York YCAL Series - Fig. 19 - Ipu II & I;O Layout

York YCAL Series

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JOHNSON CONTROLS

148

FORM 150.66-NM3

ISSUE DATE: 09/25/2020

SECTION 9 - SERVICE AND TROUBLESHOOTING

FIG. 19 – IPU II & I/O LAYOUT

LD12721

TB5

TB1

TB6

TB7

TB8

TB9

TB10

J14

J13

J12

J15

J11

J10

J9

J8

J7

J6

J5

J3

I/O BOARD

IPU

BOARD

JP1

LD12721

Table of Contents

General Safety Guidelines2
Changeability of this Document3
Revision Notes3
Table of Contents5
List of Figures10
List of Tables11
Section 1 - General Chiller Information and Safety13
- Introduction13
- Warranty13
- Safety13
  - Standards for Safety13
- Responsibility for Safety14
- About this Manual14
- Misuse of Equipment14
Section 2 - Product Description17
- Introduction17
- General System Description17
- Accessories and Options20
- Unit Components23
- Control / Power Panel Components24
- Product Identification Number (Pin)25
- Refrigerant Flow Diagram30
Fig. 1 - Refrigerant Flow Diagram30
Section 3 - Handling and Storage31
- Delivery and Storage31
- Inspection31
- Moving the Chiller31
  - Lifting Weights31
- Unit Rigging32
Section 4 - Installation33
- Installation Checklist33
- Handling33
- Inspection33
- Location and Clearances33
- Spring Isolators (Optional)34
- Compressor Mounting34
- Remote Cooler Option34
- Chilled Liquid Piping34
- Duct Work Connection35
  - General Requirements35
- Wiring35
- Compressor Heaters36
- Single-Point Supply Connection - Terminal Block, Non-Fused Disconnect Switch or Circuit Breaker (0041 - 0071)37
Fig. 2 - Single-Point Supply Connection - Terminal Block, Non-Fused37
- Disconnect Switch or Circuit Breaker (0041 - 0071)37
- Control Wiring38
Fig. 3 - Control Wiring38
Section 5 - Commissioning39
- Preparation - Power off39
- Preparation - Power on40
- Equipment Pre-Startup and Startup Checklist41
- Checking Superheat and Subcooling43
- Leak Checking43
- Unit Operating Sequence44
Section 6 - Technical Data45
- Operational Limitations (English)45
- Operational Limitations (Si)47
- Physical Data (English)50
- Table 8 - Physical Data (English)50
- Sound Data (English)52
- Table 9 - Sound Data (English)52
- Electrical Data54
- Table 10 - Electrical Data (English)54
- Table 11 - Micro Panel Power Supply56
- Table 12 - Voltage Range56
- Electrical Notes and Legend57
- Wiring Diagrams58
Fig. 4 - Control Circuit58
Fig. 5 - Power Circuit60
Fig. 6 - Wiring Details61
Fig. 7 - Connection Diagram62
Fig. 8 - Connection Diagram Microboard (Partial)63
- Dimensions64
- Technical Data - Clearances92
Fig. 9 - Unit Clearances92
- Isolators93
  - General93
  - Installation of 1" Deflection Mounts95
Section 7 - Unit Controls99
- York Millennium Control Center99
- Introduction99
- Microprocessor Board99
- Unit Switch100
- Display100
- Keypad100
- Battery Back-Up100
- Transformer100
- Single System Select and Programming # of Compressors100
- Status Key101
- Status Key Messages106
- Table 13 - Status Key Messages Quick Reference List106
- Display/Print Keys107
- Entry Keys115
  - Up and down Arrow Keys115
  - Enter/Adv Key115
- Setpoints Keys116
- Unit Keys124
  - Options Key124
- Clock128
- Table 18 - Unit Keys Programming Quick Reference List129
Section 8 - Unit Operation131
- Capacity Control131
- Suction Pressure Limit Controls131
- Discharge Pressure Limit Controls131
- Leaving Chilled Liquid Control131
- Leaving Chilled Liquid System Compressor Sequencing132
- Leaving Chilled Liquid Control Override to Reduce Cycling132
Fig. 10 - Leaving Water Temperature Control Example132
Fig. 11 - Setpoint Adjust132
- Return Chilled Liquid Control133
- Table 19 - Compressor Staging for Return Water Control133
- Return Chillled Liquid System Lead/Lag and Compressor Sequencing134
- Anti-Recycle Timer134
- Anti-Coincidence Timer134
- Evaporator Pump Control134
- Table 20 - Return Chilled Liquid Control for 4 Compressors (6 Steps)134
- Evaporator Heater Control135
- Pumpdown Control135
- Condenser Fan Control (Ycal0041 - Ycal0071 Chillers)135
- Table 21 - Return Chilled Liquid Control for 4 Compressors (6 Steps)135
- Standard Condenser Fan Control - Ycal0041 - Ycal0071136
Fig. 12 - Ycal0041 - Ycal0071 Fan Location (Typical)136
- Ambient Temperature and Discharge Pressure136
- Pressure Only136
- Table 22 - Ycal0041 - Ycal0071 Condenser Fan Control Using Outdoor136
- Table 23 - Ycal0041 - Ycal0071 Condenser Fan Control Using Discharge136
- Low Ambient Fan Control Option137
  - General137
Fig. 13 - Typical Inverter Location137
Fig. 14 - Inverter Enclosure137
- Configuration (Jumpers and Potentiometers)138
Fig. 15 - Potentiometer Settings138
- Wiring139
Fig. 16 - Inverter Power Wiring Schematic139
Fig. 17 - Inverter Wiring139
- Programming140
- Load Limiting140
- Table 24 - Inverter Option Condenser Fan Control Operation140
- Compressor Run Status141
- Alarm Status141
- Ems-Pwm Remote Temperature Reset141
- Table 25 - Compressor Operation - Load Limiting141
- Bas/Ems Temperature Reset Option142
Fig. 18 - Field and Factory Electrical Connections Optional Remote143
- Temperature Reset Board143
Section 9 - Service and Troubleshooting145
- Clearing History Buffers145
- Service Mode145
- Service Mode - Outputs145
- Service Mode - Chiller Configuration145
- Service Mode - Inputs146
- Control Inputs/Outputs147
- Table 26 - Microboard Digital Inputs147
- Table 27 - Microboard Digital Outputs147
- Table 28 - Microboard Analog Inputs147
- Table 29 - Microboard Analog Outputs147
Fig. 19 - Ipu II & I/O Layout148
- Checking Inputs and Outputs149
- Correlation150
- Temperature Sensor, and Suction Temperature Sensor: Temperature/Voltage Correlation150
  - Analog Inputs - Pressure151
  - Digital Outputs152
Fig. 20 - Microboard Relay Contact Architecture152
- Optional Printer Installation153
Fig. 21 - Printer to Microboard Electrical Connections153
Table 32 - Troubleshooting154
Section 10 - Maintenance157
- Important157
- Compressors157
  - Oil Level Check157
  - Oil Analysis157
- Condenser Fan Motors157
- Condenser Coils157
- Operating Parameters157
- On-Board Battery Back-Up157
- Plate and Frame Heat Exchanger (Evaporator) Heater157
- Overall Unit Inspection158
- Bacnet, Modbus and Yorktalk 2 Communications158
Table 33 - Minimum, Maximum and Default Values159
Fig. 22 - Micro Panel Connections159
- Table 34 - Values Required for Bas Communication160
- Table 35 - Real Time Error Numbers160
- Bacnet and Modbus Communications161
- Communications Data Map Notes161
- Table 36 - Bacnet and Modbus Communications Data Map162
- Yorktalk 2 Communications166
- Table 37 - Yorktalk 2 Communications Data Map167

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