Johnson Controls York YCRL0064 Owner's manual

Issue Date:
September 30, 2015
YCRL0064 - 0198
REMOTE CONDENSER SCROLL LIQUID CHILLERS
STYLE A (60 Hz)
50 - 170 TONS
175kW THROUGH 597kW
R410A
035-22148-101
Products are produced at a
f a c i l i t y w h o s e q u a l i t y -
management systems are
ISO9001 certified.
WATER-COOLED LIQUID CHILLERS
HERMETIC SCROLL
INSTALLATION, OPERATION, MAINTENANCE Supersedes 150.27-NM1 (511) Form 150.27-NM1 (915)

JOHNSON CONTROLS
2
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
This equipment is a relatively complicated apparatus.
During rigging, installation, operation, maintenance,
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to:
heavy objects, refrigerants, materials under pressure,
rotating components, and both high and low voltage.
Each of these items has the potential, if misused or
handled improperly, to cause bodily injury or death. It
is the obligation and responsibility of rigging, instal-
lation, and 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
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
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
rigging, installation, and operating/service personnel. It
is expected that these individuals possess 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 the on-product labels,
this document and any referenced materials. This in-
dividual shall also be familiar with and comply with
all applicable industry and 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 specific situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Indicates a potentially hazardous situa-
tion which will result in possible injuries
or damage to equipment if proper care is
not taken.
Identies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
External wiring, unless specied as an optional connection in the manufacturer’s product line, is
NOT to be connected inside the micro panel cabinet. Devices such as relays, switches, transducers
and controls and any external wiring must not be installed inside the micro panel. All wiring must
be in accordance with Johnson Controls’ published specications and must be performed only by
a qualied electrician. Johnson Controls will NOT be responsible for damage/problems resulting
from improper connections to the controls or application of improper control signals. Failure to
follow this warning will void the manufacturer’s warranty and cause serious damage to property or
personal injury.

JOHNSON CONTROLS 3
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the John-
son Controls QuickLIT website at http://cgproducts.
johnsoncontrols.com.
It is the responsibility of rigging, lifting, and operating/
service personnel to verify the applicability of these
documents to the equipment. If there is any question
regarding the applicability of these documents, rig-
ging, lifting, and operating/service personnel should
verify whether the equipment has been modified and
if current literature is available from the owner of the
equipment prior to performing any work on the chiller.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
formation and any other changes in spelling, grammar
or formatting are not included.
ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
Unit Replacement Parts 150.27-RP1
All Products - Replacement Parts Electrical Connectors 50.20-RP1
All Products - Replacement Parts Fittings 50.20-RP2

JOHNSON CONTROLS
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FORM 150.27-NM1
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THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS 5
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
TABLE OF CONTENTS
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY .....................................................................13
Introduction.....................................................................................................................................................13
Warranty .........................................................................................................................................................13
Safety .............................................................................................................................................................14
Standards for Safety..............................................................................................................................14
Responsibility for Safety........................................................................................................................14
Misuse Of Equipment .....................................................................................................................................14
Suitability for Application .......................................................................................................................14
Structural Support .................................................................................................................................14
Mechanical Strength .............................................................................................................................14
General Access .....................................................................................................................................14
Pressure Systems .................................................................................................................................14
Electrical................................................................................................................................................15
Rotating Parts........................................................................................................................................15
Sharp Edges..........................................................................................................................................15
Refrigerants and Oils.............................................................................................................................15
High Temperature and Pressure Cleaning ............................................................................................15
Emergency Shutdown ...........................................................................................................................15
SECTION 2 – PRODUCT DESCRIPTION ..............................................................................................................17
Introduction.....................................................................................................................................................17
Compressors ..................................................................................................................................................17
Refrigerant Circuits.........................................................................................................................................17
Evaporator......................................................................................................................................................18
Condenser......................................................................................................................................................18
Refrigerant Circuit ..........................................................................................................................................18
Millennium Control Center..............................................................................................................................18
Programmable Setpoints.......................................................................................................................19
Displayed Data ......................................................................................................................................19
System Safeties ....................................................................................................................................19
Unit Safeties ..........................................................................................................................................19
Power and Control Panels.....................................................................................................................19
Power Panel ..................................................................................................................................19
Accessories and Options................................................................................................................................20
Power Options.......................................................................................................................................20
Single Point Supply Terminal Block ...............................................................................................20
Single Point Non-Fused Disconnect Switch...................................................................................20
Single Point Circuit Breaker ...........................................................................................................20
Multiple Point Circuit Breaker.........................................................................................................20
Control Transformer .......................................................................................................................20
Compressor External Overloads....................................................................................................20
Controls Options....................................................................................................................................20
Building Automation System Interface ...........................................................................................20
Language LCD and Keypad...........................................................................................................20
Heat Exchanger Options .......................................................................................................................20
Flow Switch....................................................................................................................................20
Differential Pressure Switch...........................................................................................................20
Pressure Vessel Codes..................................................................................................................20
Flanges (ANSI/AWWA C-606 Couplings Type)..............................................................................20
Double Thick Insulation..................................................................................................................20

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FORM 150.27-NM1
ISSUE DATE: 09/30/2015
TABLE OF CONTENTS (CONT’D)
Chiller Options.......................................................................................................................................21
Final Paint Overspray ....................................................................................................................21
Service Isolation Valve...................................................................................................................21
Hot Gas By-pass............................................................................................................................21
Compressor Acoustic Sound Blanket.............................................................................................21
Vibration Isolation..................................................................................................................................21
Neoprene Isolation.........................................................................................................................21
One Inch Spring Isolators ..............................................................................................................21
Two Inch Seismic Isolators ............................................................................................................21
Control / Power Panel Components ...............................................................................................................22
Unit Components............................................................................................................................................24
Product Identification Number (Pin) ...............................................................................................................25
Refrigerant Flow Diagram - YCRL (Standard)................................................................................................29
Refrigerant Flow Diagram - YCRL (European)...............................................................................................30
SECTION 3 – TRANSPORTATION, HANDLING AND STORAGE ........................................................................31
Delivery and Storage......................................................................................................................................31
Inspection .......................................................................................................................................................31
Moving the Unit ..............................................................................................................................................31
Lifting by Crane / Hoist ..........................................................................................................................31
Lifting Weights................................................................................................................................................32
SECTION 4 – INSTALLATION................................................................................................................................33
Installation Checklist.......................................................................................................................................33
Location Requirements ..................................................................................................................................33
Unit Isolation (Noise Sensitive Location)........................................................................................................33
Foundation .....................................................................................................................................................33
Installation Of Vibration Isolators ...................................................................................................................34
Chilled Liquid Pipework Connection...............................................................................................................34
General Requirements ..........................................................................................................................34
Water Treatment.............................................................................................................................................36
Glycol Solutions.....................................................................................................................................36
Option Flanges ...............................................................................................................................................36
Refrigerant Relief Valve Piping.......................................................................................................................36
Condenser Relief Valve..................................................................................................................................36
Pipework Arrangement ...................................................................................................................................37
Connection Types And Sizes..........................................................................................................................37
Cooler Connections...............................................................................................................................37
Remote Condenser Piping .............................................................................................................................38
Refrigerant Line Losses .................................................................................................................................38
Pressure Drop Considerations .......................................................................................................................38
Refrigerant Line Sizing ...................................................................................................................................38
Chiller Below Condenser.......................................................................................................................39
Condenser Below Chiller.......................................................................................................................39
Oil Traps .........................................................................................................................................................39
Refrigerant Charge.........................................................................................................................................39
Refrigerant Piping Reference .........................................................................................................................39
R-410A Copper Line Sizing ...................................................................................................................39
YCRL Line Sizing Notes ........................................................................................................................39

JOHNSON CONTROLS 7
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
TABLE OF CONTENTS (CONT’D)
Electrical Connection......................................................................................................................................42
Remote Emergency Stop Device ..........................................................................................................42
Chilled Liquid Pump (CLP) (Evaporator Pump Start Contacts).............................................................42
System Run Contacts............................................................................................................................42
System Alarm (SA) (System Alarm Contacts) .......................................................................................42
Field Wiring ....................................................................................................................................................42
YCRL Connection Sizes ........................................................................................................................42
YCRL Chiller Charge Capability ............................................................................................................43
Control Panel Wiring ......................................................................................................................................43
Flow Switch (SF) ...................................................................................................................................43
Remote Start/Stop.................................................................................................................................43
Power Wiring ..................................................................................................................................................44
Units with Single-Point Power Supply Wiring ........................................................................................44
Units with Multi Point Power Supply Wiring...........................................................................................44
Control Transformer Primary Voltage Tappings.....................................................................................44
Compressor Heaters ......................................................................................................................................44
Relief Valves...................................................................................................................................................44
High Pressure Cutout .....................................................................................................................................44
Control Wiring.................................................................................................................................................45
SECTION 5 – TECHNICAL DATA ..........................................................................................................................47
Operational Limitations (English and SI) ........................................................................................................47
Voltage Limitations ................................................................................................................................47
Pressure Drop Charts.....................................................................................................................................48
Ethylene and Propolyne Glycol Correction Factors........................................................................................49
Evaporator Pressure Drop.....................................................................................................................49
Physical Data - Standard And High Efficiency - English.................................................................................50
Electrical Data - Single Point..........................................................................................................................52
Electrical Data - Dual Point ............................................................................................................................54
Single-Point Supply Connection – Terminal Block, Non-Fused Disconnect Switch Or Circuit Breaker ......... 56
Dual-Point Supply Connection – Terminal Block, Non-Fused Disconnect Switch Or Circuit Breaker ............57
Electrical Data ................................................................................................................................................58
Electrical Notes ..............................................................................................................................................59
Elementary Wiring Diagram ...........................................................................................................................62
Wiring Diagrams.............................................................................................................................................62
Unit Dimensions - English - Four Compressor ...............................................................................................83
Unit Dimensions - English - Six Compressor .................................................................................................84
Isolator Selection Data ...................................................................................................................................85
Isolator Information.........................................................................................................................................86
One Inch Deflection Spring Isolators Installation Instructions ........................................................................ 87
Installation of Duralene Vibration Isolators.....................................................................................................89
Seismic Isolator Installation and Adjustment ..................................................................................................91
SECTION 6 – COMMISSIONING............................................................................................................................93
General...........................................................................................................................................................93
Preparation – Power Off.................................................................................................................................93
Inspection .............................................................................................................................................93
Refrigerant Charge................................................................................................................................93
Service and Oil Line Valves...................................................................................................................93

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FORM 150.27-NM1
ISSUE DATE: 09/30/2015
TABLE OF CONTENTS (CONT’D)
Compressor Oil .....................................................................................................................................93
Isolation / Protection..............................................................................................................................93
Control Panel.........................................................................................................................................93
Power Connections ...............................................................................................................................93
Grounding..............................................................................................................................................94
Supply Voltage ......................................................................................................................................94
Preparation – Power On.................................................................................................................................94
Switch Settings......................................................................................................................................94
Compressor Heaters .............................................................................................................................94
Water System........................................................................................................................................94
Flow Switch ...........................................................................................................................................94
Temperature Sensor(s)..........................................................................................................................94
Equipment Pre Start-Up And Start-Up Checklist ............................................................................................95
Pre Start-up ...........................................................................................................................................95
Checking The System Prior To Initial Start (No Power) .................................................................95
Unit Checks....................................................................................................................................95
Compressor Heaters (Power On – 24 Hours Prior To Start)..........................................................95
Start-up..................................................................................................................................................95
Panel Checks (Power On – Unit switch Off) ..................................................................................95
Checking Superheat And Subcooling.............................................................................................................97
Leak Checking................................................................................................................................................97
Unit Operating Sequence ...............................................................................................................................98
SECTION 7 – UNIT CONTROLS............................................................................................................................99
Introduction.....................................................................................................................................................99
IPU II and I/O Boards ............................................................................................................................99
Unit Switch ..........................................................................................................................................100
Display.................................................................................................................................................100
Keypad ................................................................................................................................................100
Battery Back-up...................................................................................................................................100
Transformer ........................................................................................................................................100
Programming # of Compressors .........................................................................................................100
Status Key ....................................................................................................................................................101
Unit Status...........................................................................................................................................101
General Status Messages ...................................................................................................................101
Fault Safety Status Messages.............................................................................................................103
System Safeties ...........................................................................................................................103
Unit Safeties.................................................................................................................................104
Unit Warning........................................................................................................................................105
Status Key Messages..........................................................................................................................106
Display/Print Keys ........................................................................................................................................107
Oper Data Key.....................................................................................................................................107
Oper Data Quick Reference List .................................................................................................. 110
Print Key.............................................................................................................................................. 111
Operating Data Printout ............................................................................................................... 111
History Printout ............................................................................................................................ 112
History Displays................................................................................................................................... 112
Software Version.......................................................................................................................... 114
Entry Keys .................................................................................................................................................... 115
Up and Down Arrow Keys ................................................................................................................... 115
Enter/Adv Key ..................................................................................................................................... 115

JOHNSON CONTROLS 9
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
TABLE OF CONTENTS (CONT’D)
Setpoints Keys ............................................................................................................................................. 116
Cooling Setpoints ................................................................................................................................ 116
Leaving Chilled Liquid Control ..................................................................................................... 116
Return Chilled Liquid Control ....................................................................................................... 117
Remote Setpoint Control.............................................................................................................. 117
Schedule/Advance Day Key................................................................................................................ 117
Program Key ....................................................................................................................................... 119
System Trip Volts .........................................................................................................................120
Unit Trip Volts...............................................................................................................................121
Unit Keys .....................................................................................................................................................123
Options Key.........................................................................................................................................123
Option 1 – Language ...................................................................................................................123
Option 2 – System Switches ........................................................................................................123
Option 3 – Chilled Liquid Cooling Type........................................................................................123
Option 4 – Ambient Control Type .................................................................................................124
Option 5 – Local/Remote Control Type........................................................................................124
Option 6 – Unit Control Mode ......................................................................................................124
Option 7 – Display Units ..............................................................................................................124
Option 8 – Lead/Lag Type (two system units only) ......................................................................124
Option 9 – Condenser Fan Control Mode ...................................................................................124
Option 10 – Manual Override Mode.............................................................................................125
Option 11 – Current Feedback Options Installed .........................................................................125
Option 12 – Power Fail Restart....................................................................................................125
Option 13 – Soft Start Enable/Disable .........................................................................................125
Option 14 – Unit Type ..................................................................................................................125
Option 15 – Refrigerant Type.......................................................................................................126
Option 16 – Expansion Valve Type ..............................................................................................126
Option 17 – Flash Card Update ...................................................................................................126
Option 18 – Remote Temperature Reset .....................................................................................126
Option 19 – Pump Control ...........................................................................................................127
Option 20 – Pump Selection ........................................................................................................127
Clock ...................................................................................................................................................127
SECTION 8 – UNIT OPERATION .........................................................................................................................129
Capacity Control...........................................................................................................................................129
Suction Pressure Limit Controls ...................................................................................................................129
Discharge Pressure Limit Controls...............................................................................................................129
Leaving Chilled Liquid Control......................................................................................................................129
Leaving Chilled Liquid Control Override To Reduce Cycling........................................................................130
Leaving Chilled Liquid System Lead/Lag And Compressor Sequencing .....................................................130
Return Chilled Liquid Control .......................................................................................................................131
Return Chilled Liquid System Lead/Lag And Compressor Sequencing ....................................................... 132
Anti-Recycle Timer .......................................................................................................................................132
Anti-Coincidence Timer ................................................................................................................................133
Evaporator Pump Control And York Hydro Kit Pump Control.......................................................................133
Evaporator Heater Control ...........................................................................................................................133
Pumpdown Control.......................................................................................................................................133
Load Limiting ................................................................................................................................................133
Compressor Run Status ...............................................................................................................................133
Alarm Status.................................................................................................................................................134
EMS-PWM Remote Temperature Reset.......................................................................................................134
Bas/Ems Temperature Reset Using A Voltage Or Current Signal ................................................................134
VDC Pressure Setting Guidelines ................................................................................................................135

JOHNSON CONTROLS
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FORM 150.27-NM1
ISSUE DATE: 09/30/2015
TABLE OF CONTENTS (CONT’D)
SECTION 9 – SERVICE AND TROUBLESHOOTING..........................................................................................137
Clearing History Buffers................................................................................................................................137
Service Mode ...............................................................................................................................................137
Service Mode – Outputs...............................................................................................................................137
Service Mode – Chiller Configuration...........................................................................................................138
Service Mode – Analog And Digital Inputs ...................................................................................................138
Control Inputs/Outputs .................................................................................................................................139
Microboard Layout........................................................................................................................................140
Checking Inputs And Outputs.......................................................................................................................141
Digital Inputs........................................................................................................................................141
Analog Inputs – Temperature ..............................................................................................................141
Liquid and Refrigerant Sensor Test Points .........................................................................................141
Analog Inputs – Pressure ....................................................................................................................142
Digital Outputs.....................................................................................................................................143
Optional Printer Installation ..........................................................................................................................144
Parts ....................................................................................................................................................144
Assembly and Wiring...........................................................................................................................144
Obtaining a Printout.............................................................................................................................144
Troubleshooting............................................................................................................................................145
SECTION 10 – MAINTENANCE...........................................................................................................................147
Important ......................................................................................................................................................147
Compressors ................................................................................................................................................147
Oil Level Check ...................................................................................................................................147
Oil Analysis..........................................................................................................................................147
Operating Parameters ..................................................................................................................................147
On-Board Battery Back-Up...........................................................................................................................147
Overall Unit Inspection .................................................................................................................................147
Bacnet, Modbus And Yorktalk 2 Communications........................................................................................148
BACnet and Modbus Communications ...............................................................................................151
Analog Write Points .....................................................................................................................151
Binary Write Points ......................................................................................................................151
Analog Read Only Points.............................................................................................................151
Binary Monitor Only Points ..........................................................................................................151
Communications Data Map Notes.......................................................................................................151
Yorktalk 2 Communications .................................................................................................................155
Received Data (Control Data)......................................................................................................155
Transmitted Data..........................................................................................................................155
Temperature Conversion Chart ....................................................................................................................159
R410-A Pressure Temperature Chart ...........................................................................................................160
Temperature .................................................................................................................................................161

JOHNSON CONTROLS 11
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
LIST OF FIGURES
FIGURE 1 - YCRL Water Cooled Liquid Chiller.......................................................................................................17
FIGURE 2 - Control/Panel Components..................................................................................................................22
FIGURE 3 - Control Power Panel Components ......................................................................................................23
FIGURE 4 - Unit Components.................................................................................................................................24
FIGURE 5 - Refrigerant Flow Diagram (Standard)..................................................................................................29
FIGURE 6 - Refrigerant Flow Diagram (European).................................................................................................30
FIGURE 7 - Chiller Rigging And Lifting Weights......................................................................................................32
FIGURE 8 - Victaulic - Adapter Flanges ..................................................................................................................36
FIGURE 9 - Chilled Liquid System ..........................................................................................................................37
FIGURE 10 - Pipework Arrangements Legend........................................................................................................37
FIGURE 11 - Cooler Connections ...........................................................................................................................37
FIGURE 12 - Example Of Typical Effect Of Suction And Discharge Line Pressure Drop
On Capacity And Power (Ashrae)......................................................................................................38
FIGURE 13 - Control Wiring....................................................................................................................................45
FIGURE 14 - Evaporator Water Pressure Drop Curves (English and SI) ...............................................................48
FIGURE 15 - Glycol Solution Strengths ..................................................................................................................49
FIGURE 16 - Single Point Power Supply Connection – Standard Unit ................................................................... 56
FIGURE 17 - Dual Point Power Supply Connection – Optional ..............................................................................57
FIGURE 18 - Standard Power, Single Point And Multiple Point Control Panel Wiring,
4 Compressor Unit.............................................................................................................................62
FIGURE 19 - Standard Power, Single Point And Multiple Point Control Panel Wiring,
6 Compressor Unit.............................................................................................................................64
FIGURE 20 - Standard Power And Single Point Power Circuit, 4 Compressor Unit ............................................... 66
FIGURE 21 - Multiple Point Power Circuit, 4 Compressor Unit...............................................................................67
FIGURE 22 - Standard Power And Single Point Power Circuit, 6 Compressor Unit ............................................... 68
FIGURE 23 - Multiple Point Power Circuit, 6 Compressor Unit...............................................................................69
FIGURE 24 - Standard Power And Single Point Connection Wiring Diagram, 4 Compressor Unit ........................70
FIGURE 25 - Multiple Point Power Connection Wiring Diagram, 4 Compressor Unit.............................................72
FIGURE 26 - Standard Power And Single Point Connection Wiring Diagram, 6 Compressor Unit ........................74
FIGURE 27 - Multiple Point Connection Wiring Diagram, 6 Compressor Unit ........................................................76
FIGURE 28 - Standard Power, Single Point And Multiple Point Elementary Wiring Diagram Details,
4 Compressor ....................................................................................................................................78
FIGURE 29 - Standard Power, Single Point And Multiple Point Elementary Wiring Diagram Details,
6 Compressor ....................................................................................................................................80
FIGURE 30 - EEV Controller Wiring........................................................................................................................82
FIGURE 31 - Status Key Messages Quick Reference List....................................................................................106
FIGURE 32 - Operation Data ................................................................................................................................ 110
FIGURE 33 - Setpoints Quick Reference List .......................................................................................................122
FIGURE 34 - Unit Keys Options Programming Quick Reference List...................................................................128
FIGURE 35 - Leaving Water Temperature Control Example.................................................................................129
FIGURE 36 - Setpoint Adjust.................................................................................................................................130
FIGURE 37 - Microboard Layout...........................................................................................................................140
FIGURE 38 - I/O Board Relay Contact Architecture..............................................................................................143
FIGURE 39 - Printer To Microboard Electrical Connections..................................................................................144
FIGURE 40 - Micro Panel Connections.................................................................................................................149

JOHNSON CONTROLS
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FORM 150.27-NM1
ISSUE DATE: 09/30/2015
LIST OF TABLES
TABLE 1 - Condenser / Cooler Connections ..........................................................................................................37
TABLE 2 - Discharge And Liquid Line Capacities In Tons For Refrigerant 410A.................................................... 40
TABLE 3 - Minimum Refrigeration Capacity In Tons For Oil Entrain Up Hot Gas Risers (Type L Copper Tubing) .41
TABLE 4 - YCRL Connection Line Sizes ................................................................................................................43
TABLE 5 - YCRL Chiller Charges ...........................................................................................................................43
TABLE 6 - Temperatures and Flows .......................................................................................................................47
TABLE 7 - Voltage Limitations ................................................................................................................................47
TABLE 8 - Ethylene and Propolyne Glycol Correction Factors...............................................................................49
TABLE 9 - Recommended Glycol Solution Strengths.............................................................................................49
TABLE 10 - Micro Panel Power Supply ..................................................................................................................58
TABLE 11 - Voltage Range (Limitations).................................................................................................................58
TABLE 12 - Ground Lug Sizing...............................................................................................................................60
TABLE 13 - Setpoints Entry List..............................................................................................................................96
TABLE 14 - Cooling Setpoints, Programmable Limits And Defaults ..................................................................... 118
TABLE 15 - Program Key Limits And Default........................................................................................................121
TABLE 16 - Sample Compressor Staging For Return Water Control ................................................................... 131
TABLE 17 - Return Chilled Liquid Control For 4 Compressors (6 Steps) .............................................................131
TABLE 18 - Return Chilled Liquid Control For 4 Compressors (6 Steps) .............................................................132
TABLE 19 - Compressor Operation – Load Limiting.............................................................................................133
TABLE 20 - I/O Digital Inputs ................................................................................................................................139
TABLE 21 - I/O Digital Outputs .............................................................................................................................139
TABLE 22 - I/O Analog Inputs ...............................................................................................................................139
TABLE 23 - I/O Analog Outputs ............................................................................................................................139
TABLE 24 - Entering/Leaving Chilled Liquid Temperature Sensor, Temperature/Voltage Correlation.................. 141
TABLE 25 - Pressure Transducers .......................................................................................................................142
TABLE 26 - Troubleshooting .................................................................................................................................145
TABLE 27 - Minimum, Maximum and Default Values ...........................................................................................149
TABLE 28 - Values Required For Bas Communication.........................................................................................150
TABLE 29 - Real Time Error Numbers..................................................................................................................150
TABLE 30 - Bacnet And Modbus Communications Data Map .............................................................................. 152
TABLE 31 - YorkTalk 2 Communications Data Map..............................................................................................156
TABLE 32 - SI Metric Conversion .........................................................................................................................161

JOHNSON CONTROLS 13
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
1
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY
INTRODUCTION
YORK YCRL Remote Condenser Liquid Chillers pro-
vide chilled water for all air conditioning applications
that use central station air handling or terminal units.
They are self-contained and are designed for indoor
(new or retrofit) installation. Each unit includes her-
metic scroll compressors, a liquid evaporator, and a
user-friendly, diagnostic MicroComputer Control Cen-
ter all mounted on a rugged steel base. Remote con-
densers (model VDC) are available separately from
Johnson Controls. The units are produced at an ISO
9001 registered facility. The YCRL chillers are rated in
accordance with ARI Standard 550/590.
YORK YCRL chillers are manufactured to the highest
design and construction standards to ensure high per-
formance, reliability and adaptability to all types of air
conditioning installations.
The unit is intended for cooling water or glycol solu-
tions and is not suitable for purposes other than those
specified in this manual.
This manual contains all the information required for
correct installation and commissioning of the unit, to-
gether with operating and maintenance instructions.
This manual should be read thoroughly before attempt-
ing to operate or service the unit.
All procedures detailed in this manual, including in-
stallation, commissioning and maintenance tasks must
only be performed by suitably trained and qualified
personnel.
The manufacturer will not be liable for any injury or
damage caused by incorrect installation, commission-
ing, operation or maintenance resulting from a failure
to follow the procedures and instructions detailed in
the manuals.
WARRANTY
Johnson Controls warrants all equipment and materials
against defects in workmanship and materials for a pe-
riod of eighteen months from shipment unless extend-
ed warranty has been purchased as part of the contract.
The warranty is limited to parts only replacement and
shipping of any faulty part or sub-assembly which has
failed due to poor quality or manufacturing errors. All
claims must be supported by evidence that the failure
has occurred within the warranty period, and that the
unit has been operated within the designed parameters
specified. Labor warranty may be purchased as part
of the contract. Labor warranty must be performed by
Johnson Controls technicians.
All warranty claims must specify the unit model, serial
number, order number and run hours/starts. These de-
tails are printed on the unit identification plate.
The unit warranty will be void if any modification to
the unit is carried out without prior written approval
from Johnson Controls.
For warranty purposes, the following conditions must
be satisfied:
• The initial start of the unit must be carried out by
trained personnel from an Authorized Johnson
Controls Service Center. Refer to SECTION 6 –
COMMISSIONING.
• Only genuine YORK approved spare parts, oils
and refrigerants must be used.
• All the scheduled maintenance operations detailed
inthismanualmustbeperformedatthespecied
timesbysuitablytrainedandqualiedpersonnel.
Refer to SECTION 10 – MAINTENANCE.
• Failure to satisfy any of these conditions will au-
tomatically void the warranty.

JOHNSON CONTROLS
14
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY
SAFETY
Standards for Safety
YCRL chillers are designed and built within an ISO
9002 accredited design and manufacturing organiza-
tion. Products shall be designed, tested, rated and certi-
fied in accordance with, and installed in compliance
with applicable sections of the following Standards
and Codes:
1. ANSI/ASHRAE Standard 15 – Safety Code for
Mechanical Refrigeration.
2. ASHRAE90.1–EnergyEfciencyCompliance.
3. ANSI/NFPA – Standard 70 – National Electrical
Code (N.E.C.)
4. ASME Boiler and Pressure Vessel Code, Section
VIII, Division 1.
5. ASHRAE 34 – Number Designation and Safety
ClassicationofRefrigerants.
6. ARI Standard 550/590 – Positive Displacement
Compressors and Water Cooled Rotary Screw
Water-Chilling Packages.
7. Conform to UL code 1995 for construction of
chillers and provide ETL/cETL listing label.
8. Manufactured in facility registered to ISO 9001.
9. OSHA – Occupied Safety and Health Act.
Responsibility for Safety
Every care has been taken in the design and manufac-
ture of the unit to ensure compliance with the safety
requirements listed above. However, the individual
operating or working on any machinery is primarily
responsible for:
• Personal safety, safety of other personnel, and the
machinery.
• Correct utilization of the machinery in accordance
with the procedures detailed in the manuals.
MISUSE OF EQUIPMENT
Suitability for Application
The unit is intended for cooling water or glycol solu-
tions and is not suitable for purposes other than those
specified in these instructions. Any use of the equip-
ment other than its intended use, or operation of the
equipment contrary to the relevant procedures may re-
sult in injury to the operator, or damage to the equip-
ment.
The unit must not be operated outside the design pa-
rameters specified in this manual.
Structural Support
Structural support of the unit must be provided as in-
dicated in these instructions. Failure to provide proper
support may result in injury to the operator, or damage
to the equipment and/or building.
Mechanical Strength
The unit is not designed to withstand loads or stresses
from adjacent equipment, pipework or structures. Ad-
ditional components must not be mounted on the unit.
Any such extraneous loads may cause structural failure
and may result in injury to the operator, or damage to
the equipment.
General Access
There are a number of areas and features, which may
be a hazard and potentially cause injury when working
on the unit unless suitable safety precautions are taken.
It is important to ensure access to the unit is restricted
to suitably qualified persons who are familiar with the
potential hazards and precautions necessary for safe
operation and maintenance of equipment containing
high temperatures, pressures and voltages.
Pressure Systems
The unit contains refrigerant vapor and liquid under
pressure, release of which can be a danger and cause
injury. The user should ensure that care is taken during
installation, operation and maintenance to avoid dam-
age to the pressure system. No attempt should be made
to gain access to the component parts of the pressure
system other than by suitably trained and qualified per-
sonnel.

JOHNSON CONTROLS 15
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
1
Electrical
The unit must be grounded. No installation or main-
tenance work should be attempted on the electrical
equipment without first switching power OFF, isolat-
ing and locking-off the power supply. Servicing and
maintenance on live equipment must only be per-
formed by suitably trained and qualified personnel. No
attempt should be made to gain access to the control
panel or electrical enclosures during normal operation
of the unit.
Rotating Parts
Fan guards must be fitted at all times and not removed
unless the power supply has been isolated. If ductwork
is to be fitted, requiring the wire fan guards to be re-
moved, alternative safety measures must be taken to
protect against the risk of injury from rotating fans.
Sharp Edges
The fins on the air-cooled condenser coils have sharp
metal edges. Reasonable care should be taken when
working in contact with the coils to avoid the risk of
minor abrasions and lacerations. The use of gloves is
recommended.
Frame rails, brakes, and other components may also
have sharp edges. Reasonable care should be taken
when working in contact with any components to avoid
risk of minor abrasions and lacerations.
Refrigerants and Oils
Refrigerants and oils used in the unit are generally
nontoxic, non-flammable and non-corrosive, and pose
no special safety hazards. However, use of gloves and
safety glasses is recommended when working on the
unit. The buildup of refrigerant vapor, from a leak for
example, does pose a risk of asphyxiation in confined
or enclosed spaces and attention should be given to
good ventilation.
High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods
(e.g. steam cleaning) should not be used on any part
of the pressure system as this may cause operation of
the pressure relief device(s). Detergents and solvents,
which may cause corrosion, should also be avoided.
Emergency Shutdown
In case of emergency, the control panel is fitted with a
Unit Switch to stop the unit in an emergency. When op-
erated, it removes the low voltage 120VAC electrical
supply from the inverter system, thus shutting down
the unit.

JOHNSON CONTROLS
16
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY
THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS 17
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
2
SECTION 2 – PRODUCT DESCRIPTION
INTRODUCTION
YORK YCRL chillers are designed for water or water-
glycol cooling.
All models are designed for indoor installation. The
units are completely assembled with all interconnect-
ing refrigerant piping and internal wiring ready for
field connection to a remote condenser.
The unit consists of up to 6 scroll compressors in a
corresponding number of separate refrigerant circuits,
a shell and tube DX evaporator, and oil separators for
each circuit.
Before delivery, the unit is pressure tested, evacuated,
and fully charged with a nitrogen holding charge and
YORK “V” oil (POE synthetic) in each of the inde-
pendent refrigerant circuits. After assembly, an opera-
tional test is performed with water flowing through the
cooler to ensure that each refrigerant circuit operates
correctly.
The unit framework is fabricated using heavy-gauge
galvanized steel which is zinc phosphate pre-treated
and powder coated to minimize corrosion.
Additional oil change may be required
depending upon the length of piping.
COMPRESSORS
The chiller utilizes suction-gas cooled hermetic, scroll
compressors. The YCRL compressors incorporate a com-
pliant scroll design in both the axial and radial direction.
All rotating parts are statically and dynamically balanced.
A large internal volume and oil reservoir provides greater
liquid tolerance. Compressor crankcase heaters are also
included for extra protection against liquid migration. All
compressors are mounted on isolator pads to reduce trans-
mission of vibration to the rest of the unit.
REFRIGERANT CIRCUITS
Two independent refrigerant circuits are provided on
each unit. All piping will be copper with brazed joints.
Liquid line components include: a shut off valve with
charging port, a high absorption removable core filter-
drier, a solenoid valve, a sight glass with moisture indi-
cator and a thermal expansion valve. The entire suction
line and the liquid lines between the expansion valve
and the cooler are covered with flexible, closed-cell in-
sulation.
Suction line components include: a pressure relief
valve, a pressure transducer and a service valve. Op-
tional isolation ball valves are available. Suction lines
are covered with flexible, closed-cell insulation.
Discharge lines include service and isolation (ball)
valves, two high-pressure cutout switches, a pressure
transducer and a pressure relief valve.
FIGURE 1 - YCRL WATER COOLED LIQUID CHILLER
CONTROL
PANEL
COOLER
POWER SECTION
COMPRESSOR
COMPRESSOR

JOHNSON CONTROLS
18
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
SECTION 2 – PRODUCT DESCRIPTION
EVAPORATOR
The 2-pass dual circuit shell and tube type direct expan-
sion (DX) evaporator has refrigerant in the tubes and
chilled liquid flowing through the baffled shell. The
waterside (shell) design working pressure of the cooler
is 150 PSIG (10.3 barg). The refrigerant side (tubes)
design working pressure is 450 PSIG (31.0 barg). The
refrigerant side is protected by pressure relief valve(s).
The evaporator shall have water pass baffles fabricated
from galvanized steel to resist corrosion. Removable
heads are provided for access to internally enhanced,
seamless, copper tubes. Water vent and drain connec-
tions are included. The cooler is insulated with 3/4"
(19mm) flexible closed-cell foam.
Water connection to the evaporator is via Victaulic
grooved connections. Flange connections are available
as an option. The shell will be constructed and tested in
accordance with Section VII, Division 1 of the ASME
Pressure Vessel Code. The water side is exempt per
paragraph U-1 (ºC) of Section VII, Division 1 of the
ASME Pressure Vessel Code.
The evaporator is constructed and tested in accordance
with applicable sections of the ASME Pressure Vessel
Code, Section VIII, Division (1). The water side will
be exempt per paragraph U-1, (ºC) (6).
A strainer with a mesh size between .5 and 1.5 mm (40
mesh) is recommended upstream of the evaporator to
prevent clogging.
CONDENSER
The condenser can be either a field supplied YORK
VDC remote air-cooled condenser (available separate-
ly from Johnson Controls) or an evaporative condenser.
REFRIGERANT CIRCUIT
Two independent refrigerant circuits will be furnished
on each unit. All piping will be copper with brazed
joints. The liquid line will include: a shutoff valve with
charging port; sight-glass with moisture indicator; ther-
mal expansion valve; solenoid valve; and high absorp-
tion removable-core filter drier. The entire suction line
and the liquid line between the expansion valve and the
evaporator will be insulated with flexible, closed-cell,
foam insulation.
MILLENNIUM CONTROL CENTER
All controls are contained in a NEMA 1 (and equiva-
lent to IP32) powder painted steel cabinet with hinged
outer door and includes:
• Liquid Crystal Display with Light Emitting Diode
backlighting for outdoor viewing:
• Two display lines
• Twenty characters per line
• Color coded 12-button non-tactile keypad with
sections for:
• Control supply fuses and connections for a
remote emergency stop device.
• ON/OFF rocker switch, microcomputer
keypad and display, microprocessor board,
I/O expansion board, relay boards, and 24V
fused power supply board.
• Customer terminal block for control inputs
and liquid flow switch.
The microprocessor control includes:
• Automatic control of compressor start/stop, an-
ticoincidence and anti-recycle timers, automatic
pumpdown on shutdown, evaporator pump and
unit alarm contacts. Automatic reset to normal
chiller operation after power failure.
• Remote water temperature reset via a pulse width
modulated (PWM) input signal or up to two steps
of demand (load) limiting.
• Software stored in non-volatile memory
(EPROM), with programmed setpoints retained in
a lithium battery backed Real Time Clock (RTC)
memoryforaminimumofveyears.
• Forty character liquid crystal display, with de-
scription available in ve languages (English,
French, German, Spanish or Italian).
Refrigerant R410A is eld supplied.

JOHNSON CONTROLS 19
SECTION 2 – PRODUCT DESCRIPTION
FORM 150.27-NM1
ISSUE DATE: 09/30/2015
2
Programmable Setpoints
• Chilled liquid temperature setpoint and range
• Remote reset temperature range
• Set daily schedule/holiday for start/stop
• Manual override for servicing
• Low liquid temperature cutout
• Low suction pressure cutout
• High discharge pressure cutout
• Anti-recycle timer (compressor start cycle time)
• Anti-coincident timer (delay compressor starts)
Displayed Data
• Return and leaving liquid temperature
• Low leaving liquid temperature cutout setting
• Metric or Imperial data
• Discharge and suction pressure cutout settings
• System discharge and suction pressure
• Anti-recycle timer status for each compressor
• Anti-coincident system start timer condition
• Compressor run status
• No cooling load condition
• Day, date and time
• Daily start/stop times
• Holiday status
• Automatic or manual system lead/lag control
• Leadsystemdenition
• Compressor starts and operating hours (each com-
pressor)
• Run permissive status
• Number of compressors running
• Liquid solenoid valve status
• Load and unload timer status
• Water pump status
System Safeties
System Safeties cause individual compressors to per-
form auto shut down and require manual reset in the
event of three trips in a 90-minute time period:
• High discharge pressure
• Low suction pressure
• High pressure switches
• Motor protector
Unit Safeties
Unit Safeties are automatic reset and cause all com-
pressors to shut down:
• Low leaving chilled liquid temperature
• Under voltage
• Lossofliquidow(throughowswitch)
• Low battery
Power and Control Panels
All power and controls are contained in an IP32 cabi-
net with hinged, latched and gasket sealed outer doors.
Power Panel
The power panel includes factory mounted compressor
contactors and manual motor starters to provide over-
load and short circuit protection.

JOHNSON CONTROLS
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FORM 150.27-NM1
ISSUE DATE: 09/30/2015
SECTION 2 – PRODUCT DESCRIPTION
ACCESSORIES AND OPTIONS
Power Options
Single Point Supply Terminal Block
The standard power wiring connection on all models is
a single point power connection to a factory provided
terminal block. Components included are the enclo-
sure, terminal-block and interconnecting wiring to the
compressors. Separate external protection must be sup-
plied, by others, in the incoming power wiring. (Do not
include this option if either the Single-Point Non-fused
Disconnect Switch or Single-point Circuit Breaker op-
tions have been included.) (Factory-Mounted)
Single Point Non-Fused Disconnect Switch
An optional unit-mounted disconnect switch with ex-
ternal, lockable handle (in compliance with Article
440-14 of N.E.C.), can be supplied to isolate the unit
power voltage for servicing. Separate external fusing
must be supplied, by others in the power wiring, which
must comply with the National Electrical Code and/or
local codes. (Factory-Mounted)
Single Point Circuit Breaker
An optional unit mounted circuit breaker with external,
lockable handle (in compliance with N.E.C. Article
440-14); can be supplied to isolate the power voltage
for servicing. (Factory-Mounted)
Multiple Point Circuit Breaker
Optional multiple point supply with independent sys-
tem circuit breakers and locking external handles (in
compliance with Article 440-14 of N.E.C) can be fac-
tory supplied. (Factory-Mounted).
Control Transformer
Converts unit power voltage to 115-1-60 (0.5 or 1.0
KVA capacity). Factory mounting includes primary
and secondary wiring between the transformer and the
control panel. (Factory-Mounted)
Compressor External Overloads
Optional compressor motor overloads can be factory
mounted in the unit control/power panel. This option
will reduce the chiller MCA (minimum circuit ampac-
ity) and allow for reduced wire sizing to the unit. This
option is not available for applications with Leaving
Condenser Water Temperature (LCWT) greater than
105ºF (40.6ºC). (Factory-Mounted)
Controls Options
Building Automation System Interface
A standard feature of the YCRL control panel to ac-
cept a pulse width modulated (PWM), 4-20 milliamp,
or 0-10VDC input to reset the leaving chilled liquid
temperature from a Building Automation System.
(Factory-Mounted)
Language LCD and Keypad
Standard display language and keypad is in English.
Spanish, French, German, and Italian are available as
an option. (Factory-Mounted)
Heat Exchanger Options
Flow Switch
An optional flow switch can be factory supplied for the
evaporator. Vapor-proof SPDT, NEMA 3R switch, 150
PSIG (10.3 bar) DWP, 20°F to 250°F (-29°C to 121°C)
with 1" NPT (IPS) connection for upright mounting in
horizontal pipe. The flow switch or its equivalent must
be furnished with each unit. (Field mounted)
Differential Pressure Switch
An alternative option to the paddle-type flow switch.
3-45 PSIG (0.2-3 bar) range with ¼" NPTE pressure
connections. (Field Mounted)
Pressure Vessel Codes
Evaporators and condensers are to be supplied (stan-
dard) in conformance with the A.S.M.E. pressure
codes.
Flanges (ANSI/AWWA C-606 Couplings Type)
Consists of (2) flange adapters for grooved end pipe on
evaporator and condenser. Standard 150 PSI (10.3 bar).
(Field Kit, matching pipe flange by contractor.)
Double Thick Insulation
Double thick (1-1/2") insulation provided on the evap-
orator. (Factory-Mounted)