York YCAL Series Installation Operation & Maintenance
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York YCAL Series Installation Operation & Maintenance

Air-cooled scroll chillers style d with ipu ii and i/o boards (50 hz) 29 ton to 65 ton
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AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Supersedes 150.66-NM3 (110)
Form 150.66-NM3 (920)
INSTALLATION, OPERATION, MAINTENANCE
035-20895-001
YCAL0041EC–YCAL0071EC
AIR-COOLED
SCROLL CHILLERS
STYLE D
WITH IPU II and I/O BOARDS
(50 Hz)
29 TON TO 65 TON
R-410A
Issue Date:
September 25, 2020

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  • Page 1 AIR-COOLED LIQUID CHILLERS HERMETIC SCROLL Supersedes 150.66-NM3 (110) Form 150.66-NM3 (920) INSTALLATION, OPERATION, MAINTENANCE 035-20895-001 YCAL0041EC–YCAL0071EC AIR-COOLED SCROLL CHILLERS STYLE D WITH IPU II and I/O BOARDS (50 Hz) 29 TON TO 65 TON R-410A Issue Date: September 25, 2020...

  • Page 2: General Safety Guidelines

    FORM 150.66-NM3 ISSUE DATE: 09/25/2020 IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or During rigging, installation, operation, maintenance, death to themselves and people at the site. or service, individuals may be exposed to certain com- This document is intended for use by owner-authorized ponents or conditions including, but not limited to:...

  • Page 3: Changeability Of This Document

    Planned Service Agreement that leverages real time and generalized conditions. In lieu of the traditional and historical data, delivering performance reporting, maintenance program, a Johnson Controls YORK corrective actions required and data enabled guidance Conditioned Based Maintenance (CBM) program can for optimal operation and lifecycle assurance.
  • Page 4 FORM 150.66-NM3 ISSUE DATE: 09/25/2020 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 5: Table Of Contents

    FORM 150.66-NM3 ISSUE DATE: 09/25/2020 TABLE OF CONTENTS GENERAL SAFETY GUIDELINES ......................2 CHANGEABILITY OF THIS DOCUMENT ....................3 REVISION NOTES ............................3 TABLE OF CONTENTS ..........................5 LIST OF FIGURES .............................10 LIST OF TABLES ............................11 SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY ............13 INTRODUCTION ..........................13 WARRANTY ............................13 SAFETY ..............................13...
  • Page 6 FORM 150.66-NM3 ISSUE DATE: 09/25/2020 TABLE OF CONTENTS (CONT’D) REFRIGERANT FLOW DIAGRAM ....................30 SECTION 3 - HANDLING AND STORAGE .....................31 DELIVERY AND STORAGE .......................31 INSPECTION ............................31 MOVING THE CHILLER ........................31 Lifting Weights ..........................31 UNIT RIGGING ............................32 SECTION 4 - INSTALLATION ........................33 INSTALLATION CHECKLIST ......................33 HANDLING ............................33 INSPECTION ............................33...
  • Page 7 DIMENSIONS............................64 TECHNICAL DATA - CLEARANCES ....................92 ISOLATORS ............................93 General ............................93 Installation of 1" Deflection Mounts .....................95 SECTION 7 - UNIT CONTROLS .......................99 YORK MILLENNIUM CONTROL CENTER ..................99 INTRODUCTION ..........................99 MICROPROCESSOR BOARD ......................99 UNIT SWITCH ............................100 DISPLAY ............................100 KEYPAD .............................100 BATTERY BACK-UP .........................100 TRANSFORMER ..........................100...
  • Page 8 FORM 150.66-NM3 ISSUE DATE: 09/25/2020 TABLE OF CONTENTS (CONT’D) STATUS KEY MESSAGES .......................106 DISPLAY/PRINT KEYS ........................107 Oper Data Key ..........................107 Print Key ............................111 Operating Data Printout ....................... 111 History Printout ..........................112 History Displays ........................... 112 Software Version .......................... 114 ENTRY KEYS .............................115 Up and Down Arrow Keys......................
  • Page 9 FORM 150.66-NM3 ISSUE DATE: 09/25/2020 TABLE OF CONTENTS (CONT’D) EMS-PWM REMOTE TEMPERATURE RESET ................141 BAS/EMS TEMPERATURE RESET OPTION .................142 SECTION 9 - SERVICE AND TROUBLESHOOTING ................145 CLEARING HISTORY BUFFERS ....................145 SERVICE MODE ..........................145 SERVICE MODE – OUTPUTS ......................145 SERVICE MODE – CHILLER CONFIGURATION ................145 SERVICE MODE –...

  • Page 10: List Of Figures

    FORM 150.66-NM3 ISSUE DATE: 09/25/2020 LIST OF FIGURES FIG. 1 – REFRIGERANT FLOW DIAGRAM ..................30 FIG. 2 – SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER (0041 - 0071) ...........37 FIG. 3 – CONTROL WIRING ........................38 FIG.

  • Page 11: List Of Tables

    FORM 150.66-NM3 ISSUE DATE: 09/25/2020 LIST OF TABLES TABLE 1 – SETPOINTS ENTRY LIST ....................42 TABLE 2 – TEMPERATURES AND FLOWS ..................45 TABLE 3 – VOLTAGE LIMITATIONS .....................45 TABLE 4 – ETHYLENE GLYCOL CORRECTION FACTORS ...............46 TABLE 5 – TEMPERATURES AND FLOWS (SI) ..................47 TABLE 6 –...
  • Page 12 FORM 150.66-NM3 ISSUE DATE: 09/25/2020 LIST OF TABLES (CONT’D) TABLE 33 – MINIMUM, MAXIMUM AND DEFAULT VALUES .............159 TABLE 34 – VALUES REQUIRED FOR BAS COMMUNICATION ............160 TABLE 35 – REAL TIME ERROR NUMBERS ..................160 TABLE 36 - BACNET AND MODBUS COMMUNICATIONS DATA MAP ...........162 TABLE 37 - YORKTALK 2 COMMUNICATIONS DATA MAP ..............167 JOHNSON CONTROLS...

  • Page 13: Section 1 - General Chiller Information And Safety

    MISSIONING). The unit is intended for cooling water or glycol solu- • Only genuine YORK approved spare parts, oils, coolants, and refrigerants must be used. tions and is not suitable for purposes other than those specified in this manual.

  • Page 14: Responsibility For Safety

    FORM 150.66-NM3 SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY ISSUE DATE: 09/25/2020 This manual and any other document supplied with RESPONSIBILITY FOR SAFETY the unit are the property of Johnson Controls which re- Every care has been taken in the design and manufac- serves all rights.

  • Page 15: Electrical

    FORM 150.66-NM3 SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY ISSUE DATE: 09/25/2020 Electrical Refrigerants and Oils The unit must be grounded. No installation or main- Refrigerants and oils used in the unit are generally non- tenance work should be attempted on the electrical toxic, non-flammable and non-corrosive, and pose no equipment without first switching power OFF, isolat- special safety hazards.
  • Page 16 FORM 150.66-NM3 ISSUE DATE: 09/25/2020 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 17: Section 2 - Product Description

    FORM 150.66-NM3 ISSUE DATE: 09/25/2020 SECTION 2 - PRODUCT DESCRIPTION LD10950 INTRODUCTION YORK Millennium Air-Cooled Scroll Chillers provide Safety code for mechanical refrigeration, ASME, List- ® ed and labeled with Intertek Testing Services (ETL) chilled water for all air conditioning applications using central station air handling or terminal units.

  • Page 18: Condenser

    FORM 150.66-NM3 SECTION 2 - PRODUCT DESCRIPTION ISSUE DATE: 09/25/2020 Brazed plate heat exchangers shall be UL (Underwrit- Display/Print ers Laboratories) listed. Installing contractor must in- Color coded 12-button non-tactile keypad with sec- clude accommodations in the chilled water piping to tions for display and print of typical information: allow proper drainage and venting of the heat exchang- •...

  • Page 19: Unit On/Off

    • Discharge pressure (optional) two steps of demand load limiting from an external • Liquid Temperature Reset via a YORK ISN DDC building automation system. Unit alarm contacts are or Building Automation System (by others) via: standard.

  • Page 20: Accessories And Options

    PWM input signal or up to two steps of demand (load) ing (this option includes the Single-Point Power con- limiting depending on model). (The standard control nection). panel can be directly connected to a YORK Building Automated System via the standard onboard RS485 Control Transformer communication port).

  • Page 21: Compressor, Piping, Evaporator Options

    FORM 150.66-NM3 SECTION 2 - PRODUCT DESCRIPTION ISSUE DATE: 09/25/2020 Discharge Pressure Transducers and Read- Hot Gas By-Pass out Capability Permits continuous, stable operation at capacities be- The addition of pressure transducers allows models to low the minimum step of compressor unloading to as sense and display discharge pressure.

  • Page 22: Condenser And Cabinet Options

    Tamperproof Enclosure Panels prevent unauthorized access to units. Enclosure Panels can provide an aes- thetically pleasing alternative to expensive fencing. Additionally, for proper head pressure control, YORK recommends the use of: Louvered Panels (Full Unit) Louvered panels surround the front, back, and sides of the unit.

  • Page 23: Unit Components

    FORM 150.66-NM3 SECTION 2 - PRODUCT DESCRIPTION ISSUE DATE: 09/25/2020 UNIT COMPONENTS JOHNSON CONTROLS...

  • Page 24: Control / Power Panel Components

    FORM 150.66-NM3 SECTION 2 - PRODUCT DESCRIPTION ISSUE DATE: 09/25/2020 CONTROL / POWER PANEL COMPONENTS TERMINAL BLOCK FAN FUSES CR1 / CR2 LD11459 LD11460 LD11461 LD11458 LD11462 COMPRESSOR CONTACTS TB1 / CTB1 LD11463 JOHNSON CONTROLS...

  • Page 25: Product Identification Number (Pin)

    11 12 13 14 15 BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE/STARTER DESIGN/DEVELOPMENT LEVEL : High Efficiency : R-410A : YORK : Design Series D : Chiller : Engineering : Air-Cooled Odd Number: X Across the Line Change : Condensing...
  • Page 26 FORM 150.66-NM3 SECTION 2 - PRODUCT DESCRIPTION ISSUE DATE: 09/25/2020 PRODUCT IDENTIFICATION NUMBER (PIN) (CONT’D) FEATURE DESCRIPTION OPTION DESCRIPTION No BAS Reset/Offset Required BAS Reset/Offset (PIN 21) ISN Microgateway Required BAS Reset/Offset Required Special BAS Reset/Offset Required English Spanish Language (PIN 22) French German Special Language Required...
  • Page 27 FORM 150.66-NM3 SECTION 2 - PRODUCT DESCRIPTION ISSUE DATE: 09/25/2020 PRODUCT IDENTIFICATION NUMBER (PIN) (CONT’D) FEATURE DESCRIPTION OPTION DESCRIPTION 150 psig DWP Waterside DWP (PIN 38) 300 psig DWP Waterside Special DWP Standard Insulation Insulation (PIN 39) Double Thick Insulation Special Insulation Required Standard Victaulic FLANGES...
  • Page 28 FORM 150.66-NM3 SECTION 2 - PRODUCT DESCRIPTION ISSUE DATE: 09/25/2020 PRODUCT IDENTIFICATION NUMBER (PIN) (CONT’D) FEATURE DESCRIPTION OPTION DESCRIPTION No Option Required PIN 51 (PIN 51) Special Quote Standard Low Sound Fans Required FANS Sound Fans (PIN 52) Ultra Low Sound Fans Required Special Sound Fans Required No Option Required PAINT...
  • Page 29 FORM 150.66-NM3 SECTION 2 - PRODUCT DESCRIPTION ISSUE DATE: 09/25/2020 PRODUCT IDENTIFICATION NUMBER (PIN) (CONT’D) FEATURE DESCRIPTION OPTION DESCRIPTION No Option Required 1-Pump 2-Pump 1-Pump w/Expansion Tank 2-Pump w/Expansion Tank PKGOPT Pump Package Options (PIN 60) 1-Pump w/Buffer Tank 2-Pump w/Buffer Tank 1-Pump w/Expans Tank &...

  • Page 30: Refrigerant Flow Diagram

    FORM 150.66-NM3 SECTION 2 - PRODUCT DESCRIPTION ISSUE DATE: 09/25/2020 REFRIGERANT FLOW DIAGRAM AIR COOLED CONDENSERS HOT DISCHARGE GAS LINE OPTIONAL OPTIONAL DISCHARGE LINE BALL VALVE OPTIONAL SERVICE VALVE LD11417 FIG. 1 – REFRIGERANT FLOW DIAGRAM JOHNSON CONTROLS...

  • Page 31: Section 3 - Handling And Storage

    FORM 150.66-NM3 ISSUE DATE: 09/25/2020 SECTION 3 - HANDLING AND STORAGE DELIVERY AND STORAGE MOVING THE CHILLER To ensure consistent quality and maximum reliability, Prior to moving the unit, ensure that the installation site all units are tested and inspected before leaving the fac- is suitable for installing the unit and is easily capable tory.

  • Page 32: Unit Rigging

    FORM 150.66-NM3 SECTION 3 - HANDLING AND STORAGE ISSUE DATE: 09/25/2020 UNIT RIGGING Use spreader bars to avoid lifting chains hitting the chiller. Never lift the chiller using a forklift or by hooking to the top rails. Use only the lifting holes provided.

  • Page 33: Section 4 - Installation

    FORM 150.66-NM3 ISSUE DATE: 09/25/2020 SECTION 4 - INSTALLATION To ensure warranty coverage, this The unit should be lifted by inserting equipment must be commissioned and hooks through the holes provided in unit base rails. Spreader bars should be used serviced by an authorized Johnson to avoid crushing the unit frame rails with Controls service mechanic or a quali-...

  • Page 34: Foundation

    Routing the water piping too siderations should be made utilizing noise levels pub- close to the unit could make compres- lished in the YORK Engineering Guide for the specific sor servicing/replacement difficult. chiller model. Sound blankets for the compressors and low sound fans are available.

  • Page 35: Duct Work Connection

    7. A chilled water flow switch, (either by YORK or oth- ers) MUST be installed in the leaving water piping Units are supplied with outlet guards for safety and to of the cooler.

  • Page 36: Evaporator Pump Start Contacts

    FORM 150.66-NM3 SECTION 4 - INSTALLATION ISSUE DATE: 09/25/2020 Field Wiring – Power wiring must be provided Remote Emergency Cutoff through a fused disconnect switch to the unit terminals Immediate shutdown of the chiller can be accomplished (or optional molded disconnect switch) in accordance by opening a field-installed dry contact to break the with N.E.C.

  • Page 37: Single-Point Supply Connection - Terminal Block, Non-Fused Disconnect Switch Or Circuit Breaker (0041 - 0071)

    FORM 150.66-NM3 SECTION 4 - INSTALLATION ISSUE DATE: 09/25/2020 SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER (0041 - 0071) Power Panel Power Panel Power Panel Control Panel Control Panel Control Panel Terminal Block, Terminal Block, MICROPANEL MICROPANEL NF Disconnect SW...

  • Page 38: Control Wiring

    FORM 150.66-NM3 SECTION 4 - INSTALLATION ISSUE DATE: 09/25/2020 CONTROL WIRING FLOW SW REMOTE START/STOP PWM INPUT LOAD LIMIT INPUT CTB1 LD07725 * Factory wired with optional transformer. LD07730A The unit evaporator heater uses It is possible that multiple sources 120 VAC.

  • Page 39: Section 5 - Commissioning

    Commissioning of this unit should Compressor Oil only be carried out by Johnson Con- To add oil to a circuit - connect a YORK hand oil pump trols Authorized personnel. (Part No. 470-10654-000) to the 1/4 in. oil charging valve on the oil separator piping with a length of clean hose or copper line, but do not tighten the flare nut.

  • Page 40: Supply Voltage

    FORM 150.66-NM3 SECTION 5 - COMMISSIONING ISSUE DATE: 09/25/2020 Supply Voltage Verify that the site voltage supply corresponds to the Flow rates and pressure drops must be within the limits unit requirement and is within the limits given in SEC- given in the Technical Data Section.

  • Page 41: Equipment Pre-Startup And Startup Checklist

    FORM 150.66-NM3 SECTION 5 - COMMISSIONING ISSUE DATE: 09/25/2020 EQUIPMENT PRE-STARTUP AND STARTUP CHECKLIST  7. Check the control panel to ensure it is free of JOB NAME: ______________________________ foreign material (wires, metal chips, or similar SALES ORDER #: _________________________ materials).

  • Page 42: Table 1 - Setpoints Entry List

    FORM 150.66-NM3 SECTION 5 - COMMISSIONING ISSUE DATE: 09/25/2020 cur, the compressor being tested is operating in TABLE 1 – SETPOINTS ENTRY LIST the reverse direction and must be corrected. After OPTIONS verifying proper compressor rotation, turn the Display Language Unit Switch to “OFF.”...

  • Page 43: Checking Superheat And Subcooling

    FORM 150.66-NM3 SECTION 5 - COMMISSIONING ISSUE DATE: 09/25/2020 When adjusting the expansion valve (TXV only), the CHECKING SUPERHEAT AND SUBCOOLING adjusting screw should be turned not more than one The subcooling temperature of each system can be cal- turn at a time, allowing sufficient time (approximately culated by recording the temperature of the liquid line 15 minutes) between adjustments for the system and at the outlet of the condenser and subtracting it from...

  • Page 44: Unit Operating Sequence

    FORM 150.66-NM3 SECTION 5 - COMMISSIONING ISSUE DATE: 09/25/2020 UNIT OPERATING SEQUENCE The operating sequence described below relates to op- 4. Several seconds after the compressor starts, that sys- tems first condenser fan will be cycled on (outdoor eration on a hot water start after power has been ap- air temperature more than 25°F (-4°C) or discharge plied, such as start-up commissioning.

  • Page 45: Section 6 - Technical Data

    FORM 150.66-NM3 ISSUE DATE: 09/25/2020 SECTION 6 - TECHNICAL DATA OPERATIONAL LIMITATIONS (ENGLISH) TABLE 2 – TEMPERATURES AND FLOWS ENGLISH LEAVING WATER COOLER FLOW (GPM) AIR ON CONDENSER (°F) TEMPERATURE (°F) YCAL 0041 0045 0051 0055 0061 0065 0071 Excessive flow will cause damage to Voltage Limitations the cooler.

  • Page 46: Table 4 - Ethylene Glycol Correction Factors

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 OPERATIONAL LIMITATIONS (ENGLISH) ENGLISH 1000 LD13280 FLOW, GPM HEAT EXCHANGER FLOW, GPM MODEL YCAL COOLER CURVE 0041 0045,0051 0055 0061,0065, 0071 Note: Water Pressure Drop Curves may extend past the minimum and maximum water flow ranges. See “Design Parameters” in Engineering Guide (150.64-EG1) for minimum and maximum flowpoints.

  • Page 47: Operational Limitations (Si)

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 OPERATIONAL LIMITATIONS (SI) TABLE 5 – TEMPERATURES AND FLOWS (SI) SI UNITS LEAVING WATER YCAL COOLER FLOW (L/S) AIR ON CONDENSER (°C) TEMPERATURE (°DC) 0041 12.8 12.6 -17.7 51.7 0045 12.8 12.6 -17.7...

  • Page 48: Table 7 - Ethylene Glycol Correction Factors

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 OPERATIONAL LIMITATIONS (SI) 1000 LD13318 FLOW, L/S HEAT EXCHANGER FLOW, L/S MODEL YCAL COOLER CURVE 0041 0045,0051 0055 0061,0065, 0071 Note: Water Pressure Drop Curves may extend past the minimum and maximum water flow ranges. See “Design Parameters” in Engineering Guide (150.64-EG1) for minimum and maximum flowpoints.
  • Page 49 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 50: Physical Data (English)

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 PHYSICAL DATA (ENGLISH) YCAL0041_ ‑ YCAL0071_ TABLE 8 – PHYSICAL DATA (ENGLISH) 50 Hz Dimension General Unit Data Nominal Compressor Capacity Refrigerant Charge, Oil Charge, YCAL Operating, Shipping Weight Operating Weight Circuit 1 Circuit 2 Nomi-...
  • Page 51 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 PHYSICAL DATA (ENGLISH) (CONT’D) YCAL0041_ ‑ YCAL0071_ 50 Hz Condenser Fans, Low Condenser Condenser Fans, Ultra Quiet Evaporator Sound Total Min. Max. Face Number of Number of Number of Max. Max.

  • Page 52: Sound Data (English)

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 SOUND DATA (ENGLISH) YCAL0041_ ‑ YCAL0071_ TABLE 9 – SOUND DATA (ENGLISH) DUAL CIRCUIT UNITS 50 HZ LINE FREQUENCY LOW NOISE FAN (STANDARD) R-410A 1000 2000 4000 8000 YCAL0041 YCAL0045 YCAL0051 YCAL0055 YCAL0061...
  • Page 53 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 54: Electrical Data

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 ELECTRICAL DATA ELCTRICAL DATA (ENGLISH) YCAL0041_ ‑ YCAL0071_ SINGLE POINT FIELD SUPPLIED POWER WIRING (See Fig. 2) (One Field Provided Power Supply to the chiller. Field connections to Factory Provided Power Terminal Block (standard), Non-Fused Discon- nect Switch (optional) or Circuit Breaker (optional)).
  • Page 55 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 FIELD WIRING LUGS SYSTEM # 1 COMPRESSOR & SYSTEM # 2 COMPRESSOR & CIRCUIT BREAKER (OPT) OPTIONAL STANDARD ULTRA LOW SOUND FAN COMP 1 COMP2 FANS COMP 1 COMP 2 FANS LUGS/ LUG WIRE...

  • Page 56: Table 11 - Micro Panel Power Supply

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 ELECTRICAL DATA TABLE 11 – MICRO PANEL POWER SUPPLY OVER CURRENT PROTECTION, CONTROL UNIT VOLTAGE SEE NOTE B NF DISC Sw POWER NOTE A UNIT MODELS w/o VOLTAGE CONTROL 115-1-60/50 30 A / 240V TRANS MODELS w/...

  • Page 57: Electrical Notes And Legend

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 ELECTRICAL NOTES AND LEGEND NOTES: 1. Minimum Circuit Ampacity (MCA) is based on 125% of the rated load amps for the largest motor plus 100% of the rated load amps for all other loads included in the circuit, per N.E.C. Article 430-24. If the optional Factory Mounted Control Transformer is provided, add the following MCA values to the electrical tables for the system providing power to the transformer: -17, add 2.5 amps;...

  • Page 58: Wiring Diagrams

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 WIRING DIAGRAMS ELEMENTARY DIAGRAM LD13247 FIG. 4 – CONTROL CIRCUIT JOHNSON CONTROLS...
  • Page 59 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 ELEMENTARY DIAGRAM (CONT’D) LD13248 FIG. 4 (CONT’D) - CONTROL CIRCUIT JOHNSON CONTROLS...

  • Page 60: Fig. 5 - Power Circuit

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 ELEMENTARY DIAGRAM LD13249 FIG. 5 – POWER CIRCUIT JOHNSON CONTROLS...

  • Page 61: Fig. 6 - Wiring Details

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 ELEMENTARY DIAGRAM (CONT’D) LD10958 FIG. 6 – WIRING DETAILS JOHNSON CONTROLS...

  • Page 62: Fig. 7 - Connection Diagram

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 CONNECTION DIAGRAM LD13250 FIG. 7 – CONNECTION DIAGRAM JOHNSON CONTROLS...

  • Page 63: Fig. 8 - Connection Diagram Microboard (Partial)

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 CONNECTION DIAGRAM BACNET MICROGATEWAY OPTION LD10960 FIG. 8 – CONNECTION DIAGRAM MICROBOARD (PARTIAL) JOHNSON CONTROLS...

  • Page 64: Dimensions

    Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 6';...
  • Page 65 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0041 (ENGLISH) (CONT’D) 9/16" DIA MOUNTING HOLES(typ) 1 1/16" COIL COOLER 90 9/16" END CAP WIDTH 45 5/16" 1 1/16" 9 13/16" 9 13/16" ORIGIN TOP VIEW 21 13/16" 5 5/16"...
  • Page 66 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 6';...
  • Page 67 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0045 (ENGLISH) (CONT’D) 9/16" DIA MOUNTING HOLES(typ) 1 1/16" COIL COOLER 90 9/16" END CAP WIDTH 45 5/16" 1 1/16" 9 13/16" 9 13/16" ORIGIN 20 1/16" TOP VIEW 5 5/16"...
  • Page 68 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 6';...
  • Page 69 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0051 (ENGLISH) (CONT’D) 9/16" DIA MOUNTING HOLES(typ) 1 1/16" COIL COOLER 90 9/16" END CAP WIDTH 45 5/16" 1 1/16" 9 13/16" 9 13/16" ORIGIN 20 1/16" TOP VIEW 5 5/16"...
  • Page 70 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 6';...
  • Page 71 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0055 (ENGLISH) (CONT’D) 9/16" DIA MOUNTING HOLES(typ) 1 1/16" COIL COOLER 90 9/16" END CAP WIDTH 45 5/16" 1 1/16" 9 13/16" 9 13/16" ORIGIN 18 7/16" TOP VIEW 5 3/16"...
  • Page 72 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 6';...
  • Page 73 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0061 (ENGLISH) (CONT’D) 9/16" DIA MOUNTING HOLES(typ) 1 1/16" COIL COOLER 90 9/16" END CAP WIDTH 43 5/16" 1 1/16" 9 13/16" 9 13/16" ORIGIN 16 11/16" TOP VIEW 5 3/16"...
  • Page 74 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 6';...
  • Page 75 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0065 (ENGLISH) (CONT’D) 9/16" DIA MOUNTING HOLES(typ) 1 1/16" COIL COOLER 90 9/16" END CAP WIDTH 43 5/16" 1 1/16" ORIGIN 9 13/16" 9 13/16" 16 11/16" TOP VIEW 5 3/16"...
  • Page 76 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 6';...
  • Page 77 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0071 (ENGLISH) (CONT’D) 9/16" DIA MOUNTING HOLES(typ) 1 1/16" COIL COOLER 90 9/16" END CAP WIDTH 43 5/16" 1 1/16" ORIGIN 9 13/16" 9 13/16" TOP VIEW 16 11/16" 5 3/16"...
  • Page 78 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 2m;...
  • Page 79 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0041 (SI) (CONT’D) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1150 ORIGIN TOP VIEW CONTROL PANEL TWO LIFTING HOLES BOTH SIDES LD10974 3678 FRONT VIEW JOHNSON CONTROLS...
  • Page 80 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 2m;...
  • Page 81 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0045 (SI) (CONT’D) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1150 ORIGIN TOP VIEW CONTROL PANEL TWO LIFTING HOLES BOTH SIDES LD10976 3678 FRONT VIEW JOHNSON CONTROLS...
  • Page 82 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 2m;...
  • Page 83 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0051 (SI) (CONT’D) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1150 ORIGIN TOP VIEW CONTROL PANEL LD10978 TWO LIFTING HOLES BOTH SIDES 3678 FRONT VIEW JOHNSON CONTROLS...
  • Page 84 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 2m;...
  • Page 85 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0055 (SI) (CONT’D) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1151 ORIGIN TOP VIEW CONTROL PANEL TWO LIFTING HOLES BOTH SIDES LD10980 3678 FRONT VIEW JOHNSON CONTROLS...
  • Page 86 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 2m;...
  • Page 87 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0061 (SI) (CONT’D) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1100 ORIGIN TOP VIEW CONTROL PANEL TWO LIFTING HOLES BOTH SIDES LD10982 3678 FRONT VIEW JOHNSON CONTROLS...
  • Page 88 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 2m;...
  • Page 89 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0065 (SI) (CONT’D) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1100 ORIGIN TOP VIEW CONTROL PANEL TWO LIFTING HOLES BOTH SIDES LD10984 3902 FRONT VIEW JOHNSON CONTROLS...
  • Page 90 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Recommended minimum clearances: front to wall – 2m;...
  • Page 91 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 DIMENSIONS - YCAL0071 (SI) (CONT’D) 14 DIA MOUNTING HOLES(typ) COIL COOLER 2301 END CAP WIDTH 1100 ORIGIN TOP VIEW CONTROL PANEL TWO LIFTING HOLES BOTH SIDES 3902 FRONT VIEW JOHNSON CONTROLS...

  • Page 92: Technical Data - Clearances

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 TECHNICAL DATA - CLEARANCES (2 m) (1.3 m) LD10506 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 ft (3 m) apart. FIG.

  • Page 93: Isolators

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 ISOLATORS WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS General Weights of specific chiller models vary significantly as Whenever the isolator option is ordered, the isolators options are added. As a result, total weights, weights at will be shipped loose with the chiller.
  • Page 94 BASE PLATE DIMENSIONS FOR UNITS WITH ALL POINT LOADS LESS THAN 1404 LBS (637 KG) WEIGHT RANGE (LBS) WEIGHT RANGE (KG) MODEL NUMBER COLOR YORK P/N 239 to 384 lbs 108 to 174 kg CIP-B- 029-24583-002 384 to 639 lbs...

  • Page 95: Installation Of 1" Deflection Mounts

    FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 Installation of 1" Deflection Mounts 1. Floor or steel frame should be level and smooth. 5. Complete piping and fill equipment with water, refrigerant, etc. 2. For pad installations, isolators do not normally re- quire bolting.
  • Page 96 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 NEOPRENE ISOLATOR CROSS-REFERENCE ND-X "CS" Cap Screw "MBD" Max. Bolt Dia. Steel Plate - Top & Bottom Neoprene covered to prevent corrosion ENGLISH SIZE ND-C 2 9/16 2 3/ 4 5 1/ 2 1/ 4 2 5/16...
  • Page 97 215.9 15.9 34.9 355.6 311.2 133.4 88.9 5/8" *WEIGHT RANGE WEIGHT RANGE MODEL NUMBER COLOR YORK P/N (LBS) (KG) Up to 358 lbs Up to 162 kg SLRS-2-C2- 029-24585-006 358 to 443 lbs 162 to 201 kg SLRS-2-C2- White 029-24585-007...
  • Page 98 FORM 150.66-NM3 SECTION 6 - TECHNICAL DATA ISSUE DATE: 09/25/2020 SLRS SEISMIC ISOLATOR INSTALLATION AND ADJUSTMENT To Install and Adjust Mounts: 8. Turn adjustment bolt 8 turns on each mount. 1. Supports for mountings must be leveled to installa- tion's acceptable tolerances. 9.

  • Page 99: Section 7 - Unit Controls

    YORK MILLENNIUM CONTROL CENTER 00065VIP INTRODUCTION MICROPROCESSOR BOARD The YORK MicroComputer Control Center is a micro- The Microprocessor Board is the controller and deci- processor based control system designed to provide the sion maker in the control panel. System inputs such entire control for the liquid chiller.

  • Page 100: Unit Switch

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 UNIT SWITCH BATTERY BACK-UP A unit ON/OFF switch is just underneath the keypad. The Microprocessor Board contains a Real Time Clock This switch allows the operator to turn the entire unit integrated circuit chip with an internal battery backup.

  • Page 101: Status Key

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 STATUS KEY 00066VIP Unit Status R E M O T E C O N T R O L L E D S H U T D O W N Pressing the STATUS key will enable the operator to determine current chiller operating status.
  • Page 102 FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 The limiting pressure is a factory set limit to keep the S Y S C O O L L O A D system from faulting on the high discharge pressure S Y S C O O L L O A D...

  • Page 103: Fault Safety Status Messages

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 when in the MANUAL OVERRIDE mode. MANUAL S Y S L O W S U C T P R E S S OVERRIDE is to only be used in emergencies or for S Y S L O W S U C T...
  • Page 104 FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 The internal motor protector opens at 185°F to 248°F S Y S L O W E V A P T E M P (85°C to 120°C) and auto resets. The mechanical HP S Y S L O W E V A P...

  • Page 105: Unit Safeties

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 This safety will shut down a system if either suction U N I T F A U L T : temperature or suction pressure sensors read out of H I G H M T R C U R R range high or low.

  • Page 106: Status Key Messages

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 STATUS KEY MESSAGES TABLE 13 – STATUS KEY MESSAGES QUICK REFERENCE LIST STATUS KEY MESSAGES General Messages Fault Messages Unit Safeties & System Safeties Unit Switch Off Warning Messages Shutdown Remote Controlled System X High Disch Pressure Low Ambient Temp...

  • Page 107: Display/Print Keys

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 DISPLAY/PRINT KEYS 00067VIP The DISPLAY/PRINT keys allow the user to retrieve With the “UNIT TYPE” set as a liquid chiller (via no system and unit information that is useful for monitor- jumper on J11-7 to J11-12), the following list of operat- ing chiller operation, diagnosing potential problems, ing data screens are viewable under the Oper Data key...
  • Page 108 FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 The above two messages will appear sequentially for S Y S 7 2 . 1 P S I G each system. The first display shows accumulated run- = 2 2 7 . 0 P S I G ning hours of each compressor for the specific system.
  • Page 109 The third message indicates the system, and whether the liquid line solenoid or EEV pilot solenoid and hot – YORK Talk via ISN allows remote load lim- gas solenoid are being turned on by the microboard. iting and temperature reset through an ISN Note that hot gas is not available for system 2, so there system.

  • Page 110: Table 14 - Operation Data

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 The fourth message indicates what stage of condenser TABLE 14 – OPERATION DATA fan operation is active. For YCAL0041 to YCAL0071 Oper Data Key unless a low ambient kit is added, only stages 1 and 3 will be actually used to cycle the condenser fans.

  • Page 111: Print Key

    Operating Data printout is shown below. (Note: Not all COOLER INLET REFRIG 31.6 DEGF values are printed for all models.) LIQUID LINE SOLENOID HOT GAS BYPASS VALVE CONDENSER FAN STAGES YORK INTERNATIONAL CORPORATION EEV OUTPUT 0.0 % MILLENNIUM LIQUID CHILLER SYSTEM XXX.X AMPS X.X VOLTS UNIT STATUS...

  • Page 112: History Printout

    L O W L I Q U I D T E M P follows. Displays the type of fault that occurred. YORK INTERNATIONAL CORPORATION MILLENNIUM LIQUID CHILLER U N I T T Y P E SAFETY SHUTDOWN NUMBER 1 L I Q U I D...
  • Page 113 FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 L O W A M B I E N T T E M P A M B I E N T C O N T R O L C U T O U T X X X .

  • Page 114: Software Version

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 L E A D S Y S T E M S Y S L L S V X X X S Y S T E M N U M B E R H O T G A S S O L...

  • Page 115: Entry Keys

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 ENTRY KEYS 00068VIP The ENTRY keys allows the user to view, change pro- Enter/Adv Key grammed values. The Entry keys consist of an ↑ (UP) The ENTER/ADV key must be pushed after any change arrow key, ↓...

  • Page 116: Setpoints Keys

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 SETPOINTS KEYS 00069VIP Programming of the cooling setpoints, daily schedule, Leaving Chilled Liquid Control and safeties is accomplished by using the keys located S E T P O I N T 4 5 .

  • Page 117: Return Chilled Liquid Control

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 When in leaving chilled liquid temperature control, R E M S E T P 4 4 . 0 ° F the microprocessor will attempt to control the leaving R A N G E + / - 2 .

  • Page 118: Table 15 - Cooling Setpoints, Programmable Limits And Defaults

    30°F (-1.1°C). When using glycol, Leaving Chilled Liquid Setpoint should not be set below 20°F (-6.7°C). ** Do not exceed 55°F (12.8°C) setpoint before contacting the nearest YORK Office for application guidelines. The line under the 0 is the cursor. If the value is wrong,...

  • Page 119: Program Key

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 Program Key L O W A M B I E N T T E M P C U T O U T 2 5 . 0 ° F There are several operating parameters under the PRO- GRAM key that are programmable.
  • Page 120 FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 The microprocessor will not allow This MUST be programmed correctly programming the “FAN CONTROL to ensure proper chiller operation. ON PRESSURE” minus the “FAN CONTROL DIFFERENTIAL OFF PRESSURE” below 160 psig. This ensures discharge pressure does not drop too low.
  • Page 121 FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 Unit Trip Volts S Y S S U C T S U P E R H E A T For total chiller high current trip programming on S E T P O I N T X X .

  • Page 122: Table 16 - Program Key Limits And Defaults

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 TABLE 16 – PROGRAM KEY LIMITS AND DEFAULTS PROGRAM VALUE MODE LOW LIMIT HIGH LIMIT DEFAULT 325 psig 575 psig 570 psig DISCHARGE PRESSURE CUTOUT — 22.4 barg 39.6 barg 39.3 barg 80.0 psig 120 psig...

  • Page 123: Table 17 - Setpoints Quick Reference List

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 TABLE 17 – SETPOINTS QUICK REFERENCE LIST Quick Reference Programming Chart Setpoints Section Cooling Setpoints Key Schedule/ Program Mode (press key to adv.) Advance Day Key (press enter to adv.) Local Leaving Mon.

  • Page 124: Unit Keys

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 UNIT KEYS 00070VIP Options Key There are many user programmable options under the OPTIONS key. The OPTIONS key is used to scroll S Y S S W I T C H O F F S Y S S W I T C H...
  • Page 125 FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 Option 4 – Ambient Control Type Option 7 – Display Units D I S P L A Y U N I T S A M B I E N T C O N T R O L I M P E R I A L S T A N D A R D...
  • Page 126 FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 Option 9 – Condenser Fan Control Mode F A N C O N T R O L C U R R E N T F E E D B A C K D I S C H A R G E P R E S S U R E O N E...
  • Page 127 FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 If unit type needs to be changed to If the operating software is to be updated, insert the Flash Card into the Flash Card input port. Turn off the make the unit a liquid chiller, remove unit switch and set the FLASH CARD UPDATE TO power and then remove the jumper “ENABLED”...

  • Page 128: Clock

    S E L E C T I O N A U T O M A T I C When YORK HYDRO KIT PUMPS = 1, the controls will be closed to run the pumps whenever any one of Selecting Automatic allows both pumps to operate as...

  • Page 129: Table 18 - Unit Keys Programming Quick Reference List

    FORM 150.66-NM3 SECTION 7 - UNIT CONTROLS ISSUE DATE: 09/25/2020 TABLE 18 – UNIT KEYS PROGRAMMING QUICK REFERENCE LIST Options Key Expansion Valve Type (press Options Key (Thermostatic or Electric) to adv.) (Programmed under Service Display Language Mode, Viewable Only) Must be programmed for Thermostatic System Switches...
  • Page 130 FORM 150.66-NM3 ISSUE DATE: 09/25/2020 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 131: Section 8 - Unit Operation

    FORM 150.66-NM3 ISSUE DATE: 09/25/2020 SECTION 8 - UNIT OPERATION CAPACITY CONTROL LEAVING CHILLED LIQUID CONTROL To initiate the start sequence of the chiller, all run per- The setpoint, when programmed for Leaving Chilled missive inputs must be satisfied (flow/remote start/stop Liquid Control, is the temperature the unit will control switch), and no chiller or system faults exist.

  • Page 132: Leaving Chilled Liquid System Compressor Sequencing

    FORM 150.66-NM3 SECTION 8 - UNIT OPERATION ISSUE DATE: 09/25/2020 high limit. This will result in a control range the same LEAVING CHILLED LIQUID SYSTEM size as programmed but not allow the unit to run below COMPRESSOR SEQUENCING 40.0ºF. This control will not affect glycol chillers. A Lead/Lag option may be selected to help equalize average run hours between systems with 2 refriger- Hot gas, if present, will be the final step of capacity.

  • Page 133: Return Chilled Liquid Control

    FORM 150.66-NM3 SECTION 8 - UNIT OPERATION ISSUE DATE: 09/25/2020 RETURN CHILLED LIQUID CONTROL As an example of compressor staging (refer to Table (Can be used on Dual System 4, 5 & 6 Comp 19), a chiller with six compressors using a Cooling Units Only) Setpoint programmed for 45°F (7.20°C) and a Range Setpoint of 10°F (5.56°C).

  • Page 134: Return Chillled Liquid System Lead/Lag And Compressor Sequencing

    FORM 150.66-NM3 SECTION 8 - UNIT OPERATION ISSUE DATE: 09/25/2020 TABLE 20 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS) *STEP COMPRESSOR COMPRESSOR ON POINT COMPRESSOR OFF POINT SETPOINT SETPOINT 1 W/HGB SP + CR/8 (Note 1) SETPOINT 1 NO HGB SP + CR/4 SP + CR/8...

  • Page 135: Evaporator Heater Control

    FORM 150.66-NM3 SECTION 8 - UNIT OPERATION ISSUE DATE: 09/25/2020 TABLE 21 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS) LEAD SYSTEM LAG SYSTEM STEP COMP 1 COMP 2 COMP 1 COMP 2 ON + HG See NOTE 1 See NOTE 2 See NOTE 3 NOTES...

  • Page 136: Standard Condenser Fan Control - Ycal0041 - Ycal0071

    FORM 150.66-NM3 SECTION 8 - UNIT OPERATION ISSUE DATE: 09/25/2020 STANDARD CONDENSER FAN CONTROL - YCAL0041 – YCAL0071 TABLE 22 – YCAL0041 – YCAL0071 CONDENSER FAN CONTROL USING OUTDOOR AMBIENT TEMPERATURE AND DISCHARGE PRESSURE (DISCHARGE PRESSURE CONTROLS WILL NOT FUNCTION AND FAN CONTROL WILL BE BASED ON AMBIENT TEMPERATURES ONLY, UNLESS THE OPTIONAL DISCHARGE PRESSURE TRANSDUCER IS INSTALLED).

  • Page 137: Low Ambient Fan Control Option

    FORM 150.66-NM3 SECTION 8 - UNIT OPERATION ISSUE DATE: 09/25/2020 LOW AMBIENT FAN CONTROL OPTION The VFD will control fan speed when only a single fan General is running on a system. As discharge pressure rises and The low ambient option consists of a VFD (Variable falls, the fan speed will be increased from zero RPM to Frequency Drive) for each system that controls the full speed.

  • Page 138: Configuration (Jumpers And Potentiometers)

    FORM 150.66-NM3 SECTION 8 - UNIT OPERATION ISSUE DATE: 09/25/2020 The VFD will ramp up the speed of the fan as pres- POTENTIOMETER SETTINGS sure rises above the low end of the speed control range. Throughout the pressure control range, the VFD con- 180 PSI 20 PSI trols the speed of the fan based on discharge pressure in...

  • Page 139: Wiring

    FORM 150.66-NM3 SECTION 8 - UNIT OPERATION ISSUE DATE: 09/25/2020 Wiring On chillers with the low ambient op- VFD wiring is simple and requires only 3-phase power in, 3-phase power out, and a 2-wire signal from the tion, wire 127 is removed from TB7­9 transducer.

  • Page 140: Programming

    FORM 150.66-NM3 SECTION 8 - UNIT OPERATION ISSUE DATE: 09/25/2020 PROGRAMMING LOAD LIMITING Condenser fan control type must be programmed un- Load Limiting is a feature that prevents the unit from der both the OPTIONS and PROGRAM keys when a loading beyond the desired value.

  • Page 141: Compressor Run Status

    FORM 150.66-NM3 SECTION 8 - UNIT OPERATION ISSUE DATE: 09/25/2020 A contact closure on the PWM Temp Reset input at TABLE 25 – COMPRESSOR OPERATION – LOAD CTB1 terminals 13 - 20, will reset the chilled liquid LIMITING setpoint based on the length of time the contacts remain COMPRESSORS STAGE 1 STAGE 2...

  • Page 142: Bas/Ems Temperature Reset Option

    The coil of any added relay used for re- set must be suppressed to prevent pos- Max Reset Value is the “Max EMS-PWM Remote Temp. Reset” setpoint sible component damage. Use YORK value described in the program ming section under Cooling Setpoints. PN 031­00808­000 suppres sor.

  • Page 143: Fig. 18 - Field And Factory Electrical Connections Optional Remote

    FORM 150.66-NM3 SECTION 8 - UNIT OPERATION ISSUE DATE: 09/25/2020 – 035-15961-000 LD03875B FIG. 18 – FIELD AND FACTORY ELECTRICAL CONNECTIONS OPTIONAL REMOTE TEMPERATURE RESET BOARD JOHNSON CONTROLS...
  • Page 144 FORM 150.66-NM3 ISSUE DATE: 09/25/2020 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 145: Section 9 - Service And Troubleshooting

    FORM 150.66-NM3 ISSUE DATE: 09/25/2020 SECTION 9 - SERVICE AND TROUBLESHOOTING CLEARING HISTORY BUFFERS The history buffers may be cleared by pressing the HIS- Following is the order of outputs that will appear as the TORY key and then repeatedly pressing the UP arrow ENTER/ADV key is pressed: key until you scroll past the last history buffer choice.

  • Page 146: Service Mode - Inputs

    FORM 150.66-NM3 SECTION 9 - SERVICE AND TROUBLESHOOTING ISSUE DATE: 09/25/2020 Soft start, Refrigerant Type, and Ex- LEAVING LIQUID TEMP. pansion Valve Type MUST be properly RETURN LIQUID TEMP. programmed or damage to compres- SYS 2 *SUCTION PRESSURE sors and other system components SYS 2 SPARE may result.

  • Page 147: Control Inputs/Outputs

    FORM 150.66-NM3 SECTION 9 - SERVICE AND TROUBLESHOOTING ISSUE DATE: 09/25/2020 CONTROL INPUTS/OUTPUTS TABLE 28 – MICROBOARD ANALOG INPUTS Tables 26 through 29 are a quick reference list provid- Sys 1 Suction Pressure Transducer ing the connection points and a description of the in- J7‑10 puts and outputs respectively.

  • Page 148: Fig. 19 - Ipu Ii & I/O Layout

    FORM 150.66-NM3 SECTION 9 - SERVICE AND TROUBLESHOOTING ISSUE DATE: 09/25/2020 I/O BOARD BOARD TB10 LD12721 LD12721 FIG. 19 – IPU II & I/O LAYOUT JOHNSON CONTROLS...

  • Page 149: Checking Inputs And Outputs

    FORM 150.66-NM3 SECTION 9 - SERVICE AND TROUBLESHOOTING ISSUE DATE: 09/25/2020 CHECKING INPUTS AND OUTPUTS Digital Inputs TABLE 30 – OUTDOOR AIR SENSOR TEMPERATURE/VOLTAGE/ Refer to the unit wiring diagram. All digital inputs are RESISTANCE CORRELATION connected to J13 of the microboard. The term “digital” VOLTAGE refers to two states –...

  • Page 150: Liquid & Refrigerant Sensor Test Points

    FORM 150.66-NM3 SECTION 9 - SERVICE AND TROUBLESHOOTING ISSUE DATE: 09/25/2020 Liquid & Refrigerant Sensor Test Points TABLE 31 – ENTERING/LEAVING CHILLED (Table 31) LIQUID TEMP. SENSOR, COOLER INLET TEMPERATURE SENSOR, Entering Chilled Liquid Sensor AND SUCTION TEMPERATURE SENSOR: TEMPERATURE/VOLTAGE J6-5 = +5 VDC regulated supply to sensor.

  • Page 151: Analog Inputs - Pressure

    FORM 150.66-NM3 SECTION 9 - SERVICE AND TROUBLESHOOTING ISSUE DATE: 09/25/2020 Analog Inputs – Pressure V = (Pressure in psig x 0.006) + .5 Refer to the unit wiring diagram. Pressure inputs are connected to the microboard on plugs J7 and J79. These V = (Pressure in BARG x 0.09) + .5 analog inputs represent varying dc signals correspond- ing to varying pressures.

  • Page 152: Digital Outputs

    FORM 150.66-NM3 SECTION 9 - SERVICE AND TROUBLESHOOTING ISSUE DATE: 09/25/2020 The suction transducers have a range from 0 psig to Digital Outputs 400 psig (27.58 barg). The output will be linear from Refer to the unit wiring diagram and Fig. 20. The digi- 0.5 VDC to 4.5 VDC over the 400 psig (27.58 barg) tal outputs are located on TB-7, TB-8, TB-9 and TB- range.

  • Page 153: Optional Printer Installation

    The part number for the printer that is packaged spe- the keypad and then pressing either the OPER DATA cifically for YORK is P/N 950915576. The cable to key or HISTORY key. connect the printer can either be locally assembled from the parts listed, or ordered directly from WEIGH- TRONIX under part number 287-040018.

  • Page 154: Table 32 - Troubleshooting

    FORM 150.66-NM3 SECTION 9 - SERVICE AND TROUBLESHOOTING ISSUE DATE: 09/25/2020 TABLE 32 – TROUBLESHOOTING PROBLEM CAUSE SOLUTION 1. No 115VAC to 24 VAC Transformer IT. 1a. Check wiring and fuse 1FU. 1b. Check wiring emergency stop contacts 5 to L of TB1 terminal block.
  • Page 155 FORM 150.66-NM3 SECTION 9 - SERVICE AND TROUBLESHOOTING ISSUE DATE: 09/25/2020 TABLE 32 – TROUBLESHOOTING (CONT’D) PROBLEM CAUSE SOLUTION 1. condenser fans not operating or 1. Check fan motor, fuses and operating backwards. contactors. Ensure fan blows air upward. 2. Too much refrigerant. 2.
  • Page 156 FORM 150.66-NM3 SECTION 9 - SERVICE AND TROUBLESHOOTING ISSUE DATE: 09/25/2020 TABLE 32 – TROUBLESHOOTING (CONT’D) PROBLEM CAUSE SOLUTION 1. Fouled evaporator surface Low 1. Contact the local Johnson suction pressure will be observed. Controls Service representative. 2. Improper flow through the evaporator. 2.

  • Page 157: Section 10 - Maintenance

    The following is intended only as a guide and covers only the chiller unit components. It does not cover other related system components which may or may not be furnished by YORK. System com- ponents should be maintained according to the individ- OPERATING PARAMETERS ual manufacture’s recommendations as their operation...

  • Page 158: Overall Unit Inspection

    FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 RS232 or RS485 connection for port 2 communica- OVERALL UNIT INSPECTION tions. Modbus network is wired to either TB2 or TB3 In addition to the checks listed on this page, periodic as follows: overall inspections of the unit should be accomplished •...

  • Page 159: Fig. 22 - Micro Panel Connections

    FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 035-02550-xxx I/O Board FIG. 22 – MICRO PANEL CONNECTIONS The table below shows the minimum, maximum, and default values. TABLE 33 – MINIMUM, MAXIMUM AND DEFAULT VALUES DESCRIPTION MINIMUM MAXIMUM DEFAULT DE MODIFIER ADDRESS 41943 DE MODIFIER OFFSET...

  • Page 160: Table 34 - Values Required For Bas Communication

    FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 The table below shows set-up requirements for each communication protocol. TABLE 34 – VALUES REQUIRED FOR BAS COMMUNICATION PROTOCOL SETTING DESCRIPTION BACNET MS/TP MODBUS RTU YORKTALK 2 DE MODIFIER ADDRESS 0 to 41943 DE MODIFIER OFFSET 0 to 99 P1 PROTOCOL...

  • Page 161: Bacnet And Modbus Communications

    FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 BACnet and Modbus Communications Communications Data Map Notes (See Table 36) Chiller data that can be read and modified using spe- cific BACnet or Modbus Register Addresses; and the 1. IPU II based units are configured for Native BACnet data associated with the addresses, is outlined in the MS/TP and Modbus RTU communications.

  • Page 162: Table 36 - Bacnet And Modbus Communications Data Map

    FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 TABLE 36 - BACNET AND MODBUS COMMUNICATIONS DATA MAP JOHNSON CONTROLS...
  • Page 163 FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 TABLE 36 (CONT’D) - BACNET AND MODBUS COMMUNICATIONS DATA MAP JOHNSON CONTROLS...
  • Page 164 FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 TABLE 36 (CONT’D) - BACNET AND MODBUS COMMUNICATIONS DATA MAP JOHNSON CONTROLS...
  • Page 165 FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 TABLE 36 (CONT’D) - BACNET AND MODBUS COMMUNICATIONS DATA MAP JOHNSON CONTROLS...

  • Page 166: Yorktalk 2 Communications

    FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 YorkTalk 2 Communications Transmitted Data After receiving a valid transmission from the Micro- Received Data (Control Data) Gateway or E-Link, the unit will transmit either op- The unit receives eight data values from the MicroGate- erational data or history buffer data depending on the way or E-Link.

  • Page 167: Table 37 - Yorktalk 2 Communications Data Map

    FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 TABLE 37 - YORKTALK 2 COMMUNICATIONS DATA MAP JOHNSON CONTROLS...
  • Page 168 FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 TABLE 37 (CONT’D) - YORKTALK 2 COMMUNICATIONS DATA MAP JOHNSON CONTROLS...
  • Page 169 FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 TABLE 37 (CONT’D) - YORKTALK 2 COMMUNICATIONS DATA MAP JOHNSON CONTROLS...
  • Page 170 FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 TABLE 37 (CONT’D) - YORKTALK 2 COMMUNICATIONS DATA MAP JOHNSON CONTROLS...
  • Page 171 FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 TABLE 37 (CONT’D) - YORKTALK 2 COMMUNICATIONS DATA MAP JOHNSON CONTROLS...
  • Page 172 FORM 150.66-NM3 SECTION 10 - MAINTENANCE ISSUE DATE: 09/25/2020 TABLE 37 (CONT’D) - YORKTALK 2 COMMUNICATIONS DATA MAP JOHNSON CONTROLS...
  • Page 173 FORM 150.66-NM3 ISSUE DATE: 09/25/2020 NOTES JOHNSON CONTROLS...
  • Page 174 5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 1-800-524-1330 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2020 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 150.66-NM3 (920) Issue Date: September 25, 2020 Supersedes: 150.66-NM3 (110)

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