Johnson Controls York YCAL0014E Series Guide

YCAL0014E_ - YCAL0124E_

R-22 & HFC-407C

STYLE C

(60 Hz)

Standard, Glycol & Metric Models, Combined

200-3-60

230-3-60

380-3-60

460-3-60

575-3-60

MODELS ONLY

INSTALLATION, OPERATION, MAINTENANCE

AIR-COOLED LIQUID CHILLERS

HERMETIC SCROLL

New Release Form 150.62-NM6 (103)

YCAL0090 – YCAL0124 EPROM

031-02423-001

29224(R)A

YCAL0014 – YCAL0080 EPROM (031-02050-001 MICROBOARD)

031-02049-001

035-19329-000

JOHNSON CONTROLS

FORM 150.62-NM6 (103)

GENERAL SAFETY GUIDELINES

Thisequipmentisarelativelycomplicatedapparatus.Duringinstallation,operation,

maintenance or service, individuals may be exposed to certain components or

conditions including, but not limited to: refrigerants, oils, materials under pressure,

rotating components, and both high and low voltage. Each of these items has the

potential, if misused or handled improperly, to cause bodily injury or death. It is the

obligationandresponsibilityofoperating/servicepersonnelto identify andrecognize

these inherent hazards, protect themselves, and proceed safely in completing their

tasks. Failure to comply with any of these requirements could result in serious

damage to the equipment and the property in which it is situated, as well as severe

personal injury or death to themselves and people at the site.

Thisdocument isintendedforuse byowner-authorizedoperating/servicepersonnel.

It is expected that this individual possesses independent training that will enable

them to perform their assigned tasks properly and safely. It is essential that, prior

to performing any task on this equipment, this individual shall have read and un-

derstood this document and any referenced materials. This individual shall also be

familiarwithand comply with all applicable governmentalstandards and regulations

pertaining to the task in question.

SAFETY SYMBOLS

The following symbols are used in this document to alert the reader to areas of

potential hazard:

DANGERindicatesanimminentlyhazardous situationwhich,ifnotavoided,

will result in death or serious injury.

WARNING indicatesapotentially hazardoussituationwhich, ifnotavoided,

could result in death or serious injury.

IMPORTANT!

READ BEFORE PROCEEDING!

JOHNSON CONTROLS 3

FORM 150.62-NM6 (103)

CAUTION identies a hazard which could lead to damage to the machine,

damage to other equipment and/or environmental pollution. Usually an

instruction will be given, together with a brief explanation.

NOTE is used to highlight additional information which may be helpful to

you.

CHANGEABILITY OF THIS DOCUMENT

In complying with YORK’s policy for continuous product improvement, the infor-

mationcontainedin this document is subject to change withoutnotice.WhileYORK

makesno commitment to updateor provide current information automatically to the

manual owner, that information, if applicable, can be obtained by contacting the

nearest YORK Engineered Systems Service ofce.

It is the responsibility of operating/service personnel to verify 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 equip-

ment has been modied and if current literature is available.

JOHNSON CONTROLS

FORM 150.62-NM6 (103)

TABLE OF CONTENTS AND LIST OF TABLES

PAGE

PRODUCT IDENTIFICATION NUMBER........................................................7-8

REFRIGERANT FLOW DIAGRAM ................................................................... 9

SECTION 1 INSTALLATION .......................................................................... 10

ELECTRICAL DATA........................................................................................ 20

OPERATIONAL LIMITATIONS........................................................................ 30

PHYSICAL DATA............................................................................................. 34

DIMENSIONS & CLEARANCES..................................................................... 38

PRE-STARTUP CHECKLIST.......................................................................... 66

INITIAL STARTUP........................................................................................... 67

UNIT OPERATING SEQUENCE..................................................................... 69

SECTION 2 UNIT CONTROLS ...................................................................... 70

STATUS KEY................................................................................................... 72

DISPLAY/PRINT KEYS................................................................................... 78

ENTRY KEYS.................................................................................................. 88

SETPOINTS KEYS......................................................................................... 89

UNIT KEYS ..................................................................................................... 96

UNIT OPERATION........................................................................................ 101

SECTION 3 SERVICE AND TROUBLESHOOTING .....................................115

SERVICE MODE – CHILLER CONFIGURATION..........................................116

OPTIONAL PRINTER INSTALLATION ........................................................ 124

TROUBLESHOOTING CHARTS .................................................................. 125

MAINTENANCE............................................................................................ 128

ISN CONTROL.............................................................................................. 129

SECTION 4 WIRING DIAGRAMS ............................................................... 132

SECTION 5 APPENDIX 1 – ISOLATORS .................................................... 162

TABLES

1 MICRO PANEL POWER SUPPLY............................................................ 20

2 STANDARD SINGLE-POINT POWER (YCAL0014E_ - YCAL0034E_)... 21

3 STANDARD DUAL POINT POWER (YCAL0040E_ - YCAL0080E_)22 – 23

4 SINGLE-POINT POWER SUPPLY CONNECTIONS

(YCAL0040E_ - YCAL0080E_)......................................................... 24 – 25

5 MUTIPLE POINT POWER SUPPLY CONNECTIONS

(YCAL0090E_ - YCAL0124E_)......................................................... 26 – 27

6 SINGLE-POINT POWER SUPPLY CONNECTIONS W/

INDIVIDUAL CIRCUIT BREAKERS (YCAL0090E_ - YCAL0124E_)28 – 29

7 TEMPERATURES AND FLOWS (ENGLISH)........................................... 30

8 VOLTAGE LIMITATIONS.......................................................................... 30

9 COOLER PRESSURE DROP CURVES (ENGLISH) ............................... 31

JOHNSON CONTROLS 5

FORM 150.62-NM6 (103)

LIST OF TABLES

PAGE

TABLES

10 ETHYLENE GLYCOL CORRECTION FACTORS ...................................31

11 TEMPERATURES AND FLOWS (METRIC)............................................32

12 VOLTAGE LIMITATIONS (METRIC)........................................................32

13 COOLER PRESSUER DROP CURVES (METRIC) ................................33

14 ETHYLENE GLYCOL CORRECTION FACTORS ...................................33

15 PHYSICAL DATA (ENGLISH)..........................................................34 – 35

16 PHYSICAL DATA (METRIC)............................................................36 – 37

17 SETPOINTS ENTRY LIST.......................................................................67

18 STATUS KEY MESSAGES......................................................................77

19 OPERATOR DATA QUICK REFERENCE LIST.......................................82

20 COOLING SETPOINTS, PROGRAMMABLE LIMITS & DEFAULTS.......91

21 PROGRAM KEY LIMITS & DEFAULTS...................................................94

22 SETPOINTS KEY QUICK REFERENCE LIST........................................95

23 UNIT KEYS QUICK REFERENCE LIST................................................100

24 COMPRESSOR STAGING FOR RETURN WATER CONTROL...........103

25 RETURN CHILLED LIQUID CONTROL – 5 & 6 COMPRESSORS ......103

26 RETURN CHILLED LIQUID CONTROL – 4 COMPRESSORS.............104

27 YCAL0014 - YCAL0080 CONDENSER FAN CONTROL USING

OUTDOOR AMBIENT TEMP. & DP.......................................................107

28 YCAL0014 - YCAL0080 CONDENSER FAN CONTROL USING

DP ONLY ...............................................................................................107

29 YCAL0014 - YCAL0080 LOWAMBIENT CONDENSER FAN CONTROL

+ DISCHARGE PRESSURE CONTROL...............................................108

30 YCAL0090 - YCAL0094 CONDENSER FAN CONTROL......................109

31 YCAL0114 - YCAL0124 CONDENSER FAN CONTROL.......................110

32 COMPRESSOR OPERATION – LOAD LIMITING ................................112

33 MICROBOARD DIGITAL INPUTS.........................................................117

34 MICROBOARD ANALOG INPUTS........................................................117

35 MICROBOARD DIGITAL OUTPUTS.....................................................117

36 MICROBOARD ANALOG OUTPUTS....................................................117

37 OUTDOOR AIR SENSOR TEMP./VOLT./RESISTANCE .......................119

38 ENTERING & LEAVING CHILLED LIQUID TEMPERATURE

SENSOR, COOLER INLET TEMP. & SUCTION TEMP.........................120

39 KEYPAD PIN ASSIGNMENT MATRIX...................................................123

40 TROUBLESHOOTING CHARTS...........................................................125

41 ISN RECEIVED DATA............................................................................129

42 ISN TRANSMITTED DATA....................................................................129

43 ISN OPERATIONAL & FAULT CODES..................................................131

JOHNSON CONTROLS

FORM 150.62-NM6 (103)

LIST OF FIGURES

1 REFRIGERANT FLOW DIAGRAM......................................................................................9

2 SINGLE-POINT SUPPLY CONNECTION .........................................................................14

3 MULTIPLE POINT POWER SUPPLY CONNECTION.......................................................15

4 MULTIPLE POINT POWER SUPPLY WIRING – CONNECTION ...................................16

5 SINGLE-POINT SUPPLY CONNECTION .........................................................................17

6 CONTROL WIRING..........................................................................................................18

7 SETPOINTADJUST........................................................................................................102

8 LEAVING WATER TEMPERATURE CONTROL – EXAMPLE.........................................102

9 YCAL0014 - YCAL0080 FAN LOCATION (TYPICAL) .....................................................107

10 YCAL0090 - YCAL0094 FAN LOCATION........................................................................109

11 YCAL0114 - YCAL0124 FAN LOCATION........................................................................110

12 FIELD & FACTORY ELECTRICAL CONNECTIONS –

OPTIONAL REMOTE TEMPERATURE RESET BOARD..............................................114

13 MICROBOARD LAYOUT.................................................................................................118

14 MICROBOARD RELAY CONTACT ARCHITECTURE ....................................................122

15 PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS.......................................124

16 ELEMENTARY DIAGRAM – CONTROL CIRCUIT (YCAL0014E_ - YCAL0020E_)132 - 133

17 ELEMENTARY DIAGRAM – POWER CIRCUIT (YCAL0014E_ - YCAL0020E_)............134

18 ELEMENTARY DIAGRAM – CONTROL CIRCUIT (YCAL0040E_ - YCAL0060E_)136 - 137

19 ELEMENTARY DIAGRAM – POWER CIRCUIT (YCAL0040E_ - YCAL0060E_)............138

20 ELEMENTARY DIAGRAM – CONTROL CIRCUIT (YCAL0064E_ - YCAL0080E_)140 - 141

21 ELEMENTARY DIAGRAM – POWER CIRCUIT (YCAL0064E_ - YCAL0080E_)............142

22 ELEMENTARY DIAGRAM – CONTROL CIRCUIT (YCAL0090E_ - YCAL0094E_)144 - 145

23 ELEMENTARY DIAGRAM – POWER CIRCUIT (YCAL0090E_ - YCAL0094E_) 145B - 146

24 ELEMENTARY DIAGRAM, DETAILA & B (YCAL0090E_ - YCAL0094E_).....................147

25 CONNECTION DIAGRAM (YCAL0090E_ - YCAL0094E_)....................................148 - 149

26 ELEMENTARY DIAGRAM – CONTROL CIRCUIT (YCAL0104E_)........................150 - 151

27 ELEMENTARY DIAGRAM – POWER CIRCUIT (YCAL0104E_).........................151B - 152

28 ELEMENTARY DIAGRAM, DETAILA & B (YCAL0104E_)..............................................153

29 CONNECTION DIAGRAM (YCAL0104E_)......................................................................154

30 ELEMENTARY DIAGRAM – CONTROL CIRCUIT (YCAL0114E_ - YCAL0124E_)156 - 157

31 ELEMENTARY DIAGRAM – POWER CIRCUIT (YCAL0114E_ - YCAL0124E_) 157B - 158

32 ELEMENTARY DIAGRAM, DETAILA & B (YCAL0114E_ - YCAL0124E_).....................159

33 CONNECTION DIAGRAM (YCAL0114E_ - YCAL0124E_)....................................160 - 161

34 ISOLATORS, TYPE CP 1................................................................................................164

35 ISOLATORS, TYPE CP 2................................................................................................164

36 R SPRING SEISMIC ISOLATOR.....................................................................................165

37 TYPE CP MOUNTING ....................................................................................................166

38 “AEQM” SPRING-FLEX MOUNTING..............................................................................167

JOHNSON CONTROLS 7

FORM 150.62-NM6 (103)

PRODUCT IDENTIFICATION NUMBER (PIN)

BASIC MODEL NUMBER

: High Efciency : R-22

: R-407C

: YORK

: Chiller

: Air-Cooled

: Condensing

Unit

: Scroll

Even Number:

60 HZ Nominal Tons

Odd Number:

50 HZ Nominal kW

: 200 / 3/ 60

: 230 / 3 / 60

: 380 / 3 / 60

: 460 / 3 / 60

: 380-415 / 3 / 50

: 575 / 3 / 60

: Across the Line

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

BASE PRODUCT TYPE NOMINALCAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE/STARTER DESIGN/DEVELOPMENT LEVEL

Y 0 # # # E C 1 7 C

C 1 # # # B 2 8 A

A 4 0

U 4 6

5 0

L 5 8

: Design Series

: Engineering

Change

or PIN Level

YCAL0080EC46XCA

JOHNSON CONTROLS

FORM 150.62-NM6 (103)

PRODUCT IDENTIFICATION NUMBER (PIN)

EXAMPLES:

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

X X X X X X X X L X X X X X X X X X X X X X X X X X A X X X X X X X X X X X X X

S D T C A T S R L X P R S 2 5 C X 1 X X X X 3 D W S A R X B X X 4 B X X L X S D

OPTIONS MODEL NUMBER

: Aluminum

: Copper

: Black Fin

: Phenolic

: TEAO Fan

Motors

EVAP. FIELD CONDENSER FIELD CABINET FIELD

: Wire Condenser Headers Only (factory)

: Wire (Full Unit) Enc. Panels (factory)

: Wire (Full Unit) Enc. Panels (eld)

: Wire/Louvered Enc. Panels (factory)

: Wire/Louvered Enc. Panels (eld)

: Louvered (Cond. Only) Enc. Panels (factory)

: Louvered (Cond. Only) Enc. Panels (eld)

: Louvered (Full Unit) Enc. Panels (factory)

: Louvered (Full Unit) Enc. Panels (eld)

: Acoustic Sound Blanket

: Low Sound Fans

: 1" Deection

: Seismic

: Neoprene Pads

EXTENDED FIELD

: 1st Year Parts Only

: 1st Year Parts & Labor

: 2nd Year Parts Only

: 2nd Year Parts & Labor

: 5 Year Compressor Parts Only

: 5 Year Compressor Parts & Labor Only

: 5 Year Units Parts Only

: 5 Year Unit Parts & Labor

NOTES:

1. Q :DENOTES SPECIAL / S.Q.

2. # :DENOTES STANDARD

3. X :w/in OPTIONS FIELD, DENOTES NO OPTION SELECTED

4. Agency Files (i.e. U.L. / E.T.L.; CE; ARI; ETC.) will contain info. based on the rst 14 characters only.

: Low Ambient Kit (factory)

: High Ambient Kit (factory)

: Both Low / High Ambient (factory)

: BAS/EMS Temp. Reset / Offset

: Spanish LCD & Keypad Display

: French LCD & Keypad Display

: German LCD & Keypad Display

: Discharge Pressure Transducers/

Readout Kit

: Suction Pressure Transducers /

Readout Kit

: Both Discharge & Suction Pressure

Transducers / Readout

: N. American Safety Code

(cU.L./cE.T.L.)

: No Listing (typically 50 HZ non-CE,

non-U.L.

: Remote Control Panel

: Sequence Control & Automatic

Lead Transfer

: 300 PSIG DWP Waterside

: Double Thick Insulation

: Weld Flange Kit

: Victaulic Flange Kit

: Flow Switch

: ASME Pressure Vessel &

Associated Codes

: Remote DX Cooler

: SP Supply TB

: MP Supply TB

: SP Supply TB

: SP NF Disconnect Switch

: SP Circuit Breaker w/ Lockable Handle

: Control Transformer (factory)

: Power Factor Capacitor

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

POWER FIELD CONTROLS FIELD COMPRESSOR / PIPING FIELD

X X L # #

X X H

S X A C

S D T S

B X S B

F E

G 1

T I

C R X

S X

B X

MP = Multiple Point

SP = Single-Point

NF = Non-Fused

TB = Terminal Block

Ser. = Service

Ind. Sys. Brkr. & L. Ext. Handles = Individual

System Breaker & Lockable

External Handle

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

3 X X

D C 1

W B 2

V P 3

S X 4

A 5

R 7

: Leaving Supply Temp.

: Chicago Code Kit Req’d.

: Service Isolation Valves

: Both Chicago & Svc. Iso.

: Elec. Expansion Valve

: Hot Gas By-Pass req’d.

(1 circuit)

: X

: Crankcase Heater Std.

JOHNSON CONTROLS 9

FORM 150.62-NM6 (103)

LD07613

REFRIGERANT FLOW DIAGRAM

FIG. 1 – REFRIGERANT FLOW DIAGRAM

2 OR 3 COMPRESSORS PER SYSTEM

OIL EQUALIZING

LINE

AIR COOLED CONDENSERS

DX COOLER

LEAVING CHILLED WATER

ENTERING CHILLED WATER

OPTIONAL

SERVICE VALVE

OPTIONAL DISCHARGE

PRESSURE TRANSDUCER

HIGH PRESSURE

CUTOUT SWITCH

OPTIONAL

SERVICE

VALVE

LOW PRESSURE SWITCH OR

SUCTION PRESSURE TRANSDUCER

LEAVING

CHILLED WATER

TEMP. SENSOR

RETURN WATER

TEMP. SENSOR

OPTIONAL

DISCHARGE LINE

BALL VALVE

HOT DISCHARGE

GAS LINE

LIQUID LINE

SERVICE VALVE

LIQUID LINE FILTER / DRIER

LIQUID LINE

SOLENOID VALVE

SIGHT GLASS /

MOISTURE INDICATOR

SOLENOID OPERATED

HOT GAS BY PASS VALVE

OPTIONAL

SUCTION LINE

BALL VALVE

EQUALIZER

LINE

TXV

OPTIONAL

RELIEF VALVE

300 PSIG

(20.68 BARG)

YCAL REFRIGERANT FLOW DIAGRAM

(INCLUDING TEMPERATURE SENSORS & PRESSURE TRANSDUCERS)

NOTE:YCAL0040-0124 HAVE TWO REFRIGERANT

SYSTEMS AND ONE DX COOLER.

* HOT GAS OPTION - SYSTEM 1 ONLY

JOHNSON CONTROLS

FORM 150.62-NM6 (103)

29224(RIG)A

To ensure warranty coverage, this

equipment must be commissioned

and serviced by an authorized YORK

service mechanic or a qualied service

person experienced in chiller instal-

lation. Installation must comply with

all applicable codes, particularly in

regard to electrical wiring and other

safety elements such as relief valves,

HP cutout settings, design working

pressures, and ventilation require-

ments consistent with the amount and

type of refrigerant charge.

Lethalvoltagesexistwithin thecontrol

panels.Beforeservicing,openandtag

all disconnect switches.

INSTALLATION CHECK LIST

The following items, 1 through 5, must be checked be-

fore placing the units in operation.

1. Inspect the unit for shipping damage.

2. Rig unit using spreader bars.

3. Open the unit only to install water piping system.

Do not remove protective covers from water con-

nections until piping is ready for attachment. Check

water piping to ensure cleanliness.

4. Pipe unit using good piping practice (seeASHRAE

handbook section 215 and 195).

5. Check to see that the unit is installed and operated

within limitations (Refer to LIMITATIONS).

The following pages outline detailed procedures to be

followed to install and start-up the chiller.

HANDLING

Theseunits areshipped as completely assembled units

containing full operating charge, and care should be

taken to avoid damage due to rough handling.

INSTALLATION

INSPECTION

Immediately upon receiving the unit, it should be in-

spectedfor possibledamage whichmay haveoccurred

duringtransit. If damageis evident,itshould benoted in

the carrier’s freight bill.A written request for inspection

by the carrier’s agent should be made at once. See

“Instruction” manual, Form 50.15-NM for more infor-

mation and details.

LOCATION AND CLEARANCES

These units are designed for outdoor installations on

ground level, rooftop, or beside a building. Location

should be selected for minimum sun exposure and to

insure adequate supply of fresh air for the condenser.

The units must be installed with sufcient clearances

for air entrance to the condenser coil, for air discharge

away from the condenser, and for servicing access.

In installations where winter operation is intended and

snow accumulations are expected, additional height

must be provided to ensure normal condenser air

ow.

Clearances are listed under “Notes” in the “DIMEN-

The unit should be lifted by inserting hooks through

the holes provided in unit base rails. Spreader bars

should beused to avoid crushingthe unit framerails

with the lifting chains. See below.

Installation

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