York YCAL Series Owner's manual

YCAL0041EC–YCAL0071EC
AIR-COOLED
SCROLL CHILLERS
STYLE D
WITH IPU II and I/O BOARDS
(50 Hz)
29 TON TO 65 TON
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Supersedes 150.66-NM3 (110) Form 150.66-NM3 (920)
R-410A
035-20895-001
Issue Date:
September 25, 2020

JOHNSON CONTROLS
2
FORM 150.66-NM3
ISSUE DATE: 09/25/2020
This equipment is a relatively complicated apparatus.
During rigging, installation, operation, maintenance,
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to:
heavy objects, refrigerants, 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 obligation and responsibility of rigging, instal-
lation, and 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
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
rigging, installation, and operating/service personnel. It
is expected that these individuals possess 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 understood the on-product labels,
this document and any referenced materials. This in-
dividual shall also be familiar with and comply with
all applicable industry and governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Identies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Indicates a potentially hazardous situa-
tion which will result in possible injuries
or damage to equipment if proper care is
not taken.
External wiring, unless specied as an optional connection in the manufacturer’s product line, is
not to be connected inside the control cabinet. Devices such as relays, switches, transducers and
controls and any external wiring must not be installed inside the micro panel. All wiring must be in
accordance with Johnson Controls’ published specications and must be performed only by a qualied
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

FORM 150.66-NM3
ISSUE DATE: 09/25/2020
3
JOHNSON CONTROLS
AFFECTED PAGES DESCRIPTION
3 Conditioned Based Maintenance program information added
18 Millennium Control Center information updated
43 Pressure values updated in examples
78-88 SI units of measurement in tables corrected
119 Pressure values updated
122 Program key limits and defaults updated
136 Pressure values updated
151–152 Pressure values updated
162–165 BACnet and Modbus Communications Data Map updated to latest revision
167–172 YorkTalk 2 Communications Data Map updated to latest revision
Global Refrigerant updated to R-410A
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the John-
son Controls Knowledge Exchange website at https://
docs.johnsoncontrols.com/chillers/.
It is the responsibility of rigging, lifting, and operating/
service personnel to verify the applicability of these
documents to the equipment. If there is any question
regarding the applicability of these documents, rig-
ging, lifting, and operating/service personnel should
verify whether the equipment has been modified and
if current literature is available from the owner of the
equipment prior to performing any work on the chiller.
REVISION NOTES
Revisions made to this document are indicated in the following table. These revisions are to technical information,
and any other changes in spelling, grammar, or formatting are not included.
CONDITIONED BASED MAINTENANCE
Traditional chiller maintenance is based upon assumed
and generalized conditions. In lieu of the traditional
maintenance program, a Johnson Controls YORK
Conditioned Based Maintenance (CBM) program can
be substituted. This CBM service plan is built around
the specific needs for the chiller, operating conditions,
and annualized impact realized by the chiller. Your lo-
cal Johnson Controls Branch can propose a customized
Planned Service Agreement that leverages real time
and historical data, delivering performance reporting,
corrective actions required and data enabled guidance
for optimal operation and lifecycle assurance. The pro-
gram will include fault detection diagnostics, operation
code statistics, performance based algorithms and ad-
vance rules based rationale delivered by the Johnson
Controls Connected Equipment Portal.

JOHNSON CONTROLS
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THIS PAGE INTENTIONALLY LEFT BLANK

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TABLE OF CONTENTS
GENERAL SAFETY GUIDELINES ............................................................................................................2
CHANGEABILITY OF THIS DOCUMENT .................................................................................................3
REVISION NOTES.......................................................................................................................................3
TABLE OF CONTENTS...............................................................................................................................5
LIST OF FIGURES.....................................................................................................................................10
LIST OF TABLES.......................................................................................................................................11
SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY......................................................13
INTRODUCTION .................................................................................................................................13
WARRANTY.........................................................................................................................................13
SAFETY................................................................................................................................................13
Standards for Safety ......................................................................................................................13
RESPONSIBILITY FOR SAFETY......................................................................................................14
ABOUT THIS MANUAL ......................................................................................................................14
MISUSE OF EQUIPMENT ..................................................................................................................14
Suitability for Application..............................................................................................................14
Structural Support..........................................................................................................................14
Mechanical Strength .....................................................................................................................14
General Access...............................................................................................................................14
Pressure Systems ..........................................................................................................................14
Electrical .........................................................................................................................................15
Rotating Parts.................................................................................................................................15
Sharp Edges ...................................................................................................................................15
Refrigerants and Oils .....................................................................................................................15
High Temperature and Pressure Cleaning...................................................................................15
Emergency Shutdown....................................................................................................................15
SECTION 2 - PRODUCT DESCRIPTION ................................................................................................17
INTRODUCTION .................................................................................................................................17
GENERAL SYSTEM DESCRIPTION.................................................................................................17
Compressors ..................................................................................................................................17
Cooler ..............................................................................................................................................17
Condenser.......................................................................................................................................18
Millennium Control Center ............................................................................................................18
UNIT .................................................................................................................................................18
Unit On/O󰀨 ......................................................................................................................................19
Power Panel ....................................................................................................................................19
ACCESSORIES AND OPTIONS........................................................................................................20
Power Options ................................................................................................................................20
Control Options ..............................................................................................................................20
Compressor, Piping, Evaporator Options....................................................................................21
Condenser and Cabinet Options ..................................................................................................22
Sound Reduction Options .............................................................................................................22
UNIT COMPONENTS..........................................................................................................................23
CONTROL / POWER PANEL COMPONENTS .................................................................................24
PRODUCT IDENTIFICATION NUMBER (PIN) .................................................................................25

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TABLE OF CONTENTS (CONT’D)
REFRIGERANT FLOW DIAGRAM ....................................................................................................30
SECTION 3 - HANDLING AND STORAGE .............................................................................................31
DELIVERY AND STORAGE ...............................................................................................................31
INSPECTION .......................................................................................................................................31
MOVING THE CHILLER .....................................................................................................................31
Lifting Weights ...............................................................................................................................31
UNIT RIGGING ....................................................................................................................................32
SECTION 4 - INSTALLATION...................................................................................................................33
INSTALLATION CHECKLIST ............................................................................................................33
HANDLING...........................................................................................................................................33
INSPECTION .......................................................................................................................................33
LOCATION AND CLEARANCES.......................................................................................................33
Foundation......................................................................................................................................34
Ground Level Locations ................................................................................................................34
Rooftop Locations..........................................................................................................................34
Noise Sensitive Locations.............................................................................................................34
SPRING ISOLATORS (OPTIONAL) ..................................................................................................34
COMPRESSOR MOUNTING..............................................................................................................34
REMOTE COOLER OPTION..............................................................................................................34
CHILLED LIQUID PIPING ..................................................................................................................34
DUCT WORK CONNECTION ............................................................................................................35
General Requirements ..................................................................................................................35
WIRING ................................................................................................................................................35
Evaporator Pump Start Contacts..................................................................................................36
System Run Contacts ....................................................................................................................36
Alarm Status Contacts...................................................................................................................36
Remote Start/Stop Contacts..........................................................................................................36
PWM Input.......................................................................................................................................36
Load Limit Input .............................................................................................................................36
Flow Switch Input...........................................................................................................................36
COMPRESSOR HEATERS ................................................................................................................36
SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED
DISCONNECT SWITCH OR CIRCUIT BREAKER (0041 - 0071) ....................................................37
CONTROL WIRING.............................................................................................................................38
SECTION 5 - COMMISSIONING ..............................................................................................................39
PREPARATION – POWER OFF.........................................................................................................39
Inspection ......................................................................................................................................39
Refrigerant Charge.........................................................................................................................39
Service and Oil Line Valves...........................................................................................................39
Compressor Oil ..............................................................................................................................39
Fans ................................................................................................................................................39
Isolation / Protection......................................................................................................................39
Control Panel ..................................................................................................................................39
Power Connections........................................................................................................................39
Grounding .......................................................................................................................................39
Supply Voltage................................................................................................................................40

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TABLE OF CONTENTS (CONT’D)
PREPARATION – POWER ON...........................................................................................................40
Switch Settings...............................................................................................................................40
Compressor Heaters ......................................................................................................................40
Water System..................................................................................................................................40
Flow Switch.....................................................................................................................................40
Temperature Sensor(s) ..................................................................................................................40
EQUIPMENT PRE-STARTUP AND STARTUP CHECKLIST ..........................................................41
Pre-Startup......................................................................................................................................41
Startup.............................................................................................................................................41
CHECKING SUPERHEAT AND SUBCOOLING...............................................................................43
LEAK CHECKING ...............................................................................................................................43
UNIT OPERATING SEQUENCE ........................................................................................................44
SECTION 6 - TECHNICAL DATA .............................................................................................................45
OPERATIONAL LIMITATIONS (ENGLISH) ......................................................................................45
Voltage Limitations ........................................................................................................................45
OPERATIONAL LIMITATIONS (SI) ...................................................................................................47
Voltage Limitations ........................................................................................................................47
PHYSICAL DATA (ENGLISH) ............................................................................................................50
SOUND DATA (ENGLISH)..................................................................................................................52
ELECTRICAL DATA............................................................................................................................54
ELECTRICAL NOTES AND LEGEND...............................................................................................57
WIRING DIAGRAMS...........................................................................................................................58
DIMENSIONS.......................................................................................................................................64
TECHNICAL DATA - CLEARANCES ................................................................................................92
ISOLATORS.........................................................................................................................................93
General ............................................................................................................................................93
Installation of 1" Deection Mounts .............................................................................................95
SECTION 7 - UNIT CONTROLS...............................................................................................................99
YORK MILLENNIUM CONTROL CENTER.......................................................................................99
INTRODUCTION .................................................................................................................................99
MICROPROCESSOR BOARD...........................................................................................................99
UNIT SWITCH....................................................................................................................................100
DISPLAY ............................................................................................................................................100
KEYPAD .............................................................................................................................................100
BATTERY BACK-UP.........................................................................................................................100
TRANSFORMER ..............................................................................................................................100
SINGLE SYSTEM SELECT AND PROGRAMMING # OF COMPRESSORS ..............................100
STATUS KEY .....................................................................................................................................101
Unit Status ....................................................................................................................................101
General Status Messages............................................................................................................101
Fault Safety Status Messages.....................................................................................................103
System Safeties............................................................................................................................103
Unit Safeties..................................................................................................................................105
Unit Warning .................................................................................................................................105

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STATUS KEY MESSAGES...............................................................................................................106
DISPLAY/PRINT KEYS.....................................................................................................................107
Oper Data Key...............................................................................................................................107
Print Key........................................................................................................................................ 111
Operating Data Printout............................................................................................................... 111
History Printout ............................................................................................................................112
History Displays ...........................................................................................................................112
Software Version ..........................................................................................................................114
ENTRY KEYS.....................................................................................................................................115
Up and Down Arrow Keys............................................................................................................115
Enter/Adv Key...............................................................................................................................115
SETPOINTS KEYS............................................................................................................................116
Cooling Setpoints.........................................................................................................................116
Leaving Chilled Liquid Control ...................................................................................................116
Return Chilled Liquid Control .....................................................................................................117
Remote Setpoint Control .............................................................................................................117
Schedule/Advance Day Key ........................................................................................................117
Program Key .................................................................................................................................119
UNIT KEYS .......................................................................................................................................124
Options Key ..................................................................................................................................124
CLOCK ...............................................................................................................................................128
SECTION 8 - UNIT OPERATION............................................................................................................131
CAPACITY CONTROL......................................................................................................................131
SUCTION PRESSURE LIMIT CONTROLS ....................................................................................131
DISCHARGE PRESSURE LIMIT CONTROLS...............................................................................131
LEAVING CHILLED LIQUID CONTROL.........................................................................................131
LEAVING CHILLED LIQUID SYSTEM COMPRESSOR SEQUENCING .....................................132
LEAVING CHILLED LIQUID CONTROL OVERRIDE TO REDUCE CYCLING...........................132
RETURN CHILLED LIQUID CONTROL..........................................................................................133
RETURN CHILLLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING ......134
ANTI-RECYCLE TIMER....................................................................................................................134
ANTI-COINCIDENCE TIMER ...........................................................................................................134
EVAPORATOR PUMP CONTROL...................................................................................................134
EVAPORATOR HEATER CONTROL...............................................................................................135
PUMPDOWN CONTROL ..................................................................................................................135
CONDENSER FAN CONTROL (YCAL0041 – YCAL0071 CHILLERS) ........................................135
STANDARD CONDENSER FAN CONTROL - YCAL0041 – YCAL0071.......................................136
LOW AMBIENT FAN CONTROL OPTION......................................................................................137
General ..........................................................................................................................................137
Conguration (Jumpers and Potentiometers)...........................................................................138
Wiring ............................................................................................................................................139
PROGRAMMING...............................................................................................................................140
LOAD LIMITING ................................................................................................................................140
COMPRESSOR RUN STATUS.........................................................................................................141
ALARM STATUS ...............................................................................................................................141
TABLE OF CONTENTS (CONT’D)

FORM 150.66-NM3
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EMS-PWM REMOTE TEMPERATURE RESET..............................................................................141
BAS/EMS TEMPERATURE RESET OPTION.................................................................................142
SECTION 9 - SERVICE AND TROUBLESHOOTING...........................................................................145
CLEARING HISTORY BUFFERS ....................................................................................................145
SERVICE MODE................................................................................................................................145
SERVICE MODE – OUTPUTS..........................................................................................................145
SERVICE MODE – CHILLER CONFIGURATION ..........................................................................145
SERVICE MODE – INPUTS..............................................................................................................146
CONTROL INPUTS/OUTPUTS ........................................................................................................147
CHECKING INPUTS AND OUTPUTS .............................................................................................149
Digital Inputs.................................................................................................................................149
Analog Inputs – Temperature......................................................................................................149
Outside Air Sensor.......................................................................................................................149
Liquid & Refrigerant Sensor Test Points ...................................................................................150
Analog Inputs – Pressure ............................................................................................................151
Digital Outputs..............................................................................................................................152
OPTIONAL PRINTER INSTALLATION ...........................................................................................153
Parts ..............................................................................................................................................153
Assembly and Wiring...................................................................................................................153
Obtaining a Printout.....................................................................................................................153
SECTION 10 - MAINTENANCE..............................................................................................................157
IMPORTANT ......................................................................................................................................157
COMPRESSORS...............................................................................................................................157
Oil Level Check ............................................................................................................................157
Oil Analysis...................................................................................................................................157
CONDENSER FAN MOTORS ..........................................................................................................157
CONDENSER COILS........................................................................................................................157
OPERATING PARAMETERS ...........................................................................................................157
ON-BOARD BATTERY BACK-UP ...................................................................................................157
PLATE AND FRAME HEAT EXCHANGER (EVAPORATOR) HEATER .......................................157
OVERALL UNIT INSPECTION ........................................................................................................158
BACNET, MODBUS AND YORKTALK 2 COMMUNICATIONS ....................................................158
BACnet and Modbus Communications......................................................................................161
Communications Data Map Notes ..............................................................................................161
YorkTalk 2 Communications........................................................................................................166
TABLE OF CONTENTS (CONT’D)

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FORM 150.66-NM3
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LIST OF FIGURES
FIG. 1 – REFRIGERANT FLOW DIAGRAM ..........................................................................................30
FIG. 2 – SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED
DISCONNECT SWITCH OR CIRCUIT BREAKER (0041 - 0071)...........................................37
FIG. 3 – CONTROL WIRING...................................................................................................................38
FIG. 4 – CONTROL CIRCUIT..................................................................................................................58
FIG. 5 – POWER CIRCUIT......................................................................................................................60
FIG. 6 – WIRING DETAILS......................................................................................................................61
FIG. 7 – CONNECTION DIAGRAM ........................................................................................................62
FIG. 8 – CONNECTION DIAGRAM MICROBOARD (PARTIAL) .........................................................63
FIG. 9 – UNIT CLEARANCES.................................................................................................................92
FIG. 10 – LEAVING WATER TEMPERATURE CONTROL EXAMPLE ...............................................132
FIG. 11 – SETPOINT ADJUST................................................................................................................132
FIG. 12 – YCAL0041 – YCAL0071 FAN LOCATION (TYPICAL) .........................................................136
FIG. 13 – TYPICAL INVERTER LOCATION..........................................................................................137
FIG. 14 – INVERTER ENCLOSURE.......................................................................................................137
FIG. 15 – POTENTIOMETER SETTINGS ..............................................................................................138
FIG. 16 – INVERTER POWER WIRING SCHEMATIC..........................................................................139
FIG. 17 – INVERTER WIRING ................................................................................................................139
FIG. 18 – FIELD AND FACTORY ELECTRICAL CONNECTIONS OPTIONAL REMOTE
TEMPERATURE RESET BOARD ..........................................................................................143
FIG. 19 – IPU II & I/O LAYOUT ...............................................................................................................148
FIG. 20 – MICROBOARD RELAY CONTACT ARCHITECTURE.........................................................152
FIG. 21 – PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS ..........................................153
FIG. 22 – MICRO PANEL CONNECTIONS............................................................................................159