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York YCAL Series User Manual

York YCAL Series
174 pages
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YCAL0041EC–YCAL0071EC
AIR-COOLED
SCROLL CHILLERS
STYLE D
WITH IPU II and I/O BOARDS
(50 Hz)
29 TON TO 65 TON
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Supersedes 150.66-NM3 (110)
Form 150.66-NM3 (920)
R-410A
035-20895-001
Issue Date:
September 25, 2020

Table of Contents

Other manuals for York YCAL Series

Questions and Answers:

York YCAL Series Specifications

General IconGeneral
CondenserAir-cooled
Energy EfficiencyHigh
Control InterfaceMicroprocessor Control
Sound PerformanceLow sound levels due to optimized fan design and compressor enclosure options
DimensionsVaries by model
WeightVaries by model
Voltage208-230/460V
Voltage Options208-230/460V, 3-phase

Summary

GENERAL SAFETY GUIDELINES

SAFETY SYMBOLS

Explains the meaning of safety symbols used in the document.

SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY

INTRODUCTION

Provides an overview of YORK chillers and their intended use.

WARRANTY

Outlines the terms and conditions of the product warranty.

SAFETY

Lists applicable safety codes and standards the chillers comply with.

RESPONSIBILITY FOR SAFETY

Defines the safety obligations of personnel working with the equipment.

ABOUT THIS MANUAL

Explains the use of safety symbols and terms.

MISUSE OF EQUIPMENT

Covers hazards related to incorrect application and operational parameters.

SECTION 2 - PRODUCT DESCRIPTION

INTRODUCTION

Describes the YORK Millennium Air-Cooled Scroll Chillers.

GENERAL SYSTEM DESCRIPTION

Overview of the chiller's main components and design.

Millennium Control Center

Details the control center's display and keypad functions.

Display/Print

Describes the display and print capabilities of the control center.

Setpoints

Explains how to update setpoints and system values.

ACCESSORIES AND OPTIONS

Lists available power and control options for the unit.

Power Options

Details various power connection options for the unit.

Control Options

Lists available control options and their features.

Condenser and Cabinet Options

Describes protective coatings and enclosure panels for the unit.

Sound Reduction Options

Details options for reducing operational noise levels.

Vibration Isolators

Information on mounting isolators for vibration dampening.

UNIT COMPONENTS

COMPRESSORS

Identifies the location and type of compressors in the unit.

HEAT EXCHANGER

Identifies the location of the heat exchanger component.

CONTROL / POWER PANEL

Indicates the location of the main control and power panel.

PRODUCT IDENTIFICATION NUMBER (PIN)

BASIC UNIT NOMENCLATURE

Explains the coding system for the unit's model number.

SECTION 3 - HANDLING AND STORAGE

DELIVERY AND STORAGE

Precautions for unit storage before installation.

INSPECTION

Procedure for inspecting the unit upon delivery for damage.

MOVING THE CHILLER

Guidance on safe unit lifting and movement procedures.

UNIT RIGGING

Specific instructions for rigging the chiller safely.

SECTION 4 - INSTALLATION

INSTALLATION CHECKLIST

Essential items to check before operating the unit.

HANDLING

Precautions for handling the completely assembled unit.

INSPECTION

Procedure for checking unit condition after transit.

LOCATION AND CLEARANCES

Requirements for unit placement and surrounding space.

Foundation

Guidelines for creating a suitable mounting foundation.

SPRING ISOLATORS (OPTIONAL)

Information on installing vibration isolation.

CHILLED LIQUID PIPING

Recommendations for connecting the chilled water system.

DUCT WORK CONNECTION

Guidelines for connecting ductwork to the fan outlet.

WIRING

General information on unit wiring connections.

SECTION 5 - COMMISSIONING

PREPARATION – POWER OFF

Initial checks to be made with the customer power to the unit switched OFF.

PREPARATION – POWER ON

Steps to follow after applying power to the chiller.

EQUIPMENT PRE-STARTUP AND STARTUP CHECKLIST

A comprehensive checklist for unit startup procedures.

CHECKING SUPERHEAT AND SUBCOOLING

Procedures for verifying refrigerant charge and system performance.

UNIT OPERATING SEQUENCE

Description of the unit's operational steps during startup.

SECTION 6 - TECHNICAL DATA

OPERATIONAL LIMITATIONS (ENGLISH)

Defines operating limits in English units for voltage and temperature.

OPERATIONAL LIMITATIONS (SI)

Defines operating limits in SI units for voltage and temperature.

PHYSICAL DATA (ENGLISH)

Provides physical dimensions and weights in English units.

SOUND DATA (ENGLISH)

Lists sound level data in English units for various fan configurations.

ELECTRICAL DATA (ENGLISH)

Details electrical specifications in English units.

ELECTRICAL NOTES AND LEGEND

Explains electrical symbols and important notes.

TECHNICAL DATA - CLEARANCES

Specifies required installation clearances around the unit.

ISOLATORS

Information on weight distribution and isolator mounting positions.

ONE INCH DEFLECTION SPRING ISOLATOR CROSS-REFERENCE

Details on spring isolator selection based on load.

Installation of 1" Deflection Mounts

Step-by-step guide for installing 1" deflection mounts.

NEOPRENE ISOLATOR CROSS-REFERENCE

Details on neoprene isolator selection based on load.

TWO INCH DEFLECTION, SEISMIC SPRING ISOLATOR CROSS-REFERENCE

Details on seismic spring isolator selection.

SLRS SEISMIC ISOLATOR INSTALLATION AND ADJUSTMENT

Guide for installing and adjusting seismic isolators.

SECTION 7 - UNIT CONTROLS

YORK MILLENNIUM CONTROL CENTER

Overview of the chiller's microprocessor-based control center.

MICROPROCESSOR BOARD

Description of the controller's function and inputs.

UNIT SWITCH

Explanation of the unit's ON/OFF switch functionality.

DISPLAY

Details of the character display and its functions.

KEYPAD

Description of the keypad's capabilities for parameter access.

STATUS KEY

How to view the current operating status of the chiller.

Unit Status

Explains how to interpret chiller operating status messages.

General Status Messages

Lists and explains general status messages displayed by the unit.

DISPLAY/PRINT KEYS

Functionality of keys for viewing and printing data.

Oper Data Key

Accesses unit and system operating parameters.

ENTRY KEYS

Explanation of keys used for navigating and programming.

Up and Down Arrow Keys

Keys used for scrolling through data screens.

Enter/Adv Key

Key used to enter changes and advance to the next parameter.

SETPOINTS KEYS

How to access and program setpoints for unit control.

Cooling Setpoints

How to program the cooling setpoint and range.

Leaving Chilled Liquid Control

How to set the leaving chilled liquid temperature control.

Program Key

Details on programming various operational setpoints.

DISCHARGE PRESSURE CUTOUT

Programmable setpoint for system shutdown based on discharge pressure.

SUCTION PRESSURE CUTOUT

Programmable setpoint to prevent evaporator freeze-up.

UNIT KEYS

Overview of programmable options accessible via the UNIT keys.

Options Key

Guide to accessing and modifying unit options.

Option 1 – Language

Allows programming the display language (English, Spanish, etc.).

Option 2 – System Switches

Controls system operation for dual-system units.

Option 3 – Chilled Liquid Cooling Type

Sets whether the chilled liquid is water or glycol.

SECTION 8 - UNIT OPERATION

CAPACITY CONTROL

How the chiller manages cooling output based on demand.

SUCTION PRESSURE LIMIT CONTROLS

Controls to prevent the unit from reaching low-pressure cutouts.

DISCHARGE PRESSURE LIMIT CONTROLS

Controls to prevent high-pressure shutdowns.

LEAVING CHILLED LIQUID CONTROL

How the unit maintains leaving chilled liquid temperature.

RETURN CHILLED LIQUID CONTROL

How the unit controls based on return chilled liquid temperature.

EVAPORATOR HEATER CONTROL

Operation of the evaporator heater.

PUMPDOWN CONTROL

System pump-down sequence upon shutdown.

CONDENSER FAN CONTROL (YCAL0041 – YCAL0071 CHILLERS)

How condenser fans are controlled based on pressure or ambient temp.

STANDARD CONDENSER FAN CONTROL - YCAL0041 – YCAL0071

Fan control based on ambient and discharge pressure.

LOW AMBIENT FAN CONTROL OPTION

Use of VFDs for fan speed control in low ambient conditions.

Wiring

Schematic and connection details for VFD wiring.

PROGRAMMING

How to program condenser fan control and other settings.

LOAD LIMITING

Feature to prevent unit loading beyond desired values.

EMS-PWM REMOTE TEMPERATURE RESET

How to use PWM input for temperature setpoint reset.

BAS/EMS TEMPERATURE RESET OPTION

Details on using BAS/EMS for temperature reset inputs.

SECTION 9 - SERVICE AND TROUBLESHOOTING

CLEARING HISTORY BUFFERS

Procedure for resetting historical data.

Service Mode

How to enter and navigate Service Mode.

SERVICE MODE – OUTPUTS

Viewing and modifying digital outputs in Service Mode.

SERVICE MODE – CHILLER CONFIGURATION

Configuring chiller parameters in Service Mode.

SERVICE MODE – INPUTS

Viewing analog and digital inputs in Service Mode.

CHECKING INPUTS AND OUTPUTS

Procedures for verifying inputs and outputs.

Digital Inputs

Explanation of digital input connections and signals.

Analog Inputs – Temperature

Details on temperature input connections and readings.

Analog Inputs – Pressure

Details on pressure input connections and readings.

Digital Outputs

Explanation of digital output connections and signals.

OPTIONAL PRINTER INSTALLATION

Guide for installing a printer for service and data logging.

SECTION 10 - MAINTENANCE

IMPORTANT

Disclaimer regarding warranty and maintenance responsibility.

COMPRESSORS

Maintenance procedures for compressors, including oil checks.

CONDENSER FAN MOTORS

Maintenance requirements for condenser fan motors.

CONDENSER COILS

Cleaning and maintenance of condenser coils.

OPERATING PARAMETERS

Importance of regular checks on operational parameters.

OVERALL UNIT INSPECTION

Periodic overall inspections for proper equipment operation.

BACNET, MODBUS AND YORKTALK 2 COMMUNICATIONS

Information on serial communication protocols.

Communications Data Map Notes

Notes regarding BACnet and Modbus data mapping.

YorkTalk 2 Communications

Details on YorkTalk 2 communication protocol and data.

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