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

ISSUE DATE: 4/28/2017

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

ISSUE DATE: 4/28/2017

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

JOHNSON CONTROLS

FORM 150.67-NM1

ISSUE DATE: 4/28/2017

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

ISSUE DATE: 4/28/2017

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)

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