York YCAL Series User manual

SERVICE POLICY & PROCEDURES
YCAL0012-0032 60 HZ
START-UP CHECKLIST
Supersedes: 150.66-CL2 (309) Form 150.66-CL2 (820)
COMMISSIONING
Commissioning of this unit should only
be carried out by Johnson Controls
Authorized personnel.
Commissioning personnel should be thoroughly familiar
with the information contained in this literature, in ad-
dition to this section.
Perform the commissioning using the detailed checks
outlined in the Equipment Startup Checklist as the com-
missioning procedure is carried out.
PREPARATION – POWER OFF
The following basic checks should be made with the
customer power to the unit switched OFF.
Inspection
Inspect unit for installation damage. If found, take action
and/or repair as appropriate.
Refrigerant Charge
Packaged units are normally shipped as standard with a
full refrigerant operating charge. Check that refrigerant
pressure is present in both systems and that no leaks are
apparent. If no pressure is present, a leak test must be
undertaken, the leak(s) located and repaired. Remote
systems and units are supplied with a nitrogen hold-
ing charge. These systems must be evacuated with a
suitable vacuum pump/recovery unit as appropriate to
below 500 µm.
Do not liquid charge with static water in the cooler.
Care must also be taken to liquid charge slowly to avoid
excessive thermal stress at the charging point. Once the
vacuum is broken, charge into the condenser coils with
the full operating charge.
Service and Oil Line Valves
Open each compressor suction, economizer, and dis-
charge service valve. If valves are of the back-seat type,
open them fully (counterclockwise) then close one turn
of the stem to ensure operating pressure is fed to pressure
transducers. Open the liquid line service valve and oil
return line ball valve fully in each system.
Compressor Oil
To add oil to a circuit - connect a YORK hand oil pump
(Part No. 470-10654-000) to the 1/4 in. oil charging
valve on the oil separator piping with a length of clean
hose or copper line, but do not tighten the are nut. Us-
ing clean oil of the correct type (F oil), pump oil until
all air has been purged from the hose then tighten the
nut. Stroke the oil pump to add oil to the oil system.
The oil level should be between the middle of the lower
and middle of the upper sight glasses of the oil separa-
tor. Approximately 4 gal to 5 gal is present in the each
refrigerant system, with typically 1 gal to 2 gal in each
oil separator. Oil levels in the oil separators above the
top sight glass in either oil separator should be avoided
and may cause excessive oil carryover in the system.
High oil concentration in the system may cause nuisance
trips resulting from incorrect readings on the level sensor
and temperature sensors. Temperature sensor errors may
result in poor liquid control and resultant liquid overfeed
and subsequent damage to the compressor.
Fans
Check that all fans are free to rotate and are not dam-
aged. Ensure blades are at the same height when rotated.
Ensure fan guards are securely xed.
Isolation / Protection
Verify all sources of electrical supply to the unit are taken
from a single point of isolation. Check that the maximum
recommended fuse sizes given in the Technical Data
Section in IOM (150.66-NM2) has not been exceeded.

FORM 150.66-CL2 (820)
2JOHNSON CONTROLS
Control Panel
Check the panel to see that it is free of foreign materials
(wire, metal chips, or similar materials) and clean out
if required.
Power Connections
Check that the customer power cables are connected cor-
rectly to the terminal blocks or optional circuit breaker.
Ensure that connections of power cables within the pan-
els to the circuit breaker or terminal blocks are tight.
Grounding
Verify that the unit’s protective ground terminal(s) are
properly connected to a suitable grounding point. Ensure
that all unit internal ground connections are tight.
Supply Voltage
Verify that the site voltage supply corresponds to the
unit requirement and is within limits. Refer to Technical
Data Section in IOM (150.66-NM2).
PREPARATION – POWER ON
Perform the commissioning using the
detailed checks outlined in the
Equipment Startup Checklist as the
commissioning procedure is carried
out.
Apply power to the chiller. Turn ON the option panel
circuit breaker if supplied.
The machine is now live!
Switch Settings
Ensure the chiller OFF/ON UNIT switch at the bottom
of the keypad is OFF. Place the optional circuit breaker
handle on the panel door to ON. The customer’s discon-
nection devices can now be set to ON.
Verify the control panel display is illuminated. Ensure
the system switches under the SYSTEM SWITCHES
Key are in the OFF position.
Compressor Heaters
Verify the compressor heaters are energized. If the ambi-
ent temperature is above 96°F (36°C) the compressor
heaters must be on for at least 8 hours before start-up
to ensure all refrigerant liquid is driven out of the com-
pressor and the oil. If the ambient temperature is below
86°F (30°C), allow 24 hours.
Water System
Verify the chilled liquid system has been installed cor-
rectly, and has been commissioned with the correct di-
rection of water ow through the cooler. The inlet should
be at the refrigerant piping connection end of the cooler.
Purge air from the top of the cooler using the plugged
air vent mounted on the top of the cooler body.
Flow rates and pressure drops must be within limits.
Refer to the Technical Data Section of the IOM (150.66-
NM2). Operation outside of these limits is undesirable
and could cause damage.
If mains power must be switched OFF for extended
maintenance or an extended shutdown period, the com-
pressor suction, discharge and economizer service stop
valves should be closed (clockwise). If there is a pos-
sibility of liquid freezing due to low ambient tempera-
tures, the coolers should be drained or power should be
applied to the chiller. This will allow the cooler heater to
protect the cooler from freezing down to –20°F. Before
placing the unit back in service, valves should be opened
and power must be switched on (if power is removed
for more than 8 hours) for at least 8 hours (24 hours if
ambient temperature is below 86°F [30°C]) before the
unit is restarted.
Flow Switch
Verify a chilled water ow switch is correctly tted in
the customer’s piping on the cooler outlet, and wired into
the control panel correctly using shielded cable.
There should be a straight run of at least 5 pipe diameters
on either side of the ow switch. The ow switch should
be connected to terminals 2 and 13 in the panel.
Temperature Sensor(s)
Ensure the leaving liquid temperature sensor is coated
with heat conductive compound (Part No. 013-00890-
000) and is inserted to the bottom of the water outlet
sensor well in the cooler. This sensor also provides some
freeze protection and must always be fully inserted in
the water outlet sensor well.

FORM 150.66-CL2 (820)
JOHNSON CONTROLS 3
JOB NAME: ______________________________
SALES ORDER #: _________________________
LOCATION: ______________________________
SOLD BY: ________________________________
INSTALLING
CONTRACTOR: ___________________________
START-UP
TECHNICIAN/
COMPANY: _______________________________
START-UP DATE : _________________________
CHILLER MODEL #: _______________________
SERIAL #: ______________________________
CHECKING THE SYSTEM
PRIOR TO INITIAL START (NO POWER)
Unit Checks
1. Inspect the unit for shipping or installation dam-
age.
2. Ensure that all piping has been completed.
3. Visually check for refrigerant piping leaks.
4. Open suction line ball valve, discharge line ball
valve, and liquid line valve for each system.
5. The compressor oil level should be maintained so
that an oil level is visible in the sight glass. The
oil level can only be tested when the compressor
is running in stabilized conditions, guaranteeing
that there is no liquid refrigerant in the lower shell
of the compressor. In this case, the oil should be
between 1/4 and 1/2 in the sight glass. At shut-
down, the oil level can fall to the bottom limit of
the oil sight glass.
6. Ensure water pumps are on. Check and adjust
water pump ow rate and pressure drop across
the cooler. Verify ow switch operation.
Excessive ow may cause catastrophic
damage to the evaporator.
EQUIPMENT STARTUP CHECKLIST
7. Check the control panel to ensure it is free of
foreign material (wires, metal chips, or similar
material).
8. Visually inspect wiring (power and control). Wir-
ing MUST meet NEC and local codes.
9. Check tightness of power wiring inside the power
panel on both sides of the motor contactors and
overloads.
10.Check for proper size fuses in main and control
circuits, and verify overload setting corresponds
with RLA and FLA values. Refer to Electrical
Tables in the IOM (150.66-NM2) or unit name-
plate.
11.Ensure 120 VAC Control Power to TB1 has 15 A
minimum capacity.
12.Be certain all water temp sensors are inserted
completely in their respective wells and are coated
with heat conductive compound.
13.Ensure that evaporator TXV bulbs are strapped
onto the suction lines at 4 or 8 o’clock positions
or suction temp. sensors if EEVs are installed.
COMPRESSOR HEATERS
(POWER ON – 24 HOURS BEFORE START)
1. Apply 120 VAC and verify its value between
terminals 5 and 2 of TB1. The voltage should be
120 VAC ± 10%.
Power must be applied 24 hours before start-up.
Each heater should draw approximately 0.5 A to
1A.
PANEL CHECKS
(POWER ON – BOTH UNIT SWITCHES OFF)
1. Apply three-phase power and verify its value.
Voltage imbalance should be no more than 2% of
the average voltage.
2. Apply 120 VAC and verify its value on the ter-
minal block in the Power Panel. Make the mea-
surement between terminals 5 and 2 of TB1. The
voltage should be 120 VAC +/- 10%.
3. Program/verify the Cooling Setpoints, Program
Setpoints, and unit Options. Record the values in
Table 1.

FORM 150.66-CL2 (820)
4JOHNSON CONTROLS
4. Put the unit into Service Mode and cycle each
condenser fan to ensure proper rotation.
5. Connect a manifold gauge to system 1 suction and
discharge service valves.
Place the Unit Switch in the control panel to the
“ON” position. As each compressor cycles on,
ensure that the discharge pressure rises and the
suction pressure decreases. If this does not oc-
cur, the compressor being tested is operating in
the reverse direction and must be corrected. After
verifying proper compressor rotation, turn the Unit
Switch to “OFF.”
The chilled liquid setpoint may need to
be temporarily lowered to ensure all
compressors cycle “ON.”
This unit uses scroll compressors
which can only operate in one direc-
tion. Failure to observe this will lead
to compressor failure.
The chilled liquid setpoint may need to
be temporarily lowered to ensure all
compressors cycle “ON”.
CHECKING SUPERHEAT AND SUBCOOLING
The subcooling temperature of each system can be cal-
culated by recording the temperature of the liquid line
at the outlet of the condenser and subtracting it from
the liquid line saturation temperature at the liquid stop
valve (liquid line saturation temp. is converted from a
temperature/pressure chart).
Example:
Liquid line pressure =
328 psig converted to temp. 102°F
minus liquid line temp. - 87°F
Subcooling = 15°F
The subcooling should be adjusted to 15°F at design
conditions.
1. Record the liquid line pressure and its correspond-
ing temperature, liquid line temperature and sub-
cooling below:
SYS 1
Liq Line Press = _______ psig
Saturated Temp = _______ °F
Liq Line Temp = _______ °F
Subcooling = _______ °F
OPTIONS
Display Language
Sys 1 Switch
Chilled Liquid
* Ambient Control
Local/Remote Mode
Control Mode
Display Units
* Lead/Lag Control
* Fan Control
Manual Override
Current Feedback
** Soft Start
** Unit Type
** Refrigerant Type
** Expansion Valve Type
COOLING SETPOINTS
Cooling Setpoint
Range
EMS-PWM Max. Setpoint
PROGRAM
Discharge Pressure Cutout
Suct. Pressure Cutout
Low Amb. Temp. Cutout
Leaving Liquid Temp. Cutout
Anti-Recycle Time
Fan Control On Pressure
  FanDi󰀨erentialO󰀨Pressure
Total # of Compressors
* Number of Fans/System
* Unit/Sys Voltage
Unit ID
* Sys 1 Superheat Setpoint
TABLE 1 – SETPOINTS ENTRY LIST
* NOT ON ALL MODELS
** VIEWABLE ONLY

FORM 150.66-CL2 (820)
JOHNSON CONTROLS 5
After the subcooling is veried, the suction superheat
should be checked. The superheat should be checked only
after steady state operation of the chiller has been estab-
lished, the leaving water temperature has been pulled down
to the required leaving water temperature, and the unit is
running in a fully loaded condition. Correct superheat set-
ting for a system is 10°F to 15°F (5.56°C to 8.33°C) 18 in.
(46 cm) from the cooler.
Set superheat for no less than 10°F with only a single
compressor running on a circuit. The superheat is cal-
culated as the dierence between the actual temperature
of the returned refrigerant gas in the suction line enter-
ing the compressor and the temperature corresponding
to the suction pressure as shown in a standard pressure/
temperature chart.
Example:
Suction Temp = 46°F
minus Suction Press
106 psig converted to Temp - 34°F
Superheat = 12°F
When adjusting the expansion valve (TXV only), the
adjusting screw should be turned not more than one
turn at a time, allowing sucient time (approximately
15 minutes) between adjustments for the system and the
thermal expansion valve to respond and stabilize.
Ensure that superheat is set at a minimum of 10°F (5.56°C)
with a single compressor running on each circuit.
2. Record the suction temperature, suction pressure,
suction saturation temperature, and superheat of
each system below:
SYS 1
Suction Temp = _______ °F
Suction Pressure = _______ psig
Saturation Temp = _______ °F
Superheat = _______ °F
LEAK CHECKING
 1. Leak check compressors, ttings, and piping to
ensure no leaks.
If the unit is functioning satisfactorily during the initial
operating period, no safeties trip and the compressors
cycle to control water temperature to setpoint, the chiller
is ready to be placed into operation.

5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 1-800-524-1330 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2020 www.johnsoncontrols.com ALL RIGHTS RESERVED
Form 150.66-CL2 (820)
Issue Date: August 29, 2020
Supersedes: 150.66-CL2 (309)