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
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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

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THIS PAGE INTENTIONALLY LEFT BLANK

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FORM 150.27-NM1
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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

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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
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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

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FORM 150.27-NM1
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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

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FORM 150.27-NM1
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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