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YCAL0046
York YCAL0046 User Manual
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JOHNSON CONTROLS
132
FORM 150.67-NM1
ISSUE DA
TE: 4/28/2017
SECTION 5 – TECHNICAL
DA
T
A
TECHNICAL DA
T
A
– CLEARANCES
(1.3 m)
(2 m)
(2 m)
(2 m)
NOTES
:
1.
No obstructions allowed above the unit.
2.
Only one adjacent wall may be higher than the unit.
3.
Adjacent units should be 10 feet (3 Meters) apart.
LD10506
FIGURE 30 -
UNIT CLEARANCES –
ALL
MODELS
131
133
Table of Contents
Default Chapter
5
Table of Contents
5
Section 1 – General Chiller Information and Safety
15
Responsibility for Safety
16
Pressure Systems
17
FIGURE 1 - YCAL Air-Cooled Scroll Chillers
19
Section 2 – Product Description
19
Condenser
20
Unit On/Off Switch
21
Discharge Pressure Transducers and Readout Capability
22
Accessories and Options
22
Suction Pressure Transducers
23
Motor Current Module
23
Multi-Unit Sequencing
23
Compressor, Piping, Evaporator Options
23
Chicago Code Relief Valves
23
Flanges (ANSI/AWWA C-606 Couplings Type)
23
Heat Exchanger 300 PSIG (21 BARG) DWP Waterside
23
Hot Gas By-Pass
23
Low Temperature Brine
23
Service Isolation Valve
23
Copper Fin Condenser Coils
24
Enclosure Panels (Unit)
24
Louvered Panels (Full Unit)
24
Post-Coated Dipped Condenser Coils
24
Pre-Coated Fin Condenser Coils
24
Sound Reduction / Attenuation Options
24
Vibration Isolators
24
FIGURE 2 - Unit Components Single System Units
25
Unit Components YCAL0019 - 0033
25
Control - Power Panel Components YCAL0019-0033
26
FIGURE 3 - Control/Power Panel Components Single System Units
26
FIGURE 4 - Unit Components Dual System Units
27
FIGURE 5 - Control/Power Panel Components Dual System Units
28
FIGURE 6 - Refrigerant Flow Diagram
33
Refrigerant Flow Diagram
33
Basic Unit Nomenclature
29
Product Identification Number (PIN)
29
Unit Components - YCAL0043 - 0066
27
Control / Power Panel Components - YCAL0043 - 0066
28
Section 3 - Handling and Storage
35
Delivery and Storage
35
Inspection
35
Moving the Chiller (YCAL0043 - 0066 Dual System Only)
35
Lifting Weights
35
Moving the Chiller (YCAL0019 - 0033 Single Circuit Only)
35
Unit Rigging
36
Lifting Weights
36
FIGURE 7 - Unit Rigging/Lifting (YCAL0019 - 0033 Single Circuit Models Only)
36
FIGURE 8 - Unit Rigging/Lifting (YCAL0043- 0066 Dual Circuit Models)
37
Section 4 - Installation
39
Handling
39
Inspection
39
Installation Checklist
39
Location and Clearances
39
Ground Level Locations
39
Rooftop Locations
40
Noise Sensitive Locations
40
Chilled Liquid Piping
40
Compressor Mounting
40
Remote Cooler Option
40
Spring Isolators (Optional)
40
Duct Work Connection
41
Field Wiring
41
FIGURE 9 - Chilled Liquid System
41
General Requirements
41
Wiring
41
FIGURE 10 - Single-Point Supply Connection - Terminal Block, Non-Fused Disconnect Switch or Circuit Breaker
44
Control Wiring
45
Pipework Arrangement
41
Alarm Status Contacts
42
Evaporator Pump Start Contacts
42
Flow Switch Input
42
Load Limit Input
42
Remote Emergency Cutoff
42
Remote Start/Stop Contacts
42
Remote Temp Reset Input
42
System Run Contacts
42
Compressor Heaters
43
High Pressure Cutout
43
Relief Valves
43
FIGURE 11 - Control Wiring
45
TABLE 1 - Temperatures and Flows
47
TABLE 2 - Voltage Limitations
47
Operational Limitations (SI)
50
Voltage Limitations
50
Section 5 - Technical Data
47
Operational Limitations (English)
47
Voltage Limitations
47
TABLE 5 - Ethylene and Propolyne Glycol Correction Factors
50
TABLE 4 - Voltage Limitations
50
TABLE 3 - Temperatures and Flows (Si)
50
TABLE 6 - Physical Data (English)
53
Electrical Data (English)
54
TABLE 7 - Electrical Data (English)
54
TABLE 8 - Micro Panel Power Supply
58
TABLE 9 - Voltage Range
58
Electrical Notes and Legend
59
Physical Data (English)
53
FIGURE 12 - Control Wiring Diagram, Single Circuit, Ipu II
60
FIGURE 13 - Control Wiring Diagram, Single Circuit, Ipu II
63
FIGURE 14 - Control Wiring Diagram, Dual Circuit, Ipu II
64
FIGURE 15 - Control Wiring Diagram, Dual Circuit, Ipu II
66
FIGURE 16 - Control Wiring Diagram, Details, Single Circuit
68
FIGURE 17 - Control Wiring Diagram, Details, Dual Circuit
70
FIGURE 18 - Power Wiring, Single Circuit
72
FIGURE 19 - Power Wiring, Single Circuit
74
FIGURE 20 - Power Wiring, Single Circuit
76
FIGURE 21 - Power Wiring, Single Circuit
78
FIGURE 22 - Power Wiring, Dual Circuit
80
FIGURE 23 - Power Wiring, Dual Circuit
82
FIGURE 24 - Connection Wiring, Single Circuit
84
FIGURE 25 - Connection Wiring, Single Circuit
86
FIGURE 26 - Connection Wiring, Single Circuit
88
FIGURE 27 - Connection Wiring, Single Circuit
90
FIGURE 28 - Connection Wiring, Dual Circuit
92
FIGURE 29 - Connection Wiring, Dual Circuit
94
FIGURE 30 - Unit Clearances - All Models
132
General
133
Weight Distribution and Isolator Mounting Positions YCAL0019 - 0033 (Without Pump Package Option)
133
Isolator Selection
134
General
135
FIGURE 31 - One Inch Deflection Spring Isolator Cross-Reference
136
FIGURE 32 - One Inch Deflection Spring Isolators Installation Instructions
137
FIGURE 33 - Durulene Isolator Cross-Reference
138
FIGURE 34 - Installation of Durulene Vibration Isolators
139
FIGURE 35 - Two Inch Deflection Seismic Isolator Cross-Reference
140
FIGURE 36 - Seismic Isolator Installation and Adjustment
141
FIGURE 37 - One Inch Deflection Spring Isolator Cross-Reference (Cip-X)
142
FIGURE 38 - Neoprene Isolator Cross-Reference
144
FIGURE 39 - Two Inch Deflection, Seismic Spring Isolator Cross-Reference
145
FIGURE 40 - Slrs Seismic Isolator Installation and Adjustment
146
Section 6 - Commissioning
147
Commissioning
147
Preparation - Power off
147
Inspection
147
Refrigerant Charge
147
Service and Oil Line Valves
147
Compressor Oil
147
Fans
147
Isolation / Protection
147
Control Panel
147
Supply Voltage
148
Preparation - Power on
148
Switch Settings
148
Compressor Heaters
148
Water System
148
Flow Switch
148
Temperature Sensor(S)
148
Equipment Start-Up Checklist
149
Checking Superheat and Subcooling
150
TABLE 10 - Setpoints Entry List
150
Leak Checking
151
Unit Operating Sequence
152
Section 7 – Unit Controls
153
Unit Switch
154
Status Key
155
Fault Safety Status Messages
156
System Safeties
157
Unit Safeties
158
TABLE 11 - Status Key Messages Quick Reference List
160
Oper Data Quick Reference List
164
TABLE 12 - Operation Data
164
TABLE 13 - Cooling Setpoints, Programmable Limits and Defaults
171
Schedule/Advance Day Key
172
TABLE 14 - Program Key Limits and Default
173
System Trip Volts
175
TABLE 15 - Setpoints Quick Reference List
176
Unit Keys
177
Option 4 – Ambient Control Type
178
Option 9 – Condenser Fan Control Mode
179
Option 15 – Refrigerant Type
180
Option 19 – Pump Control
181
History Printout
165
History Displays
166
Software Version
168
Entry Keys
169
Setpoints Keys
170
Return Chilled Liquid Control
171
Display/Print Keys
161
TABLE 16 - Unit Keys Options Programming Quick Reference List
182
Section 8 – Unit Operation
183
FIGURE 42 - Setpoint Adjust
184
FIGURE 41 - Leaving Water Temperature Control Example
184
Return Chilled Liquid Control
185
TABLE 17 - Sample Compressor Staging for Return Water Control
185
Anti-Recycle Timer
186
TABLE 18 - Return Chilled Liquid Control for 4 Compressors (6 Steps)
186
TABLE 19 - Return Chilled Liquid Control for 4 Compressors (6 Steps)
186
Evaporator Pump Control and York Hydro Kit Pump Control
187
Leaving Chilled Liquid Control Override to Reduce Cycling
184
TABLE 21 - YCAL0019 - YCAL0033 Condenser Fan Control Using Discharge Pressure Only
188
TABLE 22 - YCAL0043 - YCAL0066 Condenser Fan Control Using Discharge Pressure
189
FIGURE 46 - Liquid Line Sensing Bulb Location
190
FIGURE 47 - Potentiometer Settings
190
FIGURE 48 - Wiring
191
FIGURE 49 - Typical VFD Enclosure Locations
192
Configuration (Jumpers and Potentiometers)
193
TABLE 25 - VFD Jumpers
193
FIGURE 43 - YCAL0019 - YCAL0033 Fan Location (Typical)
188
FIGURE 44 - YCAL0043 - YCAL0066 Fan Location (Typical)
189
FIGURE 45 - Typical VFD Location
190
Programming - YCAL0019 – 0028
192
TABLE 24 - YCAL0019 - 0028 VFD Low Ambient Option - Condenser Fan Control Operation
192
FIGURE 50 - Typical VFD Enclosure Configurations
193
FIGURE 51 - Potentiometer Settings
194
FIGURE 52 - Inverter Power Wiring Schematic
194
FIGURE 53 - Inverter Wiring
195
TABLE 26 - YCAL033 VFD Low Ambient Option - Condenser Fan Control Operation
195
YCAL0033 Programming
195
FIGURE 54 - Typical VFD Enclosure Locations
196
YCAL0043 – 0066 Low Ambient Fan Control Option
196
Configuration (Jumpers and Potentiometers)
197
FIGURE 55 - Typical VFD Enclosure Configurations
197
TABLE 27 - VFD Jumpers
197
FIGURE 56 - Inverter Power Wiring Sc
198
FIGURE 57 - Potentiometer Settings
198
Programming
198
Wiring
194
TABLE 20 - YCAL0019 - YCAL0033 Condenser Fan Control Using Discharge Pressure
188
TABLE 23 - YCAL0043 - YCAL0066 Condenser Fan Control Using Discharge Pressure Only
189
YCAL0019-0028 Low Ambient Fan Control Option
190
FIGURE 58 - Inverter Wiring
199
TABLE 28 - YCAL0043-0066 VFD Low Ambient Option - Condenser Fan Control Operation
199
TABLE 29 - Compressor Operation -Load Limiting
200
Section 9 – Service and Troubleshooting
203
Service Mode – Chiller Configuration
204
Control Inputs/Outputs
205
TABLE 32 - I/O Analog Inputs
205
TABLE 33 - I/O Analog Outputs
205
FIGURE 59 - Microboard Layout
206
Checking Inputs and Outputs
207
TABLE 34 - Outdoor Air Sensor Temperature/Voltage / Correlation
207
Liquid and Refrigerant Sensor Test Points
208
TABLE 35 - Entering/Leaving Chilled Liquid Temperature Sensor
208
Analog Inputs – Pressure
209
TABLE 36 - Pressure Transducers
209
FIGURE 60 - I/O Board Relay Contact Architecture
210
System 1 Suction Transducer
210
FIGURE 61 - Printer to Microboard Electrical Connections
211
Parts
211
TABLE 31 - I/O Digital Outputs
205
TABLE 30 - I/O Digital Inputs
205
TABLE 37 - Troubleshooting
212
Section 10 – Maintenance
215
Overall Unit Inspection
216
FIGURE 62 - Micro Panel Connections
217
TABLE 38 - Minimum, Maximum and Default Values
217
TABLE 39 - Values Required for Bas Communication
218
TABLE 40 - Real Time Error Numbers
218
TABLE 41 - Bacnet and Modbus Communications Data Map
220
TABLE 42 - Yorktalk 2 Communications Data Map
224
Temperature Conversion Chart
227
R410-A Pressure Temperature Chart
228
Yorktalk 2 Communications
223
Bacnet and Modbus Communications
219
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York YCAL0046 Specifications
General
Brand
York
Model
YCAL0046
Category
Chiller
Language
English
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