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YCAL0028
York YCAL0028 User Manual
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JOHNSON CONTROLS
60
FORM 150.67-NM2
ISSUE DA
TE: 01/31/2019
SECTION 5 – TECHNICAL
DA
T
A
LD12701
FIGURE 16 -
POWER CIRCUIT
, SINGLE, STYLE D
ELEMENT
AR
Y WIRING DIAGRAM
YCAL
0019, 0022, 0028 & 0033 ST
ANDARD UNITS
YCAL
0019, 0022, 0028 & 0033 ST
ANDARD LOW SOUND UNITS
YCAL
0028 & 0033 UL
TRA
LOW
SOUND UNITS
59
61
Table of Contents
Default Chapter
5
Table of Contents
5
Section 1 - General Chiller Information and Safety
11
Warranty
11
Safety
11
About this Manual
12
Misuse of Equipment
12
Section 2 - Product Description
15
General System Description
15
Introduction
15
Control Center
16
Accessories and Options
17
Power Panel
17
Compressor, Piping, Evaporator Options
18
Condenser and Cabinet Options
19
Sound Reduction Options
19
FIGURE 1 - Components Single System Units
20
FIGURE 2 - Control/Power Panel Components Single System Units
21
FIGURE 3 - Components Dual System Units
22
Control / Power Panel Components - YCAL0043 - 0066
23
Unit Components - YCAL0043 - 0066
22
Unit Components YCAL0019 - 0033
20
Control - Power Panel Components YCAL0019 - 0033
21
FIGURE 4 - Control/Power Panel Components Dual System Units
23
TABLE 1 - Product Identification Number (Pin)
24
Refrigerant Flow Diagram
27
FIGURE 5 - Refrigerant Flow Diagram
27
Section 3 - Handling and Storage
29
Lifting Weights
29
Delivery and Storage
29
Inspection
29
Moving the Chiller
30
Unit Removal from Shipping Container
30
Lifting Using Lugs
30
Lifting Using Shackles
30
Section 4 - Installation
31
Handling
31
Inspection
31
Installation Checklist
31
Location and Clearances
31
Chilled Liquid Piping
32
Compressor Mounting
32
Remote Cooler Option
32
Spring Isolators (Optional)
32
Duct Work Connection
33
FIGURE 6 - Chilled Liquid System
33
FIGURE 7 - Single-Point Supply Connection - Terminal Block, Non-Fused Disconnect Switch or Circuit Breaker
36
Control Wiring
37
Pipework Arrangement
33
Wiring
33
Compressor Heaters
35
High Pressure Cutout
35
Relief Valves
35
Single-Point Supply Connection
36
FIGURE 8 - Control Wiring
37
Section 5 - Technical Data
39
TABLE 3 - Voltage Limitations
39
TABLE 2 - Temperatures and Flows
39
FIGURE 9 - YCAL0019-0033 Heat Exchanger Flow, GPM
40
FIGURE 10 - YCAL0043-0066 Heat Exchanger Flow, GPM
41
Operational Limitations (SI)
43
Operation Limitations (English)
40
TABLE 5 - Voltage Limitations
43
TABLE 4 - Temperatures and Flows (SI)
43
TABLE 6 - Ethylene and Propolyne Glycol Correction Factors
43
FIGURE 11 - YCAL0019-0033 Heat Exchanger Flow, GPM
44
FIGURE 12 - YCAL0043-0066 Heat Exchanger Flow, GPM
45
TABLE 7 - Physical Data (English)
46
TABLE 8 - Sound Data - 50 Hz Line Frequency
48
Electrical Data (English)
50
FIGURE 13 - Control Circuit, SINGLE
54
FIGURE 14 - Control Circuit, Dual
56
FIGURE 15 - Power Circuit, Single
58
FIGURE 16 - Power Circuit, Single, Style D
60
FIGURE 18 - Connection Wiring Diagram Microboard, Single Circuit
64
FIGURE 19 - Connection Wiring Diagram Microboard, Dual Circuit
66
Elementary Wiring Diagram Details
68
FIGURE 20 - Elementary Wiring Diagram Details, Single Circuit
68
FIGURE 21 - Elementary Wiring Diagram Details, Dual Circuit
69
Dimensions
70
Sound Data (English)
48
TABLE 9 - Electrical Data (English)
50
TABLE 11 - Voltage Range
52
TABLE 10 - Micro Panel Power Supply
52
Electrical Notes and Legend
53
Elementary Wiring Diagram
54
FIGURE 17 - Power Circuit, Dual, Style D
62
Connection Wiring Diagram
64
Physical Data (English)
46
FIGURE 22 - Dimensions - YCAL0019
70
FIGURE 31 - Dimensions - YCAL0019 (SI)
89
FIGURE 32 - Dimensions - YCAL0022 (SI)
90
FIGURE 33 - Dimensions - YCAL0028 (SI)
92
FIGURE 34 - Dimensions - YCAL0033 (SI)
94
FIGURE 35 - Dimensions - YCAL0043 (SI)
96
FIGURE 36 - Dimensions - YCAL0046 (SI)
98
FIGURE 37 - Dimensions - YCAL0052 (SI)
100
FIGURE 38 - Dimensions - YCAL0056 (SI)
102
FIGURE 39 - Dimensions - YCAL0066 (SI)
104
FIGURE 40 - Unit Clearances - All Models
106
Isolators
107
Technical Data - Clearances
106
FIGURE 23 - Dimensions - YCAL0022
72
FIGURE 24 - Dimensions - YCAL0028
74
FIGURE 25 - Dimensions - YCAL0033
76
FIGURE 26 - Dimensions - YCAL0043
78
FIGURE 27 - Dimensions - YCAL0046
80
FIGURE 28 - Dimensions - YCAL0052
82
FIGURE 29 - Dimensions - YCAL0056
84
FIGURE 30 - Dimensions - YCAL0066
86
Dimensions (SI)
88
TABLE 12 - Isolator Selection YCAL0019 - 0033 (Without Pump Package Option)
108
Section 6 - Commissioning
121
Commissioning
121
Preparation - Power off
121
Preparation - Power on
122
Unit Operating Sequence
126
Section 7 - Unit Control Center
127
Introduction
127
Status Key
129
Status Key Messages
134
TABLE 13 - Status Key Messages Quick Reference List
134
TABLE 14 - Operation Data
138
TABLE 15 - Cooling Setpoints, Programmable Limits and Defaults
146
Program Key
147
Entry Keys
143
Setpoints Keys
144
Schedule/Advance Day Key
145
Display/Print Keys
135
TABLE 16 - Program Key Limits and Default
149
TABLE 17 - Setpoints Quick Reference List
150
Unit Keys
151
Clock
155
TABLE 18 - Unit Keys Options Programming Quick Reference List
156
Section 8 - Unit Operation
157
Capacity Control
157
Discharge Pressure Limit Controls
157
Leaving Chilled Liquid Control
157
Suction Pressure Limit Controls
157
FIGURE 41 - Setpoint Adjust
158
Leaving Chilled Liquid Control Override to Reduce Cycling
158
Leaving Chilled Liquid System Lead/Lag and Compressor Sequencing
158
Return Chilled Liquid Control
158
FIGURE 42 - Leaving Water Temperature Control Example
159
TABLE 19 - Sample Compressor Staging for Return Water Control
159
FIGURE 43 - YCAL0019 - YCAL0033 Fan Location (Typical)
163
TABLE 24 - YCAL0043 - YCAL0066 Condenser Fan Control Using Discharge Pressure
164
TABLE 25 - YCAL0043 - YCAL0066 Condenser Fan Control Using Discharge Pressure Only
164
YCAL0019 - 0033 Low Ambient Fan Control Option
165
Return Chilled Liquid System Lead/Lag and Compressor Sequencing
160
TABLE 20 - Return Chilled Liquid Control for 4 Compressors (6 Steps)
160
TABLE 21 - Return Chilled Liquid Control for 4 Compressors (6 Steps)
160
TABLE 23 - YCAL0019 - YCAL0033 Condenser Fan Control Using Discharge Pressure Only
163
TABLE 22 - YCAL0019 - YCAL0033 Condenser Fan Control Using Discharge Pressure
163
Standard Condenser Fan Control - YCAL0043 - YCAL0066
164
Anti-Coincidence Timer
161
Anti-Recycle Timer
161
Evaporator Heater Control
161
Evaporator Pump Control and York Hydro Kit Pump Control
161
Pumpdown Control
161
Standard Condenser Fan Control
161
Standard Condenser Fan Control - YCAL0019 - YCAL0033
163
FIGURE 44 - YCAL0043 - YCAL0066 Fan Location (Typical)
164
FIGURE 47 - Potentiometer Settings
165
FIGURE 45 - Typical VFD Location
165
FIGURE 46 - Liquid Line Sensing Bulb Location
165
FIGURE 53 - Inverter Wiring
170
FIGURE 52 - Inverter Power Wiring Schematic
170
FIGURE 54 - Typical VFD Enclosure Locations
171
FIGURE 55 - Typical VFD Enclosure Configurations
172
FIGURE 57 - Potentiometer Settings
173
FIGURE 56 - Inverter Power Wiring Schematic
173
TABLE 28 - YCAL0043-0066 VFD Low Ambient Option - Condenser Fan Control Operation
174
FIGURE 58 - Inverter Wiring
174
Alarm Status
175
Bas/Ems Temperature Reset Using Avoltage or Current Signal
175
Compressor Run Status
175
Load Limiting
175
FIGURE 48 - Wiring
166
TABLE 26 - YCAL0019 - 0028 VFD Low Ambient Option - Condenser Fan Control Operation
167
FIGURE 50 - Typical VFD Enclosure Configurations
168
FIGURE 49 - Typical VFD Enclosure Locations
168
FIGURE 51 - Potentiometer Settings
169
TABLE 27 - YCAL033 VFD Low Ambient Option - Condenser Fan Control Operation
170
YCAL0043 - 0066 Low Ambient Fan Control Option
171
TABLE 29 - Compressor Operation - Load Limiting
175
Section 9 - Service and Troubleshooting
177
Clearing History Buffers
177
Service Mode
177
Service Mode - Outputs
177
Service Mode - Analog and Digital Inputs
178
Service Mode - Chiller Configuration
178
Control Inputs/Outputs
179
TABLE 31 - I/O Digital Outputs
179
TABLE 34 - Outdoor Air Sensor Temperature/Voltage/Correlation
181
TABLE 35 - Entering/Leaving Chilled Liquid Temp. Sensor, Temperature/Voltage Correlation
182
TABLE 36 - Pressure Transducers
183
FIGURE 60 - I/O Board Relay Contact Architecture
184
FIGURE 61 - Printer to Microboard Electrical Connections
185
Troubleshooting
186
TABLE 32 - I/O Analog Inputs
179
TABLE 33 - I/O Analog Outputs
179
Optional Printer Installation
185
TABLE 30 - I/O Digital Inputs
179
FIGURE 59 - Microboard Layout
180
Checking Inputs and Outputs
181
TABLE 37 - Troubleshooting
186
Section 10 - Maintenance
189
Compressors
189
Condenser Coils
189
Condenser Fan Motors
189
Important
189
On-Board Battery Back-Up
189
Operating Parameters
189
Overall Unit Inspection
189
Plate and Frame Heat Exchanger (Evaporator) Heater
189
ISN Control
190
TABLE 39 - ISN Transmitted Data
190
TABLE 41 - Real Time Error Numbers
193
TABLE 42 - Minimum, Maximum and Default Values
194
Temperature Conversion Chart
197
R410-A Pressure Temperature Chart
199
TABLE 38 - ISN Received Data
190
TABLE 40 - ISN Operational and Fault Codes
192
Bacnet and Modbus Data Communication
193
4
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York YCAL0028 Specifications
General
Brand
York
Model
YCAL0028
Category
Chiller
Language
English
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