York Ycal0012ec Owner's manual

YCAL0012EC–YCAL0032EC

AIR-COOLED

SCROLL CHILLERS

STYLE D

WITH IPU II and I/O BOARDS

(60 Hz)

9 1/2 TON TO 28 TON

INSTALLATION, OPERATION, MAINTENANCE

AIR-COOLED LIQUID CHILLERS

HERMETIC SCROLL

Supersedes 150.66-NM2 (608) Form 150.66-NM2 (920)

R-410A

035-21552-000

Issue Date:

September 25, 2020

JOHNSON CONTROLS

FORM 150.66-NM2

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:

Identifies a hazard which could lead

to damage to the machine, damage to

other equipment and/or environmental

pollution if proper care is not taken or

instructions 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 warning

will void the manufacturer’s warranty and cause serious damage to property or personal injury.

FORM 150.66-NM2

ISSUE DATE: 09/25/2020

JOHNSON CONTROLS

AFFECTED PAGES DESCRIPTION

3 Conditioned Based Maintenance program information added

18 Millennium Control Center information updated

43 Pressure values updated in examples

119 Pressure values updated

121 Program key limits and defaults updated

132 Pressure values updated

149–150 Pressure values updated

Global Updated refrigerant to R-410A

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for contin-

uous product improvement, the information contained

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 appli-

cable, can be obtained by contacting the nearest John-

son Controls Service office or accessing the Johnson

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 tradition-

al 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

FORM 150.66-NM2

ISSUE DATE: 09/25/2020

TABLE OF CONTENTS

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 ...............................................................................................................................15

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

Power Panel .........................................................................................................................................19

ACCESSORIES AND OPTIONS ..............................................................................................................20

Power Options: ....................................................................................................................................20

Control Options: ..................................................................................................................................20

Compressor, Piping, Evaporator Options .........................................................................................21

Condenser and Cabinet Options........................................................................................................21

Sound Reduction Options ..................................................................................................................22

UNIT COMPONENTS ................................................................................................................................23

CONTROL / POWER PANEL COMPONENTS........................................................................................24

PRODUCT IDENTIFICATION NUMBER (PIN)........................................................................................25

BASIC UNIT NOMENCLATURE ..............................................................................................................25

REFRIGERANT FLOW DIAGRAM ..........................................................................................................30

SECTION 3 - HANDLING AND STORAGE....................................................................................31

DELIVERY AND STORAGE......................................................................................................................31

INSPECTION..............................................................................................................................................31

FORM 150.66-NM2

ISSUE DATE: 09/25/2020

JOHNSON CONTROLS

TABLE OF CONTENTS (cont’d)

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

WIRING.......................................................................................................................................................35

Evaporator Pump Start Contacts .......................................................................................................36

System Run Contacts .........................................................................................................................36

Alarm Status Contacts ........................................................................................................................36

Remote Start/Stop Contacts...............................................................................................................36

Remote Emergency Cuto󰀨 .................................................................................................................36

PWM Input ............................................................................................................................................36

Load Limit Input...................................................................................................................................36

Flow Switch Input ................................................................................................................................36

COMPRESSOR HEATERS.......................................................................................................................36

SINGLE POINT SUPPLY CONNECTION ................................................................................................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

PREPARATION – POWER ON .................................................................................................................40

Switch Settings....................................................................................................................................40

Compressor Heaters ...........................................................................................................................40