York Ycal0019 Installation and operating instructions

LD10950

R-410A

035-21456-000

DUAL CIRCUIT

SINGLE CIRCUIT

YCAL0019, 0022, 0028, 0033, 0043, 0046, 0052, 0056, 0066

AIR-COOLED SCROLL CHILLERS

STYLE E (60 HZ)

15-65 TON

Products are produced at a

f a c i l i t y w h o s e q u a l i t y -

management systems are

ISO9001 certified.

Issue Date:

April 28, 2017

AIR-COOLED LIQUID CHILLERS

HERMETIC SCROLL

INSTALLATION, OPERATION, MAINTENANCE Supersedes 150.67-NM1 (1216) Form 150.67-NM1 (417)

JOHNSON CONTROLS

FORM 150.67-NM1

ISSUE DATE: 4/28/2017

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:

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.

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.

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 accor-

dance 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.

JOHNSON CONTROLS

FORM 150.67-NM1

ISSUE DATE: 4/28/2017

This manual contains installation, op-

eration and maintenance instructions

for both single and dual refrigerant

circuit models. If your unit is a single

circuit model (YCAL0019-0033) ,

disregard references to “System 2”

which may appear in this manual. Any

references to Sys 2 are applicable to

YCAL0043-0066 models.

SINGLE CIRCUIT AND DUAL CIRCUIT MODELS

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 QuickLIT website at http://cgproducts.

johnsoncontrols.com.

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.

CHANGE BARS

Revisions made to this document are indicated with a

line along the left or right hand column in the area the

revision was made. These revisions are to technical in-

formation and any other changes in spelling, grammar

or formatting are not included.

JOHNSON CONTROLS

FORM 150.67-NM1

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THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS

FORM 150.67-NM1

ISSUE DATE: 4/28/2017

TABLE OF CONTENTS

SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY .....................................................................15

Introduction.....................................................................................................................................................15

Warranty .........................................................................................................................................................15

Safety .............................................................................................................................................................15

Standards For Safety ............................................................................................................................15

Responsibility For Safety.......................................................................................................................16

About This Manual..........................................................................................................................................16

Misuse Of Equipment .....................................................................................................................................16

Suitability for Application .......................................................................................................................16

Structural Support .................................................................................................................................16

Mechanical Strength .............................................................................................................................16

General Access .....................................................................................................................................16

Pressure Systems .................................................................................................................................17

Electrical................................................................................................................................................17

Rotating Parts........................................................................................................................................17

Sharp Edges..........................................................................................................................................17

Refrigerants and Oils.............................................................................................................................17

High Temperature and Pressure Cleaning ............................................................................................17

Emergency Shutdown ...........................................................................................................................17

SECTION 2 – PRODUCT DESCRIPTION ..............................................................................................................19

Introduction.....................................................................................................................................................19

General System Description...........................................................................................................................19

Compressors .........................................................................................................................................19

Evaporator (Heat Exchanger)................................................................................................................19

Condenser.............................................................................................................................................20

Coils ...............................................................................................................................................20

Low Sound Fans ............................................................................................................................20

Motors ............................................................................................................................................20

Millennium Control Center..............................................................................................................................20

Display/Print ..........................................................................................................................................20

Entry ......................................................................................................................................................20

Setpoints ...............................................................................................................................................20

Unit ........................................................................................................................................................20

Unit On/Off Switch.................................................................................................................................21

Communications.............................................................................................................................................21

Power Panel ...................................................................................................................................................21

Accessories And Options ...............................................................................................................................22

Power Options.......................................................................................................................................22

Compressor Power Connection .....................................................................................................22

Single-Point Supply Terminal Block ..............................................................................................22

Single-Point Non-Fused Disconnect Switch ..................................................................................22

Single-Point Circuit Breaker...........................................................................................................22

Control Transformer .......................................................................................................................22

Power Factor Correction Capacitors .............................................................................................22

Control Options .....................................................................................................................................22

Ambient Kit (Low)...........................................................................................................................22

Ambient Kit (High)..........................................................................................................................22

Building Automation System Interface ...........................................................................................22

Language LCD And Keypad Display..............................................................................................22

JOHNSON CONTROLS

FORM 150.67-NM1

ISSUE DATE: 4/28/2017

TABLE OF CONTENTS (CONT’D)

Discharge Pressure Transducers And Readout Capability ........................................................... 22

Suction Pressure Transducers.......................................................................................................23

Motor Current Module ....................................................................................................................23

Multi-Unit Sequencing....................................................................................................................23

Compressor, Piping, Evaporator Options ..............................................................................................23

Low Temperature Brine..................................................................................................................23

Chicago Code Relief Valves ..........................................................................................................23

Service Isolation Valve...................................................................................................................23

Hot Gas By-Pass ...........................................................................................................................23

Heat Exchanger 300 PSIG (21 BARG) DWP Waterside................................................................23

Flanges (ANSI/AWWA C-606 Couplings Type)..............................................................................23

Flow Switch....................................................................................................................................23

150 PSIG (10.5 BARG) DWP ........................................................................................................23

300 PSIG (21 BARG) DWP ...........................................................................................................23

Differential Pressure Switch...........................................................................................................23

Condenser And Cabinet Options...........................................................................................................23

Pre-Coated Fin Condenser Coils ...................................................................................................24

Post-Coated Dipped Condenser Coils ...........................................................................................24

Copper Fin Condenser Coils..........................................................................................................24

Enclosure Panels (Unit) .................................................................................................................24

Louvered Panels (Full Unit) ...........................................................................................................24

Sound Reduction / Attenuation Options ................................................................................................24

Vibration Isolators ..........................................................................................................................24

Unit Components YCAL0019 - 0033 ..............................................................................................................25

Control - Power Panel Components YCAL0019-0033 ...................................................................................26

Unit Components - YCAL0043 – 0066 ...........................................................................................................27

Control / Power Panel Components - YCAL0043 – 0066 ..............................................................................28

Product Identification Number (PIN)...............................................................................................................29

Basic Unit Nomenclature................................................................................................................................29

Refrigerant Flow Diagram .............................................................................................................................. 33

SECTION 3 – HANDLING AND STORAGE ...........................................................................................................35

Delivery And Storage......................................................................................................................................35

Inspection .......................................................................................................................................................35

Moving The Chiller (YCAL0043 – 0066 Dual System Only)...........................................................................35

Lifting Weights.......................................................................................................................................35

Moving The Chiller (YCAL0019 – 0033 Single Circuit Only) ..........................................................................35

Unit Rigging....................................................................................................................................................36

Lifting Weights.......................................................................................................................................36

SECTION 4 – INSTALLATION................................................................................................................................39

Installation Checklist.......................................................................................................................................39

Handling .........................................................................................................................................................39

Inspection .......................................................................................................................................................39

Location And Clearances ...............................................................................................................................39

Ground Level Locations ........................................................................................................................39

Rooftop Locations .................................................................................................................................40

Noise Sensitive Locations .....................................................................................................................40

Spring Isolators (Optional)..............................................................................................................................40

Compressor Mounting ....................................................................................................................................40

Remote Cooler Option....................................................................................................................................40

Chilled Liquid Piping.......................................................................................................................................40

Pipework Arrangement ...................................................................................................................................41

JOHNSON CONTROLS

FORM 150.67-NM1

ISSUE DATE: 4/28/2017

TABLE OF CONTENTS (CONT’D)

Duct Work Connection ................................................................................................................................... 41

General Requirements .........................................................................................................................41

Wiring .............................................................................................................................................................41

Field Wiring ...........................................................................................................................................41

Evaporator Pump Start Contacts...........................................................................................................42

System Run Contacts............................................................................................................................42

Alarm Status Contacts...........................................................................................................................42

Remote Start/Stop Contacts..................................................................................................................42

Remote Emergency Cutoff ....................................................................................................................42

Remote Temp Reset Input.....................................................................................................................42

Load Limit Input.....................................................................................................................................42

Flow Switch Input ..................................................................................................................................42

Compressor Heaters ......................................................................................................................................43

Relief Valves...................................................................................................................................................43

High Pressure Cutout .....................................................................................................................................43

Control Wiring.................................................................................................................................................45

SECTION 5 – TECHNICAL DATA ..........................................................................................................................47

Operational Limitations (English) ...................................................................................................................47

Voltage Limitations ................................................................................................................................47

Operational Limitations (SI)............................................................................................................................50

Voltage Limitations ................................................................................................................................50

Physical Data (English) ..................................................................................................................................53

Electrical Data (English) .................................................................................................................................54

Electrical Notes And Legend ..........................................................................................................................59

General................................................................................................................................................133

Weight Distribution and Isolator Mounting Positions YCAL0019 – 0033 (Without Pump Package

Option).................................................................................................................................................133

General ........................................................................................................................................135

SECTION 6 – COMMISSIONING..........................................................................................................................147

Commissioning.............................................................................................................................................147

Preparation – Power Off...............................................................................................................................147

Inspection ...........................................................................................................................................147

Refrigerant Charge..............................................................................................................................147

Service and Oil Line Valves.................................................................................................................147

Compressor Oil ...................................................................................................................................147

Fans ...................................................................................................................................................147

Isolation / Protection............................................................................................................................147

Control Panel.......................................................................................................................................147

Power Connections .............................................................................................................................147

Grounding............................................................................................................................................147

Supply Voltage ....................................................................................................................................148

Preparation – Power On...............................................................................................................................148

Switch Settings....................................................................................................................................148

Compressor Heaters ...........................................................................................................................148

Water System ......................................................................................................................................148

Flow Switch .........................................................................................................................................148

Temperature Sensor(s)........................................................................................................................148

JOHNSON CONTROLS

FORM 150.67-NM1

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TABLE OF CONTENTS (CONT’D)

Equipment Start-Up Checklist ......................................................................................................................149

Checking The System Prior To Initial Start ..........................................................................................149

Unit Checks..................................................................................................................................149

Compressor Heaters ...........................................................................................................................149

Panel Checks ......................................................................................................................................149

Checking Superheat And Subcooling...........................................................................................................150

Leak Checking..............................................................................................................................................151

Unit Operating Sequence .............................................................................................................................152

SECTION 7 – UNIT CONTROLS..........................................................................................................................153

Introduction...................................................................................................................................................153

Ipu Ii And I/O Boards ....................................................................................................................................153

Unit Switch ..........................................................................................................................................154

Display.................................................................................................................................................154

Keypad ................................................................................................................................................154

Battery Back-up...................................................................................................................................154

Transformer ........................................................................................................................................154

Single System Select and Programming # of Compressors ...............................................................154

Status Key ....................................................................................................................................................155

Unit Status...........................................................................................................................................155

General Status Messages ...................................................................................................................155

Fault Safety Status Messages.............................................................................................................156

System Safeties ...........................................................................................................................157

Unit Safeties.................................................................................................................................158

Unit Warning........................................................................................................................................158

Status Key Messages..........................................................................................................................160

DISPLAY/PRINT KEYS ................................................................................................................................161

Oper Data Key.....................................................................................................................................161

Oper Data Quick Reference List .........................................................................................................164

Print Key..............................................................................................................................................164

Operating Data Printout.......................................................................................................................164

History Printout....................................................................................................................................165

History Displays...................................................................................................................................166

Software Version .................................................................................................................................168

Entry Keys ....................................................................................................................................................169

Up and Down Arrow Keys ...................................................................................................................169

Enter/Adv Key .....................................................................................................................................169

Setpoints Keys .............................................................................................................................................170

Cooling Setpoints ................................................................................................................................170

Leaving Chilled Liquid Control.............................................................................................................170

Return Chilled Liquid Control ..............................................................................................................171

Remote Setpoint Control .....................................................................................................................171

SCHEDULE/ADVANCE DAY KEY................................................................................................................172

PROGRAM KEY...........................................................................................................................................173

System Trip Volts.................................................................................................................................175

Unit Trip Volts ......................................................................................................................................175

Unit Keys ..................................................................................................................................................... 177

Options Key.........................................................................................................................................177

Option 1 – Language ...................................................................................................................177

Option 2 – System Switches: (two system units only) .................................................................177

Option 3 – Chilled Liquid Cooling Type:.......................................................................................177

Option 4 – Ambient Control Type .................................................................................................178

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FORM 150.67-NM1

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TABLE OF CONTENTS (CONT’D)

Option 5 – Local/Remote Control Type........................................................................................178

Option 6 – Unit Control Mode ......................................................................................................178

Option 7 – Display Units ..............................................................................................................178

Option 8 – Lead/Lag Type ...........................................................................................................178

Option 9 – Condenser Fan Control Mode ...................................................................................179

Option 10 – Manual Override Mode.............................................................................................179

Option 11 – Current Feedback Options Installed: ........................................................................179

Option 12 – Power Fail Restart....................................................................................................179

Option 13 – Soft Start Enable/Disable .........................................................................................179

Option 14 – Unit Type ..................................................................................................................179

Option 15 – Refrigerant Type.......................................................................................................180

Option 16 – Expansion Valve Type ..............................................................................................180

Option 17 – Flash Card Update ...................................................................................................180

Option 18 – Remote Temperature Reset ..................................................................................... 180

Option 19 – Pump Control ...........................................................................................................181

Option 20 – Pump Selection ........................................................................................................181

CLOCK .........................................................................................................................................................181

SECTION 8 – UNIT OPERATION .........................................................................................................................183

Capacity Control...........................................................................................................................................183

Suction Pressure Limit Controls ...................................................................................................................183

Discharge Pressure Limit Controls...............................................................................................................183

Leaving Chilled Liquid Control......................................................................................................................183

Leaving Chilled Liquid Control Override To Reduce Cycling........................................................................184

Leaving Chilled Liquid System Lead/Lag And Compressor Sequencing .....................................................184

Return Chilled Liquid Control .......................................................................................................................185

Return Chilled Liquid System Lead/Lag And Compressor Sequencing .......................................................185

Anti-Recycle Timer .......................................................................................................................................186

Anti-Coincidence Timer ................................................................................................................................186

Evaporator Pump Control And York Hydro Kit Pump Control.......................................................................187

Evaporator Heater Control ...........................................................................................................................187

Pumpdown Control.......................................................................................................................................187

Standard Condenser Fan Control ................................................................................................................187

YCAL0019-0028 Low Ambient Fan Control Option .....................................................................................190

General................................................................................................................................................190

Potentiometer Conguration................................................................................................................190

Wiring ..................................................................................................................................................190

Programming - YCAL0019 – 0028 ...............................................................................................................192

YCAL0033 Low Ambient Fan Control Option......................................................................................192

General................................................................................................................................................192

Configuration (Jumpers And Potentiometers) ..............................................................................................193

Wiring ..................................................................................................................................................194

YCAL0033 Programming .............................................................................................................................195

YCAL0043 – 0066 Low Ambient Fan Control Option ...................................................................................196

General................................................................................................................................................196

Configuration (Jumpers And Potentiometers) ..............................................................................................197

Wiring ..................................................................................................................................................197

Programming ...............................................................................................................................................198

Load Limiting ................................................................................................................................................200

Compressor Run Status ...............................................................................................................................200

Alarm Status.................................................................................................................................................200

Bas/Ems Temperature Reset Using a Voltage or Current Signal ................................................................. 200

JOHNSON CONTROLS

FORM 150.67-NM1

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SECTION 9 – SERVICE AND TROUBLESHOOTING..........................................................................................203

Clearing History Buffers................................................................................................................................ 203

Service Mode ...............................................................................................................................................203

Service Mode – Outputs...............................................................................................................................203

Service Mode – Chiller Configuration...........................................................................................................204

Service Mode – Analog And Digital Inputs ...................................................................................................204

Control Inputs/Outputs .................................................................................................................................205

Checking Inputs And Outputs.......................................................................................................................207

Digital Inputs........................................................................................................................................207

Analog Inputs – Temperature ..............................................................................................................207

Outside Air Sensor ..............................................................................................................................207

Liquid and Refrigerant Sensor Test Points .........................................................................................208

Entering Chilled Liquid Sensor.....................................................................................................208

Leaving Chilled Liquid Temperature Sensor ................................................................................ 208

Analog Inputs – Pressure ....................................................................................................................209

System 1 Discharge Transducer..................................................................................................209

System 2 Discharge Transducer..................................................................................................209

System 1 Suction Transducer ......................................................................................................210

System 2 Suction Transducer ......................................................................................................210

Digital Outputs.....................................................................................................................................210

Parts .................................................................................................................................................... 211

Assembly and Wiring........................................................................................................................... 211

Obtaining a Printout............................................................................................................................. 211

SECTION 10 – MAINTENANCE...........................................................................................................................215

Important ......................................................................................................................................................215

Compressors ................................................................................................................................................215

Oil Level Check ...................................................................................................................................215

Oil Analysis..........................................................................................................................................215

Condenser Fan Motors.................................................................................................................................215

Condenser Coils...........................................................................................................................................215

Operating Parameters ..................................................................................................................................215

On-Board Battery Back-Up...........................................................................................................................215

Plate And Frame Heat Exchanger (Evaporator) Heater ...............................................................................215

Overall Unit Inspection .................................................................................................................................216

Bacnet, Modbus And Yorktalk 2 Communications........................................................................................216

BACnet and Modbus Communications ...............................................................................................219

Analog Write Points .....................................................................................................................219

Binary Write Points ......................................................................................................................219

Analog Read Only Points.............................................................................................................219

Binary Monitor Only Points ..........................................................................................................219

Communications Data Map Notes: ..............................................................................................219

Yorktalk 2 Communications.................................................................................................................223

Received Data (Control Data)......................................................................................................223

Transmitted Data..........................................................................................................................223

Temperature Conversion Chart ....................................................................................................................227

R410-A Pressure Temperature Chart ...........................................................................................................228

Adding Refrigerant Charge After Commissioning.........................................................................................228

TABLE OF CONTENTS (CONT’D)

JOHNSON CONTROLS

FORM 150.67-NM1

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LIST OF FIGURES

FIGURE 1 - YCAL Air-Cooled Scroll Chillers...........................................................................................................19

FIGURE 2 - Unit Components Single System Units................................................................................................25

FIGURE 3 - Control/Power Panel Components Single System Units ..................................................................... 26

FIGURE 4 - Unit Components Dual System Units .................................................................................................. 27

FIGURE 5 - Control/Power Panel Components Dual System Units........................................................................28

FIGURE 6 - Refrigerant Flow Diagram....................................................................................................................33

FIGURE 7 - Unit Rigging/Lifting (YCAL0019 – 0033 Single Circuit Models Only)...................................................36

FIGURE 8 - Unit Rigging/Lifting (YCAL0043- 0066 Dual Circuit Models) ............................................................... 37

FIGURE 9 - Chilled Liquid System ..........................................................................................................................41

FIGURE 10 - Single-Point Supply Connection – Terminal Block, Non-Fused Disconnect Switch Or Circuit Breaker

(0043 – 0066) ....................................................................................................................................44

FIGURE 11 - Control Wiring ....................................................................................................................................45

FIGURE 12 - Control Wiring Diagram, Single Circuit, Ipu Ii .................................................................................... 60

FIGURE 13 - Control Wiring Diagram, Single Circuit, Ipu Ii .................................................................................... 63

FIGURE 14 - Control Wiring Diagram, Dual Circuit, Ipu Ii.......................................................................................64

FIGURE 15 - Control Wiring Diagram, Dual Circuit, Ipu Ii.......................................................................................66

FIGURE 16 - Control Wiring Diagram, Details, Single Circuit .................................................................................69

FIGURE 17 - Control Wiring Diagram, Details, Dual Circuit....................................................................................70

FIGURE 18 - Power Wiring, Single Circuit ..............................................................................................................72

FIGURE 19 - Power Wiring, Single Circuit ..............................................................................................................74

FIGURE 20 - Power Wiring, Single Circuit ..............................................................................................................76

FIGURE 21 - Power Wiring, Single Circuit ..............................................................................................................78

FIGURE 22 - Power Wiring, Dual Circuit.................................................................................................................81

FIGURE 23 - Power Wiring, Dual Circuit.................................................................................................................82

FIGURE 24 - Connection Wiring, Single Circuit ......................................................................................................84

FIGURE 25 - Connection Wiring, Single Circuit ......................................................................................................86

FIGURE 26 - Connection Wiring, Single Circuit ......................................................................................................88

FIGURE 27 - Connection Wiring, Single Circuit ......................................................................................................90

FIGURE 28 - Connection Wiring, Dual Circuit.........................................................................................................93

FIGURE 29 - Connection Wiring, Dual Circuit.........................................................................................................94

FIGURE 30 - Unit Clearances – All Models...........................................................................................................132

FIGURE 31 - One Inch Deection Spring Isolator Cross-Reference.....................................................................136

FIGURE 32 - One Inch Deection Spring Isolators Installation Instructions..........................................................137

FIGURE 33 - Durulene Isolator Cross-Reference .................................................................................................138

FIGURE 34 - Installation Of Durulene Vibration Isolators ..................................................................................... 139

FIGURE 35 - Two Inch Deection Seismic Isolator Cross-Reference...................................................................140

FIGURE 36 - Seismic Isolator Installation And Adjustment ...................................................................................141

FIGURE 37 - One Inch Deection Spring Isolator Cross-Reference (Cip-X) ........................................................ 142

FIGURE 38 - Neoprene Isolator Cross-Reference................................................................................................144

FIGURE 39 - Two Inch Deection, Seismic Spring Isolator Cross-Reference ......................................................145

FIGURE 40 - Slrs Seismic Isolator Installation And Adjustment............................................................................146

FIGURE 41 - Leaving Water Temperature Control Example ................................................................................. 184

FIGURE 42 - Setpoint Adjust.................................................................................................................................184

FIGURE 43 - YCAL0019 – YCAL0033 Fan Location (Typical)..............................................................................188

FIGURE 44 - YCAL0043 – YCAL0066 Fan Location (Typical)..............................................................................189

FIGURE 45 - Typical VFD Location.......................................................................................................................190

FIGURE 46 - Liquid Line Sensing Bulb Location...................................................................................................190

FIGURE 47 - Potentiometer Settings ....................................................................................................................190

FIGURE 48 - Wiring...............................................................................................................................................191

FIGURE 49 - Typical VFD Enclosure Locations ....................................................................................................192

FIGURE 50 - Typical VFD Enclosure Congurations ............................................................................................193

FIGURE 51 - Potentiometer Settings ....................................................................................................................194

FIGURE 52 - Inverter Power Wiring Schematic .................................................................................................... 194

FIGURE 53 - Inverter Wiring .................................................................................................................................195

FIGURE 54 - Typical VFD Enclosure Locations ....................................................................................................196

JOHNSON CONTROLS

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LIST OF FIGURES (CONT’D)

FIGURE 55 - Typical VFD Enclosure Congurations ............................................................................................197

FIGURE 56 - Inverter Power Wiring Sc.................................................................................................................198

FIGURE 57 - Potentiometer Settings ....................................................................................................................198

FIGURE 58 - Inverter Wiring ................................................................................................................................199

FIGURE 59 - Microboard Layout...........................................................................................................................206

FIGURE 60 - I/O Board Relay Contact Architecture..............................................................................................210

FIGURE 61 - Printer To Microboard Electrical Connections.................................................................................. 211

FIGURE 62 - Micro Panel Connections.................................................................................................................217

JOHNSON CONTROLS

FORM 150.67-NM1

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LIST OF TABLES

TABLE 1 - Temperatures And Flows .......................................................................................................................47

TABLE 2 - Voltage Limitations ................................................................................................................................47

TABLE 3 - Temperatures And Flows (Si) ................................................................................................................50

TABLE 4 - Voltage Limitations ................................................................................................................................50

TABLE 5 - Ethylene And Propolyne Glycol Correction Factors...............................................................................50

TABLE 6 - Physical Data (English) .........................................................................................................................53

TABLE 7 - Electrical Data (English) ........................................................................................................................54

TABLE 8 - Micro Panel Power Supply ....................................................................................................................58

TABLE 9 - Voltage Range .......................................................................................................................................58

TABLE 10 - Setpoints Entry List............................................................................................................................150

TABLE 11 - Status Key Messages Quick Reference List......................................................................................160

TABLE 12 - Operation Data ..................................................................................................................................164

TABLE 13 - Cooling Setpoints, Programmable Limits And Defaults ..................................................................... 171

TABLE 14 - Program Key Limits And Default........................................................................................................173

TABLE 15 - Setpoints Quick Reference List .........................................................................................................176

TABLE 16 - Unit Keys Options Programming Quick Reference List.....................................................................182

TABLE 17 - Sample Compressor Staging For Return Water Control ...................................................................185

TABLE 18 - Return Chilled Liquid Control For 4 Compressors (6 Steps) .............................................................186

TABLE 19 - Return Chilled Liquid Control For 4 Compressors (6 Steps) .............................................................186

TABLE 20 - YCAL0019 – YCAL0033 Condenser Fan Control Using Discharge Pressure...................................188

TABLE 21 - YCAL0019 – YCAL0033 Condenser Fan Control Using Discharge Pressure Only ..........................188

TABLE 22 - YCAL0043 – YCAL0066 Condenser Fan Control Using Discharge Pressure...................................189

TABLE 23 - YCAL0043 – YCAL0066 Condenser Fan Control Using Discharge Pressure Only ..........................189

TABLE 24 - YCAL0019 – 0028 VFD Low Ambient Option – Condenser Fan Control Operation..........................192

TABLE 25 - VFD Jumpers.....................................................................................................................................193

TABLE 26 - YCAL033 VFD Low Ambient Option – Condenser Fan Control Operation........................................ 195

TABLE 27 - VFD Jumpers.....................................................................................................................................197

TABLE 28 - YCAL0043-0066 VFD Low Ambient Option – Condenser Fan Control Operation ............................199

TABLE 29 - Compressor Operation –Load Limiting..............................................................................................200

TABLE 30 - I/O Digital Inputs ................................................................................................................................205

TABLE 31 - I/O Digital Outputs .............................................................................................................................205

TABLE 32 - I/O Analog Inputs ...............................................................................................................................205

TABLE 33 - I/O Analog Outputs ............................................................................................................................205

TABLE 34 - Outdoor Air Sensor Temperature/Voltage / Correlation .....................................................................207

TABLE 35 - Entering/Leaving Chilled Liquid Temperature Sensor .......................................................................208

TABLE 36 - Pressure Transducers .......................................................................................................................209

TABLE 37 - Troubleshooting .................................................................................................................................212

TABLE 38 - Minimum, Maximum And Default Values ...........................................................................................217

TABLE 39 - Values Required For Bas Communication.........................................................................................218

TABLE 40 - Real Time Error Numbers..................................................................................................................218

TABLE 41 - Bacnet And Modbus Communications Data Map ..............................................................................220

TABLE 42 - Yorktalk 2 Communications Data Map...............................................................................................224

JOHNSON CONTROLS

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JOHNSON CONTROLS

FORM 150.67-NM1

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SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY

INTRODUCTION

YORK YCAL0019-0066 (15-65 ton, 53-218kW) chill-

ers are manufactured to the highest design and con-

struction standards to ensure high performance, reli-

ability and adaptability to all types of air conditioning

installations.

The unit is intended for cooling water or glycol solu-

tions and is not suitable for purposes other than those

specified in this manual.

This manual contains all the information required for

correct installation and commissioning of the unit, to-

gether with operating and maintenance instructions.

The manuals should be read thoroughly before at-

tempting to operate or service the unit.

All procedures detailed in the manuals, including in-

stallation, commissioning and maintenance tasks must

only be performed by suitably trained and qualified

personnel.

The manufacturer will not be liable for any injury or

damage caused by incorrect installation, commission-

ing, operation or maintenance resulting from a failure

to follow the procedures and instructions detailed in

the manuals.

WARRANTY

Johnson Controls warrants all equipment and materials

against defects in workmanship and materials for a pe-

riod of eighteen months from date of shipment, unless

labor or extended warranty has been purchased as part

of the contract.

The warranty is limited to parts only replacement and

shipping of any faulty part, or sub-assembly, which has

failed due to poor quality or manufacturing errors. All

claims must be supported by evidence that the failure

has occurred within the warranty period, and that the

unit has been operated within the designed parameters

specified.

All warranty claims must specify the unit model, serial

number, order number and run hours/starts. Model and

serial number information is printed on the unit identi-

fication plate.

The unit warranty will be void if any modification to

the unit is carried out without prior written approval

from Johnson Controls.

For warranty purposes, the following conditions must

be satisfied:

• The initial start of the unit must be carried out

by trained personnel from an Authorized John-

son Controls Service Center (see Commissioning

Page 147).

• Only genuine YORK approved spare parts, oils,

coolants, and refrigerants must be used.

• All the scheduled maintenance operations detailed

inthismanualmustbeperformedatthespecied

timesbysuitablytrainedandqualiedpersonnel

(see Maintenance Section, Page 215).

• Failure to satisfy any of these conditions will au-

tomatically void the warranty (see Warranty Pol-

icy).

SAFETY

Standards For Safety

YCAL chillers are designed and built within an ISO

9002 accredited design and manufacturing organiza-

tion. The chillers comply with the applicable sections

of the following Standards and Codes:

• ANSI/ASHRAE Standard 15 - Safety Code for

Mechanical Refrigeration.

• ANSI/NFPA Standard 70 - National Electrical

Code (N.E.C.).

• ASME Boiler and Pressure Vessel Code- Section

VIII Division 1.

• ARI Standard 550/590-98- Water Chilling Pack-

ages Using the Vapor Compression Cycle.

• ASHRAE90.1-EnergyEfciencyCompliance.

• ARI 370- Sound Rating of Large Outdoor Refrig-

eration and Air Conditioning Equipment.

• Conform to Intertek Testing Services, formerly

ETL, for construction of chillers and provide

ETL/cETL listing label.

• Manufactured in facility registered to ISO 9002.

• OSHA – Occupational Safety and Health Act.

In addition, the chillers conform to Underwriters Labo-

ratories (U.L.) for construction of chillers and provide

U.L./cU.L. Listing Label.

JOHNSON CONTROLS

FORM 150.67-NM1

ISSUE DATE: 4/28/2017

SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY

Responsibility For Safety

Every care has been taken in the design and manufac-

ture of the unit to ensure compliance with the safety

requirements listed above. However, the individual

operating or working on any machinery is primarily

responsible for:

• Personal safety, safety of other personnel, and the

machinery.

• Correct utilization of the machinery in accordance

with the procedures detailed in the manuals.

ABOUT THIS MANUAL

The following terms are used in this document to alert

the reader to areas of potential hazard.

A WARNING is given in this document to identify a

hazard, which could lead to personal injury. Usually an

instruction will be given, together with a brief explana-

tion and the possible result of ignoring the instruction.

A CAUTION identifies a hazard which could lead to

damage to the machine, damage to other equipment

and/or environmental pollution. Usually an instruction

will be given, together with a brief explanation and the

possible result of ignoring the instruction.

A NOTE is used to highlight additional information,

which may be helpful to you but where there are no

special safety implications.

The contents of this manual include suggested best

working practices and procedures. These are issued for

guidance only, and they do not take precedence over

the above stated individual responsibility and/or local

safety regulations.

This manual and any other document supplied with

the unit are the property of Johnson Controls which

reserves all rights. They may not be reproduced, in

whole or in part, without prior written authorization

from an authorized Johnson Controls representative.

MISUSE OF EQUIPMENT

Suitability for Application

The unit is intended for cooling water or glycol solu-

tions and is not suitable for purposes other than those

specified in these instructions. Any use of the equipment

other than its intended use, or operation of the equip-

ment contrary to the relevant procedures may result in

injury to the operator, or damage to the equipment.

The unit must not be operated outside the design pa-

rameters specified in this manual.

Structural Support

Structural support of the unit must be provided as in-

dicated in these instructions. Failure to provide proper

support may result in injury to the operator, or damage

to the equipment and/or building.

Mechanical Strength

The unit is not designed to withstand loads or stresses

from adjacent equipment, pipework or structures. Ad-

ditional components must not be mounted on the unit.

Any such extraneous loads may cause structural failure

and may result in injury to the operator, or damage to

the equipment.

General Access

There are a number of areas and features, which may

be a hazard and potentially cause injury when working

on the unit unless suitable safety precautions are taken.

It is important to ensure access to the unit is restricted

to suitably qualified persons who are familiar with the

potential hazards and precautions necessary for safe

operation and maintenance of equipment containing

high temperatures, pressures and voltages.

JOHNSON CONTROLS

SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY

FORM 150.67-NM1

ISSUE DATE: 4/28/2017

Pressure Systems

The unit contains refrigerant vapor and liquid under pres-

sure, release of which can be a danger and cause injury.

The user should ensure that care is taken during installa-

tion, operation and maintenance to avoid damage to the

pressure system. No attempt should be made to gain ac-

cess to the component parts of the pressure system other

than by suitably trained and qualified personnel.

Electrical

The unit must be grounded. No installation or main-

tenance work should be attempted on the electrical

equipment without first switching power OFF, isolat-

ing and locking-off the power supply. Servicing and

maintenance on live equipment must only be per-

formed by suitably trained and qualified personnel. No

attempt should be made to gain access to the control

panel or electrical enclosures during normal operation

of the unit.

Rotating Parts

Fan guards must be fitted at all times and not removed

unless the power supply has been isolated. If ductwork

is to be fitted, requiring the wire fan guards to be re-

moved, alternative safety measures must be taken to

protect against the risk of injury from rotating fans.

Sharp Edges

The fins on the air-cooled condenser coils have sharp

metal edges. Reasonable care should be taken when

working in contact with the coils to avoid the risk of

minor abrasions and lacerations. The use of gloves is

recommended.

Frame rails, brakes, and other components may also

have sharp edges. Reasonable care should be taken

when working in contact with any components to avoid

risk of minor abrasions and lacerations.

Refrigerants and Oils

Refrigerants and oils used in the unit are generally non-

toxic, non-flammable and non-corrosive, and pose no

special safety hazards. Use of gloves and safety glasses

is, however, recommended when working on the unit.

The build up of refrigerant vapor, from a leak for ex-

ample, does pose a risk of asphyxiation in confined or

enclosed spaces and attention should be given to good

ventilation.

High Temperature and Pressure Cleaning

High temperature and pressure cleaning methods

(e.g. steam cleaning) should not be used on any part

of the pressure system as this may cause operation of

the pressure relief device(s). Detergents and solvents,

which may cause corrosion, should also be avoided.

Emergency Shutdown

In case of emergency, the control panel is fitted with a

Unit Switch to stop the unit in an emergency. When op-

erated, it removes the low voltage 120VAC electrical

supply from the inverter system, thus shutting down

the unit.

JOHNSON CONTROLS

FORM 150.67-NM1

ISSUE DATE: 4/28/2017

SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY

THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS

FORM 150.67-NM1

ISSUE DATE: 4/28/2017

SECTION 2 – PRODUCT DESCRIPTION

INTRODUCTION

YORK Millennium® Air-Cooled Scroll Chillers pro-

vide chilled water for all air conditioning applications

using central station air handling or terminal units. They

are completely self-contained and are designed for out-

door (roof or ground level) installation. Each complete

packaged unit includes hermetic scroll compressors, a

liquid cooler, air cooled condenser, a charge of refriger-

ant R-410A and a weather resistant microprocessor con-

trol center, all mounted on a pressed steel base.

The units are completely assembled with all intercon-

necting refrigerant piping and internal wiring, ready for

field installation.

Prior to delivery, the packaged unit is pressure-tested,

evacuated, and fully charged with R410A refrigerant

and oil. After assembly, a complete operational test is

performed with water flowing through the cooler to as-

sure that the refrigeration circuit operates correctly.

The unit structure is heavy-gauge, galvanized steel. This

galvanized steel is coated with baked-on powder paint,

which, when subjected to ASTM B117 1000 hour, salt

spray testing, yields a minimum ASTM 1654 rating of

“6”. Corrosion resistant wire mesh panels are added to

protect the condenser coil from incidental damage and

restrict unauthorized access to internal components.

Units are designed in accordance with NFPA 70 (Na-

tional Electric Code), ASHRAE/ANSI 15 Safety code

for mechanical refrigeration, ASME, Listed and labeled

with Intertek Testing Services (ETL) and rated in accor-

dance with ARI Standard 550/590-2003.

All exposed power wiring is routed through liquid-

tight, non-metallic conduit.

GENERAL SYSTEM DESCRIPTION

Compressors

The chiller has suction-gas cooled, hermetic, scroll

compressors. The YCAL compressors incorporate a

compliant scroll design in both the axial and radial

direction. All rotating parts are statically and dynami-

cally balanced. A large internal volume and oil res-

ervoir provides greater liquid tolerance. Compressor

crankcase heaters are also included for extra protection

against liquid migration.

Evaporator (Heat Exchanger)

The Brazed Plate Heat Exchanger is equipped with

a heater controlled by the microprocessor. The heat-

er provides freeze protection for the cooler down to

-20 °F (-29 °C) ambient. The cooler is covered with

3/4" (19mm) flexible, closed-cell, foam insulation

(K~0.25).

Brazed plate heat exchangers shall be UL (Underwriters

Laboratories) listed. Installing contractor must include

accommodations in the chilled water piping to allow

proper drainage and venting of the heat exchanger. Wa-

ter inlet and outlet connections are grooved for compat-

ibility with factory supplied victaulic connections.

LD10950

Dual Circuit

FIGURE 1 - YCAL AIR-COOLED SCROLL CHILLERS

JOHNSON CONTROLS

FORM 150.67-NM1

ISSUE DATE: 4/28/2017

SECTION 2 – PRODUCT DESCRIPTION

The heat exchanger is a brazed plate stainless steel con-

struction, single or dual circuit heat exchanger capable

of refrigerant working pressure of 650 PSIG (3103

kPa) and liquid side pressure of 150 PSIG (1034 kPa)

(Option for 300 PSIG [2068 kPa] available). Each heat

exchanger is covered in 3/4" (19mm) flexible, closed

cell insulation, thermal conductivity of 0.26k ([BTU/

HR-FT2– °F] /in) maximum.

A strainer with a mesh size between .5 and 1.5 mm (40

mesh) is recommended upstream of the heat exchanger

to prevent clogging.

Condenser

Coils

Fin and tube condenser coils of seamless, internally-

enhanced, high-condensing-coefficient, corrosion re-

sistant copper tubes are arranged in staggered rows,

mechanically expanded into aluminum fins. Integral

subcooling is included. The design working pressure

of the coil is 650 PSIG (45 bar).

Low Sound Fans

The condenser fans are composed of corrosion resis-

tant aluminum hub and glass-fiber reinforced compos-

ite blades molded into a low noise airfoil section. They

are designed for maximum efficiency and are statically

and dynamically balanced for vibration free operation.

They are directly driven by independent motors, and

positioned for vertical air discharge. All blades are

statically and dynamically balanced for vibration-free

operation. The fan guards are constructed of heavy-

gauge, rust-resistant, PVC coated steel wire.

Motors

The fan motors are Totally Enclosed Air-Over (TEAO),

direct drive, 6 pole, current protected. They feature ball

bearings that are double-sealed and permanently lubri-

cated.

MILLENNIUM CONTROL CENTER

All controls are contained in a NEMA 3R/12 (and

equivalent to IP55*) cabinet with hinged outer door

and include Liquid Crystal Display (LCD) with Light

Emitting Diode (LED) backlighting for outdoor view-

ing and includes:

• Two display lines

• Twenty characters per line

Display/Print

Color coded 12-button non-tactile keypad with sec-

tions for display and print of typical information:

• Chilled liquid temperatures.

• Ambient temperature.

• System pressures (each circuit).

• Operating hours and starts (each compressor).

• Print calls up to the liquid crystal display.

• Operating data for the systems.

• History of fault shutdown data for up to the last

six fault shutdown conditions.

• An RS-232 port, in conjunction with this press-to-

print button, is provided to permit the capability

of hard copy print-outs via a separate printer (by

others).

Entry

This section is used to enter setpoints or modify system

values.

Setpoints

Updating can be performed to:

• Chilled liquid temperature setpoint and range

• Remote reset temperature range

• Set daily schedule/holiday for start/stop

• Manual override for servicing

• Low and high ambient cutouts

• Number of compressors

• Low liquid temperature cutout

• Low suction pressure cutout

• High discharge pressure cutout

• Anti-recycle timer (compressor start cycle time)

• Anti-coincident timer (delay compressor starts)

Unit

This section is used to:

• Set time

• Set unit options

* Intensity of Protection European Standard

** International Electrotechnical Commission

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