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YLPA0340SE-YLPA0610SE YLPA0355HE-YLPA0640HE
Installation, Comissioning, Operation and Maintenance
Revision 1
FORM 150.68.ICOM1.EN.CE (0911)
(035-23224-100)
REVERSE CYCLE AIR TO WATER HEAT PUMPS
WITH SCROLL COMPRESSORS
STYLE A
Cooling Capacities: 342 kW to 647 kW
Heating Capacities: 351 kW to 666 kW
R410A
150.68.ICOM1.EN.CE (0911)
Table of Contents
1.
General Unit Information and Safety .. ... ... . 1-1
Introduction
Warranty
Standards for Safety
Fluorinated Greenhouse Gases
Responsibility for Safety
About this manual
Misuse of Equipment
Emergency Shutdown
Safety Labels
Material Safety Data
2.
2-1
2-1
2-1
2-1
2-1
2-2
2-3
2-5
2-6
2-6
Transportation, Handling and Storage ... ... . 3-1
Delivery and Storage
Inspection
Moving the unit
Typical Lifting Arrangement
Lifting Weights
Application Data ... ... ... ... ... ... ... ... ... . 4-1
Location Requirements
Outdoor installations
Location Clearances
Installation of Vibration Isolators
Pipework Connection
Pipework Arrangement
Chilled Liquid System
Connection Types and Sizes
Water Treatment
Water Quality Requirements
Refrigerant Relief Valve Piping
Electrical Connection
Power Wiring
Single Point Power Supply Wiring
Control Circuit Transformer
Remote Emergency Stop Device
Control Wiring - Voltage Free Contact
Chilled Liquid Pump Starter
Run Contacts
Alarm Contacts
Control Wiring - System Inputs
Flow Switch
Remote Start/Stop
Remote Mode Selection
Remote Reset of Chilled Liquid Setpoint
Remote Load Limiting
Fan Full Speed Inhibit
EMS Analogue Input
Modbus, BACnet MS/TP and N2
Connection Diagram
1-1
1-1
1-1
1-1
1-1
1-2
1-2
1-3
1-3
1-4
Specification ... ... ... ... ... ... ... ... ... ... . 2-1
Compressors
Refrigerant Circuits
Refrigerant to Water Heat Exchanger
Ambient Coils
Power and Controls Panels
Microprocessor Controls
Accessories and Options
Refrigerant Flow Block Diagrams
Component Location Diagram
Nomenclature
3.
4.
3-1
3-1
3-1
3-2
3-2
5.
Commissioning ... ... ... ... ... ... ... ... ... . 5-1
Preparation
6.
5-1
Unit Operation.. ... ... ... ... ... ... ... ... ... . 6-1
General Description
Start-up
Normal running and cycling
Shutdown
EN
4-1
4-1
4-1
4-3
4-3
4-3
4-4
4-4
4-4
4-4
4-4
4-5
4-5
4-5
4-5
4-5
4-5
4-5
4-6
4-6
4-6
4-6
4-6
4-6
4-6
4-6
4-6
4-6
4-6
4-7
6-1
6-1
6-1
6-1
I
150.68.ICOM1.EN.CE (0911)
7.
Maintenance ... ... ... ... ... ... ... ... ... ... . 7-1
General Requirements
Daily Maintenance
Scheduled Maintenance
Heat Exchanger In-Service Inspection
8.
7-1
7-1
7-2
7-2
Trouble Shooting... ... ... ... ... ... ... ... ... . 8-1
Competent Persons Trouble Shooting Guide 8-1
Sensor Calibration Charts
8-3
9.
Technical Data . ... ... ... ... ... ... ... ... ... . 9-1
Refrigerant to Water Heat Exchanger Pressure
Drop Graph
9-1
Operating Limitations
9-1
Physical Data
9-2
Unit Electrical Data
9-3
Compressor Electrical Data
9-3
Fan Electrical Data
9-3
Dimensions - YLPA0355HE
9-4
Dimensions - YLPA0425HE
9-5
Dimensions - YLPA0505HE
9-6
Dimensions - YLPA0570HE
9-7
Dimensions - YLPA0640HE
9-8
Dimensions - YLPA0340SE
9-9
Dimensions - YLPA0415SE
9-10
Dimensions - YLPA0495SE
9-11
Dimensions - YLPA0560SE
9-12
Dimensions - YLPA0610SE
9-13
YLPA P & I Diagram
9-14
Anti Vibration Isolators Data Neoprene Isolators
9-15
Anti Vibration Isolators Data 25 mm Deflection Spring Isolators
9-16
10. Spare Parts. ... ... ... ... ... ... ... ... ... ... 10-1
Recommended Spares
Recommended Compressor Oil
Associated Drawings
10-1
10-1
10-1
11. Decommissioning, Dismantling
and Disposal ... ... ... ... ... ... ... ... ... ... 11-1
II
EN
150.68.ICOM1.EN.CE (0911)
1. General Unit Information and Safety
For warranty purposes, the following conditions must
be satisfied:
Introduction
YORK YLPA units are manufactured to the highest
design and construction standards to ensure high
performance, reliability and adaptability to all types of
air conditioning installations.
The unit is intended for cooling and heating water or
glycol solutions and is not suitable for purposes other
than those specified in this manual.
This manual contains all the information required for
correct installation and commissioning of the unit,
together with operating and maintenance instructions.
The manuals should be read thoroughly before
attempting to operate or service the unit.
All procedures detailed in the manuals, including
installation, commissioning and maintenance tasks
must only be performed by suitably trained and qualified
personnel.
The manufacturer will not be liable for any injury or
damage caused by incorrect installation, commissioning,
operation or maintenance resulting from a failure to
follow the procedures and instructions detailed in the
manuals.
Warranty
Johnson Controls warrants all equipment and materials
against defects in workmanship and materials for a
period of eighteen months from date of shipment, unless
labour or extended warranty has been purchased as
part of the contract.
The warranty is limited to parts only replacement and
shipping of any faulty part, or sub-assembly, which has
failed due to poor quality or manufacturing errors. All
claims must be supported by evidence that the failure
has occurred within the warranty period, and that the
unit has been operated within the designed parameters
specified.
All warranty claims must specify the unit model, serial
number, order number and run hours/starts. Model
and serial number information is printed on the unit
identification plate.
The unit warranty will be void if any modification to the
unit is carried out without prior written approval from
Johnson Controls.
EN
The initial start of the unit must be carried out by trained
personnel from an Authorized Johnson Controls Service
Centre.
Only genuine Johnson Controls approved spare parts,
oils, coolants, and refrigerants must be used.
All the scheduled maintenance operations detailed in
this manual must be performed at the specified times
by suitably trained and qualified personnel.
Failure to satisfy any of these conditions will
automatically void the warranty.
Standards for Safety
YLPA units are designed and manufactured within an
EN ISO 9001 accredited organisation and in conformity
with the following European Directives:

Machinery Directive (2006/42/EC)



EMC Directive (2004/108/EC)
Pressure Equipment Directive (97/23/EC)
Safety Code for Mechanical Refrigeration
(EN378-2 (2008))
Fluorinated Greenhouse Gases

This equipment contains fluorinated greenhouse
gases covered by the Kyoto Protocol.

The global warming potential of the refrigerant
(R410A) used in this unit is 1720.

The refrigerant quantity is stated in the Physical
Data table of this document.

The fluorinated greenhouse gases in this equipment
may not be vented to the atmosphere.

This equipment should only be serviced by qualified
technicians.
Responsibility for Safety
Every care has been taken in the design and
manufacture of the unit to ensure compliance with
the safety requirements listed above. However, the
individual operating or working on any machinery is
primarily responsible for:
Personal safety, safety of other personnel, and the
machinery.
Correct utilization of the machinery in accordance with
the procedures detailed in the manuals.
1-1
150.68.ICOM1.EN.CE (0911)
About this manual
Mechanical Strength
The following symbols are used in this document to
alert the reader to areas of potential hazard.
The unit is not designed to withstand loads or stresses
from adjacent equipment, pipework or structures.
Additional components must not be mounted on the
unit. Any such extraneous loads may cause structural
failure and may result in injury to the operator, or
damage to the equipment.
A WARNING is given in this document to
identify a hazard, which could lead to personal
injury. Usually an instruction will be given,
together with a brief explanation and the
possible result of ignoring the instruction.
A CAUTION identifies a hazard which could
lead to damage to the machine, damage to
other equipment and/or environmental
pollution. Usually an instruction will be given,
together with a brief explanation and the
possible result of ignoring the instruction.
A NOTE is used to highlight additional
information, which may be helpful to you but
where there are no special safety implications.
The contents of this manual include suggested best
working practices and procedures. These are issued
for guidance only, and they do not take precedence
over the above stated individual responsibility and/or
local safety regulations.
This manual and any other document supplied with
the unit are the property of Johnson Controls which
reserves all rights. They may not be reproduced, in
whole or in part, without prior written authorization from
an authorized Johnson Controls representative.
Misuse of Equipment
Suitability for Application
The unit is intended for cooling and heating water or
glycol solutions and is not suitable for purposes other
than those specified in these instructions. Any use of
the equipment other than its intended use, or operation
of the equipment contrary to the relevant procedures
may result in injury to the operator, or damage to the
equipment.
General Access
There are a number of areas and features, which may
be a hazard and potentially cause injury when working
on the unit unless suitable safety precautions are taken.
It is important to ensure access to the unit is restricted
to suitably qualified persons who are familiar with the
potential hazards and precautions necessary for safe
operation and maintenance of equipment containing
high temperatures, pressures and voltages.
Pressure Systems
The unit contains refrigerant vapor and liquid under
pressure, release of which can be a danger and cause
injury. The user should ensure that care is taken
during installation, operation and maintenance to avoid
damage to the pressure system. No attempt should
be made to gain access to the component parts of the
pressure system other than by suitably trained and
qualified personnel.
Electrical
The unit must be earthed. No installation or maintenance
work should be attempted on the electrical equipment
without first switching power OFF, isolating and
lockingoff the power supply. Servicing and maintenance
on live equipment must only be performed by suitably
trained and qualified personnel. No attempt should be
made to gain access to the control panel or electrical
enclosures during normal operation of the unit.
Rotating Parts
Fan guards must be fitted at all times and not removed
unless the main power supply has been isolated.
The unit must not be operated outside the design
parameters specified in this manual.
Structural Support
Structural support of the unit must be provided as
indicated in these instructions. Failure to provide proper
support may result in injury to the operator, or damage
to the equipment and/or building.
1-2
EN
150.68.ICOM1.EN.CE (0911)
Refrigerants and Oils
Safety Labels
Refrigerants and oils used in the unit are generally
nontoxic, 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. The build up of refrigerant vapor, from a
leak for example, does pose a risk of asphyxiation in
confined or enclosed spaces and attention should be
given to good ventilation.
The following labels are fixed to each unit to give
instruction, or to indicate potential hazards which may
exist.
White symbol on blue background
For safe operation, read the instructions
first
High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods (e.g.
steam cleaning) should not be used on any part of the
pressure system as this may cause operation of the
pressure relief device(s). Detergents and solvents,
which may cause corrosion, should also be avoided.
Black symbol on yellow background
Emergency Shutdown
Black symbol on yellow background
In case of emergency, the non-fused disconnect switch
on the power panel should be used as the emergency
stop device. When operated it removes the electrical
supply to the unit thus shutting down the unit.
Warning: This machine may start
automatically without prior warning
Warning: Hot surface
Black symbol on yellow background
Warning: Safety relief valve may discharge
gas or liquid without prior warning
Black symbol on yellow background
Warning: Isolate all electrical sources of
supply before opening or removing the
cover, as lethal voltages may exist
Black symbol on yellow background
General attention symbol
Black symbol on yellow background
Power Factor Correction fitted Warning:
On isolating the supply it may take up to
60 seconds for the capacitor voltage to fall
below 60 volts
EN
1-3
150.68.ICOM1.EN.CE (0911)
Material Safety Data
Refrigerant Safety Data R410A:
COMPOSITION/INFORMATION ON INGREDIENTS
Components Material
PENTAFLUOROETHANE (HFC-125)
DIFLUOROMETHANE (HFC-32)
CAS Number
354-33-6
75-10-5
%
50
50
HAZARDS IDENTIFICATION
Potential Health Effects
Inhalation of high concentrations of vapour is harmful and may cause heart irregularities, unconsciousness,
or death. Intentional misuse or deliberate inhalation may cause death without warning. Vapour reduces
oxygen available for breathing and is heavier than air. Liquid contact can cause frostbite.
Human Health Effects
Carcinogenicity Information
FIRST AID MEASURES
Inhalation
Skin Contact
Eye Contact
Ingestion
Notes to Physicians
FIRE FIGHTING MEASURES
Flammable Properties
Fire and Explosion Hazards
1-4
At flame temperatures, this material can decompose to hydrogen fluoride which can be lethal at much lower
concentrations.
Overexposure to the vapours by inhalation may include temporary nervous system depression with
anaesthetic effects such as dizziness, headache, confusion, incoordination, and loss of consciousness.
Higher exposures to the vapours may cause temporary alteration of the heart's electrical activity with
irregular pulse, palpitations, or inadequate circulation. Gross overexposure may be fatal. Skin contact with
the liquid may cause frostbite.
Individuals with preexisting diseases of the central nervous or cardiovascular system may have increased
susceptibility to the toxicity of increased exposures.
None of the components present in this material at concentrations equal to or greater than 0.1% are listed
by IARC, NTP, OSHA or ACGIH as a carcinogen.
If inhaled, immediately remove to fresh air. Keep person calm.
If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Call a physician.
Flush area with lukewarm water. Do not use hot water. If frostbite has occurred, call a physician.
In case of contact, immediately flush eyes with plenty of water for at least 15 minutes. Call a physician.
Do not induce vomiting. Give plenty of water in sips
THIS MATERIAL MAY MAKE THE HEART MORE SUSCEPTIBLE TO ARRHYTHMIAS. Catecholamines
such as adrenaline, and other compounds having similar effects, should be reserved for emergencies and
then used only with special caution.
Flash Point : No flash point
Flammable Limits in Air, % by Volume:
LEL : None per ASTM E681
UEL : None per ASTM E681
Autoignition: Not determined
Cylinders may rupture under fire conditions. Decomposition may occur.
Contact of welding or soldering torch flame with high concentrations of refrigerant can result in visible
changes in the size and colour of torch flames. This flame effect will only occur in concentrations of product
well above the recommended exposure limit, therefore stop all work and ventilate to disperse refrigerant
vapours from the work area before using any open flames.
R-410A is not flammable in air at temperatures up to 100 deg C (212 deg F) at atmospheric pressure.
However, mixtures of R-410A with high concentrations of air at elevated pressure and/or temperature can
become combustible in the presence of an ignition source. R-410A can also become combustible in an
oxygen enriched environment (oxygen concentrations greater than that in air). Whether a mixture
containing R-410A and air, or R-410A in an oxygen enriched atmosphere becomes combustible depends
on the inter-relationship of 1) the temperature 2) the pressure, and 3) the proportion of oxygen in the
mixture. In general, R-410A should not be allowed to exist with air above atmospheric pressure or at high
temperatures; or in an oxygen enriched environment. For example: R-410A should NOT be mixed with air
under pressure for leak testing or other purposes.
EN
150.68.ICOM1.EN.CE (0911)
Refrigerant Safety Data R410A:
Extinguishing Media
Fire Fighting Instructions
As appropriate for combustibles in area.
Cool cylinder with water spray or fog. Self-contained breathing apparatus (SCBA) is required if cylinders
rupture and contents are released under fire conditions. Water runoff should be contained and neutralized
prior to release.
ACCIDENTAL RELEASE MEASURES
Safeguards (Personnel)
NOTE: Review FIRE FIGHTING MEASURES and HANDLING (PERSONNEL)
sections before proceeding with clean-up. Use appropriate PERSONAL PROTECTIVE EQUIPMENT during
clean-up.
Accidental Release Measures
Ventilate area, especially low or enclosed places where heavy vapours might collect. Extinguish open
flames. Use self-contained breathing apparatus (SCBA) for large spills or releases. Eliminate electrical
sources.
HANDLING AND STORAGE
Handling (Personnel)
Avoid breathing vapour. Avoid liquid contact with eyes and skin. Use with sufficient ventilation to keep
employee exposure below recommended limits. See Fire and Explosion Data section.
Storage
Clean, dry area. Do not heat above 52 deg C (125 deg F).
EXPOSURE CONTROLS/PERSONAL PROTECTION
Engineering Controls
Avoid breathing vapours. Avoid contact with skin or eyes. Use with sufficient ventilation to keep employee
exposure below the recommended exposure limit. Local exhaust should be used if large amounts are
released. Mechanical ventilation should be used in low or enclosed places.
Personal Protective Equipment
Impervious gloves should be used to avoid prolonged or repeated exposure. Chemical splash goggles
should be available for use as needed to prevent eye contact. Under normal manufacturing conditions, no
respiratory protection is required when using this product provided exposure is maintained at or below
occupational limits. Self-contained breathing apparatus (SCBA) is required if a large release occurs.
Exposure Guidelines
Applicable Exposure Limits
PENTAFLUOROETHANE (HFC-125)
PEL (OSHA) : None Established
TLV (ACGIH) : None Established
AEL * (DuPont) : 1000 ppm, 8 & 12 Hr. TWA
WEEL (AIHA) : 1000 ppm, 4900 mg/m3, 8 Hr. TWA
DIFLUOROMETHANE (HFC-32)
AEL * (DuPont) : 1000 ppm, 8 & 12 Hr. TWA
WEEL (AIHA) : 1000 ppm, 8 Hr. TWA
* AEL is DuPont's Acceptable Exposure Limit. Where governmentally imposed occupational exposure limits
which are lower than the AEL are in effect, such limits shall take precedence.
PHYSICAL AND CHEMICAL PROPERTIES
Physical Data
Boiling Point : - 60.8 F (-51.6 C) @ 1 atm
Vapour Pressure : 239.7 psia 25 C (77 F)
% Volatiles : 100 WT%
Evaporation Rate : (Cl4 = 1) Greater than 1
Solubility in Water : Not determined
Odour : Slight ethereal
Form : Liquefied gas
Colour : Clear, colourless
Specific Gravity : 1.066 @ 25 C (77 F)
STABILITY AND REACTIVITY
Material is stable. However, avoid open flames and high temperatures.
Chemical Stability
Incompatibility with Other Materials Incompatible with active metals, alkali or alkaline earth metals--powdered Al, Zn, Be, etc.
Decomposition
EN
Decomposition products are hazardous. This material can be decomposed by high temperatures (open
flames, glowing metal surfaces, etc.) forming hydrofluoric acid and possibly carbonyl fluoride. These
materials are toxic and irritating. Contact should be avoided.
1-5
150.68.ICOM1.EN.CE (0911)
Refrigerant Safety Data R410A:
Polymerization
Other Hazards
Polymerization will not occur.
Decomposition : Decomposition products are hazardous. This material can be decomposed by high
temperatures (open flames, glowing metal surfaces, etc.) forming hydrofluoric acid, and possibly carbonyl
halides.
TOXICOLOGICAL INFORMATION
Animal Data
The blend is untested.
HFC-125
Inhalation 4-hour ALC: >709,000 ppm in rats
Single exposure to high doses caused: Lethargy. Laboured breathing. Weak cardiac sensitization, a
potentially fatal disturbance of heart rhythm caused by a heightened
sensitivity to the action of epinephrine. Lowest-Observed-Adverse-Effect-Level for cardiac sensitization:
100,000 ppm.
Repeated exposure caused: No significant toxicological effects. No-Observed-Adverse-EffectLevel(NOAEL): 50,000 ppm
ADDITIONAL TOXICOLOGICAL EFFECTS:
No animal data are available to define the following effects of this material: carcinogenicity, reproductive
toxicity. In animal testing this material has not caused developmental toxicity. Tests have shown that this
material does not cause genetic damage in bacterial or mammalian cell cultures, or in animals. This
material has not been tested for its ability to cause permanent genetic damage in reproductive cells of
mammals (not tested for heritable genetic damage).
HFC-32
Inhalation 4 hour-ALC: > 520,000 ppm in rats
Single exposure caused: Lethargy. Spasms. Loss of mobility in the hind limbs. Other effects include weak
cardiac sensitization, a potentially fatal disturbance of heart rhythm caused by a heightened sensitivity to
the action of epinephrine. 250,000 ppm.
Repeated exposure caused pathological changes of the lungs, liver, spleen, kidneys. In more recent
studies repeated exposure caused: No significant toxicological effects.
No-Observed-Effect-Level (NOEL): 49,100 ppm.
No animal data are available to define the following effects of this material: carcinogenicity, reproductive
toxicity. Animal data show slight fetotoxicity but only at exposure levels producing other toxic effects in the
adult animal. Tests have shown that this material does not cause genetic damage in bacterial or
mammalian cell cultures, or in animals. This material has not been tested for its ability to cause permanent
genetic damage in reproductive cells of mammals (not tested for heritable genetic damage).
DISPOSAL CONSIDERATIONS
Waste Disposal
Comply with Federal, State, and local regulations. Reclaim by distillation or remove to a permitted waste
disposal facility.
TRANSPORTATION INFORMATION
Shipping Information
DOT/IMO/IATA
Proper Shipping Name : Liquefied Gas, N.O.S. (Pentafluoroethane and Difluoromethane)
Hazard Class : 2.2
UN No. : 3163
Label(s) : Nonflammable Gas
Shipping Containers : Tank Cars. Cylinders. Ton Tanks
1-6
EN
150.68.ICOM1.EN.CE (0911)
Oil Safety Data YORK 'V' Oil:
Section 1 Substance Product Information
Product Trade Name: YORK "V" Oil.
Chemical Name: Carboxylic Ester.
Section 2 Components and Hazard Statement
This product is non-hazardous. This material has no known hazards under applicable laws.
Section 3 Safe Handling and Storage
Handling: Keep containers closed when not in use. Wash thoroughly after handling. Empty container contains product residue which may
Storage: No special storage precautions required.
Section 4 Physical Data
Appearance: Clear liquid.
Boiling Point: Not Determined.
Vapour Pressure: Not Determined.
Specific Gravity (water=1): 0.97 @ 15.6°C.
Volatiles, Percent by Volume: Unknown.
Odour: Mild.
Solubility in Water: Insoluble.
Evaporation Rate: Not Determined.
Section 5 Fire and Explosion Hazards
Flash Point: > 232°C, 450°F COC (Minimum).
Flammable Limits: not established.
Autoignition Temperature: no data.
Extinguishing Media: CO2, dry chemical or foam. Water can be used to cool and protect exposed material.
Unusual Fire and Explosion Hazards: Toxic fumes, gases or vapours may evolve on burning.
Special Fire Fighting Techniques: Firefighters should use approved self-contained breathing apparatus. Water may cause splattering. Material
Section 6 Reactivity Data
Stability: Material is normally stable at moderately elevated temperatures and pressures.
Hazardous Polymerization: Will not occur.
Incompatible Materials: Strong acids. Strong bases. Strong oxidizing agents.
Decomposition Temperature: Not Determined.
Thermal Decomposition: Smoke, carbon monoxide, carbon dioxide, aldehydes and other products of incomplete combustion.
Section 7 Health Hazard Data
First Aid Procedures
Ingestion: DO NOT INDUCE VOMITING. If conscious, give 2 glasses of water. Get immediate medical attention.
Eyes: Flush with water at least 15 minutes. Get medical attention if eye irritation develops or persists.
Skin: Wash with soap and water. Get medical attention if irritation develops. Launder contaminated clothing before reuse.
Inhalation: Remove exposed person to fresh air if adverse effects are observed.
Additional Information: Note to physician: Treat symptomatically.
Section 8 Personal Protection Information
Respiratory Protection: Use respirator with an organic vapour cartridge if exposure limit is exceeded.
Ventilation: Use with adequate ventilation.
Protective Gloves: Neoprene.
Eye/Face Protection: Safety glasses.
Clothing: Long sleeve shirt is recommended.
Section 9 Spill or Leak Procedures
Spill Procedures: Personal Protective Equipment must be worn, see Personal Protection Information (Section 8). Ventilate area if spilled in
Section 10 Waste Disposal Methods
This material, if discarded, should be disposed of in a licensed facility in accordance with local regulations.
Thermal & Acoustic Materials Data
Health Hazard & First Aid
Stability / Reactivity
Handling / Use / Disposal
Fire & Explosion
EN
Toxicity Index <10 to NES713 Issue 3 (1991): Non-hazardous, non-toxic. No first aid necessary.
Stable.
No special handling precautions required. Dispose of according to local laws and regulations governing nonbiodegradable non-hazardous solid wastes.
Flammability rating Class 1 to BS 476 pt 7: Non-flammable. If forced to burn, combustion products are
typically over 95% carbon dioxide and carbon monoxide.
1-7
150.68.ICOM1.EN.CE (0911)
Page Left Intentionally Blank
1-8
EN
150.68.ICOM1.EN.CE (0911)
2. Specification
YLPA air-to-water heat pumps are completely factory
assembled with all interconnecting refrigerant piping and
wiring ready for field installation. The unit is pressure
tested, evacuated, and fully factory charged with
refrigerant R410A and oil in each of the independent
refrigerant circuits. After assembly, an operational test is
performed with water flowing through the heat exchanger
to ensure that each refrigerant circuit operates correctly.
The unit structure is manufactured from heavygauge, galvanised steel coated with baked-on
powder paint (Champagne (RAL 7006, Munsell No.
9.8YR4.36/1.2)).
YLPA heat pumps are designed and manufactured
within an EN ISO 9001 accredited organisation and in
conformity with the following European Directives:




Machinery Directive (2006/42/EC)
EMC Directive (2004/108/EC)
Pressure Equipment Directive (97/23/EC)
Safety Code for Mechanical Refrigeration
(EN378-2 (2008))
Compressors
The unit has suction-cooled, hermetic scroll
compressors. High efficiency is achieved through
a controlled orbit and the use of advanced scroll
geometry. The compressors incorporate a compliant
scroll design in both the axial and radial directions. All
rotating parts are statically and dynamically balanced.
The compressor motors have integral protection against
overloads that will automatically reset. Starting is direct
on line, and soft start is available as an option.
The compressors are switched On and Off by the
unit microprocessor to provide capacity control. Each
compressor is fitted with a crankcase strap heater. All
compressors are mounted on isolator pads to reduce
transmission of vibration to the rest of the unit.
Refrigerant to Water Heat Exchanger
The 2-pass dual circuit shell and tube type direct
expansion (DX) heat exchanger has refrigerant in the
tubes and liquid flowing through the baffled shell. The
waterside (shell) design working pressure is 10.3 barg.
The refrigerant side (tubes) design working pressure is
44.8 barg. The refrigerant side is protected by pressure
relief valve(s).
The heat exchanger is equipped with a heater for frost
protection to -29°C and insulated with flexible closedcell foam.
Water connection to the heat exchanger is via victaulic
grooved connections. Victaulic groove to flange
converters are available as an option.
Ambient Coils
The ambient coils are seamless copper tubes, arranged
in staggered rows, mechanically expanded into coated
aluminium fins. Integral sub-cooling is included.
The ambient coil fans have metal ‘sickle’ blades
integrated into the rotor of an external rotor motor. They
are designed for maximum efficiency and statically
and dynamically balanced for vibration free operation.
They are directly driven by independent motors, and
positioned for vertical air discharge. The fan guards
are constructed from heavy-gauge, corrosion resistant,
coated steel.
The IP54 fan motors are the totally enclosed air-over
type with permanently lubricated double-sealed ball
bearings.
Power and Controls Panels
All power and controls are contained in an IP 55 cabinet
with hinged and gasket sealed outer doors.
The power panel includes:

The motor terminal boxes have IP54 weather
protection.
Refrigerant Circuits

Two independent refrigerant circuits are provided on
each unit. Each circuit uses copper refrigerant pipe
formed on computer controlled bending machines to
reduce the number of brazed joints resulting in a high
integrity and reliable system.

Each circuit shall incorporate all components necessary
for the designed operation including: a suction
accumulator, a liquid receiver, a four way reversing
valve, service valves, isolation (ball/angle) valves,
pressure relief valves, a high absorption removable
core filter-drier, a sight glass with moisture indicator,
a cooling mode thermal expansion valve and a heat
pump mode thermal expansion valve. Suction lines
shall be covered with closed-cell insulation.
EN


A factory mounted non-fused disconnect switch
with external (red/yellow) lockable handle to
enable connection of the unit power supply. The
disconnect switch can be used to isolate the power
for servicing and as a emergency stop.
Factory mounted compressor contactors and
compressor fuses provide short circuit protection.
Overload protection for each compressor is
provided by inherent motor winding temperature
sensing and a trip module.
Factory mounted fan contactors and fuses provide
short circuit protection. Overload protection for
each fan is provided by a inherent motor winding
temperature device.
Factory mounted control transformer to convert
the unit supply voltage to 110 V - 1 Ø - 50 Hz for
the control system.
Control supply fuses and connections for a remote
emergency stop device.
2-1
150.68.ICOM1.EN.CE (0911)
The control panel includes:



A Liquid Crystal Display (two display lines of twenty
characters per line) with Light Emitting Diode
backlighting for easy viewing.
A Colour coded 12-button keypad.
Customer terminal blocks for control inputs and
liquid flow switch.
Microprocessor Controls
The microprocessor control includes:

Automatic control of compressor start/stop,
anticoincidence and anti-recycle timers, pump and
unit alarm contacts. Automatic reset to normal unit
operation after power failure.

Remote water temperature setpoint reset via an
analog input or a pulse width modulated (PWM)
input signal, or up to two steps of demand (load)
limiting.

Software is loaded into the microprocessor
controller via a SD card, with programmed setpoints
retained in a lithium battery backed real time clock
(RTC) memory.

Forty character liquid crystal display, with
description available in several languages.
Programmable setpoints:

Chilled liquid temperature setpoint and range

Hot liquid temperature setpoint and range

Remote reset temperature range

Set daily schedule/holiday for start/stop

Manual override for servicing

Low ambient cutout

High ambient cutout (heating only - fixed)

Low liquid temperature cutout

Low suction pressure cutout

High discharge pressure cutout

Anti-recycle timer (compressor start cycle time)

Anti-coincident timer (delay compressor starts)
Displayed Data:

Leaving liquid temperature

Air coil defrost temperatures

Low leaving liquid temperature cutout setting

Low ambient temperature cutout setting

Ambient air temperature

Metric or Imperial data

Discharge and suction pressure cutout settings

System discharge and suction pressures

Anti-recycle timer status for each system
Anti-coincident system start timer condition


Compressor run status

No load condition

Day, date and time

Daily start/stop times

Holiday status

Automatic or manual system lead/lag control

Lead system definition

Compressor starts & operating hours (each
compressor)

Status of heat exchanger heater and fan
operation

Run permissive status

Number of compressors running

Mode solenoid valve status

Load & unload timer status

Liquid pump status
System Safeties:
Cause individual compressors to perform auto shut
down and require manual reset in the event of 3 trips in
a 90-minute time period:

High discharge pressure

Low suction pressure

High-pressure switches

Motor protector
Unit Safeties:
They are automatic reset and cause compressor to
shut down:

Low leaving chilled liquid temperature

Under voltage

Loss of liquid flow (through flow switch)
For each system a common alarm contact for:

Low leaving chilled liquid temperature

Low voltage

Low battery

High discharge pressure (per system)

Low suction pressure (per system)

Compressor motor protection
2-2
EN
150.68.ICOM1.EN.CE (0911)
Accessories and Options
EEV
Power Factor Correction
Factory fitted Electronic Expansion Valve to provide
a fl exible and reliable range of operation from brine
to comfort cooling conditions. Mandatory option for
application below -1°C chilled water temperature.
Factory mounted passive (static) power factor
correction capacitors to correct unit compressor power
factors to a target of 0.9 (depending on operating
conditions). Option not available on compressors fitted
with soft start option.
Soft Starters
Factory mounted soft starters reduce the inrush current
to the last compressor on each refrigerant circuit. They
are preset so that no field adjustment is required.
Language LCD and Keypad
Dual speed fans
Fans operate either in high mode (920 RPM) or in low
mode (670 RPM). Fan speed reduces automatically
from high to low mode as head pressure falls, or at
customer defined and programmed times within the
control software.
VSD Fans
Factory fitted, high efficiency VSD condenser fans.
With integral “EC” style inverter driven motor. Fan
speed varies with system cooling load and ambient
conditions. Speed is optimized to ensure highest
possible part load efficiency.
Language LCD and Keypad
English, French, German, Italian, Spanish, Polish,
and Portuguese and unit LCD read out and keypad
available. Standard Language is English.
38 mm Evaporator Insulation
Double thickness insulation provided for enhanced
thermal efficiency, and low temperature applications.
Flow Switch
Vapour Proof, paddle-type with 1’’NPT connection for
upright mounting in horizontal pipe. This flow switch or
its equivalent must be supplied with each unit to protect
the evaporator from loss of liquid flow (Field Mounted)
Dual Pressure Relief Valves
Two pressure relief valves mounted on a 3-way valve
in parallel of which one is operational whilst the other
remains inoperative. This feature assists with routine
maintenance on the PRVs.
Neoprene Pads Isolators
Recommended for normal installations (Field mounted)
25 mm Spring Isolators
Level adjustable, spring and cage type isolators for
mounting under the unit base rails (Field mounted).
Lifting Lug Kit
One set of ISO MK5 Camlocs to enable safe and easy
unit handling.
EN
Containerisation
Secure shipping in ISO hi-cube standard containers.
The kit consists of nylon runners fitted to the underside
of the base frame to assist with stuffing & un-stuffing of
the container plus wooden side rubbing rails that locate
the unit central to the container. As with normal road
transportation the refrigerant charge is locked away
within the ambient coil section of the unit.
Compressor Acoustic Blankets
Each compressor is individually enclosed in an
acoustic sound blanket. The sound blankets are made
with one layer of acoustical absorbent textile fibre of
15 mm thickness and one layer of anti vibrating heavy
material thickness of 3 mm. Both are closed by two
sheets of welded PVC, reinforced for temperature and
UV resistance.
Compressor Acoustic Enclosure
Factory fit acoustically lined, painted galvanised steel,
enclosure with removable panels for maintenance
purposes.
High Ambient Kit
Double skinned control panel, to offset solar heat. Must
be selected for all units operating in ambients greater
than 46°C.
Uncoated Condenser Coils
Condenser coils provided with uncoated fins. Note:
Standard coils are hydrophilic coated.
Post-Coated Epoxy Dipped Condenser Coils
Condenser coils provided with dipped-cured epoxy
for units being installed in marine or other aggressive
operating environments.
Hydro Kit
Factory fitted Hydro Kit suitable for water glycol systems
with up to 35% glycol at leaving water temperatures
between 4°C and 35°C. The kit is available in single or
dual pump variants, with open drive air cooled motor
running at 2900 rpm.
Components are mounted on a painted galvanised
steel base plate and include: one or two pumps, two
isolation valves per hydrokit, a flow switch, a water
filter (1000 microns), relief, bleed and drain valves,
a pressure gauge, a trace heater and an expansion
vessel.
The pumps and flow switch are factory wired to the
unit control system to provide auto pump starting and
running. With the dual pump option, in the event of
failure of the running pump the standby pump starts
automatically.
2-3
150.68.ICOM1.EN.CE (0911)
All pipework and fittings are painted carbon steel
and outlets are Victaulic groove type. Victaulic ring
to flange converter available as an option. 19 mm,
thermal insulation is included. Pressure tapping points
are included for differential pressure measurement
(gauges to be supplied by others). Dual pump models
have non-return valves and isolating valves.
Condenser Coil Wire Enclosure
Welded wire mesh guards mounted over the condenser
coils (factory mounted).
Condenser Coil Louvred Panels
Louvred panels mounted over the condenser coils
(factory mounted). Should be used with Dual Speed
Fans if chiller is to operate at –10°C or below.
Condenser Coil Louvred Panels and Unit Wire
Guards
Louvred panels mounted over the condenser coils, and
welded wire mesh guards mounted around the bottom
of the unit (factory mounted).
Unit Wire Enclosure
Welded wire mesh guards over condenser coils and
around the bottom of the unit (fi eld or factory mounted
options available).
Unit Louvred Panels
Louvred panels over condenser coils and around the
bottom of the unit (factory mounted). Note: When this
option is installed there will be a cooling capacity loss
of 1% and an efficiency loss of 2%.
E-Link Gateway
Interface to enable communication with building control
systems using LONworks protocol. See separate York
documentation. Modbus, BACnet MS/TP and N2
protocols are standard.
2-4
EN
150.68.ICOM1.EN.CE (0911)
Refrigerant Flow Block Diagrams
Cooling and Defrost Modes
Low pressure liquid refrigerant enters the heat exchanger and is evaporated and superheated by the heat energy
absorbed from the chilled liquid. Low pressure vapour enters the compressor, via the four-way reversing valve and
accumulator, where pressure and superheat are increased. The high pressure vapour is fed to the ambient coils and
fans, via the four way reversing valve, where heat is removed. The fully condensed and subcooled liquid passes
through the expansion valve (cooling) where pressure is reduced and further cooling takes place before returning to
the heat exchanger.
Ambient Coils
(Condenser)
4-way valve
TXV
TXV
(cooling)
(heating)
Refrigerant flow
Receiver
Heat Exchanger
Compressors
Accumulator
(Evaporator)
Heat Pump Mode
Liquid refrigerant enters the ambient coil and is fully evaporated and superheated by the energy absorbed from the
ambient air. Low-pressure superheated refrigerant vapour passes through the four-way reversing valve and the
accumulator and enters the compressor, where pressure and superheat are increased. High-pressure superheated
refrigerant vapour enters the refrigerant to water plate heat exchanger where heat is rejected to the water. The highpressure liquid refrigerant, leaving the heat exchanger passes through the liquid receiver and enters thermostatic
expansion valve (heating) where the refrigerant pressure is reduced and subsequently cooled before returning to the
ambient coil.
Ambient Coils
(Evaporator)
4-way valve
TXV
TXV
(cooling)
(heating)
Refrigerant flow
Receiver
R
iver
Heat Exchanger
Compressors
Accumulator
(Condenser)
Defrost
When ice builds up on the ambient coils defrost is initiated by operating the machine in a cooling mode. Each of the
two refrigerant circuits will be defrosted one at a time. When defrost is operative the circuit operating in heat pump
mode is in balance with the circuit operating in defrost (cooling). Therefore, heat energy is not removed from the hot
water system.
EN
2-5
150.68.ICOM1.EN.CE (0911)
Component Location Diagram
8
1
3
2
7
4
1
2
3
4
5
6
Power Panel
Non-Fused Disconnect Switch
Control Panel
Compressors
5
6
7
8
Heat Exchanger
Suction Accumulator
Ambient Coils
Fans
Nomenclature
YLPA0425HE50XBA
1
2
3
4
5
BASE PRODUCT TYPE
Y
: York
L
A
A
2-6
6
7
8
9
NOMINAL CAPACITY
#
#
#
#
: Scroll
:0340 :0355 :0415 :0425
: Heat Pump
:0495 :0505 :0560 :0570
: All Regions
:0610 :0640
UNIT DESIGNATION
kW
S
: Standard Unit
H
: High Efficiency
10
11 12 13
14 15
REFRIGERANT
VOLTAGE / STARTER
DESIGN / DEVELOPMENT LEVEL
E
: R-410A
5
0
X
: 380-415 / 3 / 50
X
: Direct on Line
B
: Design Series
A
: Development Level
EN
150.68.ICOM1.EN.CE (0911)
3. Transportation, Handling and Storage
Delivery and Storage
To ensure consistent quality and maximum reliability,
all units are tested and inspected before leaving the
factory. Units are shipped completely assembled
and containing refrigerant under pressure. Units are
shipped without export crating unless crating has been
specified on the Sales Order.
If the unit is to be put into storage, prior to installation,
the following precautions should be observed:
Moving the unit
Prior to moving the unit, ensure that the installation site
is suitable for installing the unit and is easily capable
of supporting the weight of the unit and all associated
services.
The unit should be lifted using lifting lugs and a spreader
bar or frame of sufficient width to prevent damage to
the unit from the lifting chains.
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 fork-lift truck.
Ensure that all openings, such as water connections,
are securely capped.
The unit should be stored in a location where there is
minimal activity in order to limit the risk of accidental
physical damage.
Care should be taken to avoid damaging the
ambient coil fins when moving the unit.
To prevent inadvertent operation of the pressure relief
devices the unit must not be steam cleaned.
It is recommended that the unit is periodically inspected
during storage.
Inspection
Remove any transit packing and inspect the unit to
ensure that all components have been delivered and
that no damage has occurred during transit. If any
damage is evident, it should be noted on the carrier’s
freight bill and a claim entered in accordance with the
instructions given on the advice note.
Units are provided with lifting holes in the base frame
which accept the accessory lifting lug set (part number
026L00261-000 - 4 lug set, 026-45594-000 - 6 lug set).
The lugs should be inserted into the respective holes in
the base frame and turned so that the spring loaded pin
engages into the hole and the flanges on the lug lock
behind the hole. The lugs should be attached to the
cables/chains using shackles or safety hooks.
Major damage must be reported immediately to your
local Johnson Controls representative.
EN
3-1
150.68.ICOM1.EN.CE (0911)
Typical Lifting Arrangement
Lifting Weights
The weights and weight distribution are given below:
Weight (kg)
Shipping Operating
4500
4750
5100
5400
5800
6100
6095
6495
6295
6695
4400
4600
4700
5000
4900
5200
5395
5695
5935
6235
R1
846
463
484
526
563
819
620
742
591
490
R2
466
667
701
802
804
451
668
613
597
719
R3
642
464
745
718
746
621
706
734
563
661
L1
L2
L3
L4
R1
R2
R3
R4
Point Weight (kg)
R4
L1
988
615
723
580
723
729
766
764
795
957
885
1009
538
833
671
754
L2
826
994
1024
1135
1114
801
1084
1006
937
1105
L3
983
699
1124
961
1044
952
1066
1117
800
974
L4
774
718
858
865
836
861
Control Panel
Model
0355HE
0425HE
0505HE
0570HE
0640HE
0340SE
0415SE
0495SE
0560SE
0610SE
3-2
EN
150.68.ICOM1.EN.CE (0911)
4. Application Data
Location Requirements
To achieve optimum performance and trouble-free
service, it is essential that the proposed installation site
meet with the location and space requirements for the
model being installed.
The clearances recommended are nominal for the safe
and efficient operation and maintenance of the unit
and power and control panels. Local Health and safety
regulations, or practical considerations for service
replacement of large components, may require larger
clearances than those given in this manual.
and may cause the unit to malfunction. Consideration
should also be given to the possibility of down drafts,
caused by adjacent buildings, which may cause recirculation or uneven unit air-flow.
For locations where significant cross winds are
expected, such as exposed roof tops, an enclosure of
solid or louvre type is recommended to prevent wind
turbulence interfering with the unit air-flow.
When units are installed in an enclosure, the enclosure
height should not exceed the height of the unit on more
than one side. Where accumulation of snow is likely,
additional height must be provided under the unit to
ensure normal air-flow to the unit.
Outdoor installations
The units can be installed at ground level on a suitable
and level foundation easily capable of supporting the
weight of the unit, or on a suitable rooftop location. In
both cases an adequate supply of air is required. Avoid
locations where the sound output and air discharge
from the unit may be objectionable.
The location should be selected for minimum sun
exposure and away from boiler flues and other sources
of airborne chemicals that could attack the ambient
coils and steel parts of the unit.
If located in an area accessible to unauthorized persons,
steps must be taken to prevent access to the unit by
means of a protective fence. This will help to prevent
the possibility of vandalism, accidental damage, or
possible harm caused by unauthorized removal of
protective guards or opening panels to expose rotating
or electrically live components.
For ground level locations, the unit must be installed
on a suitable flat and level concrete base that extends
to fully support the two side channels of the unit
base frame. A one-piece concrete slab, with footings
extending below the frost line is recommended. To
avoid noise and vibration transmission, the unit should
not be secured to the building foundation.
On rooftop locations, choose a place with adequate
structural strength to safely support the entire operating
weight of the unit and service personnel. The unit can
be mounted on a concrete slab, similar to ground floor
locations, or on steel channels of suitable strength.
The channels should be spaced with the same centres
as the unit side and front base rails. This will allow
vibration isolators to be fitted if required. Isolators are
recommended for rooftop locations.
Arrangement
A1
Solid Walls
Arrangement
A2
Solid Walls
Arrangement
A3
Louvres on
2 walls
Arrangement
A4
Solid Walls
Arrangement
A5
Louvres on
2 walls
Arrangement
A1
Solid Walls
Arrangement
A2
Solid Walls
Arrangement
A3
Louvres on
2 walls
Arrangement
A4
Solid Walls
Location Clearances
Adequate clearances around the unit(s) are required
for the unrestricted air-flow for the ambient coils and
to prevent re-circulation of discharge air back onto
the coils. If clearances given are not maintained, airflow restriction or re-circulation will cause a loss of
unit performance, an increase in power consumption,
EN
Arrangement
A5
Louvres on
2 walls
YLPA Standard Efficiency
Dim.
(m) 0340SE 0415SE 0495SE 0560SE 0610SE
A
1.2
1.2
1.2
1.2
1.2
B
0.8
0.8
0.8
0.8
0.8
C
0.8
0.8
0.8
0.8
0.8
D
1.4
1.4
1.4
1.4
1.4
1.2
1.2
1.2
1.2
A
1.2
B
0.8
0.8
0.8
0.8
0.8
C
0.8
0.8
0.8
0.8
0.8
D
2.7
2.7
2.7
2.7
2.7
E
1.4
1.4
1.4
1.4
1.4
A
1.2
1.2
1.2
1.2
1.2
0.8
0.8
0.8
0.8
B
0.8
0.8
0.8
0.8
0.8
0.8
C
D
2.3
2.3
2.8
2.8
2.8
E
1.4
1.4
1.4
1.4
1.4
A
1.2
1.2
1.2
1.2
1.2
B
1.2
1.2
1.2
1.2
1.2
0.8
C
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
D
0.8
E
1.7
1.7
1.7
1.7
1.7
A
1.2
1.2
1.2
1.2
1.2
B
1.2
1.2
1.2
1.2
1.2
C
0.8
0.8
0.8
0.8
0.8
0.8
0.8
D
0.8
0.8
0.8
1.4
1.4
1.4
1.4
1.4
E
YLPA High Efficiency
Dim.
(m) 0355HE 0425HE 0505HE 0570HE 0640HE
1.2
1.2
1.2
1.2
A
1.2
B
0.8
0.8
0.8
0.8
0.8
1.2
1.2
1.0
1.2
C
0.8
1.4
1.4
1.4
1.4
1.4
D
A
1.2
1.2
1.2
1.2
1.2
B
0.8
0.8
0.8
0.8
0.8
C
0.8
1.0
1.2
1.2
1.2
D
2.7
3.2
3.2
3.2
3.2
1.4
1.4
E
1.4
1.4
1.4
1.2
1.2
1.2
1.2
1.2
A
B
0.8
0.8
0.8
0.8
0.8
C
0.8
1.0
1.2
1.2
1.2
D
2.3
3.0
3.2
3.2
3.2
E
1.4
1.4
1.4
1.4
1.4
1.2
1.2
1.2
A
1.2
1.2
1.2
1.2
1.2
B
1.2
1.2
C
0.8
0.8
0.8
0.8
0.8
D
0.8
1.0
1.2
1.2
1.2
E
1.7
1.9
2.1
2.1
2.1
A
1.2
1.2
1.2
1.2
1.2
B
1.2
1.2
1.2
1.2
1.2
0.8
0.8
0.8
0.8
C
0.8
D
0.8
0.8
0.8
0.8
0.8
E
1.4
1.4
1.4
1.4
1.4
4-1
150.68.ICOM1.EN.CE (0911)
A4
A
A1
A
A1
B
B
C
D
A2
A
C
E
D
A5
A
B
E
D
C
A3
A1
A
B
B
C
E
D
C
E
4-2
D
EN
150.68.ICOM1.EN.CE (0911)
Installation of Vibration Isolators
An optional set of vibration isolators can be supplied
loose with each unit.
Pipework Connection
The following piping recommendations are intended
to ensure satisfactory operation of the unit. Failure to
follow these recommendations could cause damage to
the unit, or loss of performance, and may invalidate the
warranty.
A flow switch must be installed in the customer pipework
at the outlet of the heat exchanger as shown in the
arrangement diagrams, and wired back to the control
panel using screened cable. This is to prevent damage
to the heat exchanger caused by inadequate liquid
flow. To prevent turbulent flow, there must be straight
pipework either side of the flow switch equal in length
to at least 5 times the diameter of the pipe.
The flow switches used must have gold plated contacts
for low voltage/current operation
Alternatively, a differential pressure switch fitted across
an orifice plate may be used, preferably of the high/low
limit type.
The liquid pumps installed in the pipework systems
should discharge directly into the unit heat exchanger
sections of the system. The pumps require an autostarter (by others) to be wired to the control panel.
Pipework and fittings must be separately supported to
prevent any loading on the heat exchanger(s). Flexible
connections are recommended which will also minimize
transmission of vibrations to the building. Flexible
connections must be used if the unit is mounted on
anti-vibration mounts as some movement of the unit
can be expected in normal operation.
Pipework and fittings immediately next to the heat
exchanger(s) should be readily demountable to enable
cleaning prior to operation, and to facilitate visual
inspection of the exchanger nozzles.
The heat exchanger(s) must not be exposed to
flushing velocities or debris released during flushing.
It is recommended that a suitably sized by-pass and
valve arrangement be installed to allow flushing of the
pipework system. The by-pass can be used during
maintenance to isolate the heat exchanger(s) without
disrupting flow to other units.
Thermometer and pressure gauge connections should
be provided on the inlet and outlet connections of each
heat exchanger.
Drain and air vent connections should be provided at all
low and high points in the pipework to permit drainage
of the system, and to vent any air in the pipes.
Liquid systems at risk of freezing, due to low ambient
temperatures, should be protected using insulation and
heater tape and/or a suitable glycol solution. The liquid
pumps must also be used to ensure liquid is circulated
when the ambient temperature approaches freezing
point. Insulation should also be installed around the
heat exchanger nozzles.
Heater tape of 21 W/m under the insulation is
recommended, supplied independantly and controlled
by an ambient temperature thermostat set to switch on
at approximately 2.2ºC above the freezing temperature
of the chilled liquid.
The heat exchanger is protected by a heater mat placed
under the insulation, which are powered from the unit
control system power supply. During cold weather when
there is a risk of freezing, chiller power should be left
switched on to provide the freeze protection function
unless the liquid systems have been drained.
Pipework Arrangement
The following are suggested pipework arrangements for
single unit installations. For multiple unit installations,
each unit should be piped as shown. These are
recommendations of the Building Services Research
Association.
Each heat exchanger must be protected by a strainer,
preferably of 20 mesh, fitted as close as possible to the
liquid inlet connection, and provided with a means of
local isolation.
EN
4-3
150.68.ICOM1.EN.CE (0911)
Chilled Liquid System
Water Quality Requirements
The water used in the unit liquid system must meet the
requirements detailed in the table below:
Pressure Tapping
Air vent
Flow Switch
Isolating Valve – Normally Open
Isolating Valve – Normally Closed
Flow Regulating Valve
Strainer
Item
Unit
pH (25°C)
SO4
HCO3/SO4
Cl
PO4
NH3
Free Cl
Fe+++
Mn++
CO²
H²S
Temp
O content
Hardness
pH
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
°C
ppm
dH
Allowable
Value
7.0 to 8.5
<100
>1.0
<50
<2.0
<0.5
<0.5
<0.5
<0.05
<10
<50
<65
<0.1
4.8 to 8.5
Potential Problem
Corrosion
Fouling
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
Water quality should be inspected before unit
installation and regularly during unit operation.
The water quality must meet the limits above.
If parameters are not within limits, the heat
exchanger may leak or have problems within
scale formation.These problems may result in
the unit not operating normally, excessive
heat exchanger pressure drops and reduced
nominal capacities.
Refrigerant Relief Valve Piping
Connection Types and Sizes
Standard pipework connections are of the Victaulic
groove type.
For connection sizes relevant to individual models refer
to the physical data tables in this manual.
Water Treatment
The unit performance given in the Design Guide is
based on a fouling factor of 0.018 m² °C/kW . Dirt,
scale, grease and certain types of water treatment
will adversely affect the heat exchanger surfaces and
therefore unit performance. Foreign matter in the water
system(s) can increase the pressure drop, reducing the
flow rate and causing potential damage.
Aerated, brackish or salt water is not recommended for
use in the water systems. JCI recommends that a water
treatment specialist be consulted to determine whether
the proposed water composition will not affect the heat
exchanger materials of carbon steel and copper. The
pH value of the water flowing through the unit must be
kept between 7 and 8.5.
4-4
The heat exchanger is protected against internal
refrigerant overpressure by refrigerant relief valves. A
pressure relief valve is mounted on each of the main
refrigerant lines connecting the heat exchanger to the
compressors.
For indoor installations, pressure relief valves should
be piped to the exterior of the building.
The size of any pipework attached to a relief valve must
be of sufficient diameter so as not to cause resistance
to the operation of the valve. For critical or complex
installations refer to EN13136.
Unless otherwise specified by local regulations, the
internal diameter depends on the length of pipe required
and can be estimated with the following formula:
D5=1.447 x L
Where:
D = minimum pipe internal diameter (cm)
L = length of pipe (m).
If relief pipework is common to more than one valve its
cross sectional area must be at least the total required
by each valve. Valve types should not be mixed on a
common pipe. Precautions should be taken to ensure
that the exit of relief valves/vent pipe remain clear of
obstructions at all times.
EN
150.68.ICOM1.EN.CE (0911)
Electrical Connection
Control Circuit Transformer
The following connection recommendations are
intended to ensure safe and satisfactory operation of
the unit. Failure to follow these recommendations could
cause harm to persons, or damage to the unit, and may
invalidate the warranty.
The control circuit transformer (400 V, 2Ø, 50 Hz)
providing the 110 V, 1Ø, 50 Hz supply to the unit control
system is fitted in a separate enclosure.
No additional controls (relays, etc.) should
be mounted in the control panel. Power
and control wiring not connected to the
control panel should not be run through
the control panel. If these precautions are
not followed it could lead to a risk of
electrocution. In addition, electrical noise
could cause malfunctions or damage the
unit and its controls.
If required, a remote emergency stop device may be
wired into the unit. This device should be rated at 20
amps, 110 V, AC-15. The device should be wired into
terminals L and 5 in the power panel after removing the
factory fitted link.
Power Wiring
These units are suitable for 400 V, 3-phase,
50Hz nominal supplies only.
All electrical wiring should be carried out in accordance
with local regulations. Route properly sized cables to
the cable entries in the bottom of the power panel.
In accordance with EN 60204 it is the responsibility
of the user to install over current protection devices
between the supply conductors and the power supply
terminals on the unit.
To ensure that no eddy currents are set up in the power
panel, the cables forming each 3 phase power supply
must enter via the same cable entry.
All sources of supply to the unit must be
taken via a common point of isolation (not
supplied by JCI).
Remote Emergency Stop Device
Control Wiring - Voltage Free Contact
All wiring to the voltage free contact terminal block
requires a supply provided by the customer maximum
voltage 254 Vac, 28 Vdc.
The customer must take particular care deriving the
supplies for the voltage free terminals with regard to
a common point of isolation. Thus, these circuits when
used must be fed via the common point of isolation
so the voltage to these circuits is removed when the
common point of isolation to the unit is opened. This
common point of isolation is not supplied by JCI.
In accordance with EN 60204 it is recommended that
the customer wiring to these terminals uses orange
wires. This will ensure that circuits not switched off by
the units supply disconnecting device are distinguished
by colour, so that they can easily be identified as live
even when the unit disconnecting devices are off. The
YORK voltage free contacts are rated at 125 VA.
All inductive devices (relays) switched by the YORK
voltage free contacts must have their coil suppressed
using standard RC suppressors. If these precautions are
not followed, electrical noise could cause malfunctions
or damage to the unit and its controls.
Chilled Liquid Pump Starter
Single Point Power Supply Wiring
All models require one field provided 400 V, 3Ø, 50 Hz
+ PE (Protected Earth) supply to the unit with circuit
protection.
Connect the 3-phase supply to the non-fused disconnect
switch located in the power panel using M12 lugs.
Terminals 23 and 24 close to start the liquid pump. This
contact is closed if there is a ‘Leaving Liquid Temperature
Cutout’ or any of the compressors are running or the
daily schedule is not calling for a shutdown with the
unit switch on.
The contact must be used to ensure that the
pump is running in the event of a ‘Leaving
Liquid Temperature Cutout’.
Connect the earth wire to the main protective earth
terminal located in the power panel using a M10 lug.
The pump contact will not close to run the pump if the
unit has been powered up for less than 30 seconds, or
if the pump has run in the last 30 seconds, to prevent
pump motor overheating.
EN
4-5
150.68.ICOM1.EN.CE (0911)
Run Contacts
Fan Full Speed Inhibit
Terminals 25 and 26 close to indicate that refrigerant
system 1 is running and terminals 27 and 28 close to
indicate that refrigerant system 2 is running.
To reduce unit noise the fans can be limited to run at
a maximum step of all fans in star (reduced speed) i.e.
fan full speed is inhibited. Connect a customer voltage
free contact to terminals 13 & 15.
Alarm Contacts
Each refrigerant system has a voltage-free normally
open contact that will close when control power is
applied to the panel, if no fault conditions are present.
When a fault occurs which locks a system out, or there
is a power failure the contact opens. To obtain a system
alarm signal, connect the alarm circuit to terminals 29
and 30 for No. 1 system and terminals 31 and 32 for
No. 2 system.
Control Wiring - System Inputs
EMS Analogue Input
Provides a means of resetting the leaving chilled or hot
liquid temperature from the BAS/EMS. Accepts 4 to 20
mA, 0 to 20 mA, 0 to 10 Vdc or 2-10 Vdc. Connect to
terminal A+ and A-.
Modbus, BACnet MS/TP and N2
Enable communications with building protocol systems
using Modbus, BACnet or N2 protocol. Connect through
standard RS485 port.
All wiring to the control terminal block (nominal 30 Vdc)
must be run in screened cable, with the screen earthed
at the panel end only. Run screened cable separately
from mains cable to avoid electrical noise pick-up.
The voltage free contacts must be suitable for 30
Vdc (gold contacts recommended). If the voltage free
contacts form part of a relay or contactor, the coil of
the device must be suppressed using a standard RC
suppressor. The above precautions must be taken to
avoid electrical noise that could cause a malfunction or
damage to the unit and its controls.
Flow Switch
A chilled liquid flow switch of suitable type must be
connected to terminals 13 and 14 to provide adequate
protection against loss of liquid flow.
Remote Start/Stop
Connect a remote switch to terminals 13 and 51 to
provide remote start/stop control if required.
Remote Mode Selection
Remote mode selection can be accomplished by
connecting a contact between terminals 13 and 50.
With the contact open the unit is in the cooling mode,
with the contact closed the unit is in the heating mode.
Remote Reset of Chilled Liquid Setpoint
The PWM input (terminals 13 and 20) allows reset of
the chilled liquid setpoint by supplying a ‘timed’ contact
closure.
Remote Load Limiting
Load limiting prevents the unit from loading beyond a
desired value. The unit % load limit depends on the
number of compressors on the unit. The load limit
inputs to terminals 13 and 21 work in conjunction with
the PWM input to terminals 13 and 20.
4-6
EN
REMOTE EMERGENCY
STOP DEVICE
EN
23 24 25 26 27 28 29 30 31 32 33 34
13 14 13 15 13 20 13 21 13 50 13 51 A+ AANALOGUE TEMPERATUREE RESET SIGNALL
REMOTEE START / STOP
MODE SELECTION CLOSED
D FOR HEATING
G
1ST STA
AGE LOAD LIMITT
GE LOAD LIMIT OR PWM INPUTT
2ND STAG
YLPA CUSTOMER WIRING
FAN SPEED
D INHIBIT
TTWO SPEED FAN
N OPTION ONLYY
FLOW SWITCH
H
COOLING MODE INDICATIO
ON
VERY OPTION ONLY
HEAT RECOV
SYSTEM 2 ALARM STATTUS
POWER SECTION
SYSTEM 1 ALARM STATTUS
-XTBC2
CHILLER RUN SSTATUS SYSTEM
M2
L
-XTBC1
CHILLER RUN SSTATUS SYSTEM
M1
-XTBC3
P START CONTA
ACT
LIQUID PUMP
150.68.ICOM1.EN.CE (0911)
Connection Diagram
13 13 13 13 13 13 14 15 20 21 50 51 A+ A+
A-
5
LK
23 24 25 26 27 28 29 30 31 32 33 34
ELECTRONIC SECTION
4-7
150.68.ICOM1.EN.CE (0911)
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4-8
EN
150.68.ICOM1.EN.CE (0911)
5. Commissioning
Preparation
Commissioning of this unit should only be
carried out by Johnson Controls
Authorised personnel.
Fans: Check that all fans are free to rotate and are not
damaged. Ensure blades are at the same height when
rotated. Ensure fan guard is securely fixed.
Isolation/protection: Verify that all sources of electrical
supply to the unit are taken from a point of isolation.
Control panel: Check the panel to see that it is free of
foreign materials (wire, metal chips, etc.) and clean out
if required.
The unit On/Off switch beneath the key pad in the
electronic section of the control panel has been set to
the Off position at the factory. This switch must remain
in the Off position, preventing running of the unit until
commissioned by Authorised personnel. If the switch
has been set to the On position before commissioning
then it must be reported to Johnson Controls otherwise
the warranty may be invalidated.
Power connections: Check the customer power cables
are connected correctly. Ensure that connections of
power cables within the power panel to the non-fused
switch disconnects are tight.
Preparation - Power Off
Supply voltage: Verify that the site voltage supply
corresponds to the unit requirement and is within
the limits given in the Technical Data Section. The
phase imbalance should less than 2% of the average
voltage.
The following checks should be made with the customer
supply/supplies to the unit switched OFF.
Inspection: Inspect unit for installation damage. If
found take action and/or repair as appropriate.
Refrigerant charge: Units are normally shipped as
standard with a full refrigerant operating charge. Check
that refrigerant pressure is present in both systems and
that no leaks are apparent. If no pressure is present a
leak test must be undertaken, the leak(s) located and
repaired. Repaired systems must be evacuated with a
suitable vacuum pump/recovery unit as appropriate to
below 100 microns before charging.
Do not charge liquid refrigerant with static
water in the heat exchanger. Care must also
be taken to charge liquid refrigerant slowly to
avoid excessive thermal stress at the charging
point.
Once the vacuum is broken, charge with the full
operating charge as given in Technical Data section.
Liquid subcooling measured at the liquid line
should be between 6ºC and 8ºC when unit is
operating in cooling mode and fully loaded.
Subcooling is determined by the level of
refrigerant charge in each system.
Valves: Ensure that the compressor discharge and
suction service valves are set correctly (OPEN).
Compressor oil: The oil level in multiple scroll
compressors (piped in parallel) must be checked
directly after all compressors are shut down and have
been allowed time to stabilise.
The oil level must be between the bottom and middle
of the oil sight glass mounted in the oil equalising line
between the compressors.
EN
Earthing: Verify that the unit earth terminal is properly
connected to a suitable earthing point. Ensure that all
unit internal earth connections are tight.
Switch Settings: Ensure that the unit On/Off toggle
switch beneath the key pad in the electronic section
of the control panel is set to OFF. Set the non-fused
disconnect switch to ON. The customers disconnection
devices can now be set to ON.
The machine is now live!
Crankcase Heaters: Verify the heaters are energised.
Depending upon the ambient temperature the
crankcase heaters must be on for 12 to 24
hours before start-up.
Water System: Verify that the liquid system has been
installed correctly, and has been commissioned with
the correct direction of water flow through the heat
exchanger. Inlet should be at the refrigerant pipework
connection end of the heat exchanger. Purge air from
the heat exchanger using the air vent mounted in the
pipework.
Flow rates and pressure drops must be
within the limits given in the Technical Data
Section. Operation outside of these limits is
undesirable and could cause damage.
Flow switch: Verify a chilled liquid flow switch is
correctly fitted in the customer’s pipework on the heat
exchanger outlet, and wired into the control panel
correctly.
5-1
150.68.ICOM1.EN.CE (0911)
Temperature sensor(s): Ensure the leaving (BLCT) liquid temperature sensor is coated with heat
conductive compound (Part No. 013-00989-000) and
are inserted in the water outlet sensor pocket of the
heat exchanger.
Control supply: Verify the control panel display is
illuminated.
HP cut-out reset: Check that the hand reset mechanical
high pressure cut-outs mounted on the discharge lines
are at the correct setting and are reset.
Programmed options: Verify that the options
factory programmed into the Microprocessor Control
Centre are in accordance with the customers order
requirements by pressing the ‘OPTIONS’ key on the
keypad and reading the settings from the display. Refer
also to the Operating Instructions Manual for notes and
explanation of messages.
Programmed settings: Ensure the system cut-out and
operational settings are in accordance with operational
requirements by pressing the ‘PROGRAM’ key (refer to
Operating Instructions Manual).
Date & time: Press the ‘CLOCK’ key and set the date
and time (refer to Operating Instructions Manual).
Start/Stop schedule: Programme the daily and holiday
start/stop by pressing the ‘SCHEDULE/ADVANCE
DAY’ key (refer to Operating Instructions Manual).
Setpoints: Set the required leaving chilled and hot
liquid temperature set-point and control range using
the ‘SETPOINTS’ key (refer to Operating Instructions
Manual).
Mode Selection: Ensure under ‘OPTIONS’ key that
LOCAL REMOTE MODE is set to LOCAL and that
CONTROL MODE is set to COOLING.
Compressor Operation: Use the ‘OPTIONS’ key
to switch off each refrigerant system in turn (refer to
Operating Instructions Manual) and then check the
compressors on the active system:
Connect a manifold gauge to each refrigerant circuit
suction and discharge service valves and temporarily
start each compressor and check that the discharge
pressure rises and the suction pressure decreases
to ensure that the compressors are operating in the
correct direction. Any faults found must be corrected
before starting the unit.
After completing the checks on both circuits, set both
systems to on using the ‘OPTIONS’ key.
First Time Start-Up
During the commissioning period there should
be sufficient heat load to run the unit under
stable full load operation to enable the unit
controls, and system operation to be set up
correctly and a commissioning log taken.
5-2
Read the following section in conjunction with the
Operating Instructions Manual, then proceed step by
step as follows:
Interlocks: Verify that liquid is flowing through the
heat exchanger and that heat load is present. Ensure
that any remote run interlocks are in the run position
and that the run schedule requires the unit to run or is
overridden.
Start-up: Set the unit switch to the ON position to start
the unit (there may be a few seconds delay before
the first compressor starts because of the anti-recycle
timer). Be ready when each compressor starts, to switch
the unit off immediately if any unusual noises or other
adverse conditions develop. Refer to the Technical
Data Section for the normal operating sequence from
start-up.
Refrigerant flow: When a compressor starts a flow
of liquid refrigerant will be seen in the liquid line sight
glass. After several minutes operation and providing a
full charge of refrigerant is in the system, the bubbles
will disappear and be replaced by a solid column of
liquid. Check that the moisture indicator is satisfactory
(Green).
System Operation: Use the ‘OPER DATA’ key to
check the system pressures and temperatures.
Suction Superheat: Check suction superheat at steady
full system load only. It is important that no bubbles
show in the liquid line sight glass. Measure suction
temperature on the copper line about 150 mm before
the compressor inlet connection. Measure suction
pressure at the compressor pressure transducer gauge
connection port. Superheat should be 5ºC to 7ºC.
Thermal Expansion valve adjustment: The expansion
valves are factory set and should not need adjustment.
If any superheat values are out of range, however, the
expansion valve adjusting screw should be adjusted no
more than 1 turn at a time (‘in’ to increase superheat,
‘out’ to decrease superheat), allowing at least 10
minutes for the valve to stabilise before rechecking the
value of superheat.
Subcooling: Check liquid subcooling at steady full
compressor load only. Measure liquid line temperature
on the copper line beside the main liquid line service
valve. Measure liquid pressure at the liquid line service
valve. Subcooling should be 6ºC to 8ºC. If subcooling is
out of range add or remove refrigerant as required. Do
not overcharge the unit.
General operation: After completion of the above
checks for System 1 repeat the process for system 2.
In addition, check that loading occurs as specified in
the Technical Data Section and that general operation
is correct.
EN
150.68.ICOM1.EN.CE (0911)
6. Unit Operation
General Description
The units are designed to work independently, or
in conjunction with other equipment via a Johnson
Controls building management system or other
automated control system. When operating, the unit
controls monitor the liquid system temperatures at
the unit and take the appropriate action to maintain
the temperatures within desired limits. This action will
involve running one or more compressors to match
the duty of the refrigerating systems to the load on the
liquid system.
The following sections give an overview of the operation
of the unit. For detailed information, reference should
be made to the Operating Instructions for the unit.
Start-up
Check the main power supplies to the unit are ‘ON’,
all refrigerant service valves are open (anti-clockwise
one turn short of fully open) and liquid flow has been
established (unless the unit liquid pump start control
is being used, in which case just ensure the pump
supply is on). Ensure that the system switches under
the ‘OPTIONS’ key are in the ‘ON’ position.
Press the ‘STATUS’ key on the keypad and then switch
the unit ‘ON/OFF’ switch below the keypad to the ‘ON’
position.
The controller will perform a pre-check to ensure that
the daily/holiday schedule and any remote interlocks
will allow the unit to run, all safety cut-outs are satisfied
and that load is required (i.e. that the liquid temperature
is outside the set limits). Any problems found by the
pre-check will be displayed if present. If no problems
are present and duty is required the lead compressor
will start. The display will show the anti-coincidence
timer status for the lag compressor.
EN
Normal running and cycling
Once the unit has been started, all operations are fully
automatic. After an initial period of operation with the
lead compressor, the control system will adjust the
unit load depending on the liquid temperature and
rate of temperature change. If high load is present,
the controller will increase the capacity of the unit and
start-up the next compressor.
If very little load is present, the lead compressor may
continue to operate or may simply stop. If the latter
is the case, one compressor will restart automatically
should the liquid temperature require.
When a compressor is running the controller monitors
suction pressure and various other system parameters
such as discharge pressure, liquid temperature, etc.
Should any problems occur, the control system will
immediately take appropriate action and display
the nature of the fault (see Operating Instructions
Manual).
Shutdown
The unit can be stopped at any time by switching the
unit ‘ON/OFF’ switch just below the keypad to the
‘OFF’ position. The compressor heaters will energise
to prevent refrigerant condensing in the compressor
rotors and to prevent the compressor oil becoming
saturated with refrigerant.
To prevent damage to the unit the control
supply to the compressor heaters should not
be switched off, even when the unit is not
required to run.
If mains power must be switched off, (for extended
maintenance or a shutdown period), the compressor
suction, discharge and liquid line service valves on
both systems should be closed (clockwise) and if there
is a possibility of liquid freezing due to low ambient
temperatures, the heat exchanger should be drained.
The valves should be opened, the heat exchanger
refilled and the power must be switched on for at least
8 hours before the unit is restarted.
6-1
150.68.ICOM1.EN.CE (0911)
Page Left Intentionally Blank
6-2
EN
150.68.ICOM1.EN.CE (0911)
7. Maintenance
General Requirements
The units have been designed to operate continuously
provided they are regularly maintained and operated
within the limitations given in this manual. Each unit
should be included in a routine schedule of daily
maintenance checks by the operator/customer, backed
up by regular service inspection and maintenance visits
by a suitably qualified Service Engineer.
It is entirely the responsibility of the owner to provide
for these regular maintenance requirements and/or
enter into a maintenance agreement with a Johnson
Controls service organisation to protect the operation
of the unit. If damage or a system failure occurs due
to improper maintenance during the warranty period,
Johnson Controls shall not be liable for costs incurred
to return the unit to satisfactory condition.
This maintenance section applies to the basic
unit only and may, on individual contracts, be
supplemented by additional requirements to
cover any modifications or ancillary equipment
as applicable.
The Safety Section of this manual should
be read carefully before attempting any
maintenance operations on the unit. This
section should be read in conjunction with
the Unit Operation Section.
Daily Maintenance
The following maintenance checks should be carried
out on a daily basis by the operator/customer. Please
note that the units are not generally user serviceable
and no attempt should be made to rectify faults or
problems found during daily checks unless competent
and equipped to do so. If in any doubt, contact your
local Johnson Controls Service Centre.
Refrigerant leaks: Visually check the heat exchanger,
ambient coils, compressors and pipework for damage
and gas leaks.
Ambient Coil Fan Motors: The fan motors are
permanently lubricated and require no maintenance.
Airflow obstructions: Check the ambient coil air
intakes and adjacent areas are clear of foreign materials
or obstructions e.g. paper, leaves, etc.
Compressor oil level: Check the compressor oil level
when the compressor is operating normally. The oil
level should be between the ½ and ¾ in the oil sight
glass.
At shutdown the oil level can fall to the lower
limit of the oil sight glass.
Compressor Oil Quality: The oil used in the
compressors is pale in colour. If the oil colour darkens
or exhibits a change in colour, this may be an indication
of contaminants in the refrigerant system. If this
occurs, an oil sample should be taken and analysed. If
contaminants are present, the system must be cleaned
to prevent compressor failure.
Refrigerant Charge: When a system starts up, or
sometimes after a change of capacity, a flow of bubbles
will be seen in the liquid line sight glass. After a few
minutes of stable operation, the bubbles should clear
leaving just liquid refrigerant showing in the sight glass.
In addition to the checks listed above, periodic
inspections of the unit should be carried out to ensure
proper equipment operation. Items such as loose
equipment, component operation, unusual noises, etc.
should be investigated and corrected immediately.
Unit status: Press the ‘STATUS’ key on the keypad
and ensure no fault messages are displayed (refer
to the Operating Instruction Manual for explanation
of messages and the Trouble Shooting section for
courses of action).
Operating conditions: Read the operating pressures
and temperatures at the control panel using the ‘OPER
DATA’ key and check that these are within the operating
limitations given in the Operating Instructions Manual.
EN
7-1
150.68.ICOM1.EN.CE (0911)
Scheduled Maintenance
The maintenance operations detailed in the following table should be carried out on a regular basis by a suitably
qualified Service Engineer. It should be noted that the interval necessary between each ‘minor’ and ‘major’ service
can vary depending on, for instance, application, site conditions and expected operating schedule. Normally a ‘minor’
service should be carried out every three to six months and a ‘major’ service once a year. It is recommended that your
local Johnson Controls Service Centre is contacted for recommendations for individual sites.
SERVICE SCHEDULE
MINOR SERVICE
Unit general:
Check thermal insulation.
Check vibration isolators.
Check relief valves.
Check for pipework damage.
Check for leaks.
Check moisture indicator.
Check suction superheat.
Check liquid subcooling.
Check oil level.
Check condition of oil.
Check water flow.
Check water pressure drop.
Check heater mats.
Check for airflow obstructions.
Check fins.
Check fans and fan guards.
Check panel condition.
Check mains and control wiring.
Check sensor locations.
Check mechanical HP cut-outs.
Refrigerant systems general:
Compressors:
Heat Exchanger:
Ambients coils:
Power & Control system general:
Microprocessor controls:
Check fault history.
Check program settings.
Check HP / LP cut-out function’s.
Check load / unload function.
MAJOR SERVICE
All items under Minor Service plus:
Check main structure.
Check paint-work.
Check solenoid valves.
Check water pH / glycol strength.
Brush fins.
Check fan motor bearings.
Check all connections.
Check compressor contactors.
Check fan contactors
Check sensor / transducer calibration.
Check motor protectors.
Check contactor contacts.
Check fan control function.
Check ambient cut-out function.
Heat Exchanger In-Service Inspection
There is no corrosion on the refrigerant side therefore in-service inspection on the refrigerant side is not necessary.
For the water side, if the water used is treated in accordance with Section 4, in-service inspection is not necessary.
In the design of the vessels used in the unit, a 1 mm corrosion allowance has been used to consider slight corrosion
on the water side. This allowance is sufficient to cover the lifetime of the unit.
Johnson Controls believes that periodic in service proof testing (e.g.; hydro tests) is not required. However, Johnson
Controls recognises that national regulations may require such testing to be conducted.
7-2
EN
150.68.ICOM1.EN.CE (0911)
8. Trouble Shooting
Competent Persons Trouble Shooting Guide
PROBLEM
No display on panel — Unit will not operate
POSSIBLE CAUSE
Mains supply to unit off.
Emergency stop device off.
No supply to -T1.
No 24 Vac supply to microprocessor board.
FLOW SWITCH OPEN displayed
No 24 Vac output from Transformer -T1.
Short circuit in wiring to temperature sensors
or pressure transducers.
Defective microprocessor board or display
board.
No liquid flow through the liquid heat
exchanger
Flow switch contacts are not made.
UNIT FAULT: LOW AMBIENT TEMP
displayed in either mode or HIGHAMBIENT
TEMP displayed in heating mode
Defective flow switch.
Ambient air temperature is lower than the
programmed operating limit or, in heating
mode, higher than the trip value (See
operating manual)
Measured temperature is incorrect.
UNIT FAULT: LOW LIQUID TEMP displayed
UNIT FAULT: 115 VAC UNDERVOLTAGE
displayed
EN
Improperly adjusted leaving chilled liquid
temperature cut-out (glycol only).
Control panel setpoint/range values improperly
programmed.
Chilled liquid flow too low.
Defective -BLCT sensor. (Check the sensor is
properly installed in the bottom of the well with
a generous amount of heat conductive
compound).
Poor mains supply voltage.
ACTION
Switch on mains supply if safe to do so.
Check if remote emergency stop device is in
the ‘OFF’ position. Turn to ‘ON’ position if safe
to do so.
Check fuses -F3 and -F6 and wiring to -T1 and
fuse -F1.
Check wiring from -T1 to J14 microprocessor
board.
Change transformer -T1
Unplug connections at microprocessor board
to isolate.
Replace board after contacting Johnson
Controls Service.
Ensure that liquid pumps are running. Valves
are correctly set and flow is established.
Check the flow switch is functional and is
installed according to the manufacturers
instructions.
Note: On some systems the pump starter may
be wired to the unit and controlled to start by
the unit.
Replace flow switch.
Use the ‘OPER DATA’ key to display the
temperature and confirm that the displayed
value is approximately correct. The warning
message should clear when the ambient air
temperature reaches the programmed
operating limit.
Check the programmed settings are correct for
the options fitted to the unit.
Check sensor calibration, location and wiring.
Re-program the leaving chilled liquid
temperature cut-out.
Re-adjust setpoint/range.
Increase chilled liquid flow.
Compare sensor against a known good
temperature sensing device. Refer to sensor
calibration tables.
Check mains supply is stable and within
allowable limits.
Check for voltage dip on compressor start.
8-1
150.68.ICOM1.EN.CE (0911)
PROBLEM
SYS X HIGH DSCH PRES displayed
POSSIBLE CAUSE
Discharge pressure cut-out incorrectly set.
Contactor failure.
Compressor failure.
Fouled cooler surface. (Low suction pressure
will be observed).
ACTION
Adjust in accordance with recommended
setting.
Check for airflow restrictions caused by
blockages on intake faces of air coils. Check fir
damaged fins.
Check fan motor, fuses and contactors. Check
fan airflow is upward.
Check for non-condensables (air) in system.
Evacuate and recharge system.
Remove refrigerant.
Check discharge transducer calibration and
wiring.
Adjust in accordance with recommended
setting.
Replace valve
Check for restricted chilled liquid flow. Check
for fouled tube surfaces.
Check for leaks.
Check for blocked filter/drier.
Check for moisture in the system.
Check suction pressure transducer
calibration/pressure switch and wiring.
Verify refrigerant charge is not low. Verify
superheat setting of 5.6° - 8.3°C. Verify correct
compressor rotation. Verify compressor is not
over loaded.
See 'High Discharge Pressure Fault'.
Replace -FHP switch.
No problem.
Compare the display with a thermometer.
Should be within +/- 2 degrees. Refer to BLCT
calibration charts.
Replace defective part.
Diagnose cause of failure and replace.
Contact the local Johnson Controls service
representative.
Improper flow through the cooler
Reduce flow to within unit design specification.
Poor Airflow through the condenser coils
Condenser fans not operating or operating
backwards
Air in refrigerant system.
Excessive refrigerant charge.
Measured pressure is incorrect.
SYS X LOW SUCT PRESS displayed
Suction pressure cut-out incorrectly set.
Faulty expansion valve.
Reduced cooler performance.
Low refrigerant charge.
Restricted refrigerant flow.
Measured pressure incorrect.
SYS X MP/HPCO FAULT displayed
Compressor(s) do not start
Lack of cooling effect
Compressor internal motor protector (MP)
open.
-FHP switch open.
Defective -FHP switch.
Demand not sufficient.
Defective water temperature sensor.
Low refrigerant charge. (Low suction pressure Check subcooling and add charge as needed.
will be observed).
Check for leaks.
Replace U5 and reprogram setpoints, values,
!! LOW BATTERY !! CHECK PROG / SETP / RTC battery (U5) flat.
options, time and schedule.
OPTN displayed
8-2
EN
150.68.ICOM1.EN.CE (0911)
Sensor Calibration Charts
Discharge and Suction Pressure Transducers
(-BDP & -BSP)
Temperature Sensors
(-BLCT, 1-BACDT & 2-BACDT)
Temperature
°C
Resistance
ohms
-8
-6
-4
-2
0
2
4
6
8
10
12
14
14896
13388
12047
10856
9795
8849
8005
7251
6575
5970
5427
4937
Microboard
Voltage
Vdc
1.57
1.69
1.81
1.93
2.05
2.17
2.30
2.42
2.54
2.66
2.78
2.90
Sensor Voltage
Vdc
3.43
3.31
3.19
3.07
2.95
2.83
2.70
2.58
2.46
2.34
2.22
2.10
-BSP 0 - 27.58 Barg
Pressure Barg
Volts
Vdc
0.00
0.50
3.00
0.94
6.00
1.37
9.00
1.81
12.00
2.24
15.00
2.68
18.00
3.11
21.00
3.55
24.00
3.98
27.58
4.50
Red wire = 5 V, Black wire = Signal
-BDP 0 - 44.83Barg
Pressure
Volts
Barg
Vdc
0.00
0.50
4.00
0.86
8.00
1.21
12.00
1.57
16.00
1.93
20.00
2.28
28.00
3.00
32.00
3.36
36.00
3.71
42.00
4.25
44.83
4.50
3.35
1.65
3.57
1.43
Red wire = Signal, Black wire = 5 V
Test points:
Leaving Liquid Temperature (-BLCT)
Test points :
Sensor Voltage Input 5V
Microboard Voltage Input 0V
-AMB J6-4/1
-AMB J6-7/1
System 1 Air Coil Defrost Temperature (1-BACDT)
Sensor Voltage Input 5V
Microboard Voltage Input 0V
-AMB J8-5/2
-AMB J8-8/2
System 2 Air Coil Defrost Temperature (2-BACDT)
Sensor Voltage Input 5V
-AMB J10-5/2
Microboard Voltage Input 0V
-AMB J10-8/2
Discharge Pressure (-BDP) 44.83 barg Transducer:
Refrigerant Circuit 1
-AMB J7-11/7
Refrigerant Circuit 2
-AMB J9-11/7
Voltage = (Pressure (barg) X 0.0892) + 0.5
Suction Pressure (-BSP) 27.58 barg Transducer:
Refrigerant Circuit 1
-AMB J7-10/9
Refrigerant Circuit 2
-AMB J9-10/9
Voltage = (Pressure (barg) X 0.145) + 0.5
Ambient Air Temperature Sensor (-BAMB)
Temperature
°C
Resistance
ohms
-18
-15
-10
-5
0
5
10
15
20
25
30
35
40
85398
72950
55330
42227
32650
25390
19900
15710
12490
10000
8057
6530
5327
Microboard
Voltage
Vdc
0.67
0.77
0.97
1.20
1.45
1.72
2.00
2.29
2.58
2.85
3.11
3.35
3.57
Sensor
Voltage
Vdc
4.33
4.23
4.03
3.80
3.55
3.28
3.00
2.71
2.42
2.15
1.89
1.65
1.43
Red wire = Signal, Black wire = 5 V
Test points :
Ambient Air (-BAMB)
Sensor Voltage Input 5V
Microboard Voltage Input 0V
EN
-AMB J6-6/3
-AMB J6-9/3
8-3
150.68.ICOM1.EN.CE (0911)
Page Left Intentionally Blank
8-4
EN
150.68.ICOM1.EN.CE (0911)
9. Technical Data
Refrigerant to Water Heat Exchanger Pressure Drop Graph
210
180
150
0340SE
Pressure Drop (kPa)
120
100
80
0415SE 0495SE 0560SE
0610SE 0425HE 0505HE
60
50
40
30
20
15
0570HE
0640HE
10
0355HE
5
2
2
5
10
15 20
30 40 50 60
Flow Rate (l/s)
Operating Limitations
YLPA Standard Efficiency
Liquid Outlet Temperature (Water)
Cooling
Liquid Outlet Temperature Range (T)
Mode
Air Temperature - Standard Unit
Liquid Outlet Temperature (Water)
Heating
Liquid Outlet Temperature Range (T)
Mode
Air Temperature - Standard Unit
Heat Exchanger Flow Rate
Heat Exchanger Presssure Drop
Maximum Water Side Pressure
Maximum Refrigerant Side Pressure
Power Supply Voltage
YLPA High Efficiency
Liquid Outlet Temperature (Water)
Cooling
Liquid Outlet Temperature Range (T)
Mode
Air Temperature - Standard Unit
Liquid Outlet Temperature (Water)
Heating
Liquid Outlet Temperature Range (T)
Mode
Air Temperature - Standard Unit
Heat Exchanger Flow Rate
Heat Exchanger Presssure Drop
Maximum Water Side Pressure
Maximum Refrigerant Side Pressure
Power Supply Voltage
0340SE
Min.
Max.
0415SE
Min.
Max.
0495SE
Min.
Max.
0560SE
Min.
Max.
0610SE
Min.
Max.
4 to 15
°C
3 to 8
°C
°C
0 to 46 (1)
35 to 55
°C
3 to 8
°C
-10 to 35
°C
6
38
11
44
11
44
11
44
11
44
l/s
kPa 7.7 191.3 16.0 128.7 16.0 128.7 16.0 128.7 16.0 128.7
10.3
bar
44.8
bar
V
400V 3Ø, 50Hz (nominal) (2)
0355HE
Min.
°C
°C
°C
°C
°C
°C
8
l/s
5.3
kPa
bar
bar
V
Max.
0425HE
Min.
Max.
0505HE
Min.
Max.
0570HE
0640HE
Min.
Max.
Min.
Max.
13
54
13
54
4 to 15
3 to 8
0 to 46 (1)
35 to 55
3 to 8
-10 to 35
38
88.4
11
44
11
44
16.0 128.7 16.0 128.7 10.1 165.6 10.1 165.6
10.3
44.8
400V 3Ø, 50Hz (nominal) (2)
(1) Unit may operate unloaded up to 52ºC depending on model size and site conditions.
(2) Tolerance +/-10%
EN
9-1
150.68.ICOM1.EN.CE (0911)
Physical Data
YLPA
Number of refrigerant circuits
Refrigerant Charge (1) Circuit 1 / Circuit 2
Oil Charge
Circuit 1 / Circuit 2
Number of compressors
Compressor
Type
Number
Refrigerant to Water
Type
Heat Exchanger
Water Volume
Water Connections
Number of Fans (circuit 1 / circuit 2)
Ambient Coils Fans
Total Air Flow - Standard Models
Length
Dimensions
Width
Height
Shipping Weight
Basic Unit Weight
Operating Weight
YLPA
Number of refrigerant circuits
Refrigerant Charge (1) Circuit 1 / Circuit 2
Oil Charge
Circuit 1 / Circuit 2
Number of compressors
Compressor
Type
Number
Refrigerant to Water
Type
Heat Exchanger
Water Volume
Water Connections
Number of Fans (circuit 1 / circuit 2)
Ambient Coils Fans
Total Air Flow - Standard Models
Length
Dimensions
Width
Height
Shipping Weight
Basic Unit Weight
Operating Weight
0340SE
kg
l
40/42
11/11
2/2
l
Inch
200
m3/s
mm
mm
mm
kg
kg
3/3
35
4937
2246
2501
4400
4600
0355HE
kg
l
59/62
11/11
2/2
l
Inch
250
m3/s
mm
mm
mm
kg
kg
4/4
47
4937
2246
2501
4500
4750
0415SE
0495SE
0560SE
2
68/50
68/68
80/76
17/11
17/17
18.9/17
3/2
3/3
3/3
Scroll
1
Shell and Tubes
300
8
4/3
4/4
5/5
41
47
58
4937
4937
5854
2246
2246
2246
2501
2501
2501
4700
4900
5395
5000
5200
5695
0610SE
81/81
18.9/18.9
3/3
6/6
70
6971
2246
2501
5935
6235
0425HE
0505HE 0570HE 0640HE
2
82/82
104/95
104/110
82/60
17/11
17/17
18.9/17 18.9/18.9
3/2
3/3
3/3
3/3
Scroll
1
Shell and Tubes
300
600
8
10
10
6/4
6/6
6/6
6/6
70
70
58
70
6971
6971
5854
6971
2246
2246
2246
2246
2501
2501
2501
2501
5100
5800
6095
6295
5400
6100
6495
6695
(1) Liquid sub-cooling measured at the liquid line should be between 8.5 and 11.0°C at circuit full load.
Sub-cooling is determined by the level of refrigerant charge in each system
9-2
EN
150.68.ICOM1.EN.CE (0911)
Unit Electrical Data
Unit Data (Using Standard Fans or Two speed Optional Fans at Full Speed)
Nominal Running Maximum Running Conditions
Start up Amps
Conditions
YLPA
Direct
Soft
Amps
Amps
Amps
@ 400 V
@400V
@ 360V
on Line (1)
Start (1)
Standard
198
238
247
465
350
0340SE PF
189
229
241
458
PF & SS
194
233
244
346
Standard
207
246
255
474
359
0355HE PF
198
238
250
467
PF & SS
202
242
253
354
Standard
246
295
306
513
398
0415SE PF
234
284
299
504
PF & SS
239
289
302
391
Standard
259
308
319
526
411
247
297
312
517
0425HE PF
PF & SS
252
302
315
404
Standard
293
352
366
560
445
0495SE PF
279
339
357
549
PF & SS
284
344
360
436
Standard
311
369
383
577
462
0505HE PF
297
357
375
566
PF & SS
301
361
378
453
Standard
337
402
421
671
515
0560SE PF
320
386
406
658
PF & SS
326
392
411
504
Standard
346
411
429
680
524
0570HE PF
329
395
415
666
PF & SS
335
400
420
513
Standard
381
452
476
715
559
0610SE PF
361
433
455
698
PF & SS
368
439
462
546
Standard
381
452
476
715
559
0640HE PF
361
433
455
698
PF & SS
368
439
462
546
Soft
Start(2)
422
420
431
429
470
465
483
478
517
510
534
527
617
609
625
617
661
650
661
650
PF = Power Factor Option
PF & SS = Power Factor and Soft Start Option
(1) Start up amps is the last compressor starting with all other compressors/fans operating at nominal conditions at 400V.
(2) Value of Start up amps is the hightest possible with running compressors and all fans operationg at nominal conditions at 400V
Compressor Electrical Data
YLPA
0340SE to 0505HE Sys 1 & 2
0560SE and 0570HE Sys 2
0560SE and 0570HE Sys 1
0610SE and 0640HE Sys 1 & 2
Standard
PF Option
Standard
PF Option
Nominal
Amps
KW
@400V
43.1
25
40.8
54.9
32.3
51.5
KW
31.7
40.3
Compressor Data
Maximum
Amps
Amps
@400V
@360V
52.9
55.2
50.8
53.8
66.7
70.6
63.5
67.3
Inrush Current @ 400V
DOL
Soft Start
310
195
389
233
Fan Electrical Data
FAN TYPE
Standard
Two Speed Slow
Option Fast
VSD Option
Fan Data
KW
FLC @400V
1.64
4.33
1.15
2.45
1.64
4.33
1.4
2.2
[email protected]
18
6
18
2.2
Values are for each fan. (FLA: Full Load Amps; LRA: Lock Rotor Amps)
EN
9-3
9-4
Power cable entry via gland plate
Control cable entry
Water inlet connection to heat exchanger
Water outlet connection to heat exchanger
2
3
4
5
6
7
2
3
Mounting holes for anti vibration mounts
Rigging holes
Distance between anti vibration mounts
1
7
4
846kg
988kg
1
466kg
827kg
6
1
642kg
984kg
5
150.68.ICOM1.EN.CE (0911)
Dimensions - YLPA0355HE
EN
EN
Water inlet connection to heat exchanger
Water outlet connection to heat exchanger
4
5
6
7
2
Power cable entry via gland plate
Control cable entry
2
3
Mounting holes for anti vibration mounts
Rigging holes
Distance between anti vibration mounts
1
3
7
4
463kg
724kg
1
667kg
994kg
1
6
465kg
699kg
1
615kg
774kg
5
150.68.ICOM1.EN.CE (0911)
Dimensions - YLPA0425HE
9-5
9-6
Power cable entry via gland plate
Control cable entry
Water inlet connection to heat exchanger
Water outlet connection to heat exchanger
2
3
4
5
6
7
2
Mounting holes for anti vibration mounts
Rigging holes
Distance between anti vibration mounts
1
3
485kg
724kg
4
1
701kg
1024kg
1
7
6
745kg
1125kg
1
580kg
718kg
5
150.68.ICOM1.EN.CE (0911)
Dimensions - YLPA0505HE
EN
EN
Power cable entry via gland plate
Control cable entry
Water inlet connection to heat exchanger
Water outlet connection to heat exchanger
2
3
4
5
6
7
Mounting holes for anti vibration mounts
Rigging holes
Distance between anti vibration mounts
1
2
3
4
1
1
7
1
6
5
150.68.ICOM1.EN.CE (0911)
Dimensions - YLPA0570HE
9-7
9-8
Power cable entry via gland plate
Control cable entry
Water inlet connection to heat exchanger
Water outlet connection to heat exchanger
2
3
4
5
6
7
Mounting holes for anti vibration mounts
Rigging holes
Distance between anti vibration mounts
1
2
3
4
1
1
7
1
6
5
150.68.ICOM1.EN.CE (0911)
Dimensions - YLPA0640HE
EN
EN
Power cable entry via gland plate
Control cable entry
Water inlet connection to heat exchanger
Water outlet connection to heat exchanger
2
3
4
5
6
7
Mounting holes for anti vibration mounts
Rigging holes
Distance between anti vibration mounts
1
2
3
4
819kg
957kg
1
4937
451kg
801kg
6
7
1
621kg
5
952kg
150.68.ICOM1.EN.CE (0911)
Dimensions - YLPA0340SE
9-9
9-10
Power cable entry via gland plate
Control cable entry
Water inlet connection to heat exchanger
Water outlet connection to heat exchanger
2
3
4
5
6
7
Mounting holes for anti vibration mounts
Rigging holes
Distance between anti vibration mounts
1
2
3
7
4
620kg
886kg
1
668kg
1084kg
6
1
706kg
1066kg
5
150.68.ICOM1.EN.CE (0911)
Dimensions - YLPA0415SE
EN
EN
Power cable entry via gland plate
Control cable entry
Water inlet connection to heat exchanger
Water outlet connection to heat exchanger
2
3
4
5
6
7
2
3
Mounting holes for anti vibration mounts
Rigging holes
Distance between anti vibration mounts
1
4
7
742kg
1009kg
1
613kg
1006kg
6
1
734kg
1117kg
5
150.68.ICOM1.EN.CE (0911)
Dimensions - YLPA0495SE
9-11
9-12
Power cable entry via gland plate
Control cable entry
Water inlet connection to heat exchanger
Water outlet connection to heat exchanger
2
3
4
5
6
7
Mounting holes for anti vibration mounts
Rigging holes
Distance between anti vibration mounts
1
2
3
1
4
1
7
6
1
5
150.68.ICOM1.EN.CE (0911)
Dimensions - YLPA0560SE
EN
EN
Power cable entry via gland plate
Control cable entry
Water inlet connection to heat exchanger
Water outlet connection to heat exchanger
2
3
4
5
6
7
Mounting holes for anti vibration mounts
Rigging holes
Distance between anti vibration mounts
1
2
3
4
1
1
7
1
6
5
150.68.ICOM1.EN.CE (0911)
Dimensions - YLPA0610SE
9-13
150.68.ICOM1.EN.CE (0911)
YLPA P & I Diagram
9-14
EN
150.68.ICOM1.EN.CE (0911)
Anti Vibration Isolators Data - Neoprene Isolators
Mount
Type
RD1-WR
RD2-WR
RD3-WR
RD4-WR
L
80
99
140
159
Weight Range (kg)
Up to 375
375 to 766
766 to 1814







W
44
60
86
118
HF
32
44
73
70
Mount Type
RD3-WR
RD4-WR
RD4-WR
Dimensions (mm)
AL
AD
60
9
76
9
105
14
127
14
Colour
Charcoal
Brick Red
Charcoal
BT
5
6
6
10
CD (inch)
5/16-18 UNC X 3/4
3/8-16 UNC X 1
1/2-13 UNC X 1
1/2-13 UNC X 1
DW
32
44
64
76
JCI Part Number
029-25335-001
029-25335-002
029-25335-004
Read instructions in their entirety before beginning installation.
Isolators are shipped fully assembled and are to be positioned in accordance with the product drawings or as
otherwise recommended.
Set isolators on floor, hosuekeeping pad or subbase, ensuring that all isolators centerlines match the equipement
mounting holes. It is recommended that the isolator base be installed on a level surface. Shim or grout as
required, levelling all isolator bases to the same elevation (0.25 inch maximum difference can be tolerated).
Bolt or anchor all isolators to supporting structure utilizing base through holes.
Remove top bolt and top washer. Please equipment on top of isolators so that mounting holes in equipment or
base line up with threaded hole.
Reinstall top bolt and washer and tighten down.
Installation is complete.
EN
9-15
150.68.ICOM1.EN.CE (0911)
Anti Vibration Isolators Data - 25 mm Deflection Spring Isolators
Mount
Type
CP1
CP2
W
76
76
Weight Range (kg)
Up to 197
197 to 347
347 to 463
463 to 525
525 to 810
Up to 521
521 to 694
694 to 926
926 to 1049
1049 to 1619









D
16
16
Dimensions (mm)
L
B
C
197
165
121
267
235
197
Mount Type
CP
CP
CP
CP
CP
C2P
C2P
C2P
C2P
C2P
Colour
Black
Dark Green
Gray
White
Gray / Red
Dark Purple
Dark Green
Gray
White
Gray / Red
T
13
14
H
143
152
JCI Part Number
029-25334-002
029-25334-003
029-25334-004
029-25334-005
029-25334-006
029-25334-008
029-25334-009
029-25334-010
029-25334-012
029-25334-013
Read instructions in their entirety before beginning installation.
Isolators are shipped fully assembled and are to be positioned in accordance with the product drawings or as
otherwise recommended.
Set isolators on floor, hosuekeeping pad or subbase, ensuring that all isolators centerlines match the equipement
mounting holes. It is recommended that the isolator base be installed on a level surface. Shim or grout as
required, levelling all isolator bases to the same elevation (0.25 inch maximum difference can be tolerated).
Bolt or anchor all isolators to supporting structure utilizing base slotted holes.
Place equipment on top of isolators making sure that mounting holes of the equipment line up with isolator
positioning pin.
The adjustement process can only begin after the equipment is at its full operating weight.
Adjust each isolator in sequence by turning the spring adjusting bolt one full counterclockwise turn at a time.
Repeat this procedure on all isolators, one at a time.
Continue adjusting each isolator until a minimum of 0.25 inch clearance is achieved between the lower housing
and upper housing.
Fine adjust isolators to level equipment. Installation is complete.
9-16
EN
150.68.ICOM1.EN.CE (0911)
10. Spare Parts
Recommended Spares
Details of unit spare parts are given in the Renewal
Parts List 035-XXXXX-000. Contact your local Johnson
Controls Sales and Service Centre for information and
please quote the unit model number and serial number.
Recommended Compressor Oil
The correct type of oil must be used in the unit as
shown on the unit data plate and labels. Standard units
use the following oil:
Refrigerant
R410A
Compressor Oil
York grade V
Associated Drawings
Wiring Diagrams
Models
Schematic
Connection
Legend/Notes
EN
All
035-22892-201 to -215
035-22893-201 to -208
035-22894-201
10-1
150.68.ICOM1.EN.CE (0911)
Page Left Intentionally Blank
10-2
EN
150.68.ICOM1.EN.CE (0911)
11. Decommissioning, Dismantling
and Disposal
Never release refrigerant to the atmosphere
when emptying the refrigerating circuits.
Suitable retrieval equipment must be used.
If reclaimed refrigerant cannot be reused,
it must be returned to the manufacturer.
Never discard used compressor oil, as it
contains refrigerant in solution. Return
used oil to the oil manufacturer.
Unless otherwise indicated, the operations described
below can be performed by any properly trained
maintenance technician.
General
Isolate all sources of electrical supply to the unit
including any control system supplies switched by the
unit. Ensure that all points of isolation are secured in
the ‘OFF’ position. The supply cables may then be
disconnected and removed. For connection points
refer to Installation Section.
Remove all refrigerant from each system of the unit
into a suitable container using a refrigerant reclaim or
recovery unit. This refrigerant may then be re-used,
if appropriate, or returned to the manufacturer for
disposal. Under NO circumstances should refrigerant
be vented to atmosphere. Drain the refrigerant oil from
each system into a suitable container and dispose of
according to local laws and regulations governing the
disposal of oily wastes. Any spilt oil should be mopped
up and similarly disposed of.
Isolate the unit heat exchanger from the external water
systems and drain the heat exchanger section of the
system. If no isolation valves are installed it may be
necessary to drain the complete system.
EN
If glycol or similar solutions have been
used in the water system, or chemical
additives are contained, the solution MUST
be disposed of in a suitable and safe
manner. Under NO circumstances should
any system containing glycol or similar
solutions be drained directly into domestic
waste or natural water systems.
After draining, the water pipework may be disconnected
and removed.
Packaged units can generally be removed in one piece
after disconnection as above. Any fixing down bolts
should be removed and then the unit should be lifted
from position using the points provided and equipment
of adequate lifting capacity.
Units which cannot be removed in one piece after
disconnection as above must be dismantled in position.
Special care should be taken regarding the weight and
handling of each component. Where possible units
should be dismantled in the reverse order of installation.
Residual refrigerant oil and glycol or
similar solutions may remain in some
parts of the system. These should be
mopped up and disposed of as described
above.
It is important to ensure that whilst components are
being removed the remaining parts are supported in a
safe manner.
Only use lifting equipment of adequate
capacity
After removal from position the unit parts may be
disposed of according to local laws and regulations.
11-1
www.johnsoncontrols.com
150.68.ICOM1.EN.CE (0911) (035-23224-100)
Subject to change without notice.
ALL RIGHTS RESERVED

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