YCUL0020-YCUL0070

Products are produced at af aci l i t y whose qual i t y-management systems areISO9001 certified.R-410AYCUL0020-YCUL0072 AIR-COOLED SCROLL COMPRESSOR CONDENSING UNITSSTYLE E (50 AND 60 HZ) 15 -80 TON 50-280KWAIR-COOLED SCROLL COMPRESSOR CONDENSING UNITSINSTALLATION, OPERATION & MAINTENANCESupersedes: 150.63-NM9 Form 150.63-NM9 (913)Issue Date: September 27, 2013035-22896-000JOHNSON CONTROLS 2FORM 150.63-NM9 ISSUE DATE: 9/27/2013Thisequipmentisarelativelycomplicatedapparatus. During installation, operation maintenance or service, individuals may be exposed to certain components or conditionsincluding,butnotlimitedto:refrigerants, materialsunderpressure,rotatingcomponents,and both high and low voltage. Each of these items has the potential,ifmisusedorhandledimproperly,tocause bodily injury or death. It is the obligation and respon-sibilityofoperating/servicepersonneltoidentifyand recognizetheseinherenthazards,protectthemselves, andproceedsafelyincompletingtheirtasks.Failure to comply with any of these requirements could result in serious damage to the equipment and the property in IMPORTANT!READ BEFORE PROCEEDING!GENERAL SAFETY GUIDELINESwhich it is situated, as well as severe personal injury or death to themselves and people at the site.This document is intended for use by owner-authorized operating/servicepersonnel.Itisexpectedthatthese individualspossessindependenttrainingthatwillen-able 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 understoodthisdocumentandanyreferencedmate-rials.Thisindividualshallalsobefamiliarwithand comply with all applicable governmental standards and regulations pertaining to the task in question.SAFETY SYMBOLSThe following symbols are used in this document to alert the reader to specific situations:Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken.Indicatesapotentiallyhazardoussitua-tion which will result in possible injuries or damage to equipment if proper care is not taken.Identifesahazardwhichcouldleadto damage to the machine, damage to other equipmentand/orenvironmentalpollu-tion if proper care is not taken or instruc-tions and are not followed.Highlights additional information useful to the technician in completing the work being performed properly.External wiring, unless specifed as an optional connection in the manufacturers 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 accor-dance with Johnson Controls published specifcations and must be performed only by a qualifed 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 warn-ing will void the manufacturers warranty and cause serious damage to property or personal injury.JOHNSON CONTROLS 3FORM 150.63-NM9 ISSUE DATE: 9/27/2013MANUAL DESCRIPTION FORM NUMBERUnit Replacement Parts Guide 150.63-RP7CHANGEABILITY OF THIS DOCUMENTIn complying with Johnson Controls policy for contin-uous product improvement, the information contained inthisdocumentissubjecttochangewithoutnotice. Johnson Controls makes no commitment to update or provide current information automatically to the man-ual owner. Updated manuals, if applicable, can be ob-tained by contacting the nearest Johnson Controls Ser-vice office or accessing the Johnson Controls QuickLIT website at http://cgproducts.johnsoncontrols.com.Operating/service personnel maintain responsibility for the applicability of these documents to the equipment. Ifthereisanyquestionregardingtheapplicabilityof these documents, the technician should verify whether the equipment has been modified and if current litera-ture is available from the owner of the equipment prior to performing any work on the chiller.CHANGE BARSRevisions 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 in-formation and any other changes in spelling, grammar or formatting are not included.ASSOCIATED LITERATUREJOHNSON CONTROLS 4FORM 150.63-NM9 ISSUE DATE: 9/27/2013THIS PAGE INTENTIONALLY LEFT BLANKJOHNSON CONTROLS 5FORM 150.63-NM9 ISSUE DATE: 9/27/2013TABLE OF CONTENTSSECTION 1 GENERAL EQUIPMENT INFORMATION AND SAFETY ................................................................ 15Introduction ..................................................................................................................................................... 15Compressors .................................................................................................................................................. 15Condenser ...................................................................................................................................................... 15Coils ...................................................................................................................................................... 15Low Sound Fans ................................................................................................................................... 15Motors ................................................................................................................................................... 15Refrigerant Circuit .......................................................................................................................................... 15Warranty ......................................................................................................................................................... 15Safety And Quality .......................................................................................................................................... 16Standards for Safety and Quality .......................................................................................................... 16Responsibility for Safety ........................................................................................................................ 16About This Manual.......................................................................................................................................... 16Misuse Of Equipment ..................................................................................................................................... 16Suitability for Application ....................................................................................................................... 16Structural Support ................................................................................................................................. 17Mechanical Strength............................................................................................................................. 17General Access ..................................................................................................................................... 17Pressure Systems ................................................................................................................................. 17Electrical ................................................................................................................................................ 17Rotating Parts ........................................................................................................................................ 17Sharp Edges .......................................................................................................................................... 17Refrigerants and Oils ............................................................................................................................. 17High Temperature and Pressure Cleaning ............................................................................................ 17Emergency Shutdown ........................................................................................................................... 17SECTION 2 PRODUCT DESCRIPTION .............................................................................................................. 19Introduction ..................................................................................................................................................... 19General System Description ........................................................................................................................... 19Compressors ......................................................................................................................................... 19Condenser ............................................................................................................................................. 19Low Sound Fans ................................................................................................................................... 20Motors ................................................................................................................................................... 20Microcomputer Control Center ....................................................................................................................... 20Display/Print......................................................................................................................................... 20Entry ...................................................................................................................................................... 20Setpoints ............................................................................................................................................... 20Unit ........................................................................................................................................................ 20Unit On/Off Switch ................................................................................................................................. 20Building Automation SystemInterface ......................................................................................................................................................... 21Communications ............................................................................................................................................. 21Power Panel ................................................................................................................................................... 21Electrical Options .................................................................................................................................. 22Compressor Power Connections ................................................................................................... 22Single-Point Supply Terminal Block (standard on YCUL models).......................................................................................................... 22Single-Point Non-Fused Disconnect Switch .................................................................................. 22Single-Point Circuit Breaker ........................................................................................................... 22Control Transformer ....................................................................................................................... 22Power Factor Correction Capacitors .............................................................................................. 22JOHNSON CONTROLS 6FORM 150.63-NM9 ISSUE DATE: 9/27/2013TABLE OF CONTENTS (CONTD)Control Options ..................................................................................................................................... 22Ambient Kit (Low) ........................................................................................................................... 22Ambient Kit (High) .......................................................................................................................... 22Building Automation System Interface ........................................................................................... 22Language LCD and Keypad Display .............................................................................................. 22Discharge Pressure Transducers And Readout Capability ............................................................................ 22Suction Pressure Transducers ....................................................................................................... 23Motor Current Module .................................................................................................................... 23Multi-Unit Sequencing .................................................................................................................... 23Compressor and Piping Options ........................................................................................................... 23Chicago Code Relief Valves .......................................................................................................... 23Service Isolation Valve ................................................................................................................... 23Hot Gas By-Pass ........................................................................................................................... 23Condenser and Cabinet Options .................................................................................................... 23Pre-Coated Fin Condenser Coils ................................................................................................... 23Post-Coated Dipped Condenser Coils ........................................................................................... 23Copper Fin Condenser Coils .......................................................................................................... 23Enclosure Panels (Unit) ................................................................................................................. 23Louvered Panels (Full Unit) ........................................................................................................... 23Sound Attenuation .......................................................................................................................... 23Compressor Acoustic Sound Blanket ............................................................................................. 24Ultra Quiet Fan ............................................................................................................................... 24Vibration Isolators .......................................................................................................................... 24Basic Unit ..................................................................................................................................................... 28SECTION 3 HANDLING AND STORAGE ........................................................................................................... 35Delivery And Storage ...................................................................................................................................... 35Inspection ....................................................................................................................................................... 35Unit Rigging .................................................................................................................................................... 35Moving the Condensing Unit ................................................................................................................. 36Lifting Weights ....................................................................................................................................... 36SECTION 4 INSTALLATION ................................................................................................................................ 37Installation Checklist ....................................................................................................................................... 37Handling ......................................................................................................................................................... 37Location And Clearances ............................................................................................................................... 37Foundation ............................................................................................................................................ 37Ground Level Locations ........................................................................................................................ 37Rooftop Locations ................................................................................................................................. 37Noise Sensitive Locations ..................................................................................................................... 37Corrosive Environments....................................................................................................................... 38Spring Isolators (Optional) .............................................................................................................................. 38Compressor Mounting .................................................................................................................................... 38Pipework Arrangement ................................................................................................................................... 38Duct Work Connection ................................................................................................................................... 38Recommendations Of The Building Services Research Association. ............................................................ 38General Requirements......................................................................................................................... 38Wiring ............................................................................................................................................................. 38System Run Contacts ............................................................................................................................ 39Alarm Status Contacts ........................................................................................................................... 39Remote Start/Stop Contacts .................................................................................................................. 39JOHNSON CONTROLS 7FORM 150.63-NM9 ISSUE DATE: 9/27/2013TABLE OF CONTENTS (CONTD)Remote Emergency Cutoff .................................................................................................................... 39Remote Temp Reset Input ..................................................................................................................... 39Load Limit Input ..................................................................................................................................... 39Liquid Line Solenoid Connections ......................................................................................................... 39Discharge Air Sensor ............................................................................................................................. 39Zone Thermostats, Suction Pressure Control Only (Remote Start/Stop) .............................................. 39Air Proving Switch/Remote Start-Stop Contacts ................................................................................... 39Evaporator Blower Start Contacts........................................................................................................ 40Relief Valves ................................................................................................................................................... 40High Pressure Cutout ..................................................................................................................................... 40Compressor Heaters ...................................................................................................................................... 40Refrigerant Piping ........................................................................................................................................... 40General .................................................................................................................................................. 40Refrigerant Piping Reference ................................................................................................................ 41R-410A Copper Line Sizing ............................................................................................................ 41YCUL Line Sizing Notes................................................................................................................. 41Refrigerant Piping Notes ....................................................................................................................... 42Refrigerant Line Sizing .......................................................................................................................... 43Evaporator Below Condensing Unit ...................................................................................................... 43Condenser Below Evaporator ............................................................................................................... 43Oil Traps ....................................................................................................................................................... 43Refrigerant Charge ......................................................................................................................................... 43Refrigerant Piping Reference ......................................................................................................................... 43Filter Driers / Sight Glasses/ Txvs ................................................................................................................. 43SECTION 5 TECHNICAL DATA .......................................................................................................................... 47Voltage Limitations ................................................................................................................................ 47Electrical Notes ..................................................................................................................................... 51General .................................................................................................................................................. 97One Inch Defection Spring Isolator Cross-reference .......................................................................... 100SECTION 6 COMMISSIONING .......................................................................................................................... 107Preparation Power Off ............................................................................................................................... 107Inspection........................................................................................................................................... 107Refrigerant Charge .............................................................................................................................. 107Service and Oil Line Valves ................................................................................................................. 107Compressor Oil ................................................................................................................................... 107Isolation / Protection ............................................................................................................................ 107Control Panel ....................................................................................................................................... 107Power Connections ............................................................................................................................. 107Grounding ............................................................................................................................................ 108Supply Voltage .................................................................................................................................... 108Preparation Power On ............................................................................................................................... 108Switch Settings .................................................................................................................................... 108Compressor Heaters ........................................................................................................................... 108Air Flow Switch .................................................................................................................................... 108JOHNSON CONTROLS 8FORM 150.63-NM9 ISSUE DATE: 9/27/2013TABLE OF CONTENTS (CONTD)SECTION 7 UNIT CONTROLS .......................................................................................................................... 113Introduction ................................................................................................................................................... 113Microprocessor Board .................................................................................................................................. 113Unit Switch ................................................................................................................................................... 114Display .......................................................................................................................................................... 114Keypad ......................................................................................................................................................... 114Battery Back-Up ........................................................................................................................................... 114Transformer................................................................................................................................................. 114Single System Select AndProgramming # Of Compressors .................................................................................................................. 114Unit Status ........................................................................................................................................... 115General Status Messages ................................................................................................................... 115Fault Safety Status Messages ............................................................................................................. 117System Safeties ........................................................................................................................... 117Unit Safeties ................................................................................................................................. 118Unit Warning ........................................................................................................................................ 119Oper Data Key ..................................................................................................................................... 121Oper Data Quick Reference List ......................................................................................................... 124Print Key .............................................................................................................................................. 124Operating Data Printout ....................................................................................................................... 124History Printout .................................................................................................................................... 125History Displays ................................................................................................................................... 126Software Version ................................................................................................................................. 128Up and Down Arrow Keys ................................................................................................................... 129Enter/Adv Key ..................................................................................................................................... 129Cooling Setpoints ................................................................................................................................ 130Schedule/Advance Day Key ................................................................................................................ 132Program Key ....................................................................................................................................... 132460VAC System Trip Volts .................................................................................................................. 134460VAC Unit Trip Volts ........................................................................................................................ 134208/230VAC Units ............................................................................................................................... 134Oper Data Quick Reference List ......................................................................................................... 136Options Key ......................................................................................................................................... 137Option 1 Language ................................................................................................................... 137Option 2System Switches(two system units only) .................................................................... 137Option 3 Ambient Control Type ................................................................................................. 137Option 4 Local/Remote Control Type ........................................................................................ 138Option 5 Unit Control Mode ...................................................................................................... 138Option 6 Display Units .............................................................................................................. 138Option 7 Lead/Lag Type(two system units only) ..................................................................... 138Option 8 Condenser Fan Control Mode................................................................................... 138Option 9 Manual Override Mode ............................................................................................... 139Option 10 Current Feedback Options Installed ......................................................................... 139Option 11 Power Fail Restart .................................................................................................... 139Option 12 Soft Start Enable/Disable ......................................................................................... 139Option 13 Unit Type .................................................................................................................. 139Option 14 Refrigerant Type ....................................................................................................... 140Option 15 Expansion Valve Type .............................................................................................. 140Option 16 Flash Card Update ................................................................................................... 140Option 17 Remote Temperature Reset ..................................................................................... 140Option 18 Hot Gas Bypass Type ............................................................................................... 141Option 19 Data Logging ............................................................................................................. 141Clock ................................................................................................................................................... 141JOHNSON CONTROLS 9FORM 150.63-NM9 ISSUE DATE: 9/27/2013TABLE OF CONTENTS (CONTD)SECTION 8 UNIT OPERATION ......................................................................................................................... 143Capacity Control ........................................................................................................................................... 143Suction Pressure Limit Controls ................................................................................................................... 143Discharge Pressure Limit Controls ............................................................................................................... 143Discharge Air Temperature Control .............................................................................................................. 143Suction Pressure Control ............................................................................................................................. 145System Lead/Lag ......................................................................................................................................... 146Compressor Lead/Lag .................................................................................................................................. 146Anti-Recycle Timer ....................................................................................................................................... 146Anti-Coincidence Timer ................................................................................................................................ 146Evaporator Blower Control ........................................................................................................................... 146Evaporator Heater Control ........................................................................................................................... 146Pumpdown Control ....................................................................................................................................... 146Load Limiting ................................................................................................................................................ 149Compressor Run Status ............................................................................................................................... 149Alarm Status ................................................................................................................................................. 149BAS/EMS Discharge Air Temperature Reset Using A Voltage Or Current Signal....................................... 150SECTION 9 SERVICE AND TROUBLESHOOTING .......................................................................................... 151Clearing History Buffers................................................................................................................................ 151Service Mode ............................................................................................................................................... 151Service Mode Outputs ............................................................................................................................... 151Service Mode Condensing Unit Configuration ................................................................................................................................................ 152Service Mode Analog And DigitalInputs ............................................................................................................................................................ 152Control Inputs/Outputs ................................................................................................................................. 153Checking Inputs And Outputs ....................................................................................................................... 155Digital Inputs ........................................................................................................................................ 155Discharge Air Temperature Sensor ..................................................................................................... 156Analog Inputs Pressure .................................................................................................................... 156System 1 Discharge Transducer ......................................................................................................... 157System 2 Discharge Transducer ......................................................................................................... 157System 1 Suction Transducer ............................................................................................................. 157System 2 Suction Transducer ............................................................................................................. 157Digital Outputs ..................................................................................................................................... 158Parts .................................................................................................................................................... 159Assembly and Wiring ........................................................................................................................... 159Obtaining a Printout ............................................................................................................................. 159JOHNSON CONTROLS 10FORM 150.63-NM9 ISSUE DATE: 9/27/2013TABLE OF CONTENTS (CONTD)SECTION 10 MAINTENANCE ........................................................................................................................... 163Important ...................................................................................................................................................... 163Compressors ................................................................................................................................................ 163Oil Level check .................................................................................................................................... 163Oil Analysis .......................................................................................................................................... 163Condenser Fan Motors ................................................................................................................................. 163Condenser Coils ........................................................................................................................................... 163Operating Parameters .................................................................................................................................. 163On-Board Battery Back-Up ........................................................................................................................... 163Overall Unit Inspection ................................................................................................................................. 163Bacnet, Modbus And Yorktalk 2 Communications ........................................................................................ 164BACnet and Modbus Communications ............................................................................................... 167Communications Data Map Notes ....................................................................................................... 167Yorktalk 2 Communications ................................................................................................................. 171Received Data (Control Data) ...................................................................................................... 171Transmitted Data.......................................................................................................................... 171JOHNSON CONTROLS 11FORM 150.63-NM9 ISSUE DATE: 9/27/2013LIST OF FIGURESFIGURE 1 - YCUL Air-Cooled Scroll Compressor Condensing Unit ....................................................................... 17FIGURE 2 - Unit Components Front........................................................................................................................ 23FIGURE 3 - Power Panel Components ................................................................................................................... 24FIGURE 4 - Power Panel / Control Components .................................................................................................... 25FIGURE 5 - Refrigerant Flow Diagram .................................................................................................................... 30FIGURE 6 - Process And Instrumentation Diagram ................................................................................................ 31FIGURE 7 - Unit Rigging ......................................................................................................................................... 33FIGURE 8 - Single-Point Supply Connection Terminal Block, Non-Fused Disconnect Switch Or Circuit Breaker ................................................................................................................................ 42FIGURE 9 - Discharge Air Sensor Field Wiring ....................................................................................................... 42FIGURE 10 - Control Wiring .................................................................................................................................... 43FIGURE 11 - Control Wiring Diagram, Single Circuit, Ipu Ii..................................................................................... 54FIGURE 12 - Control Wiring Diagram, Single Circuit, IPU II ................................................................................... 57FIGURE 13 - Control Wiring Diagram, Dual Circuit, IPU II ...................................................................................... 58FIGURE 14 - Control Wiring Diagram, Dual Circuit, IPU II ...................................................................................... 60FIGURE 15 - Control Wiring Diagram, Details, Single Circuit ................................................................................. 62FIGURE 16 - Control Wiring Diagram, Details, Dual Circuit .................................................................................... 64FIGURE 17 - Power Wiring, Single Circuit .............................................................................................................. 66FIGURE 18 - Power Wiring, Single Circuit .............................................................................................................. 68FIGURE 19 - Power Wiring, Single Circuit .............................................................................................................. 70FIGURE 20 - Power Wiring, Single Circuit .............................................................................................................. 72FIGURE 21 - Power Wiring, Dual Circuit ................................................................................................................. 75FIGURE 22 - Power Wiring, Dual Circuit ................................................................................................................. 76FIGURE 23 - Connection Wiring, Single Circuit ...................................................................................................... 78FIGURE 24 - Connection Wiring, Single Circuit ...................................................................................................... 80FIGURE 25 - Connection Wiring, Single Circuit ...................................................................................................... 82FIGURE 26 - Connection Wiring, Single Circuit ...................................................................................................... 84FIGURE 27 - Connection Wiring, Dual Circuit ......................................................................................................... 87FIGURE 28 - Connection Wiring, Dual Circuit ......................................................................................................... 88FIGURE 29 - Unit Clearances All Models ............................................................................................................. 94FIGURE 30 - Sample Isolator Location Drawing ..................................................................................................... 95FIGURE 31 - Isolator Locations, 60 HZ ................................................................................................................... 96FIGURE 32 - Isolator Locations, 50 HZ ................................................................................................................... 97FIGURE 33 - One Inch Defection Spring Isolator Cross-Reference ....................................................................... 98FIGURE 34 - One Inch Defection Spring Isolators Installation Instructions............................................................ 99FIGURE 35 - Two Inch Defection Seismic Isolator Cross-Reference ................................................................... 100FIGURE 36 - Seismic Isolator Installation And Adjustment ................................................................................... 101FIGURE 37 - Durulene Isolator Cross-Reference ................................................................................................. 102FIGURE 38 - Installation Of Durulene Vibration Isolators ..................................................................................... 103FIGURE 39 - Discharge Air Temperature Control .................................................................................................. 142FIGURE 40 - Suction Pressure Control ................................................................................................................. 143FIGURE 41 - YCUL0045 YCUL0072 Fan Location (Typical) ............................................................................. 145FIGURE 42 - Microboard Layout ........................................................................................................................... 152FIGURE 43 -I/O Board Relay Contact Architecture ............................................................................................. 156FIGURE 44 - Printer To Microboard Electrical Connections .................................................................................. 157FIGURE 45 - Micro Panel Connections ................................................................................................................. 163JOHNSON CONTROLS 12FORM 150.63-NM9 ISSUE DATE: 9/27/2013LIST OF TABLESTABLE 1 - Fitting Equivalent Lengths ..................................................................................................................... 41TABLE 2 - Refrigerant Piping Charges ................................................................................................................... 41TABLE 3 - Miscellaneous Liquid Line Pressure Drops ........................................................................................... 42TABLE 4 - Refrigerant Line Connections ................................................................................................................ 42TABLE 5 - Voltage Limitations ................................................................................................................................ 47TABLE 6 - Physical Data (English) ......................................................................................................................... 48TABLE 7 - Physical Data (SI) .................................................................................................................................. 49TABLE 9 - Micro Panel Power Supply .................................................................................................................... 50TABLE 8 - Voltage Range ....................................................................................................................................... 50TABLE 10 - Status Key Messages Quick Reference List ..................................................................................... 120TABLE 11 - Operation Data .................................................................................................................................. 124TABLE 12 - Cooling Setpoints Programmable Limits And Defaults ...................................................................... 135TABLE 13 - Program Key Limits And Defaults ...................................................................................................... 135TABLE 14 -Setpoints Quick Reference List ........................................................................................................ 136TABLE 15 - Options Key Programming Quick Reference List .............................................................................. 142TABLE 16 - Discharge Air Temperature Control For 5 And 6 Compressors (7 And 8 Steps) ................................ 144TABLE 17 - Discharge Air Temperature Control For 4 Compressors (6 Steps) .................................................... 144TABLE 18 -YCUL0045 YCUL0072 Condenser Fan Control Using Outdoor Ambient Temperature And Dis-charge Pressure (Discharge Pressure Controls Will Not Function Unless The Optional Discharge Pressure Transducer Is Installed) ..................................................................................................... 147TABLE 19 - YCUL0045 YCUL0072 Condenser Fan Control Using Discharge Pressure Only .......................... 147TABLE 20 -YCUL0045 YCUL0072 Low Ambient Condenser Fan Control Discharge Pressure Control ....... 148TABLE 21 - Compressor Operation Load Limiting ............................................................................................. 149TABLE 22 -I/O Digital Inputs ............................................................................................................................... 153TABLE 23 -I/O Digital Outputs ............................................................................................................................ 153TABLE 24 - I/O Analog Inputs ............................................................................................................................... 153TABLE 25 - I/O analog outputs ............................................................................................................................. 153TABLE 26 -Outdoor Air Sensor Temperature/Voltage/Correlation ....................................................................... 155TABLE 27 -Discharge Air Temp. Sensor Temperature/Voltage/Resistance Correlation....................................... 156TABLE 28 - Pressure Transducers ....................................................................................................................... 157TABLE 29 - Troubleshooting ................................................................................................................................. 160TABLE 30 - Minimum, Maximum And Default Values ........................................................................................... 165TABLE 31 - Values Required For Bas Communication ......................................................................................... 166TABLE 32 - Real Time Error Numbers .................................................................................................................. 166TABLE 33 - Bacnet And Modbus Communications Data Map .............................................................................. 168TABLE 34 - Yorktalk 2 Communications Data Map ............................................................................................... 172JOHNSON CONTROLS 13FORM 150.63-NM9 ISSUE DATE: 9/27/20131SECTION 1 GENERAL EQUIPMENT INFORMATION AND SAFETYINTRODUCTIONThe15through80Ton(50through280kW)YCUL modelsareshippedcompletefromthefactoryready for field installation.The unit is pressure-tested, evacuated and given a ni-trogen holding charge and includes an initial oil charge (R-410A refrigerant supplied by others). After assem-bly, an operational test is performed to assure that each control device operates correctly.Theunitstructureisheavy-gauge,galvanizedsteel. Thisgalvanizedsteeliscoatedwithbaked-onpow-der paint which, when subjected to ASTM B117 1000 hour salt spray testing, yields a minimum ASTM 1654 ratingof6.Unitsaredesignedinaccordancewith NFPA 70 (National Electric Code), ASHRAE/ANSI 15 Safety code for mechanical refrigeration, and are cETL listed. All units are produced at an ISO 9000-registered facility.COMPRESSORSThecondensingunithassuction-gascooled,hermet-ic,scrollcompressors.Thecompressorsincorporate acompliantscrolldesigninboththeaxialandradial direction.Allrotatingpartsofthecompressorsare staticallyanddynamicallybalanced.Alargeinternal volume and oil reservoir provides greater liquid toler-ance. Compressor crankcase heaters are also included for extra protection against liquid migration.CONDENSERCoilsFinandtubecondensercoilsofseamless,internally-enhanced,high-condensing-coefficient,corrosionre-sistantcoppertubesarearrangedinstaggeredrows, mechanicallyexpandedintoaluminumfins.Integral subcoolingisincluded.Thedesignworkingpressure of the coil is 650 psig (45 barg).Low Sound FansThecondenserfansarecomposedofcorrosionresis-tant aluminum hub and composite blades molded into a low noise airfoil section. They are designed for maxi-mum efficiency and are statically and dynamically bal-ancedforvibration-freeoperation.Theyaredirectly driven,andpositionedforverticalairdischarge.The fan guards are constructed of heavy-gauge, rust-resis-tant, PVC (polyvinyl chloride)-coated steel wire.MotorsThe fan motors are Totally Enclosed Air-Over, squirrel-cage type, current protected. They feature ball bearings that are double-sealed and permanently lubricated.REFRIGERANT CIRCUITAll unit piping will be copper with brazed joints. The liquid line will include a field connection shutoff valve withchargingportlocatedoneachcondensercircuit. Suctionlineconnectionsareprovidedoneachrefrig-eration circuit. A filter drier and sight glass are shipped loose for field installation on each refrigerant circuit.Allexpansionvalves,liquidlinesolenoidvalves, refrigerant, and refrigerant field piping are supplied by others.WARRANTYJohnson Controls warrants all equipment and materials against defects in workmanship and materials for a pe-riod of eighteen months from date of shipment, 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 hasoccurredwithinthewarrantyperiod,andthatthe unit has been operated within the designed parameters specified.All warranty claims must specify the unit model, serial number, order number and run hours/starts. Model and serial number information is printed on the unit identi-fication plate.Theunitwarrantywillbevoidifanymodification to theunitiscarriedoutwithoutpriorwrittenapproval from Johnson Controls.For warranty purposes, the following conditions must be satisfied:The initial start of the unit must be carried out by trainedpersonnelfromanAuthorizedJohnson Controls Service Center (see SECTION 6 COM-MISSIONING).Onlygenuine YORKapprovedspareparts,oils, coolants, and refrigerants must be used. JOHNSON CONTROLS 14FORM 150.63-NM9 ISSUE DATE: 9/27/2013SECTION 1 GENERAL EQUIPMENT INFORMATION AND SAFETYAll the scheduled maintenance operations detailed in this manual must be performed at the specifed times by suitably trained and qualifed personnel (see Section 10 MAINTENANCE).Failure to satisfy any of these conditions will au-tomatically void the warranty (see Warranty Pol-icy).SAFETY AND QUALITYStandards for Safety and QualityYCULUNITSaredesignedandbuiltwithinanISO 9002accrediteddesignandmanufacturingorganiza-tion. The condensing units comply with the applicable sections of the following Standards and Codes:ANSI/ASHRAEStandard15-SafetyCodefor Mechanical Refrigeration.ANSI/NFPAStandard70-NationalElectrical Code (N.E.C.).ASME Boiler and Pressure Vessel Code- Section VIII Division 1.ARIStandard550/590-PositiveDisplacement Compressors and Air Cooled Rotary Screw Water Chilling Packages.ASHRAE 90.1- Energy Effciency compliance.ARI 370- Sound Rating of Large Outdoor Refrig-eration and Air Conditioning Equipment.ConformtoIntertekTestingServices,formerly ETL,forconstructionofcondensingunitsand provide E.T.L./c E.T.L. Listing label.Inaddition,thecondensingunitsconformtoUnder-writers Laboratories (U.L.) for construction of chillers and provide U.L./cU.L. Listing Label.Responsibility for SafetyEvery care has been taken in the design and manufac-tureoftheunittoensurecompliancewiththesafety requirementslistedabove.However,theindividual operatingorworkingonanymachineryisprimarily 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 MANUALThe following terms are used in this document to alert the reader to areas of potential hazard.A WARNINGisgiveninthisdocument to identify a hazard, which could lead to personalinjury.Usuallyaninstruction will be given, together with a brief expla-nation and the possible result of ignoring the instruction.ACAUTIONidentifesahazardwhich couldleadtodamagetothemachine, damage to other equipment and/or envi-ronmental pollution. Usually an instruc-tionwillbegiven,togetherwithabrief explanationandthepossibleresultof ignoring the instruction.ANOTEisusedtohighlightadditional information,whichmaybehelpfulto you but where there are no special safety implications.Thecontentsofthismanualincludesuggestedbest working practices and procedures. These are issued for guidanceonly,andtheydonottakeprecedenceover the above stated individual responsibility and/or local safety regulations.Thismanualandanyotherdocumentsuppliedwith theunitarethepropertyofJohnsonControlswhich reservesallrights.Theymaynotbereproduced,in wholeorinpart,withoutpriorwrittenauthorization from an authorized Johnson Controls representative.MISUSE OF EQUIPMENTSuitability for ApplicationThe unit is intended for DX cooling applications and is not suitable for purposes other than those specified in these instructions. Any use of the equipment other than its intended use, or operation of the equipment contrary totherelevantproceduresmayresultininjurytothe operator, or damage to the equipment.Theunitmustnotbeoperatedoutsidethedesignpa-rameters specified in this manual.JOHNSON CONTROLS 15SECTION 1 GENERAL EQUIPMENT INFORMATION AND SAFETYFORM 150.63-NM9 ISSUE DATE: 9/27/20131Structural SupportStructural support of the unit must be provided as in-dicated 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.Ad-ditional 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 AccessThere 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 potentialhazardsandprecautionsnecessaryforsafe operationandmaintenanceofequipmentcontaining high temperatures, pressures and voltages.Pressure SystemsTheunitcontainsrefrigerantvaporandliquidunder pressure,releaseofwhichcanbeadangerandcause 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 togainaccesstothecomponentpartsofthepressure system other than by suitably trained and qualified per-sonnel.ElectricalTheunitmustbegrounded.Noinstallationormain-tenanceworkshouldbeattemptedontheelectrical equipmentwithoutfirstswitchingpowerOFF,isolat-ingandlocking-offthepowersupply.Servicingand maintenanceonliveequipmentmustonlybeper-formed by suitably trained and qualified personnel.No attemptshouldbemadetogainaccesstothecontrol panel or electrical enclosures during normal operation of the unit.Rotating PartsFan guards must be fitted at all times and not removed unless the power supply has been isolated. If ductwork istobefitted,requiringthewirefanguardstobere-moved,alternativesafetymeasuresmustbetakento protect against the risk of injury from rotating fans.Sharp EdgesThe fins on the air-cooled condenser coils have sharp metaledges.Reasonablecareshouldbetakenwhen workingincontactwiththecoilstoavoidtheriskof minorabrasionsandlacerations. Theuseofglovesis recommended.Framerails,brakes,andothercomponentsmayalso havesharpedges.Reasonablecareshouldbetaken when working in contact with any components to avoid risk of minor abrasions and lacerations.Refrigerants and OilsRefrigerants and oils used in the unit are generally non-toxic, non-flammable and non-corrosive, and pose no special safety hazards. Use of gloves and safety glasses is, however, recommended when working on the unit. Thebuildupofrefrigerantvapor,fromaleakforex-ample, does pose a risk of asphyxiation in confined or enclosed spaces and attention should be given to good ventilation.High Temperature and Pressure CleaningHightemperatureandpressurecleaningmethods (e.g.steamcleaning)shouldnotbeusedonanypart of the pressure system as this may cause operation of thepressurereliefdevice(s).Detergentsandsolvents, which may cause corrosion, should also be avoided.Emergency ShutdownIn case of emergency, the control panel is fitted with a Unit Switch to stop the unit in an emergency. When op-erated, it removes the low voltage 120 VAC electrical supplyfromtheinvertersystem,thusshuttingdown the unit.JOHNSON CONTROLS 16FORM 150.63-NM9 ISSUE DATE: 9/27/2013SECTION 1 GENERAL EQUIPMENT INFORMATION AND SAFETYTHIS PAGE INTENTIONALLY LEFT BLANKJOHNSON CONTROLS 17SECTION 2 PRODUCT DESCRIPTIONFORM 150.63-NM9 ISSUE DATE: 9/27/20132SECTION 2 PRODUCT DESCRIPTIONINTRODUCTIONJohnsonControls YORKSeries40 Air-CooledScroll Condensing Units provide chilled water for all air con-ditioning applications using central station air handling orterminalunits.Theyarecompletelyself-contained and are designed for outdoor (roof or ground level) in-stallation. Each unit includes hermetic scroll compres-sors, a liquid cooler, air cooled condenser, and a weath-er resistant microprocessor control center, all mounted on a pressed steel base.The units are completely assembled with all intercon-nectingrefrigerantpipingandinternalwiring,ready for field installation.The unit is pressure-tested, evacuated and given a ni-trogen holding charge and includes an initial oil charge (R-410A refrigerant supplied by others). After assem-bly, a operational test is performed to assure that each control device operates correctly.Theunitstructureisheavy-gauge,galvanizedsteel. Thisgalvanizedsteeliscoatedwithbaked-onpow-der paint which, when subjected to ASTM B117 1000 hour, salt spray testing, yields a minimum ASTM 1654 ratingof6.Unitsaredesignedinaccordancewith NFPA 70 (National Electric Code), ASHRAE/ANSI 15 Safety code for mechanical refrigeration, and are cETL listed. All units are produced at an ISO 9000-registered facility.Allexposedpowerwiringisroutedthroughliquid-tight, non-metallic conduit.GENERAL SYSTEM DESCRIPTIONCompressorsThe condensing unit has suction-gas cooled, hermetic, scrollcompressors.The YCULcompressorsincorpo-rateacompliantscrolldesigninboththeaxialand radialdirection.Allrotatingpartsarestaticallyand dynamically balanced. A large internal volume and oil reservoirprovidesgreaterliquidtolerance.Compres-sorcrankcaseheatersarealsoincludedforextrapro-tection against liquid migration.An annular discharge check valve and reverse vent as-semblyprovideslowpressuredrop,silentshutdown, and reverse rotation protection.CondenserCoilsFinandtubecondensercoilsofseamless,in-ternally-enhanced, high-condensing-coefficient, corro-sionresistantcoppertubesarearrangedinstaggered rows, mechanically expanded into aluminum fins. Inte-gral subcooling is included. The design working pres-sure of the coil is 650 PSIG (45 bar).FIGURE 1 - YCUL AIR-COOLED SCROLL COMPRESSOR CONDENSING UNITJOHNSON CONTROLS 18FORM 150.63-NM9 ISSUE DATE: 9/27/2013SECTION 2 PRODUCT DESCRIPTIONLow Sound FansThecondenserfansarecomposedofcorrosionresis-tant aluminum hub and composite blades molded into a low noise airfoil section. They are designed for maxi-mum efficiency and are statically and dynamically bal-ancedforvibration-freeoperation.Theyaredirectly driven,andpositionedforverticalairdischarge.The fan guards are constructed of heavy-gauge, rust-resis-tant, PVC (polyvinyl chloride)-coated steel wire.MotorsThe fan motors are Totally Enclosed Air-Over, squirrel-cage type, current protected. They feature ball bearings that are double-sealed and permanently lubricated.MICROCOMPUTER CONTROL CENTERAllcontrolsarecontainedinaNEMA3R/12cabinet with hinged outer door and include Liquid Crystal Dis-play(LCD)withLightEmittingDiode(LED)back-lighting for outdoor viewing and includes:Two display linesTwenty characters per lineDisplay/Print Colorcoded12-buttonnon-tactilekeypadwithsec-tions for display and print of typical information:Suction temperatures (optional)Ambient temperatureSystem pressures (each circuit)Operating hours and starts (each compressor)Print calls up to the liquid crystal displayOperating data for the systemsHistoryoffaultshutdowndataforuptothelast six fault shutdown conditions.An RS-232 port, in conjunction with the press-to-print button, is provided to allow hard copy print-outs via a separate printer (by others).EntryThis section is used to enter setpoints or modify system values.SetpointsUpdating can be performed to:Suction pressure settingSuction pressure control zoneRemote reset temperature rangeSet daily schedule/holiday for start/stopManual override for servicingLow and high ambient cutoutsNumber of compressorsLow suction pressure cutoutHigh discharge pressure cutoutAnti-recycle timer (compressor start cycle time)Anti-coincident timer (delay compressor starts) UnitThis section is used to:Set clockSet optionsSet unit optionSet unit control for Discharge Air Temperature Control or for Suction Pressure Control (requires Suction Pres-sure Transducers) is standard. Unit On/Off SwitchThemicroprocessorcontrolcenteriscapableof display ing the following:Suction temperatures (optional)Low ambient temperature cutout settingEnglish or Metric dataSuction pressure cutout settingEach system suction pressure System discharge pressureJOHNSON CONTROLS 19SECTION 2 PRODUCT DESCRIPTIONFORM 150.63-NM9 ISSUE DATE: 9/27/20132Discharge Air Temperature Reset via a YORKISNDDCorBuildingAutomationSystem(by others) via:apulsewidthmodulated(PWM)inputas standarda 4 to 20ma or 0 to 10VDC input, or contact closure with the optional B.A.S. interface op-tionAnti-recycle timer status for each systemAnti-coincident system start timer conditionCompressor run statusNo cooling load conditionDay, date and timeDaily start/stop timesHoliday statusAutomaticormanualsystemlead/lagcontrol (Discharge Air Temperature control only)Automaticlead/lagofcompressorswithinasys-temCompressor starts and operating hours (each com-pressor)Status of hot gas valves, and fan operationRun permissive statusNumber of compressors runningLiquid solenoid valve statusLoad and unload timer statusProvisionsareincludedforpumpdownatshutdown, optionalremotedischargeairtemperaturereset,and twostepsofdemandloadlimitingfromanexternal buildingautomationsystem.Unitalarmcontactsare standard.The operating program is stored in non-volatile mem-ory (EPROM) to eliminate condensing unit failure due to AC powered failure/battery discharge. Programmed setpointsareretainedinlithiumbattery-backedRTC memory for 5 years minimum.BUILDING AUTOMATION SYSTEMINTERFACEThe Microprocessor Board can accept a 4 to 20ma, 0 to 10VDC or contact closure input to reset the discharge airtemperaturefromaBuilding AutomationSystem. Only one of the following remote communications op-tions can be offered on a unit at a time: BAS Interface, Remote Control Panel or Multi-unit Sequence Control (Factory Mounted).Thestandardunitcapabilitiesincluderemote start-stop,remotewatertemperatureresetviaa PWM 4 to 20ma or 0 to 10VDC input signal or up to two stages of demand (load) limiting depending on model.Thestandardcontrolpanelcanbedirectlycon-nected to a Johnson Controls Building Automated System.COMMUNICATIONSNativecommunicationcapabilityforBACnet (MS/TP) and ModbusOptionalcommunicationavailableforN2and LON via eLink optionPOWER PANELEach panel contains:Compressor power terminalsCompressor motor starting contactors per Interna-tional Electrotechnical Commission (I.E.C.).Controlpowerterminalstoacceptincomingfor 115-1-60 control powerFan contactors and overload current protectionThepowerwiringisroutedthroughliquid-tightcon-duit to the compressors and fans.JOHNSON CONTROLS 20FORM 150.63-NM9 ISSUE DATE: 9/27/2013SECTION 2 PRODUCT DESCRIPTIONACCESSORIES AND OPTIONSElectrical OptionsCompressor Power ConnectionsSingle-pointterminalblockconnection(s)areprovid-edasstandard.Thefollowingpowerconnectionsare availableasfactorymountedoptions.(SeeElectrical Data for specific voltage and options availability.)Single-Point Supply Terminal Block (standard on YCUL models). Includes enclosure, terminal-block and interconnecting wiring to the compressors. Separate external protection must be supplied, by others, in the incoming compres-sor-powerwiring.Thisoptioncannotbeincludedif eithertheSinglePointNon-FusedDisconnectSwitch or Single-Point Circuit Breaker options have been in-cluded.Single-Point Non-Fused Disconnect SwitchUnit-mounteddisconnectswitchwithexternal,lock-ablehandleincompliancewithArticle440-14of N.E.C., can be supplied to isolate the unit power volt-ageforservicing.Separateexternalfusingmustbe supplied,byothersinthepowerwiring,whichmust comply with the National Electrical Code and/or local codes.Single-Point Circuit BreakerA unit mounted circuit breaker with external, lockable handle(incompliancewithN.E.C.Article440-14), canbesuppliedtoisolatethepowervoltageforser-vicing.(ThisoptionincludestheSingle-PointPower connection.)Control TransformerThistransformerconvertsunitpowervoltageto115-1-60(0.5or1.0KVAcapacity).Factorymounting includesprimaryandsecondarywiringbetweenthe transformer and the control panel.Power Factor Correction CapacitorsThesefactorymountedcapacitorswillcorrectunit compressor to a power factor between 0.90 and 0.95.Control OptionsAmbient Kit (Low)Units will operate to 25F (-4C). This factory mounted accessory includes all necessary components to permit chilleroperationto0F(-18C). Thisoptionincludes the Discharge Pressure Transducer / Readout Capabil-ity option. For proper head pressure control in applica-tions below 25F (-4C), where wind gusts may exceed five mph, it is recommended that factory mounted op-tionalCondenserLouveredEnclosurePanelsalsobe included.Ambient Kit (High)This factory mounted kit is required if units are to op-eratewhentheambienttemperatureisabove110F (43C)andincludesdischargepressuretransducers. ThisoptionincludesthefactorymountedDischarge Pressure Transducer / Readout Capability option. Building Automation System InterfaceThe factory addition of a Printed Circuit Board to ac-cept a 4 to 20ma, 0 to10VDC or contact closure input toresettheleavingchillerliquidtemperaturefroma Building AutomationSystem.Onlyoneoffollowing optionscanbeofferedonaunitatatime:BAS,Re-moteControlPanelorMulti-unitSequenceControl. (Factory-Mounted)Thestandardunitcapabilitiesin-clude remote start/stop, remote water temperature reset via a PWM input signal or up to two steps of demand (load)limitingdependingonmodel.Thestandard controlpanelcanbedirectlyconnectedtoaJohnson Controls Building Automated System via the standard onboard RS485 communication port.Language LCD and Keypad DisplaySpanish,French,andGermanunitLCDcontrolsand keypaddisplayareavailable;howeverthestandard language is English.DISCHARGE PRESSURE TRANSDUCERS AND READOUT CAPABILITYThe addition of factory mounted pressure transducers allows models to sense and display discharge pressure. Thisisrecommendedforbrinechillingapplications. This option is included with either the low or high am-bient kits.JOHNSON CONTROLS 21SECTION 2 PRODUCT DESCRIPTIONFORM 150.63-NM9 ISSUE DATE: 9/27/20132Suction Pressure TransducersThistransducerpermitstheunittosenseanddisplay suction pressure. This capability is standard on YCUL models.Motor Current ModuleThis option allows the monitoring of compressor motor current and provides extra protection against compres-sorreverserotation,phase-lossandphaseimbalance. Thisfactorymountedoptionconsistsofonemodule per electrical system. Multi-Unit SequencingAseparatesequencingcontrolcenterisprovidedto handlesequencingcontrolofuptoeightchillersin parallelbasedonmixedliquidtemperature(intercon-nectingwiringbyothers).Theonlyoneoffollowing factory mounted options can be offered on a unit at a time:BAS,RemoteControlPanelorMulti-UnitSe-quence Control. Compressor and Piping OptionsChicago Code Relief ValvesUnitwillbeprovidedwithreliefvalvestomeetChi-cago code requirements. (Factory-Mounted)Service Isolation ValveServiceisolationvalvesarestandardtounit.Thisin-cludesasystemhighpressurereliefvalveorinter-nalcompressorreliefmechanismincompliancewith ASHRAE 15. (Factory-Mounted)Hot Gas By-PassPermitscontinuous,stableoperationatcapacitiesbe-low the minimum step of compressor unloading to as lowas5%capacity(dependingonboththeunitand operating conditions) by introducing an artificial load on the cooler. Hot gas by-pass is installed on only re-frigerantsystem#1ontwo-circuitedunits.(Factory-Mounted)Condenser and Cabinet OptionsCondensercoilprotectionagainstcorrosiveenviron-mentsisavailablebychoosinganyofthefollowing options. For additional application recommendations, refer to Form 150.12-ES1. (Factory-Mounted)Pre-Coated Fin Condenser CoilsTheunitscoilsareconstructedwithepoxycoated aluminumfins.Thiscanprovidecorrosionresistance comparable to copper-fin coils in typical seashore loca-tions. Either these or the post-coated coils (below) are recommended for units being installed at the seashore or where salt spray may hit the unit.Post-Coated Dipped Condenser CoilsThe units coils are constructed with dipped-cured con-densercoils. Thisisthechoiceforcorrosiveapplica-tions(withtheexceptionofstrongalkalis,oxidizers andwetbromine,chlorineandfluorineinconcentra-tions greater than 100 ppm).Copper Fin Condenser CoilsThe units coils are constructed with copper fins. (This is not recommended for units in areas where they may be exposed to acid rain.)Enclosure Panels (Unit)Tamperproofenclosurepanelspreventunauthorized accesstounits.Enclosurepanelscanprovideanaes-theticallypleasingalternativetoexpensivefencing. Additionally, for proper head pressure control, Johnson Controls recommends the use of louvered panels.Louvered Panels (Full Unit)Louvered panels surround the front, back, and sides of theunit.Theypreventunauthorizedaccessandvisu-allyscreenunitcomponents.Unrestrictedairflowis permitted through generously sized louvered openings. This option is applicable for any outdoor design ambi-ent temperature up to 115F (46C). (Factory-Mount-ed.)Sound AttenuationOneorbothofthefollowingfactorymountedsound attenuation options are recommended for residential or other similar sound-sensitive locations. Louvered Pan-els can be ordered for winter applications where wind gustsmayexceedfivemilesperhour.Thefollowing types of enclosure options are available:JOHNSON CONTROLS 22FORM 150.63-NM9 ISSUE DATE: 9/27/2013SECTION 2 PRODUCT DESCRIPTIONCompressor Acoustic Sound BlanketEachfactorymountedcompressorisindividuallyen-closed by an acoustic sound blanket. The sound blan-ketsaremadewithonelayerofacousticalabsorbent textilefiberof5/8(15mm)thickness;onelayerof anti-vibrating heavy material thickness of 1/8 (3mm). BothareclosedbytwosheetsofweldedPVC,rein-forced for temperature and UV resistance. Ultra Quiet FanLower RPM, 8-pole fan motors are used with steeper-pitch fans on these factory mounted devices. Vibration IsolatorsLeveladjusting,springtype1"(25.4mm)orseismic deflection or neoprene pad isolators for mounting un-der unit base rails. (Field-Mounted)UNIT COMPONENTS FIGURE 2 - UNIT COMPONENTS FRONTMICROPANEL FANSCOMPRESSORSCONDENSER COILSJOHNSON CONTROLS 23SECTION 2 PRODUCT DESCRIPTIONFORM 150.63-NM9 ISSUE DATE: 9/27/20132FIGURE 3 - POWER PANEL COMPONENTSLD13247COMPRESSOR CONTACTORSXTBF1FAN CONTACTORSFAN CONTACTORCOMPRESSOR OVERLOADSFAN FUSESDISCONNECTSWITCHPOWER PANEL COMPONENTSJOHNSON CONTROLS 24FORM 150.63-NM9 ISSUE DATE: 9/27/2013SECTION 2 PRODUCT DESCRIPTIONPOWER PANEL / CONTROL COMPONENTSFIGURE 4 - POWER PANEL / CONTROL COMPONENTSCOMPRESSOR OVERLOADSCOMPRESSOR CONTACTORSFAN CONTACTORSFAN FUSESCONTROL RELAYMICROCOMPUTER CONTROL CENTER MICROPANELDISPLAYKEYPADXTBC1XTBC2XTBF2MICROBOARDLD13248JOHNSON CONTROLS 25SECTION 2 PRODUCT DESCRIPTIONFORM 150.63-NM9 ISSUE DATE: 9/27/20132PRODUCT IDENTIFICATION NUMBER (PIN)BASIC UNITBASIC MODEL NUMBERYCUL0045EE46XEABASE PRODUCT TYPELU : UnitYC :YORK Condensing:ScrollVOLTAGE/STARTERX1 7 :200 / 3 / 602 8 :230 / 3 / 604 0 :380 / 3 / 604 6 :460 / 3 / 605 8 :575 / 3 / 605 0 :380-415 / 3 / 50:Across the Line DESIGN/DEVELOPMENT LEVELE :Design SeriesA :Engineering Changeor PIN LevelE :High EfficiencyUNIT DESIGNATORE :R-410AREFRIGERANT NOMINAL CAPACITYNominal Capacity1 2 3 4 5 6 7 8 9 10 11 1213 14 15FEATURE FEATURE DESCRIPTION OPTION OPTION DESCRIPTIONMODEL Model (PIN 1-4) YCUL YCULCAP Capacity (PIN 5-8)0020 00200024 00240031 00310035 00350045 00450051 00510055 00550065 00650072 0072UNIT Unit Designator (PIN 9) E High EffciencyREF Refrigerant (PIN 10) E R-410AVOLTS Voltage (PIN 11 & 12)17 200/3/6028 230/3/6040 380/3/6046 460/3/6050 380-415/3/5058 575/3/60STARTER Starter (PIN 13) X Across The Line StarterDESIGN Design Series (PIN 14) E Design Series EDEV Development Level (PIN 15) A Development Level APOWER Power Field (PIN 16 & 17)SX Single Point Terminal BlockSD Single Point Non-Fused DisconnectBX Single Point Circuit BreakerQQ Special Power Option RequiredTRANS Cntrl Transformer (PIN 18)X No Control Transformer RequiredT Control Transformer RequiredQ Special Control Transformer RequiredJOHNSON CONTROLS 26FORM 150.63-NM9 ISSUE DATE: 9/27/2013SECTION 2 PRODUCT DESCRIPTIONPRODUCT IDENTIFICATION NUMBER (PIN) (CONT)FEATURE FEATURE DESCRIPTION OPTION OPTION DESCRIPTIONPFC Power Factor Capacitor (19)X No Power Capacitor RequiredC Power Capacitor RequiredQ Special Power Capacitor RequiredAMB Ambient Kits (PIN 20)H High Ambient (standard)A Both Low And High Ambient (Low Ambient kit required)Q Special Ambient Kit RequiredBAS Bas Reset/Offset (PIN 21)X No BAS Reset/Offset RequiredM ISN Microgateway RequiredT BAS Reset/Offset RequiredQ Special BAS Reset/Offset RequiredLCD Language (PIN 22)X EnglishS SpanishF FrenchG GermanQ Special Language RequiredRDOUT Readout Kits (PIN 23)R Discharge Pressure Readout (standard)Q Special Pressure Readout RequiredSAFETY Safety Codes (PIN 24) L N American Safety Code (cUL/cETL)SENSOR PIN 25X No Option RequiredQ Special QuotePUMP Motor Current Module (PIN 26)X No Motor Current Readout RequiredC Motor Current ReadoutQ Special QuoteREMOTE Remote Panel (PIN 27)X No Remote Panel RequiredO Opiview Remote Panel RequiredQ Special Remote Panel RequiredSEQ Sequence Kit (PIN 28)X No Sequence Kit RequiredS Sequence Kit Required = {SEQ/S}Q Special Sequence Kit RequiredTEMP Suction Temp (PIN 29,30)NUM Suction Temp = {TEMP/NUM} DegreesQQ Special LWT RequirementsCHICAGO Chicago Code Kit (PIN 31)X Service Isolation Valves B Both Chicago Code and Serv IsolationQ Special Chicago Code Kit RequiredVALVES Valves (PIN 32)X Standard Valves ReqdQ Special Optional Valves ReqdHGBP Hot Gas Bypass (PIN 33)X No Hot Gas Bypass Required1 Hot Gas Bypass Required - 1 Circuit2 Hot Gas Bypass Required - 2 CircuitsQ Special Hot Gas Bypass Required GAUGE PIN 34X No Option RequiredQ Special QuoteOVERLOAD PIN 35X No Option RequiredQ Special QuoteJOHNSON CONTROLS 27SECTION 2 PRODUCT DESCRIPTIONFORM 150.63-NM9 ISSUE DATE: 9/27/20132FEATURE FEATURE DESCRIPTION OPTION OPTION DESCRIPTIONPIN 36 PIN 36X No Option RequiredQ Special QuoteHTR Crankcase Heater (Pin 37)X Crankcase Heater StandardQ Special Crankcase Heater RequiredDWP DWP (PIN 38)X No Option RequiredQ Special QuoteINS Insulation (PIN 39)X No Option RequiredQ Special QuoteFLANGES Flanges (PIN 40)X No Option RequiredQ Special QuoteFLOW Flow Switch (PIN 41)X No Option RequiredQ Special QuoteVESSEL Vessel Codes (PIN 42)X No Option RequiredQ Special QuoteCLR Cooler (PIN 43)X No Option RequiredQ Special QuotePIN44 PIN 44X No Option RequiredQ Special QuoteCOILS Coils (PIN 45)X Aluminum CoilB Pre-Coated Fin CoilC Copper CoilP Post-Coated Dipped CoilQ Special CoilPIN46 PIN 46X No Option RequiredQ Special QuoteFANMOTORS Fan Motors (PIN 47)X TEAO Fan MotorsQ Special Fan Motors RequiredENCL Enclosure Panels (PIN 48)1 Wire Enclosures - Factory7 Louvered Enclosure - FactoryQ Special Enclosure PanelsACOUSTIC Acoustic Blanket (PIN 49)X No Acoustic Blanket RequiredB Acoustic Blanket RequiredQ Special Acoustic Blanket RequiredSRDOCS SR Documents (PIN 50)X No Documents RequiredA Base, Material and Witness DocumentsB Base DocumentM Base and Material DocumentsW Base and Witness DocumentsQ Special QuotePIN51 PIN 51X No Option RequiredQ Special QuoteFANS Sound Fans (PIN 52)X Standard Low Sound Fans RequiredL Ultra Low Sound Fans RequiredQ Special Sound Fans RequiredPRODUCT IDENTIFICATION NUMBER (PIN) (CONTD)JOHNSON CONTROLS 28FORM 150.63-NM9 ISSUE DATE: 9/27/2013SECTION 2 PRODUCT DESCRIPTIONFEATURE FEATURE DESCRIPTION OPTION OPTION DESCRIPTIONPAINT PIN 53X No Option RequiredQ Special QuoteISOL Vibration Isolators (PIN 54)X No Isolators Required1 1" Defection Isolators RequiredN Neoprene Isolators RequiredS Seismic Isolators RequiredQ Special Isolators RequiredWARRANTY Warranty (PIN 55) Marketing Purposes Only!REFWTY Refrigerant Wty (PIN 56) Marketing Purposes Only!SHIP Ship Instructions (PIN 57)X No Containerization requiredA Buy American Act ComplianceBBoth Buy American Act Compliance and Container Shipping Kit (Factory Prep)C Container Shipping Kit (Factory Load)P Container Shipping Kit (Factory Prep)Q Special QuotePIN 58 PIN 58 Marketing Purposes Only!PKG Pump package (PIN 59)X No Option RequiredQ Special QuotePKGOPT Pump Package Options (PIN 60)X No Option RequiredQ Special QuoteMFG Plant of Mfg (PIN 61) R Plant Of Manufacture - MonterreyLOC Mfg locationCUR Curitiba, BrazilMEX Mexico, ESMTY Monterrey, BESAT San Antonio, TexasYW YorkWorks versionCV Yorkworks Confguration Version {YW/CV}UV Yorkworks Upload Version {YW/UV}SQ Special quote Q Special QuotePRODUCT IDENTIFICATION NUMBER (PIN) (CONTD)JOHNSON CONTROLS 29SECTION 2 PRODUCT DESCRIPTIONFORM 150.63-NM9 ISSUE DATE: 9/27/20132LD04284AREFRIGERANT FLOW DIAGRAMFIGURE 5 - REFRIGERANT FLOW DIAGRAM2 OR 3 COMPRESSORS PER SYSTEMOIL EQUALIZINGLINEAIR COOLED CONDENSERSSERVICE VALVEOPTIONAL DISCHARGEPRESSURE TRANSDUCERHIGH PRESSURECUTOUT SWITCHLOW PRESSURE SWITCH ORSUCTION PRESSURE TRANSDUCERLIQUID LINE SERVICE VALVELIQUID LINESOLENOID VALVE** TXVSIGHT GLASS /MOISTURE INDICATORSOLENOID OPERATEDHOT GAS BYPASS VALVE*YCUL REFRIGERANT FLOW DIAGRAMNOTE: YCUL0046-0090 HAVE TWO REFRIGERANT SYSTEMS* HOT GAS OPTION - SYSTEM 1 ONLYLIQUID LINEFILTER DRIEREVAP.AIR FLOWDISCHARGE AIRTEMPERATURE SENSOROPTIONAL SUCTIONTEMP SENSORFACTORY PIPINGFIELD PIPINGTT**One TXV and Liquid Line Solenoid shown for illustration purposes. Actual refrigerant piping may vary depending on evaporator circuiting.(OPTIONAL)SERVICEVALVE(OPTIONAL)YCULYCUL0045-0072DX COILJOHNSON CONTROLS 30FORM 150.63-NM9 ISSUE DATE: 9/27/2013SECTION 2 PRODUCT DESCRIPTIONFIGURE 6 - PROCESS AND INSTRUMENTATION DIAGRAMPROCESS AND INSTRUMENTATION DIAGRAMPSZCPR-1 ZCPR-2 ZCPR-3DVHPLHPCPDVLPC PCondenserFans Fans-YLLSVSTSee P.R.V .OptionsCompressorsControl Functions:DV - Display ValueCHT - Chilled Liquid TemperatureHPC- High Pressure CutoutLPC- Low Pressure CutoutHPL - High Pressure Load LimitingLTC- Low Temperature CutoutSPSTAmbient Air SensorDVHTCLTC585 PSIG650 PSIG450 PSIGEvaporator CoilPressure Relief Valve (ZP180 Scroll Only) *Service (Ball) ValveExpansion ValveSolenoid ValveSight GlassSensor Pressure or TemperatureService (Stop) Access ValvePressure SwitchFilter Drier (Removable Core)Components:* Smaller Compressor Scrolls Utilize Internal Reliefs.Lowpressureliquidrefrigerantentersthecoolerand isevaporatedandsuperheatedbytheheatenergyab-sorbedfromthechilledliquidpassingthroughthe coolershell.Lowpressurevaporentersthecompres-sorwherepressureandsuperheatareincreased.The high pressure vapor is fed to the air cooled condenser coil and fans where the heat is removed. The fully con-densed and subcooled liquid passes through the expan-sion valve where pressure is reduced and further cool-ing takes place before returning to the DX Coil.LD13139JOHNSON CONTROLS 31SECTION 3 HANDLING AND STORAGEFORM 150.63-NM9 ISSUE DATE: 9/27/20133SECTION 3 HANDLING AND STORAGEDELIVERY AND STORAGETo ensure consistent quality and maximum reliability, all units are tested and inspected before leaving the fac-tory.Units are shipped completely assembled and con-tainingrefrigerantunderpressure.Unitsareshipped withoutexportcratingunlesscratinghasbeenspeci-fied on the Sales Order.If the unit is to be put into storage, prior to installation, the following precautions should be observed:The unit must be blocked so that the base is not permitted to sag or bow.Ensurethatallopenings,suchaswaterconnec-tions, are securely capped.Donotstorewhereexposedtoambientairtem-peratures exceeding 110 F (43 C).Thecondensersshouldbecoveredtoprotectthe fns from potential damage and corrosion, particu-larly where building work is in progress.The unit should be stored in a location where there is minimal activity in order to limit the risk of ac-cidental physical damage.Topreventinadvertentoperationofthepressure relief devices the unit must not be steam cleaned.It is recommended that the unit is periodically in-spected during storage.INSPECTIONImmediatelyuponreceivingtheunit,itshouldbein-spected for possible damage which may have occurred during transit. If damage is evident, it should be noted in the carriers freight bill. A written request for inspec-tion by the carriers agent should be made at once. See Instruction manual, Form 50.15-NM for more infor-mation and details.Majordamagemustbereportedimmediatelytoyour local Johnson Controls representative.UNIT RIGGINGUsespreaderbarstoavoidliftingchainshittingthe unit.Neverlifttheunitusingaforkliftorby hookingtothetoprails.Useonlythe lifting holes provided.LiftingInstructionsareplacedonalabelontheunit and on the shipping bag.Theunitshouldbeliftedbyinserting hooks through the holes provided in unit base rails. Spreader bars should be used to avoid crushing the unit frame rails with the lifting chains (See Figure 7).FIGURE 7 - UNIT RIGGINGLD14326JOHNSON CONTROLS 32FORM 150.63-NM9 ISSUE DATE: 9/27/2013SECTION 3 HANDLING AND STORAGEMoving the Condensing UnitPriortomovingtheunit,ensurethattheinstallation siteissuitableforinstallingtheunitandiseasilyca-pableofsupportingtheweightoftheunitandallas-sociated services.Theunitsaredesignedtobeliftedusingcables.A spreaderbarorframeshouldbeusedinordertopre-vent damage to the unit from the lifting chains.Units are provided with lifting eyes in the sides of the baseframe,whichcanbeattachedtodirectlyusing shackles or safety hooks.The unit must only be lifted by the base frame at the points provided. Never move the unit on rollers, or lift the unit using a forklift truck.Care should be taken to avoid damaging the condenser cooling fins when moving the unit.Lifting WeightsFordetailsofweightsandweightdistribution,refer to the data shipped in the unit information packet and unit nameplate.JOHNSON CONTROLS 3