Johnson Controls YORK YLHA Series, YORK YLCA 120, YORK YLCA 60, YORK YLCA 80, YORK YLCA 100 Quick Installation Manual

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Air-condensed water chillers and heat pumps YLCA / YLHA

Quick installation guide

Ref.: N-40287_EN 0413

Index

1 Quick installation guide ...........................................................................................................1

1.1 Safety instructions....................................................................................................................2

1.2 Icons used in this document.....................................................................................................2

1.3 Instructions for storage, transport, loading and unloading of the unit......................................3

1.3.1 Inspection.................................................................................................................................3

1.3.2 Disposal of packaging..............................................................................................................3

1.3.3 Hoisting points..........................................................................................................................4

1.3.4 Disposal of the unit...................................................................................................................4

1.3.5 Handling...................................................................................................................................4

1.4 Selection guide (YLCA/YLHA).................................................................................................4

1.4.1 Selection guide with glycol (cooling units only)........................................................................6

1.5 Technical data..........................................................................................................................8

1.5.1 Limits of use.............................................................................................................................8

1.5.2 Correcting Factors....................................................................................................................8

1.5.3 Physical data..........................................................................................................................17

1.5.4 Electrical specifications..........................................................................................................21

1.6 Measurements, clearances and accesses.............................................................................22

1.6.1 Clearances.............................................................................................................................22

1.6.2 Dimensions and hydraulic connections (models YLCA/YLHA 40).........................................24

1.6.3 Dimensions and hydraulic connections (models YLCA/YLHA 50 and 60).............................25

1.6.4 Dimensions and hydraulic connections (models YLCA/YLHA 80).........................................26

1.6.5 Dimensions and hydraulic connections (models YLCA/YLHA 100, 120 and 150).................27

1.7 Cooling capacities YLHA........................................................................................................28

1.7.1 Cooling capacities YLHA 40 ÷ 150.........................................................................................28

1.7.2 Cooling capacities YLHA 40 ÷ 150 (35% ethylene glycol).....................................................29

1.7.3 Heating capacities YLHA 40 ÷ 150.........................................................................................30

1.8 Cooling capacity YLCA..........................................................................................................31

1.8.1 Cooling capacities YLCA 40 ÷ 150.........................................................................................31

1.8.2 Cooling capacities YLCA 40 ÷ 150 (35% ethylene glycol).....................................................32

1.9 Instructions for installation and connection of the unit...........................................................33

1.9.1 Characteristics of the location................................................................................................33

1.9.2 Specifications for the foundation or anchoring of the unit......................................................33

1.9.3 Hydraulic connections............................................................................................................33

1.9.4 Connection and preparation of the various connections........................................................34

1.10 Instructions for starting up the unit.........................................................................................39

1.10.1 Start-up...................................................................................................................................39

1.10.2 Rotational direction of Scroll compressors.............................................................................40

1.11 Unit sound power spectrum indication...................................................................................41

1.12 Unit installation data...............................................................................................................42

1.12.1 List of tests for unit start-up....................................................................................................42

1.12.2 Start-up data...........................................................................................................................43

Quick installation guide

1.1 Safety instructions

This document contains the necessary information for the safe and efficient transportation, assembly and installation of the air conditioning unit. This guarantees the condition of the unit and its operating safety.

Only an authorised company may assemble the air conditioning unit.

A T T E N T I O N

Only authorised companies with the appropriate technical resources and suitably trained personnel may install the air conditioning unit.

C A U T I O N

The specialists responsible for installing the air conditioning unit must make sure they have all of the information and knowledge required to correctly install, test and deliver the unit. Johnson Controls Inc. shall not be considered responsible for any damage caused by installation of the unit that is no consistent with that described in this document or others specifically provided with the unit.

During regular equipment installation, the fitter must pay special attention to certain situations in order to prevent injuries or damage to the unit.

Situations that could jeopardise the safety of the fitter or that of others nearby or that could put the unit itself at risk are clearly indicated in this manual.

A series of special symbols are used to clearly identify these situations.

Pay careful attention to these symbols and to the messages following them, as your safety and the safety of others depends on it.

1.2 Icons used in this document

D A N G E R

• The text following this symbol contains information and instructions relating directly to your safety and physical well-being.

• Not taking these instructions into account could lead to serious, very serious or even fatal injuries to you and others in the proximities of the unit.

Information can also be found on safe procedures during unit handling. This will help reduce the risk of accidents.

C A U T I O N

• The text following this symbol contains information and instructions relating directly to your safety and physical well-being.

• Not taking these instructions into account could lead to minor injuries to you and others in the proximities of the unit.

• Not taking these instructions into account could lead to unit damage.

Information can also be found on safe procedures during unit handling. This will help reduce the risk of accidents.

N O T E

• The text following this symbol contains information or instructions that may be of use or that is worthy of a more thorough explanation.

• Instructions regarding inspections to be made on unit parts or systems may also be included.

Quick installation guide

Instructions for storage, transport, loading and unloading of the unit 1.3

1.3 Instructions for storage, transport, loading and unloading of the unit

C A U T I O N

Outdoor units must be moved and stored vertically to prevent oil from leaking from the compressor.

Delivery inspection

The unit should be carefully inspected for visible damage or abnormalities as soon as it is received.

Any abnormalities or damage to the unit should be communicated to both the transportation and insurance company in writing.

Storage instructions

The unit should be stored in a place suitable to the purpose (warehouse or similar), protected from the weather, water, humidity and dust.

Cover the unit with a canvas of a suitable size.

The unit should be appropriately protected from knocks and dust, ensuring the protective parts it was supplied with remain in place. Where these are not in place, establish the necessary protections and/or barriers to keep vehicles or fork-lift trucks away.

Transport, loading and unloading of the unit

The units should only be handled by personnel from the company responsible for their installation.

Transport of the unit should be in such a manner that no damage is caused by faulty or inadequate mooring to the bed or body of the vehicle.

Where necessary, protect all of the edges of the unit against knocks and scratches and moor it to the bed or body of the vehicle using suitable textile belts or slings to keep it perfectly still.

Loading and unloading the unit from a truck or trailer should be on flat, solid ground using an appropriate crane with sufficient capacity.

1.3.1 Inspection

Upon reception, inspect the goods and notify the carrier and the insurance company, in writing, of any possible damage during transportation.

1.3.2 Disposal of packaging

The packaging is recyclable. Dispose of it in the appropriate place or take it to an appropriate collection centre. Respect the regulations in force for this type of waste in the country where the unit is being installed.

Packaging remains must be correctly disposed of. Improper disposal of packaging generates environmental problems that affect human life.

(X4)

Quick installation guide

1.4 Selection guide (YLCA/YLHA)

1.3.3 Hoisting points

The points designed for hoisting the unit are located on the beams on its base.

Before hoisting the unit, check that the cables or slings are firmly hooked to these points using shackles -2- and make sure the crane and the cables or slings are capable of lifting the weight.

Place spacers -1- at the top of the unit to prevent the cables or slings from touching it.

Attach guide ropes so that the unit does not rotate freely.

The cables or slings should be long enough to form an angle of over 45° to the horizontal plane. Hoist the unit keeping it in a horizontal position.

D A N G E R

There should not be onlookers within a radius of 10 m of the unit when it is being hoisted.

1.3.4 Disposal of the unit

When removing the unit, the components must be ecologically recovered. The cooling circuit is full of coolant that must be extracted and delivered to the gas manufacturer for recycling.

A T T E N T I O N

The refrigerant gas contains greenhouse-effect fluorinated gas covered by the Kyoto protocol.

Please see the specifications plate for type of gas and quantity per system.

GWP (Global Warming Potential): 2088

There will be oil left in the hermetic compressor, therefore it must be delivered with the circuit sealed.

The air conditioner shall be deposited in the area established by local authorities, to facilitate its selective recovery.

1.3.5 Handling

The unit must be moved using the metal rails provided for its installation and transport

1.4

Selection guide (YLCA/YLHA)

Necessary information The following information is needed to select a YLCA/YLHA water cooling unit:

1. Cooling capacity needed

2. Design cold water inlet and outlet temperatures.

3. Design water flow rate, if one of the temperatures of Point 2 above is unknown.

Quick installation guide

Selection guide (YLCA/YLHA) 1.4

4. Design inlet temperature of air to the condenser. Normally, this will be the design ambient temperature of summer air, unless influenced by the situation or other factors.

5. Altitude above sea level.

6. Design fouling factor of the evaporator.

N O T E

Points 1, 2 and 3 should be related by means of the following formulae:

l/h cold water x differential °C

Cooling capacity kW =

860

SELECTION EXAMPLE

A cooler is required to chill water from 13 °C to 7 °C, with a cooling capacity of 119 kW.

There are also other design conditions:

• Inlet ambient air in the condenser 35 °C

• Fouling factor: 0.044 m2 °C/kW

• Altitude: Sea level

Taking a quick look at the table, we can see that a YLCA 120 unit gives an approximate required capacity of 119 kW.

As the factors appearing in Tables and will be as follows:

• Cooling capacity: 119 kW

• Power consumed: 40 kW

• Water temperature: 13 °C to 7 °C (Temp. difference of 6)

Water flow rate =

Available pressure in hydraulic circuit of a unit with pack:

• From the table we infer that the YLCA 120 TP, with a 17 056 l/h flow rate, has an available pressure of 279 kPa.

Pressure drop in hydraulic circuit of a unit without pack:

• From the table we infer that the YLCA 120 T, with a 17 056 l/h flow, has an available pressure drop of 23 kPa.

Pressure drop in filter:

• From Table said filter has a pressure drop of 2.4 kPa.

YLHA selection method

1. Determine the correct size of the YLHA unit by selecting a model from Tables 3, 4 and 5 that is closest to the cooling and heating capacities required in the design conditions of the water outlet and air inlet temperatures.

2. Apply fouling (Table 11) and altitude (Table 12) correcting factors to the capacity and power values that appear in the corresponding capacity tables in cool and heat. Make sure the corrected capacity is still sufficient for your needs.

3. Using the corrected capacities of the unit, select the design temperature differential or the flow rate.

4. Check to make sure that these selections are within the YLCA/YLHA operating limits.

Pressure drop in filters, see on page 16

119 x 860

Altitude factors, see on page 11

= 17 056 l/h

, 2 ½" filter, we infer that with a 17 056 l/h flow,

are not applicable, the conditions

Quick installation guide

1.4 Selection guide (YLCA/YLHA)

YLHA SELECTION EXAMPLE

A YLHA heat pump operating at a 35°C ambient temperature should chill water from 13°C to 7°C, with a 112 kW cooling capacity.

A 110 kW heating capacity is required in 5 °C design ambient temperature and a hot water outlet temperature of 40 °C.

The fouling factor is 0.044 m2 °C/kW, with the unit operating at sea level (no corrections). With a quick glance of capacity Tables 3 and 5, we see that a YLHA 120 heat pump gives the approximate required capacities of:

• Cooling capacity = 114 kW

• Total unit absorbed power = 43.2 kW

• Cold water temperature = 13 °C to 7 °C (Temp. diff. of 6 °C)

• Hot and cold water flow = 16 340/h

• Heating capacity = 110.1 kW

• Total unit absorbed power in heat mode = 35.8 kW

• Hot water outlet temperature = 40 °C

Hot water temp. dif‐

ferential

110.1 x 860 = 5.8 °C

16 340

Thus, hot water return temperature is = 34.2°C

All values are within operating limits:

• Available pressure in hydraulic circuit of a unit with pack:

• From Table 6 we infer that the YLCA 120, with a 16 340 l/h flow, has an available pressure of 289 kPa.

• Pressure drop in hydraulic circuit of a unit without pack: – From the table we infer that the YLCA 120, with a 16 340 l/h flow, has an available pressure of 21

kPa.

• Pressure drop in filter. – From Table

flow rate, said filter has a pressure drop of 2.2 kPa.

Pressure drop in filters, see on page 16

, 2 1/2" filter, we infer that with a 16 340 l/h

1.4.1 Selection guide with glycol (cooling units only)

Necessary information The following information is needed to select a YLCA cooling unit:

1. Cooling capacity needed

2. Design cold water/glycol inlet and outlet temperatures.

3. Design water/glycol flow rate.

4. Design inlet temperature of air to the condenser. Normally, this will be the design ambient temperature of summer air, unless influenced by the situation or other factors.

5. Altitude above sea level.

6. Design fouling factor of the evaporator.

N O T E

Points 1, 2 and 3 should be related by means of the following formulae:

Temp. diff. (°C) x Flow rate (litres/sec.)

Capacity (kW) =

Glycol factor

Temp. diff. (°C) = Liquid inlet Liquid Inlet ‑ Liquid Outlet Temp.

Quick installation guide

Selection guide (YLCA/YLHA) 1.4

To determine the glycol factor, please see

(Recommended ethylene glycol concentrations) for ethylene glycol or (Recommended propylene glycol concentrations) for propylene glycol. For design outlet temperature, please see the recommended glycol concentration and the glycol factor in this concentration. This is the minimum concentration to be used for design outlet temperature. If a greater concentration is required, the glycol factor can be determined by means of in other concentrations) or (Propylene glycol in other concentrations).

Selection method

1. Determine the correct cooler model by selecting the one that is closest to the capacities required by

the design conditions of the glycol outlet and air inlet temperatures.

2. Apply the fouling correcting factors that correspond to the fouling, altitude and glycol concentration

factor, to the capacity and power values in the capacity tables. Make sure the corrected capacity is still sufficient for your needs.

3. Using the corrected capacities of the cooler, set the design temperature range, or the flow rate, to

balance the formulae appearing in

4. Always recheck to make sure these selections are within the specified design limits.

Selection example

A cooler is required to chill ethylene glycol from 1 to ‑4 °C, with an output of 75 kW.

The following design conditions are applicable:

• Fouling factor: 0,088m °C/kW

• Altitude: 1 200m

• Ambient air: 25℃

• Glycol concentration: 30% w/w

Glycol concentration and correcting tables, see on page 9

Glycol concentration and correcting tables, see on page

(Ethylene glycol

Selection guide (YLCA/YLHA), see on page 4

For a ‑4 °C ethylene glycol outlet, the concentration recommended in Figure 1 is 30%. Therefore, the specified concentration is appropriate.

From Table YLCA-120 unit, at the established design conditions, gives a capacity of 76.8 kW and a consumption of

28.8 kW.

With the design fouling factor, use the capacity correcting factors x 0.987 and power x 0.995 (see

factors, see on page 8

On design altitude, apply the capacity correcting factors x 9.973 and power x 1.020 (see

factors, see on page 11

On design glycol concentration, apply the capacity correcting factors x 1.015 and power x 1.005 (see

Correcting factors for other glycol concentrations, see on page 11

Applying these factors to the selection: YLCA ‑120

Capacity = 76.8 x 0.987 x 0.973 x 1.015 = 74.9 kW

Comp. power = 28.8 x 0.995 x 1.020 x 1.005 = 29.4 kW

For the specified glycol concentration and an outlet temperature of ‑4°C, figure 3 shows a glycol factor of 0.248. Therefore, the flow rate can be determined with the formula indicated in section

(YLCA/YLHA), see on page 4

74.9 [kW] =

Cooling capacities YLCA 40 ÷ 150 (35% ethylene glycol), see on page 32

(1 ‑ (-4)) x Flow rate [l / s]

0,248

, we infer that a

Fouling

Altitude

Selection guide

Flow rate =

74.9 x 0.248

This covers the Limits of Use.

= 3.71 [l / s] or 13374 [l / h]

1 Quick installation guide

1.5 Technical data

The evaporating unit pressure drop can be determined by taking the water pressure drop value for a YLCA 120 unit and multiplying it by the correcting factor (see

tables, see on page 9

1 + (-4)

-1.5 °C=

16 kPa x 1.22 = 19.5 kPa.

) for a 30% concentration and an average temperature of ‑1.5 °C, i.e.:

Glycol concentration and correcting

1.5 Technical data

1.5.1 Limits of use

Voltage limits

Model

YLCA

YLHA -10 (4) 20 30 50(2)

(1)

(2) 50 °C if the inlet air is 0 ºC.

(3) From a water temperature of 0 °C or lower, glycol-type antifreeze mixtures must be used.

(4)

Prior to final approval of the installation Check:

• Voltage remains between 342 ‑ 436 V.

• Power supply cable cross-section is at least as indicated in the corresponding wiring diagrams. The cable used for the unit power supply must be H05 RN-F or H07 RN ‑ F.

• Operating instructions have been given to the user.

• The warranty card has been filled out.

• Maintenance instructions have been given, or a regular maintenance contract has been signed.

Nominal at

400

Mini‐

mum

At lower water temperatures, it is advisable to use glycol-type antifreeze mixtures. Minimum temp. with glycol ‑5 °C

If the outdoor air temperature is lower than ‑5 °C or the water temperature is 0 °C or lower, it is advisable to use the 2.5 ‑ 4 bar low pressure switch.

Maxi‐

mum

342 436 -18 (4)

Inlet air temperature to the coil

Operating cycle Operating cycle

Minimum °C Maximum °C Minimum °C Maximum °C

Cold Heat Cold Heat Cold Heat Cold Heat

Water outlet temperature

5(1)

(3)(4)

Temperature

difference be‐

tween water

outlet and in‐

Mini‐

mum

°C

let

Maxi‐

mum

°C

3 7

1.5.2 Correcting Factors

Fouling factors

Fouling Factor m2 °C/kW Capacity factor

0,044 1 1

0,088 0,987 0,995

0,176 0,964 0,985

0,352 0,926 0,962

Evaporator

compressor absorbed

power factor

Glycol concentration and correcting tables

A C

Recommended ethylene glycol concentrations

Quick installation guide 1

Technical data 1.5

A % in weight a

Outlet liquid tempera‐

ture °C

Glycol factor L/S °C/kW

in recommended concentrations

Recommended concen‐ tration % in weight

b Freeze point

Glycol factor in recom‐

mended concentrations

Ethylene glycol in other concentrations.

A Glycol factor

B Outlet liquid temperature °C

C Glycol factor

Recommended propylene glycol concentrations

A % in weight a

Outlet liquid tempera‐

ture °C

Glycol factor L/S °C/

kW in recommended concentrations

Recommended concen‐ tration % in weight

b Freeze point

Glycol factor in recom‐

mended concentrations

A C

1 Quick installation guide

1.5 Technical data

Propylene glycol in other concentrations

A Glycol factor

B Outlet liquid temperature °C

C Glycol factor

Ethylene glycol pressure drop correcting factor

A Correcting Factor

B Average liquid temperature °C

C Glycol concentration P/P

Propylene glycol pressure drop correcting factor

Correcting Factor

B Average liquid temperature °C

C Glycol concentration P/P

Correcting factors for other glycol concentrations

Quick installation guide 1

Technical data 1.5

% in weight

Capacity Absorbed power Capacity Absorbed power

10 1,061 1,025 1,097 1,033

20 1,036 1,015 1,067 1,023

30 1,015 1,005 1,026 1,008

35 1 1 1 1

40 0,985 0,995 0,974 0,992

50 0,954 0'985 0,923 0,977

If it is necessary to select different glycol percentages, correct the capacity and absorbed power capacities of tables 2 and 4 (35% ethylene glycol), multiplying them by the coefficients indicated in the table.

Ethylene glycol Propylene glycol

Altitude factors

Altitude Capacity factor compressor absorbed power factor

0 1 1

600 0,987 1,01

1200 0,973 1,02

1800 0,958 1,029

2400 0,943 1,038

1 Quick installation guide

1.5 Technical data

Pressure drop in the YLCA/YLHA 40 ÷ 150 hydraulic circuit without pack (no filter fitted)

YLCA-YLHA model Flow rate l/h kPa

4750

5500 19

6250 26

7000 33

7750 42

8500 50

9250 61

10000 71

10750 84

6500

7000 28

7500 31

8000 34

8500 37

9000 40

9500 44

10000 48

10500 52

11000 57

11500 62

12000 67

12500 72

13000 77

13500 83

14000 89

14500 95

7500

8000 38

8500 40,5

9000 43

9500 45,5

10000 48

10500 51

11000 54

11500 57

12000 60

12500 64

13000 68

13500 72

14000 76

14500 81

15000 86

15500 90,5

16000 95

16500 100

17000 105

YLCA-YLHA model Flow rate l/h kPa

9500

10000 43

11000 48

12000 53

13000 59

14000 65

100

120

15000 72

16000 79

17000 87

18000 96

19000 107

20000 119

21000 132

22000 145

12000

13000 46

14000 47,5

15000 49,5

16000 52

17000 55

18000 60

19000 65

20000 70

21000 75

22000 80

23000 85

24000 92

- -

15000

16000 20

17000 23

18000 25,5

19000 28

20000 31

21000 34

22000 37

23000 40

24000 43

25000 46

26000 49

27000 52,5

28000 56,5

29000 60

30000 63

31000 67

32000 70,5

33000 74,5

34000 78

YLCA-YLHA model Flow rate l/h kPa

18000 12,5

19000 14

20000 15,5

21000 17,5

22000 19,5

23000 21,5

24000 23,5

25000 25,5

26000 27,5

27000 30

28000 32,5

29000 35

150

30000 37,5

31000 40

32000 43

33000 46

34000 49

35000 52

36000 55

37000 58

38000 61

39000 64

40000 67

41000 70

42000 73

Quick installation guide 1

Technical data 1.5

+ 32 hidden pages

Johnson Controls YORK YLHA Series, YORK YLCA 120, YORK YLCA 60, YORK YLCA 80, YORK YLCA 100 Quick Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Index

Quick installation guide

1.1 Safety instructions

Instructions for storage, transport, loading and unloading of the unit 1.3

Selection guide (YLCA/YLHA)

1.5 Technical data

Fouling factors

Glycol concentration and correcting tables

Correcting factors for other glycol concentrations

Altitude factors

Pressure drop in the YLCA/YLHA 40 ÷ 150 hydraulic circuit without pack (no filter fitted)