York Ylha plus 12 User manual

Air-condensed cooling units and heat
pumps YLCA / YLHA PLUS 5 to 27
Installation manual
Ref.: N-40314_EN 0910

Index
1Installation manual...................................................................................................................1
1.1 Safety instructions....................................................................................................................2
1.2 Icons used in this document.....................................................................................................2
1.3 Instructions for storage, transport, loading and unloading of the unit......................................3
1.3.1 Inspection.................................................................................................................................3
1.3.2 Disposal of packaging..............................................................................................................3
1.3.3 Disposal of the unit...................................................................................................................4
1.3.4 Handling...................................................................................................................................4
1.4 Selection guide (YLCA/YLHA).................................................................................................4
1.4.1 Selection guide with glycol (cool only units).............................................................................7
1.5 Technical data..........................................................................................................................9
1.5.1 Limits of use.............................................................................................................................9
1.5.2 Correcting Factors....................................................................................................................9
1.5.3 Physical data..........................................................................................................................15
1.5.4 Electrical specifications..........................................................................................................17
1.6 Measurements, clearances and accesses.............................................................................18
1.6.1 Clearances.............................................................................................................................18
1.6.2 Dimensions and hydraulic connections␤(models YLCA/YLHA PLUS 5)................................20
1.6.3 Dimensions and hydraulic connections ␤(models YLCA/YLHA PLUS 7 and 9).....................21
1.6.4 Dimensions and hydraulic connections ␤(models YLCA/YLHA PLUS 12 and 15).................22
1.6.5 Dimensions and hydraulic connections ␤(models YLCA/YLHA PLUS 20 and 27).................23
1.7 Cooling capacities YLHA........................................................................................................24
1.7.1 Cooling capacities YLHA 5 ÷ 27.............................................................................................24
1.7.2 Cooling capacities YLHA 5 ÷ 27 (35% ethylene glycol).........................................................26
1.7.3 Heating capacities YLHA 5 ÷ 27.............................................................................................27
1.8 Cooling capacity YLCA..........................................................................................................28
1.8.1 Cooling capacities YLCA 5 ÷ 27.............................................................................................28
1.8.2 Cooling capacities YLCA 5 ÷ 27 (35% ethylene glycol).........................................................29
1.9 Instructions for installation and connection of the unit...........................................................30
1.9.1 Characteristics of the location................................................................................................30
1.9.2 Specifications for anchoring the unit......................................................................................31
1.9.3 Hydraulic connections............................................................................................................32
1.9.4 Wiring diagrams.....................................................................................................................32
1.10 Instructions for starting up the unit.........................................................................................33
1.10.1 Rotational direction of Scroll compressors.............................................................................33
1.11 Unit sound pressure data.......................................................................................................33
1.12 Unit installation data...............................................................................................................34
1.12.1 List of tests for unit start-up....................................................................................................34
1.12.2 Start-up Data..........................................................................................................................35
2Electric circuit diagrams.........................................................................................................37
2.1 Electric circuit diagram YLCA/YLHA PLUS 5÷9 MC and M (230.1.50)..................................38
Index
i

2.2 Electric circuit diagram YLCA/YLHA PLUS 12 MC and M (230.1.50)....................................40
2.3 Electric circuit diagram YLCA/YLHA PLUS 7 and 9 TC and T (400.3.50)............................. 42
2.4 Electric circuit diagram YLCA/YLHA PLUS 12 and 15 TC and T (400.3.50)......................... 44
2.5 Electric circuit diagram YLCA/YLHA PLUS 20 TC and T (400.3.50)..................................... 46
2.6 Electric circuit diagram YLCA 27 TC, YLHA PLUS 27 (400.3.50)..........................................48
2.7 Electric circuit diagram YLCA PLUS 5 ÷ 9 MCS (230.1.50) SOFT START........................... 50
2.8 Electric circuit diagram YLCA PLUS 12 MCS (230.1.50) SOFT START............................... 52
Index
ii

1
Installation manual

1.1 Safety instructions
This document contains the necessary information for the safe and efficient transportation, assembly
and installation of the air conditioning unit. This guarantees the condition of the unit and its operating
safety.
Only an authorised company may assemble the air conditioning unit.
ATTENTION
Only authorised companies with the appropriate technical resources and suitably trained personnel may
install the air conditioning unit.
CAUTION
The specialists responsible for installing the air conditioning unit must make sure they have all of the
information and knowledge required to correctly install, test and deliver the unit. Johnson Controls Inc.
shall not be considered responsible for any damage caused by installation of the unit that is no consistent
with that described in this document or others specifically provided with the unit.
During regular equipment installation, the fitter must pay special attention to certain situations in order
to prevent injuries or damage to the unit.
Situations that could jeopardise the safety of the fitter or that of others nearby or that could put the unit
itself at risk are clearly indicated in this manual.
A series of special symbols are used to clearly identify these situations.
Pay careful attention to these symbols and to the messages following them, as your safety and the safety
of others depends on it.
1.2 Icons used in this document
DANGER
•The text following this symbol contains information and instructions relating directly to your safety
and physical wellbeing.
•Not taking these instructions into account could lead to serious, very serious or even fatal injuries to
you and others in the proximities of the unit.
Information can also be found on safe procedures during unit handling. This will help reduce the risk of
accidents.
CAUTION
•The text following this symbol contains information and instructions relating directly to your safety
and physical wellbeing.
•Not taking these instructions into account could lead to minor injuries to you and others in the prox‐
imities of the unit.
•Not taking these instructions into account could lead to unit damage.
Information can also be found on safe procedures during unit handling. This will help reduce the risk of
accidents.
NOTE
•The text following this symbol contains information or instructions that may be of use or that is worthy
of a more thorough explanation.
•Instructions regarding inspections to be made on unit parts or systems may also be included.
1Installation manual
1.1 Safety instructions
2

1.3 Instructions for storage, transport, loading and unloading of
the unit
CAUTION
Outdoor units must be moved and stored vertically to prevent oil from leaking from the compressor.
Delivery inspection
The unit should be carefully inspected for visible damage or abnormalities as soon as it is received.
Any abnormalities or damage to the unit should be communicated to both the transportation and insur‐
ance company in writing.
Storage instructions
The unit should be stored in a place suitable to the purpose (warehouse or similar), protected from the
weather, water, humidity and dust.
Cover the unit with a canvas of a suitable size.
The unit should be appropriately protected from knocks and dust, ensuring the protective parts it was
supplied with remain in place. Where these are not in place, establish the necessary protections and/or
barriers to keep vehicles or fork-lift trucks away.
Transport, loading and unloading of the unit
The units should only be handled by personnel from the company responsible for their installation.
Transport of the unit should be in such a manner that no damage is caused by faulty or inadequate
mooring to the bed or body of the vehicle.
Where necessary, protect all of the edges of the unit against knocks and scratches and moor it to the
bed or body of the vehicle using suitable textile belts or slings to keep it perfectly still.
Loading and unloading the unit from a truck or trailer should be on flat, solid ground using an appropriate
crane with sufficient capacity.
1.3.1 Inspection
Upon reception, inspect the goods and notify the carrier and the insurance company, in writing, of any
possible damage during transportation.
1.3.2 Disposal of packaging
The packaging is recyclable. Dispose of it in the appropriate place or take it to an appropriate collection
centre. Respect the regulations in force for this type of waste in the country where the unit is being
installed.
Packaging remains must be correctly disposed of. Improper disposal of packaging generates environ‐
mental problems that affect human life.
Installation manual 1
Instructions for storage, transport, loading and unloading of the unit 1.3
3

1.3.3 Disposal of the unit
When removing the unit, the components must be ecologically recovered. The cooling circuit is full of
coolant that must be extracted and delivered to the gas manufacturer for recycling.
ATTENTION
The refrigerant gas contains greenhouse-effect fluorinated gas covered by the Kyoto protocol.
Please see the specifications plate for type of gas and quantity per system.
GWP (Global Warning Potential): 2088
There will be oil left in the hermetic compressor, therefore it must be delivered with the circuit sealed.
The air conditioner shall be deposited in the area established by local authorities, to facilitate its selective
recovery.
1.3.4 Handling
The unit must be moved using the metal rails provided for its installation and transport
1.4 Selection guide (YLCA/YLHA)
Necessary information
The following information is needed to select a YLCA/YLHA water cooling unit:
1Cooling capacity needed
2Design cold water inlet and outlet temperatures.
3Design water flow rate, if one of the temperatures of Point 2 above is unknown.
4Design inlet temperature of air to the condenser. Normally, this will be the design ambient temperature
of summer air, unless influenced by the situation or other factors.
5Altitude above sea level.
6Design fouling factor of the evaporator.
NOTE
Points 1, 2 and 3 should be related by means of the following formulae:
Cooling capacity kW = l/h cold water x differential °C
860
1Installation manual
1.4 Selection guide (YLCA/YLHA)
4

SELECTION EXAMPLE
A cooler is required to chill water from 13°C to 7°C, with a cooling capacity of 5 kW.
There are also other design conditions:
• Inlet ambient air in the condenser 35 °C
• Fouling factor: 0,044 m2 °C/kW
• Altitude: Sea level
From a quick glance at the table Cooling capacities YLCA 5 ÷ 27, see on page 28 it can be seen that
a YLCA 5 gives approximately the required capacity of 5,38 kW.
As the factors appearing in tables Fouling factors, see on page 9 and Altitude factors, see on page
12 are not applicable, the conditions will be as follows:
• Cooling capacity: 5,38 kW
• Power consumed: 1,87 kW
• Water temperature: 13°C to 7°C (Temp. difference of 6)
Water flow rate = 5,38 x 860 = 771 l/h
6
Available pressure in the unit's hydraulic circuit:
• From Table Pressure available for the hydraulic circuit and pressure drop in the hydraulic circuit (with‐
out filter mounted), see on page 13 we infer that the YLCA 5 MC, with a flow rate of 771 l/h, has an
available pressure of 56 kPa.
Pressure drop in filter:
• From Table Pressure drop in filters, see on page 14 we infer that with a flow rate of 771 l/h, there is
a pressure drop of 1,3 kPa.
YLHA PLUS selection method
1Establish the correct size of YLHA PLUS by selecting the model from the tables Heating capacities
YLHA 5 ÷ 27, see on page 27 and Cooling capacities YLCA 5 ÷ 27, see on page 28 that is closest
to the cooling and heating capacities required in design conditions of the water outlet temperature
and air inlet temperature.
2Apply fouling correction factors (table Fouling factors, see on page 9 ) and height correction factors
(table Altitude factors, see on page 12 ) to the capacity and power values shown in the corresponding
tables of capacity for the cool and heat modes. Make sure the corrected capacity is still sufficient for
your needs.
3Using the corrected capacities of the unit, select the design temperature differential or the flow rate.
4Check to make sure that these selections are within the YLCA/YLHA PLUS operating limits.
Installation manual 1
Selection guide (YLCA/YLHA) 1.4
5

YLHA PLUS SELECTION EXAMPLE
A YLHA PLUS 5 heat pump operating at a 35 °C ambient temperature should cool water from 13 °C to
7 °C, with a 5 kW cooling capacity.
A 4 kW heating capacity is required in 0 °C design ambient temperature and a hot water outlet temper‐
ature of 45 °C.
The fouling factor is 0,044 m2 °C/kW, with the unit operating at sea level (no corrections). From a quick
glance at the tables Heating capacities YLHA 5 ÷ 27, see on page 27 and Cooling capacities YLCA 5
÷ 27, see on page 28 we see that a YLHA PLUS 5 heat pump approximately gives the required ca‐
pacities:
• Cooling capacity = 5,4 kW
• Total unit absorbed power = 1,91 kW
• Cold water temperature = 13 °C to 7 °C (Temp. diff. of 6 °C)
• Hot and cold water flow rate = 774 l/h
• Heating capacity = 4,15 kW
• Total unit absorbed power in heat mode = 1,88 kW
• Hot water outlet temperature = 45 °C
Hot water temp. dif‐
ferential =4,15 x 860 = 4,60 °C
774
Thus, hot water return temperature is = 40,4 °C
All values are within operating limits:
• Available pressure in hydraulic circuit of a unit with pack:
• From Table Pressure available for the hydraulic circuit and pressure drop in the hydraulic circuit (with‐
out filter mounted), see on page 13 we infer that the YLHA PLUS 5 MC, with a flow rate of 748 l/h,
has an available pressure of 56,5 kPa.
• Pressure drop in filter.
– From Table Pressure drop in filters, see on page 14 , 1" filter, we infer that with a 748 l/h flow
rate, said filter has a pressure drop of 1,2 kPa.
1Installation manual
1.4 Selection guide (YLCA/YLHA)
6

1.4.1 Selection guide with glycol (cool only units)
Necessary information
The following information is needed to select a YLCA cooling unit:
1Cooling capacity needed
2Design cold water/glycol inlet and outlet temperatures.
3Design water/glycol flow rate.
4Design inlet temperature of air to the condenser. Normally, this will be the design ambient temperature
of summer air, unless influenced by the situation or other factors.
5Altitude above sea level.
6Design fouling factor of the evaporator.
NOTE
Points 1, 2 and 3 should be related by means of the following formulae:
Capacity (kW) = Temp. diff. (°C) x Flow rate (litres/sec.)
Glycol factor
Temp. differential (°C) = Liquid Inlet Temp. ‑ Liquid Outlet Temp.
To determine the glycol factor, please see Glycol concentration and correcting tables, see on page
10 (Recommended ethylene glycol concentrations) for ethylene glycol or (Recommended propylene
glycol concentrations) for propylene glycol. For design outlet temperature, please see the recommended
glycol concentration and the glycol factor in this concentration. This is the minimum concentration to be
used for design outlet temperature. If a greater concentration is required, the glycol factor can be deter‐
mined by means of Glycol concentration and correcting tables, see on page 10 (Ethylene glycol in other
concentrations) or (Propylene glycol in other concentrations).
Selection method
1Determine the correct cooling unit model by selecting the one that is closest to the capacities required
by the design conditions of the glycol outlet and air inlet temperatures.
2Apply the fouling correcting factors that correspond to the fouling, altitude and glycol concentration
factor, to the capacity and power values in the capacity tables. Make sure the corrected capacity is
still sufficient for your needs.
3Using the corrected capacities of the cooler, set the design temperature range, or the flow rate, to
balance the formulae appearing in Selection guide (YLCA/YLHA), see on page 4 .
4Always recheck to make sure these selections are within the specified design limits.
Selection example
A cooler is required to chill ethylene glycol from 1 a to ‑4 °C, with an output of 3,5 kW.
The following design conditions are applicable:
• Fouling factor: 0,088m °C/kW
• Altitude: 1 200m
• Ambient air: 30 °C
• Glycol concentration: 30% w/w
For a ‑4 °C ethylene glycol outlet, the concentration recommended in Figure 1 is 30%. Therefore, the
specified concentration is appropriate.
From Table
Cooling capacities YLCA 5 ÷ 27 (35% ethylene glycol), see on page 29 , we infer that a
YLCA 5 unit, at the established design conditions, gives a capacity of 3,4 kW and a consumption of 1,35
kW.
With the design fouling factor, use the capacity correcting factors x 0,987 and power x 0,995 (see Fouling
factors, see on page 9 ).
On design altitude, apply the capacity correcting factors x 10,973 and power x 1,020 (see Altitude fac‐
tors, see on page 12 ).
Installation manual 1
Selection guide (YLCA/YLHA) 1.4
7