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York YCAL0019 User Manual

York YCAL0019
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151
JOHNSON CONTROLS
SECTION 6 – COMMISSIONING
FORM 150.67-NM1
ISSUE DATE: 4/28/2017
6
1. Record the liquid line pressure and its correspond-
ing temperature, liquid line temperature and
subcooling below:
SYS 1 SYS 2
Liq Line Press = _______ _______ PSIG
Saturated Temp = _______ _______ °F
Liq Line Temp = _______ _______ °F
Subcooling = _______ _______ °F
After the subcooling is verified, the suction superheat
should be checked. The superheat should be checked
only after steady state operation of the chiller has been
established, the leaving water temperature has been
pulled down to the required leaving water temperature,
and the unit is running in a fully loaded condition. Cor-
rect superheat setting for a system is 10 °F to 15 °F
(5.56 °C to 8.33 °C) 18" (46 cm) from the heat ex-
changer.
Superheat should typically be set for no less than 10
°F with only a single compressor running on a cir-
cuit. The superheat is calculated as the difference be-
tween the actual temperature of the returned refrigerant
gas in the suction line entering the compressor and the
temperature corresponding to the suction pressure as
shown in a standard pressure/temperature chart.
Example:
Suction Temp = 46 °F
Minus Suction Press
105 PSIG converted to Temp - 34 °F
Superheat = 12 °F
When adjusting the expansion valve (TXV only), the
adjusting screw should be turned not more than one
turn at a time, allowing sufficient time (approximately
15 minutes) between adjustments for the system and
the thermal expansion valve to respond and stabilize.
Assure that superheat is set at a minimum of 10 °F (5.56
°C) with a single compressor running on each circuit.
2. Record the suction temperature, suction pressure,
suction saturation temperature, and superheat of
each system below:
SYS 1 SYS 2
Suction Temp = _______ _______ °F
Suction Pressure = _______ _______ PSIG
Saturation Temp = _______ _______ °F
Superheat = _______ _______ °F
LEAK CHECKING
1. Leakcheckcompressors,ttings,andpipingto
ensure no leaks.
If the unit is functioning satisfactorily during the ini-
tial operating period, no safeties trip and the compres-
sors cycle to control water temperature to setpoint, the
chiller is ready to be placed into operation.

Table of Contents

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York YCAL0019 Specifications

General IconGeneral
Tonnage19 Tons
Refrigerant TypeR-410A
Energy Efficiency Ratio (EER)10.5
Power Supply460V/3Ph/60Hz
Sound Level72 dBA
Cooling Capacity228, 000 BTU/hr

Summary

General Chiller Information and Safety

Safety

Outlines safety standards and compliance for the chillers, including ANSI, ASHRAE, and OSHA requirements.

Misuse of Equipment

Details improper uses and their potential consequences, covering suitability, structural support, and access.

Electrical

Safety precautions related to electrical equipment, including grounding and lockout procedures.

Product Description

General System Description

Explains the overall system design and components of the YCAL air-cooled scroll chillers.

Millennium Control Center

Overview of the microprocessor-based control center, its components, and interface functions.

Accessories and Options

Lists available power and control options for the chiller, detailing their features and benefits.

Product Identification Number (PIN)

Explains the structure and meaning of the Product Identification Number for model configuration.

Refrigerant Flow Diagram

Illustrates the refrigerant flow path within the YCAL chiller system.

Installation

Wiring

Information regarding factory-mounted controls and essential field wiring connections.

Single-Point Supply Connection

Wiring diagram and instructions for single-point supply connections (terminal block, disconnect, breaker).

Control Wiring

Diagrams illustrating control wiring connections for various YCAL chiller models.

Technical Data

Physical Data (English)

Physical dimensions, weights, and capacities of the chiller units in English units.

Electrical Data (English)

Electrical specifications, circuit protection, and wiring lug information in English units.

Control Wiring Diagrams

Detailed diagrams illustrating control wiring for various YCAL chiller configurations.

Commissioning

Equipment Start-Up Checklist

A comprehensive checklist of critical steps for starting up the chiller equipment.

Checking Superheat and Subcooling

Procedures for checking superheat and subcooling of the refrigerant system for optimal performance.

Unit Operating Sequence

Describes the sequence of unit operation during startup, including compressor staging and fan control.

Unit Controls

IPU II and I/O Boards

Description of the IPU II and I/O boards, their functions, and how they manage chiller operations.

Status Key

Explanation of the STATUS key function for checking chiller operating status and interpreting messages.

Fault Messages

Explanation of fault messages, their categories (System Safeties, Unit Safeties), and display meanings.

Unit Safeties

Explanation of unit safeties that cause all running compressors to shut down and require manual reset.

Display/Print Keys

Explains the function of the display and print keys for retrieving system and unit information.

Setpoints Keys

The keys used for programming cooling setpoints, daily schedules, and safeties.

Cooling Setpoints

How to program the cooling setpoint and range for the chiller.

Schedule/Advance Day Key

Instructions for programming the seven-day daily and holiday schedule for unit operation.

Program Key

Accessing and programming various operating parameters such as cutouts and timers.

Options Key

Quick reference for accessing and programming unit options via the OPTIONS key.

Option 14 – Unit Type

Setting the unit type to "Liquid Chiller" to prevent component damage from incorrect operation.

Unit Operation

Capacity Control

How the chiller manages capacity based on cooling demand and setpoints.

Leaving Chilled Liquid Control

How the chiller regulates leaving chilled liquid temperature to meet the desired setpoint.

Leaving Chilled Liquid System Lead/Lag and Compressor Sequencing

Strategies for lead/lag operation and compressor sequencing to equalize run hours.

Return Chilled Liquid Control

Capacity control strategy based on return chilled liquid temperature, for dual-system units.

Standard Condenser Fan Control

Condenser fan control based on discharge pressure or ambient/discharge pressure.

YCAL0019-0028 Low Ambient Fan Control Option

Low ambient fan control using a Variable Frequency Drive (VFD) for speed adjustment.

YCAL0033 Low Ambient Fan Control Option

Low ambient fan control option for YCAL0033 using a VFD for fan speed adjustment.

Load Limiting

Feature to prevent unit loading beyond desired values by limiting compressor operation.

Service and Troubleshooting

Service Mode

How to enter and use Service Mode for configuration, parameter viewing, and diagnostics.

Service Mode – Chiller Configuration

Accessing chiller configuration settings such as data logging and refrigerant type in Service Mode.

Service Mode – Analog and Digital Inputs

Viewing analog and digital inputs to the microboard for diagnostic purposes.

Checking Inputs and Outputs

Procedures for checking digital and analog inputs, including voltage references.

Troubleshooting

Table listing common problems, their causes, and recommended solutions for diagnosis.

Maintenance

Compressors

Maintenance procedures related to the compressors, including oil level checks and analysis.

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