Johnson Controls YORK YLCA 40 User manual

Air-condensed water chillers and

heat pumps YLCA / YLHA 100, 120

and 150

User manual

Ref.: N-40291_EN 0112

Index

1User manual ............................................................................................................................1

1.1 General description of the unit.................................................................................................2

1.1.1 Models available and capacities...............................................................................................2

1.1.2 Technical specifications...........................................................................................................4

1.1.3 Operating instructions µC3 (YLCA / YLHA 100, 120 and 150).................................................7

1.1.4 Regular maintenance activities for which the user is responsible..........................................24

Index

User manual

1.1 General description of the unit

The YLCA/YLHA units are high-performance air-water chillers and heat pumps using R-410A ecological

coolant.

These units are designed for air conditioning or industrial applications that require cold or hot water.

They are silent and compact units, equipped with vertical air discharge axial fans, that can be installed

directly outdoors.

They are available in two versions: with and without a hydro kit, which includes a buffer tank and a high

head pressure pump.

The control system of these units is a specially programmed electronic controller to be used on air-water

coolers and heat pumps equipped with tandem compressors. Easy to use and safe, these units precision

control the water return temperature of the installation, carry out defrost cycles, modulate fan speeds

and control compressor, pump and electric heater start-up. By reading the control probes and safety

elements, the controller protects the entire equipment against malfunctions. The system allows

connecting the unit to a standard RS-485 monitoring network.

For further information, please see Operating Instructions.

The YLCA/YLHA units are made of proven quality components and manufactured in compliance with

standards in force (ISO 9001 certification).

1.1.1 Models available and capacities

Cool-only

model YLCA 40 YLCA 50 YLCA 60 YLCA 80 YLCA 100 YLCA 120 YLCA 150

Cooling ca‐

pacity(1) 39,3 51,8 60,1 72,1 100,3 118,5 150,5

Cooling ca‐

pacity(2) 39,6 52,1 60,5 72,6 101 119 151

(1) Net cooling capacities in kW for 7 °C of water inlet/outlet temperature and 35 °C of ambient temperature according

to the EUROVENT EN14511:2011 certification

(2) Gross cooling capacities in kW for 7 °C of water inlet/outlet temperature and 35 °C of ambient temperature ac‐

cording to the EUROVENT EN14511:2011 certification

Heat pump

model YLHA 40 YLHA 50 YLHA 60 YLHA 80 YLHA 100 YLHA 120 YLHA 150

Cooling ca‐

pacity(1) 37,6 51,7 60,1 71,7 95,4 113,6 144,5

Heating ca‐

pacity(2) 39 52,8 60 75,2 104,6 120 150,5

Cooling ca‐

pacity(3) 37,8 52 60,5 72,2 96 114 145

Heating ca‐

pacity(4) 38,6 52,5 59,6 74,7 104 119,6 150

(1) Net cooling capacities in kW for 7 °C of water inlet/outlet temperature and 35 °C of ambient temperature according

to the EUROVENT EN14511:2011 certification

(2) Net heating capacities in kW for 45 °C of water inlet/outlet temperature and 7 °C of ambient temperature according

to the EUROVENT EN14511:2011 certification

(3) Gross cooling capacities in kW for 7 °C of water inlet/outlet temperature and 35 °C of ambient temperature ac‐

cording to the EUROVENT EN14511:2011 certification

(4) Gross heating capacities in kW for 45 °C of water inlet/outlet temperature and 7 °C of ambient temperature ac‐

cording to the EUROVENT EN14511:2011 certification

1 User manual

1.1 General description of the unit

User manual 1

General description of the unit 1.1

1.1.2 Technical specifications

These units are supplied completely factory-assembled and with all coolant tubing and wiring ready for

installation on site. After mounting, these units must go through an operational test with water. Coolant

leaks will also be checked during this process.

Sheeting cover

The units are made of galvanized steel sheeting and anticorrosion nuts and bolts. Panels can be removed

for access to internal components. The casing parts are painted with white RAL9001 oven-baked

polymerized enamel.

Compressors

One, two or four hermetic Scroll compressors are used, mounted in tandem on rails and antivibratory

supports. The compressors are connected for operation with one single cooling circuit. Start-up is carried

out by two independent starters. These compressors are equipped with mechanical elements that protect

them against high operating temperatures. The sump heaters operate only when the compressor is

inoperative.

Water-side exchanger

Comprises a stainless steel plate exchanger, adequately insulated by a layer of closed-cell elastomer

foam. Includes an antifreeze heater monitored by the controller. The coolant side of said exchanger

accepts an operating pressure of 45 bar, whereas the water side accepts 10 bar. When the unit includes

a hydro kit, maximum admissible pressure on the water side is 6 bar (adjustment of the tank safety valve).

Air-side exchanger

Made up of two notched aluminium blue fin coils and grooved copper tubing mechanically expanded

within the fin assembly.

Fans

Of the axial and low sound level type. Equipped with single-phase motors with IP54 protection. These

motors allow speed control by means of a phase cut-out shifter controlled by the unit controller. This

allows unit operation at low ambient temperatures (-10°C). On cool only units with an optional low ambient

temperature kit can reach ‑18°C. On heat pumps, the fan will remain inoperative during defrosting.

Electrical and control panel

Located at the front of the unit, and with IP44 protection. The operating and control components are

factory mounted, wired and tested. The door of this control panel is equipped with a locking isolator that

turns power supply off. Inside we find the contactors for compressors and the pump, the transformer,

magneto-thermal protectors, controller electronic plates, speed control, connecting strip and the

keyboard-display with the unit controls.

Control keyboard-display

This device is accessible through an external leak-tight plastic cover. This is an easy-to-use control with

three access levels: direct, user (password) and factory (password). For further information, please see

Operating Instructions.

Cooling circuit

The cool only unit cooling circuit includes: expansion valve, filter-dryer, liquid sight glass, high and low-

pressure switches, service valves for isolating the condensing unit, and Schrader valves on the high and

low sides. The heat pump model also includes, in addition, a four-way valve (energized in summer cycle

and during defrosts), retaining valves, a heat cycle expansion valve and a liquid tank. The suction tubing

is coated with closed-cell elastomer.

1User manual

1.1 General description of the unit

Hydro kit (pack)

These units include a pack assembled with the components of a hydro kit. This assembly is located within

the unit frame and does not increase the footprint of same. It includes the following components: Lined

buffer tank and with an antifreeze heater, centrifugal pump, expansion vessel charged with nitrogen at

1.5 bar, safety valve set to 6 bar, water circuit, pressure gauge, two air bleed valves, filling valve and

drain valve. Also includes a mesh filter for the water circuit. This filter is supplied loose for installation at

the most convenient point.

Flow switch

Assures sufficient water flow when the unit is in operation.

Options and accessories

Units without hydro kit

This includes the elements described in the previously mentioned specifications, less the hydro kit (pack).

The water circuit includes an air bleed valve. Connections are ready for on-site installation.

Two pumps

Accessory available with models 50 to 150 with hydro kit. The second pump becomes operative when

the thermal magnetic switch protector of the first pump is activated (models 50, 60 and 80), or through

the controller program (models 100, 120 and 150).

Water filter

Supplied as a standard element on units including the hydro kit. Stainless steel mesh with 1 mm. diameter

perforations. Optional on units not including the hydro kit. The warranty of the unit will not be valid if a

water filter has not been installed.

Remote control

Wall-mounted remote control unit with keyboard for cool/heat and ON/OFF functions. Includes LEDs for

power supply, alarm and cool/heat. Maximum cable length: 50 m.

Remote terminal

For total access and control of the system by means of the display and buttons. It allows for selection of

cool, heat and off functions. Operating parameters can also be modified and the system can also be

supervised. Can be installed at a maximum distance of 1040 m.

BMS connections

With a serial board it is possible to connect the system to a standard RS-485 monitoring network.

Low sound level units (LN)

Include anti-noise covers mounted on the compressors and sound isolating plates, covering the

compressor chamber.

Gentle starter

For the soft motor start. Specially designed for Scroll compressors. (Maximum outdoor temperature: 50

°C).

Protecting grids

To protect the coils from possible impacts. Made of steel rods and painted with oven baked polymerized

white enamel (RAL9001).

User manual 1

General description of the unit 1.1

Antivibration supports

Whenever necessary to reduce vibrations and noise

produced by the unit to a maximum, a set of steel

spring antivibratory supports can be used. These

should be installed between the chassis support of the

unit and the base or floor on which it is to sit.

This base must be solid and dimensioned in

accordance with the load to be supported.

The antivibratory support accessory for models

YLCA/YLHA 40, 50 and 60 includes 4 units, whereas

for models YLCA/YLHA 80, 100, 120 and 150

includes 6.

These spring supports should be distributed and

fastened in the drilled holes at the base of the cooler,

the location of which is detailed in the General

Dimensions section.

YLCA/YLHA 40

YLCA/YLHA 50 ÷ 150

Ø 10

Ø 75

125

14,5

115

14,5

1User manual

1.1 General description of the unit

1.1.3 Operating instructions µC3 (YLCA / YLHA 100, 120 and 150)

This is a specially programmed controller for air-water coolers and heat pumps with four capacity stages.

These are divided into two independent cooling circuits equipped with two tandems that act upon a

common water circuit. Both systems are equipped with two fans each, the speed of which is controlled

by pressure sensors. The controller operates through the following intakes and outlets.

Digital inputs

ID1 ‑ J1/8 General protection (PG)

ID2 ‑ J1/1 Flow switch (FS)

ID3 ‑ J1/9 Remote ON/OFF (ROO)

ID4 ‑ J1/2 Pump protector No. 1 (Q5)

ID5 ‑ J1/10 Low-pressure switch circuit 1 (LP1)

ID6 ‑ J4/8 High-pressure switch circuit 1 (HP1)

ID7 ‑ J4/1 Thermal protector compressor 1 (THPC1)

ID8 ‑ J4/9 Thermal protector compressor 2 (THPC2)

ID9 ‑ J4/2 Thermal protector circuit 1 fans (THPF 1-2)

ID10 ‑ J4/10 Low-pressure switch circuit 2 (LP2)

ID11 ‑ J7/6 High-pressure switch circuit 2 (HP2)

ID12 ‑ J7/1 Thermal protector compressor 3 (THPC3)

ID13 ‑ J7/8 Thermal protector compressor 4 (THPC4)

ID14 ‑ J7/3 Thermal protector circuit 2 fans (THPF 3-4)

ID15 ‑ J7/9 Remote COOL/HEAT (RCH)

ID18 ‑ J7/5 Pump protector No. 2 (Q6)

Digital outputs

N01/C1-2 Compressor 1 circuit 1 (K1)

N02/C1-2 Compressor 2 circuit 1 (K2)

N05/C5 Pump 1

N06/C6-7 Compressor 3 circuit 2 (K3)

N07/C6-7 Compressor 4 circuit 2 (K4)

N08/C8-9 Pump 2

N010/C10 Alarm

N011/C11-12 Antifreeze heater circuit 1-2

N012/C11-12 Back-up heater

N013/C13-14 4-way valve circuit 1 (V4V1)

N014/C13-14 4-way valve circuit 2 (V4V2)

User manual 1

General description of the unit 1.1

Analogue inputs

B3 ‑ J2 Coil pressure circuit 1

B4 ‑ J3 Coil pressure circuit 2

B5 ‑ J4/13 Water temperature at exchanger inlet

B6 ‑ J4/12 Water temperature at exchanger outlet

Analogue outputs

Y3 Circuit 1 fan speed control (PWM)

Y4 Circuit 2 fan speed control (PWM)

System components

The system is made up of the following basic components:

• Touch screen

• µC3 controller

• Fan speed controllers (FSC1 and FSC2)

• Pressure sensors (B3 and B4)

• NTC probes (B5 and B6)

Touch screen

This consists of a screen and six keys with the

following functions:

• Alarm ‑2-

• Programming ‑1-

• Esc (Escape)

• Up ‑3-

• Enter ‑4-

• Down ‑5-

The following functions can be selected from this

screen:

• ON/OFF

• COLD/HEAT

• Read the unit status

• Access the configuration menus (by means of a password)

• Read the alarm messages and reset these alarms

• Read operating pressures and temperatures

• etc...

µC3 controller

This contains the unit software and the entire digital

and analogue input and output connector system.

This module is also equipped with connectors for the

program download key and the serial communication

connection to an RS-485 monitoring system.

122 44

1User manual

1.1 General description of the unit

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