York YMAA 0045 User manual

FORM NO.:6U6K-B01E-NB-EN
JOHNSON CONTROLS
1
AIR-COOLED CHILLER
AND HEAT PUMP
Supersedes: 6U6K-B01E-NA-EN
FORM NO.: 6U6K-B01E-NB-EN
INSTALLATION,COMMISSIONING,
OPERATION & MAINTENANCE
R410A
Issue Date:
February 26, 2018
YMAA / YMPA 0045-0260
AIR-COOLED CHILLER AND HEAT PUMP
50Hz
44-255kW
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FORM NO.:6U6K-B01E-NB-EN
JOHNSON CONTROLS
2
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 certain
components 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 has the 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 wellas 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
whichwillresultindeathorseriousinjury
if proper care is not taken.
Identifies a hazard which could lead to
damage to the machine, damage toother
equipment and/or environmental
pollution if proper care is not taken or
instructions and are notfollowed.
Indicates a potentially hazardous
situation which will result in possible
injuries or damage to equipment if
proper care is not taken.
Highlightsadditionalinformationuseful
to the technician in completing the work
being performedproperly.
Externalwiring,unlessspecifiedasanoptionalconnectioninthemanufacturer’sproductline,isnot
to be connected insidethe controlcabinet. Devices such as relays, switches, transducers andcontrols
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.JohnsonControlswillNOT beresponsiblefordamage/problemsresultingfrom
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.
This equipment is a relatively complicated apparatus.
During rigging, installation, operation, maintenance,
or service, individuals may be exposed to certain
components 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 has the 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,
The following symbols are used in this document to alert the reader to specic situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Indicates a potentially hazardous situation
which will result in possible injuries or
damage to equipment if proper care is not
taken.
External wiring, unless specied 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 specications and must be performed only by a qualied 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.
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 not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
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
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3JOHNSON CONTROLS
FORM NO.: 6U6K-B01E-NB-EN
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 to the manual or product owner. Updated manuals,
if applicable, can be obtained by contacting the nearest Johnson
Controls Service office or accessing the Johnson Controls
website.
It is the responsibility of rigging, lifting, and operating/ service
personnel to verify the applicability of these documents to the
equipment. If there is any question
This manual contains installation, operation and maintenance
instructions for both single and dual refrigerant circuit models.
If your unit is a single circuit model
CHANGEABILITY OF THIS DOCUMENT
ASSOCIATED LITERATURE
SINGLE CIRCUIT AND DUAL CIRCUIT MODELS
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 technical information and any other
changes in spelling, grammar or formatting are not included.
MANUAL DESCRIPTION
SC-EQ Communication Card Installation Instructions
FORM NUMBER
450.50-N1
(YMAA/YMPA 0045-0065), disregard references to “System
2” which may appear in this manual. Any references to Sys 2
are applicable to YMAA/YMPA 0080-0260 models.
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FORM NO.:6U6K-B01E-NB-EN
JOHNSON CONTROLS
4
BASIC UNIT NOMENCLATURE
Y M PA 0045 P E 50 Voltage
50: 400V/3Ph/50Hz
Refrigerant
E: R410A
Unit Designator
P: Premium Efficiency
Nominal Capacity
(Unit: kW)
Design Series
Chiller Type
P: Heat Pump
A: Chiller
Modular
YORK
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5JOHNSON CONTROLS
FORM NO.: 6U6K-B01E-NB-EN
SECTION 1 – GENERAL INFORMATION AND SAFETY
INTRODUCTION
WARRANTY
SAFETY
ABOUT THIS MANUAL
MISUSE OF EQUIPMENT
SECTION 2 – PRODUCT DESCRIPTION
INTRODUCTION
GENERAL SYSTEM DESCRIPTION
OPTIVIEW LT CONTROLLER
POWER PANEL
DRIVER PANEL
STANDARD EQUIPMENT
OPTIONS
HYDRO KIT
REFRIGERANT FLOW DIAGRAM
UNIT COMPONENTS
SECTION 3 – HANDLING AND STORAGE
LIFTING WEIGHTS
DELIVERYAND STORAGE
OPERATING AND STORAGE CONDITIONS
INSPECTION
MOVING THE UNIT BY FORKLIFT TRUCKS
LIFTING THE UNIT
SECTION 4 – INSTALLATION
INSTALLATION CHECKLIST
HANDLING
INSPECTION
LOCATION AND CLEARANCES
ISOLATORS (OPTIONAL)
COMPRESSOR MOUNTING
CHILLED LIQUID PIPING
PIPEWORK ARRANGEMENT
WIRING
CIRCUIT BREAKER
EMERGENCY CUTOUT BUTTON
COMPRESSOR HEATERS
BPHE AND PIPING HEATERS
DUAL PRESSURE RELIEF VALVES
PRESSURE CUTOUT
WIRE CONTROLLER
SC-EQUIPMENT COMMUNICATION CARD
POWER SUPPLY CONNECTION
CONTROL WIRING
Table of Contents
8
8
8
8
9
9
11
11
11
12
12
13
13
14
14
15
18
27
27
27
28
28
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31
31
31
31
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37
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37
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37
37
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41
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FORM NO.:6U6K-B01E-NB-EN
JOHNSON CONTROLS
6
SECTION 5 – TECHNICAL DATA
OPERATIONAL LIMITATIONS
PHYSICAL DATA
ELECTRICAL DATA
ELECTRICAL DIAGRAM
WIRING DIAGRAM
DIP SWITCH SETTING
DIMENSIONS
TECHNICAL DATA – CLEARANCES
ISOLATORS – WEIGHT DISTRIBUTIONAND ISOLATOR MOUNTING POSITIONS
ISOLATOR DETAILS – ONE INCH DEFLECTION SPRING ISOLATOR CROSS-REFERENCE
ONE INCH DEFLECTION – SPRING ISOLATORS INSTALLATION INSTRUCTIONS
TWO INCH DEFLECTION SPRING ISOLATOR CROSS-REFERENCE
TWO INCH DEFLECTION SPRING ISOLATOR INSTALLATION AND ADJUSTMENT
NEOPRENE ISOLATOR CROSS-REFERENCE
NEOPRENE ISOLATOR INSTALLATION AND ADJUSTMENT
SECTION 6 – COMMISSIONING
COMMISSIONING
PREPARATION – POWER OFF
PREPARATION – POWER ON
UNIT OPERATING SEQUENCE
HYDRO KIT COMMISSIONING
CIRCULATION PUMP
CONTROL MODES
MODE SETTING
DISPLAY
OPERATION
SECTION 7 – OPTIVIEW LT OPERATION
INTRODUCTION
MAIN INTERFACE
PRIVILEGE MANAGEMENT
SYSTEM
SYSTEM SETPOINTS
UNIT
FAULT
HMI
SCHEDULE
DIAGNOSIS
SECTION 8 – WIRE CONTROLLER OPERATION
INTRODUCTION
INTERFACE
BASIC OPERATIONS
ADVANCED OPERATIONS
43
45
47
49
51
52
63
65
75
76
80
83
84
87
88
91
93
93
93
94
98
98
98
99
100
100
101
102
102
102
102
102
103
104
105
106
107
107
109
109
109
110
110
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7JOHNSON CONTROLS
FORM NO.: 6U6K-B01E-NB-EN
SECTION 9 – UNIT OPERATION
CAPACITY CONTROL
SUCTION PRESSURE LIMIT CONTROLS
DISCHARGE PRESSURE LIMIT CONTROLS
COMPRESS RATIO LIMIT CONTROLS
DISCHARGE TEMPERATURE CONTROLS
INVERTER FREQUENCY CONTROL
LIQUID TEMP. CONTROL
VARIABLE LEAVING WATER TEMPERATURE CONTROLS
COMPRESSOR SEQUENCING
DEFROST CONTROLS
ANTI-RECYCLE TIMER
ANTI-COINCIDENCE TIMER
EVAPORATOR AND PIPING HEATER CONTROLS
COMPRESSOR CRANKCASE HEATERS
AUXILIARY HEATER CONTROL
EC FAN CONTROL
ALARM STATUS
SECTION 10 – SERVICE AND TROUBLESHOOTING
SERVICE MODE
ANALOG AND DIGITAL INPUTS
DIGITAL/PWM OUTPUTS AND COMMUNICATIONS
RUNNING STATUS
TROUBLESHOOTING
SECTION 11 – MAINTENANCE
IMPORTANT
COMPRESSORS
CONDENSER COILS
OPERATING PARAMETERS
CONDENSER FAN MOTORS
BPHE (EVAPORATOR) HEATER
EXPANSION TANK
OVERALL UNIT INSPECTION
PRESSURE RELIEF VALVES
MODBUS PROTOCOL
BACNET POINT TABLE
PRESSURE TRANSDUCER DIAGRAM
EC FAN SPEED CHART
R410A PRESSURE TEMPERATURE CHART
112
112
112
112
112
113
113
115
116
117
118
119
119
119
119
119
119
119
120
120
120
121
121
122
124
124
124
124
124
124
124
124
124
124
128
137
141
142
143
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FORM NO.:6U6K-B01E-NB-EN
JOHNSON CONTROLS
8
SECTION 1 – GENERAL INFORMATION AND SAFETY
SECTION 1 – GENERAL INFORMATION AND SAFETY
INTRODUCTION
YORK YMAA/YMPA 0045-0260 (12-72 ton, 44-255 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 an
industry leading DC Inverter technology allowing the unit’s
compressors to operate more efficiently than constant speed
units across all capacity-load and ambient-temperature
conditions. It is designed for part-load efficiency exceeding
EcoDesign 2021.
The unit is intended for cooling and heating water or glycol
solutions and is not suitable for purposes other than those
specied 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 qualied 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 in workmanship 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 specied.
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 identication plate.
The unit warranty will be void if any modication to the unit
is carried out without prior written approval from Johnson
Controls.
For warranty purposes, the following conditions must be
satised:
•The initial start of the unit must be carried out by trained
personnel from an Authorized Johnson Controls Service Center
(see SECTION 6 – COMMISSIONING).
•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 (see SECTION 11 –
MAINTENANCE).
•Failure to satisfy any of these conditions will automatically
void the warranty (see Warranty Policy).
SAFETY
Standards for Safety
YMAA/YMPA units are designed and built within an ISO 9001
accredited design and manufacturing organization. The units
comply with the applicable sections of the following Standards
and Codes:
•Machinery Directive (2006/42/EC)
•EMC Directive (2014/30/EU)
•Pressure Equipment Directive (2014/68/EU)
•Safety Code for Mechanical Refrigeration EN 378-2
•Safety of machinery - Electrical Equipment of Machine (EN
60204-1)
•Generic emissions and immunity standards for industrial
environment EN61000-6-4&61000-6-2
•Fluorinated greenhouse gases regulation ((EU) No 517/2014)
In addition, the units conform to European Conformity (CE) for
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9JOHNSON CONTROLS
FORM NO.: 6U6K-B01E-NB-EN SECTION 1 – GENERAL INFORMATION AND SAFETY
construction of units and provide CE Listing Label.
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 uorinated 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.
ABOUT THIS MANUAL
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 forApplication
The unit is intended for cooling/heating water or glycol
solutions and is not suitable for purposes other than those
specied 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
specied 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
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
qualied personnel.
Electrical
The unit must be grounded. No installation or maintenance
work should be attempted on the electrical equipment without
rst 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.
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FORM NO.:6U6K-B01E-NB-EN
JOHNSON CONTROLS
10
Heat Radiation
Some of the visible parts like discharge pipe and driver heat
sink may work under high temperatures, thus radiate high heat
ux. Special attention must be paid while getting close to the
unit. Touching is prohibited during normal operation.
Rotating Parts
Fan guards must be tted 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.
Use of gloves and safety glasses is, however, recomm-ended
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.
Emergency Shutdown
In case of emergency, the HMI panel or the control panel is
tted with a Unit Switch to stop the unit in an emergency. When
operated, it removes the low voltage 230 VAC electrical supply
of the control panel, thus shutting down the unit.
Safety Labels
The following labels are xed to each unit to give instruction,
or to indicate potential hazards which may exist.
Black symbol on yellow background
Warning: This machine may start automatically
without prior warning
Black symbol on yellow background
Warning: Hot surface
Black symbol on yellow background
Warning: Safety relief valve may discharge gas
or liquid without prior warning
Black symbol on yellow background
Warning: Isolate all electrical sources of supply
before opening or removing the cover, as lethal
voltages may exist
Black symbol on yellow background
General attention symbol
SECTION 1 – GENERAL INFORMATION AND SAFETY
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11JOHNSON CONTROLS
FORM NO.: 6U6K-B01E-NB-EN SECTION 2 – PRODUCT DESCRIPTION
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-R410Aand oil.
After assembly, a complete operational test is performed with
water owing 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.
The unit conforms with the essential requirements of the
following relevant EC directives:
• Pressure Equipment Directive 2014/68/EU
• EMC Directive 2014/30/EU
• Machinery Directive 2006/42/EC
• Ecodesign Directive (2009/125/EC)
• Energy Label Directive 2010/30/EU
GENERAL SYSTEM DESCRIPTION
Compressor
Each unit has a DC (direct current) inverter scroll compressor
which is driven directly by an external driver, located next to
the control panel. The compressor is capable to run at the speed
of 40 to 110 Hz. Standard sound insulation includes an acoustic
blanket and a sheet metal enclosure.
The unit also has fixed speed, hermetic, scroll compressors.
High efciency 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, pressure
relief valves, an oil separator (only available for inverter
system), a bi-ow electrical expansion valve. Suction lines shall
be covered with closed-cell insulation.
Electronic Expansion Valve
Electronic Expansion Valve works as throttle device. The valve
supports automatic adjustment of refrigerant ow rate and makes
the system work under optimized conditions for the purpose of
fast cooling or heating, precise temperature control and energy
saving. It permits operation at both low temperatures and
comfort cooling applications without a capacity loss or derate at
either condition (Factory mounted).
Evaporator (Heat Exchanger)
The compact, high efficiency Brazed Plate Heat Exchanger
(BPHE) is constructed with 316 stainless steel corrugated
channel plates with a ller material between each plate. It offers
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FORM NO.:6U6K-B01E-NB-EN
JOHNSON CONTROLS
12
excellent heat transfer performance with a compact size and
low weight, reducing structural steel requirements on the job
site.
The heat exchanger is manufactured in a precisely controlled
vacuum-brazing process that allows the ller 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 Brazed Plate Heat Exchanger is equipped with a heater
controlled by the microprocessor. The heater provides freeze
protection for the cooler down to -20 °C ambient. The cooler
is covered with 1-1/2” (38mm) flexible, closed-cell, foam
insulation.
Installing contractor must include accommodations in the
chilled water piping to allow proper drainage and venting of the
heat exchanger. Water inlet and outlet connections are grooved
for compatibility with factory supplied victaulic connections.
A strainer with a mesh size between 0.8 and 1.0 mm (20 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 ns. The design working
pressure of the coil is 45 bar (650 PSIG).
Fans – The condenser fans are composed of corrosion resistant
aluminum blades sprayed with PP plastic and galvanized sheet
steel fan housing coated with black plastic. They are designed
for maximum efficiency with integrated variable speed drive.
They are directly driven by independent EC motors, and
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.
EC Motors – The fans are directly driven by EC (Electrical
Commutation) motors. Thermal loading protection and line
under-voltage, phase failure detections are integrated. Fan speed
is controlled through ModBus communication. They feature
ball bearings that are double-sealed and permanently lubricated.
OPTIVIEW LT CONTROLLER
The HMI is contained in a protection class IP54 cabinet
installed in the middle beam with hinged outer door and
includes a 7-inch 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 Section 7 - OPTIVIEW LT OPERATION for details.
POWER PANEL
The control elements are tted in a factory installed and wired
IP54 rain/dust tight, powder painted steel cabinets with tool
lockable, hinged, latched, and gasket sealed outer doors. Main
power connection(s), compressor starters, 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 eld 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.
Power panel contains:
SECTION 2 – PRODUCT DESCRIPTION
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13JOHNSON CONTROLS
FORM NO.: 6U6K-B01E-NB-EN
• IPU3 (including I/O board and core board)
• Compressor and fan contactors
• Compressor thermal relays
• Main circuit breaker
• Power sequence protector
• Power and control wiring terminals
• Compressor power terminals
Short Circuit Withstand Rating of the unit electrical enclosure
shall be (400V: 5,000 Amps). Rating shall be published in
accordance with EN 60204-1.
The power wiring is routed through liquid-tight conduit to the
compressors, fans, driver and transformer.
DRIVER PANEL
The inverter compressor driver is enclosed in a separate panel
on the base frame. It converts alternating current into direct
current to drive the compressor rotating at the rate of 10 RPS
(round per second) as a minimum and 130 RPS as a maximum.
To improve the heat emission efciency, a cooling fan is tted
at the backside of the panel for forced convection. Driver
operation status and faults are displayed through the icker of
the LEDs.
Driver panel contains:
• Filter board
• Rectication circuit
• Inverter
• Terminals
• Cooling ns and fan
All the wirings inside are factory-mounted.
STANDARD EQUIPMENT
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).
CONTROL TRANSFORMER – Power panel shall be
supplied with a factory mounted and wired control transformer
that will supply all unit control voltage from the main unit
power supply. Transformer shall utilize scheduled line voltage
on the primary side and provide 230V/1N on secondary
(Factory-Mounted).
COMMUNICATIONS – Communication capability for
BACnet (MS/TP), Modbus and N2 as standard via SC-EQUIP
(SC-EQ) board (Factory-Mounted).
The SC-EQ board is designed with four active serial ports: The
J12 BAS (RS-485) port, the J7 Equipment (RS-232) port, the
J8 Equipment (RS-485) port and the J1 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.
SERVICE ISOLATION VALVE – Service suction and disch-
arge (ball type) isolation valves are added to unit per system
(Factory-Mounted).
DUAL RELIEF VALVES – Two relief valves are tted at low
pressure, and two relief valves at high pressure side for each
refrigeration circuit (Factory-Mounted).
FLOW SWITCH – Vapor proof, paddle-type with 1''NPT
connection for upright mounting in horizontal pipe. This ow
switch or its equivalent must be supplied with each unit to
protect the heat exchanger from loss of liquid flow (Factory
Mounted).
ENCLOSURE PANELS – Consists of steel panel guards
mounted on bottom part of the unit to prevent unauthorized
access (Factory mounted).
COMPRESSOR ACOUSTIC BLANKETS AND ENCLOS-
URES – The inverter compressor is individually enclosed in
an acoustic sound blanket made of two layers of acoustical
absorbent polyester fiber of 15 mm thickness and one layer
of anti-vibrating heavy material thickness of 1 mm with
lined cotton. The blanket is closed by two sheets of PVC,
reinforced for temperature and UV resistance. Also it goes
SECTION 2 – PRODUCT DESCRIPTION
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

FORM NO.:6U6K-B01E-NB-EN
JOHNSON CONTROLS
14
with acoustically lined, painted galvanized steel, enclosure
with removable panels for maintenance purposes (Factory
Mounted).
OPTIONS
TOUCH SCREEN WIRE CONTROLLER – The wire
controller is applicable for dual HMI control, together with
standard 7 inch HMI. Both of the controllers are valid to
operate the unit simultaneously (Field-Mounted).
LOW SOUND KIT – The option provides sound attenuation
congurations. It is composed of compressor acoustic blankets
for all the compressors and melamine foam for lower panels.
Also the fan conguration is changed to provide lower sound
emissions. They are recommended for residential or other
similar sound sensitive locations (Factory-Mounted).
VIBRATION ISOLATION
Elastomeric Isolation – This option is recommended for
normal installations. It provides very good performance in most
applications for the least cost (Field-Mounted).
25 mm (1") Spring Isolators – Spring and cage type isolators
for mounting under the unit base rails are available to support
unit. They are level adjustable. 25 mm (1") nominal deection
may vary slightly by application (Field-Mounted).
50 mm (2") Restrained Spring Isolators – Restrained Spring-
Flex Mounting isolators incorporate a rugged welded steel
housing with vertical and horizontal limit stops. Housings
designed to withstand a minimum 1.0g accelerated force in all
directions up to 51 mm (2"). The deection may vary slightly by
application. They are level adjustable (Field-Mounted).
MODULARITY KITS – 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).
HYDRO KIT
Factory tted Hydro Kit is suitable for water and glycol systems
with up to 30% glycol. DOWTHERM SR-1 or other equivalent
solutions are recommended as inhibited ethylene glycol-based
heat transfer uids. Contact local JCI service representatives for
any applications that require a higher concentration of glycol or
the composition is different (Factory-Mounted).
Variable speed pump is optional for all models. The kit is
available in single, standard head, with open drive air cooled
Electrical Commutation motor.
Fixed speed pump is optional for models from 45 to 130 kW.
The hydro-kit option comes standard with a single pump, a 30
mesh strainer, an expansion tank, an air purger and drainage
valves.
Auxiliary heaters are strapped around the water pipes to provide
anti-freezing protections.
The pumps are factory wired to the unit control system to
provide auto pump starting and running.
SECTION 2 – PRODUCT DESCRIPTION
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

15JOHNSON CONTROLS
FORM NO.: 6U6K-B01E-NB-EN
REFRIGERANT FLOW DIAGRAM
SYSTEM PID
FIGURE 1 – REFRIGERANT FLOW DIAGRAM
Notes
1.The piping and instrument diagram is exemplied by dual circuit YMPA130;
2.Congurations may vary for different models.
gnilooC gnitaeH
ROTALUMUCCA
YAWRUOF
VALVE
LACIRTCELE NOISNAPXE
VALVE
FILTERS
REVIECER
ROTOM&NAF
EHPB
SEVLAVKCEHC
EVLAVLLAB
EVLAVLLAB
FEILERERUSSERP
VALVES
29 BARG
SROSSERPMOC
COILS
FEILERERUSSERP
VALVES GRAB8.44
ERUSSERP
RELIEFSEVLAV GRAB92
LACIRTCELE NOISNAPXE
VALVE
FILTERS
FEILERERUSSERP
VALVES GRAB8.44
ROTALUMUCCA
SROSSERPMOC
EVLAVLLAB
EVLAVLLAB
METSYSDEEPSDEXIF METSYSRETREVNI
SECTION 2 – PRODUCT DESCRIPTION
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

FORM NO.:6U6K-B01E-NB-EN
JOHNSON CONTROLS
16
COOLING MODE
Low pressure liquid refrigerant enters the evaporator BPHE and
is evaporated and superheated by the heat energy absorbed from
the chilled liquid. Through 4-way valve, suction accumulator,
the superheated low pressure vapor enters the compressors and
HEATING MODE
Two-phase refrigerant liquid enters RTPF (round tube and plate
n) coils and fully evaporated there by absorbing the heat from
the flowing air driven by the EC fan. Through 4-way valve
and accumulator, superheated low suction vapor enters the
compressor(s). The compressors rework to compress vapor to
is compressed to high pressure. The high pressure vapor is fed
to the ambient coils and fans, via the four way reversing valve,
where heat is removed. The fully condensed and subcooled
liquid passes through the electronic expansion valve where
pressure is reduced and turned into two-phase refrigerant
mixture to make chilled water in evaporator BPHE.
higher pressure, which flow into BPHE (as a condenser) and
condensed into refrigerant liquid by rejecting the heat to the
flowing water to make hot water. The subcooled refrigerant
liquid goes through EEV and re-enters into RTPF coils (as
evaporator) to repeat the circulation.
FIGURE 2 – COOLING FLOW DIAGRAM
SECTION 2 – PRODUCT DESCRIPTION
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17JOHNSON CONTROLS
FORM NO.: 6U6K-B01E-NB-EN
DEFROST
When ice builds up on the ambient coils defrost is initiated by
operating the machine in a cooling mode. The two refrigerant
circuits will be defrosted individually without affecting each
other for dual circuit units. When one system is in defrosting,
the other must be working in heating mode even though it is the
time to defrost.
FIGURE 3 – HEATING FLOW DIAGRAM
SECTION 2 – PRODUCT DESCRIPTION
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FORM NO.:6U6K-B01E-NB-EN
JOHNSON CONTROLS
18
UNIT COMPONENTS YMAA/YMPA0045-0065
FIGURE 4 – COMPONENTS YMAA/YMPA0045-0065
Receiver Transformer
Driver Panel
Coils
Fan
Control and
Optiview LT Panel
Compressors
Accumulator
Brazed Plate
Heat Exchanger
SECTION 2 – PRODUCT DESCRIPTION
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

19JOHNSON CONTROLS
FORM NO.: 6U6K-B01E-NB-EN SECTION 2 – PRODUCT DESCRIPTION
UNIT COMPONENTS – YMAA/YMPA0080-0100
FIGURE 5 – COMPONENTS YMAA/YMPA0080-0100
Fan 1
Coils
Driver Panel Transformer
Control Panel
Compressors Accumulators
HMI Panel
Brazed Plate
Heat Exchanger
Fan 2
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FORM NO.:6U6K-B01E-NB-EN
JOHNSON CONTROLS
20
UNIT COMPONENTS – YMAA/YMPA0130
FIGURE 6 – COMPONENTS YMAA/YMPA0130
Coils
Driver Panel Transformer
Control Panel
Compressors Accumulators
Optiview LT Panel
Brazed Plate
Heat Exchanger
Fan 1
Fan 2
SECTION 2 – PRODUCT DESCRIPTION
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz