34
PRE-STARTUP AND STARTUP CHECKLIST............................................................................................58
INITIAL START-UP......................................................................................................................................59
UNIT OPERATING SEQUENCE .................................................................................................................61
SECTION 2 - UNIT CONTROLS........................................................................................................62
“STATUS” KEY...........................................................................................................................................64
DISPLAY/PRINT KEYS...............................................................................................................................70
“ENTRY” KEYS...........................................................................................................................................79
“SETPOINTS” KEYS ..................................................................................................................................80
“UNIT” KEYS .............................................................................................................................................87
UNIT OPERATION.......................................................................................................................................92
SECTION 3 - SERVICE AND TROUBLESHOOTING .....................................................................106
SERVICE MODE – CHILLER CONFIGURATION.....................................................................................107
OPTIONAL PRINTER INSTALLATION.....................................................................................................115
TROUBLESHOOTING CHARTS ..............................................................................................................116
MAINTENANCE ........................................................................................................................................119
ISN CONTROL ..........................................................................................................................................120
SECTION 4 - WIRING DIAGRAMS .................................................................................................124
APPENDIX 1....................................................................................................................................179

JOHNSON CONTROLS
4
FORM 150.62-NM9 (709)
LIST OF TABLES
TABLE 1 – MICRO PANEL POWER SUPPLY ................................................................................20
TABLE 2 – TEMPERATURES AND FLOWS...................................................................................26
TABLE 3 – VOLTAGE LIMITATIONS ..............................................................................................26
TABLE 4 – COOLER PRESSURE DROP CURVES .......................................................................27
TABLE 5 – ETHYLENE / PROPYLENE GLYCOL CORRECTION FACTORS.................................27
TABLE 6 – TEMPERATURES AND FLOWS...................................................................................28
TABLE 7 – VOLTAGE LIMITATIONS ..............................................................................................28
TABLE 8 – COOLER PRESSURE DROP CURVES .......................................................................29
TABLE 9 – ETHYLENE / PROPYLENE GLYCOLCORRECTION FACTORS ..................................29
TABLE 10 – PHYSICAL DATA (ENGLISH).......................................................................................30
TABLE 11 – SETPOINTS ENTRY LIST.............................................................................................59
TABLE 12 – STATUS KEY MESSAGES...........................................................................................69
TABLE 13 – OPERATION DATA.......................................................................................................73
TABLE 14 – COOLING SETPOINTS, PROGRAMMABLE LIMITS AND DEFAULTS......................82
TABLE 15 – PROGRAM KEY LIMITS AND DEFAULTS ..................................................................85
TABLE 16 – SETPOINTS QUICK REFERENCE LIST......................................................................86
TABLE 17 – UNIT KEYS PROGRAMMING QUICK REFERENCE LIST..........................................91
TABLE 18 – COMPRESSOR STAGING FOR RETURN WATER CONTROL...................................94
TABLE 19 – RETURN CHILLED LIQUID CONTROL FOR 5 & 6 COMPRESSORS
(7 & 8 STEPS)................................................................................................................94
TABLE 20 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS)............95
TABLE 21 – YCAL0043 – YCAL0107 CONDENSER FAN CONTROL
USING DISCHARGE PRESSURE................................................................................98
TABLE 22 – YCAL0043 – YCAL0107 CONDENSER FAN CONTROL
USING DISCHARGE PRESSURE ONLY.....................................................................98
TABLE 23 – YCAL0117 – YCAL0253 CONDENSER FAN CONTROL
USING OUTDOOR AMBIENT TEMPERATURE AND DISCHARGE PRESSURE. .....99
TABLE 24 – YCAL0117 – YCAL0253 CONDENSER FAN CONTROL
USING DISCHARGE PRESSURE ONLY.....................................................................99
TABLE 25 – YCAL0117 - YCAL0253 LOW AMBIENT CONDENSER FAN CONTROL –
DISCHARGE PRESSURE CONTROL .......................................................................100
TABLE 26 – YCAL0287 - YCAL0377 CONDENSER FAN CONTROL ..........................................101
TABLE 27 – COMPRESSOR OPERATION – LOAD LIMITING......................................................103
TABLE 28 – I/O BOARD DIGITAL INPUTS.....................................................................................108
TABLE 29 – I/O BOARD ANALOG INPUTS...................................................................................108
TABLE 30 – I/O BOARD DIGITAL OUTPUTS.................................................................................108
TABLE 31 – I/O BOARD ANALOG OUTPUTS...............................................................................108
TABLE 32 – OUTDOOR AIR SENSOR TEMPERATURE/VOLTAGE/
RESISTANCE CORRELATION ..................................................................................110

JOHNSON CONTROLS 5
FORM 150.62-NM9 (709)
LIST OF TABLES (CONT.)
LIST OF FIGURES
TABLE 33 – ENTERING/LEAVING CHILLED LIQUID TEMP. SENSOR, COOLER INLET
TEMPERATURE SENSOR, AND SUCTION TEMPERATURE SENSOR:
TEMPERATURE/VOLTAGE/RESISTANCE CORRELATION.....................................111
TABLE 34 – KEYPAD PIN ASSIGNMENT MATRIX........................................................................114
TABLE 35 – TROUBLESHOOTING ................................................................................................116
TABLE 36 – ISN RECEIVED DATA.................................................................................................120
TABLE 37 – ISN TRANSMITTED DATA..........................................................................................120
TABLE 38 – ISN OPERATIONAL AND FAULT CODES.................................................................122
FIG. 1 – REFRIGERANT FLOW DIAGRAM......................................................................................9
FIG. 2 – SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK,
NON-FUSED DISCONNECTSWITCH OR CIRCUIT BREAKER (YCAL0043 - 0253)......14
FIG. 3 – MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL BLOCK
(YCAL0117 - 0253) ............................................................................................................15
FIG. 4 – MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL BLOCK,
NON-FUSED DISCONNECT SWITCHES OR CIRCUIT BREAKERS
(YCAL0287 - 0377)............................................................................................................16
FIG. 5 – OPTIONAL SINGLE-POINT POWER WIRING .................................................................17
FIG. 6 – CONTROL WIRING ..........................................................................................................18
FIG. 7 – SETPOINT ADjUST ..........................................................................................................93
FIG. 8 – LEAVING WATER TEMPERATURE CONTROL EXAMPLE.............................................93
FIG. 9 – YCAL0043 – YCAL0107 FAN LOCATION (TYPICAL)......................................................98
FIG. 10 – YCAL0117 – YCAL0253 FAN LOCATION (TYPICAL)......................................................99
FIG. 11 – YCAL0287 – YCAL0377 FAN LOCATION.......................................................................101
FIG. 12 – FIELD AND FACTORY ELECTRICAL CONNECTIONSOPTIONAL
REMOTE TEMPERATURE RESET BOARD...................................................................105
FIG. 13 – I/O BOARD LAYOUT.......................................................................................................109
FIG. 14 – I/O BOARD RELAY CONTACT ARCHITECTURE..........................................................113
FIG. 15 – PRINTER TO I/O BOARD ELECTRICAL CONNECTIONS ............................................115
FIG. 16 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0043E_ - YCAL0087E_ ........124
FIG. 16A – ELEMENTARY DIAGRAM, CONTROL CIRCUIT –
YCAL0043E_ - YCAL0087E_ REMOTE COOLER......................................................126
FIG. 17 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0043E_ - YCAL0087E_ ............128
FIG. 18 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0043E_ - YCAL0087E_ ...........130
FIG. 19 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0043E_ - YCAL0087E_ ...........132
FIG. 20 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0107E_ ....................................134

JOHNSON CONTROLS
6
FORM 150.62-NM9 (709)
LIST OF FIGURES (CONT)
FIG. 20A – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0107E_
REMOTE COOLER........................................................................................................136
FIG. 21 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0107E_......................................138
FIG. 22 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0107E_.....................................140
FIG. 23 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0107E_.....................................142
FIG. 24 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0117E_ - YCAL0173E_ ........144
FIG. 24A – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0117E_ - YCAL0173E_
REMOTE COOLER..........................................................................................................146
FIG. 25 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0117E_ - YCAL0173E_.............148
FIG. 26 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0117E_ - YCAL0173E_............150
FIG. 27 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0117E_ - YCAL0173E_............152
FIG. 28 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0197E_ - YCAL0253E_ ........154
FIG. 28A – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0197E_ - YCAL0253E_
REMOTE COOLER.......................................................................................................156
FIG. 29 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0197E_ - YCAL0253E_ ............158
FIG. 30 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0197E_ - YCAL0253E_ ...........160
FIG. 31 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0197E_ - YCAL0253E_ ...........162
FIG. 32 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0287E_ - YCAL0317E_ ........164
FIG. 33 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0287E_ - YCAL0317E_ ...........166
FIG. 34 – CONNECTION DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE –
YCAL0287E_ - YCAL0317E_..........................................................................................168
FIG. 35 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0287E_ - YCAL0317E_ ..........170
FIG. 36 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0347E_ - YCAL0377E_ ........172
FIG. 37 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0347E_ - YCAL0377E_ ............174
FIG. 38 – CONNECTION DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE –
YCAL0347E_ - YCAL0377E_..........................................................................................176
FIG. 39 – ELEMENTARY DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE –
YCAL0347E_ - YCAL0377E_..........................................................................................178
FIG. 40 – TYPE CP 1.......................................................................................................................185
FIG. 41 – TYPE CP 2.......................................................................................................................185
FIG. 42 – R SPRING SEISMIC ISOLATOR.....................................................................................186
FIG. 43 – TYPE CP MOUNTING......................................................................................................187
FIG. 44 – “AEQM” SPRING-FLEX MOUNTING .............................................................................188

JOHNSON CONTROLS 7
FORM 150.62-NM9 (709)
PRODUCT IDENTIFICATION NUMBER (PIN)
BASIC MODEL NUMBER
YCAL0075EC50XA
BASE PRODUCT TYPE
L
U :Condensing
Unit
A :Air-Cooled
C :Chiller
Y :YORK
:Scroll
VOLTAGE/STARTER
X
5 0 :380-415 / 3 / 50
:Across the Line
DESIGN/DEVELOPMENT LEVEL
C :Design Series
A :Engineering Change
or PIN Level
E :High Efficiency
UNIT DESIGNATOR
B :R407C
C :R22
REFRIGERANT
NOMINAL CAPACITY
#
##0 #
##1
Even Number:
60 HZ Nominal Tons
Odd Number:
50 HZ Nominal Kw
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

JOHNSON CONTROLS
8
FORM 150.62-NM9 (709)
PRODUCT IDENTIFICATION NUMBER (PIN)
EXAMPLES:
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
X X X X X X X X L X X X X X X X X X X X X X X X X X A X X X X X X X X X X X X X
S D T C A T S R L X P R S 2 5 C X 1 X X X X 3 D W S A R X B X X 4 B X X L X S D
OPTIONS MODEL NUMBER
: Aluminum : Copper : Black Fin : Phenolic : TEAO Fan Motors
EVAP. FIELD CONDENSER FIELD CABINET FIELD
: Wire Condenser Headers Only (factory) : Wire (Full Unit) Enc. Panels (factory) : Wire (Full Unit) Enc. Panels (eld) : Wire/Louvered Enc. Panels (factory) : Wire/Louvered Enc. Panels (eld) : Louvered (Cond. Only) Enc. Panels (factory) : Louvered (Cond. Only) Enc. Panels (eld) : Louvered (Full Unit) Enc. Panels (factory) : Louvered (Full Unit) Enc. Panels (eld) : Acoustic Sound Blanket : Low Sound Fans : 1" Deection : Seismic : Neoprene Pads
55 EXTENDED FIELD X
B C D E F G H
: 1st Year Parts Only : 1st Year Parts & Labor : 2nd Year Parts Only : 2nd Year Parts & Labor : 5 Year Compressor Parts Only : 5 Year Compressor Parts & Labor Only : 5 Year Units Parts Only : 5 Year Unit Parts & Labor
NOTES: 1. Q :DENOTES SPECIAL / S.Q. 2. # :DENOTES STANDARD 3. X :w/in OPTIONS FIELD, DENOTES NO OPTION SELECTED 4. Agency Files (i.e. U.L. / E.T.L.; CE; ARI; ETC.) will contain info. based on the rst 14 characters only.
: Low Ambient Kit (factory) : High Ambient Kit (factory) : Both Low / High Ambient (factory) : BAS/EMS Temp. Reset / Offset : Spanish LCD & Keypad Display : French LCD & Keypad Display : German LCD & Keypad Display : Discharge Pressure Transducers/ Readout Kit : Suction Pressure Transducers / Readout Kit : Both Discharge & Suction Pressure Transducers / Readout : N. American Safety Code (cU.L./cE.T.L.) : No Listing (typically 50 HZ non-CE, non-U.L. : Remote Control Panel : Sequence Control & Automatic Lead Transfer
: 300 PSIG DWP Waterside : Double Thick Insulation : Weld Flange Kit : Victaulic Flange Kit : Flow Switch : ASME Pressure Vessel & Associated Codes : Remote DX Cooler
: SP Supply TB : MP Supply TB : SP Supply TB : SP NF Disconnect Switch : SP Circuit Breaker w/ Lockable Handle : Control Transformer (factory) : Power Factor Capacitor
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 POWER FIELD CONTROLS FIELD COMPRESSOR / PIPING FIELD X X L # # X X H S X A C
S D T S B X S B F E G 1 T I C R X S X B X X L N C R S
MP = Multiple Point SP = Single-Point NF = Non-Fused TB = Terminal Block Ser. = Service Ind. Sys. Brkr. & L. Ext. Handles = Individual System Breaker & Lockable External Handle
38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 3 X X
D C 1 W B 2 V P 3 S X 4 A 5 6 R 7 8 B L 1 S N
: Leaving Supply Temp. : Chicago Code Kit Req’d. : Service Isolation Valves : Both Chicago & Svc. Iso. : Elec. Expansion Valve : Hot Gas By-Pass req’d. (1 circuit) : X : X : X : Crankcase Heater Std.

JOHNSON CONTROLS 9
FORM 150.62-NM9 (709)
LD07613A
REFRIGERANT FLOW DIAGRAM
FIG. 1 – REFRIGERANT FLOW DIAGRAM
OPTIONAL
2 OR 3 COMPRESSORS PER SYSTEM
OIL EQUALIZING
LINE
AIR COOLED CONDENSERS
DX COOLER
LEAVING CHILLED WATER
ENTERING CHILLED WATER
OPTIONAL
SERVICEVALVE
OPTIONAL DISCHARGE
PRESSURETRANSDUCER
HIGH PRESSURE
CUTOUT SWITCH
OPTIONAL
SERVICE
VALVE
LOW PRESSURE SWITCH OR
SUCTION PRESSURE TRANSDUCER
LEAVING
CHILLEDWATER
TEMP. SENSOR
RETURNWATER
TEMP. SENSOR
OPTIONAL
DISCHARGE LINE
BALLVALVE
HOT DISCHARGE
GAS LINE
LIQUID LINE
SERVICEVALVE
LIQUID LINE FILTER / DRIER
LIQUID LINE
SOLENOIDVALVE
SIGHT GLASS /
MOISTURE INDICATOR
SOLENOID OPERATED
HOT GAS BY PASS VALVE
*
OPTIONAL
SUCTION LINE
BALLVALVE
EQUALIZER
LINE
TXV
OPTIONAL
RELIEFVALVE
300 PSIG
(20.68 BARG)
YCAL REFRIGERANT FLOW DIAGRAM
(INCLUDINGTEMPERATURE SENSORS & PRESSURETRANSDUCERS)
NOTE:YCAL0040-0134 HAVE TWO REFRIGERANT
SYSTEMS AND ONE DX COOLER.
* HOT GAS OPTION - SYSTEM 1 ONLY
YCAL0117-0377

JOHNSON CONTROLS
10
FORM 150.62-NM9 (709)
INTRODUCTION
29224(RIG)A
    
   
-
     


-

-

-





INSTALLATION CHECKLIST
The following items, 1 through 5, must be checked
before placing the units in operation.
1. Inspect the unit for shipping damage.
2. Rig unit using spreader bars.
3. Open the unit only to install water piping system.
Do not remove protective covers from water con-
nections untilpiping is ready for attachment. Check
water piping to ensure cleanliness.
4. Pipe unit using good piping practice (seeASHRAE
handbook section 215 and 195).
5. Check to see that the unit is installed and operated
within limitations (Refer to LIMITATIONS).
The following pages outline detailed procedures to be
followed to install and start-up the chiller.
HANDLING
These units are shipped as completely assembled units
containing full operating charge, and care should be
taken to avoid damage due to rough handling.

     

      


SECTION 1 - INSTALLATION
INSPECTION
Immediately upon receiving the unit, it should be in-
spected for possible damage which may have occurred
during transit. If damage is evident, it should be noted
in the carrier’s freight bill.Awritten request for inspec-
tion by the carrier’s agent should be made at once. See
“Instruction” manual, Form 50.15-NM for more infor-
mation and details.
LOCATION AND CLEARANCES
These units are designed for outdoor installations on
ground level, rooftop, or beside a building. Location
should be selected for minimum sun exposure and to
insure adequate supply of fresh air for the condenser.
The units must be installed with sufcient clearances for
airentrance to the condensercoil,forairdischargeaway
from the condenser, and for servicing access.
In installations where winter operation is intended and
snowaccumulationsareexpected,additionalheightmust
be provided to ensure normal condenser air ow.
Clearances are listed under “Notes” in the “DIMEN-
SIONS” section.

JOHNSON CONTROLS 11
FORM 150.62-NM9 (709)
1
FOUNDATION
The unit should be mounted on a at and level founda-
tion, oor, or rooftop capable of supporting the entire
operating weight of the equipment. See PHYSICAL
DATA for operating weight. If the unit is elevated be-
yond the normal reach of service personnel, a suitable
catwalkmustbecapableofsupporting servicepersonnel,
their equipment, and the compressors.
GROUND LEVEL LOCATIONS
It is important that the units be installed on a substantial
base that will not settle. A one piece concrete slab with
footers extended below the frost line is highly recom-
mended. Additionally, the slab should not be tied to
the main building foundations as noise and vibration
may be transmitted. Mounting holes are provided in the
steel channel for bolting the unit to its foundation. (See
DIMENSIONS.)
For ground level installations, precautions should be
taken to protect the unit from tampering by or injury to
unauthorized persons. Screws and/or latches on access
panels will prevent casual tampering. However, further
safetyprecautions suchas afenced-in enclosure or lock-
ing devices on the panels may be advisable.
ROOFTOP LOCATIONS
Choose aspotwithadequatestructural strengthto safely
support the entire weight of the unit and service person-
nel. Care must be taken not to damage the roof.
Consult the building contractor or architect if the roof is
bonded. Roof installations should have wooden beams
(treated to reduce deterioration), cork, rubber, or vibra-
tion isolators under the base to minimize vibration.
NOISE SENSITIVE LOCATIONS
Efforts should be made to assure that the chiller is not
located next to occupied spaces or noise sensitive areas
where chiller noise level would be a problem. Chiller
noise is a result of compressor and fan operation. Con-
siderations should be made utilizing noise levels pub-
lished in the YORK Engineering Guide for the specic
chiller model. Sound blankets for the compressors and
low sound fans are available.
SPRING ISOLATORS (OPTIONAL)
When ordered, four (4) isolators will be furnished.
Identifytheisolator, locateattheproper mountingpoint,
and adjust per instructions. See APPENDIX 1.
COMPRESSOR MOUNTING
The compressors are mounted on four (4) rubber iso-
lators. The mounting bolts should not be loosened or
adjusted at installation of the chiller.
REMOTE COOLER OPTION
Forunitsusingremotecooleroption,refertoinstructions
included with miscellaneous cooler parts kit.
The unit and remote cooler are shipped with a 6 lb. (2.7
kg) nitrogen holding charge. The nitrogen charge must
be removed, and system evacuated, and the refrigerant
charge must be weighed-in according to the operating
charge listed under PHYSICAL DATA. Additional
charge must also be added for the refrigerant lines.
CHILLED WATER PIPING
General – When the unit has been located in its
nal position, the unit water piping may be connected.
Normal installation precautions should be observed in
order to receive maximum operating efciencies. Pip-
ing should be kept free of all foreign matter.All chilled
waterevaporatorpipingmustcomply inallrespectswith
local plumbing codes and ordinances.
Since elbows, tees and valves decrease pump capacity,
all piping should be kept as straight and as simple as
possible. All piping must be supported independent
of the chiller.
-

     
-


JOHNSON CONTROLS
12
FORM 150.62-NM9 (709)
INTRODUCTION
Hand stop valves should be installed in all lines to fa-
cilitate servicing.
Piping to the inlet and outlet connections of the chiller
should include high-pressure rubber hose or piping
loops to ensure against transmission of water pump
vibration. The necessary components must be obtained
in the eld.
Drain connections should be provided at all low points
to permit complete drainage of the cooler and system
water piping.
Asmallvalveorvalvesshouldbeinstalled at the highest
point or points in the chilled water piping to allow any
trapped air to be purged. Vent and drain connections
should be extended beyond the insulation to make them
accessible.
The piping to and from the cooler must be designed to
suit the individual installation. It is important that the
following considerations be observed:
1. The chilled liquid piping system should be laid out
so that the circulating pump discharges directly
into the cooler. The suction for this pump should
be taken from the piping system return line and not
the cooler. This piping scheme is recommended,
but is not mandatory.
2. The inlet and outlet cooler connection sizes are 3"
(YCAL0043 - 0073), 4" (YCAL0087 - 0107), 6"
(YCAL0117 - 0377).
3. A strainer, preferably 40 mesh, must be installed
in the cooler inlet line just ahead of the cooler. This
is important to protect the cooler from entrance of
large particles which could cause damage to the
evaporator.
4. All chilled liquid piping should be thoroughly
ushed to free it from foreign material before the
system is placed into operation. Use care not to ush
any foreign material into or through the cooler.
5. As an aid to servicing, thermometers and pressure
gauges should be installed in the inlet and outlet
water lines.
6. The chilled water lines that are exposed to outdoor
ambients should be wrapped with supplemental
heater cable and insulated to protect against freeze-
up during low ambient periods, and to prevent
formation of condensation on lines in warm humid
locations.
7. A chilled water ow switch, (either by Johnson
Controls or others) MUST be installed in the leav-
ing water piping of the cooler. There should be a
straighthorizontalrunofatleast5diametersoneach
side of the switch. Adjust the ow switch paddle
to the size of the pipe in which it is to be installed.
(See manufacturer’s instructions furnished with the
switch.) The switch is to be wired to terminals 13 -
14 of CTB1 located in the control panel, as shown
on the unit wiring diagram.




WIRING
Liquid Chillers are shipped with all factory-mounted
controls wired for operation.
FieldWiring – Powerwiringmust beprovidedthrough
a fused disconnect switch to the unit terminals (or op-
tional molded disconnect switch) in accordance with
N.E.C. or local code requirements. Minimum circuit
ampacityandmaximumdual elementfusesizearegiven
in the Tables 2 – 6.
A 120-1-60, 15 amp source must be supplied for the
control panel through a fused disconnect when a control
panel transformer (optional) is not provided. Refer to
Table 1 and Figures 2 - 6.
See Figures 2 - 6 and unit wiring diagrams for eld and
power wiring connections, chilled water pump starter
contacts,alarmcontacts,compressorrun statuscontacts,
PWM input, and load limit input. Refer to section on
UNIT OPERATION for a detailed description of opera-
tion concerning aforementioned contacts and inputs.

JOHNSON CONTROLS 13
FORM 150.62-NM9 (709)
1
EVAPORATOR PUMP START CONTACTS
TerminalblockCTB2 –terminals23to24,arenormally-
open contacts that can be used to switch eld supplied
power to provide a start signal to the evaporator pump
contactor. The contacts will be closed when any of the
following conditions occur:
1. Low Leaving Chilled Liquid Fault
2. Any compressor is running
3. Daily schedule is not programmed OFF and the
Unit Switch is ON
The pump will not run if the micro panel has been pow-
ered upforlessthan30seconds,orifthe pumphasrunin
the last 30 seconds, to prevent pump motor overheating.
Refer to Figure 6 and unit wiring diagram.
SYSTEM RUN CONTACTS
Contacts are available to monitor system status. Nor-
mally-open auxiliary contacts from each compressor
contactor are wired in parallel with TB1 – terminals 25
to 26 for system 1, and TB1 – terminals 27 to 28 for
system 2 (YCAL0117 - YCAL0377). Refer to Figure 6
and unit wiring diagram.
ALARM STATUS CONTACTS
Normally-open contacts are available for each re-
frigerant system. These normally-open contacts close
when the system is functioning normally. The respec-
tive contacts will open when the unit is shut down
on a unit fault, or locked out on a system fault. Field
connections are at TB1 terminals 29 to 30 (system
1), and terminals 31 to 32 (system 2 YCAL0117 -
YCAL0377).
REMOTE START/STOP CONTACTS
To remotely start and stop the chiller, dry contacts can
be wired in series with the ow switch and CTB1 -
terminals 13 to 14. Refer to Figure 6 and unit wiring
diagram.
REMOTE EMERGENCY CUTOFF
Immediate shutdown of the chiller can be accomplished
by opening a eld-installed dry contact to break the elec-
trical circuit between terminals 5 to Lon terminal block
TB1. The unit is shipped with a factory jumper installed
between terminals 5 to L, which must be removed if
emergency shutdown contacts are installed. Refer to
Figure 6 and unit wiring diagram.
PWM INPUT
The PWM input allows reset of the chilled liquid set-
point by supplying a “timed” contact closure. Field
wiring should be connected to TB1 – terminals 13 to 20.
A detailed explanation is provided in the Unit Control
section. Refer to Figure 6 and unit wiring diagram.
LOAD LIMIT INPUT
Load limiting is a feature that prevents the unit from
loading beyond a desired value. The unit can be “load
limited” either 33%, 40%, 50%, 66% or 80%, depend-
ing on the number of compressors on unit. The eld
connections are wired to TB1 – terminals 13 to 21, and
work in conjunction with the PWM inputs. A detailed
explanation is provided in the Unit Control section.
Refer to Figure 6 and unit wiring diagram.
     
     
   
   


FLOW SWITCH INPUT
The ow switch is eld wired to CTB1 terminals 13 - 14.
See Figure 6 and unit wiring diagram.
COMPRESSOR HEATERS
Compressor heaters are standard. If power is OFF more
than two hours, the crankcase heaters must be energized
for 18 - 24 hours prior to restarting a compressor. This
will assure that liquid slugging and oil dilution does not
damage the compressors on start.

JOHNSON CONTROLS
14
FORM 150.62-NM9 (709)
INTRODUCTION
FIG. 2 – SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED DISCONNECT
SWITCH OR CIRCUIT BREAKER (YCAL0043 - 0253)
SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED
DISCONNECT SWITCH OR CIRCUIT BREAKER (YCAL0043 - YCAL0107)
Electrical Notes and Legend located on page 19.






LD07719
Power PanelControl Panel
Terminal Block,
NF Disconnect SW
or Circuit Breaker
1L11L2 1L3
GRD
MICROPANEL
2
L
CTB2
13 14
CTB1
Field Provided Unit Power Supply
Field Provided 120- 1-60
Micropanel Power Supply ifControl
Transformer not Supplied
Flow Switch
See electrical note 9
Power PanelControl PanelPower PanelControl Panel
Terminal Block,
NF Disconnect SW
or Circuit Breaker
1L11L2 1L31L11L2 1L3
GRDGRDGRD
MICROPANEL
2
L
CTB2
2
L
CTB2
13 1413 14
CTB1
Field Provided Unit Power Supply
Field Provided 120- 1-60
Micropanel Power Supply ifControl
Transformer not Supplied
Flow Switch
See electrical note 9

JOHNSON CONTROLS 15
FORM 150.62-NM9 (709)
1
Electrical Notes and Legend located on page 19.
FIG. 3 – MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL BLOCK (YCAL0117 - 0253)
MULTIPLE POINT POWER SUPPLY CONNECTION –
TERMINAL BLOCK (YCAL0117 - YCAL0253)






Power PanelControl Panel
Terminal
Block1 Terminal Block2
1L11L2 1L32L12L2 2L3
GRD GRD
MICROPANEL
2
L
CTB2
13 14
CTB1
Field Provided Unit Power Supply
Field Provided 120- 1-60
Micropanel Power Supply ifControl
Transformer not Supplied
Flow Switch
See electrical note 9
Power PanelControl PanelPower PanelControl Panel
Terminal
Block1 Terminal Block2
1L11L2 1L31L11L2 1L32L12L2 2L32L12L2 2L3
GRDGRDGRD GRDGRDGRD
MICROPANEL
2
L
CTB2
2
L
CTB2
13 1413 14
CTB1
Field Provided Unit Power Supply
Field Provided 120- 1-60
Micropanel Power Supply ifControl
Transformer not Supplied
Flow Switch
See electrical note 9
LD07720

JOHNSON CONTROLS
16
FORM 150.62-NM9 (709)
INTRODUCTION
Electrical Notes and Legend located on page 19.
FIG. 4 – MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED
DISCONNECT SWITCHES OR CIRCUIT BREAKERS (YCAL0287 - 0377)
MULTIPLE POINT POWER SUPPLY CONNECTION –
TERMINAL BLOCK, NON-FUSED DISCONNECT SWITCHES OR
CIRCUIT BREAKERS (YCAL0287 - YCAL0377)






LD07721
Power PanelControl Panel
Terminal Block1,
NF Disconnect
SW1
or CircuitBreaker1
Terminal Block2,
NF Disconnect
SW2
or CircuitBreaker2
1L1 1L2 1L3 2L12L2 2L3
GRD GRD
MICROPANEL
2
L
CTB2
13 14
CTB1
Field Provided Unit Power Supply
Field Provided 120-1-60
Micropanel Power Supplyif
Control Transformer not Supplied
Flow Switch
See electrical note 9
Power PanelControl PanelPower PanelControl Panel
Terminal Block1,
NF Disconnect
SW1
or CircuitBreaker1
Terminal Block2,
NF Disconnect
SW2
or CircuitBreaker2
1L1 1L2 1L31L1 1L2 1L3 2L12L2 2L32L12L2 2L3
GRDGRDGRD GRDGRDGRD
MICROPANEL
2
L
CTB2
2
L
CTB2
13 1413 14
CTB1
Field Provided Unit Power Supply
Field Provided 120-1-60
Micropanel Power Supplyif
Control Transformer not Supplied
Flow Switch
See electrical note 9

JOHNSON CONTROLS 17
FORM 150.62-NM9 (709)
1
Electrical Notes and Legend located on page 19.
FIG. 5 – OPTIONAL SINGLE-POINT POWER WIRING
SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK
OR NON-FUSED DISCONNECT SWITCH TO INDIVIDUAL
SYSTEM CIRCUIT BREAKERS (YCAL0287 - 0317)






Power PanelControl Panel
Terminal Block or
NF Disconnect SW
1L11L2 1L3
GRD
MICROPANEL
2
L
CTB2
13 14
CTB1
Field Provided Unit Power Supply
Field Provided 120- 1-60
Micropanel Power Supply ifControl
Transformer not Supplied
Flow Switch
See electrical note 9
Circuit
Breaker1 Circuit Breaker2
Power PanelControl PanelPower PanelControl Panel
Terminal Block or
NF Disconnect SW
1L11L2 1L31L11L2 1L3
GRDGRDGRD
MICROPANEL
2
L
CTB2
2
L
CTB2
13 1413 14
CTB1
Field Provided Unit Power Supply
Field Provided 120- 1-60
Micropanel Power Supply ifControl
Transformer not Supplied
Flow Switch
See electrical note 9
Circuit
Breaker1 Circuit Breaker2
LD07722

JOHNSON CONTROLS
18
FORM 150.62-NM9 (709)
INTRODUCTION
FIG. 6 – CONTROL WIRING
CONTROL WIRING
LD07730A

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
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
CTB1
21
13
20
13
14
13
FLOW SW REMOTE START/STOP
PWM INPUT
LOAD LIMIT INPUT
*
* Factory wired with optional transformer.
LD07725

JOHNSON CONTROLS 19
FORM 150.62-NM9 (709)
1
ELECTRICAL NOTES AND LEGEND
NOTES:
1. Minimum CircuitAmpacity (MCA) is based on 125% of the rated load amps for the largest motor plus 100% of
the rated load amps for all other loads included in the circuit, per N.E.C.Article 430.33. If the Factory-mounted
Control Transformer is provided, add the following to the system MCA values in the electrical tables for the
system supplying power to the optional transformer. -17, add 2.5 amps; -28, add 2.3 amps; -40, add 1.5 amps,
-46, add 1.3 amps; -58, add 1 amp.
2. The minimum recommended disconnect switch is based on 115% of the rated load amps for all loads included
in the circuit, per N.E.C. Article 440.12 (A) 1.
3. Minimum fuse size is based upon 150% of the rated load amps for the largest motor plus 100% of the rated load
amps for all other loads included in the circuit to avoid nuisance trips at start-up due to lock rotor amps. It is not
recommended in applications where brown outs, frequent starting and stopping of the unit, and/or operation at
ambient temperatures in excess of 95°F is anticipated.
4. Maximum fuse size is based upon 225% of the rated load amps for the largest motor plus 100% of the rated
load amps for all other loads included in the circuit, per N.E.C. Article 440.22.
5. Circuit breakers must be U.L. listed and CSA certied and maximum size is based on 225% of the rated load
amps for the largest motor plus 100% of the rated load amps for all other loads included in the circuit. Excep-
tion: YCAL0043 and YCAL0057 must have the optional factory overloads installed to use a standard circuit
breaker. Otherwise, an HACR-type circuit breakers must be used. Maximum HACR circuit breaker rating is
based on 225% of the rated load amps for the largest motor plus 100% of the rated load amps for all other loads
included in the circuit.
6. The “INCOMING WIRE RANGE” is the minimum and maximum wire size that can be accommodated by
the unit wiring lugs. The (2) preceding the wire range indicates the number of termination points available per
phase of the wire range specied. Actual wire size and number of wires per phase must be determined based on
the National Electrical Code, using copper connectors only. Field wiring must also comply with local codes.
7. A ground lug is provided for each compressor system to accommodate a eld grounding conductor per N.E.C.
Table 250.122. A control circuit grounding lug is also supplied.
8. The supplied disconnect is a “Disconnecting Means” as dened in the N.E.C. 100.I, and is intended for isolat-
ing the unit for the available power supply to perform maintenance and troubleshooting. This disconnect is not
intended to be a Load Break Device.
9. Field Wiring by others which complies to the National Electrical Code and Local Codes.
VOLTAGE CODE
-50 = 380/415-3-50
LEGEND
ACR-LINE ACROSS -THE-LINE START
C.B. CIRCUIT BREAKER
D.E. DUAL ELEMENT FUSE
DISC SW DISCONNECT SWITCH
FACT MOUNT CB FACTORY-MOUNTED CIRCUIT BREAKER
FLA FULL LOAD AMPS
HZ HERTZ
MAX MAXIMUM
MCA MINIMUM CIRCUIT AMPACITY
MIN MINIMUM
MIN NF MINIMUM NON FUSED
RLA RATED LOAD AMPS
S.P. WIRE SINGLE-POINT WIRING
UNIT MTD SERV SW UNIT MOUNTED SERVICE (NON-FUSED
DISCONNECT SWITCH)
LRA LOCKED ROTOR AMPS
Field Wiring
Factory Wiring
LEGEND:

JOHNSON CONTROLS
20
FORM 150.62-NM9 (709)
INTRODUCTION
ELECTRICAL DATA
TABLE 1 – MICRO PANEL POWER SUPPLY
See Notes and Legend on page 19
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OVER CURRENT PROTECTION,
UNIT VOLTAGE UNIT VOLTAGE CONTROLPOWER MCA SEE NOTE B NF DISC Sw
NOTEA MIN MAX
MODELS w/o
CONTROL TRANS 115-1-60/50 15A 10A 15A 30A/ 240V
MODLES W.
CONTROL TRANS. -50 380/415-3-50 15A 10A 15A 30A/ 480V
A. Minimum #14AWG, 75°C, Copper Recommended
B. Minimum and Maximum Over Current Protection, Dual Element Fuse or Circuit Breaker
VOLTAGE RANGE
VOLTAGE CODE UNIT POWER MIN. MAX.
-50 380/415-3-50 342 440