Johnson Controls York YCRL0200HE Owner's manual

INSTALLATION, OPERATION & MAINTENANCE
YCRL0200HE-YCRL0610HE
Revision 0 Form 150.27-NM2.EN.CE (0312)
REMOTE CONDENSER SCROLL LIQUID CHILLERS
STYLE A (50 HZ)
(178-556 KW)
HE - HIGH EFFICIENCY
035-21965-100
R410A

2EN
FORM 150.27-NM2.EN.CE (0312)
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, materials under pressure, rotating components, and
lethal 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
operating/service personnel to identify and recognize
these inherent hazards, protect themselves, and proceed
safely in completing their tasks. Failure to comply with
any of these requirements could result in serious damage
to the equipment and the property in which it is situated,
IMPORTANT!
Read BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
as well as severe personal injury or death to themselves
and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
individual possesses independent training that will
enable them to perform their assigned tasks properly
and safely. It is essential that, prior to performing any
task on this equipment, this individual shall have read
and understood this document and any referenced
materials. This individual shall also be familiar with and
comply with all applicable governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
CAUTION identifies a hazard which could
lead to damage to the machine, damage
to other equipment and/or environmental
pollution. Usually an instruction will be
given, together with a brief explanation.
NOTE is used to highlight additional
information which may be helpful to you.
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in death or serious injury.
DANGER
WARNING indicatesapotentiallyhazardous
situation which, if not avoided, could result
in death or serious injury.
External wiring, unless specified 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 may not be installed inside the panel. No external wiring is allowed to be run through
the micro panel. All wiring must be in accordance with Johnson Controls published specifications
and must be performed only by qualified Johnson Controls personnel. Johnson Controls will not
be responsible for damages/problems resulting from improper connections to the controls or
application of improper control signals. Failure to follow this will void the manufacturer’s warranty
and cause serious damage to property or injury to persons.

3
FORM 150.27-NM2.EN.CE (0312)
EN
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for continuous product improvement, the information contained in this
document is subject to change without notice. While Johnson Controls makes no commitment to update or provide
current information automatically to the manual owner, that information, if applicable, can be obtained by contacting
the nearest Johnson Controls Service Centre.
It is the responsibility of operating/service personnel to verify the applicability of these documents to the equipment in
question. If there is any question in the mind of operating/service personnel as to the applicability of these documents,
then prior to working on the equipment, they should verify with the owner whether the equipment has been modified
and if current literature is available.

4EN
FORM 150.27-NM2.EN.CE (0312)
TABLE OF CONTENTS
GENERALCHILLERINFORMATION&SAFETY
INTRODUCTION ............................................... 6
WARRANTY....................................................... 6
SAFETY .............................................................. 6
Standards for Safety............................................. 6
FLUORINATED GREENHOUSE GASES ........ 7
RESPONSIBILITY FOR SAFETY..................... 7
MISUSE OF EQUIPMENT................................. 7
Suitability for Application ................................... 7
Structural Support................................................ 7
Mechanical Strength ........................................... 7
General Access..................................................... 7
Pressure Systems ................................................. 7
Electrical .............................................................. 8
Refrigerants and Oils ........................................... 8
High Temperature and Pressure Cleaning............ 8
Emergency Shutdown .......................................... 8
Safety Labels........................................................ 8
MATERIAL SAFETY DATA .............................. 9
PRODUCT DESCRIPTION
INTRODUCTION ............................................. 13
Compressors ...................................................... 13
Refrigerant Circuits ........................................... 13
Evaporator.......................................................... 14
Condenser .......................................................... 14
Power and Control Panels.................................. 14
Programmable setpoints: .................................. 15
Displayed Data: ................................................. 15
Alarm Contacts: ................................................ 15
OPTIONS & ACCESSORIES ........................... 16
Soft Starters ....................................................... 16
Language LCD and Keypad .............................. 16
38 mm Evaporator Insulation ............................ 16
Dual Pressure Relief Valves............................... 16
Suction Service Valves....................................... 16
Victaulic Flange Kit........................................... 16
Compressor Acoustic Blankets .......................... 16
Flow switch........................................................ 16
Differential Pressure Switch .............................. 16
Neoprene Pad Isolators ...................................... 16
25 mm Spring Isolators...................................... 16
REFRIGERANT FLOW DIAGRAM................ 17
UNIT COMPONENTS...................................... 18
MODEL NUMBER NOMENCLATURE.......... 19
HANDLING AND STORAGE
DELIVERY AND STORAGE........................... 20
INSPECTION .................................................... 20
MOVING THE CHILLER ................................ 20
Lifting by Crane/Hoist....................................... 20
LIFTING WEIGHTS......................................... 20
INSTALLATION
Location Requirements...................................... 21
Installation of Vibration Isolators ...................... 21
Pipework Connection......................................... 21
Water Treatment................................................. 22
Chilled Liquid System ....................................... 22
Connection Types & Sizes................................. 22
Refrigerant Relief Valve Piping......................... 23
SYSTEM REFRIGERANT PIPING ................. 23
General .............................................................. 23
Pressure Drop Considerations............................ 23
Refrigerant Line Sizing...................................... 26
Chiller Below Condenser................................... 26
Condenser Below Chiller................................... 26
Oil traps ............................................................. 26
Refrigerant Charge............................................. 26
R-410A Copper Line Sizing .............................. 26
YCRL Line Sizing Notes................................... 26
YCRL Connection Sizes .................................... 27
ELECTRICAL CONNECTION ........................ 28
Power Wiring ..................................................... 28
Single Point Power Supply Wiring .................... 28
Remote Emergency Stop Device ....................... 28
Control Wiring - Voltage Free Contacts............. 28
Chilled Liquid Pump Starter.............................. 28
Run Contacts...................................................... 28
Alarm Contacts .................................................. 29
Control Wiring - System Inputs......................... 29
Flow Switch ....................................................... 29
Remote Start/Stop.............................................. 29
Remote Reset of Chilled Liquid Setpoint.......... 29
Remote Load Limiting....................................... 29
EMS Analogue Input ......................................... 29
Modbus and BACnet MS/TP............................. 29
CONNECTION DIAGRAM ............................. 30

5
FORM 150.27-NM2.EN.CE (0312)
EN
COMMISSIONING
PREPARATION................................................. 31
Preparation - Power Off..................................... 31
Soft Start (Option) ............................................. 32
THE MACHINE IS NOW LIVE! ..................... 32
FIRST TIME START-UP................................... 33
TECHNICAL DATA
EVAPORATOR PRESSURE DROP GRAPH... 34
PRESSURE DROP FORMULAE ..................... 34
OPERATING LIMITATIONS - YCRL-HE....... 35
PHYSICAL DATA - YCRL-HE ........................ 36
ELECTRICAL DATA - YCRL HE.................... 37
DIMENSIONS - YCRL0200HE, YCRL0230HE,
YCRL0260HE, YCRL0300HE, YCRL0345HE 38
DIMENSIONS - YCRL0385HE, YCRL0445HE,
YCRL0530HE AND YCRL0610HE ................. 40
DURULENE ISOLATOR SPECIFICATIONS . 42
DURULENE ISOLATOR INSTALLATION .... 43
25 MM ISOLATOR SPECIFICATION............. 44
25 MM ISOLATOR INSTALLATION.............. 45
UNIT OPERATION
GENERAL DESCRIPTION.............................. 46
START-UP ......................................................... 46
NORMAL RUNNING AND CYCLING........... 46
SHUTDOWN .................................................... 46
MAINTENANCE
GENERAL REQUIREMENTS......................... 47
DAILY MAINTENANCE ................................. 47
SCHEDULED MAINTENANCE ..................... 47
Evaporator In-Service Inspection ...................... 48
TROUBLE SHOOTING
Competent Persons Trouble Shooting Guide..... 49
Sensor Calibration Charts .................................. 51
Liquid Temperature (-BLCT and BECT) .......... 51
Discharge Pressure (-BDP) and Suction (-BSP)
Transducers ........................................................ 51
SPARE PARTS
RECOMMENDED SPARES............................. 52
RECOMMENDED COMPRESSOR OIL......... 52
ASSOCIATED DRAWINGS............................. 52
DECOMMISSIONING. DISMANTLING AND
DISPOSAL
GENERAL......................................................... 53
ANNEX A - INSTALLER RESPONSIBILITIES
FOR DESIGN, SAFETY, CERTIFICATION
ANDCEMARKINGOFINSTALLEDCHILLER
Relevant EC directives: ..................................... 55

6EN
FORM 150.27-NM2.EN.CE (0312)
INTRODUCTION
YORK YCRL Remote Condenser Liquid Chillers
provide 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 hermetic
scroll compressors, a liquid evaporator, and a user-
friendly, diagnostic MicroComputer Control Center all
mounted on a rugged steel base. Remote condensers
(model VDC) are available separately from Johnson
Controls.
The units are produced at an ISO 9001 registered facility
and manufactured to the highest design and construction
standards to ensure high performance, reliability and
adaptability to all types of air conditioning installations..
The unit is intended for cooling water or glycol solutions
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,
together with operating and maintenance instructions.
The manuals should be read thoroughly before
attempting to operate or service the unit.
All procedures detailed in the manuals, including
installation, 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, commissioning,
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
period of eighteen months from date of shipment, unless
labour or extended 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.
GENERAL CHILLER INFORMATION & SAFETY
All warranty claims must specify the unit model, serial
number, order number and run hours/starts. Model
and serial number information is 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 anAuthorized Johnson Controls
Service Centre. See Section 5, Commissioning.
• Only genuine Johnson Controls approved spare parts,
oils, coolants, and refrigerants must be used.
• All the scheduled maintenance operations detailed
in this manual must be performed at the specified
times by suitably trained and qualified personnel. See
Section 7, Maintenance,
Failure to satisfy any of these conditions will
automatically void the warranty..
SAFETY
Standards for Safety
YCRL units are designed and built within an
EN ISO 9002 accredited manufacturing organisation.
The YCRL unit does not have a Declaration of
Conformity (CE Mark) as the unit can not be used
independently without a remote condenser.
It is the installers responsibility to ensure the
completed system conforms to CE standards and
local regulations.
The YCRL unit is shipped with a Declaration of
Incorporation and the unit components have Declarations
of Conformity where applicable (i.e. compressors,
vessels, safety devices etc.) assembly instructions are
also included with the shipment.

7
FORM 150.27-NM2.EN.CE (0312)
EN
FLUORINATED GREENHOUSE GASES
• The equipment wheninstalled will contain fluorinated
greenhouse gases covered by the Kyoto Protocol.
• The global warming potential of the refrigerant
(R410A) that will be used in this unit is 1720.
• The refrigerant quantity required will be dependant
on system design.
• The fluorinated greenhouse gases that will beused in
this equipment may not be vented to the atmosphere.
• This equipment should only be serviced by qualified
technicians.
RESPONSIBILITY FOR SAFETY
Every care has been taken in the design and manufacture
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.
It is the installers responsibility to ensure the
completed system conforms to CE standards and
local regulations. The Installer is also responsible
for approvals by a Notified Body and CE marking
of the completed system, before the system goes into
operation.
In addition, the installer is responsible for ensuring
thefollowingareperformed fortheinstalled system:
Relevant EC directives:
Pressure Equipment Directive 97/23/EC
Machinery Safety 2006/42/EC
EMC2004/108/EC.
Applied harmonized standards:
EN60204-1(2006),
EN378-2(2008)/A1(2009)*,
EN61000-6-4(2007), EN61000-6-2(2005)
* Safety accessories according to essential requirements
in PED paragraph 2.11.1 have been calculated according
to EN13136:2001/A1:2005 and are not following the
requirements in EN378-2:2008 paragraph 6.2.6.2, unless
dual relief valves are fitted.
The contents of this manual include suggested best
working practices and procedures. These are issued for
guidance only, and they do not take precedence over
the above stated individual responsibility and/or local
safety regulations.
This manual and any other document supplied with the
unit are the property of Johnson Controls which reserves
all rights. They may not be reproduced, in whole or
in part, without prior written authorization from an
authorized Johnson Controls representative.
MISUSE OF EQUIPMENT
Suitability for Application
The unit is intended for cooling water or glycol solutions
and is not suitable for purposes other than those specified
in these instructions. Any use of the equipment other
than its intended use, or operation of the equipment
contrary to the relevant procedures may result in injury
to the operator, or damage to the equipment.
The unit must not be operated outside the design
parameters specified in this manual.
Structural Support
Structural support of the unit must be provided as
indicated 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.
Additional 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.
1

8EN
FORM 150.27-NM2.EN.CE (0312)
Pressure Systems
The unit will contain refrigerant vapour 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 damage
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
personnel.
Electrical
The unit must be earthed. No installation or maintenance
work should be attempted on the electrical equipment
without first switching power OFF, isolating and locking-
off the power supply. Servicing and maintenance on live
equipment must only be performed 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.
Refrigerants and Oils
Refrigerants and oils used in the unit are generally
nontoxic, non-flammable and non-corrosive, and pose
no special safety hazards. Use of gloves and safety
glasses is, however, recommended when working on the
unit. The build up of refrigerant vapour, 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
incoming supply non-fused disconnect switch which can
be used as the emergency stop device. When operated it
removes the electrical supply to the control circuit thus
shutting down the unit.
Safety Labels
The following labels are fixed to each unit to give
instruction, or to indicate potential hazards which may
exist.
White symbol on blue background
For safe operation, read the Instructions
first
Black symbol on yellow background
Warning: This machine may start
automatically without prior warning
Black symbol on yellow background
Warning: Hot surface
Black symbol on yellow background
Warning: Safety relief valve may discharge
gas or liquid without prior warning
Black symbol on yellow background
Warning: Isolate all electrical sources of
supply before opening or removing the
cover, as lethal voltages may exist
Black symbol on yellow background
General attention symbol
Black symbol on yellow background
Power Factor Correction fitted
Warning: On isolating the supply it may
take up to 60 seconds for the capacitor
voltage to fall below 60 volts

9
FORM 150.27-NM2.EN.CE (0312)
EN
MATERIAL SAFETY DATA
Components Material PENTAFLUOROETHANE (HFC-125) DIFLUOROMETHANE (HFC-32)
CAS Number 354-33-6 75-10-5
% 50 50
Inhalation of high concentrations of vapour is harmful and may cause heart irregularities,
unconsciousness, or death. Intentional misuse or deliberate inhalation may cause death
without warning. Vapour reduces oxygen available for breathing and is heavier than air. Liquid
contact can cause frostbite.
At flame temperatures, this material can decompose to hydrogen fluoride which can be lethal
at much lower concentrations.
Overexposure to the vapours by inhalation may include temporary nervous system
depression with anaesthetic effects such as dizziness, headache, confusion, incoordination,
and loss of consciousness. Higher exposures to the vapours may cause temporary alteration
of the heart's electrical activity with irregular pulse, palpitations, or inadequate circulation.
Gross overexposure may be fatal. Skin contact with the liquid may cause frostbite.
Individuals with preexisting diseases of the central nervous or cardiovascular system may
have increased susceptibility to the toxicity of increased exposures.
Carcinogenicity Information
None of the components present in this material at concentrations equal to or greater than
0.1% are listed by IARC, NTP, OSHA or ACGIH as a carcinogen.
If inhaled, immediately remove to fresh air. Keep person calm.
If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Call a physician.
Skin Contact
Flush area with lukewarm water. Do not use hot water. If frostbite has occurred, call a
physician.
Eye Contact
In case of contact, immediately flush eyes with plenty of water for at least 15 minutes. Call a
physician.
Ingestion Do not induce vomiting. Give plenty of water in sips
Notes to Physicians
THIS MATERIAL MAY MAKE THE HEART MORE SUSCEPTIBLE TO ARRHYTHMIAS.
Catecholamines such as adrenaline, and other compounds having similar effects, should be
reserved for emergencies and then used only with special caution.
Flash Point : No flash point
Flammable Limits in Air, % by Volume:
LEL : None per ASTM E681
UEL : None per ASTM E681
Autoignition: Not determined
Cylinders may rupture under fire conditions. Decomposition may occur.
Contact of welding or soldering torch flame with high concentrations of refrigerant can result
in visible changes in the size and colour of torch flames. This flame effect will only occur in
concentrations of product well above the recommended exposure limit, therefore stop all work
and ventilate to disperse refrigerant vapours from the work area before using any open
flames.
R-410A is not flammable in air at temperatures up to 100 deg C (212 deg F) at atmospheric
pressure. However, mixtures of R-410A with high concentrations of air at elevated pressure
and/or temperature can become combustible in the presence of an ignition source. R-410A
can also become combustible in an oxygen enriched environment (oxygen concentrations
greater than that in air). Whether a mixture containing R-410A and air, or R-410A in an
oxygen enriched atmosphere becomes combustible depends on the inter-relationship of 1)
the temperature 2) the pressure, and 3) the proportion of oxygen in the mixture. In general, R-
410A should not be allowed to exist with air above atmospheric pressure or at high
temperatures; or in an oxygen enriched environment. For example: R-410A should NOT be
mixed with air under pressure for leak testing or other purposes.
Flammable Properties
Fire and Explosion Hazards
Human Health Effects
FIRST AID MEASURES
Inhalation
FIRE FIGHTING MEASURES
Refrigerant Safety Data R410A:
COMPOSITION/INFORMATION ON INGREDIENTS
HAZARDS IDENTIFICATION
Potential Health Effects
1

10 EN
FORM 150.27-NM2.EN.CE (0312)
Extinguishing Media As appropriate for combustibles in area.
Fire Fighting Instructions
Cool cylinder with water spray or fog. Self-contained breathing apparatus (SCBA) is required
if cylinders rupture and contents are released under fire conditions. Water runoff should be
contained and neutralized prior to release.
NOTE: Review FIRE FIGHTING MEASURES and HANDLING (PERSONNEL)
sections before proceeding with clean-up. Use appropriate PERSONAL PROTECTIVE
EQUIPMENT during clean-up.
Accidental Release Measures
Ventilate area, especially low or enclosed places where heavy vapours might collect.
Extinguish open flames. Use self-contained breathing apparatus (SCBA) for large spills or
releases. Eliminate electrical sources.
Handling (Personnel)
Avoid breathing vapour. Avoid liquid contact with eyes and skin. Use with sufficient ventilation
to keep employee exposure below recommended limits. See Fire and Explosion Data section.
Storage Clean, dry area. Do not heat above 52 deg C (125 deg F).
Engineering Controls
Avoid breathing vapours. Avoid contact with skin or eyes. Use with sufficient ventilation to
keep employee exposure below the recommended exposure limit. Local exhaust should be
used if large amounts are released. Mechanical ventilation should be used in low or enclosed
places.
Personal Protective
Equipment
Impervious gloves should be used to avoid prolonged or repeated exposure. Chemical splash
goggles should be available for use as needed to prevent eye contact. Under normal
manufacturing conditions, no respiratory protection is required when using this product
provided exposure is maintained at or below occupational limits. Self-contained breathing
apparatus (SCBA) is required if a large release occurs.
Applicable Exposure Limits
PENTAFLUOROETHANE (HFC-125)
PEL (OSHA) : None Established
TLV (ACGIH) : None Established
AEL * (DuPont) : 1000 ppm, 8 & 12 Hr. TWA
WEEL (AIHA) : 1000 ppm, 4900 mg/m3, 8 Hr. TWA
DIFLUOROMETHANE (HFC-32)
AEL * (DuPont) : 1000 ppm, 8 & 12 Hr. TWA
WEEL (AIHA) : 1000 ppm, 8 Hr. TWA
* AEL is DuPont's Acceptable Exposure Limit. Where governmentally imposed occupational
exposure limits which are lower than the AEL are in effect, such limits shall take precedence.
Boiling Point : - 60.8 F (-51.6 C) @ 1 atm
Vapour Pressure : 239.7 psia 25 C (77 F)
% Volatiles : 100 WT%
Evaporation Rate : (Cl4 = 1) Greater than 1
Solubility in Water : Not determined
Odour : Slight ethereal
Form : Liquefied gas
Colour : Clear, colourless
Specific Gravity : 1.066 @ 25 C (77 F)
Chemical Stability Material is stable. However, avoid open flames and high temperatures.
Incompatibility with Other
Materials
Incompatible with active metals, alkali or alkaline earth metals--powdered Al, Zn, Be, etc.
Decomposition
Decomposition products are hazardous. This material can be decomposed by high
temperatures (open flames, glowing metal surfaces, etc.) forming hydrofluoric acid and
possibly carbonyl fluoride. These materials are toxic and irritating. Contact should be avoided.
Refrigerant Safety Data R410A:
Physical Data
STABILITY AND REACTIVITY
HANDLING AND STORAGE
EXPOSURE CONTROLS/PERSONAL PROTECTION
Exposure Guidelines
PHYSICAL AND CHEMICAL PROPERTIES
ACCIDENTAL RELEASE MEASURES
Safeguards (Personnel)

11
FORM 150.27-NM2.EN.CE (0312)
EN
1
Polymerization Polymerization will not occur.
Other Hazards
Decomposition : Decomposition products are hazardous. This material can be decomposed
by high temperatures (open flames, glowing metal surfaces, etc.) forming hydrofluoric acid,
and possibly carbonyl halides.
The blend is untested.
HFC-125
Inhalation 4-hour ALC: >709,000 ppm in rats
Single exposure to high doses caused: Lethargy. Laboured breathing. Weak cardiac
sensitization, a potentially fatal disturbance of heart rhythm caused by a heightened
sensitivity to the action of epinephrine. Lowest-Observed-Adverse-Effect-Level for cardiac
sensitization: 100,000 ppm.
Repeated exposure caused: No significant toxicological effects. No-Observed-Adverse-Effect-
Level(NOAEL): 50,000 ppm
ADDITIONAL TOXICOLOGICAL EFFECTS:
No animal data are available to define the following effects of this material: carcinogenicity,
reproductive toxicity. In animal testing this material has not caused developmental toxicity.
Tests have shown that this material does not cause genetic damage in bacterial or
mammalian cell cultures, or in animals. This material has not been tested for its ability to
cause permanent genetic damage in reproductive cells of mammals (not tested for heritable
genetic damage).
HFC-32
Inhalation 4 hour-ALC: > 520,000 ppm in rats
Single exposure caused: Lethargy. Spasms. Loss of mobility in the hind limbs. Other effects
include weak cardiac sensitization, a potentially fatal disturbance of heart rhythm caused by a
heightened sensitivity to the action of epinephrine. 250,000 ppm.
Repeated exposure caused pathological changes of the lungs, liver, spleen, kidneys. In more
recent studies repeated exposure caused: No significant toxicological effects.
No-Observed-Effect-Level (NOEL): 49,100 ppm.
No animal data are available to define the following effects of this material: carcinogenicity,
reproductive toxicity. Animal data show slight fetotoxicity but only at exposure levels
producing other toxic effects in the adult animal. Tests have shown that this material does not
cause genetic damage in bacterial or mammalian cell cultures, or in animals. This material
has not been tested for its ability to cause permanent genetic damage in reproductive cells of
mammals (not tested for heritable genetic damage).
Waste Disposal
Comply with Federal, State, and local regulations. Reclaim by distillation or remove to a
permitted waste disposal facility.
DOT/IMO/IATA
Proper Shipping Name : Liquefied Gas, N.O.S. (Pentafluoroethane and Difluoromethane)
Hazard Class : 2.2
UN No. : 3163
Label(s) : Nonflammable Gas
Shipping Containers : Tank Cars. Cylinders. Ton Tanks
DISPOSAL CONSIDERATIONS
TRANSPORTATION INFORMATION
Shipping Information
Refrigerant Safety Data R410A:
TOXICOLOGICAL INFORMATION
Animal Data

12 EN
FORM 150.27-NM2.EN.CE (0312)
Section 9 Spill or Leak Procedures
Spill Procedures: Personal Protective Equipment must be worn, see Personal Protection Information (Section 8). Ventilate
Section 10 Waste Disposal Methods
This material, if discarded, should be disposed of in a licensed facility in accordance with local regulations.
Ventilation: Use with adequate ventilation.
Protective Gloves: Neoprene.
Eye/Face Protection: Safety glasses.
Clothing: Long sleeve shirt is recommended.
Inhalation: Remove exposed person to fresh air if adverse effects are observed.
Additional Information: Note to physician: Treat symptomatically.
Section 8 Personal Protection Information
Respiratory Protection: Use respirator with an organic vapour cartridge if exposure limit is exceeded.
First Aid Procedures
Ingestion: DO NOT INDUCE VOMITING. If conscious, give 2 glasses of water. Get immediate medical attention.
Eyes: Flush with water at least 15 minutes. Get medical attention if eye irritation develops or persists.
Skin: Wash with soap and water. Get medical attention if irritation develops. Launder contaminated clothing before reuse.
Incompatible Materials: Strong acids. Strong bases. Strong oxidizing agents.
Decomposition Temperature: Not Determined.
Thermal Decomposition: Smoke, carbon monoxide, carbon dioxide, aldehydes and other products of incomplete combustion.
Section 7 Health Hazard Data
Special Fire Fighting Techniques: Firefighters should use approved self-contained breathing apparatus. Water may cause
Section 6 Reactivity Data
Stability: Material is normally stable at moderately elevated temperatures and pressures.
Hazardous Polymerization: Will not occur.
Flammable Limits: not established.
Autoignition Temperature: no data.
Extinguishing Media: CO2, dry chemical or foam. Water can be used to cool and protect exposed material.
Unusual Fire and Explosion Hazards: Toxic fumes, gases or vapours may evolve on burning.
Solubility in Water: Insoluble.
Evaporation Rate: Not Determined.
Section 5 Fire and Explosion Hazards
Flash Point: > 232°C, 450°F COC (Minimum).
Vapour Pressure: Not Determined.
Specific Gravity (water=1): 0.97 @ 15.6°C.
Volatiles, Percent by Volume: Unknown.
Odour: Mild.
Storage: No special storage precautions required.
Section 4 Physical Data
Appearance: Clear liquid.
Boiling Point: Not Determined.
Section 2 Components and Hazard Statement
This product is non-hazardous. This material has no known hazards under applicable laws.
Section 3 Safe Handling and Storage
Handling: Keep containers closed when not in use. Wash thoroughly after handling. Empty container contains product
Oil Safety Data YORK 'V' Oil:
Section 1 Substance Product Information
Product Trade Name: YORK "V" Oil.
Chemical Name: Carboxylic Ester.
Health Hazard & First Aid
Toxicity Index <10 to NES713 Issue 3 (1991): Non-hazardous, non-toxic. No first aid
necessary.
Stability / Reactivity Stable.
Handling / Use / Disposal
No special handling precautions required. Dispose of according to local laws and regulations
governing non-biodegradable non-hazardous solid wastes.
Fire & Explosion
Flammability rating Class 1 to BS 476 pt 7: Non-flammable. If forced to burn, combustion
products are typically over 95% carbon dioxide and carbon monoxide.
Thermal & Acoustic Materials Data

13
FORM 150.27-NM2.EN.CE (0312)
EN
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 interconnecting
refrigerant piping and internal wiring ready for field
connection to a remote condenser.
The unit consists of 4 or 6 scroll compressors in two
separate refrigerant circuits (2 or 3 compressors per
circuit), a shell and tube DX evaporator (cooler), and a
power and control panel.
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
independent refrigerant circuits. After assembly, an
operational test is performed with water flowing through
the cooler to ensure that each refrigerant circuit operates
correctly.
Y
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 unit has suction-cooled, hermetic scroll compressors.
High efficiency is achieved through a controlled orbit and
the use of advanced scroll geometry. The compressors
incorporate a compliant scroll design in both the axial
and radial directions. All rotating parts are statically and
dynamically balanced. A large internal volume and oil
reservoir provides greater liquid tolerance.
The compressor motors have integral protection against
overloads. The overload protection will automatically
reset. Starting is direct on line, but soft start is available
as an option.
The compressors are switched On and Off by the unit
microprocessor to provide capacity control. Each
compressor is fitted with a crankcase strap heater. All
compressors are mounted on isolator pads to reduce
transmission 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
indicator 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 insulation.
2
CONTROL
PANEL
COOLER
POWER SECTION
COMPRESSOR
COMPRESSOR

14 EN
FORM 150.27-NM2.EN.CE (0312)
Suction line components include: a pressure relief valve,
a pressure transducer and a service valve. Optional
isolation ball valves are available. Suction lines are
covered with flexible, closed-cell insulation.
Discharge lines include service and isolation (ball)
valves, one or two high-pressure cutout switches, and a
pressure transducer.
Refrigerant R410A is field supplied.
Evaporator
The 2-pass dual circuit shell and tube type direct
expansion (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 10.3 bar g. The refrigerant side (tubes) design working
pressure is 31.0 bar g.The refrigerant side is protected
by pressure relief valves on the suction lines.
The evaporator shall have water pass baffles fabricated
from galvanised steel to resist corrosion. Removable
heads are provided for access to internally enhanced,
seamless, copper tubes. Water vent and drain connections
are included. The cooler is insulated with flexible closed-
cell foam.
Water Connection to the evaporator is via victaulic-
grooved connections. Flange connections are available
as an option.
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 separately from
Johnson Controls) or an evaporative condenser.
Power and Control Panels
All power and controls are contained in a IP32 cabinet
with hinged, latched and gasket sealed outer doors.
The power panel includes:
• A factory mounted non-fused disconnect switch with
external, lockable handle to enable connection of the
unit power supply. The disconnect switch can be used
to isolate the power for servicing.
• Factory mounted compressor contactors and manual
motor starters to provide overload and short circuit
protection.
• Factory mounted control transformer to convert the
unit supply voltage to 110 V - 1 Ø - 50 Hz for the
control system.
• Control supply fuses and connections for a remote
emergency stop device.
The control panel includes:
• A Liquid Crystal Display (two display lines of twenty
characters per line) with Light Emitting Diode
backlighting for easy viewing.
• A Colour coded 12-button keypad.
• Customer terminal block for control inputs and liquid
flow switch.
The microprocessor control includes:
• Automatic control of compressor start/stop, anti-
coincidence 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 is loaded into the microprocessor controller
via a SD card, with programmed setpoints retained
in a lithium battery backed real time clock (RTC)
memory.
• Forty character liquid crystal display, with description
available in several languages.

15
FORM 150.27-NM2.EN.CE (0312)
EN
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 pressures
• 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 definition
• Compressor starts & operating hours (each
compressor)
• Run permissive status
• Number of compressors running
• Liquid solenoid valve status
• Load & unload timer status
• Water pump status
System Safeties:
Cause individual compressors to perform auto shut
down and require manual reset in the event of 3 trips in
a 90-minute time period:
• High discharge pressure
• Low suction pressure
• High pressure switches
• Motor protector
Unit Safeties:
Are automatic reset and cause compressor to shut down
• Low leaving chilled liquid temperature
• Under voltage
• Loss of liquid flow (through flow switch)
Alarm Contacts:
• Low leaving chilled liquid temperature
• Low voltage
• Low battery
• High discharge pressure (per system)
• Low suction pressure (per system)
2

16 EN
FORM 150.27-NM2.EN.CE (0312)
ACCESSORIES AND OPTIONS
Soft Starters
Factory mounted soft starters reduce the inrush current
to the last compressor on each refrigerant circuit. They
are preset so that no field adjustment is required.
Language LCD and Keypad
English, French, German, Italian and Spanish unit LCD
read-out and keypad available. Standard language is
English.
38 mm Evaporator Insulation
Double thickness insulation provided for enhanced
efficiency, and low temperature applications.
Dual Pressure Relief Valves
Two pressure relief valves mounted on a 3-way valve
in parallel of which one is operational and the other one
assist during maintenance.
Suction Service Valves
A ball valve is added to each suction line pipework for
isolation.
Victaulic Flange Kit
Victaulic PN10 Flange joint kit supplied loose for field
installation. Includes flange and companion flange and
all necessary nuts, bolts and gaskets.
Compressor Acoustic Blankets
Each compressor is individually enclosed in an acoustic
sound blanket. The sound blankets are made with one
layer of acoustical absorbent textile fibre of 15 mm
thickness and one layer of anti vibrating heavy material
thickness of 3 mm. Both are closed by two sheets
of welded PVC, reinforced for temperature and UV
resistance.
Flow switch
Vapour Proof, paddle-type, 10.3 barg DWP, -29°C to
121°C with 1”NPT connection for upright mounting in
horizontal pipe. This flow switch or its equivalent must
be supplied with each unit to protect vessels from loss
of liquid flow (Field Mounted)
Differential Pressure Switch
Alternative to the paddle type flow switch. 0-3 bar range
with ¼” NPTE pressure connections (field mounted).
Neoprene Pad Isolators
Recommended for normal installations (field
mounted).
25 mm Spring Isolators
Level adjustable, spring and cage type isolators for
mounting under the unit base rails (field mounted).

17
FORM 150.27-NM2.EN.CE (0312)
EN
Low-pressure liquid refrigerant enters the cooler
tubes and is evaporated and superheated by the
heat energy absorbed from the chilled liquid pass-
ing through the cooler shell. Low-pressure vapour
enters the compressor where pressure and super-
heat are increased. The high pressure superheat
refrigerant enters the remote air cooled condenser
where heat is rejected via the condenser coil &
fans The fully condensed and subcooled liquid
leaves the remote air cooled condenser and enters
the expansion valve, where pressure reduction
and further cooling takes place. The low-pressure
liquid refrigerant then returns to the cooler.
Evaporator
Remote Condenser
Compressors
27.6 bar
Refer to
Options
Components:
Pressure Relief Valve
Service (Ball) Valve
Expansion Valve
Solenoid Valve
Sight Glass
Sensor Pressure
or Temperature
Service (Stop) Access Valve
Pressure Switch
Filter Drier
(Removable Core)
S
PS
Option
Control Functions:
DV - Display Value
CHT - Chilled Liquid Temperature
HPC - High Pressure Cutout
LPC - Low Pressure Cutout
HPL - High Pressure Load Limiting
-YLLSV
FHP1
38.7 bar
FHP2*
40.3 bar
BY OTHERS
BY
OTHERS
Note: Only 1 Circuit Shown
*FHP2 (HP cut-out) not fitted on models:
0200HE, 0230HE, 0260HE & 0300HE
ZCPR-3 not fitted on models: 0200HE,
0230HE, 0260HE, 0300HE & 0345HE
2
REFRIGERANT FLOW DIAGRAM

18 EN
FORM 150.27-NM2.EN.CE (0312)
FILTER
DRIER
UNIT COMPONENTS
SINGLE SPEED SCROLL
COMPRESSORS
SINGLE SPEED SCROLL
COMPRESSORS
POWER PANEL
EVAPORATOR
FORMED STEEL
BASE RAILS
LIQUID LINE
STUB-OUT
FILTER
DRIERS LIQUID
LINE
SOLENOID
VALVE
CONTROL PANEL
WITH KEYPAD AND
DISPLAY
SIGHT
GLASS TXV
VALVE
OPTIONAL ISOLATION VALVE
COMPRESSOR
CRANKCASE HEATER
EVAPORATOR
LIQUID
LINE
SOLENOID
VALVE
SIGHT
GLASS
TXV
VALVE
EVAPORATOR
WATER INLET
EVAPORATOR
WATER OUTLET
ISOLATION VALVES
(OPT)
LD14534
DISCHARGE LINE
STUB-OUT
LIQUID LINE
STUB-OUT

19
FORM 150.27-NM2.EN.CE (0312)
EN
NOMENCLATURE
The model number denotes the following characteristics of the unit.
UNIT MODEL NUMBER NOMENCLATURE
Y C R L - 0445 - H - E - 50 - X - AB
YORK
CHILLER
REMOTE CONDENSER
SCROLL
COMPRESSOR
MODEL NUMBER
0200, 0230, 0260, 0300, 0345,
0385, 0445, 0530, 0610
UNIT DESIGNATOR H - High Efficiency
REFRIGERANT - R410A
VOLTAGE CODE 50=380 - 415/3/50
DESIGN SERIES/
DEVELOPMENT LEVEL
DOL STARTING
2

20 EN
FORM 150.27-NM2.EN.CE (0312)
HANDLING AND STORAGE
DELIVERY AND STORAGE
To ensure consistent quality and maximum reliability,
all units are tested and inspected before leaving the
factory. Units are shipped completely assembled and
containing a nitrogen holding charge. Units are shipped
without export crating unless crating has been specified
on the Sales Order.
If the unit is to be put into storage, prior to installation,
the following precautions should be observed:
• Ensure that all openings, such as water connections,
are securely capped.
• Do not store where exposed to ambient air temperatures
exceeding 42°C.
• The unit should be stored in a location where there is
minimal activity in order to limit the risk of accidental
physical damage.
• To prevent inadvertent operation of the pressure relief
devices the unit must not be steam cleaned.
• It is recommended that the unit is periodically
inspected during storage.
INSPECTION
Remove any transit packing and inspect the unit to
ensure that all components have been delivered and that
no damage has occurred during transit. If any damage
is evident, it should be noted on the carrier’s freight bill
and a claim entered in accordance with the instructions
given on the advice note.
Major damage must be reported immediately to your
local Johnson Controls representative.
MOVING THE CHILLER
Prior to moving the unit, ensure that the installation site
is suitable for installing the unit and is easily capable
of supporting the weight of the unit and all associated
services.
The units are designed to be lifted using lifting
chains.
Lifting by Crane/Hoist
Attach the lifting chains to the lifting lugs on each corner
of the unit framework. A spreader frame should be used
to prevent damage to the unit from the lifting chains.
The unit must only be lifted at the points provided.
LIFTING WEIGHTS
Lifting weights are given in the table below.
LIFTING WEIGHTS - High Efficiency (HE)
YCRL MODEL (kg)
0200HE 0230HE 0260HE 0300HE 0345HE 0385HE 0445HE 0530HE 0610HE
(1309) (1481) (1471) (1593) (1683) (1947) (2266) (2264) (2263)