MODELS YCAL0019, 0022, 0028, 0033, 0043, 0046, 0052, 0056, AND 0066

Transcription

1 AIR-COOLED LIQUID CHILLERS HERMETIC SCROLL Renewal Parts Supercedes: RP (30) Form: RP (5) MODELS YCAL009, 00, 008, 0033, 0043, 0046, 005, 0056, AND STYLE "E" R-40A 5-60 TON 53-8 Kw 50Hz and 60Hz Issue Date: May 8, / MODELS ONLY

2 FORM RP (5) ISSUE DATE 5/8/0 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls policy for continuous improvement, the information contained in this document is subjected to change without notice. While Johnson Controls makes no commitment to update or provide current information automatically to the manual user, that information, if applicable, can be obtained by contacting the nearest Johnson Controls Engineered Systems Service office. It is the responsibility of operating/service personnel as to the applicability of these documents to the equipment in question. If there is any question in the mind of operating/ service personnel as to the applicability of these documents, then, prior to working on the equipment, they should verify with the owner, whether the equipment has been modified and if the current literature is available. WARNING HIGH VOLTAGE Is used in the operation of this equipment. DEATH OR SERIOUS INJURY may result if personnel fail to observe safety precautions. Work on electronic equipment should not be undertaken unless the individual(s) have been trained in the proper maintenance of equipment and is (are) familiar with its potential hazards. Shut off power supply to the equipment before beginning work and follow lockout procedures. When working inside equipment with power off, take care to discharge every capacitor likely to hold dangerous potential. Be careful not to contact high voltage connections when installing or operating this equipment. LOW VOLTAGE DO NOT be misled by the term low voltage. Voltages as low as 50 volts may cause death. JOHNSON CONTROLS

3 FORM RP (5) ISSUE DATE 5/8/0 TABLE OF CONTENTS Table - SWEP HEAT EXCHANGER - STANDARD INSULATION...5 Table - SWEP HEAT EXCHANGER - DOUBLE INSULATION...7 Table 3 - SWEP HEAT EXCHANGER PARTS (STANDARD AND DOUBLE INSULATION) YCAL009 - YCAL Table 4 - SWEP HEAT EXCHANGER AND TXV PARTS (STANDARD AND DOUBLE INSULATION) YCAL YCAL Table 5 - ALFA LAVAL HEAT EXCHANGER AND RELATED COMPONENTS... Table 6 - CONDENSER COIL COMPONENTS...5 Table 7 - CONDENSER COIL COMPONENTS...6 Table 8 - FAN COMPONENTS - MODELS YCAL009 and YCAL Table 9 - FAN COMPONENTS - YCAL008, 0033, 0043, 0046, 005, 0056 & YCAL Table 0 - REFRIGERANT PIPING COMPONENTS...9 Table - RECOMMENDED OIL TYPE...7 Table - R-40A COMPRESSOR PART NUMBERS...7 Table 3 - COMPRESSOR HEATER AND COMPRESSOR SOUND BLANKET PART NUMBERS...9 Table 4 - OPTION PANEL AND POWER PANEL CONFIGURATIONS...3 Table 5 - CONTROL PANEL AND POWER PANEL IDENTIFIERS...33 Table 6 - CONTROL AND POWER PANEL COMPONENTS...34 Table 7 - CONTROL WIRING HARNESSES...5 Table 8 - SENSOR HARNESS WIRING...5 Table 9 - TEMPERATURE SENSORS AND TRANSDUCERS...53 Table 0 - TRANSDUCER AND THERMISTOR WIRE HARNESS CONNECTORS - FIELD REPLACEMENT PARTS...54 Table - WIRE KIT OPTIONS...55 Table - WIRE ENCLOSURE PARTS...55 Table 3 - LOUVERED ENCLOSURE PARTS...56 Table 4 - ENCLOSURE KIT OPTIONS...57 Table 5 - WIRE ENCLOSURE PARTS...57 Table 6 - LOUVERED ENCLOSURE PARTS...58 Table 7 - VIBRATION ISOLATORS PART NUMBERS...59 Table 8 - FIELD INSTALLED OPTIONS KIT NUMBERS...60 Table 9 - CONTROL TRANSFORMER KIT...60 Table 30 - OPTIVIEW REMOTE CONTROL CENTER PARTS...6 Table 3 - REMOTE RESET WIRING...6 Table 3 - REMOTE TEMPERATURE RESET KIT COMPONENTS...6 Table 33 - RECOMMENDED SPARE PARTS - YCAL STYLE 'E' CHILLERS...63 JOHNSON CONTROLS 3

4 UNIT NOMENCLATURE NAMEPLATE ENGINEERING DATA FORM RP (5) ISSUE DATE 5-8-/0 Basic Part Number YCAL006EC8XDA Base product type nominal capacity unit designator refrigerant voltage/starter design/development level y : YORK # # # # Tons/Kw E High Efficiency E :R-40A 7 :00/3/60 E c : Chiller :30/3/60 a : Air Cooled L : Scroll to :380/3/60 :460/3/60 B 5 0 :385-45/3/ :575/3/60 x :Across the Line :Design Series E :Engineering Change or PIN Level PART NUMBER letter codes POWER FIELD CONTROLS FIELD COMPRESSOR / PIPING FIELD S S B X D X T C : SP Terminal Block : SP NF Disconnect Switch : SP Circuit Breaker : Transformer 5/4V (factory) : Power Factor Capacitor MP = Multiple Point SP = Single Point NFDS = Non-Fused Disconnect Switch TB = Terminal Block Ser. = Service CB = Circuit Breaker L H A M T S F G R L C O : Low Ambient Kit (factory) : High Ambient Kit (factory) : Both Low / High Ambient (factory) : ISN E-Link Microgateway Gateway : BAS/EMS Temp. Reset / Offset : Spanish LCD & Keypad Display : French LCD & Keypad Display : German LCD & Keypad Display : Disch Press Transducers / Readout : N. American Safety Code (cu.l./cetl) : Motor Current Module : OptiView Remote Control Panel S : Special Kit Required # # T S C S B :Leaving Water Temp :Thermal Storage :Chicago Relief Code :Serv Isolation Valves :Both Chicago Code & Serv Isolation :Hot Gas By-Pass - Ckt :Hot Gas By-Pass - Ckt X :Comp. Heater (R-40A) EVAP. FIELD CONDENSER FIELD CABINET FIELD 3 : 300 PSIG DWP Waterside X : Aluminum D : Double Thick Insulation C : Copper 7 X : Weld Standard Flange Victaulic Kit B : Black Pre-coated Fin Fin B V : Victaulic Flange to Flange Kit Adapter P : Phenolic Post-coated Dipped L S T : One Flow Switch : Two Flow Switch X : TEAO Fan Motors : " Deflection S : Seismic U : Three Flow Switch N : Neoprene Pads D : One Diff. Press. Switch E : Two Diff. Press. Switch REFRIGERANT PUMP PACKAGE OPTIONS F : Three Diff. Press. Switch WARRANTY A : ASME Pressure Vessel Code 55 EXTENDED FIELD WARRANTY X B C D E F G H R : Remote DX Cooler : st Year Parts Only : st Year Parts & Labor : nd Year Parts Only : nd Year Parts & Labor : 5 Year Compressor Parts Only : 5 Year Compressor Parts & Labor Only : 5 Year Units Parts Only : 5 Year Unit Parts & Labor : Year Refrigerant : Year Refrigerant 5 :5 Year Refrigerant A :-Pump B :-Pumps C : Pump with Expansion Tank D : -Pumps with Expansion Tank E : -Pump with Buffer Tank F : -Pumps with Buffer Tank G : -Pump with Expansion Tank and Buffer Tank H : -Pumps with Expansion Tank and Buffer Tank : Wire Enclosure Panels (factory) : Louvered Enclosure Panels (factory) : Acoustic Sound Blanket : Ultra Low Sound Fans 6 PLANT OF MANUFACTURE R : Plant Of Manufacture - Monterrey CUR :Curitiba, Brazil MEX :Mexico, ES MTY :Monterrey, BE SAT :San Antonio, Texas NOTES:. Q :DENOTES SPECIAL / S.Q.. # :DENOTES STANDARD 3. X :w/in OPTIONS FIELD, DENOTES NO OPTION SELECTED 4. Agency Files (i.e. U.L. / ETL; CE; ARI; ETC.) will contain info. based on the first 4 characters only. 5. Plant of manufacture to include PIN 56 upon entering the chiller order. 4 JOHNSON CONTROLS

5 FORM RP (5) ISSUE DATE 5/8/0 SECTION - SWEP HEAT EXCHANGER AND RELATED COMPONENTS SECTION - SWEP HEAT EXCHANGER AND RELATED COMPONENTS Table - SWEP HEAT EXCHANGER - STANDARD INSULATION ITEM DESCRIPTION HEAT EXCHANGER PART STANDARD REMOTE NUMBER* MODELS QUANITY X X YCAL009 X X YCAL00, YCAL008, YCAL0033 X N/A YCAL0043 N/A X YCAL0043, YCAL005 Heat Exchanger X N/A YCAL0046 N/A X YCAL0046, YCAL0056, 3, 4 X N/A YCAL005 X N/A YCAL0056 X N/A YCAL0066 N/A X YCAL Heater, 0 Volts, 00 Watts X N/A ALL, 3, 4 Cover Water Side X X YCAL009, YCAL00, 6 YCAL008, YCAL0033 YCAL0043,, 3, 4 Cover Water Side X X YCAL0046,YCAL005, YCAL0056, YCAL0066 Cover Refrigerant Side X X YCAL009, YCAL00, YCAL008, YCAL YCAL0043,, 3, 4 Cover Refrigerant Side X X YCAL0046,YCAL005, YCAL0056, YCAL0066 Cover (Standard Insulation) X X YCAL009 8 Cover (Standard Insulation) Cover (Standard Insulation) Cover, (Standard Insulation) Cover (Standard Insulation) X X YCAL00, YCAL008, YCAL0033 X X YCAL0043, YCAL005 X X YCAL0046, YCAL0056 X X YCAL0066 * Part numbers for heat exchangers include mounting bracket, wells and rails. On older YCAL's with Alfa Laval heat exchangers, piping modifications may be needed to install the SWEP heat exchangers. See "Figure 4 - SWEP HEAT EXCHANGER - (STANDARD AND DOUBLE INSULATION) YCAL YCAL0066" on page and "Table 5 - ALFA LAVAL HEAT EXCHANGER AND RELATED COM- PONENTS" on page for Alfa Laval heat exchanger and related component part numbers. The TXV's are not included with the heat exchanger., 3, 4 JOHNSON CONTROLS 5

6 SECTION - SWEP HEAT EXCHANGER AND RELATED COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 6 8 Refrigerant # Out 7 Refrigerant # Out Refrigerant # In Refrigerant # In IN 5 OUT LD578 YCAL0046 SHOWN Figure - SWEP HEAT EXCHANGER - STANDARD INSULATION 6 JOHNSON CONTROLS

7 FORM RP (5) ISSUE DATE 5/8/0 SECTION - SWEP HEAT EXCHANGER AND RELATED COMPONENTS Table - SWEP HEAT EXCHANGER - DOUBLE INSULATION ITEM DESCRIPTION HEAT EXCHANGER PART STANDARD REMOTE NUMBER* MODELS QUANITY X X YCAL009 X X YCAL00 X N/A YCAL0043 N/A X YCAL0043, YCAL005 Heat Exchanger X N/A YCAL0046 N/A X YCAL0046, YCAL0056, 3, 4 X N/A YCAL005 X N/A YCAL0056 N/A X YCAL0066 X N/A YCAL Heater, 0 Volts, 00 Watts X N/A ALL, 3, 4 X X YCAL009, YCAL00, YCAL008,YCAL Cover Water Side YCAL0043, YCAL0046,, 3, 4 X X YCAL005,YCAL0056, YCAL Cover Refrigerant Side Cover Inside, (Double Insulation) Cover Outside (Double Insulation) X X YCAL009, YCAL00,YCAL008, YCAL0033 X N/A YCAL005, YCAL0056 X X YCAL0066 N/A X YCAL009 X X YCAL00,YCAL008, YCAL0033 X X YCAL0043, YCAL005 X X YCAL0046 X X YCAL0056 X X YCAL0066 X X YCAL009 X X YCAL00 X X YCAL008, YCAL0033 X X YCAL0043, YCAL005 X X YCAL0046, YCAL0056 X X YCAL0066 * Part numbers for heat exchangers include mounting bracket, wells and rails. On older YCAL's with Alfa Laval heat exchangers, piping modifications may be needed to install the SWEP heat exchangers. See "Figure 4 - SWEP HEAT EXCHANGER - (STANDARD AND DOUBLE INSULATION) YCAL YCAL0066" on page and "Table 5 - ALFA LAVAL HEAT EXCHANGER AND RELATED COMPONENTS" on page for Alfa Laval heat exchanger and related component part numbers. The TXV's are not included with the heat exchanger., 3, 4, 3, 4, 3, 4 JOHNSON CONTROLS 7

8 SECTION - SWEP HEAT EXCHANGER AND RELATED COMPONENTS FORM RP (5) ISSUE DATE 5/8/ Refrigerant # Out 7 Refrigerant # Out Refrigerant # In Refrigerant # In IN 5 OUT LD579 YCAL0046 SHOWN Figure - SWEP HEAT EXCHANGER - DOUBLE INSULATION 8 JOHNSON CONTROLS

9 FORM RP (5) ISSUE DATE 5/8/0 SECTION - SWEP HEAT EXCHANGER AND RELATED COMPONENTS Table 3 - SWEP HEAT EXCHANGER PARTS (STANDARD AND DOUBLE INSULATION) YCAL009 - YCAL0033 ITEM DESCRIPTION PART NUMBER MODELS QUANITY Bracket, Heat Exchanger YCAL YCAL00, YCAL008, YCAL HHCS, X.000 Gr 5 Emp YCAL009, YCAL00, YCAL008, YCAL Washer, Plain, 3/8 ID X 7/8 OD YCAL009, YCAL00, YCAL008, YCAL Lockwasher, Spg Hel, 3/8 Reg YCAL009, YCAL00, YCAL008, YCAL Nut, Hex, 3/8-6unc-b YCAL009, YCAL00, YCAL008, YCAL Bracket, Heat Exchanger YCAL009, YCAL00, YCAL008, YCAL Screw, Cap Hex, 5/6-8unc YCAL009, YCAL00, YCAL008, YCAL Well Thermo YCAL009, YCAL00, YCAL008, YCAL Washer, Plain, 7/6 ID X OD YCAL009, YCAL00, YCAL008, YCAL IN 4, 5, 9 3 OUT 5, 6, 7 WATER SIDE Refrigerant # Out Refrigerant # Out 3 3, 4, 5, 6 Refrigerant # In 4, 5, 6, 7 YCAL009 SHOWN REFRIGERANT SIDE Refrigerant # In LD5730 Figure 3 - SWEP HEAT EXCHANGER - (STANDARD AND DOUBLE INSULATION) YCAL009 - YCAL0033 JOHNSON CONTROLS 9

10 SECTION - SWEP HEAT EXCHANGER AND RELATED COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 Table 4 - SWEP HEAT EXCHANGER AND TXV PARTS (STANDARD AND DOUBLE INSULATION) YCAL YCAL0066 ITEM DESCRIPTION PART NUMBER MODELS QUANITY Bracket, Heat Exchanger YCAL0043, YCAL005, YCAL0046, YCAL0056, YCAL YCAL0043, YCAL005 3 Rail, Heat Exchanger YCAL0046, YCAL YCAL HHCS, X.000 Gr 5 Emp YCAL0043, YCAL005, YCAL0046, YCAL0056, YCAL Washer, Plain, 3/8 ID X 7/8 OD X YCAL0043, YCAL005, YCAL0046, YCAL0056, YCAL Lockwasher, Spg Hel, 3/8 Reg YCAL0043, YCAL005, YCAL0046, YCAL0056, YCAL Nut, Hex, 3/8-6unc-b YCAL0043, YCAL005, YCAL0046, YCAL0056, YCAL YCAL0046 Rod, Tie, Continuous Thread, 3/ YCAL0043, YCAL005, YCAL0056 Rod, Tie, Continuous Thread, YCAL0066 3/8-6unc-a Valve, TXV, Tgel YCAL0043, YCAL Valve, TXV, Tgel YCAL005 Valve, TXV, Tgel YCAL0056 Valve, TXV, Tgel YCAL Pipe, Liquid YCAL0043, YCAL0046, YCAL005, YCAL0056, YCAL0066 Tee, Sld C X C X C 5/8 X YCAL0043, YCAL0046, YCAL005, YCAL0056, YCAL0066 Valve, Charging, Brass YCAL0043, YCAL0046, YCAL005, YCAL0056, YCAL Washer, Plain, 7/6 ID X OD X YCAL009, YCAL00, YCAL008, YCAL Red Sld Ftg X C -/8 X YCAL0043, YCAL0046, YCAL005, YCAL0056, YCAL Well Thermo YCAL0043, YCAL0046, YCAL0056, YCAL005, YCAL0066 Valve, TXV, Tgel YCAL0043, YCAL Valve, TXV, Tgel YCAL005 Valve, TXV, Tgel YCAL0056, YCAL Washer, Plain, 7/6 ID X OD X YCAL0043, YCAL0046, YCAL0056, YCAL005, YCAL JOHNSON CONTROLS

11 FORM RP (5) ISSUE DATE 5/8/0 SECTION - SWEP HEAT EXCHANGER AND RELATED COMPONENTS 9 IN 9 OUT 4 6, 7 8 6, 7 Refrigerant # Out Refrigerant # Out Refrigerant # In 0,, 3, 4 0 Refrigerant # In 9, 0,,, , 7 WATER SIDE 4, 5, 6, 7 REFRIGERANT SIDE LD573 YCAL0043 SHOWN Figure 4 - SWEP HEAT EXCHANGER - (STANDARD AND DOUBLE INSULATION) YCAL YCAL0066 JOHNSON CONTROLS

12 SECTION - SWEP HEAT EXCHANGER AND RELATED COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 Table 5 - ALFA LAVAL HEAT EXCHANGER AND RELATED COMPONENTS ITEM QUANITY DESCRIPTION DWP UNIT MODEL YCAL UNIT MODEL YCAL Heat Exchanger, less Heater& Insulation ALL Insulation (3/4"x49"x65") ALL - Insulation ( /"x49"x65") Heater, Cooler 00 Watt ALL Valve, Thermal Expansion ALL Valve, Charging ALL Valve, Relief ALL Tube (Use w/ Item 6) ALL Valve, Access (Suction) ALL Well, Thermo ALL ITEM QUANITY DESCRIPTION DWP UNIT MODEL YCAL UNIT MODEL YCAL Heat Exchanger, less Heater & Insulation ALL Insulation (3/4"x49"x65") ALL - Insulation ( /"x49"x65") Heater, Cooler 00 Watt ALL Valve, Thermal Expansion ALL Valve, Charging ALL Valve, Relief ALL Tube (Use w/ Item 6) ALL Valve, Access (Suction) ALL Well, Thermo ALL ITEM QUANITY DESCRIPTION DWP UNIT MODEL YCAL Heat Exchanger, less Heater & Insulation ALL Insulation (3/4"x49"x65") ALL - Insulation ( /"x49"x65") Heater, Cooler 00 Watt ALL Valve, Thermal Expansion ALL Valve, Charging ALL Valve, Relief ALL Tube (Use w/ Item 6) ALL Valve, Access (Suction) ALL Well, Thermo ALL JOHNSON CONTROLS

13 FORM RP (5) ISSUE DATE 5/8/0 SECTION - SWEP HEAT EXCHANGER AND RELATED COMPONENTS TABLE 5 - ALFA LAVAL HEAT EXCHANGER AND RELATED COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION DWP UNIT MODEL YCAL UNIT MODEL YCAL Heat Exchanger, less Heater& Insulation ALL Insulation (3/4"x49"x65") ALL - Insulation ( /"x49"x65") Heater, Cooler 00 Watt ALL Sys Valve, Thermal Expansion Sys Valve, Charging ALL Valve, Relief ALL Tube (Use w/ Item 6) ALL Valve, Access (Suction) ALL Well, Thermo ALL ITEM QUANITY DESCRIPTION DWP UNIT MODEL YCAL UNIT MODEL YCAL Heat Exchanger, less Heater and Insulation ALL Insulation (3/4"x49"x65") ALL - Insulation ( /"x49"x65") Heater, Cooler 00 Watt ALL Sys Valve, Thermal Expansion Sys Valve, Charging ALL Valve, Relief ALL Tube (Use w/ Item 6) ALL Valve, Access (Suction) ALL Well, Thermo ALL JOHNSON CONTROLS 3

14 SECTION - SWEP HEAT EXCHANGER AND RELATED COMPONENTS FLOW SWITCHES: Standard 50 psig DWP cooler Optional 300 psig DWP cooler FORM RP (5) ISSUE DATE 5/8/0 Service Note: Pin Location 38 in Model Number will be X for 50 psig cooler. 3 for 300 psig cooler. 9 3" Victaulic Connection (WATER IN) Do not install insulation until refrigerant connections are made " Victaulic Connection (WATER OUT) 9 Refrigerant # Out 0 Refrigerant # Out Refrigerant # In Refrigerant # In B Figure 5 - ALFA LAVAL HEAT EXCHANGER COMPONENTS 4 JOHNSON CONTROLS

15 FORM RP (5) ISSUE DATE 5/8/0 SECTION - CONDENSER COIL COMPONENTS SECTION - CONDENSER COIL COMPONENTS Table 6 - CONDENSER COIL COMPONENTS ITEM DESCRIPTION QUANITY YCAL009 YCAL00 YCAL008 and YCAL0033 ALUMINUM FIN COILS Coil Module* COPPER COILS Coil Module* BLACK FIN COILS Coil Module* PHENOLIC COILS Coil Module* *Note: Coil Module includes coil and headers. Front End of Unit Back End of Unit *Note: Single Circuit Model Shown. Figure 6 - CONDENSER COIL LAYOUT JOHNSON CONTROLS 5

16 SECTION - CONDENSER COIL COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 Table 7 - CONDENSER COIL COMPONENTS ITEM DESCRIPTION QUANITY YCAL0043 and YCAL0046 YCAL005 and YCAL0056 YCAL0066 ALUMINUM FIN COILS Coil Module* COPPER COILS Coil Module* BLACK FIN COILS Coil Module* PHENOLIC COILS Coil Module* *Note: Coil Module includes coil and headers *Note: Dual Circuit Model Shown. 3 4 LD477b Figure 7 - CONDENSER COIL LAYOUT 6 JOHNSON CONTROLS

17 FORM RP (5) ISSUE DATE 5/8/0 SECTION 3 - FAN COMPONENTS SECTION 3 - FAN COMPONENTS Table 8 - FAN COMPONENTS - MODELS YCAL009 and YCAL00 FAN TYPE VOLTAGE ITEM DESCRIPTION CODE s Motor, Fan,.5 HP (YCAL009 & YCAL00) STANDARD 7/8", 075 RPM ULTRA LOW NOISE 7/8", 850 RPM s Blade All n/a 3 Guard All Orifice All Support, Fan All n/a 6 Support, Ring All Hub, Square All S = Recommended Spare Parts n/a 8 6 Service Note: Fan Hub to Shaft Joint should be sealed with protective coating - factory uses RUST VETO a solvent type, rust preventative coating. Service Note: Pin Location 5 in Model Number will be X for Standard Fan, or L for Ultra Low Noise Fan. See "UNIT NOMENCLATURE NAMEPLATE ENGINEERING DATA" on page Figure 8 - FAN COMPONENTS - MODELS YCAL009 and YCAL00 JOHNSON CONTROLS 7

18 SECTION 3 - FAN COMPONENTS Table 9 - FAN COMPONENTS - YCAL008, 0033, 0043, 0046, 005, 0056 & YCAL0066 ITEM DESCRIPTION s Motor, Fan, HP (008, 0033, 0043, 0046, 005, 0056 & 0066) VOLTAGE CODE STANDARD 7/8", 50 RPM FAN TYPE FORM RP (5) ISSUE DATE 5/8/0 ULTRA LOW NOISE 7/8", 850 RPM s Blade (008, 0033, 005, 0056 & 0066) All Blade (0043 & 0046) Guard (008, 0033, 005, 0056 & 0066) All Guard (0043 & 0046) Orifice (008, 0033, 005, 0056 & 0066) All Orifice (0043 & 0046) Support, Fan ( ) All Support, Fan (008 & 0033, 0043, 0046) All Support, Fan (005, 0056, 0066) 7, 8, 40, Support, Fan (005, 0056, 0066) 46 & Support, Ring All Spacer (.375 I.D.) All Screw, Cap (M8x5) All Spacer (.406 I.D.) All Hub, Square ( ) All Hub, Square (008, 0033, 005, 0056, 0066) 7, 8, 40, Hub, Square (008, 0033) 46 & Hub, Square (005, 0056, 0066) 46 & Hub, Square (0043 & 0046) All S = Recommended Spare Parts Service Note: Pin Location 5 in Model Number will be X for Standard Fan, or L for Ultra Low Noise Fan. See "UNIT NOMENCLATURE NAMEPLATE ENGINEERING DATA" on page Service Note: Fan Hub to Shaft Joint should be sealed with protective coating - factory uses RUST VETO a solvent type, rust preventative coating. Figure 9 - FAN COMPONENTS - YCAL008, 0033, 0043, 0046, 005, 0056 and YCAL JOHNSON CONTROLS

19 FORM RP (5) ISSUE DATE 5/8/0 SECTION 4 - REFRIGERANT PIPING COMPONENTS SECTION 4 - REFRIGERANT PIPING COMPONENTS Table 0 - REFRIGERANT PIPING COMPONENTS ITEM QUANITY DESCRIPTION SYSTEM CHILLER MODEL YCAL STYLE 'E' YCAL009 and YCAL00 YCAL008 YCAL0033 s Valve, Thermal Expansion Valve, Charging (Liquid Line) Valve, Solenoid (Liquid Line) s Valve, Stop (Liquid Line) Drier A Moisture Indicator Valve, Access (Suction) Valve, Relief (Suction) Tube w/ Nut (Use with Item 8) A Valve, Ball (Suction) Valve, Access (Discharge) A Valve, Ball (Discharge) Compressor See Tables and 3 4 Valve, Relief (Discharge) Inline Sight Glass S = Recommended Spare Part JOHNSON CONTROLS 9

20 SECTION 4 - REFRIGERANT PIPING COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 TABLE 0 REFRIGERANT PIPING COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION SYSTEM YCAL0043 YCAL0046 YCAL005 s Valve, Thermal Sys Expansion Sys Valve, Charging (Liquid Line) Both Valve, Solenoid (Liquid Line) Both s Valve, Stop (Liquid Line) Both Dehydrator Both A Moisture Indicator, Body Both B Moisture Indicator, Sight Glass Cap Both Valve, Access (Suction) Both Valve, Relief (Suction) Both Tube w/ Nut (Use with Item 8) Both A Sys Valve, Ball (Suction) 0B Sys Valve, Access (Discharge) Both A Sys Valve, Ball (Discharge) B Sys 3 4 Compressor Both See Tables and 3 4 Valve, Relief (Discharge) Both Inline Sight Glass Both S = Recommended Spare Part 0 JOHNSON CONTROLS

21 FORM RP (5) ISSUE DATE 5/8/0 SECTION 4 - REFRIGERANT PIPING COMPONENTS TABLE 0 REFRIGERANT PIPING COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION SYSTEM YCAL YCAL0066 s Sys Valve, Thermal Expansion Sys Valve, Charging (Liquid Line) Both Valve, Solenoid (Liquid Line) Both s Valve, Stop (Liquid Line) Both Dehydrator Both A Moisture Indicator, Body Both B Moisture Indicator, Sight Glass Cap Both Valve, Access (Suction) Both Valve, Relief (Suction) Both Tube w/ Nut (Use with Item 8) Both A Sys Valve, Ball (Suction) B Sys Valve, Access (Discharge) Both A Sys Valve, Ball (Discharge) B Sys 3 4 Compressor Both See Tables and 3 4 Valve, Relief (Discharge) Both Inline Sight Glass Both S = Recommended Spare Part 0 JOHNSON CONTROLS

22 SECTION 4 - REFRIGERANT PIPING COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 6A, 6B 5 SYSTEM , , 9 3 SUCTION & LIQUID PIPING SYSTEM 5 4 6A, 6B Figure 0 - REFRIGERANT PIPING COMPONENTS (SUCTION AND LIQUID) - MODEL YCAL0066 SHOWN JOHNSON CONTROLS

23 FORM RP (5) ISSUE DATE 5/8/0 SECTION 4 - REFRIGERANT PIPING COMPONENTS SYSTEM 0A 0B SYSTEM SUCTION PIPING Figure - REFRIGERANT PIPING COMPONENTS (SUCTION) - MODEL YCAL0066 SHOWN JOHNSON CONTROLS 3

24 SECTION 4 - REFRIGERANT PIPING COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 B SYSTEM DISCHARGE PIPING SYSTEM A Figure - REFRIGERANT PIPING COMPONENTS (DISCHARGE) - MODEL YCAL0066 SHOWN 4 JOHNSON CONTROLS

25 FORM RP (5) ISSUE DATE 5/8/0 SECTION 4 - REFRIGERANT PIPING COMPONENTS SYSTEM 5 OIL PIPING SYSTEM Figure 3 - REFRIGERANT PIPING COMPONENTS (OIL) - MODEL YCAL0066 SHOWN JOHNSON CONTROLS 5

26 SECTION 4 - REFRIGERANT PIPING COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 THIS PAGE INTENTIONALY LEFT BLANK 6 JOHNSON CONTROLS

27 FORM RP (5) ISSUE DATE 5/8/0 SECTION 5 - COMPRESSOR COMPONENTS SECTION 5 - COMPRESSOR COMPONENTS Table - RECOMMENDED OIL TYPE ITEM COOLANT DESCRIPTION (6) GALLON 5 GALLON OIL s OIL, COMPRESSOR R-40A (TYPE 'V') S = Recommended Spare Part Table - R-40A COMPRESSOR PART NUMBERS MODEL SYSTEM SYSTEM VOLTAGE # COMPRESSOR # COMPRESSOR CODE PART # MODEL # PART # MODEL # -7 & ZP03KCE ZP03KCE YCAL ZP03KCE ZP03KCE -46 & ZP03KCE ZP03KCE ZP03KCE ZP03KCE -7 & ZP0KCE ZP0KCE YCAL ZP0KCE ZP0KCE -46 & ZP0KCE ZP0KCE ZP0KCE ZP0KCE -7 & ZP8KCE ZP54KCE YCAL ZP8KCE ZP54KCE -46 & ZP8KCE ZP54KCE ZP8KCE ZP54KCE -7 & ZP8KCE* ZP8KCE* YCAL ZP8KCE* ZP8KCE* (New P/N)* -46 & ZP8KCE* ZP8KCE* ZP8KCE* ZP8KCE* YCAL0033 (Old P/N)* YCAL0043 YCAL & ZP80KCE* ZP80KCE* ZP80KCE* ZP80KCE* -46 & ZP80KCE* ZP80KCE* ZP80KCE* ZP80KCE* -7 & ZP0KCE ZP0KCE ZP0KCE ZP0KCE -46 & ZP0KCE ZP0KCE ZP0KCE ZP0KCE -7 & ZP37KCE ZP37KCE ZP37KCE ZP37KCE -46 & ZP37KCE ZP37KCE ZP37KCE ZP37KCE * Compressors are not interchangeable. The correct compressor must be used; substitutions are not possible. Select the proper compressor Part Number based on the compressor model on the unit. JOHNSON CONTROLS 7

28 SECTION 5 - COMPRESSOR COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 TABLE - R-40A COMPRESSOR PART NUMBERS (CONT'D) MODEL SYSTEM SYSTEM VOLTAGE #4 COMPRESSOR #5 COMPRESSOR CODE PART # MODEL # PART # MODEL # -7 & -8 n/a n/a n/a n/a YCAL n/a n/a n/a n/a -46 & -50 n/a n/a n/a n/a -58 n/a n/a n/a n/a -7 & -8 n/a n/a n/a n/a YCAL00-40 n/a n/a n/a n/a -46 & -50 n/a n/a n/a n/a -58 n/a n/a n/a n/a -7 & -8 n/a n/a n/a n/a YCAL n/a n/a n/a n/a -46 & -50 n/a n/a n/a n/a -58 n/a n/a n/a n/a -7 & -8 n/a n/a n/a n/a 4 YCAL n/a n/a n/a n/a -46 & -50 n/a n/a n/a n/a -58 n/a n/a n/a n/a -7 & ZP0KCE ZP0KCE YCAL ZP0KCE ZP0KCE -46 & ZP0KCE ZP0KCE ZP0KCE ZP0KCE -7 & ZP0KCE ZP0KCE YCAL ZP0KCE ZP0KCE -46 & ZP0KCE ZP0KCE ZP0KCE ZP0KCE MODEL YCAL005 YCAL0056 YCAL0066 SYSTEM SYSTEM VOLTAGE # COMPRESSOR # COMPRESSOR CODE PART # MODEL # PART # MODEL # -7 & ZP54KCE ZP54KCE ZP54KCE ZP54KCE -46 & ZP54KCE ZP54KCE ZP54KCE ZP54KCE -7 & ZP8KCE ZP8KCE ZP8KCE ZP8KCE -46 & ZP8KCE ZP8KCE ZP8KCE ZP8KCE -7 & ZP35KCE ZP35KCE ZP35KCE ZP35KCE -46 & ZP35KCE ZP35KCE ZP35KCE ZP35KCE 8 JOHNSON CONTROLS

29 FORM RP (5) ISSUE DATE 5/8/0 SECTION 5 - COMPRESSOR COMPONENTS TABLE - R-40A COMPRESSOR PART NUMBERS (CONT'D) MODEL SYSTEM SYSTEM VOLTAGE #4 COMPRESSOR #5 COMPRESSOR CODE PART # MODEL # PART # MODEL # -7 & ZP54KCE ZP54KCE YCAL ZP54KCE ZP54KCE -46 & ZP54KCE ZP54KCE ZP54KCE ZP54KCE -7 & ZP8KCE ZP8KCE YCAL ZP8KCE ZP8KCE -46 & ZP8KCE ZP8KCE ZP8KCE ZP8KCE -7 & ZP8KCE ZP8KCE 4 YCAL ZP8KCE ZP8KCE (New P/N)* -46 & ZP8KCE ZP8KCE ZP8KCE ZP8KCE YCAL0066 (Old P/N)* -7 & ZP80KCE ZP80KCE ZP80KCE ZP80KCE -46 & ZP80KCE ZP80KCE ZP80KCE ZP80KCE * Compressors are not interchangeable. The correct compressor must be used; substitutions are not possible. Select the proper compressor Part Number based on the compressor model on the unit. Table 3 - COMPRESSOR HEATER AND COMPRESSOR SOUND BLANKET PART NUMBERS COMPRESSOR PART NUMBER HEATER PART NUMBER QUANTITY PER COMPRESSOR SOUND BLANKET PART NUMBER QUANTITY PER COMPRESSOR xxx xxx xxx xxx xxx xxx xxx JOHNSON CONTROLS 9

30 SECTION 5 - COMPRESSOR COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 COMPRESSOR #4 COMPRESSOR # SYSTEM # SYSTEM # COMPRESSOR # COMPRESSOR #5 HEATER A Figure 4 - COMPRESSOR - TYPICAL LAYOUT 30 JOHNSON CONTROLS

31 FORM RP (5) ISSUE DATE 5/8/0 SECTION 6 - control panel and power Panel configurations SECTION 6 - control panel and power Panel configurations Power panels and option panels are offered in several different configurations using three (3) major components:. Terminal Blocks. Circuit Breakers 3. Non-Fused Disconnect Switches The most basic chiller power wiring configuration uses Terminal Blocks in the power panels, and an options panel with no power wire termination hardware. The model pin number locations 6 and 7 would be as shown in the table below to reflect this basic combination. Identify model pin number locations 6 and 7 to identify the chiller power wiring connections and hardware listed below. See "UNIT NOMENCLATURE NAMEPLATE ENGINEER- ING DATA" on page 4. Table 4 - OPTION PANEL AND POWER PANEL CONFIGURATIONS PIN 6 & 7 LETTER CODE CONFIGURATIONS IDENTIFIERS S X Single Point Supply Terminal Block S D Single Point Supply Non-Fused Disconnect Switch B X Single Point Supply Circuit Breaker NAMEPLATE aa Figure 5 - CONTROL AND POWER PANEL IDENTIFIER LOCATION JOHNSON CONTROLS 3

32 SECTION 6 - control panel and power Panel configurations FORM RP (5) ISSUE DATE 5/8/0 THIS PAGE INTENTIONALY LEFT BLANK 3 JOHNSON CONTROLS

33 FORM RP (5) ISSUE DATE 5/8/0 SECTION 7 - control panel and power Panel COMPONENTS SECTION 7 - control panel and power Panel COMPONENTS To identify replacement part numbers, select Panel Identifier Number from the table below or from the panel nameplate shown on Figure 5 on page 3, then refer to the Control and Power Panel Components information (Table 6 on page 34; see also Figure 6 on page 49 and Figure 7 on page 50). Table 5 - CONTROL PANEL AND POWER PANEL IDENTIFIERS MODEL YCAL009 YCAL00 YCAL008 YCAL0033 YCAL0043 YCAL0046 YCAL005 YCAL0056 YCAL0066 VOLTAGE CODE SINGLE POINT TERMINAL BLOCK (SX) SINGLE POINT NON-FUSED DISCONNECT SWITCH (SD) SINGLE POINT CIRCUIT BREAKER (BX) 7 & & & & & & & & & & & & & & & & & & , 8 & , 50 & , 8 & , 50 & & & & JOHNSON CONTROLS 33

34 SECTION 7 - control panel and power Panel COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 Table 6 - CONTROL AND POWER PANEL COMPONENTS ITEM QUANITY DESCRIPTION YCAL009-7 & YCAL009-8 YCAL00-7 & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. 34 JOHNSON CONTROLS

35 FORM RP (5) ISSUE DATE 5/8/0 SECTION 7 - control panel and power Panel COMPONENTS TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL & YCAL YCAL00-40 & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. JOHNSON CONTROLS 35

36 SECTION 7 - control panel and power Panel COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL & YCAL YCAL00-50 & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. 36 JOHNSON CONTROLS

37 FORM RP (5) ISSUE DATE 5/8/0 SECTION 7 - control panel and power Panel COMPONENTS TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL008-7 & YCAL008-8 YCAL & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. JOHNSON CONTROLS 37

38 SECTION 7 - control panel and power Panel COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL & YCAL YCAL & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. 38 JOHNSON CONTROLS

39 FORM RP (5) ISSUE DATE 5/8/0 SECTION 7 - control panel and power Panel COMPONENTS TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL & YCAL YCAL & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. JOHNSON CONTROLS 39

40 SECTION 7 - control panel and power Panel COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL & YCAL0043-8YCAL & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. 40 JOHNSON CONTROLS

41 FORM RP (5) ISSUE DATE 5/8/0 SECTION 7 - control panel and power Panel COMPONENTS TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL & YCAL YCAL & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. JOHNSON CONTROLS 4

42 SECTION 7 - control panel and power Panel COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL & YCAL YCAL & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. 4 JOHNSON CONTROLS

43 FORM RP (5) ISSUE DATE 5/8/0 SECTION 7 - control panel and power Panel COMPONENTS TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL005-7, YCAL005-8 & YCAL005-40YCAL0056-7, YCAL & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. JOHNSON CONTROLS 43

44 SECTION 7 - control panel and power Panel COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL005-46YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. 44 JOHNSON CONTROLS

45 FORM RP (5) ISSUE DATE 5/8/0 SECTION 7 - control panel and power Panel COMPONENTS TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL & YCAL005-58YCAL & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. JOHNSON CONTROLS 45

46 SECTION 7 - control panel and power Panel COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. 46 JOHNSON CONTROLS

47 FORM RP (5) ISSUE DATE 5/8/0 SECTION 7 - control panel and power Panel COMPONENTS TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. JOHNSON CONTROLS 47

48 SECTION 7 - control panel and power Panel COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 TABLE 6 - CONTROL AND POWER PANEL COMPONENTS (CONT'D) ITEM QUANITY DESCRIPTION YCAL & YCAL SX** SD** BX** Control Transformer Single Point Terminal Block N/A N/A A Single Point Circuit Breaker N/A N/A Single Point NF Disconnect Switch N/A N/A B Lugs N/A C Ground Lug A Control Board, IPU * * * 3B Flash Card A 4 Compressor Contactor B 4 Surge Suppressor D 4 Auxiliary Contact N/A N/A N/A 5 Control Relay A Surge Suppressor B Display D Switch F Ribbon Cable C 4 Fan Contactor D 4 Surge Suppressor E Fuse Block F 6 Fuse Ground Bar Fuse Block A Fuse SX** SD** BX** SINGLE POINT TERMINAL BLOCK SINGLE POINT NON-FUSED DISCONNECT SWITCH SINGLE POINT CIRCUIT BREAKER Service Note: Locate the PANEL NUMBER sticker on the upper right hand corner of the power panel, then refer to the appropriate parts list for that number. Or, identify PIN number positions 6 and 7 on unit identification plate (See example on Page 4) then compare to table directly above for power configuration options. *Note: Replacement Control Board (Item 3A) should be ordered as kit # (Kit contains assembled I/O Board and Control Board, as well as a Flash Card. The dual system Control Board can be used in both single and dual system YCAL units. 48 JOHNSON CONTROLS

49 FORM RP (5) ISSUE DATE 5/8/0 SECTION 7 - control panel and power Panel COMPONENTS A B C 4A 4D 7C 7D 7E 7F 4B A 5 5A 0 3A MICROPROCESSOR & I/O BOARD CONTROL BOARD IPU sht 3B Figure 6 - CONTROL AND POWER PANEL COMPONENTS (CONTROL BOARD) JOHNSON CONTROLS 49

50 SECTION 7 - control panel and power Panel COMPONENTS FORM RP (5) ISSUE DATE 5/8/0 6B 6D 6B 6F D Figure 7 - CONTROL AND POWER PANEL COMPONENTS (FRONT AND REAR VIEW) 50 JOHNSON CONTROLS

51 FORM RP (5) ISSUE DATE 5/8/0 SECTION 8 - WIRING HARNESSES Table 7 - CONTROL WIRING HARNESSES SECTION 8 - WIRING HARNESSES ITEM DESCRIPTION SYSTEM YCAL PART NUMBER HARNESS, LIQUID LINE SOLENOID VALVE # N/A N/A HARNESS, LIQUID LINE SOLENOID VALVE # HARNESS, HIGH PRESSURE CUT OUT* # ALL HARNESS, HIGH PRESSURE CUT OUT* # ALL * Service Note: High Pressure Cut-Out Harness includes High Pressure Cut-Out Switch SYS. # HPCO SYS. # HPCO LLSV LLSV CONTROL WIRING a Figure 8 - CONTROL WIRING HARNESSES JOHNSON CONTROLS 5

52 SECTION 8 - WIRING HARNESSES FORM RP (5) ISSUE DATE 5/8/0 Table 8 - SENSOR HARNESS WIRING PLUG DETAIL PLUG AND PINP/N Plug = Pin = Plug = Pin = PLUG "P" NUMBER P4 P7 PLUG PIN NUMBER WIRE COLOR 5 Red 0 White Black Drain 7 Red White 8 Black 9 Drain 5 Red 0 White Black Drain 7 Red White 8 Black 9 Drain CABLE NUMBER SSP SDP SSP SDP FUNCTION System # Suction Pressure System # Discharge Pressure System # Suction Pressure System # Discharge Pressure HARNESS ASSEMBLY PART NUMBER OAT SSP SSP SYS. # SYS. # SDP EWT LWT SDP Figure 9 - SENSOR WIRING HARNESSES 5 JOHNSON CONTROLS

53 FORM RP (5) ISSUE DATE 5/8/0 SECTION 8 - WIRING HARNESSES Table 9 - TEMPERATURE SENSORS AND TRANSDUCERS ITEM QUANITY DESCRIPTION MODELS PART NUMBER s * Sensor, Outside Air Temperature * (Cable Included) * Not Shown s * Sensor, Entering Water Temp * (Cable Included) * 3 s * Sensor, Leaving Water Temp * (Cable Included) * Compound, Heat Conductive** All s Transducer, Suction Pressure (0-400psi) All s Transducer, Discharge Pressure (0-650psi) All s Switch, High Pressure Cut-Out All Not Shown s Recommended Spare Part * Note: Sensor only = ** Note: Used with items and 3. 5, SYS. # SYS. # 6 3, A Figure 0 - TEMPERATURE SENSORS AND TRANSDUCERS JOHNSON CONTROLS 53

54 SECTION 8 - WIRING HARNESSES FORM RP (5) ISSUE DATE 5/8/0 Table 0 - TRANSDUCER AND THERMISTOR WIRE HARNESS CONNECTORS - FIELD REPLACEMENT PARTS ITEM LOCATION DESCRIPTION PINS PART NUMBER Transducer Plug Connector 3 Pin End C HARNESS BLK = PIN A (GND) RED = PIN B (SUPPLY) WHT = PIN C (OUTPUT) TRANSDUCER (3 PIN) A B WHT BLK RED A C B LD573 Figure - TRANSDUCER AND THERMISTOR WIRE HARNESS CONNECTORS - FIELD REPLACEMENT PART NUMBERS 54 JOHNSON CONTROLS

55 FORM RP (5) ISSUE DATE 5/8/0 SECTION 9 - ENCLOSURES SECTION 9 - ENCLOSURES Table - WIRE KIT OPTIONS MODEL NUMBER YCAL009 YCAL00 YCAL008 YCAL0033 Refer to Tables And 3 WIRE ENCLOSURE (FACTORY INSTALLED) LOUVERED ENCLOSURE (FIELD INSTALLED) Table - WIRE ENCLOSURE PARTS YCAL009 and YCAL00 YCAL008 and YCAL0033 ITEM DESCRIPTION QUANITY QUANITY WIRE PANEL, SIDES WIRE PANEL, REAR Figure - WIRE ENCLOSURE PARTS JOHNSON CONTROLS 55

56 SECTION 9 - ENCLOSURES FORM RP (5) ISSUE DATE 5/8/0 Table 3 - LOUVERED ENCLOSURE PARTS YCAL009 AND YCAL00 YCAL008 AND YCAL0033 ITEM DESCRIPTION QUANITY QUANITY LOUVERED PANEL LOUVERED PANEL Figure 3 - LOUVERED ENCLOSURE PARTS 56 JOHNSON CONTROLS

57 FORM RP (5) ISSUE DATE 5/8/0 SECTION 9 - ENCLOSURES Table 4 - ENCLOSURE KIT OPTIONS MODEL NUMBER WIRE ENCLOSURE (FACTORY INSTALLED) LOUVERED ENCLOSURE (FIELD INSTALLED) YCAL0043 YCAL YCAL005 YCAL YCAL Refer to Tables 5 and 6 Table 5 - WIRE ENCLOSURE PARTS ITEM DESCRIPTION YCAL0043 AND YCAL0046 YCAL005 AND YCAL QUANITY QUANITY WIRE PANEL, SIDES WIRE PANEL, REAR ITEM DESCRIPTION YCAL QUANITY WIRE PANEL, SIDES WIRE PANEL, REAR Figure 4 - WIRE ENCLOSURE PARTS JOHNSON CONTROLS 57

58 SECTION 9 - ENCLOSURES FORM RP (5) ISSUE DATE 5/8/0 Table 6 - LOUVERED ENCLOSURE PARTS ITEM DESCRIPTION YCAL0043 and YCAL0046 YCAL005 and YCAL QUANITY QUANITY LOUVERED PANEL LOUVERED PANEL LOUVERED PANEL ITEM DESCRIPTION YCAL QUANITY LOUVERED PANEL LOUVERED PANEL LOUVERED PANEL Figure 5 - LOUVERED ENCLOSURE PARTS 58 JOHNSON CONTROLS