York YCAL0014SC, YCAL0080SC User Manual

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Page 1

MILLENNIUM

AIR-COOLED LIQUID CHILLERS

HERMETIC SCROLL

INST ALLA TION, OPERA TION, MAINT.

YCAL0014SC - YCAL0080SC

Supersedes: 150.62-NM1 (899)

Form 150.62-NM1 (700)

Standard, Glycol & Metric Models, Combined

29224(R)A

200-3-60 230-3-60 380-3-60 460-3-60 575-3-60

MODELS ONLY

Page 2

IMPORTANT!

READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

This equipment is a relatively complicated apparatus. During installation, operation, maintenance or service, individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, oils, materials under pressure, rotating components, and both high and low voltage. Each of these items has the potential, if mis-used or handled improperly , to cause bodily injury or death. It is the obligation and responsibility of operating/service personnel to identify and recognize these inherent hazards, protect themselves, and proceed safely in completing their tasks. Failure to comply with any of these requirements could result in serious damage to the equipment and the property in which it is situated, as well as severe personal injury or death to themselves and people at the site.

This document is intended for use by owner-authorized operating/service personnel. It is expected that this individual possesses independent training that will enable them to perform their assigned tasks properly and safely. It is essential that, prior to performing any task on this equipment, this individual shall have read and understood this document and any referenced materials. This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question.

SAFETY SYMBOLS

The following symbols are used in this document to alert the reader to areas of potential hazard:

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

YORK INTERNATIONAL

Page 3

FORM 150.62-NM1

CAUTION identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution. Usually an instruction will be given, together with a brief explanation.

NOTE is used to highlight additional information which may be helpful to you.

CHANGEABILITY OF THIS DOCUMENT

In complying with YORK’s policy for continuous product improvement, the information contained in this document is subject to change without notice. While YORK makes no commitment to update or provide current information automatically to the manual owner, that information, if applicable, can be obtained by contacting the nearest YORK Engineered Systems Service office.

It is the responsibility of operating/service personnel to verify the applicability of these documents to the equipment in question. If there is any question in the mind of operating/service personnel as to the applicability of these documents, then prior to working on the equipment, they should verify with the owner whether the equipment has been modified and if current literature is available.

YORK INTERNATIONAL

Page 4

TABLE OF CONTENTS AND TABLES

PAGE

PRODUCT IDENTIFICA TION NUMBER..........................................................7

REFRIGERANT FLOW DIAGRAM...................................................................9

SECTION 1 INST ALLATION ..........................................................................10

ELECTRICAL DA TA .......................................................................................20

OPERA TIONAL LIMITATIONS .......................................................................30

PHYSICAL DA TA............................................................................................34

DIMENSIONS & CLEARANCES .................................................................... 38

PRE-ST A R TUP CHECKLIST ......................................................................... 54

INITIAL STARTUP.......................................................................................... 55

UNIT OPERA TING SEQUENCE .................................................................... 57

SECTION 2 UNIT CONTROLS ......................................................................58

ST ATUS KEY..................................................................................................60

DISPLA Y/PRINT KEYS .................................................................................. 66

ENTRY KEYS................................................................................................. 73

SETPOINTS KEY ........................................................................................... 74

UNIT KEYS .................................................................................................... 81

UNIT OPERATION .........................................................................................85

SECTION 3 SERVICE AND TROUBLESHOOTING ...................................... 95

OPTIONAL PRINTER INST ALLATION......................................................... 104

TROUBLESHOOTING CHARTS..................................................................105

MAINTENANCE ........................................................................................... 108

ISN CONTROL............................................................................................. 109

SECTION 4 WIRING DIAGRAMS ............................................................... 112

SECTION 5 APPENDIX 1 – ISOLA T ORS ....................................................128

YORK APPLIED SYSTEMS FIELD OFFICE LISTING ................................. 134

TABLES

1 MICROP ANEL POWER SUPPLY ............................................................20

2 STANDARD SINGLE POINT POWER..................................................... 21

3 STANDARD DUAL POINT POWER ................................................ 22 – 23

4 OPTIONAL SINGLE POINT POWER .............................................. 24 – 25

5 OPTIONAL SINGLE POINT POWER .............................................. 26 – 27

6 OPTIONAL SINGLE POINT POWER .............................................. 28 – 29

7 TEMPERATURES AND FLOWS (ENGLISH) .......................................... 30

8 VOL TAGE LIMITATIONS (ENGLISH)....................................................... 30

9 COOLER PRESSURE DROPS (ENGLISH)............................................. 31

10 ETHYLENE GL YCOL CORRECTION FACTORS .................................... 31

11 TEMPERATURES AND FLOWS (METRIC) ............................................ 32

12 VOLTAGE LIMITA TIONS (METRIC) ........................................................ 32

YORK INTERNATIONAL

Page 5

TABLES AND FIGURES

TABLES

13 COOLER PRESSURE DROPS (METRIC)............................................. 33

14 ETHYLENE GL YCOL CORRECTION FACTORS .................................. 33

15 PHYSICAL DATA (ENGLISH) ........................................................ 34 – 35

16 PHYSICAL DA TA (METRIC) .......................................................... 36 – 37

17 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (ENGLISH) ............. 39

18 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (ENGLISH) ............. 41

19 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (ENGLISH) ............. 43

20 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (ENGLISH) ............. 45

21 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (METRIC) ............... 47

22 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (METRIC) ............... 49

23 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (METRIC) ............... 51

24 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (METRIC) ............... 53

FORM 150.62-NM1

PAGE

25 SETPOINT ENTRY LIST ....................................................................... 54

26 ST ATUS KEY MESSAGES .................................................................... 65

27 OPERA TOR DA TA QUICK REFERENCE .............................................. 69

28 COOLING SETPOINTS PROGRAMMABLE LIMITS & DEFAULTS....... 76

29 PROGRAM KEY LIMITS & DEFAULTS ................................................. 79

30 SETPOINTS KEY QUICK REFERENCE ............................................... 80

31 UNIT KEYS QUICK REFERENCE......................................................... 84

32 LEA VING CHILLED LIQUID CONTROL – 6 COMPRESSORS ............. 86

33 LEA VING CHILLED LIQUID CONTROL – 4 COMPRESSORS ............. 86

34 LEA VING CHILLED LIQUID CONTROL – 3 COMPRESSORS ............. 87

35 LEA VING CHILLED LIQUID CONTROL – 2 COMPRESSORS ............. 87

36 COMPRESSOR STAGING FOR RETURN WATER CONTROL ............ 89

37 RETURN CHILLED LIQUID CONTROL – 6 COMPRESSORS.............. 89

38 RETURN CHILLED LIQUID CONTROL – 4 COMPRESSORS.............. 89

39 CONDENSER FAN CONTROL USING OUTDOOR AMBIENT

TEMPERA TURE AND DISCHARGE ..................................................... 90

40 CONDENSER FAN CONTROL USING DISCHARGE ONLY ................. 90

41 LOW AMBIENT CONDENSER FAN CONTROL – AMBIENT

42 LOW AMBIENT CONDENSER FAN CONTROL – DISCHARGE

43 COMPRESSOR OPERA TION – LOAD LIMITING ................................. 92

44 MICROBOARD BINARY INPUTS .......................................................... 97

45 MICROBOARD ANALOG INPUTS ........................................................ 97

46 MICROBOARD OUTPUTS .................................................................... 97

47 OUTDOOR AIR SENSOR VALUES....................................................... 99

YORK INTERNATIONAL

TEMPERATURE AND DISCHARGE PRESSURE CONTROL............. 91

PRESSURE CONTROL....................................................................... 91

Page 6

TABLES/FIGURES

TABLES

48 ENTERING & LEA VING CHILLED LIQUID TEMPERATURE

SENSOR VALUES............................................................................ 100

49 KEYP AD PIN ASSIGNMENT MATRIX ................................................. 103

50 TROUBLESHOOTING CHARTS ............................................... 105 – 107

51 ISN RECEIVED DA TA.......................................................................... 109

52 ISN TRANSMITTED DATA .................................................................. 109

53 ISN TRANSMITTED DATA .................................................................. 110

54 ISN OPERA TIONAL & FAULT CODES.................................................111

FIGURES

1 REFRIGERANT FLOW DIAGRAM .......................................................... 9

2 STANDARD POWER SUPPLY WIRING................................................ 14

3 OPTIONAL SINGLE POINT POWER SUPPLY WIRING ....................... 15

4 OPTIONAL SINGLE POINT POWER SUPPLY WIRING –

N-F DISC SW OR CIRC BKR ............................................................. 16

PAGE

5 CONTROL WIRING.............................................................................. 17

6 LEAVING WATER TEMPERATURE CONTROL –

COMPRESSOR ST AGING .................................................................. 86

7 FIELD & FACT ORY ELECTRICAL CONNECTIONS –

REMOTE TEMPERATURE RESET BOARD ....................................... 94

8 MICROBOARD LA YOUT ....................................................................... 98

9 MICROBOARD RELA Y CONTACTS ARCHITECTURE....................... 103

10 PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS ........... 104

1 1 ELEMENT AR Y DIAGRAM ................................................................... 1 12

12 ELEMENTARY DIAGRAM – POWER CIRCUIT .................................. 114

13 ELEMENT ARY DIAGRAM ................................................................... 116

14 ELEMENTARY DIAGRAM – POWER CIRCUIT .................................. 118

15 ELEMENT ARY DIAGRAM ................................................................... 120

16 ELEMENTARY DIAGRAM – POWER CIRCUIT .................................. 122

17 ELEMENT ARY DIAGRAM ................................................................... 124

18 ELEMENTARY DIAGRAM – POWER CIRCUIT .................................. 126

19 TYPE CP 1........................................................................................... 130

20 TYPE CP 2........................................................................................... 130

21 R SPRING SEISMIC ISOLATOR ......................................................... 131

22 TYPE CP MOUNTING ......................................................................... 132

23 “AEQM” SPRING-FLEX MOUNTING................................................... 133

YORK INTERNATIONAL

Page 7

FORM 150.62-NM1

PRODUCT IDENTIFICATION NUMBER (PIN)

EXAMPLES:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

YCAS1385EA50YFA YCAL0080SC46XAA

BASIC MODEL NUMBER

YCAL0080SC46xAA

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE/STARTER DESIGN/DEVELOPMENT LEVEL Y 0### S C 1 7 A

C 1### 2 8 A

: YORK : Chiller

A 40

: Air-Cooled

U 46

: Condensing Unit

L 58

: Scroll

Even Number: 60 HZ Nominal Tons Odd Number: 50 HZ Nominal kW

: Standard Unit

: R-22

: 200 / 3/ 60 : 230 / 3 / 60 : 380 / 3 / 60 : 460 / 3 / 60 : 380-415 / 3 / 50 : 575 / 3 / 60

: Across the Line

: Design Series A : Engineering Change or PIN Level

YORK INTERNATIONAL

Page 8

OPTIONS MODEL NUMBER

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

POWER FIELD CONTROLS FIELD COMPRESSOR / PIPING FIELD XX L ##

XX H SX A C SD T

BX S

MP = Multiple Point SP = Single Point NF = Non-Fused TB = Terminal Block Ser. = Service Ind. Sys. Brkr. & L. Ext. Handles = Individual

System Breaker & Lockable External Handle

: SP Supply TB : MP Supply TB : SP Supply TB : SP NF Disconnect Switch : SP Circuit Breaker w/ Lockable Handle

: Control Transformer (factory)

: Power Factor Capacitor

CR E

G 1

S B

L N C

: Low Ambient Kit (factory) : High Ambient Kit (factory) : Both Low / High Ambient (factory) : BAS/EMS T emp. Reset / Offset : Spanish LCD & Keypad Display : French LCD & Keypad Display : German LCD & Keypad Display : Discharge Pressure Transducers/

Readout Kit

: Suction Pressure Transducers /

Readout Kit : Both Discharge & Suction Pressure Transducers / Readout : N. American Safety Code

(cU.L./cE.T.L.) : No Listing (typically 50 HZ non-C.E.,

non-U.L.

: Remote Control Panel

: Sequence Control & Automatic

Lead Transfer

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

EVA P. FIELD CONDENSER FIELD CABINET FIELD

:Leaving Supply Temp. :Chicago Relief Code

:Hot Gas By-Pass (# circuits) :Compressor External Overload

EXAMPLES:

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

XXXXXXXXLXXXXXXXXXXXXXXXXXAXXXXXXXXXXXXX

SDTCATSRLXPRS25CX1XXXX3DWSARXBXX4BXXLXSD

PRODUCT IDENTIFICATION NUMBER (PIN)

3Xx

DC1

WB2

VP3

SX4

A 5

: 300 PSIG DWP Waterside : Double Thick Insulation : Weld Flange Kit : Victaulic Flange Kit : Flow Switch : ASME Pressure Vessel &

Associated Codes

: Remote DX Cooler

: Aluminum : Copper : Black Fin : Phenolic : TEAO Fan Motors

6 8

: Wire Condenser Headers Only (factory) : Wire (Full Unit) Enc. Panels (factory) : Wire (Full Unit) Enc. Panels (field) : Wire/Louvered Enc. Panels (factory) : Wire/Louvered Enc. Panels (field) : Louvered (Cond. Only) Enc. Panels (factory) : Louvered (Cond. Only) Enc. Panels (field) : Louvered (Full Unit) Enc. Panels (factory) : Louvered (Full Unit) Enc. Panels (field) : Acoustic Sound Blanket

: Low Sound Fans

: 1" Deflection

: Seismic

: Neoprene Pads

EXTENDED FIELD

YORK INTERNATIONAL

: 1st Year Parts Only

: 1st Year Parts & Labor

: 2nd Year Parts Only

: 2nd Year Parts & Labor

: 5 Year Compressor Parts Only

: 5 Year Compressor Parts & Labor Only

: 5 Year Units Parts Only

: 5 Year Unit Parts & Labor

NOTES:

1. Q :DENOTES SPECIAL / S.Q.

2. # :DENOTES STANDARD

3. X :w/in OPTIONS FIELD, DENOTES NO OPTION SELECTED

4. Agency Files (i.e. U.L. / E.T .L.; C.E.; ARI; ETC.) will contain info. based on the first 14 characters only.

Page 9

HOT DISCHARGE GAS LINE

REFRIGERANT FLOW DIAGRAM

AIR COOLED CONDENSERS

(INCLUDING TEMPERATURE SENSORS & PRESSURE TRANSDUCERS)

LIQUID LINE FILTER / DRIER

LIQUID LINE SERVICE V ALVE

FORM 150.62-NM1

YCAL REFRIGERANT FLOW DIAGRAM

NOTE: YCAL0040-0080 HAVE TWO REFRIGERANT

SYSTEMS AND ONE DX COOLER.

* HOT GAS OPTION - SYSTEM 1 ONLY

SIGHT GLASS / MOISTURE INDICATOR

LIQUID LINE

SOLENOID VALVE

DISCHARGE LINE BALL VALVE

SERVICE V ALVE

2 OR 3 COMPRESSORS PER SYSTEM

OPTIONAL DISCHARGE PRESSURE TRANSDUCER

HIGH PRESSURE CUTOUT SWITCH

SERVICE

VALVE

LOW PRESSURE SWITCH OR

SUCTION PRESSURE TRANSDUCER

OIL EQUALIZING LINE

SUCTION LINE

BALL VALVE

LEAVING CHILLED WATER

SOLENOID OPERATED

HOT GAS BY PASS VALVE

RELIEF VALVE 300 PSIG (20.68 BARG)

DX COOLER

LEAVING

CHILLED WATER

TEMP. SENSOR

TXV

EQUALIZER

RETURN WATER

TEMP. SENSOR

ENTERING CHILLED WATER

LINE

LD03844

FIG. 1 – REFRIGERANT FLOW DIAGRAM

YORK INTERNATIONAL

Page 10

Installation

INSTALLATION

To ensure warranty coverage, this equipment must be commissioned and serviced by an authorized YORK service mechanic or a qualified service person experienced in chiller installation. Installation must comply with all applicable codes, particularly in regard to electrical wiring and other safety elements such as relief valves, HP cut-out settings, design working pressures, and ventilation requirements consistent with the amount and type of refrigerant charge.

Lethal voltages exist within the control panels. Before servicing, open and tag all disconnect switches.

INST ALLATION CHECK LIST

The following items, 1 thru 5, must be checked before placing the units in operation.

1. Inspect the unit for shipping damage.

2. Rig unit using spreader bars.

3. Open the unit only to install water piping system. Do not remove protective covers from water connections until piping is ready for attachment. Check water piping to insure cleanliness.

4. Pipe unit using good piping practice (see ASHRAE handbook section 215 and 195.

5. Check to see that the unit is installed and operated within limitations (Refer to LIMIT ATIONS).

The following pages outline detailed procedures to be followed to install and start-up the chiller.

HANDLING

The unit should be lifted by inserting hooks through the holes provided in unit base rails. Spreader bars should be used to avoid crushing the unit frame rails with the lifting chains. See below.

29224(RIG)A

INSPECTION

Immediately upon receiving the unit, it should be inspected for possible damage which may have occurred during transit. If damage is evident, it should be noted in the carrier’s freight bill. A written request for inspection by the carrier’s agent should be made at once. See “Instruction” manual, Form 50.15-NM for more information and details.

LOCA TION AND CLEARANCES

These units are designed for outdoor installations on ground level, rooftop, or beside a building. Location should be selected for minimum sun exposure and to insure adequate supply of fresh air for the condenser. The units must be installed with sufficient clearances for air entrance to the condenser coil, for air discharge away from the condenser, and for servicing access.

In installations where winter operation is intended and snow accumulations are expected, additional height must be provided to insure normal condenser air flow.

These units are shipped as completely assembled units containing full operating charge, and care should be taken to avoid damage due to rough handling.

Clearances are listed under “Notes” in the “DIMENSIONS” section.

YORK INTERNATIONAL

Page 11

FORM 150.62-NM1

FOUNDATION

The unit should be mounted on a flat and level foundation, floor, or rooftop capable of supporting the entire operating weight of the equipment. See PHYSICAL DATA for operating weight. If the unit is elevated beyond the normal reach of service personnel, a suitable catwalk must be capable of supporting service personnel, their equipment, and the compressors.

GROUND LEVEL LOCATIONS

It is important that the units be installed on a substantial base that will not settle. A one piece concrete slab with footers extended below the frost line is highly recommended. Additionally , the slab should not be tied to the main building foundations as noise and vibration may be transmitted. Mounting holes are provided in the steel channel for bolting the unit to its foundation. (See DIMENSIONS.)

For ground level installations, precautions should be taken to protect the unit from tampering by or injury to unauthorized persons. Screws and/or latches on access panels will prevent casual tampering. However, further safety precautions such as a fenced-in enclosure or locking devices on the panels may be advisable.

ROOFTOP LOCATIONS

Choose a spot with adequate structural strength to safely support the entire weight of the unit and service personnel. Care must be taken not to damage the roof.

SPRING ISOLA TORS (OPTIONAL)

When ordered, four (4) isolators will be furnished. Identify the isolator, and locate at the proper mounting

point, and adjust per instructions. See Appendix 1.

COMPRESSOR MOUNTING

The compressors are mounted on four (4) rubber isolators. The mounting bolts should not be loosened or adjusted at installation of the chiller.

REMOTE COOLER OPTION

For units using remote cooler option, refer to instructions included with miscellaneous cooler parts kit.

The unit is shipped with a 6 lb. (2.7 kg) holding charge. The remainder of the charge must be weighed-in according to the operating charge listed under Physical Data. Additional charge must also be added for the refrigerant lines.

CHILLED WATER PIPING General – When the unit has been located in its final

position, the unit water piping may be connected. Normal installation precautions should be observed in order to receive maximum operating efficiencies. Piping should be kept free of all foreign matter. All chilled water evaporator piping must comply in all respects with local plumbing codes and ordinances.

Consult the building contractor or architect if the roof is bonded. Roof installations should have wooden beams (treated to reduce deterioration), cork, rubber, or vibration isolators under the base to minimize vibration.

NOISE SENSITIVE LOCA TIONS

Efforts should be made to assure that the chiller is not located next to occupied spaces or noise sensitive areas where chiller noise level would be a problem. Chiller noise is a result of compressor and fan operation. Considerations should be made utilizing noise levels published in the YORK Engineering Guide for the specific chiller model. Sound blankets for the compressors and low sound fans are available.

Since elbows, tees and valves decrease pump capacity, all piping should be kept as straight and as simple as possible possible. All piping must be supported

independent of the chiller.

Consideration should be given to compressor access when laying out water piping. Routing the water piping too close to the unit could make compressor servicing/replacement difficult.

YORK INTERNATIONAL

Page 12

Installation

Hand stop valves should be installed in all lines to facilitate servicing.

Piping to the inlet and outlet connections of the chiller should include high-pressure rubber hose or piping loops to insure against transmission of water pump vibration. The necessary components must be obtained in the field.

Drain connections should be provided at all low points to permit complete drainage of the cooler and system water piping.

A small valve or valves should be installed at the highest point or points in the chilled water piping to allow any trapped air to be purged. Vent and drain connections should be extended beyond the insulation to make them accessible.

The piping to and from the cooler must be designed to suit the individual installation. It is important that the following considerations be observed:

1. The chilled liquid piping system should be laid out so that the circulating pump discharges directly into the cooler. The suction for this pump should be taken from the piping system return line and not the cooler. This piping scheme is recommended, but is not mandatory.

2. The inlet and outlet cooler connection sizes are 3" (YCAL0014 - 0030), 4" (YCAL0034 - 0060), or 6" (YCAL0064 - 0080).

3. A strainer, preferably 40 mesh, must be installed in the cooler inlet line just ahead of the cooler. This is important to protect the cooler from entrance of large particles which could cause damage to the evaporator.

4. All chilled liquid piping should be thoroughly flushed to free it from foreign material before the system is placed into operation. Use care not to flush any foreign material into or through the cooler.

5. As an aid to servicing, thermometers and pressure gauges should be installed in the inlet and outlet wa-

ter lines.

6. The chilled water lines that are exposed to outdoor ambients should be wrapped with supplemental heater cable and insulated to protect against freezeup during low ambient periods, and to prevent formation of condensation on lines in warm humid locations.

7. A chilled water flow switch, (either by YORK or others) MUST be installed in the leaving water piping of the cooler. There should be a straight horizontal run of at least 5 diameters on each side of the switch. Adjust the flow switch paddle to the size of the pipe in which it is to be installed. (See manufacturer’s instructions furnished with the switch.) The switch is to be wired to terminals 13 – 14 of CTB1 located in the control panel, as shown on the unit wiring diagram.

The Flow Switch MUST NOT be used to start and stop the chiller (i.e. starting and stopping the chilled water pump). It is intended only as a safety switch.

WIRING

Liquid Chillers are shipped with all factory mounted controls wired for operation.

Field Wiring – Power wiring must be provided through a fused disconnect switch to the unit terminals (or optional molded disconnect switch) in accordance with N.E.C. or local code requirements. Minimum circuit ampacity and maximum dual element fuse size are given in the Tables 2 – 6.

A 120-1-60, 15 amp source must be supplied for the control panel through a fused disconnect when a control panel transformer (optional) is not provided. Refer to Table 1 and Figures 2 - 4.

See Figures 2 - 5 and unit wiring diagrams for field and power wiring connections, chilled water pump starter contacts, alarm contacts, compressor run status contacts, PWM input, and load limit input. Refer to section on UNIT OPERATION for a detailed description of operation concerning aforementioned contacts and inputs.

YORK INTERNATIONAL

Page 13

FORM 150.62-NM1

EV APORATOR PUMP START CONTACTS

Terminal block CTB2 - terminals 23 to 24, are normally open contacts that can be used to switch field supplied power to provide a start signal to the evaporator pump contactor. The contacts will be closed when any of the following conditions occur:

1. Low Leaving Chilled Liquid Fault

2. Any compressor is running.

3. Daily schedule is not programmed OFF and the Unit Switch is ON.

The pump will not run if the micropanel has been powered up for less than 30 seconds, or if the pump has run in the last 30 seconds, to prevent pump motor overheating. Refer to figure 5 and unit wiring diagram.

SYSTEM RUN CONTACTS

Contacts are available to monitor system status. Normally-open auxiliary contacts from each compressor contactor are wired in parallel with CTB2 - terminals 25 to 26 for system 1, and CTB2 - terminals 27 to 28 for system 2 (YCAL0040 - YCAL0080). Refer to Figure 5 and unit wiring diagram.

ALARM ST ATUS CONTACTS

REMOTE EMERGENCY CUTOFF

Immediate shutdown of the chiller can be accomplished by opening a field installed dry contact to break the electrical circuit between terminals 5 to L on terminal block CTB2. The unit is shipped with a factory jumper installed between terminals 5 to L, which must be removed if emergency shutdown contacts are installed. Refer to Figure 5 and unit wiring diagram.

PWM INPUT

The PWM input allows reset of the chilled liquid setpoint by supplying a “timed” contact closure. Field wiring should be connected to CTB1 - terminals 13 to 20. A detailed explanation is provided in the Unit Control section. Refer to Figure 5 and unit wiring diagram.

LOAD LIMIT INPUT

Load limiting is a feature that prevents the unit from loading beyond a desired value. The unit can be “load limited” either 33%, 50%, or 66%, depending on the number of compressors on unit. The field connections are wired to CTB1 - terminals 13 to 21, and work in conjunction with the PWM inputs. A detailed explanation is provided in the Unit Control section. Refer to figure 5 and unit wiring diagram.

Normally-open contacts are available for each refrigerant system. These normally-open contacts close when the system if functionally normally . The respective contacts will open when the unit is shut down on a unit fault, or locked out on a system fault. Field connections are at CTB2 terminals 29 to 30 (system 1), and terminals 31 to 32 (system 2 YCAL0040 - YCAL0080).

REMOTE ST ART/STOP CONTACTS

To remotely start and stop the chiller, dry contacts can be wired in series with the flow switch and CTB1 - terminals 13 to 14. Refer to Figure 5 and unit wiring diagram.

When using the Load Limit feature, the PWM feature will not function SIMULTANEOUS OPERATION OF LOAD LIMITING AND TEMPERATURE RESET (PWM INPUT) CANNOT BE DONE.

FLOW SWITCH INPUT

The flow switch is field wired to CTB1 terminals 13 - 14. See Figure 5 and unit wiring diagram.

YORK INTERNATIONAL

Page 14

Installation

STANDARD POWER SUPPLY WIRING – (0014 - 0080)

Power Panel

Circuit # 1

1L1

1L2

1L3

*Circuit # 2

2L1

2L2

GRD

See electrical note 9

2L3

GRD

CTB2

2 L

Control Panel

Micropanel

CTB1

Field 120-1-60 Micropanel Power Supply if control transformer not supplied

Field Unit Power Supply

Flow Switch

LD04483

IT IS POSSIBLE THAT MULTIPLE SOURCES OF POWER CAN BE SUPPLYING THE UNIT POWER PANEL. TO PREVENT SERIOUS INJURY OR DEATH, THE TECHNICIAN SHOULD VERIFY THAT NO LETHAL VOLTAGES ARE PRESENT INSIDE THE P ANEL AFTER DISCONNECTING POWER, PRIOR TO WORKING ON EQUIPMENT.

THE UNIT EVAPORATOR HEATER USES 120 VAC. DISCONNECTING 120 VAC POWER FROM THE UNIT, AT OR BELOW FREEZING TEMPERATURES, CAN RESULT IN DAMAGE TO THE EVAPORATOR AND UNIT AS A RESULT OF THE CHILLED LIQUID FREEZING.

Electrical Notes and Legend located on Page 18 and 19.

FIG. 2 – MULTI POINT POWER SUPPLY WIRING

YORK INTERNATIONAL

Page 15

FORM 150.62-NM1

OPTIONAL SINGLE POINT POWER SUPPLY WIRING – (0040 - 0080)

Power Panel

1L1

1L3

1L2

See electrical note 9

GRD

Control Panel

2 L

CTB2

Field Unit Power Supply

Micropanel

Flow Switch

CTB1

Field 120-1-60 Micropanel Power Supply if control transformer not supplied

LD04484

Electrical Notes and Legend located on Page 18 and 19.

FIG. 3 – OPTIONAL SINGLE POINT POWER SUPPLY WIRING

YORK INTERNATIONAL

Page 16

Installation

OPTIONAL SINGLE-POINT POWER SUPPLY WIRING

N-F DISC SW OR CIRC BKR (0014 - 0080)

Power Panel

N-F Disconnect Sw. OR Molded Case Circuit Bkr.

1L1

1L2

1L3

2 L

GRD

See electrical note 9

CTB2

Field Unit Power Supply

Control Panel

Micropanel

CTB1

Field 120-1-60 Micropanel Power Supply if control transformer not supplied

Flow Switch

Electrical Notes and Legend located on Page 18 and 19.

LD04485

FIG. 4 – OPTIONAL SINGLE POINT POWER WIRING

YORK INTERNATIONAL

Page 17

CONTROL WIRING

FORM 150.62-NM1

14 13

CTB1

FLOW SW

PWM INPUT

LOAD LIMIT INPUT

REMOTE START/STOP

LD03819

FIG. 5 – CONTROL WIRING

YORK INTERNATIONAL

* Factory wired with optional transformer.

LD03611

Page 18

Installation

ELECTRICAL NOTES

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 Factory Mounted Control Transformer is provided, add the following to the system MCA values in the electrical tables for the system supplying power to the optional transformer. -17, add 2.5 amps; -28, add 2.3 amps; -40, add 1.5 amps, 46, add 1.3 amps; -58, add 1 amp.

2. The minimum recommended disconnect switch is based on 115% of the rated load amps for all loads included in the circuit, per N.E.C. Article 440.

3. Minimum fuse size is based upon 150% of the rated load amps for the largest motor plus 100% of the rated load amps for all other loads included in the circuit to avoid nuisance trips at start-up due to lock rotor amps. It is not recommended in applications where brown outs, frequent starting and stopping of the unit, and/or operation at ambient temperatures in excess of 95 °F is anticipated.

4. Maximum fuse size is based upon 225% 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 440-22.

5. Circuit breakers must be U.L. listed and CSA certified and maximum size is based on 225% of the rated load amps for the largest motor plus 100% of the rated load amps for all other loads included in the circuit. Exception: YCA0014 and YCAL0020 must have the optional factory overloads installed to use a standard circuit breaker. Otherwise, an HACR-type circuit breakers must be used. Maximum HACR circuit breaker rating is based on 225% of the rated load amps for the largest motor plus 100% of the rated load amps for all other loads included in the circuit.

6. The “INCOMING WIRE RANGE” is the minimum and maximum wire size that can be accommodated by the unit wiring lugs. The (2) preceding the wire range indicates the number of termination points available per phase of the wire range specified. Actual wire size and number of wires per phase must be determined based on the National Electrical Code, using copper connectors only . Field wiring must also comply with local codes.

7. A ground lug is provided for each compressor system to accommodate a field grounding conductor per N.E.C. Table 250-95. A control circuit grounding lug is also supplied.

8. The supplied disconnect is a “Disconnecting Means” as defined in the N.E.C. 100, and is intended for isolating the unit for the available power supply to perform maintenance and troubleshooting. This disconnect is not intended to be a Load Break Device.

9. Field Wiring by others which complies to the National Electrical Code and Local Codes.

YORK INTERNATIONAL

Page 19

ELECTRICAL NOTES

LEGEND

ACR-LINE ACROSS THE LINE START C.B. CIRCUIT BREAKER D.E. DUAL ELEMENT FUSE DISC SW DISCONNECT SWITCH FACT MOUNT CB FACTOR Y MOUNTED CIRCUIT BREAKER FLA FULL LOAD AMPS HZ HERTZ MAX MAXIMUM MCA MINIMUM CIRCUIT AMP ACITY MIN MINIMUM MIN NF MINIMUM NON FUSED RLA RA TED LOAD AMPS S.P. WIRE SINGLE POINT WIRING

UNIT MTD SERV SW LRA LOCKED ROTOR AMPS

UNIT MOUNTED SERVICE (NON-FUSED DISCONNECT SWITCH)

FORM 150.62-NM1

VOL TAGE CODE

-17 = 200-3-60

-28 = 230-3-60

-40 = 380-3-60

-46 = 460-3-60

-58 = 575-3-60

LEGEND: Field Wiring

Factory Wiring

YORK INTERNATIONAL

Page 20

Installation

ELECTRICAL DA TA

T ABLE 1 – MICROPANEL POWER SUPPLY

UNIT VOLTAGE UNIT VOLTAGE CONTROL POWER

MODELS w/o CONTROL TRANS

-17 200-1-60 15A 10A 15A 30 A / 240V

MODELS w/ CONTROL TRANS

A. Minimum #14 AWG, 75°C, Copper Recommended B. Minimum and Maximum Over Current Protection, Dual Element Fuse or Circuit Breaker

-28 230-1-60 15A 10A 15A 30 A / 240V

-40 380-1-60 15A 10A 15A 30 A / 480V

-46 460-1-60 15A 10A 15A 30 A / 480V

-58 575-1-60 15A 10A 15A 30 A / 600V

115-1-60/50 15A 10A 15A 30 A / 240V

MCA

NOTE A MIN MAX

OVER CURRENT PROTECTION,

SEE NOTE B NF DISC Sw

YORK INTERNATIONAL

Page 21

ELECTRICAL DATA – STANDARD SINGLE POINT POWER

YCAL0014SC - YCAL0034SC

T ABLE 2 – S TANDARD SINGLE POINT POWER

SINGLE POINT FIELD SUPPLIED WIRING SYSTEM #1 COMPRESSOR & FAN

MODEL

VOLT HZ MCA

YCAL

200 60 75 100 90 100 90 100 # 4 - # 1 26.0 195 26.0 195 ——2 8.2 230 60 70 100 80 90 80 90 # 4 - # 1 24.1 195 24.1 195 ——2 7.8

0014SC

0020SC

0024SC

0030SC

0034SC

See notes and legend on pages 18 and 19.

380 60 42 60 45 50 45 50 # 8 - # 4 14.0 113 14.0 1 13 ——2 4.8 460 60 34 60 40 40 40 40 # 10 - # 6 11.5 98 11.5 98 ——2 3.8 575 60 27 30 30 35 30 35 # 10 - # 6 9.2 80 9.2 80 ——2 3.1 200 60 100 150 110 125 1 10 125 # 2 - 1/0 37.0 237 37.0 237 ——2 8.2 230 60 93 100 110 125 1 1 0 125 # 2 - 1/0 34.3 237 34.3 237 ——2 7.8 380 60 52 60 60 60 60 60 # 6 - # 2 18.5 154 18.5 154 ——2 4.8 460 60 45 60 50 60 50 60 # 8 - # 4 16.3 130 16.3 130 ——2 3.8 575 60 36 60 40 45 40 45 # 8 - # 4 13.1 85 13.1 85 ——2 3.1 200 60 127 150 150 175 150 175 # 1 - 2/0 49.1 298 49.1 298 ——2 8.2 230 60 118 150 150 150 150 150 # 1 - 2/0 45.5 298 45.5 298 ——2 7.8 380 60 76 100 90 100 90 100 # 4 - # 1 29.5 235 29.5 235 — — 2 4.8 460 60 57 60 70 70 70 70 # 6 - # 2 21.7 170 21.7 170 — — 2 3.8 575 60 46 60 50 60 50 60 # 8 - # 4 17.3 140 17.3 140 — — 2 3.1 200 60 140 150 175 175 175 175 1/0 - 3/0 54.7 420 54.7 420 — — 2 8.2 230 60 130 150 150 175 150 175 1/0 - 3/0 50.7 420 50.7 420 — — 2 7.8 380 60 75 100 90 100 90 100 # 4 - # 1 28.7 235 28.7 235 — — 2 4.8 460 60 62 100 70 80 70 80 # 6 - # 2 24.1 175 24.1 175 — — 2 3.8 575 60 50 60 60 60 60 60 # 6 - # 2 19.3 140 19.3 140 — — 2 3.1 200 60 183 200 200 225 200 225 3/0 - 250 51.2 298 51.2 298 51.2 298 2 8.2 230 60 170 200 200 200 200 200 2/0 - 4/0 47.4 298 47.4 298 47.4 298 2 7.8 380 60 103 150 110 125 110 125 # 2 - 1/0 28.7 235 28.7 235 28.7 235 2 4.8 460 60 81 100 90 100 90 100 # 4 - # 1 22.6 175 22.6 175 22.6 175 2 3.8 575 60 65 100 70 80 70 80 # 4 - # 1 18 140 18 140 18 140 2 3.1

MIN N/F D.E. FUSE CKT. BKR.

DISC SW

MIN3MAX4MIN MAX RANGE6RLA LRA RLA LRA RLA LRA QTY FLA (EA)

INCOMING

WIRE

FORM 150.62-NM1

COMPR. #1 COMPR. #2 COMPR. #3 FANS

YORK INTERNATIONAL

Page 22

Installation

ELECTRICAL DATA – STANDARD DUAL POINT POWER

YCAL0040SC - YCAL0080SC

T ABLE 3 – STANDARD DUAL POINT POWER

SYSTEM #1 FIELD SUPPLIED WIRING SYSTEM #1 COMPRESSOR & FAN

MODEL

VOLT HZ MCA

YCAL

200 60 91 100 100 110 100 110 # 2 - 1/0 32.9 265 32.9 265 ——2 8.2 230 60 85 100 100 110 100 110 # 4 - # 1 30.5 265 30.5 265 ——2 7.8

0040SC

0044SC

0050SC

0060SC

0064SC

0070SC

0074SC

0080SC

See notes and legend on pages 18 and 19.

380 60 54 60 60 70 60 70 # 6 - # 2 19.4 155 19.4 155 ——2 4.8 460 60 41 60 45 50 45 50 # 8 - # 4 14.5 120 14.5 120 ——2 3.8 575 60 33 60 40 40 40 40 # 10 - # 6 11.6 80 11.6 80 ——2 3.1 200 60 13 0 150 150 175 150 175 # 1 - 2/0 50.2 298 50.2 298 ——2 8.2 230 60 12 1 150 150 150 150 150 # 1 - 2/0 46.5 298 46.5 298 ——2 7.8 380 60 73 100 80 100 80 100 # 4 - # 1 28.1 235 28.1 235 ——2 4.8 460 60 58 60 70 70 70 70 # 6 - # 2 22.1 170 22.1 170 ——2 3.8 575 60 47 60 60 60 60 60 # 8 - # 4 17.7 140 17.7 140 ——2 3.1 200 60 146 200 175 200 175 200 1/0 - 3/0 57.4 420 57.4 420 ——2 8.2 230 60 136 150 150 175 150 175 1/0 - 3/0 53.1 420 53.1 420 ——2 7.8 380 60 79 100 90 100 90 100 # 4 - # 1 30.8 235 30.8 235 ——2 4.8 460 60 65 100 80 80 80 80 # 4 - # 1 25.3 175 25.3 175 ——2 3.8 575 60 52 60 60 70 60 70 # 6 - # 2 20.2 140 20.2 140 — — 2 3.1 200 60 141 150 175 175 175 175 1/0 - 3/0 55.0 420 55.0 420 ——2 8.2 230 60 131 150 150 175 150 175 1/0 - 3/0 50.9 420 50.9 420 ——2 7.8 380 60 77 100 90 100 90 100 # 4 - # 1 29.6 235 29.6 235 ——2 4.8 460 60 63 100 70 80 70 80 # 6 - # 2 24.2 175 24.2 175 ——2 3.8 575 60 50 60 60 60 60 60 # 6 - # 2 19.4 140 19.4 140 ——2 3.1 200 60 187 200 200 225 200 225 3/0 - 250 52.4 298 52.4 298 52.4 298 2 8.2 230 60 174 200 200 200 200 200 2/0 - 4/0 48.6 298 48.6 298 48.6 298 2 7.8 380 60 10 5 150 125 125 125 125 # 2 - 1/0 29.3 235 29.3 235 29.3 235 2 4.8 460 60 83 100 90 100 90 100 # 4 - # 1 23.1 170 23.1 170 23.1 170 2 3.8 575 60 67 100 80 80 80 80 # 4 - # 1 18.5 140 18.5 140 18.5 140 2 3.1 200 60 185 200 200 225 200 225 3/0 - 250 51.8 298 51.8 298 51.8 298 2 8.2 230 60 172 200 200 200 200 200 2/0 - 4/0 48.0 298 48.0 298 48.0 298 2 7.8 380 60 10 4 150 125 125 125 125 # 2 - 1/0 29.0 235 29.0 235 29.0 235 2 4.8 460 60 82 100 90 100 90 100 # 4 - # 1 22.9 170 22.9 170 22.9 170 2 3.8 575 60 66 100 80 80 80 80 # 4 - # 1 18.3 140 18.3 140 18.3 140 2 3.1 200 60 208 250 225 250 225 250 4/0 - 300 58.9 420 58.9 420 58.9 420 2 8.2 230 60 193 250 225 225 225 225 3/0 - 250 54.5 420 54.5 420 54.5 420 2 7.8 380 60 11 3 150 125 125 125 125 # 2 - 1/0 31.6 235 31.6 235 31.6 235 2 4.8 460 60 92 100 100 110 100 110 # 2 - 1/0 26.0 175 26.0 175 26.0 175 2 3.8 575 60 74 100 80 90 80 90 # 4 - # 1 20.8 140 20.8 140 20.8 140 2 3.1 200 60 207 250 225 250 225 250 4/0 - 300 58.6 420 58.6 420 58.6 420 2 8.2 230 60 192 250 225 225 225 225 3/0 - 250 54.2 420 54.2 420 54.2 420 2 7.8 380 60 11 2 150 125 125 125 125 # 2 - 1/0 31.5 235 31.5 235 31.5 235 2 4.8 460 60 92 100 100 110 100 110 # 2 - 1/0 25.8 175 25.8 175 25.8 175 2 3.8 575 60 74 100 80 90 80 90 # 4 - # 1 20.7 140 20.7 140 20.7 140 2 3.1

MIN N/F

DISC SW

D.E. FUSE CKT. BKR.

MIN3MAX4MIN MAX RANGE6RLA LRA RLA LRA RLA LRA QTY FLA (EA)

INCOMING

WIRE

COMPR. #1 COMPR. #2 COMPR. #3 FANS

YORK INTERNATIONAL

Page 23

FORM 150.62-NM1

ELECTRICAL DATA – STANDARD DUAL POINT POWER

YCAL0040SC - YCAL0080SC

SYSTEM #2 FIELD SUPPLIED WIRING SYSTEM #2 COMPRESSOR & FAN

INCOMING

MIN N/F D.E. FUSE CKT. BRK.

MCA

91 100 100 110 100 110 # 2 - 1/0 32.9 265 32.9 265 — — 2 8.2 85 100 100 110 100 110 # 4 - # 1 30.5 265 30.5 265 ——2 7.8 54 60 60 70 60 70 # 6 - # 2 19.4 15 5 19.4 155 — — 2 4.8 41 60 45 50 45 50 # 8 - # 4 14.5 12 0 14.5 120 — — 2 3.8

33 60 40 40 40 40 # 10 - # 6 11.6 80 11.6 80 ——2 3.1 130 150 150 175 150 175 # 1 - 2/0 50.2 298 50.2 298 — — 2 8.2 121 150 150 150 150 150 # 1 - 2/0 46.5 298 46.5 298 — — 2 7.8

73 100 80 100 80 100 # 4 - # 1 28.1 235 28.1 235 — — 2 4.8

58 60 70 70 70 70 # 6 - # 2 22.1 17 0 22.1 170 — — 2 3.8

47 60 60 60 60 60 # 8 - # 4 17.7 14 0 17.7 140 — — 2 3.1 130 150 150 175 150 175 # 1 - 2/0 49.5 298 49.5 298 — — 2 8.2 121 150 150 150 150 150 # 1 - 2/0 45.9 298 45.9 298 ——2 7.8

73 100 80 100 80 100 # 4 - # 1 27.8 235 27.8 235 ——2 4.8

58 60 70 70 70 70 # 6 - # 2 21.8 17 0 21.8 170 —–2 3.8

47 60 60 60 60 60 # 8 - # 4 17.5 14 0 17.5 140 ——2 3.1 141 150 175 175 175 175 1/0 - 3/0 55.0 420 55.0 420 ——2 8.2 131 150 150 175 150 175 1/0 - 3/0 50.9 420 50.9 420 ——2 7.8

77 100 90 100 90 100 # 4 - # 1 29.6 235 29.6 235 ——2 4.8

63 100 70 80 70 80 # 6 - # 2 24.2 175 24.2 175 ——2 3.8

50 60 60 60 60 60 # 6 - # 2 19.4 14 0 19.4 140 ——2 3.1 128 150 150 150 150 150 # 1 - 2/0 34.2 265 34.2 265 34.2 265 2 8.2 119 150 150 150 150 150 # 1 - 2/0 31.6 265 31.6 265 31.6 265 2 7.8

76 100 90 90 90 90 # 4 - # 1 20.2 155 20.2 155 20.2 155 2 4.8

57 100 70 70 70 70 # 6 - # 2 15.1 120 15.1 120 15.1 120 2 3.8

46 60 50 50 50 50 # 8 - # 4 12.0 80 12.0 80 12.0 80 2 3.1 185 200 200 225 200 225 3/0 - 250 51.8 298 51.8 298 51.8 298 2 8.2 172 200 200 200 200 200 2/0 - 4/0 48.0 298 48.0 298 48.0 298 2 7.8 104 150 125 125 125 125 # 2 - 1/0 29.0 235 29.0 235 29.0 235 2 4.8

82 100 90 100 90 100 # 4 - # 1 22.9 170 22.9 170 22.9 170 2 3.8

66 100 80 80 80 80 # 4 - # 1 18.3 140 18.3 140 18.3 140 2 3.1 181 200 200 225 200 225 3/0 - 250 50.5 298 50.5 298 50.5 298 2 8.2 168 200 200 200 200 200 2/0 - 4/0 46.8 298 46.8 298 46.8 298 2 7.8 102 150 110 125 110 125 # 2 - 1/0 28.3 235 28.3 235 28.3 235 2 4.8

80 100 90 100 90 100 # 4 - # 1 22.3 170 22.3 170 22.3 170 2 3.8

65 100 70 80 70 80 # 6 - # 2 17.8 140 17.8 140 17.8 140 2 3.1 207 250 225 250 225 250 4/0 - 300 58.6 420 58.6 420 58.6 420 2 8.2 192 250 225 225 225 225 3/0 - 250 54.2 420 54.2 420 54.2 420 2 7.8 112 150 125 125 125 125 # 2 - 1/0 31.5 235 31.5 235 31.5 235 2 4.8

92 100 100 110 100 110 # 2 - 1/0 25.8 175 25.8 175 25.8 175 2 3.8

74 100 80 90 80 90 # 4 - # 1 20.7 140 20.7 140 20.7 140 2 3.1

DISC SW

MIN3MAX4MIN MAX

WIRE

COMPR. #1 COMPR. #2 COMPR. #3 FANS

RLA LRA RLA LRA RLA LRA QTY FLA (EA)RANGE

YORK INTERNATIONAL

Page 24

Installation

ELECTRICAL DATA – OPTIONAL SINGLE POINT POWER

YCAL0014SC - YCAL0034SC

T ABLE 4 – OPTIONAL SINGLE POINT POWER

MODEL

YCAL

VOLT HZ MCA

200 60 75 10 0 90 100 90 1 0 0 # 4 - # 1 # 4 - # 1 230 60 70 10 0 80 90 80 90 # 4 - # 1 # 4 - # 1

0014SC

380 60 42 60 45 50 45 50 # 8 - # 4 # 8 - # 4 460 60 34 60 40 40 40 40 # 10 - # 6 # 10 - # 6 575 60 27 30 30 35 30 35 # 10 - # 6 # 10 - # 6 200 60 100 150 110 125 110 125 # 2 - 1/0 # 2 - 1/0 230 60 93 10 0 110 125 110 125 # 2 - 1/0 # 2 - 1/0

0020SC

380 60 52 60 60 60 60 60 # 6 - # 2 # 6 - # 2 460 60 45 60 50 60 50 60 # 8 - # 4 # 8 - # 4 575 60 36 60 40 45 40 45 # 8 - # 4 # 8 - # 4 200 60 127 150 150 175 150 175 # 1 - 2/0 # 1 - 2/0 230 60 118 150 150 150 150 150 # 1 - 2/0 # 1 - 2/0

0024SC

380 60 76 10 0 90 100 90 100 # 4 - # 1 # 4 - # 1 460 60 57 60 70 70 70 70 # 6 - # 2 # 6 - # 2 575 60 46 60 50 60 50 60 # 8 - # 4 # 8 - # 4 200 60 140 150 175 17 5 175 175 1/0 - 3/0 1/0 - 3/0 230 60 130 150 150 17 5 150 175 1/0 - 3/0 1/0 - 3/0

0030SC

380 60 75 10 0 90 100 90 100 # 4 - # 1 # 4 - # 1 460 60 62 10 0 70 80 70 80 # 6 - # 2 # 6 - # 2 575 60 50 60 60 60 60 60 # 6 - # 2 # 6 - # 2 200 60 183 200 200 2 25 200 225 3/0 - 250 3/0 - 250 230 60 170 200 200 20 0 200 200 2/0 - 4/0 2/0 - 4/0

0034SC

380 60 103 150 110 125 110 125 # 2 - 1/0 # 2 - 1/0 460 60 81 10 0 90 100 90 100 # 4 - # 1 # 4 - # 1 575 60 65 10 0 70 80 70 80 # 4 - # 1 # 4 - # 1

See notes and legend on pages 18 and 19.

SINGLE POINT FIELD SUPPLIED WIRING

MIN N/F

DISC SW

D.E. FUSE CKT. BKR.

MIN3MAX4MIN MAX DISCONNECT BREAKER

INCOMING WIRE RANGE

FACTORY SUPPLIED OPTIONAL

YORK INTERNATIONAL

Page 25

ELECTRICAL DATA – OPTIONAL SINGLE POINT POWER

YCAL0014SC - YCAL0034SC

SYSTEM #1 COMPRESSOR & FAN

COMPR. #1 COMPR. #2 COMPR. #3 FANS

RLA LRA RLA LRA RLA LRA QTY FLA (EA)

26.0 195 26.0 195 —— 2 8.2

24.1 195 24.1 195 — — 2 7.8

14.0 113 14.0 113 — — 2 4.8

11.5 98 11.5 98 — — 2 3.8

9.2 80 9.2 80 — — 2 3.1

37.0 237 37.0 237 — — 2 8.2

34.3 237 34.3 237 — — 2 7.8

18.5 154 18.5 154 — — 2 4.8

16.3 130 16.3 130 —— 2 3.8

13.1 85 13.1 85 —— 2 3.1

49.1 298 49.1 298 —— 2 8.2

45.5 298 45.5 298 —— 2 7.8

29.5 235 29.5 235 —— 2 4.8

21.7 170 21.7 170 —— 2 3.8

17.3 140 17.3 140 —— 2 3.1

54.7 420 54.7 420 —— 2 8.2

50.7 420 50.7 420 —— 2 7.8

28.7 235 28.7 235 —— 2 4.8

24.1 175 24.1 175 —— 2 3.8

19.3 140 19.3 140 —— 2 3.1

51.2 298 51.2 298 51.2 298 2 8.2

47.4 298 47.4 298 47.4 298 2 7.8

28.7 235 28.7 235 28.7 235 2 4.8

22.6 175 22.6 175 22.6 175 2 3.8 18 140 18 140 18 140 2 3.1

FORM 150.62-NM1

YORK INTERNATIONAL

Page 26

Installation

ELECTRICAL DATA – OPTIONAL SINGLE POINT POWER

YCAL0040SC - YCAL0060SC

T ABLE 5 – OPTIONAL SINGLE POINT POWER

MODEL

YCAL

VOLT HZ MCA

200 60 173 200 200 200 200 200 2/0 - 4/0 2/0 - 4/0 2/0 - 4/0 230 60 161 200 175 175 175 175 2/0 - 4/0 2/0 - 4/0 2/0 - 4/0

0040SC

380 60 102 150 110 110 110 110 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 460 60 77 100 90 90 90 90 # 4 - # 1 # 4 - # 1 # 4 - # 1 575 60 62 100 70 70 70 70 # 6 - # 2 # 6 - # 2 # 6 - # 2 200 60 247 400 300 300 300 300 250 - 350 250 - 350 250 - 350 230 60 229 250 250 250 250 250 4/0 - 300 4/0 - 300 4/0 - 300

0044SC

380 60 139 200 150 150 150 150 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 460 60 110 150 125 125 125 125 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 575 60 88 100 100 100 100 100 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 200 60 261 400 300 300 300 300 300 - 400 300 - 400 300 - 400 230 60 243 400 300 300 300 300 250 - 350 250 - 350 250 - 350

0050SC

380 60 145 200 175 175 175 175 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 460 60 116 150 125 125 125 125 # 1 - 2/0 # 1 - 2/0 # 1 - 2/0 575 60 93 150 100 110 100 110 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 200 60 267 400 300 300 300 300 300 - 400 300 - 400 300 - 400 230 60 248 400 300 300 300 300 250 - 350 250 - 350 250 - 350

0060SC

380 60 145 200 175 175 175 175 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 460 60 119 150 125 125 125 125 # 1 - 2/0 # 1 - 2/0 # 1 - 2/0 575 60 95 150 100 110 100 110 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0

See notes and legend on pages 18 and 19.

SINGLE POINT FIELD SUPPLIED WIRING

MIN N/F

DISC SW

D.E. FUSE CKT. BKR.

MIN3MAX4MIN MAX SINGLE POINT DISCONNECT BREAKER

INCOMING WIRE RANGE

FACTORY SUPPLIED OPTIONAL

YORK INTERNATIONAL

Page 27

FORM 150.62-NM1

ELECTRICAL DATA – OPTIONAL SINGLE POINT POWER

YCAL0040SC - YCAL0060SC

SYSTEM #1 COMPRESSOR & FAN SYSTEM #2 COMPRESSOR & FAN

COMPR. #1 COMPR. #2 COMPR. #3 FANS COMPR. #1 COMPR. #2 COMPR. #3 FANS

RLA LRA RLA LRA RLA LRA QTY FLA (EA) RLA LRA RLA LRA RLA LRA QTY FLA (EA)

32.9 265 32.9 265 ——2 8.2 32.9 265 32.9 265 ——2 8.2

30.5 265 30.5 265 ——2 7.8 30.5 265 30.5 265 ——2 7.8

19.4 155 19.4 155 ——2 4.8 19.4 155 19.4 155 ——2 4.8

14.5 120 14.5 120 ——2 3.8 14.5 120 14.5 120 ——2 3.8

11.6 80 11.6 80 ——2 3.1 11.6 80 11.6 80 ——2 3.1

50.2 298 50.2 298 ——2 8.2 50.2 298 50.2 298 ——2 8.2

46.5 298 46.5 298 ——2 7.8 46.5 298 46.5 298 ——2 7.8

28.1 235 28.1 235 ——2 4.8 28.1 235 28.1 235 ——2 4.8

22.1 170 22.1 170 — — 2 3.8 22.1 170 22.1 170 ——2 3.8

17.7 140 17.7 140 — — 2 3.1 17.7 140 17.7 140 ——2 3.1

57.4 420 57.4 420 — — 2 8.2 49.5 298 49.5 298 ——2 8.2

53.1 420 53.1 420 — — 2 7.8 45.9 298 45.9 298 ——2 7.8

30.8 235 30.8 235 ——2 4.8 27.8 235 27.8 235 ——2 4.8

25.3 175 25.3 175 ——2 3.8 21.8 170 21.8 170 ——2 3.8

20.2 140 20.2 140 ——2 3.1 17.5 140 17.5 140 ——2 3.1

55.0 420 55.0 420 ——2 8.2 55.0 420 55.0 420 ——2 8.2

50.9 420 50.9 420 ——2 7.8 50.9 420 50.9 420 ——2 7.8

29.6 235 29.6 235 ——2 4.8 29.6 235 29.6 235 ——2 4.8

24.2 175 24.2 175 ——2 3.8 24.2 175 24.2 175 ——2 3.8

19.4 140 19.4 140 ——2 3.1 19.4 140 19.4 140 ——2 3.1

YORK INTERNATIONAL

Page 28

Installation

ELECTRICAL DATA – OPTIONAL SINGLE POINT POWER

YCAL0064SC - YCAL0080SC

T ABLE 6 – OPTIONAL SINGLE POINT POWER

MODEL

YCAL

VOLT HZ MCA

200 60 306 400 350 350 350 350 350 - 500 350 - 500 350 - 500 230 60 284 400 300 300 300 300 300 - 400 300 - 400 300 - 400

0064SC

380 60 175 200 200 200 200 200 3/0 - 250 3/0 - 250 3/0 - 250 460 60 136 150 150 150 150 150 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 575 60 109 150 125 125 125 125 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 200 60 357 400 400 400 400 400 500 - (2) 4/0 500 - (2) 4/0 500 - (2) 4/0 230 60 332 400 350 350 350 350 400 - 600 400 - 600 400 - 600

0070SC

380 60 201 250 225 225 225 225 4/0 - 300 4/0 - 300 4/0 - 300 460 60 159 200 175 175 175 175 2/0 - 4/0 2/0 - 4/0 2/0 - 4/0 575 60 127 150 150 150 150 150 # 1 - 2/0 # 1 - 2/0 # 1 - 2/0 200 60 376 600 400 400 400 400 500 - (2) 4/0 500 - (2) 4/0 500 - (2) 4/0 230 60 349 400 400 400 400 400 500 - (2) 4/0 500 - (2) 4/0 500 - (2) 4/0

0074SC

380 60 207 250 225 225 225 225 4/0 - 300 4/0 - 300 4/0 - 300 460 60 167 200 175 175 175 175 2/0 - 4/0 2/0 - 4/0 2/0 - 4/0 575 60 134 150 150 150 150 150 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 200 60 399 600 450 450 450 450 600 - (2) 250 600 - (2) 250 600 - (2) 250 230 60 371 600 400 400 400 400 500 - (2) 4/0 500 - (2) 4/0 500 - (2) 4/0

0080SC

380 60 216 250 225 225 225 225 4/0 - 300 4/0 - 300 4/0 - 300 460 60 177 200 200 200 200 200 3/0 - 250 3/0 - 250 3/0 - 250 575 60 142 200 150 150 150 150 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0

See notes and legend on pages 18 and 19.

SINGLE POINT FIELD SUPPLIED WIRING

MIN N/F

DISC SW

D.E. FUSE CKT. BKR.

MIN3MAX4MIN MAX SINGLE POINT DISCONNECT BREAKER

INCOMING WIRE RANGE

FACTORY SUPPLIED OPTIONAL

YORK INTERNATIONAL

Page 29

FORM 150.62-NM1

ELECTRICAL DATA – OPTIONAL SINGLE POINT POWER

YCAL0064SC - YCAL0080SC

SYSTEM #1 COMPRESSOR & FAN SYSTEM #2 COMPRESSOR & FAN

COMPR. #1 COMPR. #2 COMPR. #3 FANS COMPR. #1 COMPR. #2 COMPR. #3 FANS

RLA LRA RLA LRA RLA LRA QTY FLA (EA) RLA LRA RLA LRA RLA LRA QTY FLA (EA)

52.4 298 52.4 298 52.4 298 2 8.2 34.2 265 34.2 265 34.2 265 2 8.2

48.6 298 48.6 298 48.6 298 2 7.8 31.6 265 31.6 265 31.6 265 2 7.8

29.3 235 29.3 235 29.3 235 2 4.8 20.2 155 20.2 155 20.2 155 2 4.8

23.1 170 23.1 170 23.1 170 2 3.8 15.1 120 15.1 120 15.1 120 2 3.8

18.5 140 18.5 140 18.5 140 2 3.1 12.0 80 12.0 80 12.0 80 2 3.1

51.8 298 51.8 298 51.8 298 2 8.2 51.8 298 51.8 298 51.8 298 2 8.2

48.0 298 48.0 298 48.0 298 2 7.8 48.0 298 48.0 298 48.0 298 2 7.8

29.0 235 29.0 235 29.0 235 2 4.8 29.0 235 29.0 235 29.0 235 2 4.8

22.9 170 22.9 170 22.9 170 2 3.8 22.9 170 22.9 170 22.9 170 2 3.8

18.3 140 18.3 140 18.3 140 2 3.1 18.3 140 18.3 140 18.3 140 2 3.1

58.9 420 58.9 420 58.9 420 2 8.2 50.5 298 50.5 298 50.5 298 2 8.2

54.5 420 54.5 420 54.5 420 2 7.8 46.8 298 46.8 298 46.8 298 2 7.8

31.6 235 31.6 235 31.6 235 2 4.8 28.3 235 28.3 235 28.3 235 2 4.8

26.0 175 26.0 175 26.0 175 2 3.8 22.3 170 22.3 170 22.3 170 2 3.8

20.8 140 20.8 140 20.8 140 2 3.1 17.8 140 17.8 140 17.8 140 2 3.1

58.6 420 58.6 420 58.6 420 2 8.2 58.6 420 58.6 420 58.6 420 2 8.2

54.2 420 54.2 420 54.2 420 2 7.8 54.2 420 54.2 420 54.2 420 2 7.8

31.5 235 31.5 235 31.5 235 2 4.8 31.5 235 31.5 235 31.5 235 2 4.8

25.8 175 25.8 175 25.8 175 2 3.8 25.8 175 25.8 175 25.8 175 2 3.8

20.7 140 20.7 140 20.7 140 2 3.1 20.7 140 20.7 140 20.7 140 2 3.1

YORK INTERNATIONAL

Page 30

Installation

OPERATIONAL LIMITATIONS (ENGLISH)

T ABLE 7 – TEMPERATURES AND FLOWS

LEAVING WATER

YCAL00

14SC 40 55 30 60 25 125 20SC 40 55 30 60 25 125 24SC 40 55 35 70 25 125 30SC 40 55 45 75 25 125 34SC 40 55 75 110 25 125 40SC 40 55 75 250 25 125 44SC 40 55 75 250 25 125 50SC 40 55 75 250 25 125 60SC 40 55 75 250 25 125 64SC 40 55 130 390 25 125 70SC 40 55 130 390 25 125 74SC 40 55 130 390 25 125 80SC 40 55 120 430 25 125

TEMPERATURE (°F )

MIN

MAX

COOLER FLOW (GPM

MIN MAX MIN

) AIR ON CONDENSER (°F)

MAX

VOL T AGE LIMITATIONS

Excessive flow will cause damage to the cooler. Do not exceed max. cooler

The following voltage limitations are absolute and operation beyond these limitations may cause serious damage to the compressor.

flow. Special care should be taken when multiple chillers are fed by a single pump.

T ABLE 8 – VOLTAGES

UNIT POWER MIN. MAX.

200-3-60 180 220 230-3-60 207 253 380-3-60 355 415 460-3-60 414 506 575-3-60 517 633

NOTES:

1. Standard units cannot be operated below 40°F leaving chilled water temperature.

2. For leaving water temperature higher than 55°F, contact the nearest YORK Office for application guidelines.

3. The evaporator is protected against freeze-up to -20.0°F with an electrical heater as standard.

4. Operation below 25°F requires Optional Low Ambient Kit for operation to 0°F.

5. Operation above 115°F requires Optional High Ambient Kit for operation to 125°F.

YORK INTERNATIONAL

Page 31

Press. Drop, Ft. H

60.00

50.00

40.00

30.00

20.00

10.00

OPERATIONAL LIMITATIONS (ENGLISH)

Cooler Pressure Drop

YCAL0030

FORM 150.62-NM1

Press. Drop, Ft. H

0.00

40.00

30.00

20.00

10.00

0.00

Flow, GPM

Cooler Pressure Drop

YCAL0034

60 70

Flow, GPM

100

110

120

120 130

130

140

150

LD04966

150

LD04967

T ABLE 9 – COOLER PRESSURE DROP CURVES

MODEL YCAL00 COOLER CURVE

14SC, 20SC, A 24SC B 30SC NEW 34SC NEW 40SC, 44SC, 50SC, 60SC 64SC, 70SC, 74SC D 80SC E

YORK INTERNATIONAL

T ABLE 10 – ETHYLENE GLYCOL CORRECTION

FACT ORS

% WT FACTORS

ETHYLENE POINT

TONS

COMPR. DELTA GPM/

kW P TON

10 .994 .997 1.03 24.1 26 20 .986 .993 1.06 24.9 16 30 .979 .990 1.09 25.9 5 40 .970 .985 1.13 27.3 -10 50 .959 .980 1.16 29.0 -32

FREEZE

F)GLYCOL

(

Page 32

Installation

OPERATIONAL LIMITATIONS (METRIC)

T ABLE 11 – TEMPERATURES AND FLOWS

LEAVING WATER

YCAL00

14SC 4.4 12.8 1.9 3.8 -3.9 51.7 20SC 4.4 12.8 1.9 3.8 -3.9 51.7 24SC 4.4 12.8 2.2 4.4 -3.9 51.7 30SC 4.4 12.8 2.8 4.7 -3.9 51.7 34SC 4.4 12.8 4.7 6.9 -3.9 51.7 40SC 4.4 12.8 4.7 15.8 -3.9 51.7 44SC 4.4 12.8 4.7 15.8 -3.9 51.7 50SC 4.4 12.8 4.7 15.8 -3.9 51.7 60SC 4.4 12.8 4.7 15.8 -3.9 51.7 64SC 4.4 12.8 8.2 24.6 -3.9 51.7 70SC 4.4 12.8 8.2 24.6 -3.9 51.7 74SC 4.4 12.8 8.2 24.6 -3.9 51.7 80SC 4.4 12.8 7.6 27.1 -3.9 51.7

TEMPERA TURE (°C)

MIN

MAX

COOLER FLOW (L/S) AIR ON CONDENSER (°C) MIN MAX MIN

MAX

VOL T AGE LIMITATIONS

Excessive flow will cause damage to the cooler. Do not exceed max. cooler

The following voltage limitations are absolute and operation beyond these limitations may cause serious damage to the compressor.

flow. Special care should be taken when multiple chillers are fed by a single pump.

T ABLE 12 – VOLTAGES

UNIT POWER MIN. MAX.

200-3-60 180 220 230-3-60 207 253 380-3-60 355 415 460-3-60 414 506 575-3-60 517 633

NOTES:

1. Standard units cannot be operated below 4.4°C leaving chilled water temperature.

2. For leaving water temperature higher than 12.8°C, contact the nearest YORK Office for application guidelines.

3. The evaporator is protected against freeze-up to -28.9°C with an electrical heater as standard.

4. Operation below -3.9°C requires Optional Low Ambient Kit for operation to -17.8 °C.

5. Operation above 46.1°C requires Optional High Ambient Kit for operation to 51.7°C.

YORK INTERNATIONAL

Page 33

FORM 150.62-NM1

OPERATIONAL LIMITATIONS (METRIC)

Cooler Press. Drop

180

160

140

120

100

Press. Drop, kPa

YCAL0030

Flow l/s

LD04968

Cooler Pressure Drop

100

90 80 70 60 50

Press. Drop, kPa

40 30 20 10

T ABLE 13 – COOLER PRESSURE DROP CURVES

MODEL YCAL00 COOLER CURVE 14SC, 20SC, 24SC, 30SC 34SC B 40SC, 44SC, 50SC, 60SC 64SC, 70SC, 74SC, D 80SC E

YCAL0034

Flow l/s

T ABLE 14 – ETHYLENE GLYCOL CORRECTION

FACT ORS

% WT

ETHYLE-

GLYCOL kW P TON

TONS

10 .994 .997 1.03 24.1 -3 20 .986 .993 1.06 24.9 -9 30 .979 .990 1.09 25.9 -15 40 .970 .985 1.13 27.3 -23 50 .959 .980 1.16 29.0 -36

FACTORS

COMPR. DELTA GPM/

LD04969

FREEZE

POINT

(

YORK INTERNATIONAL

Page 34

Installation

PHYSICAL DATA (ENGLISH)

YCAL0014SC - YCAL0080SC

T ABLE 15 – PHYSICAL DATA (ENGLISH)

Model YCAL00 14SC 20SC 24SC 30SC 34SC 40SC 44SC Nominal Tons 13.6 17.9 23.3 27.1 34.7 38.2 47.4 Number of Refrigerant Circuits 1111122 Compressors per circuit 2222322 Compressors per unit 2222344 Condenser

Total Face Area ft Number of Rows 2 2 23322 Fins per Inch 14 14 14 14 14 14 14

Condenser Fans

Number of Fans total 2 2 22244 Fan hp/kw 2 / 1.4 2 / 1.4 2 / 1.4 2 / 1.4 2 / 1.4 2 / 1.4 2 / 1.4 Fan RPM 1 140 1140 1140 1 140 1140 1140 1140 Number of Blades 3 3 33333 Total Chiller CFM 16257 16257 23500 23500 23500 47360 47360

Evaporator, Direct Expansion

Diameter x Length 8"x6' 8"x6' 8"x6.5' 8"x7' 10"x7' 11"x8' 11"x8' Water Volume, gallons 9.6 9.6 9.6 10.8 12 24 24 Maximum Water Side Pressure, PSIG 150 150 150 150 150 150 150 Maximum Refrigerant Side Pressure, PSIG 300 300 300 300 300 300 300 Minimum Chiller Water Flow Rate, gpm 30 30 35 45 75 75 75 Maximum Chiller Water Flow Rate, gpm 60 60 70 75 110 250 250 Water Connections, inches 3 3 33444

Shipping Weight

Aluminum Fin Coils, lbs 2152 2168 2356 2560 3007 4123 4222 Copper Fin Coils, lbs 2319 2329 2540 2860 3358 4510 4610

Operating Weight

Aluminum Fin Coils, lbs 2225 2241 2435 2647 3117 4363 4462 Copper Fin Coils, lbs 2392 2402 2619 2947 3468 4750 4850

Refrigerant Charge, R22, ckt1 / ckt2, lbs 32 38 58 65 69 45/45 54/54 Oil Charge, ckt1 / ckt2, gallons 1.7 1.7 2.1 3.5 3.2 2.0/2.0 2.1/2.1

47.2 47.2 66.1 66.1 66.1 128.0 128.0

YORK INTERNATIONAL

Page 35

PHYSICAL DATA (ENGLISH)

YCAL0014SC - YCAL0080SC

50SC 60SC 64SC 70SC 74SC 80SC

49.9 54.0 62.4 69.4 74.0 79.1 22 2 2 22 22 3 3 33 44 6 6 66

128.0 128.0 149.3 149.3 149.3 149.3 23 2 2 33

14 14 14 16 12 14

44 4 4 44

2 / 1.4 2 / 1.4 2 / 1.7 2 / 1.7 2 / 1.7 2 / 1.7

1140 1140 1140 1140 1140 1140

33 3 3 33

47360 46080 55253 55253 54550 53760

FORM 150.62-NM1

11"x8' 11"x8' 14"x8' 14"x8' 14"x8' 14"x8'

24 24 41 41 41 38 150 150 150 150 150 150 300 300 300 300 300 300

75 75 130 130 130 120 250 250 390 390 390 430

44 6 6 66

4300 4596 5207 5322 5569 5819 4688 5275 5735 5925 6247 6611

4540 4836 5501 5616 5863 6128 4928 5515 6029 6219 6541 6919

60/54 72/72 75/62 75/75 92/83 100/100

3.5/2.1 3.5/3.5 3.2/3.0 3.2/3.2 5.2/3.2 5.2/5.2

YORK INTERNATIONAL

Page 36

Installation

PHYSICAL DATA (METRIC)

YCAL0014SC - YCAL0080SC

T ABLE 16 – PHYSICAL DATA (METRIC)

Model YCAL00 14SC 20SC 24SC 30SC 34SC 40SC 44SC Nominal kW 46.8 63.0 82.0 95.3 121.9 135.6 168.0 Number of Refrigerant Circuits 1111122 Compressors per circuit 2222322 Compressors per unit 2222344 Condenser

Total Face Area meters Number of Rows 2223322 Fins per mm 518 518 518 518 518 518 518

Condenser Fans

Number of Fans total 2222244 Fan hp/kw 2 / 1.4 2 / 1.4 2 / 1.4 2 / 1.4 2 / 1.4 2 / 1.4 2 / 1.4 Fan RPM 1 140 1140 1140 1140 1140 1140 1140 Number of Blades 3333333 Total Chiller Airflow l/s 7672 7672 11091 11091 11091 22351 22351

Evaporator, Direct Expansion

Diameter x Length 203x1829 203x1830 203x1981 203x2134 254x2134 279x2438 279x2438 Water Volume, liters 36 36 36 41 45 91 91 Maximum Water Side Pressure, bar 10 10 10 10 10 10 10 Maximum Refrigerant Side Pressure, bar 21 21 21 21 21 21 21 Minimum Chiller Water Flow Rate, l/s 2223555 Maximum Chiller Water Flow Rate, l/s 444571616 Water Connections, inches 3333444

Shipping Weight

Aluminum Fin Coils, kg 976 983 1069 1161 1364 1870 1915 Copper Fin Coils, kg 1052 1057 1152 1297 1523 2046 2091

Operating Weight

Aluminum Fin Coils, kg 1009 1016 1104 1201 1414 1979 2024 Copper Fin Coils, kg 1085 1090 1188 1337 1573 2155 2200

Refrigerant Charge, R22, ckt1 / ckt2, kg 15 17 24 30 31 21/21 25/25 Oil Charge, ckt1 / ckt2, liters 6 6 8 13 12 8.0/8.0 8.0/8.0

446661212

YORK INTERNATIONAL

Page 37

PHYSICAL DATA (METRIC)

YCAL0014SC - YCAL0080SC

50SC 60SC 64SC 70SC 74SC 80SC

177.1 191.6 221.3 246.0 262.6 278.1 222222 223333 446666

12 12 14 14 14 14

232233

518 518 518 518 518 518

444444

2 / 1.4 2 / 1.4 2 / 1.7 2 / 1.7 2 / 1.7 2 / 1.7

1140 1140 1140 1140 1140 1 140

333333

22351 21747 26076 26076 25744 25371

FORM 150.62-NM1

279x2438 279x2438 356x2438 356x2438 356x2438 356x2438

91 91 155 155 155 144 10 10 10 10 10 10 21 21 21 21 21 21

558888

16 16 25 25 25 27

446666

1950 2085 2362 2414 2526 2640 2126 2393 2601 2687 2834 2999

2059 2194 2495 2547 2659 2780 2235 2502 2735 2821 2967 3138

27/25 33/33 34/28 34/34 42/38 46/46

13/8 13/13 12/11.4 12.0/12.0 20/12 20/20

YORK INTERNATIONAL

Page 38

InstallationInstallation

DIMENSIONS (ENGLISH)

YCAL0014SC - YCAL0020SC

LD03848

Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. 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. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'0; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit.

YORK INTERNATIONAL

Page 39

DIMENSIONS (ENGLISH)

YCAL0014SC - YCAL0020SC

FORM 150.62-NM1

LD03847

TABLE 17 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY

MODEL WEIGHT DISTRIBUTION CENTER OF GRA VITY

YCAL00 A B C D TOTAL X Y Z

14SC 587 525 587 525 2225 50.1 25.8 23.3 20SC 591 529 591 529 2241 50.2 25.9 23.2

YORK INTERNATIONAL

Page 40

Installation

DIMENSIONS (ENGLISH)

YCAL0024SC - YCAL0034SC

LD03846

* Refers to Model YCAL0030SC

** Refers to Model YCAL0034SC

Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. 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. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit.

YORK INTERNATIONAL

Page 41

DIMENSIONS (ENGLISH)

YCAL0024SC - YCAL0034SC

FORM 150.62-NM1

LD03845

TABLE 18 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY

MODEL WEIGHT DISTRIBUTION CENTER OF GRAVITY

YCAL00 A B C D TOTAL X Y Z

24SC 636 581 636 581 2435 50.6 25.9 28.5 30SC 692 632 692 632 2647 50.6 25.8 28.9 34SC 868 690 868 690 3129 48.0 25.4 26.9

YORK INTERNATIONAL

Page 42

Installation

DIMENSIONS (ENGLISH)

YCAL0040SC - YCAL0060SC

LD03850

Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. 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. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit.

YORK INTERNATIONAL

Page 43

DIMENSIONS (ENGLISH)

YCAL0040SC - YCAL0060SC

FORM 150.62-NM1

LD03849

TABLE 19 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY

MODEL WEIGHT DISTRIBUTION CENTER OF GRAVITY

YCAL00 A B C D TOTAL X Y Z

40SC 111 0 1071 1110 1071 4363 58.6 40.3 28.9 44SC 1133 1098 1133 1098 4462 58.7 40.3 28.6 50SC 1151 1119 1151 1119 4540 58.8 40.5 28.4 60SC 1217 1201 1217 1201 4836 59.2 40.3 29.9

YORK INTERNATIONAL

Page 44

Installation

DIMENSIONS (ENGLISH)

YCAL0064SC - YCAL0080SC

LD03852

Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. 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. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit.

YORK INTERNATIONAL

Page 45

DIMENSIONS (ENGLISH)

YCAL0064SC - YCAL0080SC

FORM 150.62-NM1

LD03851

TABLE 20 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY

MODEL WEIGHT DISTRIBUTION CENTER OF GRAVITY

YCAL00 A B C D TOTAL X Y Z

64SC 1463 1288 1463 1288 5501 56.3 46.0 30.1 70SC 1492 1315 1492 1315 5616 56.3 45.6 30.1 74SC 1551 1380 1551 1380 5863 56.5 45.9 31.0 80SC 1620 1444 1620 1444 6128 56.6 45.6 30.8

YORK INTERNATIONAL

Page 46

Installation

DIMENSIONS (METRIC)

YCAL0014SC - YCAL0020SC

LD03854

All dimensions in millimeters unless otherwise noted.

Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. 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. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit.

YORK INTERNATIONAL

Page 47

DIMENSIONS (METRIC)

YCAL0014SC - YCAL0020SC

FORM 150.62-NM1

LD03853

All dimensions in millimeters unless otherwise noted.

TABLE 21 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY

MODEL WEIGHT DISTRIBUTION (kg) CENTER OF GRAVITY (mm)

YCAL00 A B C D TOTAL X Y Z

14SC 266 238 266 238 1009 1273 655 592 20SC 268 240 268 240 1016 1275 658 589

YORK INTERNATIONAL

Page 48

Installation

DIMENSIONS (METRIC)

YCAL0024SC - YCAL0034SC

LD03856

All dimensions in millimeters unless otherwise noted.

Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. 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. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit.

YORK INTERNATIONAL

Page 49

DIMENSIONS (METRIC)

YCAL0024SC - YCAL0034SC

FORM 150.62-NM1

LD03855

All dimensions in millimeters unless otherwise noted.

TABLE 22 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY

MODEL WEIGHT DISTRIBUTION CENTER OF GRAVITY

YCAL00 A B C D TOTAL X Y Z

24SC 288 264 288 264 1104 1285 658 724 30SC 314 287 314 287 1201 1285 655 734 34SC 390 317 390 317 1414 1219 645 683

YORK INTERNATIONAL

Page 50

Installation

DIMENSIONS (METRIC)

YCAL0040SC - YCAL0060SC

LD03858

All dimensions in millimeters unless otherwise noted.

Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. 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. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m'; rear to wall – 2m'; control panel to end wall – 1.2m'; top – no obstructions allowed; distance between adjacent units – 3m'. No more than one adjacent wall may be higher than the unit.

YORK INTERNATIONAL

Page 51

DIMENSIONS (METRIC)

YCAL0040SC - YCAL0060SC

FORM 150.62-NM1

LD03857

All dimensions in millimeters unless otherwise noted.

TABLE 23 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY

MODEL WEIGHT DISTRIBUTION CENTER OF GRAVITY

YCAL00 A B C D TOTAL X Y Z

40SC 503 486 503 486 1979 1488 1024 734 44SC 514 498 514 498 2024 1491 1024 726 50SC 522 508 522 508 2059 1494 1029 721 60SC 552 545 552 545 2194 1504 1024 759

YORK INTERNATIONAL

Page 52

Installation

DIMENSIONS (METRIC)

YCAL0064SC - YCAL0080SC

LD03860

All dimensions in millimeters unless otherwise noted.

Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. 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. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit.

YORK INTERNATIONAL

Page 53

DIMENSIONS (METRIC)

YCAL0064SC - YCAL0080SC

FORM 150.62-NM1

LD03859

All dimensions in millimeters unless otherwise noted.

TABLE 24 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY

MODEL WEIGHT DISTRIBUTION CENTER OF GRAVITY

YCAL00 A B C D TOTAL X Y Z

64SC 664 584 664 584 2495 1430 1168 765 70SC 677 596 677 596 2547 1430 1158 765 74SC 704 626 704 626 2659 1435 1166 787 80SC 735 655 735 655 2780 1438 1158 782

YORK INTERNATIONAL

Page 54

Installation

PRE-STARTUP CHECKLIST

JOB NAME: ______________________________ SALES ORDER #: _________________________ LOCA TION: _______________________________ SOLD BY : ________________________________ INSTALLING

CONTRACTOR: ___________________________ ST ART-UP

TECHNICIAN/ COMP ANY : _______________________________

ST ART-UP DA TE : _________________________

CHILLER MODEL #: _______________________ SERIAL #: ________________________________

CHECKING THE SYSTEM PRIOR TO INITIAL START (NO POWER)

Unit Checks

G 1. Inspect the unit for shipping or installation

damage.

G 2. Assure that all piping has been completed. G 3. Visually check for refrigerant piping leaks. G 4. Open suction line ball valve, discharge line

ballvalve, and liquid line valve for each system.

G 5.The compressor oil level should be maintained so

that an oil level is visible in the sight glass.The oil level can only be tested when the compressor is running in stabilized conditions, guaranteeing that there is no liquid refrigerant in the lower shell of the compressor. In this case, the oil should be between 1/4 and 3/4 in the sight glass. At shutdown, the oil level can fall to the bottom limit of the oil sight glass.

G 6. Assure water pumps are on. Check and adjust

water pump flow rate and pressure drop across the cooler (see LIMIT A TIONS). V erify flow switch operation.

Excessive flow may cause catastrophic damage to the evaporator.

G 7. Check the control panel to assure it is free of

foreign material (wires, metal chips, etc.).

G 8. Visually inspect wiring (power and control). Wir-

ing MUST meet N.E.C. and local codes. See Figures 2- 5, pages 14 - 17.

G 9. Check tightness of power wiring inside the power

panel on both sides of the motor contactors and overloads.

G10. Check for proper size fuses in main and control

circuits, and verify overload setting corresponds with RLA and FLA values in electrical tables.

G11. Assure 120V AC Control Power to CTB2 has 15

AMP minimum capacity . See Table 1, page 20.

G12. Be certain all water temp sensors are inserted

completely in their respective wells and are

coated with heat conduc-

tive compound.

G13. Assure that evaporator TXV bulbs are strapped

onto the suction lines at 4 or 8 o’clock positions.

P ANEL CHECKS (POWER ON – BOTH UNIT SWITCH OFF)

G 1. Apply 3-phase power and verify its value. Volt-

age imbalance should be no more than 2% of the average voltage.

G 2. Apply 120VAC and verify its value on the termi-

nal block in the Power Panel. Make the measurement between terminals 5 and 2 of CTB2. The voltage should be 120V AC +/- 10%.

T ABLE 25 – SETPOINTS

OPTIONS

Display Language Sys 1 Switch Sys 2 Switch Unit Type Chilled Liquid Ambient Control Local/ Remote Mode Control Mode Display Units Lead/Lag Control Fan Control Manual Override

COOLING SETPOINTS

Cooling Setpoint Range EMS-PWM Max. Setpoint

PROGRAM

Discharge Pressure Cutout Suct. Pressure Cutout Low Amb. Temp. Cutout Leaving Liquid Temp. Cutout Anti-Recycle Time Fan Control On-Pressure Fan Differential Off-Pressure Total # of Compressors

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Page 55

G 3. Program/verify the Cooling Setpoints, Program

Setpoints, and unit Options. Record the values below (see sections on Setpoints and Unit keys for programming instruction).

FORM 150.62-NM1

The chilled liquid setpoint may need to be temporarily lowered to ensure all compressors cycle “on.”

G 4. Put the unit into Service Mode (as described un-

der the Control Service And Troubleshooting section) and cycle each condenser fan to ensure proper rotation.

G 5. Prior to this step, turn system 2 off (if applicable -

refer to Option 2 under “Unit Keys” section for more information on system switches.) Connect a manifold gauge to system 1 suction and discharge service valves.

Place the Unit Switch in the control panel to the ON position. As each compressor cycles on,

ensure that the discharge pressure rises and the suction pressure decreases. If this does

not occur, the compressor being tested is operating in the reverse direction and must be corrected. After verifying proper compressor rotation, turn the Unit Switch to “OFF.”

The chilled liquid setpoint may need to be temporarily lowered to ensure all compressors cycle “on.”

This unit uses scroll compressors which can only operate in one direction. Failure to observe these steps could lead to compressor failure.

G 7. After verifying compressor rotation, return the Unit

Switch to the off position and ensure that both Systems are programmed for “ON” (refer to Option 2 under “Unit Keys” section for more information on system switches).

INITIAL START-UP

After the preceding checks have been completed and the control panel has been programmed as required in the pre-startup checklist, the chiller may be placed into operation.

G 1. Place the Unit Switch in the control panel to the

ON position.

G 2. The first compressor will start and a flow of re-

frigerant will be noted in the sight glass. After several minutes of operation, the vapor in the sight glass will clear and there should be a solid column of liquid when the TXV stabilizes.

G 3. Allow the compressor to run a short time, being

ready to stop it immediately if any unusual noise or adverse conditions develop.

G 4. Check the system operating parameters. Do this

by selecting various displays such as pressures and temperatures and comparing these readings to pressures and temperatures taken with manifold gauges and temperature sensors.

G 5. With an ammeter, verify that each phase of the

condenser fans and compressors are within the RLA as listed under Electrical Data.

G 6. YCAL0040 - YCAL0080 units only – Turn system

1 off and system 2 on (refer to Option 2 under “Unit Keys” section for more information on system switches.)

Place the Unit Switch in the control panel to the ON position. As each compressor cycles “on,”

ensure that the discharge pressure rises and the suction pressure decreases. If this does

not occur, the compressor being tested is operating in the reverse direction and must be corrected. After verifying proper compressor rotation, turn the Unit Switch to “OFF.”

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CHECKING SUPERHEAT AND SUBCOOLING

The subcooling and superheat should always be checked when charging the system with refrigerant. When the refrigerant charge is correct, there will be no vapor in the liquid sight glass with the system operating under full load conditions, and there will be 15°F (8.34°C) subcooled liquid leaving the condenser. An overcharged system should be guarded against. The temperature of the liquid refrigerant out of the condenser should be no more than 15°F (8.34°C) subcooled at design conditions.

Page 56

Installation

The subcooling temperature of each system can be calculated by recording the temperature of the liquid line at the outlet of the condenser and subtracting it from the liquid line saturation temperature at the liquid stop valve (liquid line saturation temp. is converted from a temperature/pressure chart).

Example:

Liquid line pressure =

202 PSIG converted to 102°F

minus liquid line temp. - 87°F

SUBCOOLING = 15°F

The subcooling should be adjusted to 15°F at design conditions.

G 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

Example:

Suction Temp = 46°F

minus Suction Press

60 PSIG converted to Temp -

Superheat = 12°F

When adjusting the expansion valve, 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 10°F (5.56°C).

G 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

34°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. Correct superheat setting for a system is 10°F (5.56°C) 18" (46 cm) from the cooler.

The superheat is calculated as the difference between 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.

LEAK CHECKING

G 1. Leak check compressors, fittings, and piping to

assure no leaks.

If the unit is functioning satisfactorily during the initial operating period, no safeties trip and the compressors cycle to control water temperature to setpoint, the chiller is ready to be placed into operation.

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UNIT OPERATING SEQUENCE

FORM 150.62-NM1

The operating sequence described below relates to operation on a hot water start after power has been applied, such as start-up commissioning. When a compressor starts, internal timers limit the minimum time before another compressor can start to 1 minute.

1. For the chiller system to run, the Flow Switch must be closed, any remote cycling contacts must be closed, the Daily Schedule must not be scheduling the chiller off, and temperature demand must be present.

2. When power is applied to the system, the microprocessor will start a 2 minute timer. This is the same timer that prevents an instantaneous start after a power failure.

3. At the end of the 2 minute timer, the microprocessor will check for cooling demand. If all conditions allow for start, the first compressor on the lead system will start and the liquid line solenoid will open. The compressor with the least run time in that system will be the first to start. Coincident with the start, the anticoincident timer will be set and begin counting downward from “60” seconds to “0” seconds.

If the unit is programmed for Auto Lead/Lag, the system with the shortest average run-time of the compressors will be assigned as the “lead” system. A new lead/lag assignment is made whenever all systems shut down.

4. Several seconds after the compressor starts, that systems first condenser fan will be cycled on (out-

door air temperature > 25°F (-4°C)). See the section on Operating Controls for details concerning condenser fan cycling.

5. After 1 minutes of compressor run time, the next compressor in sequence will start when a system has to load. This compressor will be the one with the least run time that is currently not running in that system. Additional compressors will be started at 60 second intervals as needed to satisfy temperature setpoint.

6. If demand requires, the lag system will cycle on with the same timing sequences as the lead system. Refer to the section on Capacity Control for a detailed explanation of system and compressor staging.

7. As the load decreases below setpoint, the compressors will be shut down in sequence. This will occur at intervals of either 60, 30, or 20 seconds based on water temperature as compared to setpoint, and control mode. See the section on Capacity Control for a detailed explanation.

8. When the last compressor in a “system” (two or three compressors per system), is to be cycled off, the system will initiate a pump-down. Each “system” has a pump-down feature upon shut-off. On a non-safety , non-unit switch shutdown, the LLSV will be turned off, and the last compressor will be allowed to run until the suction pressure falls below the suction pressure cutout or for 180 seconds, which ever comes first.

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Unit Controls

UNIT CONTROLS

YORK

INTRODUCTION MICROPROCESSOR BOARD

MILLENNIUM

CONTROL CENTER

00065VIP

The YORK MicroComputer Control Center is a microprocessor based control system designed to provide the entire control for the liquid chiller. The control logic embedded in the microprocessor based control system will provide control for the chilled liquid temperatures, as well as sequencing, system safeties, displaying status, and daily schedules. The MicroComputer Control Center consists of four basic components, 1) microprocessor board, 2) transformer, 3) display and 4) keypad. The keypad allows programming and accessing setpoints, pressures, temperatures, cutouts, daily schedule, options, and fault information.

Remote cycling, demand limiting and chilled liquid temperature reset can be accomplished by field supplied contacts.

Compressor starting/stopping and loading/unloading decisions are performed by the Microprocessor to maintain leaving or return chilled liquid temperature. These decisions are a function of temperature deviation from setpoint.

A Master ON/Off switch is available to activate or deactivate the unit.

The Microprocessor Board is the controller and decision maker in the control panel. System inputs such as pressure transducers and temperature sensors are connected directly to the Microprocessor Board. The Microprocessor Board circuitry multiplexes the analog inputs, digitizes them, and scans them to keep a constant watch on the chiller operating conditions. From this information, the Microprocessor then issues commands to the Relay Outputs to control contactors, solenoids, etc. for Chilled Liquid T emperature Control and to react to safety conditions.

Keypad commands are acted upon by the micro to change setpoints, cutouts, scheduling, operating requirements, and to provide displays.

The on-board power supply converts 24VAC from the 1T transformer to a +12VDC and +5VDC regulated supply located on the Microprocessor Board. This voltage is used to operate integrated circuitry on the board. The 40 character display and unit sensors are supplied power from the micro board 5VDC supply .

24VAC is rectified and filtered to provide unregulated +30 VDC to supply the flow switch, PWM remote temperature reset, and demand limit circuitry which is available to be used with field supplied contacts.

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FORM 150.62-NM1

The Microprocessor Board energizes on-board relays to output 120V AC to motor contactors, solenoid valves, etc. to control system operation.

UNIT SWITCH

A UNIT ON/OFF switch is just underneath the keypad. This switch allows the operator to turn the entire unit OFF if desired. The switch must be placed in the ON position for the chiller to operate.

DISPLAY

The 40 Character Display (2 lines of 20 characters) is a liquid crystal display used for displaying system parameters and operator messages.

The display in conjunction with the keypad, allows the operator to display system operating parameters as well as access programmed information already in memory . The display has a lighted background for night viewing and for viewing in direct sunlight.

When a key is pressed, such as the OPER DATA key, system parameters will be displayed and will remain on the display until another key is pressed. The system parameters can be scrolled with the use of the up and down arrow keys. The display will update all information at a rate of about 2 seconds.

Display Messages may show characters indicating “greater than” (>) or “less than” (<). These characters indicate the actual values are greater than or less than the limit values which are being displayed.

KEYPAD

The 12 button non-tactile keypad allows the user to retrieve vitals system parameters such as system pressures, temperatures, compressor running times and starts, option information on the chiller, and system setpoints. This data is useful for monitoring chiller operation, diagnosing potential problems, troubleshooting, and commissioning the chiller.

It is essential the user become familiar with the use of the keypad and display . This will allow the user to make full use of the capabilities and diagnostic features avail- able.

BA TTERY BACK-UP

The Microprocessor Board contains a Real Time Clock integrated circuit chip with an internal battery back-up. The purpose of this battery back-up is to assure any programmed values (setpoints, clock, cutouts, etc.) are not lost during a power failure regardless of the time involved in a power cut or shutdown period.

UNIT STATUS

Pressing the STATUS key will enable the operator to determine current chiller operating status. The messages displayed will include running status, cooling demand, fault status, external cycling device status, load limiting and anti-recycle/coincident timer status. The display will be a single message relating to the highest priority message as determined by the micro. Status messages fall into the categories of General Status and Fault Status.

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Unit Controls

“STATUS” KEY

00066VIP

The following messages are displayed when the “Status” key is pressed. Following each displayed message is an explanation pertaining to that particular display.

GENERAL ST A TUS MESSAGES

In the case of messages which apply to individual systems, SYS 1 and, SYS 2 messages will both be displayed and may be different. In the case of single system units, all SYS 2 messages will be blank.

UNIT SWITCH OFF

SHUTDOWN

This message informs the operator that the UNIT switch on the control panel is in the OFF position which will not allow the unit to run.

REMOTE CONTROLLED

SHUTDOWN

The REMOTE CONTROLLED SHUTDOWN message indicates that either an ISN or BAS system has turned the unit off, not allowing it to run.

DA I LY SCHEDULE

SHUTDOWN

The DAILY SCHEDULE SHUTDOWN message indicates that the daily/holiday schedule programmed is keeping the unit from running.

FLOW SWI TCH/REM STOP

NO RUN PERMISS I VE

NO RUN PERM shows that either the flow switch is open or a remote start/stop contact is open in series with the flow switch.

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FORM 150.62-NM1

SYS 1 SYS SWITCH OFF SYS 2 SYS SWITCH OFF

Sys Switch Off tells that the system switch under OPTIONS is turned off. The system will not be allowed to run until the switch is turned back on.

SYS 1 NO COOL LOAD SYS 2 NO COOL LOAD

These messages inform the operator that the chilled liquid temperature is below the point (determined by the setpoint and control range) that the micro will bring on a system or that the micro has not loaded the lead system far enough into the loading sequence to be ready to bring the lag system ON. The lag system will display this message until the loading sequence is ready for the lag system to start.

SYS 1 COMPS RUN X SYS 2 COMPS RUN X

SYS 1 AC T IMER XX S SYS 2 AC T IMER XX S

The anti-coincident timer is a software feature that guards against 2 systems starting simultaneously . This assures instantaneous starting current does not become excessively high due to simultaneous starts. The micro limits the time between compressor starts to 1 minute regardless of demand or the anti-recycle timer being timed out. The anti-coincident timer is only present on two system units.

SYS 1 DSCH LIMI T ING SYS 2 DSCH LIMI T ING

When this message appears, discharge pressure limiting is in effect. The Discharge Pressure Limiting feature is integral to the standard software control; however the discharge transducer is optional. Therefore, it is important to keep in mind that this control will not function unless the optional discharge transducer is installed in the system.

The COMPS RUNNING message indicates that the respective system is running due to demand. The “X” will be replaced with the number of compressors in that system that are running.

SYS 1 AR T IMER XX S SYS 2 AR T IMER XX S

The anti-recycle timer message shows the amount of time left on the respective systems anti-recycle timer. This message is displayed when the system is unable to start due the anti-recycle timer being active.

The limiting pressure is a factory set limit to keep the system from faulting on the high discharge pressure cutout due to high load or pull down conditions. When the unload point is reached, the micro will automatically unload the affected system by deenergizing one compressor. The discharge pressure unload will occur when the discharge pressure gets within 15 PSIG of the programmed discharge pressure cutout. This will only happen if the system is fully loaded and will shut only one compressor off. If the system is not fully loaded, discharge limiting will not go into effect. Reloading the affected system will occur when the discharge pressure drops to 85% of the unload pressure and 10 minutes have elapsed.

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Unit Controls

SYS 1 SUCT L IMIT I NG SYS 2 SUCT L IMIT I NG

When this message appears, suction pressure limiting is in effect. Suction Pressure Limiting is only available on units that have the suction pressure transducer installed. If a low pressure switch is installed instead, suction pressure limiting will not function.

The suction pressure limit is a control point that limits the loading of a system when the suction pressure drops to within 15% above the suction pressure cutout. On a standard system programmed for 44 PSIG/3.0 Bar suction pressure cutout, the micro would inhibit loading of the affected system with the suction pressure less than or equal to 1.15 * 44 PSIG/3.0 Bar = 50 PSIG/3.5 Bar. The system will be allowed to load after 60 seconds and after the suction pressure rises above the suction pressure limit point.

SYS 1 LOAD LIMI T XX% SYS 2 LOAD LIMI T XX%

This message indicates that load limiting is in effect and the percentage of the limiting in effect. This limiting could be due to the load limit/pwm input or an ISN controller could be sending a load limit command.

expect to see any other STATUS messages when in the MANUAL OVERRIDE mode. MANUAL OVERRIDE is to only be used in emergencies or for servicing. Manual override mode automatically disables itself after 30 minutes.

SYS 1 PUMP I NG DOWN SYS 2 PUMP I NG DOWN

The PUMPING DOWN message indicates that a compressor in the respective system is presently in the process of pumping the system down. When pumpdown is initiated, the liquid line solenoid will close and a compressor will continue to run. When the suction pressure decreases to the suction pressure cutout setpoint, the compressor will cycle off. If pump down cannot be achieved three minutes after the liquid line solenoid closes, the compressor will cycle off.

FAUL T STATUS MESSAGES

Safeties are divided into two categories - system safeties and unit safeties. System safeties are faults that cause the individual system to be shut down. Unit safeties are faults that cause all running compressors to be shut down. Following are display messages and explanations.

MANUAL

OVERRI DE

If MANUAL OVERRIDE mode is selected, the ST A TUS display will display this message. This will indicate that the Daily Schedule is being ignored and the chiller will start-up when chilled liquid temperature allows, Remote Contacts, UNIT switch and SYSTEM switches permitting. This is a priority message and cannot be overridden by anti-recycle messages, fault messages, etc. when in the STATUS display mode. Therefore, do not

SYSTEM SAFETIES

System safeties are faults that cause individual systems to be shut down if a safety threshold is exceeded for 3 seconds. They are auto reset faults in that the system will be allowed to restart automatically after the fault condition is no longer present. However, if 3 faults on the same system occur within 90 minutes, that system will be locked out on the last fault. This condition is then a manual reset. The system switch (under OPTIONS key) must be turned off and then back on to clear the lockout fault.

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Page 63

FORM 150.62-NM1

SYS 1 HIGH DSCH PRES SYS 2 HIGH DSCH PRES

The Discharge Pressure Cutout is a software cutout in the microprocessor and is backed-up by a mechanical high pressure cutout switch located in the refrigerant circuit. It assures that the system pressure does not exceed safe working limits. The system will shutdown when the programmable cutout is exceeded and will be allowed to restart when the discharge pressure falls below the cutout.

Discharge transducers must be in-

stalled for this function to operate.

SYS 1 LOW SUCT PRESS SYS 2 LOW SUCT PRESS

The Suction Pressure Cutout is a software cutout that protects the chiller from an evaporator freeze-up should the system attempt to run with a low refrigerant charge or a restriction in the refrigerant circuit.

At system start, the cutout is set to 10% of programmed value. During the next 3 minutes the cutout point is ramped up to the programmed cutout point. If at any time during this 3 minutes the suction pressure falls below the ramped cutout point, the system will stop.

This cutout is ignored for the first 90 seconds of system run time to avoid nuisance shutdowns, especially on units that utilize a low pressure switch in place of the suction pressure transducer.

of the programmed value and ramps up the cutout over the next 30 seconds. If at any time during this 30 seconds the suction pressure falls below the ramped cutout, the system will stop. This transient protection scheme only works if the suction pressure transducer is installed. When using the mechanical LP switch, the operating points of the LP switch are: opens at 23 PSIG +/- 5 PSIG (1.59 barg +/- .34 barg), and closes at 35 PSIG +/- 5 PSIG (2.62 barg +/- .34 barg).

SYS 1 MP/HPCO FAULT SYS 2 MP/HPCO FAULT

The Motor Protector/Mechanical High Pressure Cutout protect the compressor motor from overheating or the system from experiencing dangerously high discharge pressure. This fault condition is present when CR1 (SYS 1) or CR2 (SYS 2) relays de-energize due to the HP switch or the motor protector opening. This causes the respective CR contacts to open causing 0 VDC to be read on the inputs to the microboard. The fault condition is cleared when a 30 VDC signal is restored to the input.

The internal motor protector opens at 185°F - 248°F (85°C - 120°C) and auto resets. The mechanical HP switch opens at 405 PSIG +/- 10 PSIG (27.92 barg +/.69 barg) and closes at 330 PSIG +/- 25 PSIG (22.75 barg +/- 1.72 barg).

UNIT SAFETIES

After the first 3 minutes, if the suction pressure falls below the programmed cutout setting, a “transient protection routine” is activated. This sets the cutout at 10%

Unit safeties are faults that cause all running compressors to be shut down. Unit faults are auto reset faults in that the unit will be allowed to restart automatically after the fault condition is no longer present.

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Unit Controls

UN I T FAULT :

LOW AMBI ENT TEMP

The Low Ambient Temp Cutout is a safety shutdown designed to protect the chiller from operating in a low ambient condition. If the outdoor ambient temperature falls below the programmable cutout, the chiller will shut down. Restart can occur when temperature rises 2°F above the cutoff.

UN I T FAULT :

LOW L IQU I D TEMP

The Low Leaving Chilled Liquid Temp Cutout protects the chiller form an evaporator freeze-up should the chilled liquid temperature drop below the freeze point. This situation could occur under low flow conditions or if the micro panel setpoint values are improperly programmed. Anytime the leaving chilled liquid temperature (water or glycol) drops below the cutout point, the chiller will shutdown. Restart can occur when chilled liquid temperature rises 2°F above the cutout.

UN I T FAULT :

115VAC UNDER VOLTAGE

Restart is allowed after the unit is fully powered again and the anti-recycle timers have finished counting down.

UNIT WARNING

The following message is not a unit safety and will not be logged to the history buffer . It is a

unit warning

and will not auto-restart. Operator intervention is required to allow a re-start of the chiller.

!! LOW BATTERY !!

CHECK PROG/ SETP / OPTN

The Low Battery Warning can only occur at unit powerup. On micro panel power-up, the RTC battery is checked. If a low battery is found, all programmed setpoints, program values, options, time, schedule, and history buffers will be lost. These values will all be reset to their default values which may not be the desired operating values. Once a faulty battery is detected, the unit will be prevented from running until the PROGRAM key is pressed. Once PROGRAM is pressed the antirecycle timers will be set to the programmed anti-recycle time to allow the operator time to check setpoints, program values, and options.

The Under Voltage Safety assures that the system is not operated at voltages where malfunction of the microprocessor could result in system damage. When the115VAC to the micro panel drops below a certain level, a unit fault is initiated to safely shut down the unit.

If a low battery is detected, it should be replaced as soon as possible. The programmed values will all be lost and the unit will be prevented from running on the next power interruption. The RTC/battery is located at U17 on the microboard.

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STATUS KEY MESSAGES

T ABLE 26 – STATUS KEY MESSAGES

General Messages Fault Messages

FORM 150.62-NM1

STATUS KEY MESSAGES

Unit Switch Off

Shutdown

Remote Controlled

Shutdown

Daily Schedule

Shutdown

Flow Switch/Rem Stop

No Run Permissive

System X Switch Off

System X

No Cooling load

System X Comps Run

System Safeties

System X Low Suct Pressure

System X MP/HPCO Fault 115 VAC Undervoltage

Unit Safeties

Low Ambient TempSystem X High Disch Pressure

Low Liquid Temp

Low Battery

Check Prog/Step/Optn

(Unit Warning Message)

System X AR Timer

System X AC Timer

System X Disch Limiting

System X Suction Limiting

System X Percentage Load Limiting

Manual Overide Status

System X Pumping Down (on shutdown)

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LD04144

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Unit Controls

DISPLAY/PRINT KEYS

The Display/Print keys allow the user to retrieve system and unit information that is useful for monitoring chiller operation, diagnosing potential problems, troubleshooting, and commissioning the chiller.

System and unit information, unit options, setpoints, and scheduling can also be printed out with the use of a printer. Both real-time and history information are available.

OPER DA TA Key

The OPER DATA key gives the user access to unit and system operating parameters. When the OPER DATA key is pressed, system parameters will be displayed and remain on the display until another key is pressed. After pressing the OPER DA T A key , the various operating data screens can be scrolled through by using the UP and DOWN arrow keys located under the “ENTRY” section.

00067VIP

With the “UNIT TYPE” programmed as a liquid chiller (under the Options key), the following is a list of operating data screens in the order that they are displayed:

LCHLT = 46 . 2 ° F RCHLT = 5 7 . 4 ° F

This display shows chilled leaving and return liquid temperatures. The minimum limit on the display for these parameters are 9.2°F (-12.7°C). The maximum limit on the display is 85.4°F (29.7°C).

AMB I ENT A I R TEMP

=87.5° F

This display shows the ambient air temperature. The minimum limit on the display is 0.4°F (-17.6°C).The maximum limit on the display is 131.2°F (55.1°C).

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Page 67

FORM 150.62-NM1

SYS 1 SP = 72.1 PSIG

DP =227.0 PSIG

SYS 2 SP = 73.6 PSIG

DP =219.8 PSIG

These displays show suction and discharge pressures for systems 1 & 2. The discharge pressure transducer is optional on all models

If the

optional

discharge pressure would display 0 PSIG (0 barg). Some models come factory wired with a low pressure

switch in place of the suction transducer. In this case, the suction pressure would only be displayed as the maximum suction pressure reading of >200 PSIG (13.79 barg) when closed, or < 0 PSIG (0 barg) when open.

The minimum limits for the display are: Suction Pressure: 0 PSIG (0 barg) Discharge Pressure: 0 PSIG (0 barg)

discharge transducer is not installed, the

LOAD T IMER = 58 SEC

UNLOAD TI MER = 0 SEC

This display of the load and unload timers indicate the time in seconds until the unit can load or unload. Whether the systems loads or unloads is determined by how far the actual liquid temperature is from setpoint. A detailed description of unit loading and unloading is covered under the topic of Capacity Control.

COOL I NG DEMAND

2 OF 8 STEPS

The display of COOLING DEMAND indicates the current “step” in the capacity control scheme. The number of available steps are determined by how many compressors are in the unit. In the above display, the “2” does not mean that two compressor are running but only indicates that the capacity control scheme is on step 2 of 8. Capacity Control is covered in more detail in this publication which provides specific information on compressor staging.

The maximum limits for the display are: Suction Pressure: 200 PSIG (13.79 barg) Discharge Pressure: 400 PSIG (27.58 barg)

SYS X HOURS 1=XXXXX

2=XXXXX, 3=XXXXX

SYS X STARTS 1=XXXXX

2=XXXXX, 3=XXXXX

The above two messages will appear sequentially for each system. The first display shows accumulated running hours of each compressor for the specific system. The second message shows the number of starts for each compressor on each system.

LEAD SYSTEM I S

SYSTEM NUMBER 2

This display indicates the current LEAD system. In this example system 2 is the LEAD system, making system 1 the LAG compressor. The LEAD system can be manually selected or automatic. Refer to the programming under the “Options” key.

A unit utilizing hot gas bypass should be programmed for MANUAL with system 1 as the lead system. Failure to do so will prevent hot gas operation if system 2 switches to the lead system when programmed for AUTOMATIC LEAD/LAG.

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Unit Controls

EVAP PUMP I S ON

EVAP HEATER I S OFF

This display indicates the status of the evaporator pump contacts and the evaporator heater.

The evaporator pump dry contacts are energized when any compressor is running, or the unit is not OFF on the daily schedule and the unit switch is on, or the unit has shutdown on a Low Leaving Chilled Liquid fault. However, even if one of above is true, the pump will not run if the micro panel has been powered up for less than 30 seconds or if the pump has run in the last 30 seconds to prevent pump motor overheating.

The evaporator heater is controlled by ambient air temperature. When the ambient temperature drops below 40°F the heater is turned on. When the temperature rises above 45°F the heater is turned off. An under voltage condition will keep the heater off until full voltage is restored to the system.

ACTI VE REMOTE CTRL

NONE

SYS X NUMBER OF

COMPS RUNN I NG X

SYS X RUNTIME

XX-XX-XX-XX D-H-M-S

SYS X LLSV I S ON HOT GAS SOL I S OFF

SYS X FAN STAGE 3

The above four message will appear sequentially, first for system 1, then for system 2.

The first message indicates the system and number of compressors that are being commanded on by the micro board.

The second message indicates the system run time in days – hours – minutes – seconds. Please note that this is not accumulated run time but pertains only to the current system cycle.

There are several types of remote systems that can be used to control or monitor the unit. The following messages indicate the type of remote control mode active:

NONE – no remote control active. Remote monitoring

may be via ISN ISN – YorkTalk via ISN (Remote Mode) *LOAD LIM – load limiting enabled. Can be either stage

1 or stage 2 of limiting.

*PWM TEMP – EMS-PWM temperature reset

The third message indicates the system, and whether the liquid line solenoid and hot gas solenoid are being commanded on by the micro board. Please note that hot gas in not available for system 2, so there is no message pertaining to the hot gas solenoid when system 2 message is displayed.

The fourth message indicates what stage of condenser fan operation is active. Unless a low ambient kit is added, only stages 1 and 2 will be used to cycle the condenser fans. However, stage 3 may be shown in this display without a low ambient kit added, but it has no effect.

See the section on Condenser Fan Control in the Unit Operation section.

*Refer to the section on Operating Controls

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OPER DA TA Quick Reference List

The following table is a quick reference list for information available under the OPER DA TA key.

T ABLE 27 – OPERATION DATA

Oper Data Key

Leaving & Chilled Liquid Temps

Ambient Air Temperature

System 1 Discharge & Suction Pressure

FORM 150.62-NM1

System 2 Discharge & Suction Pressure

*System X Accumulated Run Times

*System X Accumulated Starts

Load and Unload Timers

Cooling Demand Steps

Lead System Indicator

Evaporator Pump Contacts & Heater Status

Remote Control Active?

* Block of information repeats for each system

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*System X Number of Comp. Running

*System X Run Time

Sys 1 LLSV & HGSV Status

LD03684

*System X Condenser Fan Staging

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Unit Controls

PRINT Key The PRINT key allows the operator to obtain a printout

of real-time system operating data or a printout of system data at the “instant of the fault” on the last six faults which occurred on the unit. An optional printer is required for the printout.

YORK INTERNATIONAL CORPORATION

MILLENNIUM LIQUID CHILLER

UNIT STATUS

2:04PM 01 JAN 99 SYS 1 NO COOLING LOAD SYS 2 COMPRESSORS RUNNING 2

OPTIONS CHILLED LIQUID WATER AMBIENT CONTROL STANDARD LOCAL/REMOTE MODE REMOTE CONTROL MODE LEAVING LIQUID LEAD/LAG CONTROL AUTOMATIC FAN CONTROL AMB & DSCH PRESS

PROGRAM VALUES DSCH PRESS CUTOUT 395 PSIG SUCT PRESS CUTOUT 44 PSIG LOW AMBIENT CUTOUT 25.0 DEGF LEAVING LIQUID CUTOUT 25.0 DEGF ANTI RECYCLE TIME 600 SECS FAN CONTROL ON PRESS 230 PSIG FAN DIFF OFF PRESS 80 PSIG NUMBER OF COMPRESSORS 6

UNIT DATA RETURN LIQUID TEMP 58.2 DEGF LEAVING LIQUID TEMP 53.0 DEGF DISCHARGE AIR TEMP 55.3 DEGF COOLING RANGE 42.0 +/- 2.0 DEGF SYS 1 SETPOINT 70 +/- 3 PSIG SYS 2 SETPOINT 70 +/-3 PSIG AMBIENT AIR TEMP 74.8 DEGF LEAD SYSTEM SYS 2 EVAPORATOR PUMP ON EVAPORATOR HEATER OFF ACTIVE REMOTE CONTROL NONE SOFTWARE VERSION C.M02.01.00

OPERATING DATA PRINT OUT

Pressing the PRINT key and then OPER DA TA key allows the operator to obtain a printout of current systemoperating parameters. When the OPER DATA key is pressed, a snapshot will be taken of system operating conditions and panel programming selections. This data will be temporarily stored in memory and transmission of this data will begin to the printer. A sample Oper Data printout is shown below.

SYSTEM 1 DATA

COMPRESSORS STATUS OFF RUN TIME 0- 0- 0- 0 D-H-M-S SUCTION PRESSURE 66 PSIG DISCHARGE PRESSURE 219 PSIG SUCTION TEMPERATURE 52.8 DEGF LIQUID LINE SOLENOID OFF HOT GAS BYPASS VALVE OFF CONDENSER FAN STAGES OFF

SYSTEM 2 DATA

COMPRESSORS STATUS 2 RUN TIME 0- 0- 1-46 D-H-M-S SUCTION PRESSURE 51 PSIG DISCHARGE PRESSURE 157 PSIG LIQUID LINE SOLENOID ON CONDENSER FAN STAGES 3

DAILY SCHEDULE

S M T W T F S *=HOLIDAY MON START=00:00AM STOP=00:00AM TUE START=00:00AM STOP=00:00AM WED START=00:00AM STOP=00:00AM THU START=00:00AM STOP=00:00AM FRI START=00:00AM STOP=00:00AM SAT START=00:00AM STOP=00:00AM HOL START=00:00AM STOP=00:00AM

See Service And Troubleshooting section for Printer Installation information.

YORK INTERNATIONAL

Page 71

HISTORY PRINTOUT

Pressing the PRINT key and then the HISTORY key allows the operator to obtain a printout of information relating to the last 6 Safety Shutdowns which occurred. The information is stored at the instant of the fault, regardless of whether the fault caused a lockout to occur. The information is also not affected by power failures (long term internal memory battery back-up is built into the circuit board) or manual resetting of a fault lock-out.

When the HISTORY key is pressed, a printout is transmitted of all system operating conditions which were stored at the “instant the fault occurred” for each of the 6 Safety Shutdowns buffers. The printout will begin with the most recent fault which occurred. The most recent fault will always be stored as Safety Shutdown No. 1. Identically formatted fault information will then be printed for the remaining safety shutdowns.

FORM 150.62-NM1

YORK INTERNATIONAL CORPORATION MILLENNIUM LIQUID CHILLER

SAFETY SHUTDOWN NUMBER 1 SHUTDOWN @ 3:56PM 29 JAN 99

SYS 1 HIGH DSCH PRESS SHUTDOWN SYS 2 NO FAULTS

HISTORY DISPLAYS

The HISTORY key gives the user access to many unit and system operating parameters at the time of a unit or system safety shutdown. When the HISTORY key is pressed the following message is displayed.

Information contained in the Safety Shutdown buffers is very important when attempting to troubleshoot a system problem. This data reflects the system conditions at the instant the fault occurred and often reveals other system conditions which actually caused the safety threshold to be exceeded.

The history printout is similar to the operational data printout shown in the previous section. The differences are in the header and the schedule information. The daily schedule is not printed in a history print.

One example history buffer printout is shown below . The data part of the printout will be exactly the same as the operational data print so it is not repeated here. The difference is that the Daily Schedule is not printed in the history print and the header will be as shown below.

DISPLAYSAFETYSHUT-

DOWN NO . 1 ( 1 TO6 )

While this message is displayed, the UP or DOWN arrow keys can be used to select any of the six history buffers. Buffer number 1 is the most recent, and buf fer number 6 is the oldest safety shutdown that was saved.

After selecting the shutdown number, pressing the ENTER key displays the following message which shows when the shutdown occurred.

SHUT DOWN OCCURRED

11:23 PM 29 MAY 98

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Unit Controls

The UP and DOWN arrows are used to scroll forwards and backwards through the history buffer to display the shutdown conditions. Following is a list of displayed history data screens in the order that they are displayed:

UN I T FAULT :

LOW L IQUI D TEMP

UNI T TYPE

LIQUID CHILLER

CH I LLED L I QUI D

XXXXX

AMB I ENT CONTROL

XXXXXXXXXX

LOCAL / REMOTE MODE

XXXXXXXXX

FAN CONTROL ON

PRESSURE=XXX PSIG

F A N D I F F E R E N T I A L OFF

PRESSURE= PS I G

LCHLT = XXX. X ° F RCHLT = XXX . X ° F

SETPOINT = XX . X ° F

RANGE = + / - ° F

AMB I ENT A I R TEMP

= XXX . X ° F

LEAD SYSTEM I S SYSTEM NUMBER X

CONTROL MODE

LEAVI NG LIQUID

LEAD / LAG CONTROL

XXXXXXXX

FAN CONTROL

DI SCHARGE PRESSURE

MANUAL OVERR I DE MODE

XXXXXXXXX

D I SCHARGE PRESSURE CUTOUT = XXXX PS IG

SUCT ION PRESSURE CUTOUT = XXXX PS IG

EVAP PUMP I S XXX

EVAP HEATER I S XXX

ACTI VE REMOTE CTRL

XXXX

SYS X NUMBER OF

COMPS RUNN I NG X

SYS X RUN TIME

XX-XX-XX-XX D-H-M-S

S YS X SP = XXXX PS IG

DP = XXXX PS IG

SYS X LLSV IS XXX HOT GAS SOL I S XXX

LOW AMBI ENT TEMP

CUTOUT = XXX . X ° F

LEAV ING LIQU I D TEMP

CUTOUT = XXX . X ° F

SYS X FAN STAGE XXX

Explanation of the above displays are covered under the STATUS, DISPLAY/PRINT, SETPOINTS, or UNIT keys.

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Page 73

“ENTRY” KEYS

FORM 150.62-NM1

The Entry Keys allows the user to view, change programmed values. The ENTRY keys consist of an UP ARROW key , DOWN ARROW key , and an ENTER/ADV key.

UP AND DOWN ARROW KEYS

Used in conjunction with the OPER DATA and HISTORY keys, the UP and DOWN arrow keys allow the user to scroll through the various data screens. Refer to the section on “Display/Print” keys for specific information on the displayed information and specific use of the UP and DOWN arrow keys.

The UP and DOWN arrow keys are also used for programming the control panel such as changing cooling

00068VIP

setpoints, setting the daily schedule, changing safety setpoints, chiller options, and setting the clock.

ENTER/ADV key

The ENTER key must be pushed after any change is made to the cooling setpoints, daily schedule, safety setpoints, chiller options, and the clock. Pressing this key “enters” the new values into memory. If the ENTER key is not pressed after a value is changed, the changes will not be “entered” and the original values will be used to control the chiller.

Programming and a description on the use of the UP and DOWN arrow and ENTER/ADV keys are covered in detail under the SETPOINTS, and UNIT keys.

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Unit Controls

“SETPOINTS” KEYS

Unit must first be programmed for “Unit Type” Liquid Chiller under Option S key to allow programming of appropriate setpoints.

Programming of the cooling setpoints, daily schedule, and safeties is accomplished by using the keys located under the SETPOINTS section.

The three keys involved are labeled COOLING SETPOINTS, SCHEDULE/ADV ANCE DA Y, and PROGRAM.

Following are instructions for programming the respective setpoints. The same instruction should be used to view the setpoints with the exception that the setpoint will not be changed.

COOLING SETPOINTS

The Cooling setpoint and Range can be programmed by pressing the COOLING SETPOINTS key. After pressing the COOLING SETPOINTS key, the Cooling Mode (leaving chilled liquid or return chilled liquid) will

00069IP

be displayed for a few seconds, and then the setpoint entry screen will be displayed.

Following are the four possible messages that can be displayed after pressing the COOLING SETPOINT key , indicating the cooling mode:

LOCAL LEAV I NG

WAT ER TEMP CONT ROL

This message indicates that the cooling setpoint is under LOCAL control. That is, the cooling setpoint is controlling to the sage also indicates that the control point is based on LEA VING water temperature out of the evaporator.

WAT ER TEMP CONT ROL

This message indicates that the cooling setpoint is under LOCAL control (the cooling setpoint is controlling to the

locally

like the previous message, it is now indicating that the control point is based on RETURN water temperature into the evaporator.

locally

programmed setpoint. The mes-

LOCAL RETURN

programmed cooling setpoint). However, un-

YORK INTERNATIONAL

Page 75

FORM 150.62-NM1

REM0TE LEAVING

WAT ER TEMP CONT ROL

This message indicates that the cooling setpoint is under REMOTE control. When under remote control, the cooling setpoint will be determined by a remote device such as an ISN control. The message also indicates that the control point is based on LEAVING water temperature out of the evaporator.

REMOTE RETURN

WAT ER TEMP CONT ROL

This message indicates that the cooling setpoint is under REMOTE control. When under remote control, the cooling setpoint will be determined by a remote device such as an ISN control. This message also indicates that the control point is based on RETURN water temperature into the evaporator.

Immediately after the control mode message is displayed, the COOLING SETPOINT entry screen will be displayed. If the unit is programmed for LEA VING liquid control the following message will be displayed:

SETPOINT = 45.0° F

RANGE = +/- 2 . 0 ° F

After using the UP and DOWN arrows to adjust to the desired setpoint, the ENTER/ADV key must be pressed to enter this number into memory and advance to the RANGE SETPOINT.

This will be indicated by the cursor moving under the current RANGE setpoint. The UP and DOWN arrow keys are used to set the RANGE, in .5 °F increments, to the desired RANGE setpoint. After adjusting the setpoint, the ENTER/ADV key must be pressed to enter the data into memory .

Notice that the RANGE was programmed for This indicates the SETPOINT to be in the

+/-

center

X.X° F.

of the control range. If the control mode has been programmed for RETURN LIQUID control, the message below would be displayed in place of the previous message.

SETPOINT = 45.0 ° F

RANGE = +2 . 0 ° F

(return chilled liquid control)

Notice that the range no longer has a a

+ X.X °F

RANGE setpoint. This indicates that the

+/- X.X °F

, but only

setpoint is not centered within the RANGE but could be described as the bottom of the control range A listing of the limits and the programmable values for the COOLING SETPOINTS are shown in Table 27.

(leaving chilled water control)

The above message shows the current chilled water temperature SETPOINT at 45.0°F (notice the cursor positioned under the number 5). Pressing either the UP or DOWN arrow will change the setpoint in .5°F increments.

The SETPOINT and RANGE displays just described were based on LOCAL control. If the unit was programmed for REMOTE control (under the OPTIONS key), the above programmed setpoints would have no effect.

Both LEAVING and RETURN control are described in detail under the section on Capacity Control.

YORK INTERNATIONAL

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Unit Controls

Pressing the COOLING SETPOINTS key a second time will display the remote setpoint and cooling range. This display automatically updates about every 2 seconds. Notice that these setpoints are not “locally” programmable, but are controlled by a remote device such as an ISN control. These setpoints would only be valid if the unit was operating in the REMOTE mode.

The messages below illustrate both leaving chilled liquid control and return chilled liquid control respectively

REM SETP = 44 . 0 ° F

RANGE = + / - 2 . 0 ° F

(leaving chilled liquid control)

REM SETP = 44 . 0 ° F

RANGE = 10 . 0 ° F

(return chilled liquid control)

Pressing the COOLING SETPOINTS a third time will bring up the display that allows the Maximum EMSPWM Temperature Reset to be programmed. This message is shown below.

M A X E M S - P W M R E M O T E

TEMP RESET = + 2 0° F

The T emp Reset value is the maximum allowable reset of the temperature setpoint. The setpoint can be

reset

upwards by the use of a contact closure on the PWM Temp Reset input (CTB1 terminals 13 - 20)). See the section on Operating Controls for a detailed explanation of this feature.

As with the other setpoints, the Up Arrow and Down Arrow keys are used to change the Temp Reset value. After using the UP and DOWN ARROWS to adjust to the desired setpoint, the ENTER/ADV key must be pressed to enter this number into memory.

The low limit, high limit, and default values for the keys under “SETPOINTS” are listed in Table 28.

T ABLE 28 – COOLING SETPOINTS PROGRAMMABLE LIMITS AND DEFAULTS

SETPOINT KEY MODEL LOW LIMIT HIGH LIMIT DEFAULT

WATER COOLING

LEAVING CHILLED LIQUID SETPOINT

GLYCOL COOLING

LEAVING CHILLED LIQUID CONTROL RANGE 0.8

WATER COOLING 40.0°F 70.0°F 44.0°F

RETURNED CHILLED LIQUID SETPOINT

GLYCOL COOLING

RETURN CHILLED LIQUID CONTROL RANGE 2.2°C 11.1°C 5.6°C MAX EMS-PWM REMOTE TEMPERATURE RESET 1.0°C 22.0°C 11.0°C

* Refer to Engineering Guide for operation below 30°F (-1.1°C). Alternate thermal expansion valves must be used

below 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.

—

40.0°F **70.0°F 44.0°F

4.4°C 21.1°C 6.7°C

*10.0°F **70.0°F 44.0°F

-12.2°C 21.1°C 6.7°C

1.5°F 2.5°F 2.0°F

°C 1.4°C 1.1°C

4.4°C 21.1°C 6.7°C

10.0°F 70.0°F 44.0°F

-12.2°C 21.1°C 6.7°C

4.0°F 20.0°F 10.0°F

2°F40°F20°F

YORK INTERNATIONAL

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FORM 150.62-NM1

SCHEDULE/ADV ANCE DA Y key

The SCHEDULE is a seven day daily schedule that allows one start/stop time per day . The schedule can be programmed Monday through Sunday with an alternate holiday schedule available. If no start/stop times are programmed, the unit will run on demand, providing the chiller is not shut off on a unit or system shutdown. The daily schedule is considered “not programmed” when the times in the schedule are all zeros (00:00 AM).

To set the schedule, press the SCHEDULE/ADVANCE DAY

key . The display will immediately show the follow-

ing display .

MON START = 0 0 : 0 0 AM

STOP = 00: 00 AM

The line under the 0 is the cursor. If the value is wrong, it may be changed by using the UP and DOWN arrow keys until correct. Pressing the ENTER/ADV key will enter the times and then move the cursor to the minute box. The operation is then repeated if necessary . This process may be followed until the hour, minutes, and meridian (AM or PM) of both the START and STOP points are set. After changing the meridian of the stop time, pressing the ENTER/ADV key will advance the schedule to the next day .

Whenever the daily schedule is changed for Monday, all the other days will change to the new Monday schedule. This means if the Monday times are not applicable for the whole week then the exceptional days would need to be reprogrammed to the desired schedule.

To page to a specific day press the SCHEDULE/

VANCE DAY

may be programmed differently using the UP and DOWN arrow, and ENTER/ADV keys.

After SUN (Sunday) schedule appears on the display a subsequent press of the SCHEDULE/ADVANCE DAY key will display the Holiday schedule. This is a two part display . The first reads:

HOL START = 0 0 : 0 0 AM

The times may be set using the same procedure as described above for the days of the week. After changing the meridian of the stop time, pressing the ENTER/ ADV key will advance the schedule to the following display:

The line below the empty space next to the S is the cursor and will move to the next empty space when the ENTER/ADV key is pressed. To set the Holiday, the cursor is moved to the space following the day of the week of the holiday and the UP arrow key is pressed. An * will appear in the space signifying that day as a holiday . The * can be removed by pressing the DOWN arrow key.

The Holiday schedule must be programmed weeklyonce the holiday schedule runs , it will revert to the normal daily schedule.

key. The start and stop time of each day

STOP = 00: 00 AM

S _M T W T F S

HOL I DAY NOTED BY *

AD-

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Page 78

Unit Controls

PROGRAM key

There are six operating parameters under the PROGRAM key that are programmable. These setpoints can be changed by pressing the PROGRAM key , and then the ENTER/ADV key to enter ing to press the ENTER/ADV key will display each operating parameter. While a particular parameter is being displayed, the UP and DOWN arrow keys can be used to change the value. After the value is changed, the ENTER/ADV key must be pressed to enter the data into memory. Table 29 shows the programmable limits and default values for each operating parameter.

Following are the displays for the programmable values in the order they appear:

@ D I SCHARGE PRESSURE

CUTOUT = 395 PSIG

DISCHARGE PRESSURE CUTOUT is the discharge pressure at which the system will shutdown as monitored by the software shutdown that acts as a backup for the mechanical high pressure switch located in the refrigerant circuit. The system can restart when the discharge pressure drops 40 PSIG (2.76 BARG) below the cutout point.

If the optional discharge pressure transducer is not installed, this programmable safety would not apply. It should be noted that every system has a high pressure cutout that protects against excessive high discharge pressure regardless of whether or not the optional discharge pressure is installed.

optional

discharge transducer. This is a

Program Mode

. Continu-

mechanical

There are some exceptions when the suction pressure is permitted to temporarily drop below the cutout point. Details are explained under the topic of System Safeties.

LOW AMBI ENT TEMP

CUTOUT = 25 . 0 ° F

The LOW AMBIENT TEMP CUTOUT allows the user to select the chiller outside ambient temperature cutout point. If the ambient falls below this point, the chiller will shut down. Restart can occur when temperature rises 2°F (1.11 °C) above the cutout setpoint.

LEAV ING LIQU I D TEMP

CUTOUT = 36 . 0 ° F

The LEAVING LIQUID TEMP CUTOUT protects the chiller from an evaporator freeze-up. Anytime the leaving chilled liquid temperature drops to the cutout point, the chiller shuts down. Restart will be permitted when the leaving chilled liquid temperature rises 2°F (1.11 °C) above the cutout setpoint.

When water cooling mode is programmed (Options key), the value is fixed at 36.0°F (2.22°C) and cannot be changed. Glycol cooling mode can be programmed to values listed in Table 28.

ANT I RECYCLE T IME

= 600 SEC

SUCT ION PRESSURE

CUTOUT = 44 . 0 PS IG

The SUCTION PRESSURE CUTOUT protects the chiller from an evaporator freeze-up. If the suction pressure drops below the cutout point, the system will shut down.

The anti-recycle timer message shows the amount of time left on the respective systems anti-recycle timer. The programmed ANTI RECYCLE TIME will start to count down at the start of the systems number one compressor. In ef fect, this is the minimum time start-to-start on the respective systems number one compressor.

YORK INTERNATIONAL

Page 79

FORM 150.62-NM1

Another anti-recycle timer is started each time the systems number one compressor cycles off. This anti-recycle time is fixed at 120 seconds and starts to countdown when the systems number one compressor cycles off.

The anti-recycle message is displayed when the system is unable to start due to either of the anti-recycle timers being active (counting down). The actual time displayed will be the longer of the two timers, start-tostart or stop-to-start.

FAN CONTROL ON

PRESSURE= XXXPS I G

The Fan Control On Pressure is the programmed pressure value that is used to stage the condenser fans on, in relation to discharge pressure. Refer to Condenser Fan Control in the UNIT OPERATION section and Tables 38, 39, and 40, 41.

FAN DIFFERENTIAL OFF

PRESSURE = XXX PS I G

The Fan Differential Off Pressure is the programmed differential pressure value that is used to stage the condenser fans off, in relation to discharge pressure. Refer to Condenser Fan Control in the UNIT OPERATION section and Tables 38, 39 and 40, 41.

TOTAL NUMBER OF COMPRESSORS = 6

The TOTAL NUMBER OF COMPRESSORS are the amount of compressors in the chiller, and determines the stages of cooling available. Notice in Table 29 the chiller is a single or dual refrigerant circuit.

This must be programmed correctly to assure proper chiller operation.

T ABLE 29 – PROGRAM KEY LIMITS AND DEFAULTS

PROGRAM VALUE MODEL LOW LIMIT HIGH LIMIT DEFAULT

DISCHARGE PRESSURE CUTOUT

WATER COOLING

SUCTION PRESSURE CUTOUT

GL YCOL COOLING

STANDARD AMBIENT

LOW AMBIENT TEMP. CUTOUT

LEAVING CHILLED LIQUID TEMP . CUTOUT

ANTI-RECYCLE TIMER — 300 SEC. 600 SEC. 600 SEC. FAN CONTROL ON-PRESSURE —

FAN DIFFERENTIAL OFF-PRESSURE —

TOT AL NUMBER OF COMPRESSORS

WATER COOLING — —

GL YCOL COOLING

SINGLE SYSTEM 2 3 3

—

LOW AMBIENT

TWO SYSTEMS 4 6 6

200 PSIG 399 PSIG 395 PSIG

13.8 BARS 27.5 BARS 27.2 BARS

44.0 PSIG 70.0 PSIG 44.0 PSIG

3.03 BARS 4.83 BARS 3.03 BARS

20.0 PSIG 70.0 PSIG 44.0 PSIG

1.38 BARS 4.83 BARS 3.03 BAR

25.0°F 60.0°F 25.0°F

-3.9°C 15.6°C -3.9°C 0°F 60.0°F 25.0°F

-17.8°C 15.6°C -3.9°C 36°F

2.2°C

8.0°F 36.0°F 36.0°F

-13.3°C 2.2°C 2.2°C

225 PSIG 300 PSIG 230 PSIG

15.5 BARS 20.7 BARS 15.9 BARS 50 PSIG 150 PSIG 80 PSIG

3.45 BARS 10.3 BARS 5.52 BARS

YORK INTERNATIONAL

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Unit Controls

T able 30 provides a quick reference of the setpoints list for the Setpoints Keys.

T ABLE 30 – 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. – Sun. Discharge

Water Temp Control & Pressure

(Display Only) Holiday Cutout

Chilled Liquid Suction

Setpoint Pressure

& Cutout

Range

Remote Setpoint Low Ambient Temp.

& Cutout

Range

(Display Only)

EMS - PWM Temperature

Remote T emp Cutout

Reset Setpoint

Schedule

Leaving Liquid

Anti-Recycle

Timer

Fan Control

On-Pressure

Fan Differential

Off-Pressure

Total Numbers

Compressors

LD03685

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Page 81

“UNIT” KEYS

FORM 150.62-NM1

00070VIP

OPTIONS key

There are eleven programmable options (nine for units with a single refrigerant system) under the OPTIONS key . The OPTIONS key is used to scroll through the list of options by repeatedly pressing the OPTIONS key . After the selected option has been displayed, the UP and DOWN arrow keys are then used to change that particular option. After the option is changed, the ENTER/ADV key must be pressed to enter the data into memory. Table 31 shows the programmable options. Following are the displays in the order they appear:

Option 1 – Language

DISPLAY LANGUAGE

ENGL I SH

Option 2 – System Switches (two system units only)

SYS 1 SWITCH ON SYS 2 SWITCH ON

This keeps system 2 off

SYS 1 SWI TCH OFF SYS 2 SWI TCH ON

This keeps system 1 off

Option 3 – Unit Type

UNI T TYPE

LIQUID CHILLER

selected for YCAL Chillers

UNI T TYPE

CONDENS I NG UN I T

selected for YCUL Condensing units.

This allows both systems to run

SYS 1 SWITCH ON SYS 2 SWITCH OFF

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Option 4 – Chilled Liquid Cooling Type

CH I LLED L I QUI D

WAT ER

The chilled liquid is water. The Cooling Setpoint can be programmed from 40°F to 70°F (4.4°C to 21.1°C)

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Unit Controls

ABCDEFGH I JKLMNOPQRST

1234567890° ,./%-()*X

CH I LLED L I QUI D

GLYCOL

The chilled liquid is glycol. The Cooling Setpoint can be programmed from 10°F to 70°F (-12.2°C to 21.1°C).

Option 5 – Ambient Control Type

ABCDEFGH I JKLMNOPQRST

AMB I ENT CONTROL

1234567890° ,./%-()*X

STANDARD

The low ambient cutout is adjustable from 25°F to 60°F (-3.9°C to 15.6°C).

AMB I ENT CONTROL

LOW AMBI ENT

The low ambient cutout is programmable down to 0°F (-17.8°C). A low ambient kit MUST be installed for this option to be chosen.

Option 6 – Local/Remote Control Type

LOCAL / REMOTE MODEL

LOCAL

ate on locally programmed values and ignore all commands from the remote devices. The chiller will communicate and send data to the remote monitoring devices.

LOCAL /REMOTE MODE

REMOTE

This mode should be selected when an ISN or RCC control is to be used to control the chiller. This mode will allow the ISN to control the following items: Remote Start/Stop, Cooling Setpoint, Load Limit, and History Buffer Request. If the unit receives no valid ISN transmission for 5 minutes, it will revert back to the locally programmed values.

Option 7 – Unit Control Mode

CONTROL MODE

RETURN L I QU I D

Unit control is based on return chilled liquid temp. It can only be selected on units that have 4 or 6 compressors (dual system units).

CONTROL MODE

LEAV ING LIQU I D

When programmed for LOCAL, an ISN or RCC control can be used to monitor only . The micro panel will oper-

Unit control is based on leaving chilled liquid temp. Refer to section on Capacity Control for details on load-

ing and unloading sequences.

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FORM 150.62-NM1

Option 8 – Units Type

DISPLAY UNITS

IMPERIAL

Display messages will show units of measure in Imperial units (

°F or PSI

DISPLAY UNITS

Display messages will show units of measure in SI units (°C or Bar).

Option 9 – Lead/Lag Type (two systems only)

LEAD / LAG CONTROL

MANUAL SYS 1 LEAD

SYS 1 selected as lead compressor.

LEAD / LAG CONTROL

MANUAL SYS 2 LEAD

Condenser fans are controlled by ambient tempera-

ure and discharge pressure. This mode must be chosen if the discharge pressure transducers are not installed, or if the fan cycling is a concern.

Option 11 – Manual Override Mode

MANUAL OVERR I DE MODE

DI SABLED

This option allows overriding of the daily schedule that

is programmed. MANUAL OVERRIDE MODE-DISABLED indicates that override mode has no effect.

MANUAL OVERR I DE MODE

ENABLED

Manual Override Mode is enabled. This is a service function and when enabled, will allow the unit to start when shut down on the daily schedule. It will automatically be disabled after 30 minutes.

CLOCK

SYS 2 selected as lead compressor.

LEAD / LAG CONTROL

AUTOMAT I C

In this mode the micro determines which system is assigned to the lead and lag. A new lead/lag assignment is made whenever all compressors shut down. The micro will then assign the “lead” to the compressor with the shortest average run time.

Option 10 – Condensed Fan Control Mode

FAN CONTROL

D I SCHARGE PRESSURE

Condenser fans are controlled by discharge pressure only. This mode may only be chosen when discharge pressure transducers are installed, or if fan cycling is not a concern.

The CLOCK display shows the current day, time, and date. Pressing the CLOCK key will show the current day , time, and date.

It is important that the date and time be correct, otherwise the daily schedule will not function as desired if programmed. In addition, for ease of troubleshooting via the History printouts, the day , time, and date should be correct.

To change the day, time, and date press the CLOCK key. The display will show something similar to the following:

TODAY IS FRI 08 : 51AM

1MAY98

The line under the F is the cursor. If the day is correct, press the ENTER/ADV key . The cursor will move under the 0 in 08 hours. If the day is incorrect, press the UP or DOWN arrow keys until the desired day is displayed and then press the ENTER/ADV key at which time the day will be accepted and the cursor will move under the

0. In a similar manner, the hour , minute, meridian, month, day , and year may be programmed, whenever the cursor is under the first letter/numeral of the item.

FAN CONTROL

AMB I ENT & DSCH PRESS

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Jumper J11 on the microboard must be set to the “CLKON” position to turn on the clock. If this is not done the clock will not function.

Page 84

Unit Controls

Table 31 provides a quick reference list for the Unit key setpoints.

T ABLE 31 – UNIT KEYS PROGRAMMING QUICK REFERENCE LIST

Quick Reference Programming Chart

Unit Keys Section

Options Key Clock

(press key to adv.)

Display Language Day – Time – Date

System Switches

on/off

Unit Type

(Chiller or Condensing Unit)

Chilled Liquid Type

(water or glycol)

Ambient Control

(standard or low)

Local/Remote Mode

Unit Control

Mode

(Based on Unit Type)

Display Units

(English or Metric)

Lead/Lag Control

Fan Control Mode

Override Mode

LD03686

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Page 85

UNIT OPERATION

FORM 150.62-NM1

CAP ACITY CONTROL

To initiate the start sequence of the chiller, all run permissive inputs must be satisfied (flow/remote start/stop switch), and no chiller or system faults exist.

The first phase of the start sequence is initiated by the Daily Schedule Start or a Remote Cycling Device. If the unit is shut down on the daily schedule, the chilled water pump microboard contacts (TB5 3-4) will close when the daily schedule start time has been reached. Once flow has been established and the flow switch closes, capacity control functions are initiated.

If unit cycling is accomplished with a remote cycling device wired in series with the flow switch, the chilled water pump contacts will always be energized as long as the unit switch is turned on. When the flow switch and remote cycling contacts are closed, the capacity control functions will be initiated.

It should be noted that the chilled water pump contacts (TB5 3-4) are not required to be used to cycle the chilled water pump. However, in all cases the flow switch must be closed to allow unit operation.

The control system will evaluate the need for cooling by comparing the actual leaving or return chilled liquid temperature to the desired setpoint, and regulate the leaving or return chilled liquid temperature to meet that desired setpoint.

LEA VING CHILLED LIQUID CONTROL

The setpoint, when programmed for Leaving Chilled Liquid Control, is the temperature the unit will control to within +/- the cooling range. The Setpoint High Limit is the Setpoint plus the Cooling Range. The Setpoint Low Limit is the Setpoint minus the Cooling Range. See Figure 6.

If the leaving chilled liquid temperature is above the Setpoint High Limit, the lead compressor on the lead system will be energized along with the liquid line solenoid. Upon energizing any compressor, the 60 second Anti-Coincidence timer will be initiated.

If after 60 seconds of run-time the leaving chilled liquid temperature is still above the Setpoint High Limit, the next compressor in sequence will be energized. Additional loading stages are energized at a rate of once every 60 seconds if the chilled liquid temperature remains above the Setpoint High Limit. In this case, the load timer will be 60 seconds.

If the chilled liquid temperature falls below the Setpoint High Limit but is greater than the Setpoint Low Limit, loading and unloading do not occur. This area of control is called the control range.

If the chilled liquid temperature drops to less than 0.5°F (.28°C) below the Setpoint Low Limit, unloading occurs at a rate of 60 seconds. If the chilled liquid temperature falls to a value greater than 0.5°F (.28°C) below the Setpoint Low Limit but not greater than 1.5°F (.83°C) below the Setpoint Low Limit, unloading occurs at a rate of 30 seconds. If the chilled liquid temperature falls to a value greater than 1.5°F (.83°C) below the Setpoint Low Limit, unloading occurs at a rate of 20 seconds.

The leaving chilled liquid setpoint is programmable from 40°F to 70°F (4.4°C to 21.1°C) in water chilling mode and from 10°F to 70°F (-12.2°C to 21.1°C) in glycol chilling mode. In both modes, the cooling range can be from +/-1.5°F to +/-2.5°F (+/-.83°C to 1.39°C).

The sequences of Capacity Control (compressor staging) for loading and unloading are shown in Table 32 through Table 35.

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Unit Controls

20 sec. 30 sec. 60 sec. control range 60 sec. unloading unloading unloading (no compressor staging) loading

LWT

42.5°F 43.5°F 44.0°F 46.0°F 48.0° (5.8°C) (6.4°C) (6.7°C) (7.8°C) (8.9°C)

Low Limit Setpoint High limit

Leaving Water Temp. Control – Compressor Staging

Setpoint = 46.0°F (7.8°C) Range = +/- 2°F(1.1°C)

FIG. 6 – LEAVING WATER TEMPERATURE CONTROL

T ABLE 32 – LEAVING CHILLED LIQUID CONTROL FOR 6 COMPRESSORS (8 STEPS)

LEAD SYSTEM LAG SYSTEM

*STEP COMP 1 COMP 2 COMP 3 COMP 1 COMP 2 COMP 3

0 OFF OFF OFF OFF OFF OFF 1 ON+HG OFF OFF SEE NOTE 1 OFF OFF OFF 2 ON OFF OFF OFF OFF OFF 3 ON OFF OFF SEE NOTE 2 ON OFF OFF 4 ON ON OFF SEE NOTE 3 OFF OFF OFF 5 ON ON OFF ON OFF OFF 6 ON ON OFF ON ON OFF 7 ON ON ON ON ON OFF 8 ON ON ON ON ON ON

T ABLE 33 – LEAVING CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS)

LEAD SYSTEM LAG SYSTEM

*STEP COMP 1 COMP 2 COMP 1 COMP 2

0 OFF OFF OFF OFF 1 ON+HG OFF SEE NOTE 1 OFF OFF 2 ON OFF OFF OFF 3 ON OFF SEE NOTE 2 ON OFF 4 ON ON SEE NOTE 3 OFF OFF 5 ON ON ON OFF 6 ON ON ON ON

* STEP can be viewed using the OPER DATA key and scrolling to COOLING DEMAND.

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Page 87

FORM 150.62-NM1

T ABLE 34 – LEAVING CHILLED LIQUID CONTROL FOR 3 COMPRESSORS (SINGLE SYSTEM)

*STEP COMP 1 COMP 2 COMP 3

0 OFF OFF OFF 1 ON+HG OFF OFF SEE NOTE 1 2 ON OFF OFF 3 ON ON OFF 4 ON ON ON

T ABLE 35 – LEAVING CHILLED LIQUID CONTROL FOR 2 COMPRESSORS (SINGLE SYSTEM)

*STEP COMP 1 COMP 2

0 OFF OFF 1 ON+HG OFF SEE NOTE 1 2 ON OFF 3 ON ON

Notes:

1. Step 1 is Hot Gas Bypass and is skipped when loading occurs. Hot Gas Bypass operation is inhibited during Pumpdown. For Leaving Chilled Liquid Control the Hot Gas Bypass solenoid is energized only when the lead compressor is running and the LWT < SP, the Hot Gas Bypass solenoid is turned off when the LWT > SP + CR/2

2. Step 3 is skipped when loading occurs.

3. Step 4 is skipped when unloading occurs.

* STEP can be viewed using the OPER DATA key and scrolling to COOLING DEMAND.

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Unit Controls

RETURN CHILLED LIQUID CONTROL (DUAL SYSTEM 4 AND 6 COMP UNITS ONLY)

Return chilled liquid control is based on staging the compressors to match the cooling load. The chiller will be fully loaded when the return water temperature is equal to the Cooling Setpoint plus the Range Setpoint. The chiller will be totally unloaded (all compressors off) when the return water temperature is equal to the Cooling Setpoint. At return water temperatures between the Cooling Setpoint, and Cooling Setpoint plus Range Setpoint, compressor loading and unloading will be determined by the formulas in Table 37 or Table 38.

Normal loading will occur at intervals of 60 seconds according to the temperatures determined by the formulas. Unloading will occur at a rate of 30 seconds according the temperatures determined in the formulas.

The return chilled liquid setpoint is programmable from 40°F to 70°F (4.4°C to 21.1°C) in water chilling mode and from 10°F to 70°F (-12.2°C to 21.1°C) in glycol chilling mode. In both modes, the cooling range can be from 4°F to 20°F (2.2° to 11.1°C).

determining the separation between segments. Note also that the Cooling Setpoint is the point at which all compressors are off, and Cooling Setpoint plus Range Setpoint is the point all compressors are on. Specifically, if the return water temperature is 55°F (12.8°C), then all compressors will be on, providing full capacity. At nominal gpm, this would provide approximately 45°F (7.2°C) leaving water temperature out of the evaporator.

If the return water temperature drops to 53.3°F (1 1.8°C), one compressor would cycle off leaving five compressors running. The compressors would continue to cycle off approximately every 1.7°F (.94°C), with the excep- tion of hot gas bypass. Notice that the hot gas bypass would be available when the return water temperature dropped to 46.25°F (7.9°C). At this point one compressor would be running.

Should the return water temperature rise from this point to 46.7°F (8.2°C), the hot gas bypass would shut off, still leaving one compressor running. As the load increased, the compressors would stage on every 1.7°F (.94°C).

As an example of compressor staging (refer to Table 36 and T able 37), a chiller with six compressors using a Cooling Setpoint programmed for 45°F (7.20°C) and a Range Setpoint of 10°F (5.56°C). Using the formulas in T able 37, the control range will be split up into six (seven including hot gas) segments, with the Control Range

Also notice that Tables 37 and 38 not only provide the formulas for the loading (ON POINT) and unloading (OFF POINT) of the system, the “STEP” is also shown in the tables. The “STEP” is that sequence in the capacity control scheme that can be viewed under the OPER DA T A key . Please refer to the section on the DISPLA Y/PRINT keys for specific information on the OPER DA TA key.

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Page 89

FORM 150.62-NM1

Compressor Staging for Return Water Control –

6 Compressors

Cooling Setpoint = 45° F (7.2° C) Range = 10° F (5.6° C)

TABLE 36 – COMPRESSOR STAGING FOR RETURN WATER CONTROL

# OF COMP ON 0 *1+HG 123456

RWT

*Unloading only

T ABLE 37 – RETURN CHILLED LIQUID CONTROL FOR 6 COMPRESSORS (8 STEPS)

*STEP COMPRESSOR ON POINT COMPRESSOR OFF POINT

0 1 SETPOINT 2 SP + CR/6 SP + CR/8 SEE NOTE 1 3 SP + 2*CR/6 SP + CR/6 SEE NOTE 2 4 SP + 2*CR/6 SP + CR/6 SEE NOTE 3 5 SP + 3*CR/6 SP + 2*CR/6 6 SP + 4*CR/6 SP + 3*CR/6 7 SP + 5*CR/6 SP + 4*CR/6 8 SP + CR SP + 5*CR/6

45°F 46.25°F 46.7°F 48.3°F 50.0°F 51.7°F 53.4°F 55.0°F

(7.2°C) (7.9°C) (8.2°C) (9.1°C) (10.0°C) (11.0°C) (11.9°C) (12.8°C)

T ABLE 38 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS)

*STEP COMPRESSOR ON POINT COMPRESSOR OFF POINT

0 1 SETPOINT 2 SP + CR/4 SP + CR/8 SEE NOTE 1 3 SP + 2*CR/4 SP + CR/4 SEE NOTE 2 4 SP + 2*CR/4 SP + CR/4 SEE NOTE 3 5 SP + 3*CR/4 SP + 2*CR/4 6 SP + CR SP + 3*CR/4

Notes:

1. Step 1 is Hot Gas Bypass and is skipped when loading occurs. Hot Gas Bypass operation is inhibited during Pumpdown.

2. Step 3 is skipped when loading occurs.

3. Step 4 is skipped when unloading occurs.

* STEP can be viewed using the OPER DATA key and scrolling to COOLING DEMAND.

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Page 90

Unit Controls

EV APORATOR PUMP CONTROL

The evaporator pump dry contacts (CTB2 - terminals 23 - 24) are energized when any of the following conditions are true:

1. Low Leaving Chilled Liquid Fault

2. Any compressor is running

3. Daily Schedule is not programmed OFF and Unit Switch is ON.

The pump will not run if the micro panel has been powered up for less than 30 seconds or if the pump has run in the last 30 seconds to prevent pump motor overheating.

EV APORA T OR HEATER CONTROL

The evaporator heater is controlled by ambient air temperature. When the ambient temperature drops below 40°F (4.4°C) the heater is turned on. When the temperature rises above 45°F (7.2°C) the heater is turned off. An under voltage condition will keep the heater off until full voltage is restored to the system.

CONDENSER FAN CONTROL

Condenser fan operation must be programmed with the Options key under “Fan Control.” Condenser fan control can be selected for Ambient T emp. and Disch. Pressure, or Discharge Pressure Only .

The condenser fan control by “Ambient Temperature and Discharge Pressure” is a feature that is integral to the standard software control. If the optional discharge transducer is not installed, the condenser fans will operate based on outdoor ambient temperature only. See Table 39.

The condenser fan control by “Discharge Pressure” is a feature that can be selected if the discharge pressure transducer is installed and fan recycling is not a concern. Fan control by discharge pressure will work according to Table 40. The fan control on-pressure (ctrl_press) and fan differential off-pressure (diff_press) are programmable under the PROGRAM key.

T ABLE 39 – CONDENSER FAN CONTROL USING OUTDOOR AMBIENT TEMPERATURE AND DISCHARGE

PRESSURE

FAN STAGE ON OFF

1 FAN FWD

2 FANS FWD

DP > ctrl_press + 20 PSIG (1.38 Bars) DP < ctrl_press - diff_press + 20 PSIG (1.38 Bars)

OAT >25° F (-3.9°C) OAT < 20° F (-6.7°C)

OR AND

DP > ctrl_press DP < ctrl_press - diff_press

OAT >45° F (7.2°C) OAT < 40° F (4.4°C)

OR AND

T ABLE 40 – CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONL Y

FAN STAGE ON OFF

1 FAN FWD

2 FANS FWD

DP > ctrl_press + 20 PSIG (1.38 Bars) DP < ctrl_press - diff_press + 20 PSIG (1.38 Bars)

DP > ctrl_press DP < ctrl_press - diff_press

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Page 91

FORM 150.62-NM1

LOW AMBIENT CONDENSER FAN CONTROL

Again, notice that condenser fan operation can be programmed for either “temperature and discharge pres-

For unit operation below 25°F (-3.9°C) a low ambient kit is required. The kit consists of a discharge pressure

sure control,” or “discharge pressure control only” as described under Condenser Fan Control.

transducer(s) and reversing contactors.

The fan control on-pressure (ctrl_press) and the fan def-

With the low ambient kit installed and the unit programmed for low ambient operation, the condenser fans

erential off-pressure (diff_press) are programmable under the PROGRAM key .

will operate as shown in Tables 41 and 42.

T ABLE 41 – LOW AMBIENT CONDENSER FAN CONTROL – AMBIENT TEMPERATURE AND DISCHARGE

PRESSURE CONTROL

FAN STAGE ON OFF

1 FAN REV

1 FAN FWD

2 FANS FWD

DP > ctrl_press + 20 PSIG (1.38 Bars) DP < ctrl_press - diff_press + 20 PSIG (1.38 Bars)

DP > ctrl_press + 40 PSIG (2.76 Bars) DP < ctrl_press - diff_press + 40 PSIG (2.76 Bars)

OAT >25° F (-3.9°C) OAT < 20° F (-6.7°C)

OR AND

DP > ctrl_press DP < ctrl_press - diff_press

OAT >45°F (7.2°C) OAT < 40°F (-4.40°C)

OR AND

OAT > 65°F (18.3°C) OAT < 60°F (15.6°C)

OR AND

T ABLE 42 – LOW AMBIENT CONDENSER FAN CONTROL – DISCHARGE PRESSURE CONTROL

FAN STAGE ON OFF

1 FAN REV DP > ctrl_press DP < ctrl_press - diff_press

1 FAN FWD DP > ctrl_press + 20 PSIG (1.38 Bars) DP < ctrl_press - diff_press + 20 PSIG (1.38 Bars)

2 FANS FWD DP > ctrl_press + 40 PSIG (2.76 Bars) DP < ctrl_press - diff_press + 40 PSIG (2.76 Bars)

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Page 92

Unit Controls

PUMPDOWN (LLSV) CONTROL

Each system has a Pumpdown feature upon shut-off. On a non-safety, non-unit switch shutdown, all compressors but one in the system will be shut off. The LLSV will also be turned off. The final compressor will be allowed to run until the suction pressure falls below the cutout or for 180 seconds, which ever comes first. Manual pumpdown from the keypad is not possible.

LOAD LIMITING

Load Limiting is a feature that prevents the unit from loading beyond the desired value. 2 and 4 compressor units can be load limited to 50%. This would allow only 1 compressor per system to run. 3 and 6 compressor units can be load limited to 33% or 66%. The 66% limit would allow up to 2 compressors per system to run, and the 33% limit would allow only 1 compressor per system to run. No other values of limiting are available.

There are two ways to load limit the unit. The first is through remote communication via an ISN.

Table 43 shows the load limiting permitted for the various number of compressors.

NOTE: Simultaneous operation of Load Limiting and

EMS-PWM Temperature Reset (described on following pages) cannot occur.

COMPRESSOR RUN STATUS Compressor run status is indicated by closure of con-

tacts at CTB2 – terminals 25 to 26 for system 1 and CTB2 – terminals 27 to 28 for system 2.

ALARM ST A TUS

System or unit shutdown is indicated by normally-open alarm contacts opening whenever the unit shuts down on a unit fault, or locks out on a system fault. System 1 alarm contacts are located at CTB2 - terminals 29 to

30. System 2 alarm contacts are located at CTB2 - terminals 31 to 32. The alarm contacts will close when conditions allow the unit to operate.

A second way to load limit the unit is through closing

COMPRESSOR SEQUENCING

contacts connected to the Load Limit (CTB1-T erminals 13-21) and PWM inputs (CTB1-T erminals 13-20). Stage 1 of load limiting involves closing the Load Limit input. Stage 2 of load limiting involves closing both the Load Limit and PWM inputs. The first stage of limiting is either 66% or 50%, depending on the number of compressors on the unit. The second stage of limiting is 33% and is only available on 3 and 6 compressor units.

The unit control will attempt to equalize the total run hours on individual compressors within a system. When a system is about to start, the compressor with the least run time in that system will be the first to start. When the system has to load, the next compressor to start will be the one with the least run time that is currently not running in that system.

T ABLE 43 – COMPRESSOR OPERATION – LOAD LIMITING

COMPRESSORS IN UNIT STAGE 1 STAGE 2

2 50% – 3 66% 33% 4 50% – 6 66% 33%

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Page 93

FORM 150.62-NM1

EMS-PWM REMOTE TEMPERATURE RESET

EMS-PWM Remote Temperature Reset is a value that resets the Chilled Liquid Setpoint based on a PWM input (timed contact closure) to the microboard. This PWM input would typically be supplied by an Energy Management System.

A contact closure on the PWM Temp Reset input at CTB 1 terminals 13 - 20, will reset the chilled liquid setpoint based on the length of time the contacts remain closed. The maximum temperature reset is achieved at a contact closure of 1 1 seconds. This is the longest contact closure time allowed. One second is the shortest time allowed and causes the Chilled Liquid Setpoint to revert back to the Local programmed value. The reset value is always added to the Chilled Liquid Setpoint, meaning that this function never lowers the Chilled Liquid Setpoint below the locally programmed value, it can only reset to a higher value. The microboard must be refreshed between 30 seconds and 30 minutes. Any contact closure occurring sooner than 30 seconds will be ignored. If more than 30 minutes elapse before the next contact closure, the setpoint will revert back to the locally programmed value. The new chilled liquid setpoint is calculated by the following equations:

setpoint = local chilled liquid setpoint + °reset °reset = (Contact Closure - 1) x

(*Max. Reset V alue)

10 Example: Local Chilled Liquid Setpoint = 45°F (7.22°C). *Max Reset V alue = 10°F (5.56°C) Contact Closure Time = 6 Seconds.

(English) (6 sec. - 1) (10°F/10) = 5°F Reset

So...the new chilled liquid setpoint = 45°F + 5°F= 50°F. This can be viewed by pressing the Cooling Setpoints key twice. The new value will be displayed as “REM SETP = 50.0°F.”

(Metric) (6 sec - 1) * (5.56°C/10) = 2.78°C Reset Cooling Setpoint = 7.22°C + 2.78°C = 10.0°C

So...the new reset Cooling Setpoint = 7.22 °C + 2.78°C = 10°C. This can be viewed by pressing the Cooling Setpoints key twice. The new value will be displayed as “REM SETP =

10.0°C.”

BAS/EMS TEMPERA TURE RESET OPTION

The Remote Reset Option allows the Control Center of the unit to reset the chilled liquid setpoint using a 0 - 10 VDC input, a 4-20mA input, or a contact closure input. The Remote Reset circuit board converts the signals mentioned above into pulse width modulated (PWM) signals which the microprocessor can understand. Whenever a reset is called for, the change may be noted by pressing the Cooling Setpoints key twice. The new value will be displayed as “REM SETP = XXX°F”

The optional Remote Reset option would be used when reset of the chilled liquid setpoint is required and a PWM signal (timed contact closure) cannot be supplied by an Energy Management System. The Remote Temp. Reset Board will convert a voltage, current, or contact signal that is available from an EMS to a PWM signal, and every 80 seconds provide a PWM input to the microboard. Figure 3 shows a diagram of the field and factory electrical connections.

If a 0 - 10VDC signal is available, it is applied to terminals A+ and A-, and jumpers are applied to JU4 and JU2 on the reset board. This dc signal is conditioned to a 1 - 11 second PWM output and supplied to the PWM input on the microboard at CTB 1 terminals 13 - 20. To calculate the reset chilled liquid setpoint for values between 0VDC and 10VDC use the following formula:

setpoint = local chilled liquid setpoint + °reset °reset = (dc voltage signal) x (*Max Reset V alue)

10 Example: Local Chilled Liquid Setpoint = 45°F (7.22°C) *Max Reset V alue = 20°F (11.11°C) Input Signal = 6 VDC

(English) °reset = 6VDC x 20°F = 12°F reset

setpoint = 45 °F + 12 °F = 57°F (Metric)

°reset = 6VDC x 1 1. 11°C = 6.67°C reset

setpoint = 7.22°C + 6.67°C = 13.89°C

Max Reset Value is the “Max EMS-PWM Remote Temp. Reset” setpoint value described in the programming section under Cooling Setpoints. Programmable values are from 2°F to 40°F (1.11°C to 22.22°C).

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Page 94

035-15961-000

–

Unit Controls

FIG. 7 – FIELD AND FACT OR Y ELECTRICAL CONNECTIONS

OPTIONAL REMOTE TEMPERATURE RESET BOARD

If a 4-20mA signal is available, it is applied to terminals A+ and A- and jumpers are applied to JU5 and JU3 on the reset board. The mA signal is conditioned to a 1-11 second PWM output. The PWM output is then supplied to the PWM input on the microboard at CTB 1 terminals 13 - 20. To calculate the chilled liquid setpoint for values between 4mA and 20 ma use the following formula:

If the Contact Closure input is used. The connections are made to terminals C and D and only jumper JUI

setpoint = local chilled liquid setpoint + °reset

must be in place on the reset board. This input is used when a

°reset = (mA signal - 4) x (*Max Reset Value)

Example:

are closed, the remote temperature reset board will convert this contact closure to a PWM signal that is applied to CTB 1 terminals 13 - 20.

Local Chilled Liquid Setpoint = 45° (7.22°C) *Max Reset V alue = 10°F (5.56°C) Input Signal = 12 mA

T o set the PWM output, the contacts must be closed on inputs C - D, and potentiometer R11 (located on the front edge of the PC board) is adjusted to 10VDC as mea-

(English) °reset = 8mA x 10°F = 5°F reset

setpoint = 45°F + 5°F = 50°F (Metric)

sured at TP3 to terminal 10 on the circuit board. The reset value will be the “Max EMS-PWM Remote Temp. Reset” setpoint value programmed in the SETPOINTS section under the Cooling Setpoints key .

NOTE: The coil of any added relay used for reset must

°reset = 8mA x 5.56°C = 2.78°C reset

setpoint = 7.22°C + 2.78°C = 10.0°C

035-15961-000

LD03875

A 240-24 Volt Ratio Transformer (T3) is used to derive nominal 12 volt output from the 120 volt supply.

single

reset value is needed. When the contacts

be suppressed to prevent possible component damage. Use YORK PN031-00808-000 suppressor.

* Max Reset Value is the “Max EMS-PWM Remote T emp. Reset” setpoint value described in the programming section under Cooling Setpoints.

Programmable values are from 2°F to 40°F (1.11°C to 11.11°C).

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SERVICE AND TROUBLESHOOTING

FORM 150.62-NM1

CLEARING HISTORY BUFFERS

The history buffers may be cleared by pressing the HISTORY key and then repeatedly pressing the UP arrow key until you scroll past the last history buffer choice. The following message will be displayed:

1 INITIALIZE HISTORY

ENTER = YES

Pressing the ENTER/ADV key at this display will cause the history buffers to be cleared. Pressing any other key will cancel the operation.

SOFTWARE VERSION

The software version may be viewed by pressing the HISTORY key and then repeatedly pressing the DOWN arrow key until you scroll past the first history buffer choice. The following message is an example of what will be displayed:

SOFTWARE VERS ION

C.MMC.01.01

SERVICE MODE

Following is the order of digital outputs that will appear as the ENTER/ADV key is pressed:\

SYS 1 COMPRESSOR 1

SYS 1 LIQUID LINE SOLENOID VALVE

SYS 1 COMPRESSOR 2 SYS 1 COMPRESSOR 3

SYS 1 HOT GAS BYPASS SOLENOID VALVE

SYS 2 COMPRESSOR 1

SYS 2 LIQUID LINE SOLENOID VALVE

SYS 2 COMPRESSOR 2 SYS 2 COMPRESSOR 3

SYS 1 FAN STAGE 1 SYS 1 FAN STAGE 2 SYS 1 FAN STAGE 3 SYS 2 FAN STAGE 1 SYS 2 FAN STAGE 2 SYS 2 FAN STAGE 3

EVAPORATOR HEATER

SYS 1 ALARM SYS 2 ALARM

EVAPORATOR PUMP

SYS 1 & 2 ACCUM RUN TIME/STARTS

Service Mode is a mode that allows the user to view all the inputs to the microboard and enable or disable all of the outputs (except compressors) on the unit. Some internal timers and counters will be viewable and modifiable as well.

T o enter Service Mode, turn the unit switch off and press the following keys in the sequence shown; PROGRAM, UP ARROW, UP ARROW, DOWN ARROW, DOWN ARROW, ENTER.

SERVICE MODE - DIGITAL OUTPUTS

After pressing the key sequence as described, the control will enter the Service Mode permitting the

puts (except compressors), operating hours, and start counters to be viewed/modified

is used to advance through the digital outputs. Using the UP/DOWN ARROW keys will turn the respective digital output on/off.

. The ENTER/ADV key

digital out-

Each display will also show the output connection on the microboard for the respective digital output status shown. For example:

SYS 1 LLSV STATUS

TB3 - 2 I S OFF

This display indicates that the system 1 liquid line solenoid valve is OFF, and the output connection from the microboard is coming from terminal block 3 - pin 2.

Pressing the UP Arrow key will energize the liquid line solenoid valve and OFF will change to ON in the display as the LLSV is energized.

The last display shown on the above list is for the accumulated run and start timers for each system. These values can also be changed using the UP and Down ARROW keys, but under normal circumstances would not be advised.

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Service and Troubleshooting

SERVICE MODE - INPUTS

After entering the Service Mode,

all digital and analog inputs to the microboard can be viewed by pressing the OPER DATA key.

the UP ARROW and DOWN ARROW keys are used to scroll through the analog and digital inputs.

Following is the order of analog and digital inputs that will appear when sequenced with the ARROW keys:

(analog inputs)

After pressing the OPER DATA key,

SYS 1 *SUCT PRESSURE

SYS 1 SPARE

SYS 1 **DISCH PRESSURE SYS 1 SUCT TEMP (YCUL ONLY) SYS 2 SUCT TEMP (YCUL ONLY)

SPARE SPARE

AMBIENT AIR

LEAVING LIQUID

RETURN LIQUID

SYS 2 *SUCTION PRESSURE

SYS 2 SPARE

SYS 2 **DISCH PRESSURE

SYS 1 GRND FLT SYS 2 GRND FLT

(binary inputs)

PWM TEMP RESET INPUT

LOAD LIMIT INPUT

FLOW SW / REM START

SYS 2 ZONE THERM (YCUL ONLY)

SINGLE SYSTEM SELECT

SYS 1 MP / HPCO INPUT SYS 2 MP / HPCO INPUT

The analog inputs will display the input connection, the temperature or pressure, and corresponding input voltage such as:

SYS 1 SUCT PR J4 - 10

2.1VDC=81PSIG

This example indicates that the system 1 suction pressure input is connected to plug 4 - pin 10 (J4-10) on the microboard. It indicates that the voltage is 2.1 volts dc which corresponds to 81 PSIG (5.6 bars) suction pressure.

The digital inputs will display the input connection and ON/OFF status such as:

FLOW SW/REM START

J9-5 IS ON

This indicates that the flow switch/remote start input is connected to plug 9- pin 5 (J9-5) on the microboard, and is ON (ON = +30 VDC unregulated input, OFF = O VDC input on digital inputs).

CONTROL INPUTS/OUTPUTS

Tables 44 and 45 are a quick reference list providing the connection points and a description of the binary and analog inputs respectively . Table 46 lists the connection points for the outputs. All input and output connections pertain to the connections at the microboard.

Figure 8 illustrates the physical connections on the microboard.

* The suction pressure transducer is optional on YCAL0014 - YCAL0060. A low pressure switch is standard on these models in place of the

suction transducer.

** The discharge pressure transducer is optional on all models.

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FORM 150.62-NM1

T ABLE 44 – MICROBOARD BINARY INPUTS

*J9-1 30VDC UNREGULATED SUPPLY J9-2 UNIT ON/OFF SWITCH J9-3 PWM TEMP RESET

OR LOAD LIMIT STAGE 2 ON 3 & 6 COMP UNITS

J9-4 LOAD LIMIT STAGE 1 J9-5 FLOW SWITCH AND REMOTE START / STOP

(SYS 1 ZONE THERMOSTAT - YCUL ONLY)

J9-6 SYSTEM 2 ZONE THERMOSTAT - YCUL ONLY J9-7 SINGLE SYSTEM SELECT

(JUMPER = SINGLE SYS, NO JUMPER=TWO SYS)

J9-8 CR1 (SYS 1 MOTOR PROTECTOR / HIGH

PRESS CUTOUT)

J9-9 CR2 (SYS 2 MOTOR PROTECTOR / HIGH

PRESS CUTOUT)

T ABLE 45 – MICROBOARD ANALOG INPUTS

J4-10 Sys 1 Suction Press Transducer or

Sys 1 Low Press Switch

J4-11 SPARE J4-12 Sys 1 Discharge Pressure Transducer (optional) J5-12 Sys 1 Suction Temp Sensor - YCUL Option J5-13 Sys 2 Suction Temp Sensor - YCUL Option J5-14 SPARE J5-15 SPARE J6-7 Ambient Air Temperature Sensor J6-8 Leaving Chilled Liquid Temperature Sensor

T ABLE 46 – MICROBOARD OUTPUTS

TB3-2 SYSTEM 1 COMPRESSOR 1 TB3-3 SYS 1 LIQUID LINE SOLENOID VALVE TB3-4 SYSTEM 1 COMPRESSOR 2 TB3-5 SYSTEM 1 COMPRESSOR 3 TB3-6 SYSTEM 1 HOT GAS BYPASS VALVE TB3-8 SYSTEM 2 COMPRESSOR 1 TB3-9 SYS 2 LIQUID LINE SOLENOID VALVE TB3-10 SYSTEM 2 COMPRESSOR 2 TB4-1 SYSTEM 2 COMPRESSOR 3 TB4-2 SYS 1 CONDENSER FAN STAGE 1 TB4-4 SYS 1 CONDENSER FAN STAGE 2 TB4-5 SYS 1 CONDENSER FAN STAGE 3 TB4-6 SYS 2 CONDENSER FAN STAGE 1 TB4-8 SYS 2 CONDENSER FAN STAGE 2 TB4-9 SYS 2 CONDENSER FAN STAGE 3 TB4-10 EVAPORA T OR HEATER TB5-1 SYSTEM 1 ALARM TB5-2 SYSTEM 2 ALARM TB5-3 EV APORATOR PUMP STARTER

Return Chilled Liquid Temperature Sensor

J6-9

J7-10

J7-11 SPARE J7-12 Sys 2 Discharge Pressure Transducer (optional) J8-5 Sys 1 Ground Fault Circuit J8-6 Sys 2 Ground Fault Circuit

* The 30 dc unregulated supply is not an input. This voltage originates on the microboard and is used to supply the contacts for the binary

or Discharge Air Temp Sensor - YCUL Only

Sys 2 Suct Press Transducer or Sys 2 Low Press Switch

inputs.

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Service and Troubleshooting

TB5

TB4

TB1 TB2

CLOCK ON/OFF JUMPER

TB3

FIG. 8 – MICROBOARD LA YOUT

00071VIP

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Page 99

FORM 150.62-NM1

CHECKING INPUTS AND OUTPUTS

BINARY INPUTS

Refer to the unit wiring diagram. All binary inputs are connected to J9 of the microboard. The term “binary” refers to two states –- either on or off. As an example, when the flow switch is closed, 30 volts

will be applied to J9, pin 5 (J9-5) of the microboard. If the flow switch is open, 0 volts dc will then be present at J9-5.

Pin 1 of J9 is an age

source

unregulated

30VDC that is the dc volt-

used to supply the dc voltage to the various contacts, unit switch, flow switch, etc. This dc source is factory wired to CTB1, terminal 13. Any switch or contact used as a binary input would be connected to this terminal, with the other end connecting to it’s respective binary input on the microboard. Anytime a switch or contact is closed, 30VDC would be applied to that particular binary input. Anytime a switch or contact is open, 0VDC would be applied to that particular binary input.

Typically, as high as 34VDC could be measured for the dc voltage on the binary inputs. This voltage is in reference to ground. The unit case should be sufficient as a reference point when measuring binary input voltages.

ANALOG INPUTS – T emperature

Refer to the unit wiring diagram. T emperature inputs are connected to the microboard on plug J6. These

analog

inputs represent varying dc signals corresponding to varying temperatures. All voltages are in reference to the unit case (ground). Following are the connections for the temperature sensing inputs:

T ABLE 47 – OUTDOOR AIR SENSOR

TEMPERATURE/VOLTAGE/ RESIST ANCE CORRELATION

TEMP °F VOLTAGE RESISTANCE TEMP C°

0 0.7 85398 -18

5 0.8 72950 -15 10 0.9 62495 -12 15 1.0 53685 -9 20 1.1 46240 -7 25 1.2 39929 -4 30 1.4 34565 -1 35 1.5 29998 2 40 1.7 26099 4 45 1.8 22673 7 50 2.0 19900 10 55 2.2 17453 13 60 2.3 15309 16 65 2.5 13472 18 70 2.6 11881 21 75 2.8 10501 24 80 2.9 9298 27 85 3.1 8250 29 90 3.2 7332 32 95 3.4 6530 35

100 3.5 5827 38 105 3.6 5209 41

110 3.7 4665 43

115 3.8 4184 46 120 3.9 3759 49 125 4.0 3382 52 130 4.1 3048 54

Outside Air Sensor J6-4 = +5VDC regulated supply to sensor.

J6-7 = VDC input signal to the microboard. See Table

47 for voltage readings that correspond to

specific outdoor temperatures.

J6-1 = drain (shield connection = 0VDC)

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Service and Troubleshooting

T ABLE 48 – ENTERING AND LEAVING CHILLED

LIQUID TEMP. SENSOR TEMPERATURE/VOLTAGE/ RESISTANCE CORRELATION

TEMP °F VOLTAGE RESISTANCE TEMP °C

0 1.71 25619 -18 2 1.78 24046 -17 4 1.85 22580 -16 6 1.93 21214 -14

8 2.00 19939 -13 10 2.07 18749 -12 12 2.15 17637 -11 14 2.22 16599 -10 16 2.30 15629 -9 18 2.37 14721 -8 20 2.45 13872 -7 22 2.52 13077 -6 24 2.59 12333 -4 26 2.67 11636 -3 28 2.74 10982 -2 30 2.81 10370 -1 32 2.88 9795 0 34 2.95 9256 1 36 3.02 8750 2 38 3.08 8276 3 40 3.15 7830 4 42 3.21 7411 6 44 3.27 7017 7 46 3.33 6647 8 48 3.39 6298 9 50 3.45 5970 10 52 3.51 5661 11 54 3.56 5370 12 56 3.61 5096 13 58 3.67 4837 14 60 3.72 4593 16 62 3.76 4363 17 64 3.81 4145 18 66 3.86 3941 19 68 3.90 3747 20 70 3.94 3564 21 72 3.98 3392 22 74 4.02 3228 23 76 4.06 3074 24 78 4.10 2928 26 80 4.13 2790 27

Entering Chilled Liquid Sensor J6-6 = +5VDC regulated supply to sensor .

J6-9 = VDC input signal to the microboard. See Table

48 for voltage readings that correspond to

specific liquid temperatures.

J6-3 = drain (shield connection = 0VDC) Leaving Chilled Liquid Temp. Sensor

J6-5 = +5VDC regulated supply to sensor . J6-8 = VDC input signal to the microboard. See Table

48 for voltage readings that correspond to

specific liquid temperatures.

J6-2 = drain (shield connection = 0VDC)

100

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