York YCAE065 User manual

AIR-COOLED MODULAR CHILLER AND
HEAT PUMP
INSTALLATION, COMMISSIONING,
OPERATION & MAINTENANCE
Supersedes: NOTHING
FORM NO.: 6U6H-B01C-NB-EN
YCAE065/100/130-X
AIR-COOLED MODULAR CHILLER AND HEAT PUMP
50Hz
R410A
Issue Date:
October 31, 2018
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IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. During rigging, installation, operation,
maintenance, or service, individuals may be exposed to certaincomponents or conditions including, but
not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and both high
and low voltage. Each of these items hasthe potential, if misused or handled improperly, to cause bodily
injury or death. It is the obligation and responsibility of rigging, installation, and 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.
This document is intended for use by owner-authorized rigging, installation, and operating/service
personnel. It is expected that these individuals possess 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 shall have read and understood the on-product labels, this document and
any referenced materials. This individual shall also be familiar with and comply with all applicable
industry and 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 specific situations:
Indicates a possible hazardous situation which will result in death or serious injury if
proper care is not taken.
Identifies a hazard which could lead to damage to the machine, damage to other
equipment and/or environmental pollution if proper care is not taken or instructions
and are notfollowed.
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Indicates a potentially hazardous situation which will result in possible injuries or
damage to equipment if proper care is not taken.
Highlights additional information useful to the technician in completing the work
being performed properly.
External wiring, unless specified as an optional connection in the manufacturer’s
product line, is not to be connected inside the control cabinet. Devices such as relays,
switches, transducers and controls and any external wiring must not be installed
inside the micro panel. All wiring must be in accordance with Johnson Controls’
published specifications and must be performed only by a qualified electrician.
Johnson Controls will NOT be responsible for damage/problems resulting from
improper connections to the controls or application of improper control signals.
Failure to follow this warning will void the manufacturer’s warranty and cause serious
damage to property or personal injury.
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CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for continuous product improvement, the information
contained in this document is subject to change without notice. Johnson Controls makes no commitment
to update or provide current information automatically tothe manual or product owner. Updated manuals,
if applicable, can be obtained by contacting the nearest Johnson Controls Service office or accessing
theJohnson Controls website.
Itisthe responsibilityof rigging,lifting,andoperating/ service personnel to verify the applicability of these
documents to the equipment. If there is any question regarding the applicability of these documents,
rigging, lifting, and operating/service personnel should verify whether the equipment has been modified
and if current literature is available from the owner of the equipment prior to performing any work on the
chiller.
CHANGE BARS
Revisions made to this document are indicated with a line along the left or right hand column in the
area the revision was made. These revisions are to technicalinformation and any other changes in
spelling, grammar or formatting are not included.
ASSOCIATED LITERATURE
MANUAL DESCRIPTION
FORM NUMBER
SC-EQ Communication Card Installation Instructions
450.50-N1
SINGLE CIRCUIT AND DUAL CIRCUIT MODELS
This manual contains installation, operation and maintenance instructions for both single and dual
refrigerant circuit models. If your unit is a single circuit model (YCAE065X), disregard references to
“System 2” which may appear in this manual. Any references to System 2 are applicable to
YCAE100/130X models.
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BASIC UNIT NOMENCLATURE
NAME
Y
C
A
E
1
3
0
X
R
M
E
5
0
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
1
Y: YORK
2
C: Chiller
3
A: Air-cooled
4
E: Scroll Compressor
5/6/7
Rated Cooling Capacity: 65-65kW; 100-100kW; 130-130kW
8
X: Product Series
9
R: R-Heat Pump
10
M: Modular
11
E: Refrigerant R410A
12/13
50: Power Supply 380V/3N/50Hz
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Contents
SECTION 1 –GENERAL INFORMATION AND SAFETY........................................................................ 8
INTRODUCTION ...................................................................................................................................... 8
WARRANTY.............................................................................................................................................. 8
SAFETY..................................................................................................................................................... 9
MISUSE OF EQUIPMENT ...................................................................................................................... 9
SECTION 2 –PRODUCT DESCRIPTION ................................................................................................. 12
INTRODUCTION .................................................................................................................................... 12
GENERAL SYSTEM DESCRIPTION.................................................................................................. 12
POWER PANEL ..................................................................................................................................... 13
ACCESSORIES...................................................................................................................................... 14
OPTIONS................................................................................................................................................. 14
SECTION 3 –HANDLING AND STORAGE.............................................................................................. 16
LIFTING WEIGHTS................................................................................................................................ 16
DELIVERY AND STORAGE ................................................................................................................ 16
OPERATING AND STORAGE CONDITIONS................................................................................... 17
INSPECTION........................................................................................................................................... 17
MOVING THE UNIT BY FORKLIFT TRUCKS.................................................................................. 17
SECTION 4 –INSTALLATION.................................................................................................................... 18
INSTALLATION CHECKLIST.............................................................................................................. 18
HANDLING.............................................................................................................................................. 18
INSPECTION........................................................................................................................................... 18
LOCATION AND CLEARANCES........................................................................................................ 18
ISOLATORS (OPTIONAL) ................................................................................................................... 20
COMPRESSOR MOUNTING ............................................................................................................... 20
CHILLED LIQUID PIPING..................................................................................................................... 20
PIPEWORK ARRANGEMENT............................................................................................................. 22
WIRING.................................................................................................................................................... 23
POWER SUPPLY CONNECTION....................................................................................................... 26
CONTROL WIRING ............................................................................................................................... 28
SECTION 5 –TECHNICAL DATA .............................................................................................................. 31
PHYSICAL DATA................................................................................................................................... 31
ELECTRICAL DATA.............................................................................................................................. 32
ELECTRICAL DIAGRAM...................................................................................................................... 32
DIP SWITCH SETTING......................................................................................................................... 36
DIMENSIONS.......................................................................................................................................... 38
CLEARANCES ....................................................................................................................................... 39
SECTION 6 –COMMISSIONING................................................................................................................ 40
COMMISSIONING.................................................................................................................................. 40
PREPARATION –POWER OFF ......................................................................................................... 40
PREPARATION –POWER ON ........................................................................................................... 41
UNIT OPERATING SEQUENCE ......................................................................................................... 42
SECTION 7 –WIRE CONTROLLER OPERATION.................................................................................. 44
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INTRODUCTION .................................................................................................................................... 44
BASIC OPERATIONS........................................................................................................................... 45
ADVANCED OPERATIONS................................................................................................................. 45
SECTION 8 –MAINTENANCE.................................................................................................................... 48
IMPORTANT ........................................................................................................................................... 48
COMPRESSORS.................................................................................................................................... 48
CONDENSER COILS............................................................................................................................ 48
OPERATING PARAMETERS .............................................................................................................. 48
CONDENSER FAN MOTORS.............................................................................................................. 48
OVERALL UNIT INSPECTION............................................................................................................ 48
EXPANSION TANK ............................................................................................................................... 49
ModBus Protocol.......................................................................................................................................... 50
PRESSURE TRANSDUCER DIAGRAM.................................................................................................... 59
R410A PRESSURE TEMPERATURE CHART......................................................................................... 60
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SECTION 1 –GENERAL INFORMATION AND SAFETY
INTRODUCTION
YORK YCAE065/100/130X (18-36 ton, 65-130 kW) chillers and heat pumps are manufactured to the
highest design and construction standards to ensure high performance, reliability and adaptability to
all types of air conditioning installations.
The unit combines a multiple step control design with tandem technology allowing the unit’s
compressors to operate more efficiently across all capacity-load and ambient-temperature conditions.
The unit is intended for cooling and heating water and is not suitable for purposes other than those
specified in this manual.
This manual contains all the information required for correct installation and commissioning of the unit,
together with operating and maintenance instructions. The manual should be read thoroughly before
attempting to operate or service the unit.
All procedures detailed in the manual, including installation, commissioning and maintenance tasks
must only be performed by suitably trained and qualified personnel.
The manufacturer will not be liable for any injury or damage caused by incorrect installation,
commissioning, operation or maintenance resulting from a failure to follow the procedures and
instructions detailed in the manual.
WARRANTY
Johnson Controls warrants all equipment and materials against defects inworkmanship and materials
for a period of one year from date of initial start-up or eighteen (18) months from date of shipment,
whichever occurs first, unless labor or extended warranty has been purchased as part of the contract.
The warranty is limited to parts only replacement and shipping of any faulty part, or sub-assembly,
which has failed due to poor quality or manufacturing errors. All claims must be supported by evidence
that the failure has occurred within the warranty period, and that the unit has been operated within
the designed parameters specified.
All warranty claims must specify the unit model, serial number, order number and run hours/starts.
Model and serial number information is printed on the unit identification plate.
The unit warranty will be void if any modification to the unit is carried out without prior written approval
from Johnson Controls.
For warranty purposes, the following conditions must be satisfied:
•The initial start of the unit must be carried out by trained personnel from an Authorized Johnson
Controls Service Center.
•Only genuine YORK approved spare parts, oils, coolants, and refrigerants must be used.
•All the scheduled maintenance operations detailed in this manual must be performed at the
specified times by suitably trained and qualified personnel.
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•Failure to satisfy any of these conditions will automatically void the warranty.
SAFETY
YCAE-X units are designed and built within an ISO 9001 accredited design and manufacturing
organization.
Fluorinated Greenhouse Gases
•This equipment contains fluorinated greenhouse gases covered by the Kyoto Protocol.
•The GWP (global warming potential) of the refrigerant (R410A) used in this unit is 2088.
•The refrigerant quantity is stated in the Physical Data table of this document.
•The fluorinated greenhouse gases in this equipment may not be vented to the atmosphere.
•This equipment should only be serviced by qualified technicians.
Responsibility for Safety
Every care has been taken in the design and manufacture of the unit to ensure compliance with the
safety requirements listed above. However, the individual operating or working on any machinery is
primarily responsible for:
•Personal safety, safety of other personnel, and the machinery.
•Correct utilization of the machinery in accordance with the procedures detailed in the manuals.
The contents of this manual include suggested best working practices and procedures. These are
issued for guidance only, and they do not take precedence over the above stated individual
responsibility and/or local safety regulations.
This manual and any other document supplied with the unit are the property of Johnson Controls
which reserves all rights. They may not be reproduced, in whole or in part, without prior written
authorization from an authorized Johnson Controls representative.
MISUSE OF EQUIPMENT
Suitability for Application
The unit is intended for cooling/heating water or glycol solutions and is not suitable for purposes other
than those specified in these instructions. Any use of the equipment other than its intended use, or
operation of the equipment contrary to the relevant procedures may result in injury to the operator, or
damage to the equipment.
The unit must not be operated outside the design parameters specified in this manual.
Structural Support
Structural support of the unit must be provided as indicated in these instructions. Failure to provide
proper support may result in injury to the operator, or damage to the equipment and/or building.
Mechanical Strength
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The unit is not designed to withstand loads or stresses from adjacent equipment, pipework or
structures. Additional components must not be mounted on the unit. Any such extraneous loads may
cause structural failure and may result in injury to the operator, or damage to the equipment.
General Access
There are a number of areas and features, which may be a hazard and potentially cause injury when
working on the unit unless suitable safety precautions are taken. It is important to ensure access to
the unit is restricted to suitably qualified persons who are familiar with the potential hazards and
precautions necessary for safe operation and maintenance of equipment containing high
temperatures, pressures and voltages.
Pressure Systems
The unit contains refrigerant vapor and liquid under pressure, release of which can be a danger and
cause injury. The user should ensure that care is taken during installation, operation and maintenance
to avoid dam- age to the pressure system. No attempt should be made to gain access to the
component parts of the pressure system other than by suitably trained and qualified personnel.
Electrical
The unit must be grounded. No installation or maintenance work should be attempted on the electrical
equipment without first switching power OFF, isolating and locking-off the power supply. Servicing
and maintenance on live equipment must only be performed by suitably trained and qualified
personnel. No attempt should be made to gain access to the control panel or electrical enclosures
during normal operation of the unit.
Heat Radiation
Some of the visible parts like discharge pipe may work under high temperatures, thus radiate high
heat flux. Special attention must be paid while getting close to the unit. Touching is prohibited during
normal operation.
Rotating Parts
Fan guards must be fitted at all times and not removed unless the power supply has been isolated.
Sharp Edges
The fins on the air-cooled condenser coils have sharp metal edges. Reasonable care should be taken
when working in contact with the coils to avoid the risk of minor abrasions and lacerations. The use
of gloves is recommended.
Frame rails, panels, and other components may also have sharp edges. Reasonable care should be
taken when working in contact with any components to avoid risk of minor abrasions and lacerations.
Refrigerants and Oils
Refrigerants and oils used in the unit are generally non-toxic, non-flammable and non-corrosive, and
pose no special safety hazards. They are pre-charged before delivery to customer and normally
dispense with the need of additional charging, unless the machine is not working properly.
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Use of gloves and safety glasses is, however, recommended when working on the unit. The buildup
of refrigerant vapor, from a leak for example, does pose a risk of asphyxiation in confined or enclosed
spaces and attention should be given to good ventilation.
High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods (e.g. steam cleaning) should not be used on any
part of the pressure system as this may cause operation of the pressure relief device(s). Detergents
and solvents, which may cause corrosion, should also be avoided.
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SECTION 2 –PRODUCT DESCRIPTION
INTRODUCTION
YORK Air-Cooled Modular Chiller and Heat Pump provide chilled water or (and) hot water for all air
conditioning applications using central station air handling or terminal units. They are completely self-
contained and are designed for outdoor (roof or ground level) installation. Each complete packaged
unit includes hermetic scroll compressors, a liquid cooler, air cooled condensers, a charge of
refrigerant R410A and a weather resistant microprocessor control center, all mounted on a welded
steel base.
The units are completely assembled with all interconnecting refrigerant piping and internal wiring,
ready for field installation.
Prior to delivery, the packaged unit is pressure-tested, evacuated, and fully charged with Refrigerant
R410A and oil. After assembly, a complete operational test is performed with water flowing through
the cooler to assure that the refrigeration circuit operates correctly.
The unit structure is heavy-gauge, galvanized steel. This galvanized steel is coated with baked-on
powder paint, which, when subjected to ISO 9227 500 hour, salt spray testing, yields a minimum ISO
10289 rating of “6”. Corrosion resistant wire mesh grills and lower panels are added to protect the
condenser coil from incidental damage and restrict unauthorized access to internal components.
All exposed power wiring is routed through liquid-tight, UV-stabilized, non-metallic conduit.
GENERAL SYSTEM DESCRIPTION
Compressor
The unit has fixed speed, hermetic, scroll compressors. High efficiency is achieved through a
controlled orbit and the use of advanced scroll geometry. The compressors incorporate a compliant
scroll design in both the axial and radial direction. All rotating parts are statically and dynamically
balanced. A large internal volume and oil reservoir provides greater liquid tolerance. Compressor
crankcase heaters are also included for extra protection against liquid migration.
Refrigerant Circuits
One or two independent refrigerant circuits are provided on each unit. Each circuit uses copper
refrigerant pipe formed on computer controlled bending machines to reduce the number of brazed
joints resulting in a reliable and leak resistant system.
Each circuit shall incorporate all components necessary for the designed operation including: a
suction accumulator, a liquid receiver, a four way reversing valve, service valves, a bi-flow electrical
expansion valve. Suction lines shall be covered with closed-cell insulation.
Evaporator (Heat Exchanger)
The compact, high efficiency Brazed Plate Heat Exchanger (BPHE) is constructed with 316 stainless
steel corrugated channel plates with a filler material between each plate. It offers excellent heat
transfer performance with a compact size and low weight, reducing structural steel requirements on
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the job site.
The heat exchanger is manufactured in a precisely controlled vacuum-brazing process that allows the
filler material to form a brazed joint at every contact point between the plates, creating complex
channels.
The units with two refrigerant systems use dual circuit BPHEs. Asymmetric channels provide optimal
efficiency in the most compact design. This results in low refrigerant charge or lower pressure drop
on the water or brine side. The asymmetry guarantees the best performance in both full and partial-
load conditions. The integrated distribution system ensures an even distribution of the refrigerant
throughout the plate package.
The refrigerant side design working pressure of the heat exchanger is 45 bar and the waterside(piping)
design working pressure is 10 bar.
The cooler is covered with 7/8” (19mm) flexible, closed-cell, foam insulation.
Installing contractor must include accommodations in the chilled water piping to allow properdrainage
and venting of the heat exchanger. Water inlet and outlet connections are grooved for compatibility
with factory supplied victaulic connections (except 65 kW unit with thread connections).
A strainer with a mesh size 0.3 mm (50 mesh) is recommended upstream of the heat exchanger to
prevent clogging.
A factory-wired flow switch is standard, installed in a pipe section at the outlet of the evaporator.
Condenser
Coils –Fin and tube condenser coils of seamless, internally-enhanced, high-condensing-coefficient,
corrosion resistant copper tubes are arranged in staggered rows, mechanically expanded into
hydrophilic aluminum fins. The design working pressure of the coil is 45 bar (650 PSIG).
Fans –The condenser fans are designed for maximum efficiency with two-staged fan motor. The fans
are positioned for vertical air discharge. All blades are statically and dynamically balanced for
vibration-free operation. The fan grilles are constructed of heavy-gauge, rust-resistant, coated steel.
AC Motors –The fans are directly driven by two-staged motors. Thermal loading protection is
integrated. They feature ball bearings that are double-sealed and permanently lubricated.
POWER PANEL
The control elements are fitted in a factory installed and wired IP55 rain/dust tight, powder painted
steel cabinets with tool lockable, hinged, latched, and gasket sealed outer doors. Main power
connection(s), compressor starters, fan motor contactors, current overloads are provided and factory
wired.
A unit-mounted Circuit Breaker with external lockable handle shall be provided at the point of incoming
single point connection for field connection, interconnecting wiring to the compressors, and isolating
the power voltage for servicing. Incoming power wiring must comply with local codes. Circuit breaker
shall be sized to provide the motor branch circuit protection, short circuit protection and ground fault
protection for the motor branch-circuit conductors, the motor control apparatus and the motors.
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Power panel contains:
•IPU3 (including I/O board and core board)
•Compressor and fan contactors
•Compressor thermal relays
•Power sequence protector
•Power and control wiring terminals
•Compressor power terminals
Short Circuit Withstand Rating of the unit electrical enclosure shall be (380V: 5,000 Amps).
The power wiring is routed through liquid-tight conduit to the compressors and fans.
ACCESSORIES
DISCHARGE PRESSURE TRANSDUCERS –The addition of pressure transducers allows models to
sense and display discharge pressure. This allows the unit to automatically adjust condenser fan
speed to suit different ambient conditions, as well as protect the unit from over pressure (Factory-
Mounted).
SUCTION PRESSURE TRANSDUCERS - Permits unit to sense and display suction pressure. This
capability is standard on all models. The suction pressure is monitored for system superheat control
(Factory-Mounted).
TOUCH SCREEN WIRE CONTROLLER –The wire controller is applicable for dual HMI control,
together with optional 7 inch HMI. Both of the controllers are valid to operate the unit simultaneously
(Field- Mounted).
FLOW SWITCH –Vapor proof, paddle-type with 1''NPT connection for upright mounting in horizontal
pipe. This flow switch or its equivalent must be supplied with each unit to protect the heat exchanger
from loss of liquid flow (Factory Mounted).
OPTIONS
HMI CONTROLLER
The HMI is contained in aprotection class IP54cabinet installed in the middle beam with hinged outer
door and includes a 7-inch capacitive touch screen controller backlighting for outdoor viewing.
Different operation levels are accessible for viewer, operator and service. Password will be required
for high level entries. Refer to Optiview LT OPERATION for details.
AESTHETIC ENCLOSURE PANELS (Special Quotation*) –Welded wire mesh guards mounted over
the condenser coils and louvered panels mounted around the bottom of the unit. Tamperproof
Enclosure Panels prevent unauthorized access to units. Enclosure Panels can provide an
aesthetically pleasing alternative to expensive fencing (Factory-Mounted).
SC-EQ CARD –The SC-EQUIP (SC-EQ) Communication Card supersedes the E-Link Gateway and
provides BAS network connectivity for equipments like YCAE. It is designed with four active serial
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ports: The J12 BAS (RS-485) port, the J7 Equipment (RS-232) port, the J8 Equipment (RS-485) port
and the J11 CS port which allows equipment data to be sent to the Johnson Controls Remote
Operation Center for remote unit monitoring and diagnostics. Refer to Wiring Diagram for details
(Factory-Mounted).
VIBRATION ISOLATORS –Level adjusting, spring type 1” (25.4mm) or seismic deflection or
neoprene pad isolators for mounting under unit base rails (Field- Mounted).
WATER TEMPERATURE SENSOR –An additional outlet water temperature sensor will be required
for modular control. The sensor is used for compressor sequencing and water side protections (Field-
Mounted).
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SECTION 3 –HANDLING AND STORAGE
Rigging and lifting should only be done by a professional rigger in accordance
with a written rigging and lifting plan. The most appropriate rigging and lifting
method will depend on job specific factors, such as the rigging equipment
available and site needs. Therefore, a professional rigger must determine the
rigging and lifting method to be used, and it is beyond the scope of this manual
to specify rigging and lifting details.
LIFTING WEIGHTS
Refer to the unit nameplate for unit shipping weight. Note that weight may vary depending on unit
configuration at the time of lifting. Refer to the Physical Data tables within this manual for further
information regarding shipping and operating weights.
DELIVERY AND STORAGE
To ensure consistent quality and maximum reliability, all units are tested and inspected before leaving
the factory. Units are shipped completely assembled and containing refrigerant under pressure. Units
are shipped without export crating unless crating has been specified on the Sales Order.
If the unit is to be put into storage, prior to installation, the following precautions should be observed:
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• The unit must be “blocked” so that the base is not permitted to sag or bow.
• Ensure that all openings, such as water connections, are securely capped.
• Do not store where exposed to high ambient air temperatures that may exceed relief valve settings.
• The condensers should be covered to protect the coils and fins from potential damage and corrosion,
particularly where building work is in progress.
• The unit should be stored in a location where there is minimal activity in order to limit the risk of
accidental physical damage.
• To prevent inadvertent operation of the pressure relief devices the unit must not be steam cleaned.
• It is recommended that the unit is periodically inspected during storage.
OPERATING AND STORAGE CONDITIONS
Standard leaving chilled water temp: 5~20°C
Standard ambient at cooling mode: 10~48°C
Standard leaving hot water temp.: 25~55°C
Ambient temp. at heating mode: -15~25°C
Unit storage ambient temp.: -20~55°C
INSPECTION
Remove any transit packing and inspect the unit to ensure that all components have been delivered
and that no damage has occurred during transit. If any damage is evident, it should be noted on the
carrier’s freight bill and a claim entered in accordance with the instructions given on the advice note.
Major damage must be reported immediately to your local Johnson Controls representative.
MOVING THE UNIT BY FORKLIFT TRUCKS
For models of YCAE065-130, it is recommended that the units are moved by forklift trucks for transit
transfer. A wooden pallet is added for forklift use before shipment.
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SECTION 4 –INSTALLATION
To ensure warranty coverage, this equipment must be commissioned and
serviced by an authorized YORK service mechanic or a qualified service person
experienced in unit installation.
Installation must comply with all applicable codes, particularly in regard to electrical wiring and other
safety elements such as relief valves, HP cutout settings, design working pressures, and ventilation
requirements consistent with the amount and type of refrigerant charge.
Lethal voltages exist within the control panels. Before servicing, open and tag all disconnect switches.
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
connections until piping is ready for attachment. Check water piping to ensure cleanliness.
4. Pipe unit using good piping practice.
5. Check to see that the unit is installed and operated within limitations (Refer to Operational
Limitations).
The following pages outline detailed procedures to be followed to install and start-up the unit.
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.
INSPECTION
Immediately upon receiving the unit, it should be inspected for possible damage which may have
occurred during transit. If damage is evident, it should be noted in the carrier’s freight bill.
A written request for inspection by the carrier’s agent should be made at once.
LOCATION AND CLEARANCES
These units are designed for outdoor installations on ground level, rooftop, or besides a building.
Location should be selected for minimum sun exposure and away from boiler flues and other sources
of airborne chemicals that could attack the ambient coils and steel parts of the unit. The units must
be installed with sufficient clearancesfor air entrance to the condenser coil to ensure adequate supply
of fresh air, for air discharge away from the condenser, and for servicing access.
In installations where winter operation is intended and snow accumulations are expected, additional
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height must be provided to prevent ice accretion in base frame of the unit.
Clearances are listed under “Notes” in the Dimensions section. The clearances recommended are
nominal for the safe and efficient operation and maintenance of the unit and power and control panels.
Local Health and safety regulations, or practical considerations for service replacement of large
components, may require larger clearances than those given in this manual.
Foundation
The unit should be mounted on a flat and level foundation, floor, or rooftop capable of supporting the
entire operating weight of the equipment. See PHYSICAL DATA for operating weight.
If the unit is elevated beyond the normal reach of service personnel, a suitable catwalk must be
capable of supporting service personnel, 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 recommended.
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 section).
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 safety precautions such as a fenced-in enclosure or locking devices on the panels
may be advisable. This will help to prevent the possibility of vandalism, accidental damage, or possible
harm caused by unauthorized removal of protective guards or opening panels to expose rotating or
electrically live components.
Rooftop Locations
Choose a spot with adequate structural strength to safely support the entire weight of the unit and
service personnel. Care must be taken not to damage the roof.
The unit can be mounted on a concrete slab, similar to ground floor locations, or on steel channels of
suitable strength. The channels should be spaced with the same centers as the unit side and front
base rails. This will allow vibration isolators to be fitted if required.
Consult the building contractor or architect if the roof is bonded.
Roof installations should have wooden beams (treated to reduce deterioration), cork, rubber, or
vibration isolators under the base to minimize vibration. Isolators are recommended for rooftop
locations.
Noise Sensitive Locations
Efforts should bemade to assure that the unit is not locatednext to occupied spaces or noise sensitive
areas where unit noise level would be a problem. Unit noise is a result of compressor and fan
operation. Considerations should be made utilizing noise levels published in the YORK Engineering
Guide for the specific unit model. Sound blankets for the compressors and enclosure panels are
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available as options.
Cold Climate Locations
If the unit is operating in low ambient temperature, be sure to follow the instructions listed below.
1. A baffle plate installed on the airside of the unit is recommended to prevent exposure to snow in
winter.
2. In heavy snowfall areas, make sure the coil and fan will not be affected by the snow. Construct a
lateral canopy if necessary.
3. Deice before operating if the fan blades fail to rotate after long time standby in snow.
4. Flexible hoses must be installed to ensure effective condensation water drainage while operating.
Corrosion Locations
The unit is designed to withstand most of the climate conditions. If the unit is installed near the sea
where high levels of salt may shorten the life of the unit, make sure it is not exposed to sea winds
directly.
For any units being installed at the seashore, or where salt spray may hit the units, or where acid rain
is prevalent, please contact Johnson Controls.
ISOLATORS (OPTIONAL)
An optional set of vibration isolators can be supplied loose with each unit. When ordered, four (4)
isolators will be furnished if the unit is installed without pump kit. Two (2) additional isolators will be
required if pump kit is picked.
Identify the isolator, locate at the proper mounting point, and adjust per instructions.
COMPRESSOR MOUNTING
The compressors are mounted on four (4) rubber or steel isolators. The mounting bolts should not be
loosened or adjusted at installation of the unit.
CHILLED LIQUID PIPING
General –When the unit(s) has been located in its final position, the unit water piping may be
connected. Normal installation precautions should be observed in order to receive maximum
operating efficiencies. Piping should be kept free of all foreign matter. All chilled water evaporator
piping must comply in all respects with 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 unit.
Consideration should be given to compressor and control panel access when laying out water piping.
Routing the water piping too close to the unit could make compressor/ control panel servicing/
replacement difficult.
Hand stop valves should be installed in all lines to facilitate servicing.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz