York YCAL0066 User Manual

LD10950
R-410A
035-21456-000
DUAL CIRCUIT
SINGLE CIRCUIT
YCAL0019, 0022, 0028, 0033, 0043, 0046, 0052, 0056, 0066
AIR-COOLED SCROLL CHILLERS
STYLE E (60 HZ)
15-65 TON
Products are produced at a
f a c ilit y wh o s e qu a l i t y -
management systems are
ISO9001 certified.
Issue Date:
April 28, 2017
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
INSTALLATION, OPERATION, MAINTENANCE
Supersedes 150.67-NM1 (1216) Form 150.67-NM1 (417)

York YCAL0066 Specifications

General

Model	YCAL0066
Type	Air-Cooled Chiller
Refrigerant	R-410A
Compressor Type	Scroll
Power Supply	460V/3Ph/60Hz
Cooling Capacity	66 tons
Operating Temperature Range	115°F

Summary

GENERAL SAFETY GUIDELINES

SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY

WARRANTY

Details the warranty terms and conditions for the equipment.

SAFETY

Details safety information and standards for chillers.

MISUSE OF EQUIPMENT

SECTION 2 – PRODUCT DESCRIPTION

GENERAL SYSTEM DESCRIPTION

MILLENNIUM CONTROL CENTER

Display/Print

Entry

ACCESSORIES AND OPTIONS

Power Options

Control Options

Compressor, Piping, Evaporator Options

Flow Switch

Describes standard and optional flow switches.

Condenser And Cabinet Options

UNIT COMPONENTS YCAL0019 - 0033

CONTROL - POWER PANEL COMPONENTS YCAL0019-0033

UNIT COMPONENTS - YCAL0043 – 0066

CONTROL / POWER PANEL COMPONENTS - YCAL0043 – 0066

PRODUCT IDENTIFICATION NUMBER (PIN)

BASIC UNIT NOMENCLATURE

Explains the coding system for the unit's product identification number.

REFRIGERANT FLOW DIAGRAM

SECTION 3 – HANDLING AND STORAGE

MOVING THE CHILLER (YCAL0043 – 0066 DUAL SYSTEM ONLY)

UNIT RIGGING

SECTION 4 – INSTALLATION

INSTALLATION CHECKLIST

Lists essential checks to perform before placing units in operation.

LOCATION AND CLEARANCES

Foundation

Specifies requirements for a flat, level foundation or rooftop support.

CHILLED LIQUID PIPING

DUCT WORK CONNECTION

General Requirements

WIRING

Field Wiring

Details requirements for power wiring, including disconnect switches and wire types.

Load Limit Input

Flow Switch Input

SECTION 5 – TECHNICAL DATA

OPERATIONAL LIMITATIONS (ENGLISH)

Defines the operating limits for English units.

OPERATIONAL LIMITATIONS (SI)

Voltage Limitations

States absolute voltage limitations to prevent compressor damage.

PHYSICAL DATA (ENGLISH)

ELECTRICAL DATA (ENGLISH)

ELECTRICAL DATA

ELECTRICAL NOTES AND LEGEND

CONTROL WIRING DIAGRAMS

FIGURE 12 - CONTROL WIRING DIAGRAM, SINGLE CIRCUIT, IPU II

Wiring diagram for single-circuit IPU II control systems.

CONTROL WIRING DIAGRAM, DUAL CIRCUIT, IPU II

CONNECTION WIRING, SINGLE CIRCUIT

DIMENSIONS (ENGLISH)

DIMENSIONS – YCAL0019 (ENGLISH)

Provides overall dimensions and clearances for the YCAL0019 in English units.

DIMENSIONS – YCAL0022 (ENGLISH)

Provides overall dimensions and clearances for the YCAL0022 in English units.

DIMENSIONS – YCAL0028 (ENGLISH)

Provides overall dimensions and clearances for the YCAL0028 in English units.

DIMENSIONS – YCAL0033 (ENGLISH)

Provides overall dimensions and clearances for the YCAL0033 in English units.

DIMENSIONS – YCAL0043 (ENGLISH)

Provides overall dimensions and clearances for the YCAL0043 in English units.

DIMENSIONS – YCAL0046 (ENGLISH)

Provides overall dimensions and clearances for the YCAL0046 in English units.

DIMENSIONS – YCAL0052 (ENGLISH)

Provides overall dimensions and clearances for the YCAL0052 in English units.

DIMENSIONS – YCAL0056 (ENGLISH)

Provides overall dimensions and clearances for the YCAL0056 in English units.

DIMENSIONS – YCAL0066 (ENGLISH)

Provides overall dimensions and clearances for the YCAL0066 in English units.

DIMENSIONS (SI)

DIMENSIONS – YCAL0019 (SI)

Provides overall dimensions and clearances for the YCAL0019 in SI units.

DIMENSIONS – YCAL0022 (SI)

Provides overall dimensions and clearances for the YCAL0022 in SI units.

DIMENSIONS – YCAL0028 (SI)

Provides overall dimensions and clearances for the YCAL0028 in SI units.

DIMENSIONS – YCAL0033 (SI)

Provides overall dimensions and clearances for the YCAL0033 in SI units.

DIMENSIONS – YCAL0043 (SI)

Provides overall dimensions and clearances for the YCAL0043 in SI units.

DIMENSIONS – YCAL0046 (SI)

Provides overall dimensions and clearances for the YCAL0046 in SI units.

DIMENSIONS – YCAL0052 (SI)

Provides overall dimensions and clearances for the YCAL0052 in SI units.

DIMENSIONS – YCAL0056 (SI)

Provides overall dimensions and clearances for the YCAL0056 in SI units.

DIMENSIONS – YCAL0066 (SI)

Provides overall dimensions and clearances for the YCAL0066 in SI units.

TECHNICAL DATA – CLEARANCES

FIGURE 30 - UNIT CLEARANCES – ALL MODELS

Illustrates recommended clearances for all chiller models.

ISOLATORS

WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS YCAL0019 – 0033 (WITHOUT PUMP PACKAGE OPTION)

Details weight distribution and isolator positions for specific models.

ISOLATOR LOCATIONS

ISOLATOR SELECTION YCAL0019 – 0033 (WITHOUT PUMP PACKAGE OPTION)

WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS YCAL0043 – 0066

Approximate Isolator Locations

ISOLATOR DETAILS - UNITS SHIPPED ON OR AFTER JUNE 15, 2008

ONE INCH DEFLECTION SPRING ISOLATOR CROSS-REFERENCE

Cross-reference for one-inch deflection spring isolators by model number and capacity.

ONE INCH DEFLECTION SPRING ISOLATORS INSTALLATION INSTRUCTIONS

DURULENE ISOLATOR CROSS-REFERENCE

INSTALLATION OF DURULENE VIBRATION ISOLATORS

TWO INCH DEFLECTION SEISMIC ISOLATOR CROSS-REFERENCE

SEISMIC ISOLATOR INSTALLATION AND ADJUSTMENT

ISOLATOR DETAILS - UNITS SHIPPED BEFORE JUNE 15, 2008

CIP-X ONE INCH DEFLECTION SPRING ISOLATOR CROSS-REFERENCE

Cross-reference for CIP-X single spring isolators.

INSTALLATION OF 1" DEFLECTION MOUNTS

NEOPRENE ISOLATOR CROSS-REFERENCE

TWO INCH DEFLECTION, SEISMIC SPRING ISOLATOR CROSS-REFERENCE

SLRS SEISMIC ISOLATOR INSTALLATION AND ADJUSTMENT

SECTION 6 – COMMISSIONING

Commissioning of this unit should only be carried out by YORK Authorized personnel.

States that commissioning must be performed by authorized YORK personnel.

CHECKING SUPERHEAT AND SUBCOOLING

Describes how to calculate and verify subcooling and suction superheat.

PREPARATION – POWER OFF

Outlines basic checks to perform with the unit power switched OFF.

PREPARATION – POWER OFF

Refrigerant Charge

Details checks for refrigerant pressure and leaks.

Isolation / Protection

Power Connections

PREPARATION – POWER ON

Flow Switch

EQUIPMENT START-UP CHECKLIST

Checking The System Prior To Initial Start (No Power)

Lists essential checks to perform before placing units in operation.

Panel Checks (Power On – Both Unit Switch Off)

Apply 3-phase power and verify its value. Voltage imbalance should be no more than 2% of the average voltage.

Apply 120VAC and verify its value on the terminal block in the Power Panel. Make the measurement between terminals 5 and 2 of CTB2. The voltage should be 120VAC plus or minus 10%.

Program/verify the Cooling Setpoints, Program Setpoints, and Unit Options. Record the values (see sections on Setpoints and Unit Keys for programming instruction) in Table 10.

Program and verify cooling setpoints, program setpoints, and unit options.

Put the unit into Service Mode (as described under the Service and Troubleshooting section) and cycle each condenser fan to ensure proper rotation.

Enter Service Mode and cycle condenser fans to check rotation.

CHECKING SUPERHEAT AND SUBCOOLING

LEAK CHECKING

UNIT OPERATING SEQUENCE

SECTION 7 – UNIT CONTROLS

IPU II AND I/O BOARDS

Explains the function of the IPU II and I/O boards in the control system.

STATUS KEY

Unit Status

Explains how to use the STATUS key to view chiller operating status.

Fault Messages

Fault Safety Status Messages

ANTI-RECYCLE TIMER

Displays time remaining on the anti-recycle timer.

ANTI-COINCIDENCE TIMER

Explains the feature guarding against simultaneous compressor starts.

DISCHARGE PRESSURE LIMITING

Indicates discharge pressure limiting is active due to high pressure.

SUCTION PRESSURE LIMITING

Indicates suction pressure limiting is active due to low pressure.

LOAD LIMIT XX%

System Safeties

HIGH DSCH PRESSURE

LOW SUCT PRESSURE

UNIT FAULT: LOW AMBIENT TEMP

Status Key Messages

TABLE 11 - STATUS KEY MESSAGES QUICK REFERENCE LIST

DISPLAY/PRINT KEYS

Oper Data Key

Oper Data Key Quick Reference List

TABLE 12 - OPERATION DATA

Print Key

Operating Data Printout

History Printout

History Displays

ENTRY KEYS

Up and Down Arrow Keys

Enter/Adv Key

SETPOINTS KEYS

Cooling Setpoints

Leaving Chilled Liquid Control

Remote Setpoint Control

Return Chilled Liquid Control

TABLE 13 - COOLING SETPOINTS, PROGRAMMABLE LIMITS AND DEFAULTS

SCHEDULE/ADVANCE DAY KEY

PROGRAM KEY

DISCHARGE PRESSURE CUTOUT

SUCTION PRESSURE CUTOUT

LOW AMBIENT TEMP CUTOUT

LEAVING LIQUID TEMP CUTOUT

ANTI RECYCLE TIMER

SYS TRIP VOLTS

TABLE 16 - UNIT KEYS OPTIONS PROGRAMMING QUICK REFERENCE LIST

UNIT KEYS

Options Key

Option 4 – Ambient Control Type

Option 5 – Local/Remote Control Type

Option 6 – Unit Control Mode

Option 8 – Lead/Lag Type (two system units only)

Option 9 – Condenser Fan Control Mode

Option 11 – Current Feedback Options Installed:

Option 12 – Power Fail Restart

Option 14 – Unit Type

Option 15 – Refrigerant Type

Option 16 – Expansion Valve Type

Option 18 – Remote Temperature Reset

Option 19 – Pump Control

CLOCK

SECTION 8 – UNIT OPERATION

CAPACITY CONTROL

Details the start sequence and capacity control functions.

Wiring

SUCTION PRESSURE LIMIT CONTROLS

Describes controls to prevent reaching low-pressure cutout.

FIGURE 52 - INVERTER POWER WIRING SCHEMATIC

DISCHARGE PRESSURE LIMIT CONTROLS

Explains controls to unload system before safety limits are reached.

LEAVING CHILLED LIQUID CONTROL

Describes how the unit controls leaving chilled liquid temperature.

LEAVING CHILLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING

RETURN CHILLED LIQUID CONTROL

RETURN CHILLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING

TABLE 17 - SAMPLE COMPRESSOR STAGING FOR RETURN WATER CONTROL

TABLE 18 - RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS)

ANTI-RECYCLE TIMER

ANTI-COINCIDENCE TIMER

STANDARD CONDENSER FAN CONTROL

STANDARD CONDENSER FAN CONTROL – YCAL0019 – YCAL0033

TABLE 20 - YCAL0019 – YCAL0033 CONDENSER FAN CONTROL USING DISCHARGE PRESSURE

TABLE 21 - YCAL0019 – YCAL0033 CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONLY

STANDARD CONDENSER FAN CONTROL – YCAL0043 – YCAL0066

TABLE 22 - YCAL0043 – YCAL0066 CONDENSER FAN CONTROL USING DISCHARGE PRESSURE

TABLE 23 - YCAL0043 – YCAL0066 CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONLY

YCAL0019-0028 LOW AMBIENT FAN CONTROL OPTION

Potentiometer Configuration

PROGRAMMING - YCAL0019 – 0028

YCAL0033 Low Ambient Fan Control Option

Describes the low ambient fan control for YCAL0033 using VFD.

TABLE 24 - YCAL0019 – 0028 VFD LOW AMBIENT OPTION – CONDENSER FAN CONTROL OPERATION

CONFIGURATION (JUMPERS AND POTENTIOMETERS)

TABLE 25 - VFD JUMPERS

TABLE 27 - VFD JUMPERS

YCAL0033 PROGRAMMING

TABLE 26 - YCAL033 VFD LOW AMBIENT OPTION – CONDENSER FAN CONTROL OPERATION

YCAL0043 – 0066 LOW AMBIENT FAN CONTROL OPTION

PROGRAMMING

FIGURE 57 - POTENTIOMETER SETTINGS

FIGURE 58 - INVERTER WIRING

TABLE 28 - YCAL0043-0066 VFD LOW AMBIENT OPTION – CONDENSER FAN CONTROL OPERATION

LOAD LIMITING

TABLE 29 - COMPRESSOR OPERATION –LOAD LIMITING

ALARM STATUS

BAS/EMS TEMPERATURE RESET USING A VOLTAGE OR CURRENT SIGNAL

Details how to reset chilled liquid setpoint via remote signals.

SECTION 9 – SERVICE AND TROUBLESHOOTING

CLEARING HISTORY BUFFERS

SERVICE MODE

Explains how to enter Service Mode for configuration and diagnostics.

SERVICE MODE – OUTPUTS

SERVICE MODE – CHILLER CONFIGURATION

Soft start (disabled), Refrigerant Type (R410A), and Expansion Valve Type (Thermostatic), and North American Feature (Enabled) MUST be properly programmed or damage to compressors and other system components may result.

Critical warning regarding proper programming of key configuration parameters.

SERVICE MODE – ANALOG AND DIGITAL INPUTS

CONTROL INPUTS/OUTPUTS

FIGURE 59 - MICROBOARD LAYOUT

CHECKING INPUTS AND OUTPUTS

Digital Inputs

Analog Inputs – Temperature

TABLE 35 - ENTERING/LEAVING CHILLED LIQUID TEMPERATURE SENSOR

Entering Chilled Liquid Sensor

Leaving Chilled Liquid Temperature Sensor

Analog Inputs – Pressure

System 1 Discharge Transducer

System 1 Suction Transducer

System 2 Discharge Transducer

System 2 Suction Transducer

TABLE 36 - PRESSURE TRANSDUCERS

Digital Outputs

FIGURE 60 - I/O BOARD RELAY CONTACT ARCHITECTURE

TABLE 37 - TROUBLESHOOTING

NO DISPLAY ON PANEL UNIT WILL NOT OPERATE

HIGH DISCHARGE PRESSURE FAULT

FLOW SWITCH/REM STOP NO RUN PERMISSIVE

LOW LIQUID TEMP FAULT

LOW SUCTION PRESSURE FAULT

MP / HPCO FAULT

COMPRESSOR(S) WON’T START

TROUBLESHOOTING (CONT’D)

TABLE 37 - TROUBLESHOOTING

Provides a table for troubleshooting common chiller problems.

LACK OF COOLING EFFECT

SECTION 10 – MAINTENANCE

IMPORTANT

Yorktalk 2 Communications

COMPRESSORS

OPERATING PARAMETERS

BACNET, MODBUS AND YORKTALK 2 COMMUNICATIONS

TABLE 39 - VALUES REQUIRED FOR BAS COMMUNICATION

TABLE 40 - REAL TIME ERROR NUMBERS

TABLE 38 - MINIMUM, MAXIMUM AND DEFAULT VALUES

FIGURE 62 - MICRO PANEL CONNECTIONS

BACnet and Modbus Communications

Communications Data Map Notes:

TABLE 41 - BACNET AND MODBUS COMMUNICATIONS DATA MAP

TABLE 41 - BACNET AND MODBUS COMMUNICATIONS DATA MAP (CONT’D)

TABLE 42 "Yorktalk 2 Communications Data Map"

TABLE 42 - YORKTALK 2 COMMUNICATIONS DATA MAP

TABLE 42 - YORKTALK 2 COMMUNICATIONS DATA MAP (CONT’D)

R410-A PRESSURE TEMPERATURE CHART

ADDING REFRIGERANT CHARGE AFTER COMMISSIONING