York YVAG012 Manual

DC INVERTER AIR-COOLED
CHILLER AND HEAT PUMP
Installation , Operation & Maintenance Manual FORM NO.: 6U5M-A11M-NB-EN
YVAG012~040RSE
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 2
Table of Contents
GENERAL SAFETY GUIDELINES ................................................................................................................................... 4
SECTION 1-PRODUCT DESCRIPTION........................................................................................................................... 6
INTRODUCTION ...................................................................................................................................................... 6
BASIC UNIT NOMENCLATURE ................................................................................................................................ 6
THE UNIT DIMENSION ............................................................................................................................................ 6
OPERATING RANGE ................................................................................................................................................ 8
SECTION 2 –INSTALLATION REQUIREMENTS ............................................................................................................. 9
INSPECTION ............................................................................................................................................................ 9
MOVING THE UNIT ................................................................................................................................................. 9
INSPECTION CHEC LIST........................................................................................................................................ 10
HANDLING ............................................................................................................................................................ 10
LOCATION ............................................................................................................................................................ 11
FOUNDATION ....................................................................................................................................................... 11
INSTALL SPACING ................................................................................................................................................. 13
INSTALLATION CLEARANCES ................................................................................................................................ 13
WATER SYSTEM INSTALLATION ........................................................................................................................... 15
UNIT EXTERNAL HEAD .......................................................................................................................................... 21
ELECTRICAL CONNECTION ................................................................................................................................... 23
ACCESSORY DIMENSIONS .................................................................................................................................... 24
SECTION 3 –ELECTRICAL CONTINUITY ..................................................................................................................... 26
ELECTRICAL CONNECTION ................................................................................................................................... 26
ELECTRICAL DIAGRAM ......................................................................................................................................... 27
ELECTRICAL SCHEMATIC DIAGRAM ..................................................................................................................... 35
SECTION 4 – WIRE CONTROLLER OPERATION ......................................................................................................... 39
INTRODUCTION .................................................................................................................................................... 39
INTERFACE ........................................................................................................................................................... 39
BASIC OPERATIONS .............................................................................................................................................. 40
ADVANCED OPERATIONS ..................................................................................................................................... 40
SECTION 5 – MAINTENANCE .................................................................................................................................... 46
IMPORTANT ......................................................................................................................................................... 46
COMPRESSORS ..................................................................................................................................................... 46
OIL CHARGE .......................................................................................................................................................... 46
ADD TROPICAL PREHEATING ............................................................................................................................... 46
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 3
CONDENSER COILS ............................................................................................................................................... 46
OPERATING PARAMETERS ................................................................................................................................... 46
CONDENSER FAN MOTORS .................................................................................................................................. 46
OVERALL UNIT INSPECTION ................................................................................................................................. 46
MODBUS PROTOCOL ........................................................................................................................................... 47
TROUBLE SHOOTING ............................................................................................................................................ 50
TROUBLE SHOOTING (CONT’D) ............................................................................................................................ 51
POISONOUS AND HARMFUL SUBSTANCE CONTENT TABLE UNIT ....................................................................... 52
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 4
GENERAL SAFETY GUIDELINES
This equipme t is a relatively complicated apparatus.
Duri g riggi g, i stallatio , operatio , mai te a ce,
or service, i dividuals may be exposed to certai
compo e ts or co ditio s i cludi g, but ot limited
to: heavy objects, refrigera ts, materials u der
pressure, rotati g compo e ts, a d both high a d low
voltage. Each of these items has the pote tial, if
misused or ha dled improperly, to cause bodily i jury
or death. It is the obligatio a d respo sibility of
riggi g, i stallatio , a d operati g/service perso el
to ide tify a d recog ize these i here t hazards,
protect themselves, a d proceed safely i completi g
their tasks. Failure to comply with a y of these
requireme ts could result i serious damage to the
equipme t a d the property i which it is situated, as
well as severe perso al i jury or death to themselves
a d people at the site.
This docume t is i te ded for use by ow er-authorized
riggi g, i stallatio , a d operati g/service perso el.
It is expected that these i dividuals possess
i depe de t trai i g that will e able them to perform
their assig ed tasks properly a d safely. It is esse tial
that, prior to performi g a y task o this equipme t,
this i dividual shall have read a d u derstood the o -
product labels, this docume t a d a y refere ced
materials. This i dividual shall also be familiar with
a d comply with all applicable i dustry a d
gover me tal sta dards a d regulatio s pertai i g to
the task i questio .
Pay atte tio to keep this docume t a d you ca
acquire it from local authorized YORK service center
i case it would be lost.
SAFETY SYM OLS
The followi g symbols are used i this docume t to alert the reader to specific situatio s:
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 e uipment if
proper care is not taken.
Identifies a hazard which could lead to
damage to the machine, damage to
other e uipment 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.
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 ualified 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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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 5
CHANGEA ILITY OF THIS DOCUMENT
I complyi g with Joh so Co trols’ policy for
co ti uous product improveme t, the i formatio
co tai ed i this docume t is subject to cha ge without
otice. Joh so Co trols makes o commitme t to
update or provide curre t i formatio automatically to
the ma ual or product ow er. Updated ma uals, if
applicable, ca be obtai ed by co tacti g the earest
Joh so Co trols Service office or accessi g the
Joh so Co trols website.
It is the respo sibility of riggi g, lifti g, a d operati g/
service perso el to verify the applicability of these
docume ts to the equipme t. If there is a y questio
regardi g the applicability of these docume ts, riggi g,
lifti g, a d operati g/service perso el should verify
whether the equipme t has bee modified a d if curre t
literature is available from the ow er of the equipme t
prior to performi g a y work o the chiller.
CHANGE ARS
Revisio s made to this docume t are i dicated with a
li e alo g the left or right ha d colum i the area the
revisio was made. These revisio s are to tech ical
i formatio a d a y other cha ges i spelli g,
grammar or formatti g are ot i cluded.
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 6
SECTION 1-PRODUCT DESCRIPTION
INTRODUCTION
YORK DC I verter Air-Cooled Chiller a d Heat Pump U it provide chilled water a d hot water for all air
co ditio i g applicatio s usi g ce tral statio air ha dli g or termi al u its. They are completely self-co tai ed
a d are desig ed for outdoor (roof or grou d level) i stallatio . Each complete packaged u it i cludes hermetic
rotary compressors, a liquid cooler, air cooled co de sers, a charge of refrigera t R410A a d a weather resista t
microprocessor co trol ce ter, all mou ted i a sheet metal shell.
ASIC UNIT NOMENCLATURE
Named Y V A G 0 1 2 R S E 2 0
Number 1 2 3 4 5 7 8 9 10 11 12
The number 1： Y–YORK
The number 2： V–Variable Frequency
The number 3： A –Air-cooled
The number 4： –Design Series
The number 5、6、7： Nominal Capacity，(Unit: kW)
The number 8： Specific Function， R- Integral & Heat Pump
The number 9： Single/Modular， S- Single
The number 10： Refrigerant，E-R410a
The number 11、12： Voltage，20- 220V ~50Hz ，50- 380V 3N~50Hz
30- 230V ~50Hz ，53- 400V 3N~50Hz
THE UNIT DIMENSION
U it：mm
1021
FIGURE 1 – YVAG012-018 DIMENSIONS
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 7
FIGURE 2 YVA 020-033 DIMENSIONS
FIGURE 3 YVA 040 DIMENSIONS
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 8
OPERATING RANGE
Voltage Range
The maximum fluctuatio ra ge of supply voltage is ±10%
Three-phase electric phase unbalance rate should be less than 2%.
Temperature range
TA LE 1-Temperature range(YVA 012~040)
Project 012~018 020~040
Relative humidity <90％，No lon <90％，No lon
Wire controller using the environment
temperature
-10℃～55℃ -10℃～55℃
The unit running environment
temperature range
Cooling -5℃～48℃
Heating -20℃～43℃
Cooling -5℃～48℃
Heating -25℃～43℃
Chilled water temperature range
（Leaving water temperature）
Cooling 5℃～25℃
Heating 30℃～52℃
Cooling 5℃～25℃
Heating 30℃～58℃
Chilled water temperature range
（Enter water temperature）
Cooling 10℃～30℃
Heating 25℃～47℃
Cooling 10℃～30℃
Heating 25℃～53℃
Please note that
The return water temperature control is default by the unit controller, and return water temperature
control is recommended.
The above data are obtained in the laboratory, the practical use there will be deviation affected by
the installation position and so on.
For applications with temperature below -25℃, please consult YORK company.
Applicable Medium
The sta dard desig applicable medium of the u it is purified water. Please co sult YORK Compa y for special
medium such as glycol a tifreeze fluid.
Altitude
No more tha 2000m
Wind side external static pressure
No more tha 30Pa
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 9
SECTION 2 –INSTALLATION REQUIREMENTS
INSPECTION
Remove a y tra sit packi g a d i spect the u it to
e sure that all compo e ts have bee delivered a d that
o damage has occurred duri g tra sit. If a y damage
is evide t, it should be oted o the carrier’s freight bill
a d a claim e tered i accorda ce with the i structio s
give o the advice ote.
Major damage must be reported immediately to your
local Joh so Co trols represe tative.
MOVING THE UNIT
Prior to movi g the u it, e sure that the i stallatio site
is suitable for i stalli g the u it a d is easily capable of
supporti g the weight of the u it a d all associated
services.
The u it should be lifted usi g lifti g lugs a d a
spreader bar or frame of sufficie t width to preve t
damage to the u it from the lifti g chai s.
The u its shall be suitable for elevator or forklift truck
or cra e for co ve ie ce of lifti g. Whe tra sporti g
with a cra e, a ca vas hammock shall be used to come
rou d the u it base a d be faste ed. If the packagi g
box has bee removed, i order to move the machi e,
please apply suitable partitio to protect the surface a d
the side pa el, as show i the picture below. Duri g
the tra sit, the machi e shall be kept i level co ditio
to avoid damagi g the u it due to crude operatio .
Be particularly careful to ensure unit
steady. Pay special attention to the
weight distribution of the unit to avoid
maldistribution and the center of
gravity leans to the side of compressor.
Please try once before hoisting and
observe whether it is tightened and
whether there is any risk of tip-over of
the unit. The hoisting shall be slowly
lifted with constant speed to avoid the
tip-over of the unit and attention shall
be paid to the security of personnel
nearby.
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 10
TA LE 2 – PRODUCT WEIGHT
U it/Parameters 012 014 016/018 020/022/025 028/033 040
Gross weight kg 136 138 151 220 225 360
Operati g weight kg 126 128 141 210 215 350
Schematic Diagram of Hoisti g with Packagi g Schematic Diagram of Hoisti g without Packagi g
With a woode cork base Without a woode cork base
FIGURE 4 –HOISTING DIAGRAMMATIC DRAWING
To ensure warranty coverage, this e uipment must be commissioned and serviced by an
authorized YORK service mechanic or a ualified 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 HP cutout settings, design working pressures, and ventilation
re uirements consistent with the amount and type of refrigerant charge.
Lethal voltages exist within the control panels. Before servicing, open and tag all disconnect
switches.
INSPECTION CHECKLIST
The followi g items, 1 through 4, must be checked
before placi g the u its i operatio .
1. The ameplate co te t of the u it is ide tical with
the order;
2. The accompa yi g docume ts of the u it are
complete;
3. The accessories of the u it are i accorda ce with
the items listed i the packi g list;
4. Immediately upo receivi g the u it, it should be
i spected for possible damage which may have
occurred duri g tra sit. If damage is evide t, it
should be oted i the carrier’s freight bill. A
writte request for i spectio by the carrier’s
age t should be made at o ce.
HANDLING
These u its are shipped as completely assembled u its
co tai i g full operati g charge, a d care should be
take to avoid damage due to rough ha dli g.
Locatio of
compressor
I sert u der boardi g or cloth
Ce ter of gravity of the u it i cli ed to o e
side, please hoisti g accordi g to the above
picture a d the requireme ts of i stallatio
ma ual. Please refer to the parameter list for
the weight of the u it.
Ce ter of gravity of the u it i cli ed to o e
side, please hoisti g accordi g to the above
picture a d the requireme ts of i stallatio
ma ual. Please refer to the parameter list for
the weight of the u it.
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 11
LOCATION
These u its are desig ed for outdoor i stallatio s o
grou d level, rooftop, balco y, a d a y other place that
is suitable for i stallatio with reliable load beari g.
Locatio should be selected for mi imum su exposure
a d away from boiler flues a d other sources of
airbor e corrosive or flammable gas that could attack
the ambie t coils a d steel parts of the u it. The u its
must be i stalled with sufficie t cleara ces for air
e tra ce to the co de ser coil to e sure adequate
supply of fresh air, for air discharge away from the
co de ser, a d for servici g access.
If the u its are located at a place where u authorized
perso el could reach, isolatio security measures shall
be take , such as setti g protective guard, to avoid
huma sabotage a d preve t the co trol cabi et from
bei g ope ed a d the operati g electrical compo e t
from bei g exposed;
The highest poi t of the air co ditio i g system shall
ot be 20m over the u it (for 20m higher, please co sult
YORK Compa y);
I i stallatio s where wi ter operatio is i te ded a d
s ow accumulatio s are expected, additio al height
must be provided to e sure ormal co de ser air flow.
For places with special installation
re uirements, please consult to the
building contractor or the architect and
designer or other professionals.
Noise Sensitive Locations
Efforts should be made to assure that the u it is ot
located ext to occupied spaces or oise se sitive areas
where u it oise level would be a problem.
Please make the u it face the place that is se sitive to
oise as far as possible to reduce the i flue ce of
operati g oise of the u it;
If the heat excha ger part is without block, protective
baffle plate ca be added to reduce the i flue ce of
operati g oise of the u it.
Cold Climate Locations
If the u it is operati g i low ambie t temperature, be
sure to follow the i structio s listed below.
1. A baffle plate i stalled o the airside of the u it is
recomme ded to preve t exposure to s ow i wi ter.
2. I areas with large s ow precipitatio , make sure
the coil a d fa will ot be affected by the s ow.
Co struct a lateral ca opy if ecessary.
3. Deice before operati g if the fa blades fail to
rotate after lo g time sta dby i s ow.
FOUNDATION
The u it should be mou ted o a flat a d level
fou datio , floor, or rooftop capable of supporti g the
e tire operati g weight of the equipme t. See
PHYSICAL DATA for operati g weight. If the u it is
elevated beyo d the ormal reach of service perso el,
a suitable catwalk must be capable of supporti g
service perso el, their equipme t, a d the
compressors.
To e sure the outdoor u it is placed flat o the base, the
outdoor u it must be placed after co firmi g the pla e
where the outdoor u it would be placed is eve . After
the i stallatio of the outdoor u it the outdoor u it shall
be exami ed whether it is leveled, a d the a gle of
i cli atio shall be smaller tha 10°; for a u it with a
absorber, the level i spectio shall be i stalled after the
i stallatio of absorber;
There are i stalli g holes o the fou datio of the u it,
a d they ca be used to closely co ect the u it a d the
fou datio ;
Ground location
For the grou d i stallatio , the steel fou datio of the
u it shall be placed o smooth a d flat co crete
fou datio . DO NOT co ect the u it fou datio with
the buildi g fou datio for fear that oise a d vibratio
would be tra smitted;
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 12
Roof location
If the u it is i stalled o the roof, the roof must have
sufficie t stre gth to support the weight of the u it a d
mai tai er. The u it ca be placed o the co crete
fou datio that is for the similar grou d i stallatio or
o a box iro shelf;
Isolators (optional)
It is recomme ded to place damped spri g vibratio
isolator (especially for u its with rack mou ti g or
i stalled o the roof floor) betwee the base a d the
fou datio of the outdoor u it. The isolator mou ti g
shall be selected a d i stalled accordi g to desig
requireme ts to satisfy the dema d of vibratio
isolatio a d to avoid phe ome a i cludi g solid-
bor e sou d tra smissio a d reso a ce; ge erally the
co structio shall be u dertake by professio als with
the models provided by the desig e gi eer; the table
below is the recomme ded model selectio of absorber,
a proximal absorber ca be selected ear the give
optimal load a d vertical stiff ess:
YVAG012~033:
YVAG040:
TA LE 3 – ABSORBER SELECT
Unit Total No. of
isolators
Optimal Load of
A/B Side (kg)
Optimal Load of
C/D Side (kg)
YVAG
012~018 4 20 65
YVAG
020~033 4 35 80
YVAG040 4 150/110 110
Draining
There should be drai age way arou d the u it so that
the rai water a d water ge erated from heati g for
defrosti g a d heati g co de satio ca be discharged;
if there is o drai age way, please add water po d o
the bottom of the u it a d lead it with pipeli e to a
suitable place.
1. Drainage way (012~018)
There is a 26mm a d three 20mm drai holes o the
bottom of the base plate. For u its that eed ce tralized
drai age i warmer district, block the three 20mm holes
with the i cide tal drai plugs of the u it, a d i stall
The drai age joi t i to the 26mm hole a d co ect
suitable hosepipe to discharge the co de sed water to
the ce tralized drai age place. For u its eed
ce tralized drai age i severe cold area, the drai pa
eed to be desig ed o site; the drai hole o the base
plate could ot be blocked, or it would lead to freezi g
due to impeded drai age of the base plate.
FIGURE 5- ACKPLANE SCHEMATIC（012~018)
2. Drainage way (020~040)
YVAG020~033 without drai age way, please add
water po d o the bottom of the u it a d lead it with
pipeli e to a suitable place.
FIGURE 6- ACKPLANE SCHEMATIC（020~033)
Φ20mm Φ20mm
Φ20mm
Φ26mm
Φ28mm
Φ28mm
Φ
28mm
Φ28mm
Φ
28mm
Φ
28mm
Φ
28mm
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 13
FIGURE 7- ACKPLANE SCHEMATIC（040)
Compressor mounting
The compressor is mou ted o four (4) rubber or steel
isolators. The mou ti g bolts should ot be loose ed or
adjusted duri g i stallatio of the u it.
INSTALL SPACING
Placeme t o a level surface of free of obstructio s
(i cludi g s ow, for wi ter operatio ) or air circulatio
e sures rated performa ce, reliable operatio , a d ease
of mai te a ce. Site restrictio s may compromise
mi imum cleara ces i dicated above, resulti g i
u predictable airflow patter s a d possible dimi ished
performa ce. YORK’s u it co trol will optimize
operatio without uisa ce high-pressure safety
cutouts; however, the system desig er must co sider
pote tial performa ce degradatio .
The i flue ce of dow ward flow caused by tall
buildi gs arou d the u it toward the exhaust air of the
u it shall also be take i to co sideratio i i stallatio .
If the u it is i stalled at a place with viole t airflow,
such as exposed roof, measures i cludi g parapet or
bli ds shall be take to preve t turbule t flow from
i terferi g the air flow i to the u it. If the u it eeds to
set parapet, the height shall ot be taller tha the u it
a d the cleara ce betwee the u it a d the parapet or
the bli ds shall also satisfy the mi imum cleara ce
requireme t for u it i stallatio .
Whe the u it is placed o a s ow covered surface, the
bottom face of the u it should be at least 100mm higher
tha the surface of the s ow cover to guara tee the air
successfully flow through the coil excha ger.
No obstructio s allowed i fro t of the airflow outlet
except grilli g of bli ds. The effective aperture
ope i g ratio of the grati g shall be over 80% a d the
a gle of i cli atio of the grati g blades shall be over
20°, a d the blade pitch shall be over 100mm
INSTALLATION CLEARANCES
U its are surrou ded by walls or other obstacles, i stallatio spaci g, referri g to the followi g figure.
YVAG012~033
21*
Φ
30
mm
20*
Φ
20
mm
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 14
YVAG040
注：
1.The above data unit is mm；
2.With the exception of special instructions, the high wall limits for each mode
are：Front Wall：1500mm；Back Wall：500mm；Side Wall：Height unlimited
The installation space shown in the figure depends on the outdoor temperature of 35 degrees in the refrigeration
operation。When the specified outdoor temperature exceeds 35 degrees or when the heat
of all outdoor machines exceeds the maximum allowable value,Should be above the suction side
of the space increases.
3.If the above the wall is higher than the h1 and h2, should be in at right side entry and suction side to increase the
h2/2 and h1/2 spare space.
4.In order to obtain the most appropriate space, should bear in mind that in the machine and the wall between the
pedestrian to set aside enough, and to ensure smooth flow channel.（More than the number of the mode of air
conditioners, when installation should consider the possibility of airflow short circuit。）
5.On-site installation of air conditioning, should set aside enough space in front of the machine to facilitate pipe
laying road。
≥300
≥800 ≥500
(Model 1）
≥100
Front of the
unit
Single Install
(Model 1）
≥300
(Model 2）
≥300
≥300
(Model 3）
≥300
≥800
Installation in
rows
(Model 1）
≥300
≥500
≥500
(Model 2）
≥300
≥500
Stack
mounting
≥300 ≥300
≥300 ≥300
≥300
≥300
≥500
≥800
(Model 2）
≥300 ≥300
≥300 ≥300
≥300
≥300 ≥300
Back wall, Height unlimited
≥800
Back wall
Front wall
Side wall, Height unlimited
≥500≥800
(Model 4）
≥300
≥500
≥500
(Model 3）
≥300
≥500 ≥500
≥500 ≥500
≥500 ≥500
≥500 ≥500
1500mm h2
500mm h1
≥300
≥300
Back wall
Front of the
unit
Side wall,
Height unlimited
Front of the
unit
Side wall, Height unlimited
Back wall
Front wall
Front of the
unit
Front of the
unit
Front of the
unit
Side wall, Height unlimited
Back wall, Height unlimited
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Side wall, Height unlimited
Side wall, Height unlimited
Side wall, Height unlimited
Side wall, Height unlimited
Back wall
Front wall
Back wall
Front wall
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Back wall, Height unlimitedBack wall, Height unlimited
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the
unit
Front of the unit
Air inlet
FIGURE 8- INSTALLATION SPACE DIA RAM
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 15
WATER SYSTEM INSTALLATION
Chilled liquid piping specification
General – Whe the u it(s) has bee located i its fi al
positio , the u it water pipi g may be co ected.
Normal i stallatio precautio s should be observed i
order to receive maximum operati g efficie cies. All
chilled water evaporator pipi g must comply with local
plumbi g codes a d ordi a ces i all aspects.
Si ce elbows, tees a d valves decrease pump capacity,
all pipi g should be kept as straight a d as simple as
possible. All pipi g must be supported i depe de t of
the u it.
The followi g co sideratio s of pipi g specificatio
should be observed:
a) The pipe diameter of the pipes i let a d outlet u it
shall ot be smaller tha the joi t specificatio (DN25).
Also pipi g of DN32 or above is recomme ded
b) Pipi g to the i let a d outlet co ectio s of the
u it should i clude high-pressure rubber hose or pipi g
loops to e sure agai st tra smissio of water pump
vibratio . The ecessary compo e ts must be obtai ed
i the field.
c) PP-R material is recomme ded for the water
supply a d retur pipi g of the u it for the household
water system. It will be be eficial, as the possibility of
the filth blockage a d the water resista ce will decrease.
d) Galva ized steel pipe ( ot recomme ded) shall be
desig ed as screwed co ectio . Whe the pipe
diameter is larger tha DN100, clamp, fla ge or welded
joi t ca be applied for co ectio .
e) For welded co ectio ( ot recomme ded)
applied for pipi g, a tiseptic treatme t (rust clea i g
before pai ti g) shall be co ducted to the surface of
welded joi t a d heat-effected area.
f) Galva ized steel pipi g, PP-R pipi g a d the
correspo di g screwed joi ts are i dicated i pipi g
specificatio of TABLE 2, a d just for refere ce o ly.
Chilled liquid piping installation
Water pipeli e co ectio shall observe releva t
i stallatio regulatio s. Pipi g should be kept free of
foreig matter.
The pipi g to a d from the chiller must be desig ed to
suit the i dividual i stallatio . It is importa t that the
followi g co sideratio s are observed:
a) The operati g flow rate of the u it shall ot exceed
40% of rated flow for each u it type, too large or too
small water flow rate would affect the ormal use of the
u it.
b) The water flow directio of the u it shall be
co ected accordi g to the i let a d outlet pipe marks
o the u it, otherwise the performa ce of the u it might
be affected.
c) The pipeli e must have i depe de t support a d
should ot be placed o the u it.
d) Ha d stop valves, thermometers a d pressure
gauges should be i stalled i both i let a d outlet li e
for adjusti g water flow rate a d facilitati g servici g.
e) The exter al water pump a d its co troller cabi et
eed to be i stalled o site; the mai e gi e provides
230V~ co trol sig al to realize the li kage of the u it
a d the water pump. A sta d-by pump shall be i stalled
o the site i case that the pump i commo use would
break dow a d affect the u it operatio ;
f) The water filter i cluded the u it shall be i stalled
o the i let pipe of each u it to preve t the cooler from
large particles e teri g, which could cause damage to
the evaporator.
g) A water filter of o less tha 60 mesh per i ch shall
be i stalled o the i let pipe of the exter al water pump
to guara tee reliable operatio of the water pump.
h) At least o e ve t valve should be i stalled at the
highest poi ts i the chilled water pipeli e to allow a y
trapped air to be exhausted. It ca avoid ge erati g
cavitatio oise a d damagi g the water pump.
i) Auto-supply valve shall be i stalled for closed
type of water system (without ope expa sio ta k) i
case that the u it could ot operate ormally whe the
system is short of water. It is suggested to set the outlet
water pressure of the auto-supply valve 0.3bar higher
tha the static pressure of the system, but the set value
shall be lower tha the suppleme ti g water pressure
(the source of the water suppleme ti g), or it would ot
co duct ormal water suppleme t. The auto-supply
valve is usually i stalled at the retur water li e of the
system; heat isolatio measures shall be co ducted to
the water suppleme t pipeli e a d water supply valve
to agai st freeze-up i wi ter.
j) The chilled water li es that are exposed to ambie t
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 16
should be wrapped with suppleme tal heater cable a d
i sulated to protect agai st freeze-up duri g low
ambie t periods, a d to preve t formatio of
co de satio o li es i warm humid locatio s. Ve t
valves a d drai valves do ot eed heat isolatio for
the co ve ie ce of mai te a ce
k) The i let mi imal pressure of water pump shall
reach 20kPa to avoid cavitatio oise a d damage of
water pump due to cavitatio .
l) It is recomme ded that a suitably sized by-pass
a d valve arra geme t shall be i stalled to allow
flushi g of the pipework system. The by-pass ca be
used duri g mai te a ce to isolate the cooler without
disrupti g flow to other u its.
m) Drai co ectio s should be provided at all low
poi ts to permit complete drai age of the cooler a d
system water pipi g duri g low ambie t temperature
period a d the u it would ot be used with a lo g time.
U it power should be left switched o to provide the
freeze protectio fu ctio u less the liquid systems
have bee drai ed. Also u it power should be left
switched off to avoid u it failure by auto starti g for
the freeze protectio fu ctio while the liquid systems
have bee drai ed.
) The fa coil i the water system shall be equipped
with a three-way valve or a by-pass valve to make the
water system circulate flue tly duri g the period whe
a ti-freezi g water pump is operati g i wi ter.
o) For module applicatio , a place for thermometer
se sor shall be retai ed o the mai outlet pipe of the
water system so that the leavi g water temperature
se sor ca be i stalled.
p) A chilled water flow switch is already i stalled i
the leavi g water pipi g of the cooler. If the u its are
modularized, it is recomme ded to i stall a other flow
switch i mai liquid leavi g pipe.
The Flow Switch MUST NOT be used
to start and stop the unit (i.e. starting
and stopping the chilled water pump). It
is intended only as a safety switch.
Quality of the chilled water should
comply with the re uirement in chilled
water re uirement in SECTION 5. No
air will be permitted in water system.
Piping specification Thread specification
G3/4 G1 G1-1/4 G1-1/2 G2 G2-1/2 G3 G4
Specification of galvanized steel pipes
DN20 DN2 DN32 DN40 DN 0 DN6 DN80 DN100
Outer diameters of galvanized steel
pipes (mm) 27 34 42 48 60 76 89 114
Specification of PP-R pipes D2 D32 D40 D 0 D63 D7 D90 D110
Outer diameters of PP-R pipes (mm) 2 32 40 0 63 7 90 110
TABLE 4 – PIPE LINES SPECIFICATIONS
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 17
Water system Pipework arrangement
The followi g are suggested pipework arra geme ts for si gle u it with built-i pump i stallatio s. For multiple
u it i stallatio s, each u it should be piped as show .
Chilled water system for single unit
FIGURE 9 – SINGLE UNIT SYSTEM (WITHOUT EXTERNAL PUMP)
FIGURE 10 – SINGLE UNIT SYSTEM (WITH EXTERNAL PUMP)
Notes： Parts in the dotted box are optional components, and if the site does not need installation, the pipeline
here can be directly connected
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 18
Chilled water system for modular unit
T
F
W a te r R e tu rn P ip e
W a te r S u p ply P ip e
A u to - su p p ly
V a lv e
W a te r
D ra in
V a lv e
V e n t V a lv e
R elie f
V a lv e
P r es s u re
G u a g e
W a te r F ilte r
T h e rm o m e te r
P r e ss u re
G u a g e
C h e c k V alv e
T h e rm o m e te r W a te r
D ra in
V a lv e
A u xilia r y E le c tric
H e a te r
T e m p e ra tu re
S e n s o r
E x p a n s io n T a n k(P o t)
S ta n d -b y
V a lv e
FIGURE 11 – MODULAR UNIT SYSTEM (WITHOUT EXTERNAL PUMP)
FIGURE 12 – MODULAR UNIT SYSTEM (WITH EXTERNAL PUMP)
Notes:
1. Parts in the dotted box are optional components, and if the site does not need installation, the pipeline here can be directly
connected.
2. In modular connection, considering the balance of water pressure drop and water flow rate, the same route design should
be applied. If pipelines could not be installed in the same route due to the limitation of installation space, please contact the
local JCI office for confirmation.
3. In modular connection system with external water pump, the standby water pump is not necessary; but the standby water
pump is recommended to be included in case that the water pump in common use might break down and affect the normal
use of the unit.
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 19
TA LE 5– COMPONENTS SYMBOL
Modular Connections
The u its are able to be co ected i a pipe etwork for ce tralized co trol. The co trol system is desig ed to
work effectively withi a maximum of 4 co trol boards (commu icatio addresses) co ected. Follow the
arra geme ts below for side by side a d back by back layout.
Side by Side Layout
FIGURE 13 – SIDE BY SIDE LAYOUT
ack y ack Layout
FIGURE 14 – BACK BY BACK LAYOUT
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FORM NO.: 6U5M-A11M-NB-EN
JOHNSON CONTROLS 20
Notes:
1. The distances between the walls and peripheral units should employ the same rules as shown in Clearance
in SECTION 5, if the units are surrounded by walls
2. Installation contractor must include vent and drain accommodations in chilled water piping near the evaporator.
3. Stop valves must be installed at the inlet of each unit to balance chilled liquid distribution.
4. A minimum interval of 700 mm must be reserved for field wiring, commissioning and maintenance.
5. Detailed dimensions refer to single unit drawings.
System Leaving Water Temperature Sensor
Whe the system is modular co ectio a d the user
chooses leavi g water temperature as co trol method,
there should be a leavi g water temperature se sor
i stalled o the mai water supply pipe. The leavi g
water temperature se sor is co ected with 1# u it. No
requireme t for temperature se sor i stallatio if
leavi g water temperature co trol is ot applied.
I stallatio methods of temperature se sor:
a) G1/2’ tee joi t of i ter al thread is i stalled o the
mai water supply pipe.
b) G1/2’ bli d tube of exter al thread is i stalled o
the tee joi t of i ter al thread.
c) Co ductio oil is i jected i to the bli d tube, the
the temperature se sor is i serted a d sealed tightly
with thread locks.
The bli d tube should be i stalled i horizo tal
directio , perpe dicular to the mai pipe, i case of
freeze-up i the tube.
For accuracy of temperature se si g, the se sor should
be i serted at the bottom of the bli d tube.
uffer Water Tank
Whe water volume capacity for the water system is
little, sharp drop of water temperature would affect
defrosti g whe the u it is operati g i heat mode for
defrosti g. To avoid this, buffer water ta k should be
applied or the diameter of mai water pipe should be
e larged to meet the recomme ded ra ge i the
followi g table.
The refere tial i stallatio methods for buffer water
ta k as show below.
Expansion Tank (Pot)
There is o expa sio ta k as sta dard compo e ts
built-i the u it. When the site water system is set as
a closed cycle system, Ex ansion Tank must be
installed on the return i e of the unit. Expa sio
ta k should be applied whe water volume capacity of
water system is higher tha that i the followi g table.
I stalli g height of the expa sio water ta k should be
withi 50 m above the u it. The desig pressure of
expa sio ta k should be 6 bar at least.
Water Treatment
The declared cooli g capacity of u it o ameplate or
other catalogs is based o the situatio that fouli g
factor is 0.018m2℃/kW. Dirt, filth, oil or other
impurities all will have a egative effect o the heat
tra sfer efficie cy a d the u it performa ce. Foreig
matters i chilled water would i crease water pressure
drop of the heat excha ger, reduce water flow a d
cause mecha ical damage for pipes of heat excha ger.
Strict measureme t should be carried out for water
quality for the water system of u it, a d water quality
should co form to requireme ts i the table of chiller
water requirement i TABLE 6.
PROJECT UNIT value
result
corrosion scale
PH（25℃） 7.5-8.0 ○
SO4-- ppm <100 ○
HCO3-/ SO4-- ppm ＞1.0 ○
Cl- ppm <50 ○
PO4 ppm <2.0 ○
NH3 ppm <0.5 ○
Free Chlorine ppm <0.5 ○
Fe+++ ppm <0.5 ○
Mn++ ppm <0.05 ○
CO2 ppm <10 ○
H2S ppb <50 ○
Temperature ℃ <65 ○ ○
Oxygen
content ppm <0.1 ○
Total
hardness dH 4.8-8.5
○
TABLE 6- Water quality standards
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