MODELS YCRL0064, 0074, 0084, 0096, 0118, 0126, 0156, 0177, 0198, 0200, 0230, 0260, 0300, 0345, 0385, 0445, 0530 and YCRL0610 STYLE "A"

Transcription

1 WATER-COOLED LIQUID CHILLERS HERMETIC SCROLL RENEWAL PARTS Supercedes: RP1 (709) Form: RP1 (810) MODELS YCRL0064, 0074, 0084, 0096, 0118, 016, 0156, 0177, 0198, 000, 030, 060, 0300, 0345, 0385, 0445, 0530 and YCRL0610 STYLE "A" YCRL 01 R-410A 50Hz & 60Hz Products are produced at a f a c i l i t y wh o s e qualitymanagement systems are ISO9001 certified /3/ MODELS ONLY

2 FORM RP1 (810) 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 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. SUPERCESSION DATE ITEM AFFECTED PAGE 709 Added models 0177 & 0198 All 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 RP1 (810) TABLE OF CONTENTS PAGE Unit nomenclature nameplate engineering data EVAPORATOR COMPONENTS...6 REFRIGERANT PIPING COMPONENTS COMPRESSOR CONTROL PANEL AND POWER panel CONFIGURATIONS...0 CONTROL PANEL AND POWER PANEL COMPONENTS SENSOR WIRING HARNESSES...44 temperature sensors AND Transducers...48 TRANSDUCER AND THERMISTOR wire harness connectors VIBRATOR ISOLATORs...5 YCRL CHILLER OPTIONS...53 Recommended spare parts...54 JOHNSON CONTROLS 3

4 FORM RP1 (810) UNIT NOMENCLATURE NAMEPLATE ENGINEERING DATA Basic Part Number YCRL0118SE40XAA Base product type nominal capacity unit designator refrigerant voltage/starter design/development level y : YORK # # # # Tons S Standard E :R-410A 1 7 :00/3/60 A c : Chiller 0064,0074 H High Efficiency 8 :30/3/60 B R : Water Cooled 0084, L : Scroll 0118, , , , , , ,0610 X T :380/3/60 :460/3/60 : /3/50 :575/3/60 :Across the Line Start :Soft Start :Design Series A :Development Level B PART NUER letter codes POWER FIELD CONTROLS FIELD COMPRESSOR / PIPING FIELD X X : SP TB X : # # B X : SP CB X : BAS/EMS Temp. Reset / Offset T S S D : SP NF Disc. Sw. X : English Language Kit (Standard) G M B : MP TB w/ Sep. Sys. CB F : French LCD & Keypad Display G I : German LCD & Keypad Display : Italian LCD & Keypad Display R S S : Spanish Language Kit X X : Discharge & Suction Press. Transducers C : European Safety Code (CE) E T : Control Transformer (Factory) L : N. American Safety Code (cu.l./cetl) X : No Sequence Kit 1 MP = Multiple Point SP = NF = Non-Fused TB = Terminal Block Ser. = Service Ind. Sys. Brkr. & L. Ext. Handles = Individual System Breaker & Lockable External Handle : Leaving Supply Temp. : Thermal Storage : Both Suction Isolation & Dual Relief Valves : Dual Relief Valves : Service Isolation Valve : Liquid Line Solenoid Valve : Electronic Expansion Valve : Hot Gas By-Pass (1 circuit) EVAP. FIELD CONDENSER FIELD CABINET FIELD E : Comp. Ext. Overloads D E F : Diff. Press. Sw. : Diff. Press. Sw. : 3 Diff. Press. Sw. X X :150# PSI DWP S T : Flow Sw. : Flow Sw. D :Double Thick Insulation U : 3 Flow Sw. B V :Victaulic Flange A : ASME Pressure Vessel 57 E : CE Pressure Vessel SHIPPING INSTRUCTIONS A C B 61 PLANT OF MANUFACTURE R : Buy American Act Compliance : Container Shipping Kit : Buy American Act Compliance & Container Shipping Kit : Monterrey : Copper Tubes : Compressor Sound Enclosure : Form 1 Ship (Full Charge) : Form Ship (Holding Charge) : Final Overspray Paint : 1" Deflection : Seismic : Neoprene Pads NOTES: 1. 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 14 characters only. 5. Plant of manufacture to include PIN 61 upon entering the chiller order. X S 1 S N 4 JOHNSON CONTROLS

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6 Evaporator FORM RP1 (810) EVAPORATOR COMPONENTS Service Note: Pin location 38 in Model Number will be "X" for 150# DWP Cooler. Pin location 38 in Model Number will be "3" for 300# DWP Cooler LIQUID OUT LIQUID IN 3 1/4" PURGE /4" DRAIN Service Note: Standard 150# DWP Cooler Flow Switch Optional 300# DWP Cooler Flow Switch Differential Pressure Switch FIG. 1 evaporator COMPONENTS (ref. table 1, page 7) 6 JOHNSON CONTROLS

7 FORM RP1 (810) EVAPORATOR COMPONENTS (CONT'D) 1 table 1 evaporator COMPONENTS - PIN #9 = 'H' (see fig. 1, page 6) ITEM # QTY PER UNIT 1 1 DESCRIPTION Evaporator, Fully Insulated with Heater Evaporator, less Heater & Insulation UNIT MODELS YCRL0064 AND YCRL000 UNIT MODELS YCRL0074, 0084, 0118, 030 AND YCRL0345 UNIT MODELS YCRL0096 AND YCRL Head, Connection End Head, Back End Baffle, Connection End Baffle, Back End Gasket, Baffle and Head Insulation (3/4"x49"x65") Insulation (1 1/"x49"x65") qt. Adhesive (Use with #6) Sensor, Water Temp (EWT) Sensor, Water Temp (LWT) Well, Thermo table 1 (CONT'D) evaporator COMPONENTS - PIN #9 = 'H' (see fig. 1, page 6) ITEM # QTY PER UNIT 1 1 DESCRIPTION Evaporator, Fully Insulated with Heater Evaporator, less Heater & Insulation UNIT MODELS YCRL016, 0156, 0177, 0198, 0445, 0530 AND YCRL0610 UNIT MODELS YCRL060 AND YCRL Head, Connection End Head, Back End Baffle, Connection End Baffle, Back End Gasket, Baffle and Head Insulation (3/4"x49"x65") Insulation (1 1/"x49"x65") qt. Adhesive (Use with #6) Sensor, Water Temp (EWT) Sensor, Water Temp (LWT) Well, Thermo JOHNSON CONTROLS 7

8 Refrigerant Piping FORM RP1 (810) REFRIGERANT PIPING COMPONENTS CHILLER MODEL YCRL 14 RELIEF VALVE SYSTEM 1 SYSTEM 8 7A DISCHARGE 7B FIG. A DISCHARGE PIPING COMPONENTS - 4 COMPRESSOR model shown (REF. TABLE, pages 13 THRU 15) 8 JOHNSON CONTROLS

9 FORM RP1 (810) REFRIGERANT PIPING COMPONENTS (CONT'D) CHILLER MODEL YCRL SUCTION A FIG. B SUCTION PIPING COMPONENTS - 4 COMPRESSOR model shown (REF. TABLE, pages 13 THRU 15) JOHNSON CONTROLS 9

10 Refrigerant Piping FORM RP1 (810) REFRIGERANT PIPING COMPONENTS (CONT'D) CHILLER MODEL YCRL 8 SUCTION B FIG. C SUCTION PIPING COMPONENTS - 4 COMPRESSOR model shown (REF. TABLE, pages 13 THRU 15) 10 JOHNSON CONTROLS

11 FORM RP1 (810) REFRIGERANT PIPING COMPONENTS (CONT'D) CHILLER MODEL YCRL LIQUID SYSTEM # A FIG. D LIQUID PIPING COMPONENTS - 4 COMPRESSOR model shown (REF. TABLE, pages 13 THRU 15) JOHNSON CONTROLS 11

12 Refrigerant Piping FORM RP1 (810) REFRIGERANT PIPING COMPONENTS (CONT'D) CHILLER MODEL YCRL LIQUID SYSTEM # B FIG. E LIQUID PIPING COMPONENTS - 4 COMPRESSOR model shown (REF. TABLE, pages 13 THRU 15) 1 JOHNSON CONTROLS

13 FORM RP1 (810) REFRIGERANT PIPING COMPONENTS (CONT'D) CHILLER MODEL YCRL TABLE REFRIGERANT PIPINg components - PIN #9 = 'H' (see figs. A, B, C, D AND E, pages 8 THRU 1) ITEM NO. QTY. SYS. DESCRIPTION YCRL xxx YCRL xxx YCRL xxx YCRL xxx YCRL xxx YCRL xxx 1 s 1 1 Valve, Thermal Expansion Both Dehydrator, Body (Replacable Core) s 4 Both Core, Dehydrator Valve, Liquid Line 1 Solenoid Moisture Indicator A 1 1 Ball Valve, Discharge B Both Valve, Transducer Both Compressor See Pages 17 and Both Valve, Charging Valve, Liquid Line Service Both 13 Valve, Suction Relief (400 PSIG) Ball Valve, Suction Both Valve, Discharge Relief (560 PSIG) S = Recommended Spare Parts JOHNSON CONTROLS 13

14 Refrigerant Piping FORM RP1 (810) REFRIGERANT PIPING COMPONENTS (CONT'D) CHILLER MODEL YCRL TABLE (CONT'D) REFRIGERANT PIPINg components - PIN #9 = 'S or H' (see figs. A, B, C, D AND E, pages 8 THRU 1) ITEM NO. QTY. SYS. DESCRIPTION YCRL xxx YCRL xxx YCRL xxx YCRL xxx YCRL xxx YCRL xxx 1 s 1 1 Valve, Thermal Expansion Both Dehydrator, Body (Replacable Core) s 4 Both Core, Dehydrator Valve, Liquid Line Solenoid Moisture Indicator Ball Valve, Discharge Both Valve, Transducer Both Compressor See Pages 17 and Both Valve, Charging Valve, Liquid Line Service Both 13 Valve, Relief (400 PSIG) Ball Valve, Suction Both Valve, Discharge Relief (560 PSIG) S = Recommended Spare Parts 14 JOHNSON CONTROLS

15 FORM RP1 (810) REFRIGERANT PIPING COMPONENTS (CONT'D) CHILLER MODEL YCRL TABLE (CONT'D) REFRIGERANT PIPINg components - PIN #9 = 'H' (see figs. A, B, C, D AND E, pages 8 THRU 1) ITEM NO. QTY. SYS. DESCRIPTION YCRL xxx YCRL xxx YCRL xxx YCRL xxx YCRL xxx YCRL xxx 1 s 1 1 Valve, Thermal Expansion Dehydrator, Body (Replacable Core) s 4 Both Core, Dehydrator Valve, Liquid Line Solenoid Moisture Indicator Ball Valve, Discharge Both Valve, Transducer Both Compressor See Pages 17 and Both Valve, Charging Valve, Liquid Line Service Both Both Valve, Relief (400 PSIG) Ball Valve, Suction Valve, Discharge Relief (560 PSIG) S = Recommended Spare Parts JOHNSON CONTROLS 15

16 Compressor FORM RP1 (810) COMPRESSOR Note: System 1 Compressor #3 and System Compressor #6 are omitted on the 4 compressor units. SYSTEM #1 SYSTEM # 4 COMPRESSOR UNIT SYSTEM #1 SYSTEM # COMPRESSOR UNIT Note: System 1 Compressor #3 is omitted on the 5 compressor units. FIG. 3 COMPRESSOR PART NUERS (REF. TABLE 3, pages 17 AND 18) 16 JOHNSON CONTROLS

17 FORM RP1 (810) COMPRESSOR (CONT'D) TABLE 3 compressor part numbers (SEE FIG. 3, PAGE 16) CHILLER MODEL YCRL0064 YCRL0074 YCRL0084 YCRL0096 YCRL0118 YCRL016 YCRL0156 YCRL0177 YCRL0198 VOLTAGE SYSTEM 1 SYSTEM COMP. COMPRESSOR COMPRESSOR COMPRESSOR COMP. COMPRESSOR COMPRESSOR COMPRESSOR CODE MODEL # #1 # #3 MODEL # #4 #5 #6-17 & N/A N/A N/A N/A ZP180KCE ZP180KCE N/A N/A N/A N/A -17 & N/A N/A N/A N/A ZP35KCE ZP180KCE N/A N/A N/A N/A -17 & N/A N/A N/A N/A ZP35KCE ZP35KCE N/A N/A N/A N/A -17 & ZP180KCE ZP180KCE & N/A N/A N/A N/A ZP385KCE ZP85KCE N/A N/A N/A N/A -17 & ZP35KCE ZP35KCE & ZP85KCE ZP85KCE & N/A -40 BITZER BITZER N/A N/A N/A -17 & BITZER BITZER JOHNSON CONTROLS 17

18 Compressor FORM RP1 (810) COMPRESSOR (CONT'D) TABLE 3 (CONT'D) compressor part numbers (SEE FIG. 3, PAGE 16) CHILLER MODEL VOLTAGE CODE COMP. MODEL # SYSTEM 1 SYSTEM COMPRESSOR COMPRESSOR COMPRESSOR COMP. COMPRESSOR COMPRESSOR #1 # #3 MODEL # #4 #5 COMPRESSOR YCRL ZP180KCE N/A ZP180KCE N/A YCRL ZP35KCE N/A ZP180KCE N/A YCRL ZP35KCE N/A ZP35KCE N/A YCRL ZP85KCE N/A ZP85KCE N/A YCRL ZP385KCE N/A ZP85KCE N/A YCRL ZP35KCE ZP35KCE YCRL ZP85KCE ZP85KCE YCRL ZP385KCE ZP85KCE YCRL ZP385KCE ZP385KCE #6 TABLE 3A compressor HEATER AND COMPRESSOR SOUND BLANKET part numbers COMPRESSOR PART NUER HEATER PART NUER QUANTITY PER COMPRESSOR SOUND BLANKET PART NUER QUANTITY PER COMPRESSOR xxx xxx xxx xxx xxx TABLE 3B recommended oil type ITEM REF. DESCRIPTION 1 QUART CAN (6) 1 GALLON 5 GALLON OIL s R-410A Oil, Copeland Compressor (Type 'V') Oil, Bitzer Compressor (Type 'YORK PVE')* n/a n/a S = Recommended Spare Parts *Note: Type 'YORK PVE' synthetic oil used on models YCRL0177 and YCRL0198 only. 18 JOHNSON CONTROLS

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20 Control and Power Panels FORM RP1 (810) CONTROL PANEL AND POWER PANEL CONFIGURATIONS Power panels and option panels are offered in several different configurations using three (3) major components: 1. 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. See figures on previous page. The model pin number locations 16 and 17 would be X and X to reflect this basic combination. Identify model pin number locations 16 and 17 to identify the chiller power wiring connections and hardware listed below. PIN 16 & 17 LETTER CODE OPTION PANEL AND POWER PANEL CONFIGURATIONS IDENTIFIERS X X Supply Terminal Block B X Supply Circuit Breaker S D Supply Non-Fused Disconnect Switch M B Multi Point Terminal Block with Separate System Circuit Breakers MODEL 60Hz required TRANSFORMER CONTROL POWER VOLTAGE TRANSFORMER KIT CODE PART NUER KVA N/A* * Note: The Control Transformer is standard on all 50 Hz CE models. 0 JOHNSON CONTROLS

21 FORM RP1 (810) CONTROL PANEL AND POWER PANEL COMPONENTS X 1JR-X TESTED BY-X Panel Identifier Label 4 I / O IPU CTB1 YORK CTB CONTROL PANEL FIG. 4 CONTROL AND POWER PANEL IDENTIFIER LOCATION JOHNSON CONTROLS 1

22 Control and Power Panels FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 4 CONTROL PANEL AND POWER PANEL IDENTIFIERS (TO IDENTIFY REPLACEMENT PART NUERS, SELECT PANEL IDENTIFIER NUER FROM THE TABLES BELOW OR FROM THE PANEL IDENTIFIER LABEL SHOWN ON PAGE 1, THEN REFER TO THE 'CONTROL AND POWER PANEL COMPONENTS' TABLES, PAGES 7-4 AND FIGS. 5A, 5B, 5C & 5D ON PAGES 4, 5, 6 & 39). Model YCRL0064 YCRL0074 YCRL0084 YCRL0096 YCRL0118 YCRL016 YCRL0156 Voltage Code Terminal Block () Circuit Breaker () Multi Point Terminal Block w/ Sep. Sys. Circuit Breakers () 17 & & & & & & 8 N/A & 8 N/A JOHNSON CONTROLS

23 FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 4 CONTROL PANEL AND POWER PANEL IDENTIFIERS (TO IDENTIFY REPLACEMENT PART NUERS, SELECT PANEL IDENTIFIER NUER FROM THE TABLES BELOW OR FROM THE PANEL IDENTIFIER LABEL SHOWN ON PAGE 1, THEN REFER TO THE 'CONTROL AND POWER PANEL COMPONENTS' TABLES, PAGES 7-4 AND FIGS. 5A, 5B, 5C & 5D ON PAGES 4, 5, 6 & 39) Model YCRL0177 YCRL0198 Voltage Code Terminal Block () Circuit Breaker () Multi Point Terminal Block w/ Sep. Sys. Circuit Breakers () 17 & 8 N/A N/A & 8 N/A N/A Model Voltage Code Efficiency (PIN 9 = H) Across the Line Start Non-Fused Disconnect (SD) Soft Start YCRL H YCRL H YCRL H YCRL H YCRL H YCRL H YCRL H YCRL H YCRL H JOHNSON CONTROLS 3

24 Control and Power Panels FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) 3E 3F 3Y DISPLAY KEYPAD 3E 3F ON OFF 3S FRONT VIEW FIG. 5A CONTROL PANEL components (ref. TABLE 4A, PAGE 4) TABLE 4A CONTROL PANEL components (SEE FIGS. 5A AND 5B, PAGES 4-5) ITEM # QTY VOLT CODE DESCRIPTION PART NUER 3A 1 All I/O & IPU Board Kit B 1 All Fuse Block C 1 All Fuse D 1 All Control Transformer E All Twist Latch F All Twist Latch Key Q s 1 60Hz Flash Cards 50Hz S 1 All Switch Y 1 All Display s = Recommended Spare Part 4 JOHNSON CONTROLS

25 FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) X 1JR-X TESTED BY-X 3B 3C TB1 I / O IPU J15 TB TB3 1FU 10 V 1A J1 J CTB1 IPU X J6 J7 J8 J9 IPU I/O X J10 1T J14 J13 J1 J11 3A LOAD (75 VA) 1T LINE 4 TB4 YORK 3D CTB b FIG. 5B CONTROL PANEL components (ref. TABLE 4A, PAGE 4) JOHNSON CONTROLS 5

26 FORM RP1 (810) M C 7 6 T CAUTION OPTIONAL 6 8FU 9FU CR CR1 4A L1/U L/V L3/W 4A PE 3OL OL 1OL 3OL OL 1OL RIGHT -K1 1-K1 LEFT 4B NFDS or CB 4B 1F 1F L1/U L/V L3/W PTB I Control and Power Panels control panel and power Panel COMPONENTS (CONT'D) 1A 1A 3M 4M 5M 6M 1M M DOOR PLATE (CB / NFDS) ON 1E 1E OFF 1E A 1E 1E 1E O 1A 1A POWER OPTION PTB or NFDS or CB 1A 1A L FIG. 5C POWER PANEL components (ref. TABLE 6, PAGES 7-41) 6 JOHNSON CONTROLS

27 FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 CONTROL AND POWER PANEL components (SEE FIG. 5C, PAGES 6) Item Qty Description * YCRL & YCRL YCRL YCRL * * * * * * * * Comp. Contactor (L) 1A Comp. Contactor (R) 1E Ground Lug F Surge Suppressor Terminal Block N/A N/A N/A N/A N/A N/A A 1 Circuit Breaker N/A N/A N/A N/A N/A N/A Multiple Point Circuit Breaker N/A N/A N/A N/A N/A N/A B 1** Lug Kit N/A N/A N/A C 1** Ground Lug L 1 Handle N/A N/A N/A M 1 Shaft (8.86") N/A N/A N/A Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. * SINGLE POINT TERMINAL BLOCK **Service Note: Quantity of Ground Lugs for Multiple Point Circuit Breaker units. * SINGLE POINT CIRCUIT BREAKER * MULTI POINT CIRCUIT BREAKERS 4 JOHNSON CONTROLS 7

28 Control and Power Panels FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIG. 5C, PAGES 6) Item Qty Description * YCRL YCRL & YCRL YCRL * * * * * * * * Comp. Contactor (L) A Comp. Contactor (R) Ground Lug (L) 1E Ground Lug (R) 1F Surge Suppressor Terminal Block N/A N/A N/A N/A N/A N/A A 1 Circuit Breaker N/A N/A N/A N/A N/A N/A Multiple Point Circuit Breaker N/A N/A N/A N/A N/A N/A B 1** Lug Kit N/A N/A N/A C 1** Ground Lug L 1 Handle N/A N/A N/A M 1 Shaft (8.86") N/A N/A N/A Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. * SINGLE POINT TERMINAL BLOCK **Service Note: Quantity of Ground Lugs for Multiple Point Circuit Breaker units. * SINGLE POINT CIRCUIT BREAKER * MULTI POINT CIRCUIT BREAKERS 8 JOHNSON CONTROLS

29 FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIG. 5C, PAGES 6) Item Qty Description * YCRL YCRL YCRL & YCRL * * * * * * * * Comp. Contactor (L) 1A Comp. Contactor (R) 1E 4 Ground Lug F Surge Suppressor Terminal Block N/A N/A N/A N/A N/A N/A A 1 Circuit Breaker N/A N/A N/A N/A N/A N/A Multiple Point Circuit Breaker N/A N/A N/A N/A N/A N/A B 1** Lug Kit N/A N/A N/A C 1** Ground Lug L 1 Handle N/A N/A N/A M 1 Shaft (8.86") N/A N/A N/A Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. **Service Note: Quantity of Ground Lugs for Multiple Point Circuit Breaker units. * SINGLE POINT TERMINAL BLOCK * SINGLE POINT CIRCUIT BREAKER * MULTI POINT CIRCUIT BREAKERS 4 JOHNSON CONTROLS 9

30 Control and Power Panels FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIG. 5C, PAGES 6) Item Qty Description * YCRL YCRL YCRL * * * * * * * * Comp. Contactor (L) 1A Comp. Contactor (R) 1E 4 Ground Lug F Surge Suppressor Terminal Block N/A N/A N/A N/A N/A N/A A 1 Circuit Breaker N/A N/A N/A N/A N/A N/A Multiple Point Circuit Breaker N/A N/A N/A N/A N/A N/A B 1** Lug Kit N/A N/A N/A C 1** Ground Lug L 1 Handle N/A N/A N/A M 1 Shaft (8.86") N/A N/A N/A Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. * SINGLE POINT TERMINAL BLOCK **Service Note: Quantity of Ground Lugs for Multiple Point Circuit Breaker units. * SINGLE POINT CIRCUIT BREAKER * MULTI POINT CIRCUIT BREAKERS 30 JOHNSON CONTROLS

31 FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIG. 5C, PAGES 6) Item Qty Description * YCRL & YCRL YCRL YCRL * * * * * * * * Comp. Contactor (L) 1A Comp. Contactor (R) 1E 4 Ground Lug F Surge Suppressor Terminal Block *** N/A N/A N/A N/A N/A N/A A 1 Circuit Breaker N/A N/A N/A N/A N/A N/A Multiple Point Circuit Breaker N/A N/A N/A N/A N/A N/A B 1** Lug Kit N/A N/A C 1** Ground Lug L 1 Handle N/A N/A M 1 Shaft (8.86") N/A N/A Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar ***Service Note: Due to size constraints, a Non-Fused Disconnect Switch (part *Service Note: number ) is used in place of the Terminal Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in Block option on panel the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. * SINGLE POINT TERMINAL BLOCK **Service Note: Quantity of Ground Lugs for Multiple Point Circuit Breaker units. * SINGLE POINT CIRCUIT BREAKER * MULTI POINT CIRCUIT BREAKERS 4 JOHNSON CONTROLS 31

32 Control and Power Panels FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIG. 5C, PAGES 6) Item Qty Description * YCRL YCRL & YCRL008 YCRL * * * * * * * * Comp. Contactor (L) A Comp. Contactor (R) E 4 Ground Lug F Surge Suppressor Terminal Block N/A N/A N/A N/A N/A N/A A 1 Circuit Breaker N/A N/A N/A N/A N/A N/A Multiple Point Circuit Breaker N/A N/A N/A N/A N/A N/A Lug Kit (L) B 1** N/A N/A N/A Lug Kit (R) Ground Lug (L) C 1** Ground Lug (R) L 1 Handle N/A N/A N/A M 1 Shaft (8.86") N/A N/A N/A Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. **Service Note: Quantity of Ground Lugs for Multiple Point Circuit Breaker units. * SINGLE POINT TERMINAL BLOCK * SINGLE POINT CIRCUIT BREAKER * MULTI POINT CIRCUIT BREAKERS 3 JOHNSON CONTROLS

33 FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIG. 5C, PAGES 6) Item Qty Description * YCRL YCRL YCRL & YCRL * * * * * N/A * * Comp. Contactor (L) A Comp. Contactor (R) E 4 Ground Lug F Surge Suppressor Terminal Block N/A N/A N/A N/A N/A N/A A 1 Circuit Breaker N/A N/A N/A N/A N/A Multiple Point Circuit Breaker N/A N/A N/A N/A N/A B 1** Lug Kit N/A N/A N/A C 1** Ground Lug L 1 Handle N/A N/A M 1 Shaft (8.86") N/A N/A Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar **Service Note: Quantity of Ground Lugs for Multiple Point Circuit Breaker units. *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. * SINGLE POINT TERMINAL BLOCK * SINGLE POINT CIRCUIT BREAKER * MULTI POINT CIRCUIT BREAKERS 4 JOHNSON CONTROLS 33

34 Control and Power Panels FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIG. 5C, PAGES 6) Item Qty Description * YCRL YCRL YCRL * * * * * * * * Comp. Contactor (L) 1A Comp. Contactor (R) 1E 4 Ground Lug F Surge Suppressor Terminal Block N/A N/A N/A N/A N/A N/A A 1 Circuit Breaker N/A N/A N/A N/A N/A N/A Multiple Point Circuit Breaker N/A N/A N/A N/A N/A N/A B 1** Lug Kit N/A N/A N/A C 1** Ground Lug L 1 Handle N/A N/A N/A M 1 Shaft (8.86") N/A N/A N/A Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar **Service Note: Quantity of Ground Lugs for Multiple Point Circuit Breaker units. *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. * SINGLE POINT TERMINAL BLOCK * SINGLE POINT CIRCUIT BREAKER * MULTI POINT CIRCUIT BREAKERS 34 JOHNSON CONTROLS

35 FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIG. 5C, PAGES 6) Item Qty Description N/A YCRL & YCRL YCRL YCRL * * * * * * * * Comp. Contactor (L) 1A Comp. Contactor (R) 1E 4 Ground Lug F Surge Suppressor Terminal Block*** N/A N/A N/A N/A N/A A 1 Circuit Breaker N/A N/A N/A N/A N/A Multiple Point Circuit Breaker N/A N/A N/A N/A B 1** Lug Kit N/A NO RAM INFO AS OF 07/01/ N/A N/A C 1** Ground Lug L 1 Handle N/A N/A M 1 Shaft (8.86") N/A N/A Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar ***Service Note: Due to size constraints, a Non-Fused Disconnect Switch (part *Service Note: number ) is used in place of the Terminal Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in Block option on panel the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. **Service Note: Quantity of Ground Lugs for Multiple Point Circuit Breaker units. * SINGLE POINT TERMINAL BLOCK * SINGLE POINT CIRCUIT BREAKER * MULTI POINT CIRCUIT BREAKERS 4 JOHNSON CONTROLS 35

36 Control and Power Panels FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIG. 5C, PAGES 6) Item Qty Description * YCRL YCRL & YCRL YCRL * * N/A N/A * * * * Comp. Contactor (L) 1A LC1D115F7 LC1D115F7 Comp. Contactor (R) 1E 4 Ground Lug F Surge Suppressor Terminal Block N/A N/A N/A N/A A 1 Circuit Breaker N/A N/A N/A N/A N/A Multiple Point Circuit Breaker N/A N/A N/A B 1** Lug Kit N/A N/A N/A N/A C 1** Ground Lug NO RAM INFO AS OF 07/01/ L 1 Handle N/A N/A M 1 Shaft (8.86") N/A N/A Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar **Service Note: Quantity of Ground Lugs for Multiple Point Circuit Breaker units. *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. * SINGLE POINT TERMINAL BLOCK * SINGLE POINT CIRCUIT BREAKER * MULTI POINT CIRCUIT BREAKERS 36 JOHNSON CONTROLS

37 FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIG. 5C, PAGES 6) Item Qty Description * YCRL YCRL YCRL & YCRL * * * * * N/A N/A * Comp. Contactor (L) 1A 5 LC1D80G7 LC1D80G LC1D80G Comp. Contactor (R) 1E 5 Ground Lug F 5 Surge Suppressor Terminal Block N/A N/A N/A N/A N/A A 1 Circuit Breaker N/A N/A N/A N/A N/A Multiple Point Circuit Breaker N/A N/A N/A N/A B 1** Lug Kit N/A N/A N/A N/A C 1** Ground Lug L 1 Handle N/A N/A M 1 Shaft (8.86") N/A N/A Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar **Service Note: Quantity of Ground Lugs for Multiple Point Circuit Breaker units. *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. * SINGLE POINT TERMINAL BLOCK * SINGLE POINT CIRCUIT BREAKER * MULTI POINT CIRCUIT BREAKERS JOHNSON CONTROLS 37

38 Control and Power Panels FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIG. 5C, PAGES 6) Item Qty Description * YCRL YCRL YCRL * * * * * * * * Comp. Contactor (L) 1A LC1D115F7 LC1D115F7 LC1D80G7 LC1D80G Comp. Contactor (R) 1E 4 Ground Lug F Surge Suppressor Terminal Block N/A N/A N/A N/A N/A N/A A 1 Circuit Breaker N/A N/A N/A N/A N/A Multiple Point Circuit Breaker N/A N/A N/A N/A N/A B NO RAM INFO 1** Lug Kit N/A N/A AS OF 07/01/10 C 1** Ground Lug L 1 Handle N/A N/A M 1 Shaft (8.86") N/A N/A Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar **Service Note: Quantity of Ground Lugs for Multiple Point Circuit Breaker units. *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. * SINGLE POINT TERMINAL BLOCK * SINGLE POINT CIRCUIT BREAKER * MULTI POINT CIRCUIT BREAKERS 38 JOHNSON CONTROLS

39 FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) 4A LEFT 4B POWER OPTION PTB or NFDS or CB 1A 1A FIG. 5D POWER PANEL components - SOFT START (ref. TABLE 6, PAGES 37-41) 4 4A RIGHT 4B JOHNSON CONTROLS 39

40 Control and Power Panels FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIGS. 5C AND 5D, PAGES 6 AND 39) Item Qty Description * SD (ATL) YCRL YCRL YCRL * SD (YD) * SD (ATL) * SD (YD) * SD (ATL) * SD (YD) Comp. Contactor (L) A Comp. Contactor (R) E 4 Ground Lug F Surge Suppressor A 1 NF Disconnect Switch B 1 Lug Kit C 1 Ground Lug L 1 Handle M 1 Shaft (8.86") Manual Starter (L) A Manual Starter (R) Auxiliary Contact (L) B Auxiliary Contact (R) Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar Control Transformer Fuse, Time Delay Power Relay N/A N/A N/A Ground Lug N/A N/A N/A Surge Suppressor N/A N/A N/A SD* SINGLE POINT NON-FUSED DISCONNECT SWITCH *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. 40 JOHNSON CONTROLS

41 FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIGS. 5C AND 5D, PAGES 6 AND 39) Item Qty Description * SD (YTL) YCRL YCRL YCRL * SD (YD) * SD (ATL) * SD (YD) * SD (ATL) * SD (YD) Comp. Contactor (L) A Comp. Contactor (R) Ground Lug (L) E Ground Lug (R) F Surge Suppressor A 1 NF Disconnect Switch B 1 Lug Kit C 1 Ground Lug L 1 Handle M 1 Shaft (8.86") A 4 Manual Starter B 4 Auxiliary Contact Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar Control Transformer Fuse, Time Delay Power Relay N/A N/A N/A Ground Lug N/A N/A N/A Surge Suppressor N/A N/A N/A SD* SINGLE POINT NON-FUSED DISCONNECT SWITCH *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. JOHNSON CONTROLS 41

42 Control and Power Panels FORM RP1 (810) control panel and power Panel COMPONENTS (CONT'D) TABLE 5 (CONT'D) CONTROL AND POWER PANEL components (SEE FIGS. 5C AND 5D, PAGES 6 AND 39) Item Qty Description * SD (ATL) YCRL YCRL YCRL * SD (YD) * SD (YTL) * SD (YD) * SD (ATL) * SD (YD) Comp. Contactor (L) A Comp. Contactor (R) Ground Lug (L) E Ground Lug (R) F Surge Suppressor A 1 NF Disconnect Switch B 1 Lug Kit C 1 Ground Lug L 1 Handle M 1 Shaft (8.86") A 4 Manual Starter B 4 Auxiliary Contact Control Relay Surge Suppressor Fuse Block Fuse Control Transformer Ground Bar Control Transformer Fuse, Time Delay Power Relay N/A N/A N/A Ground Lug N/A N/A N/A Surge Suppressor N/A N/A N/A SD* SINGLE POINT NON-FUSED DISCONNECT SWITCH *Service Note: Locate the PANEL NUER sticker on the enclosure sheet metal above the back panel in the Micro Panel section (Fig. #4), then refer to the appropriate parts list for that number. Or, identify PIN number positions 16 and 17 on unit identification plate (See example on Page 4) then compare to table at right for power configuration options. 4 JOHNSON CONTROLS

43 FORM RP1 (810) 4 This page intentionally left blank JOHNSON CONTROLS 43

44 Wiring Harnesses FORM RP1 (810) SENSOR HARNESSES SYSTEM # COMPR. #/1-M COMPR. #1/1-M1 10 BLCT (LWT) BECT (EWT) 1-YLLSV (1LLSV) d FIG. 6A SENSOR HARNESSES (ref. TABLE 6, PAGE 47) 44 JOHNSON CONTROLS

45 FORM RP1 (810) SENSOR HARNESSes (CONT'D) SYSTEM # 4 5 COMPR. #5/-M COMPR. #4/-M e FIG. 6B SENSOR HARNESSES (ref. TABLE 6, PAGE 47) JOHNSON CONTROLS 45

46 Wiring Harnesses FORM RP1 (810) SENSOR HARNESSes (CONT'D) SYSTEM # SENSORS YLLSV (LLSV) f FIG. 6C SENSOR HARNESSES (ref. TABLE 6, PAGE 47) 46 JOHNSON CONTROLS

47 FORM RP1 (810) SENSOR HARNESSes (CONT'D) TABLE 6 SENSOR harness WIRING (see figs. 6A, 6B and 6C, pages 44-46) Plug Detail DIN CONNECTOR DIN CONNECTOR Plug and Pin P/N Plug = Pin = Plug = Pin = Plug = Pin = Plug "P" No. MICRO P6 MICRO P7 MICRO P9 Plug = SOLENOID Plug = SOLENOID UNIT SENSOR WIRING Plug Wire Pin Color No. 7 Black 4 Red 1 Drain 8 Black 5 Red Drain 5 Red 10 White 9 Black 1 Drain 6 Red 11 White 7 Black Drain 5 Red 10 White 9 Black 1 Drain 6 Red 11 White 7 Black Drain Red Blue Yellow/ Green Red Blue Yellow/ Green Cable # N/A N/A N/A 3 N/A N/A N/A Function Leaving Water Temperature LWT Entering Water Temperature EWT System #1 Suction Pressure System #1 Discharge Pressure System # Suction Pressure System # Discharge Pressure System #1 Liquid Line Solenoid Valve System # Liquid Line Solenoid Valve System #1 High Pressure Cut Out System # High Pressure Cut Out Harness Assembly Part Number JOHNSON CONTROLS 47

48 Wiring Harnesses FORM RP1 (810) TRANSDUCERS, CUT-OUTS AND TEMP SENSORS SYS. #1 SUCTION PRESS. 1-BSP (S1SP) SYSTEM #1 SYS. #1 1-FHP1 (1HPCO) 5 4 COMPR. #/1-M COMPR. #1/1-M1 3 SYS. #1 1-BDP (S1DP) 1 BECT (EWT) 1 BLCT (LWT) dd fig. 7A TRANSDUCERS, CUT-OUTS AND temp sensors (ref. table 7, PAGE 50) 48 JOHNSON CONTROLS

49 FORM RP1 (810) transducers, CUT-OUTS and temp sensors (CONT'D) SYS. # SUCTION PRESS. -BSP (SSP) 4 SYSTEM # SYS. # -FHP1 (HPCO) 5 5 COMPR. #5/-M COMPR. #4/-M1 3 SYS. # -BDP (SDP) ee fig. 7B TRANSDUCERS AND temp sensors (ref. table 7, PAGE 50) JOHNSON CONTROLS 49

50 Wiring Harnesses FORM RP1 (810) transducers, CUT-OUTS and temp sensors (CONT'D) TABLE 7 transducers, temp sensors AND HIGH PRESSURE CUT-OUT SWITCH (see figs. 7A AND 7B, PAGES 48 AND 49) Item # Quantity Description Voltage Code Part Number 1 s 1 Sensor, Water Temp. (EWT) 1 Sensor, Water Temp. (LWT) All Compound, Heat Conductive All s 1 per system Transducer, Discharge Pressure (0-650psi) All s 1 per system Transducer, Suction Pressure (0-400psi) All per system High Pressure Cut Out Switch All s = Recommended Spare Part 50 JOHNSON CONTROLS

51 FORM RP1 (810) TRANSDUCER AND THERMISTOR WIRE HARNESS CONNECTORS field replacement part numbers C BLK - PIN A (GND) RED - PIN B (SUPPLY) WHT - PIN C (OUTPUT) 1 A B A B 3 C 5 Item No. Location Description Pins Part Number 1 Transducer (0-00 PSIS) (0-400 PSIS) Pin (0-650 PSIS) End (0-150 PSIS) (0-175 PSIS) Plug Connector 3 Pin Wire Harness 3 Contact Pins End c 9 6 Item No. Location Description Pins Part Number 4 Plug Connector Temperature Pin 5 Contact Pins Sensor End 6 Rubber Collar Plug Connector Pin 8 Wire Harness Contact Pins End 9 Rubber Collar FIG. 8 TRANSDUCER AND THERMISTOR WIRE HARNESS CONNECTORs - FIELD REPLACEMENT PART NUERS JOHNSON CONTROLS 51