York YCAL0019 Owner's manual

YCAL0019, 0022, 0028, 0033, 0043, 0046, 0052, 0056, 0066
AIR-COOLED SCROLL CHILLERS
STYLE E (50 Hz)
15-65 TON
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Supersedes 150.67-NM2 (1007) Form 150.67-NM2 (209)
LD10950
R-410A
035-21456-100
DUAL CIRCUIT
SINGLE CIRCUIT

JOHNSON CONTROLS
2
FORM 150.67-NM2 (209)
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, 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 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
operating/service personnel. It is expected that this
individual possesses 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 this document and any referenced
materials. This individual shall also be familiar with and
comply with all applicable 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 areas of potential hazard:
CAUTION identifies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instructionwillbegiven,togetherwith
a brief explanation.
NOTE is used to highlight additional
information which may be helpful to
you.
DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or serious
injury.
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or se-
rious injury.
External wiring, unless specified as an optional connection in the manufacturer’s product
line,isNOTto be connected inside the micropanelcabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the panel. NO external wiring is al-
lowed to be run through the micro panel. All wiring must be in accordance with YORK’s
publishedspecificationsand must be performed ONLYbyqualifiedYORKpersonnel.YORK
will not be responsible for damages/problems resulting from improper connections to the
controls or application of improper control signals. Failure to follow this will void the
manufacturer’s warranty and cause serious damage to property or injury to persons.

FORM 150.67-NM2 (209)
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JOHNSON CONTROLS
CHANGEABILITY OF THIS DOCUMENT
In complying with YORK’s policy for continuous product improvement, the information contained in this document
is subject to change without notice. While YORK makes no commitment to update or provide current information
automatically to the manual owner, that information, if applicable, can be obtained by contacting the nearest YORK
Engineered Systems Service office.
It is the responsibility of operating/service personnel to verify the applicability of these documents to the equipment in
question. If there is any question in the mind of operating/service personnel as to the applicability of these documents,
then prior to working on the equipment, they should verify with the owner whether the equipment has been modified
and if current literature is available.
SINGLE CIRCUIT AND DUAL CIRCUIT MODELS
This manual contains installation, operation and maintenance instructions for both single and dual refriger-
ant 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.

JOHNSON CONTROLS
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FORM 150.67-NM2 (209)
TABLE OF CONTENTS
SECTION 1 – GENERAL CHILLER INFORMATION & SAFETY......................................................................10
INTRODUCTION .........................................................................................................................................10
WARRANTY ................................................................................................................................................10
SAFETY.......................................................................................................................................................10
Standards for Safety ...........................................................................................................................10
Responsibility for Safety ....................................................................................................................11
ABOUT THIS MANUAL...............................................................................................................................11
MISUSE OF EQUIPMENT...........................................................................................................................11
Suitability for Application...................................................................................................................11
Structural Support...............................................................................................................................11
Mechanical Strength ..........................................................................................................................11
General Access....................................................................................................................................11
Pressure Systems ...............................................................................................................................12
Electrical...............................................................................................................................................12
Rotating Parts......................................................................................................................................12
Sharp Edges.........................................................................................................................................12
Refrigerants and Oils..........................................................................................................................12
High Temperature and Pressure Cleaning........................................................................................12
Emergency Shutdown.........................................................................................................................12
SECTION 2 – PRODUCT DESCRIPTION.........................................................................................................13
INTRODUCTION .........................................................................................................................................13
GENERAL SYSTEM DESCRIPTION..........................................................................................................13
Compressors .......................................................................................................................................13
Evaporator (Heat Exchanger).............................................................................................................13
Condenser............................................................................................................................................14
MILLENIUM CONTROL CENTER...............................................................................................................14
POWER PANEL...........................................................................................................................................15
ACCESSORIES AND OPTIONS.................................................................................................................16
Power Options.....................................................................................................................................16
Control Options...................................................................................................................................16
Compressor, Piping, Evaporator Options.........................................................................................17
Condenser and Cabinet Options........................................................................................................17
Sound Reduction Options..................................................................................................................17
UNIT COMPONENTS YCAL0019 - 0033....................................................................................................19
CONTROL - POWER PANEL COMPONENTS YCAL0019-0033...............................................................20
UNIT COMPONENTS - YCAL0043 – 0066.................................................................................................21
CONTROL / POWER PANEL COMPONENTS - YCAL0043 – 0066..........................................................22
PRODUCT IDENTIFICATION NUMBER (PIN)............................................................................................23
BASIC UNIT NOMENCLATURE.................................................................................................................23
REFRIGERANT FLOW DIAGRAM .............................................................................................................28
SECTION 3 – HANDLING AND STORAGE......................................................................................................29
DELIVERY AND STORAGE........................................................................................................................29
INSPECTION...............................................................................................................................................29

FORM 150.67-NM2 (209)
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JOHNSON CONTROLS
TABLE OF CONTENTS (CONT’D)
MOVING THE CHILLER..............................................................................................................................29
Lifting Weights.....................................................................................................................................29
UNIT RIGGING............................................................................................................................................31
SECTION 4 – INSTALLATION...........................................................................................................................33
INSTALLATION CHECKLIST......................................................................................................................33
HANDLING..................................................................................................................................................33
INSPECTION...............................................................................................................................................33
LOCATION AND CLEARANCES................................................................................................................33
Foundation...........................................................................................................................................33
SPRING ISOLATORS (OPTIONAL)............................................................................................................34
COMPRESSOR MOUNTING ......................................................................................................................34
REMOTE COOLER OPTION ......................................................................................................................34
CHILLED LIQUID PIPING...........................................................................................................................34
Ground Level Locations .....................................................................................................................34
Rooftop Locations...............................................................................................................................34
Noise Sensitive Locations..................................................................................................................34
PIPEWORK ARRANGEMENT....................................................................................................................35
DUCT WORK CONNECTION ....................................................................................................................36
General Requirements .......................................................................................................................36
WIRING........................................................................................................................................................36
Evaporator Pump Start Contacts.......................................................................................................36
System Run Contacts .........................................................................................................................36
Alarm Status Contacts........................................................................................................................37
Remote Start/Stop Contacts...............................................................................................................37
Remote Emergency Cutoff .................................................................................................................37
Remote Temp Reset Input ..................................................................................................................37
Load Limit Input...................................................................................................................................37
Flow Switch Input................................................................................................................................37
COMPRESSOR HEATERS.........................................................................................................................37
RELIEF VALVES .........................................................................................................................................37
HIGH PRESSURE CUTOUT .......................................................................................................................37
SINGLE-POINT SUPPLY CONNECTION ...................................................................................................38
CONTROL WIRING.....................................................................................................................................39
SECTION 5 – TECHNICAL DATA .....................................................................................................................40
OPERATIONAL LIMITATIONS (ENGLISH) ................................................................................................40
Voltage Limitations..............................................................................................................................40
Temperatures and Flows ....................................................................................................................40
OPERATIONAL LIMITATIONS (SI).............................................................................................................43
Voltage Limitations..............................................................................................................................43
Temperatures and Flows (Si)..............................................................................................................43
Ethylene & Propolyne Glycol Correction Factors ............................................................................43
PHYSICAL DATA (ENGLISH) .....................................................................................................................46
SOUND DATA (ENGLISH) ..........................................................................................................................48
ELECTRICAL DATA (ENGLISH).................................................................................................................50

JOHNSON CONTROLS
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FORM 150.67-NM2 (209)
ELECTRICAL NOTES AND LEGEND ........................................................................................................53
ELEMENTARY WIRING DIAGRAM............................................................................................................54
CONNECTION WIRING DIAGRAM ............................................................................................................64
ELEMENTARY WIRING DIAGRAM DETAILS............................................................................................68
DIMENSIONS (ENGLISH)...........................................................................................................................70
TECHNICAL DATA – CLEARANCES.......................................................................................................106
ISOLATORS ..............................................................................................................................................107
Weight Distribution and Isolator Mounting PositionsYCAL0019 – 0033
(Without Pump Package Option).....................................................................................................107
Weight Distribution and Isolator Mounting PositionsYCAL0043 – 0066......................................109
Isolator Details - Units Shipped On Or After June 15, 2008...........................................................110
Isolator Details - Units Shipped Before June 15, 2008...................................................................116
SECTION 6 – COMMISSIONING.....................................................................................................................121
COMMISSIONING.....................................................................................................................................121
PREPARATION – POWER OFF................................................................................................................121
Inspection ..........................................................................................................................................121
Refrigerant Charge............................................................................................................................121
Service and Oil Line Valves..............................................................................................................121
Compressor Oil..................................................................................................................................121
Fans ...................................................................................................................................................121
Isolation / Protection.........................................................................................................................121
Control Panel.....................................................................................................................................121
Power Connections...........................................................................................................................121
Grounding..........................................................................................................................................121
Supply Voltage...................................................................................................................................122
PREPARATION – POWER ON .................................................................................................................122
Switch Settings..................................................................................................................................122
Compressor Heaters.........................................................................................................................122
Water System.....................................................................................................................................122
Flow Switch........................................................................................................................................122
Temperature Sensor(s) .....................................................................................................................122
EQUIPMENT STARTUP CHECKLIST ......................................................................................................123
Checking The System Prior To Initial Start (No Power).................................................................123
Unit Checks........................................................................................................................................123
Compressor Heaters(Power On – 24 Hours Prior To Start)...........................................................123
Panel Checks(Power On – Both Unit Switch Off).........................................................................123
SETPOINTS ENTRY LIST.........................................................................................................................124
CHECKING SUPERHEAT AND SUBCOOLING.......................................................................................125
LEAK CHECKING.....................................................................................................................................125
UNIT OPERATING SEQUENCE ...............................................................................................................126
TABLE OF CONTENTS (CONT’D)

FORM 150.67-NM2 (209)
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JOHNSON CONTROLS
SECTION 7 – UNIT CONTROLS.....................................................................................................................127
INTRODUCTION .......................................................................................................................................127
IPU II and I/O Boards.........................................................................................................................127
Unit Switch.........................................................................................................................................128
Display................................................................................................................................................128
Keypad................................................................................................................................................128
Battery Back-up.................................................................................................................................128
Transformer .......................................................................................................................................128
Single System Select and Programming # of Compressors........................................................128
“STATUS” KEY.........................................................................................................................................129
Unit Status..........................................................................................................................................129
General Status Messages.................................................................................................................129
Fault Safety Status Messages..........................................................................................................131
Unit Warning ......................................................................................................................................133
Status Key Messages........................................................................................................................134
Status Key Messages Quick Reference List...................................................................................134
DISPLAY/PRINT KEYS.............................................................................................................................135
Oper Data Key....................................................................................................................................135
Oper Data Quick Reference List.......................................................................................................138
Print Key.............................................................................................................................................139
Operating Data Printout....................................................................................................................139
History Printout .................................................................................................................................140
History Displays ................................................................................................................................140
Software Version ...............................................................................................................................142
“ENTRY” KEYS.........................................................................................................................................143
Up and Down Arrow Keys.................................................................................................................143
Enter/adv Key.....................................................................................................................................143
“SETPOINTS” KEYS ................................................................................................................................144
Cooling Setpoints..............................................................................................................................144
Leaving Chilled Liquid Control ........................................................................................................144
Return Chilled Liquid Control ..........................................................................................................145
Remote Setpoint Control..................................................................................................................145
SCHEDULE/ADVANCE DAY KEY............................................................................................................145
PROGRAM KEY........................................................................................................................................147
System Trip Volts...............................................................................................................................148
Unit Trip Volts ....................................................................................................................................149
PROGRAM KEY LIMITS AND DEFAULT.................................................................................................149
SETPOINTS QUICK REFERENCE LIST..................................................................................................150
“UNIT” KEYS ...........................................................................................................................................151
Options Key .......................................................................................................................................151
CLOCK ......................................................................................................................................................155
UNIT KEYS OPTIONS PROGRAMMING QUICK REFERENCE LIST.....................................................156
TABLE OF CONTENTS (CONT’D)

JOHNSON CONTROLS
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FORM 150.67-NM2 (209)
SECTION 8 – UNIT OPERATION....................................................................................................................157
CAPACITY CONTROL ..............................................................................................................................157
SUCTION PRESSURE LIMIT CONTROLS ..............................................................................................157
DISCHARGE PRESSURE LIMIT CONTROLS.........................................................................................157
LEAVING CHILLED LIQUID CONTROL...................................................................................................157
LEAVING CHILLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING .....................158
LEAVING CHILLED LIQUID CONTROLOVERRIDE TO REDUCE CYCLING.........................................158
RETURN CHILLED LIQUID CONTROL....................................................................................................159
RETURN CHILLLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING....................160
ANTI-RECYCLE TIMER............................................................................................................................161
ANTI-COINCIDENCE TIMER....................................................................................................................161
EVAPORATOR PUMP CONTROL & YORK HYDRO KIT PUMP CONTROL ..........................................161
EVAPORATOR HEATER CONTROL........................................................................................................161
PUMPDOWN CONTROL...........................................................................................................................161
STANDARD CONDENSER FAN CONTROL............................................................................................161
YCAL0019 - 0028 LOW AMBIENT FAN CONTROL OPTION..................................................................165
General......................................................................................................................................................165
Potentiometer Configuration............................................................................................................165
Wiring .................................................................................................................................................166
Programming.....................................................................................................................................167
YCAL0033 LOW AMBIENT FAN CONTROL OPTION.............................................................................168
General...............................................................................................................................................168
Configuration (Jumpers and Potentiometers)................................................................................169
Wiring .................................................................................................................................................169
Programming.....................................................................................................................................169
YCAL0043 - 0066 LOW AMBIENT FAN CONTROL OPTION..................................................................171
General...............................................................................................................................................171
Configuration (Jumpers and Potentiometers)................................................................................172
Wiring .................................................................................................................................................173
Programming ....................................................................................................................................173
LOAD LIMITING........................................................................................................................................175
COMPRESSOR RUN STATUS .................................................................................................................175
ALARM STATUS.......................................................................................................................................175
BAS/EMS TEMPERATURE RESET USINGA VOLTAGE OR CURRENT SIGNAL.................................176
SECTION 9 – SERVICE AND TROUBLESHOOTING.....................................................................................177
CLEARING HISTORY BUFFERS..............................................................................................................177
SERVICE MODE........................................................................................................................................177
SERVICE MODE – OUTPUTS ..................................................................................................................177
SERVICE MODE – CHILLER CONFIGURATION.....................................................................................178
SERVICE MODE – ANALOG & DIGITAL INPUTS...................................................................................178
CONTROL INPUTS/OUTPUTS.................................................................................................................179
MICROBOARD LAYOUT ..........................................................................................................................180
TABLE OF CONTENTS (CONT’D)

FORM 150.67-NM2 (209)
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JOHNSON CONTROLS
CHECKING INPUTS AND OUTPUTS.......................................................................................................181
Digital Inputs......................................................................................................................................181
Analog Inputs – Temperature...........................................................................................................181
Outside Air Sensor............................................................................................................................181
Liquid & Refrigerant Sensor Test Points ........................................................................................182
Analog Inputs – Pressure.................................................................................................................183
Digital Outputs...................................................................................................................................184
OPTIONAL PRINTER INSTALLATION.....................................................................................................185
Parts....................................................................................................................................................185
The following parts are required:.....................................................................................................185
Assembly and Wiring........................................................................................................................185
Obtaining a Printout..........................................................................................................................185
TROUBLESHOOTING ..............................................................................................................................186
SECTION 10 – MAINTENANCE......................................................................................................................189
IMPORTANT..............................................................................................................................................189
COMPRESSORS.......................................................................................................................................189
Oil Level check ..................................................................................................................................189
Oil Analysis........................................................................................................................................189
CONDENSER FAN MOTORS...................................................................................................................189
CONDENSER COILS................................................................................................................................189
OPERATING PARAMETERS....................................................................................................................189
ON-BOARD BATTERY BACK-UP............................................................................................................189
PLATE AND FRAME HEAT EXCHANGER (EVAPORATOR) HEATER...................................................189
OVERALL UNIT INSPECTION..................................................................................................................189
ISN CONTROL ..........................................................................................................................................190
Received Data (Control Data)...........................................................................................................190
Transmitted Data ...............................................................................................................................190
ISN Operational and Fault Codes.....................................................................................................192
BACNET AND MODBUS DATA COMMUNICATION................................................................................193
Serial Communication Analog Value Data ......................................................................................196
Serial Communication Binary Value Data.......................................................................................196
Serial Communication Analog Input Data.......................................................................................196
Serial Communication Binary Input Data........................................................................................198
TEMPERATURE CONVERSION CHART.................................................................................................199
R410-APRESSURE TEMPERATURE CHART.........................................................................................200
TABLE OF CONTENTS (CONT’D)

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FORM 150.67-NM2 (209)
General Chiller Introduction & Safety
SECTION 1 – GENERAL CHILLER INFORMATION & SAFETY
INTRODUCTION
YORK YCAL0019-0066 (15-65 ton, 53-218Kw)
chillers are manufactured to the highest design and
construction standards to ensure high performance,
reliability and adaptability to all types of air
conditioning installations.
The unit is intended for cooling water or glycol
solutions 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,
together with operating and maintenance instructions.
The manuals should be read thoroughly before
attempting to operate or service the unit.
All procedures detailed in the manuals, including
installation, 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,
commissioning, 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 period 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 identification 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 Johnson
Controls Service Center (see Commissioning
Page 121).
• 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 specified
times by suitably trained and qualified personnel
(see Maintenance Section, Page 189).
• Failure to satisfy any of these conditions will
automatically void the warranty (see Warranty
Policy).
SAFETY
Standards for Safety
YCAL chillers are designed and built within an ISO
9002 accredited design and manufacturing organization.
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
Packages Using the Vapor Compression Cycle.
• ASHRAE 90.1- Energy Efficiency compliance.
• ARI 370- Sound Rating of Large Outdoor
Refrigeration 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
Laboratories (U.L.) for construction of chillers and
provide U.L./cU.L. Listing Label.