Johnson Controls YORK YCAL0043E Series Owner's manual

YCAL0043E_ - YCAL0377E_
R-22 & HFC-407C
STYLE C
(50 Hz)
WITH IPU II AND I/O BOARDS
Standard, Glycol & Metric Models, Combined
380/415-3-50
MODELS ONLY
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
New Release Form 150.62-NM9 (709)
29224(R)A
035-22321-000

JOHNSON CONTROLS
2
FORM 150.62-NM9 (709)
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils,materials underpressure, rotatingcomponents, 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 obligation and respon-
sibility of operating/service personnel to identify and
recognize 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.
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
individual possesses independent training that will en-
able them to perform their assigned tasks properly and
safely. It is essential that, prior to performing any task
on this equipment, this individual will have read and
understood thisdocumentandanyreferenced materials.
This individual will also be familiar with and comply
with all applicable governmental standards and regula-
tions 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:

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    
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
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
   
    
      -

   
    
-


not
notno
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only 
-




JOHNSON CONTROLS 3
FORM 150.62-NM9 (709)
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for continu-
ous product improvement, the information contained
in this document is subject to change without notice.
While Johnson Controls makes no commitment to
update or provide current information automatically to
the manual owner, that information, if applicable, can
be obtained by contacting the nearest Johnson Controls
Service ofce.
It is the responsibility of operating/service personnel to
verify the applicability of these documents to the equip-
ment 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 equip-
ment, they should verify with the owner whether the
equipment has been modied and if current literature
is available.
TABLE OF CONTENTS
PRODUCT IDENTIFICATION NUMBER (PIN)....................................................................................7
REFRIGERANT FLOW DIAGRAM......................................................................................................9
SECTION 1 - INSTALLATION ...........................................................................................................10
ELECTRICAL DATA....................................................................................................................................20
OPERATIONAL LIMITATIONS (ENGLISH) ................................................................................................26
PHYSICAL DATA (ENGLISH) .....................................................................................................................30
DIMENSIONS AND CLEARANCES............................................................................................................34
PRE-STARTUP AND STARTUP CHECKLIST............................................................................................58
INITIAL START-UP......................................................................................................................................59
UNIT OPERATING SEQUENCE .................................................................................................................61
SECTION 2 - UNIT CONTROLS........................................................................................................62
“STATUS” KEY...........................................................................................................................................64
DISPLAY/PRINT KEYS...............................................................................................................................70
“ENTRY” KEYS...........................................................................................................................................79
“SETPOINTS” KEYS ..................................................................................................................................80
“UNIT” KEYS .............................................................................................................................................87
UNIT OPERATION.......................................................................................................................................92
SECTION 3 - SERVICE AND TROUBLESHOOTING .....................................................................106
SERVICE MODE – CHILLER CONFIGURATION.....................................................................................107
OPTIONAL PRINTER INSTALLATION.....................................................................................................115
TROUBLESHOOTING CHARTS ..............................................................................................................116
MAINTENANCE ........................................................................................................................................119
ISN CONTROL ..........................................................................................................................................120
SECTION 4 - WIRING DIAGRAMS .................................................................................................124
APPENDIX 1....................................................................................................................................179

JOHNSON CONTROLS
4
FORM 150.62-NM9 (709)
LIST OF TABLES
TABLE 1 – MICRO PANEL POWER SUPPLY ................................................................................20
TABLE 2 – TEMPERATURES AND FLOWS...................................................................................26
TABLE 3 – VOLTAGE LIMITATIONS ..............................................................................................26
TABLE 4 – COOLER PRESSURE DROP CURVES .......................................................................27
TABLE 5 – ETHYLENE / PROPYLENE GLYCOL CORRECTION FACTORS.................................27
TABLE 6 – TEMPERATURES AND FLOWS...................................................................................28
TABLE 7 – VOLTAGE LIMITATIONS ..............................................................................................28
TABLE 8 – COOLER PRESSURE DROP CURVES .......................................................................29
TABLE 9 – ETHYLENE / PROPYLENE GLYCOLCORRECTION FACTORS ..................................29
TABLE 10 – PHYSICAL DATA (ENGLISH).......................................................................................30
TABLE 11 – SETPOINTS ENTRY LIST.............................................................................................59
TABLE 12 – STATUS KEY MESSAGES...........................................................................................69
TABLE 13 – OPERATION DATA.......................................................................................................73
TABLE 14 – COOLING SETPOINTS, PROGRAMMABLE LIMITS AND DEFAULTS......................82
TABLE 15 – PROGRAM KEY LIMITS AND DEFAULTS ..................................................................85
TABLE 16 – SETPOINTS QUICK REFERENCE LIST......................................................................86
TABLE 17 – UNIT KEYS PROGRAMMING QUICK REFERENCE LIST..........................................91
TABLE 18 – COMPRESSOR STAGING FOR RETURN WATER CONTROL...................................94
TABLE 19 – RETURN CHILLED LIQUID CONTROL FOR 5 & 6 COMPRESSORS
(7 & 8 STEPS)................................................................................................................94
TABLE 20 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS)............95
TABLE 21 – YCAL0043 – YCAL0107 CONDENSER FAN CONTROL
USING DISCHARGE PRESSURE................................................................................98
TABLE 22 – YCAL0043 – YCAL0107 CONDENSER FAN CONTROL
USING DISCHARGE PRESSURE ONLY.....................................................................98
TABLE 23 – YCAL0117 – YCAL0253 CONDENSER FAN CONTROL
USING OUTDOOR AMBIENT TEMPERATURE AND DISCHARGE PRESSURE. .....99
TABLE 24 – YCAL0117 – YCAL0253 CONDENSER FAN CONTROL
USING DISCHARGE PRESSURE ONLY.....................................................................99
TABLE 25 – YCAL0117 - YCAL0253 LOW AMBIENT CONDENSER FAN CONTROL –
DISCHARGE PRESSURE CONTROL .......................................................................100
TABLE 26 – YCAL0287 - YCAL0377 CONDENSER FAN CONTROL ..........................................101
TABLE 27 – COMPRESSOR OPERATION – LOAD LIMITING......................................................103
TABLE 28 – I/O BOARD DIGITAL INPUTS.....................................................................................108
TABLE 29 – I/O BOARD ANALOG INPUTS...................................................................................108
TABLE 30 – I/O BOARD DIGITAL OUTPUTS.................................................................................108
TABLE 31 – I/O BOARD ANALOG OUTPUTS...............................................................................108
TABLE 32 – OUTDOOR AIR SENSOR TEMPERATURE/VOLTAGE/
RESISTANCE CORRELATION ..................................................................................110

JOHNSON CONTROLS 5
FORM 150.62-NM9 (709)
LIST OF TABLES (CONT.)
LIST OF FIGURES
TABLE 33 – ENTERING/LEAVING CHILLED LIQUID TEMP. SENSOR, COOLER INLET
TEMPERATURE SENSOR, AND SUCTION TEMPERATURE SENSOR:
TEMPERATURE/VOLTAGE/RESISTANCE CORRELATION.....................................111
TABLE 34 – KEYPAD PIN ASSIGNMENT MATRIX........................................................................114
TABLE 35 – TROUBLESHOOTING ................................................................................................116
TABLE 36 – ISN RECEIVED DATA.................................................................................................120
TABLE 37 – ISN TRANSMITTED DATA..........................................................................................120
TABLE 38 – ISN OPERATIONAL AND FAULT CODES.................................................................122
FIG. 1 – REFRIGERANT FLOW DIAGRAM......................................................................................9
FIG. 2 – SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK,
NON-FUSED DISCONNECTSWITCH OR CIRCUIT BREAKER (YCAL0043 - 0253)......14
FIG. 3 – MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL BLOCK
(YCAL0117 - 0253) ............................................................................................................15
FIG. 4 – MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL BLOCK,
NON-FUSED DISCONNECT SWITCHES OR CIRCUIT BREAKERS
(YCAL0287 - 0377)............................................................................................................16
FIG. 5 – OPTIONAL SINGLE-POINT POWER WIRING .................................................................17
FIG. 6 – CONTROL WIRING ..........................................................................................................18
FIG. 7 – SETPOINT ADjUST ..........................................................................................................93
FIG. 8 – LEAVING WATER TEMPERATURE CONTROL EXAMPLE.............................................93
FIG. 9 – YCAL0043 – YCAL0107 FAN LOCATION (TYPICAL)......................................................98
FIG. 10 – YCAL0117 – YCAL0253 FAN LOCATION (TYPICAL)......................................................99
FIG. 11 – YCAL0287 – YCAL0377 FAN LOCATION.......................................................................101
FIG. 12 – FIELD AND FACTORY ELECTRICAL CONNECTIONSOPTIONAL
REMOTE TEMPERATURE RESET BOARD...................................................................105
FIG. 13 – I/O BOARD LAYOUT.......................................................................................................109
FIG. 14 – I/O BOARD RELAY CONTACT ARCHITECTURE..........................................................113
FIG. 15 – PRINTER TO I/O BOARD ELECTRICAL CONNECTIONS ............................................115
FIG. 16 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0043E_ - YCAL0087E_ ........124
FIG. 16A – ELEMENTARY DIAGRAM, CONTROL CIRCUIT –
YCAL0043E_ - YCAL0087E_ REMOTE COOLER......................................................126
FIG. 17 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0043E_ - YCAL0087E_ ............128
FIG. 18 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0043E_ - YCAL0087E_ ...........130
FIG. 19 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0043E_ - YCAL0087E_ ...........132
FIG. 20 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0107E_ ....................................134

JOHNSON CONTROLS
6
FORM 150.62-NM9 (709)
LIST OF FIGURES (CONT)
FIG. 20A – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0107E_
REMOTE COOLER........................................................................................................136
FIG. 21 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0107E_......................................138
FIG. 22 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0107E_.....................................140
FIG. 23 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0107E_.....................................142
FIG. 24 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0117E_ - YCAL0173E_ ........144
FIG. 24A – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0117E_ - YCAL0173E_
REMOTE COOLER..........................................................................................................146
FIG. 25 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0117E_ - YCAL0173E_.............148
FIG. 26 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0117E_ - YCAL0173E_............150
FIG. 27 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0117E_ - YCAL0173E_............152
FIG. 28 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0197E_ - YCAL0253E_ ........154
FIG. 28A – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0197E_ - YCAL0253E_
REMOTE COOLER.......................................................................................................156
FIG. 29 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0197E_ - YCAL0253E_ ............158
FIG. 30 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0197E_ - YCAL0253E_ ...........160
FIG. 31 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0197E_ - YCAL0253E_ ...........162
FIG. 32 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0287E_ - YCAL0317E_ ........164
FIG. 33 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0287E_ - YCAL0317E_ ...........166
FIG. 34 – CONNECTION DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE –
YCAL0287E_ - YCAL0317E_..........................................................................................168
FIG. 35 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0287E_ - YCAL0317E_ ..........170
FIG. 36 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0347E_ - YCAL0377E_ ........172
FIG. 37 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0347E_ - YCAL0377E_ ............174
FIG. 38 – CONNECTION DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE –
YCAL0347E_ - YCAL0377E_..........................................................................................176
FIG. 39 – ELEMENTARY DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE –
YCAL0347E_ - YCAL0377E_..........................................................................................178
FIG. 40 – TYPE CP 1.......................................................................................................................185
FIG. 41 – TYPE CP 2.......................................................................................................................185
FIG. 42 – R SPRING SEISMIC ISOLATOR.....................................................................................186
FIG. 43 – TYPE CP MOUNTING......................................................................................................187
FIG. 44 – “AEQM” SPRING-FLEX MOUNTING .............................................................................188

JOHNSON CONTROLS 7
FORM 150.62-NM9 (709)
PRODUCT IDENTIFICATION NUMBER (PIN)
BASIC MODEL NUMBER
YCAL0075EC50XA
BASE PRODUCT TYPE
L
U :Condensing
Unit
A :Air-Cooled
C :Chiller
Y :YORK
:Scroll
VOLTAGE/STARTER
X
5 0 :380-415 / 3 / 50
:Across the Line
DESIGN/DEVELOPMENT LEVEL
C :Design Series
A :Engineering Change
or PIN Level
E :High Efficiency
UNIT DESIGNATOR
B :R407C
C :R22
REFRIGERANT
NOMINAL CAPACITY
#
##0 #
##1
Even Number:
60 HZ Nominal Tons
Odd Number:
50 HZ Nominal Kw
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

JOHNSON CONTROLS
8
FORM 150.62-NM9 (709)
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-NM9 (709)
LD07613A
REFRIGERANT FLOW DIAGRAM
FIG. 1 – REFRIGERANT FLOW DIAGRAM
OPTIONAL
2 OR 3 COMPRESSORS PER SYSTEM
OIL EQUALIZING
LINE
AIR COOLED CONDENSERS
DX COOLER
LEAVING CHILLED WATER
ENTERING CHILLED WATER
OPTIONAL
SERVICEVALVE
OPTIONAL DISCHARGE
PRESSURETRANSDUCER
HIGH PRESSURE
CUTOUT SWITCH
OPTIONAL
SERVICE
VALVE
LOW PRESSURE SWITCH OR
SUCTION PRESSURE TRANSDUCER
LEAVING
CHILLEDWATER
TEMP. SENSOR
RETURNWATER
TEMP. SENSOR
OPTIONAL
DISCHARGE LINE
BALLVALVE
HOT DISCHARGE
GAS LINE
LIQUID LINE
SERVICEVALVE
LIQUID LINE FILTER / DRIER
LIQUID LINE
SOLENOIDVALVE
SIGHT GLASS /
MOISTURE INDICATOR
SOLENOID OPERATED
HOT GAS BY PASS VALVE
*
OPTIONAL
SUCTION LINE
BALLVALVE
EQUALIZER
LINE
TXV
OPTIONAL
RELIEFVALVE
300 PSIG
(20.68 BARG)
YCAL REFRIGERANT FLOW DIAGRAM
(INCLUDINGTEMPERATURE SENSORS & PRESSURETRANSDUCERS)
NOTE:YCAL0040-0134 HAVE TWO REFRIGERANT
SYSTEMS AND ONE DX COOLER.
* HOT GAS OPTION - SYSTEM 1 ONLY
YCAL0117-0377

JOHNSON CONTROLS
10
FORM 150.62-NM9 (709)
INTRODUCTION
29224(RIG)A
    
   
-
     


-

-

-





INSTALLATION CHECKLIST
The following items, 1 through 5, must be checked
before 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 untilpiping 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
These units are shipped as completely assembled units
containing full operating charge, and care should be
taken to avoid damage due to rough handling.

     

      


SECTION 1 - INSTALLATION
INSPECTION
Immediately upon receiving the unit, it should be in-
spected for possible damage which may have occurred
during transit. If damage is evident, it should be noted
in the carrier’s freight bill.Awritten request for inspec-
tion 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
airentrance to the condensercoil,forairdischargeaway
from the condenser, and for servicing access.
In installations where winter operation is intended and
snowaccumulationsareexpected,additionalheightmust
be provided to ensure normal condenser air ow.
Clearances are listed under “Notes” in the “DIMEN-
SIONS” section.