York Millennium ycul0016sc User manual

YCUL0016SC - YCUL0090SC

Standard & Metric Models, Combined

200-3-60

230-3-60

380-3-60

460-3-60

575-3-60

MODELS ONLY

INSTALLATION, OPERATION & MAINTENANCE

MILLENNIUM

AIR-COOLED CONDENSING UNITS

HERMETIC SCROLL

New Release Form 150.63-NM1 (700)

00096VIP

YORK INTERNATIONAL

TABLE OF CONTENTS

Manual Usage and Revisions...................................... 5

Product Identification Number ................................... 6

Refrigerant Flow Diagram .......................................... 8

SECTION 1INSTALLATION

General ........................................................................ 9

Installation Check List ................................................ 9

Handling...................................................................... 9

Inspection .................................................................... 9

Location & Clearances................................................ 9

Foundation ................................................................ 10

Ground Level Locations ........................................... 10

Rooftop Locations..................................................... 10

Noise Sensitive Locations......................................... 10

Spring Isolators (Optional) ....................................... 10

Compressor Mounting .............................................. 10

Electrical Wiring ....................................................... 10

Zone Thermostats...................................................... 11

PWM Input................................................................ 12

Refrigerant Piping ..................................................... 12

Refrigerant Line Sizing............................................. 12

Oil Traps ................................................................... 13

Refrigerant Charge .................................................... 13

Filter Driers ............................................................... 13

Refrigerant Piping Reference.................................... 13

Refrigerant Piping Notes .......................................... 18

Power Connection Options ....................................... 19

Multi-Point Power Supply Wiring.......................... 19

Single-Point Power Supply Wiring ........................ 20

Optional Single-Point Power Wiring - Non-Fused

Disconnect Switch or Circuit Breaker.................... 21

Control Wiring .......................................................... 22

Electrical Notes......................................................... 24

Electrical Data........................................................... 25

Micropanel Power Supply ...................................... 25

Single-Pont Power (Standard or Optional

Disconnect or Breakers) ......................................... 26

Standard Dual Point Power .................................... 28

Optional Single Point Power

(Models YCUL0046 – YCUL0066) ...................... 30

Optional Single Point Power

(Models YCUL0076 – YCUL0090) ...................... 32

Operational Limitations ............................................ 34

Physical Data (English)............................................. 36

Physical Data (Metric) .............................................. 38

Dimensions (English)................................................ 40

Model YCUL0016C ............................................... 40

Model YCUL0026C ............................................... 42

Model YCUL0030C ............................................... 44

Model YCUL0036C ............................................... 46

Model YCUL0040C ............................................... 48

Model YCUL0046C ............................................... 50

Model YCUL0056C ............................................... 52

Model YCUL0060C ............................................... 54

Model YCUL0066C ............................................... 56

Model YCUL0076C ............................................... 58

Model YCUL0080C ............................................... 60

Model YCUL0086C ............................................... 62

Model YCUL0090C ............................................... 64

Dimensions (Metric) ................................................. 66

Model YCUL0016C ............................................... 66

Model YCUL0026C ............................................... 68

Model YCUL0030C ............................................... 70

Model YCUL0036C ............................................... 72

Model YCUL0040C ............................................... 74

Model YCUL0046C ............................................... 76

Model YCUL0056C ............................................... 78

Model YCUL0060C ............................................... 80

Model YCUL0066C ............................................... 82

Model YCUL0076C ............................................... 84

Model YCUL0080C ............................................... 86

Model YCUL0086C ............................................... 88

Model YCUL0090C ............................................... 90

SECTION 2INITIAL START-UP

Pre-Start Up Checklist .............................................. 92

Checking The System Prior To Initial Start ........... 92

Initial Start-Up........................................................ 93

Checking Superheat and Subcooling...................... 93

Leak Checking ........................................................ 94

Unit Operating Sequence .......................................... 95

SECTION 3UNIT CONTROLS

Status Key ................................................................. 98

Display/Print Keys .................................................. 103

Entry Keys............................................................... 110

Setpoint Keys .......................................................... 111

Unit Keys ................................................................ 117

Unit Operation ........................................................ 121

SECTION 4CONTROL SERVICE AND

TROUBLESHOOTING

Clearing History Buffers......................................... 130

Software Version ..................................................... 130

Service Mode .......................................................... 130

Service Mode - Digital Outputs............................ 130

Service Mode - Inputs .......................................... 131

Control Inputs and Outputs..................................... 134

Analog Inputs .......................................................... 134

Temperature .......................................................... 134

Pressure................................................................. 137

Digital Outputs ........................................................ 138

Keypad .................................................................... 139

Optional Printer Installation ................................... 140

Parts......................................................................... 140

Assembly & Wiring ................................................ 140

Obtaining A Printout............................................... 140

Troubleshooting ...................................................... 141

YORK INTERNATIONAL

FORM 150.63-NM1

Maintenance ............................................................ 144

Compressors ......................................................... 144

Condenser Fan Motors ......................................... 144

Condenser Coils.................................................... 144

Operating Parameters ........................................... 144

Overall Unit Inspection ........................................ 144

ISN Control ............................................................. 145

Received Data (Control Data) .............................. 145

Transmitted Data .................................................. 145

SECTION 5ELEMENTARY DIAGRAMS

YCUL0016 – YCUL0036....................................... 148

YCUL0040.............................................................. 152

YCUL0046 – YCUL0066....................................... 156

YCUL0076 – YCUL0090....................................... 160

APPENDIX AISOLATOR DETAILS

Aluminum Coils ...................................................... 164

Copper Coils ........................................................... 165

Isolator Dimensions ................................................ 166

Type CP-1 and CP-2 ............................................. 166

R-Spring Seismic Isolators ................................... 167

Isolator Installation and Adjustment....................... 168

Type CP Mounting................................................ 168

AEQM Spring-Flex Mounting.............................. 169

York Service Offices (North America) ................... 171

LIST OF TABLES

Table 1 - Fitting Equivalent Lengths ........................13

Table 2 - Miscellaneous Liquid Line Pressure

Drops .........................................................13

Table 3 - Refrigerant Piping Charges .......................13

Table 4 - Refrigerant Line Connections....................13

Table 5 - Refrigerant Line Pressure Drops

(English) ....................................................14

Table 6 - Refrigerant Line Pressure Drops

(Metric)......................................................16

Table 7 - Micropanel Power Supply .........................25

Table 8 - Voltage Limitations (English) ....................34

Table 9 - Physical Data .............................................36

Table 10 - Setpoint Entry List.....................................92

Table 11 - Status Message Quick Reference

Table ........................................................102

Table 12 - Operation Data Quick Reference

Table ........................................................106

Table 13 - Cooling Setpoints Programmable Limits

& Defaults ...............................................114

Table 14 - Program Key Limits & Defaults ..............115

Table 15 - Setpoints Key Quick Reference

Table ........................................................116

Table 16 - Unit Keys Programming Quick Reference

Table ........................................................120

Table 17 - Discharge Air Temperature Control -

6 Compressors .........................................122

Table 18 - Discharge Air Temperature Control -

4 Compressors .........................................122

Table 19 - Discharge Air Temperature Control -

3 Compressors .........................................123

Table 20 - Discharge Air Temperature Control -

2 Compressors .........................................123

Table 21 - Condenser Fan Control Using Outdoor

Ambient Temperature and Discharge

Pressure ...................................................125

Table 22 - Condenser Fan Control Using Discharge

Pressure Only ..........................................125

Table 23 - Low Ambient Condenser Fan Control -

Ambient Temperature And Discharge

Pressure Control ......................................126

Table 24 - Low Ambient Condenser Fan Control -

Discharge Pressure Control .....................126

Table 25 - Compressor Operation - Load Limiting ..127

Table 26 - Microboard Binary Inputs .......................132

Table 27 - Microboard Analog Inputs ......................132

Table 28 - Microboard Outputs ................................132

Table 29 - Outdoor Air Sensor - Temperature/Voltage/

Resistance Correlation.............................134

Table 30 - Discharge Air Temperature Sensor -

Temperature/Voltage/Resistance

Correlation...............................................135

Table 31 - Suction Temperature Sensor -

Temperature/LT Voltage/Resistance

Correlation...............................................136

Table 32 - Discharge Pressure Transducer Pressure

To Voltage Conversion Formula..............137

Table 33 - Suction Pressure Transducer Pressure To

Voltage Conversion Formula ...................138

Table 34 - Keypad Pin Assignment Matrix...............139

Table 35 - Troubleshooting Charts ................ 141 - 143

Table 36 - ISN Received Data ..................................145

Table 37 - ISN Transmitted Data ..............................145

Table 38 - ISN Transmitted Data ..............................146

Table 39 - ISN Operational and Fault Codes............147

YORK INTERNATIONAL

LIST OF FIGURES

Figure 1 - Refrigerant Flow Diagram ............................................................8

Figure 2 - Multi-Point Power Supply Wiring – Standard Unit ...................19

Figure 3 - Single Point Power Supply Wiring .............................................20

Figure 4 - Optional Single Point Power Supply Wiring –

Non-Fused Disconnect Switch or Circuit Breaker .....................21

Figure 5 - CTB1 Field Control Wiring........................................................22

Figure 6 - CTB2 Field Control Wiring........................................................22

Figure 7 - CTB3 Field Control Wiring........................................................22

Figure 8 - Discharge Air Sensor Field Wiring ............................................23

Figure 9 - Optional Suction Temperature Sensor Field Wiring ..................23

Figure 10 - Discharge Air Temperature Control .........................................121

Figure 11 - Suction Pressure Control ..........................................................124

Figure 12 - Field & Factory Electrical Connections –

Optional Remote Temperature Reset Board ............................. 129

Figure 13 - MicroBoard Layout ..................................................................133

Figure 14 - MicroBoard Relay Contact Architecture ..................................139

Figure 15 - Printer-To-Microboard Electrical Connections ........................140

Figure 16 - Elementary Diagram (YCUL0016 – YCUL0036).................... 148

Figure 17 - Elementary Diagram (YCUL0040) ..........................................152

Figure 18 - Elementary Diagram (YCUL0046 – YCUL0066).................... 156

Figure 19 - Elementary Diagram (YCUL0076 – YCUL0090).................... 160

Figure 20 - Isolator Dimensions - Type CP-1..............................................166

Figure 21 - Isolator Dimensions - Type CP-2..............................................166

Figure 22 - Isolator Dimensions - R-Spring Seismic Isolators....................167

Figure 23 - Isolator Installation & Adjustment - Type CP Mounting .........168

Figure 24 - Isolator Installation & Adjustment -

AEQM Spring-Flex Mounting..................................................169

YORK INTERNATIONAL

FORM 150.63-NM1

MANUAL USAGE AND REVISIONS

In complying with YORK’s policy for continuous product improvement, the information contained in this docu-

ment is subject to change without notice. While YORK makes no commitment to update or provide current infor-

mation automatically to the manual owner, that information, if applicable, can be obtained by contacting the nearest

YORK Service office. 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, verification with the equipment owner pertaining to equipment modifications and

current literature should be made prior to operating or servicing the equipment.

This document is intended for use by owner-authorized operating/service personnel. It is expected that anyone

operating or servicing this equipment possesses the knowledge that will enable them to perform tasks properly and

safely. It is essential that prior to performing any task on this equipment, the individual shall have read and under-

stood this document and any referenced materials. This individual shall also comply with all applicable governmen-

tal standards and regulations pertaining to the task in question.

It is the obligation and responsibility of operating/service personnel to work safely. Failure to comply with any of

these requirements could result in serious damage to the equipment and/or the property in which it is situated, as

well as severe personal injury or death to people at the site.

GENERAL SAFETY GUIDELINES

During installation, operation, maintenance or service, individuals may be exposed to certain components or condi-

tions including, but not limited to, refrigerants, oils, materials under pressure, rotating components, and both high

and low electrical voltages. Each of these items has the potential, if misused or handled improperly, to cause bodily

injury or death. It is essential that operating/service personnel identify and recognize these inherent hazards, protect

themselves, and proceed safely in completing their tasks.

Work on electronic equipment should not be undertaken unless the individual(s) have been

trained in the proper maintenance of equipment and is (are) familiar with its potential hazards.

Shut off power supply to the equipment before beginning work and follow lockout procedures.

When working inside equipment with power off, take care to discharge every capacitor likely to

hold dangerous potential.

Be careful not to contact high voltage connections when installing or operating this equipment.

LOW VOLTAGE

DO NOT be misled by the term “low voltage.” Voltages as low as 50 volts may cause death.

WARNING

HIGH VOLTAGE

Is used in the operation of this equipment.

DEATH OR SERIOUS INJURY

may result if personnel fail to observe safety precautions.

YORK INTERNATIONAL

PRODUCT IDENTIFICATION NUMBER (PIN)

YCUL0080SC46xAA

:R-22

BASIC MODEL NUMBER

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

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

Y 0### S C 1 7 A

C 1### 2 8 A

A40

U46

L58X

: YORK

: Chiller

: Air-Cooled

: Condensing

Unit

: Scroll

60HZ: Nominal Tons: Even Number

50HZ: Nominal kW: Odd Number

: Standard Unit :200 / 3/ 60

:230 / 3 /60

:380 / 3/ 60

:460 / 3/ 60

:575 / 3/ 60

:Across the Line

:Design Series A

:Engineering

Change

or PIN Level

EXAMPLES:

12345678910 11 12 13 14 15

YCUL0080SC46XAA

YORK INTERNATIONAL

FORM 150.63-NM1

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

SDTCATSRLXPRS25CX1XXXX3DWSARXBXX4BXXLXSD

OPTIONS MODEL NUMBER

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

: Aluminum

: Copper

: Black Fin

: Phenolic

: TEAO Fan

Motors

EVAPORATOR FIELD CONDENSER FIELD CABINET FIELD

: MP Supply TB

: SP Supply TB

: SP NF Disconnect Switch

: SP Circuit Breaker w/ Lockable Handle

: Control Transformer (factory)

: Power Factor Capacitor

: Wire Condenser Headers Only (factory)

: Wire (Full Unit) Enclosure Panels (factory)

: Wire (Full Unit) Enclosure Panels (field)

: Wire/Louvered Enclosure Panels (factory)

: Wire/Louvered Enclosure Panels (field)

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

: Louvered (Cond. Only) Enclosure Panels (field)

: Louvered (Full Unit) Enclosure Panels (factory)

: Louvered (Full Unit) Enclosure Panels (field)

: Acoustic Sound Blanket

: Low Sound Fans

: 1" Deflection

: Seismic

: Neoprene Pads

: 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./cETL)

: No Listing (typically 50HZ non-CE,

non-U.L.

: Remote Control Panel

: Sequence Control & Automatic

Lead Transfer

: Temp. Brine (LBrT)

: Thermal Storage

: Chicago Relief

Code

: Hot Gas By-Pass

(# circuits)

: 300 PSIG DWP Waterside

: Double Thick Insulation

: Weld Flange Kit

: Victaulic Flange Kit

: Flow Switch

: ASME Pressure Vessel &

Associated Codes

: Remote DX Cooler

1617 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

XX L ##

SX H TS

SD A C

BX TS

GX1

CSXXXX

XPRS

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. / ETL; CE; ARI; ETC.) will contain info. based on the first 14 characters only.

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

May differ in

thefuture.

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

3XX

DC1

WB2

VP3

SXX4

A 5

XXXLX1

YORK INTERNATIONAL

2 OR 3 COMPRESSORS PER SYSTEM

OIL EQUALIZING

LINE

AIR COOLED CONDENSERS

SERVICE VALVE

OPTIONAL DISCHARGE

PRESSURE TRANSDUCER

HIGH PRESSURE

CUTOUT SWITCH

SERVICE

VALVE

LOW PRESSURE SWITCH OR

SUCTION PRESSURE TRANSDUCER

DISCHARGE LINE

BALL VALVE

LIQUID LINE

SERVICE VALVE

LIQUID LINE

SOLENOID VALVE

** TXV

SUCTION LINE

BALL VALVE

SIGHT GLASS /

MOISTURE INDICATOR

SOLENOID OPERATED

HOT GAS BYPASS VALVE

YCUL REFRIGERANT FLOW DIAGRAM

NOTE:YCUL0046-0090 HAVE TWO REFRIGERANT SYSTEMS

* HOT GAS OPTION - SYSTEM 1 ONLY

LIQUID LINE

FILTER DRIER

EVAP.

AIR FLOW

DISCHARGE AIR

TEMPERATURE SENSOR

OPTIONAL SUCTION

TEMP SENSOR

FACTORY PIPING

FIELD PIPING

**One TXV and Liquid Line Solenoid shown for illustration purposes. Actual refrigerant piping may vary depending on evaporator circuiting.

LD04284

REFRIGERANT FLOW DIAGRAM

FIG. 1 – REFRIGERANT FLOW DIAGRAM

Installation

YORK INTERNATIONAL

FORM 150.63-NM1

GENERAL

To ensure warranty coverage, this

equipmentmustbecommissioned and

serviced by an authorized YORK ser-

vice mechanic or a qualified 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 cut-out settings, design working

pressures, and ventilation require-

mentsconsistent with theamountand

type of refrigerant charge.

Lethal voltages exist within the con-

trolpanels.Beforeservicing,openand

tag 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 (see photo below).

3. Open the unit only after piping is installed and

evacuation is complete.

4. Pipe unit using good piping practice (refer to

ASHRAE handbook).

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 unit.

HANDLING

These condensing units are shipped as completely as-

sembled units containing a 6 lb. (2.7 kg) refrigerant

holding charge, but require field installation of a liquid

line filter drier, TXV, liquid line solenoid, sight glass,

discharge air temperature sensor, and refrigerant pip-

ing to the air handling unit. Care should be taken to

avoid damage due to rough handling.

The unit should be lifted by inserting hooks through

the holes provided in unit base rails. Spreader bars must

be used to avoid crushing the unit frame rails with the

lifting chains (See photo).

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. A written request for in-

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

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

information and details.

LOCATION AND CLEARANCES

These units are designed for rooftop or ground level

outdoor installations. Location should be selected for

minimum sun exposure and to insure adequate supply

of fresh air for the condenser coils. The units must be

installed with sufficient clearances for air entrance to

the condenser coil, for air discharge away from the con-

denser, and for servicing access.

In installations where winter operation is intended and

snow accumulations are expected, additional height

must be provided to insure normal condenser air flow.

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

SIONS” section.

00096 (rig)VIP

SECTION 1 – INSTALLATION

YORK INTERNATIONAL

FOUNDATION

The unit should be mounted on a flat and level founda-

tion, floor, or rooftop capable of supporting the entire

operating weight of the equipment. See PHYSICAL

DATA for operating weight. If the unit is elevated be-

yond the normal reach of service personnel, a suitable

catwalk must be capable of supporting service person-

nel, their equipment, and the compressors.

GROUND LEVEL LOCATIONS

It is important that the units be installed on a substan-

tial base that will not settle. A one piece concrete slab

with footers extended below the frost line is highly rec-

ommended. Additionally, the slab should not be tied to

the main building foundations as noise and vibration

may be transmitted. Mounting holes are provided in

the steel channel for bolting the unit to its foundation.

(See DIMENSIONS.)

For ground level installations, precautions should be

taken to protect the unit from tampering by or injury to

unauthorized persons. Screws and/or latches on access

panels will prevent casual tampering. However, further

safety precautions such as a fenced-in enclosure or lock-

ing devices on the panels may be advisable.

ROOFTOP LOCATIONS

Choose a spot with adequate structural strength to safely

support the entire weight of the unit and service per-

sonnel. Care must be taken not to damage the roof.

Consult the building contractor or architect if the roof

is bonded. Roof installations should have rubber, or vi-

bration isolators under the base to minimize vibration.

NOISE SENSITIVE LOCATIONS

Efforts should be made to assure that the unit is not

located next to occupied spaces or noise sensitive ar-

eas where noise level would be a problem. The unit

noise is a result of compressor and fan operation. Con-

siderations should be made utilizing noise levels pub-

lished in the YORK Engineering Guide for the specific

unit model. Sound blankets for the compressors and

low sound fans are available.

SPRING ISOLATORS (OPTIONAL)

When ordered, four (4) isolators will be furnished.

Identify the isolator, and locate at the proper mounting

point, and adjust per instructions. See Appendix 1.

COMPRESSOR MOUNTING

The compressors are mounted on four (4) rubber isola-

tors. The mounting bolts should not be loosened or ad-

justed at installation of the condensing unit.

ELECTRICAL WIRING

Field Wiring

Power wiring must be provided through a fused discon-

nect switch to the unit terminals (or optional molded

disconnect switch) in accordance with N.E.C. or local

coderequirements. Minimumcircuit ampacityand maxi-

mum dual element fuse size are given in the ELECTRI-

CAL DATA tables.

A 120-1-60, 15 amp source must be supplied for the

control panel through a fused disconnect when a con-

trol panel transformer (optional) is not provided. Refer

to Table 6 and Figures 2 - 4.

See Figures 1 - 4 and unit wiring diagrams for field and

power wiring connections. Refer to section on UNIT

OPERATIONfor adetailed descriptionof operationcon-

cerning unit contacts and inputs.

Liquid Line Solenoid Connections

The field supplied and installed liquid line solenoid

valves should be installed at the evaporator and wired

using 18 AWG minimum wire. Electrical connections

should be made at Terminal Board CTB3. CTB3 is lo-

cated in the power panel on the right side of the panel.

Note that power for the solenoid coil is 120 VAC.

Refer to Figure 7 and unit wiring diagram.

Discharge Air Sensor

The discharge air sensor and associated connector hard-

wareis factory supplied but mustbe fieldinstalled. Field

Installation

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