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
2
FORM 150.62-NM6 (103)
2
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)
3
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
4
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
6
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
X
: Design Series
: Engineering
Change
or PIN Level
YCAL0080EC46XCA

JOHNSON CONTROLS
8
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
55 EXTENDED FIELD X
B C D E F G H
: 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 X L N C R S
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 6 R 7 8 B
L 1 S N
: 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 : X : 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
10
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