York YCAL Series - UNIT COMPONENTS; COMPRESSORS; HEAT EXCHANGER; CONTROL; POWER PANEL

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FORM 150.66-NM3

ISSUE DATE: 09/25/2020

JOHNSON CONTROLS

SECTION 2 - PRODUCT DESCRIPTION

UNIT COMPONENTS

COMPRESSORS

HEAT EXCHANGER

CONTROL / POWER PANEL

LD10950

COMPRESSORS

CONDENSER COILS

LD11457

LD11464

LD11419

LD11420

Main Page

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

York YCAL Series - UNIT COMPONENTS; COMPRESSORS; HEAT EXCHANGER; CONTROL; POWER PANEL

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