York YCAL0014E Series Owner's manual

YCAL0014E_ - YCAL0134E_
AIR COOLED SCROLL CHILLERS
STYLE C
WITH IPU II AND I/O BOARDS
60 Hz
Standard, Glycol & Metric Models, Combined
200-3-60
230-3-60
380-3-60
460-3-60
575-3-60
MODELS ONLY
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Supersedes 150.62-NM8 (410) Form 150.62-NM8 (1020)
035-22320-000
R-22 & HFC-407C

JOHNSON CONTROLS
2
FORM 150.62-NM8 (1020)
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, materials under pressure, rotating components,
and both high and low voltage. Each of these items
has the potential, if 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, as well as severe personal injury or
death to themselves and people at the site.
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
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 will have read
and understood this document and any referenced
materials. This individual will 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 identies 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 seri-
ous injury.
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or seri-
ous injury.
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 may NOT be installed inside the micro panel. NO external wiring
is allowed to be run through the micro panel. All wiring must be in accordance with John-
son Controls published specications and must be performed ONLY by qualied Johnson
Controls personnel. Johnson Controls will not be responsible for damages/problems result-
ing 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.

JOHNSON CONTROLS 3
FORM 150.62-NM8 (1020)
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 Knowledge Exchange website at https://
docs.johnsoncontrols.com/chillers/.
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.
REVISION NOTES
Revisions made to this document are indicated in the following table. These revisions are to technical information,
and any other changes in spelling, grammar, or formatting are not included.
AFFECTED PAGES DESCRIPTION
3 Conditioned Based Maintenance program information added
CONDITIONED BASED MAINTENANCE
Traditional chiller maintenance is based upon assumed
and generalized conditions. In lieu of the traditional
maintenance program, a Johnson Controls YORK
Conditioned Based Maintenance (CBM) program can
be substituted. This CBM service plan is built around
the specific needs for the chiller, operating conditions,
and annualized impact realized by the chiller. Your lo-
cal Johnson Controls Branch can propose a customized
Planned Service Agreement that leverages real time
and historical data, delivering performance reporting,
corrective actions required and data enabled guidance
for optimal operation and lifecycle assurance. The pro-
gram will include fault detection diagnostics, operation
code statistics, performance based algorithms and ad-
vance rules based rationale delivered by the Johnson
Controls Connected Equipment Portal.

JOHNSON CONTROLS
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FORM 150.62-NM8 (1020)
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JOHNSON CONTROLS 5
FORM 150.62-NM8 (1020)
TABLE OF CONTENTS
SECTION 1 - INSTALLATION .........................................................................................................19
INSTALLATION CHECK LIST ...................................................................................................................19
HANDLING ..................................................................................................................................................19
INSPECTION ...............................................................................................................................................19
LOCATION AND CLEARANCES...............................................................................................................19
Foundation..............................................................................................................................................20
Ground Level Locations ........................................................................................................................20
Rooftop Locations .................................................................................................................................20
Noise Sensitive Locations.....................................................................................................................20
SPRING ISOLATORS (OPTIONAL)..........................................................................................................20
COMPRESSOR MOUNTING .....................................................................................................................20
REMOTE COOLER OPTION .....................................................................................................................20
CHILLED WATER PIPING..........................................................................................................................20
General ...................................................................................................................................................20
WIRING ........................................................................................................................................................21
Field Wiring.............................................................................................................................................21
Evaporator Pump Start Contacts..........................................................................................................22
System Run Contacts ............................................................................................................................22
Alarm Status Contacts...........................................................................................................................22
Remote Start/Stop Contacts .................................................................................................................22
Remote Emergency Cuto󰀨 ....................................................................................................................22
PWM Input...............................................................................................................................................22
Load Limit Input .....................................................................................................................................22
Flow Switch Input...................................................................................................................................22
Compressor Heaters..............................................................................................................................22
SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED DISCONNECT
SWITCH OR CIRCUIT BREAKER (0014 - 0080)......................................................................................23
MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL BLOCK (0040 - 0080).................24
MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL BLOCK,
NON-FUSED DISCONNECT SWITCHES OR CIRCUIT BREAKERS (0090 - 0134).............................25
SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK OR NON-FUSED DISCONNECT
SWITCH TO INDIVIDUAL SYSTEM CIRCUIT BREAKERS (0090 - 0134).............................................26
CONTROL WIRING.....................................................................................................................................27
ELECTRICAL NOTES AND LEGEND.......................................................................................................28

JOHNSON CONTROLS
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FORM 150.62-NM8 (1020)
TABLE OF CONTENTS (CONT'D)
ELECTRICAL DATA....................................................................................................................................29
Single-Point Power Supply Connections – YCAL0014E_ - YCAL0034E_ .........................................30
Electrical Data – Dual Point Power Supply Connections – YCAL0040E_ - YCAL0080E_ ...............32
Electrical Data – Dual Point Power Supply Connections – YCAL0040E_ - YCAL0080E_ ...............33
Electrical Data – Single Point Power Supply Connections – YCAL0040E_ - YCAL0080E_ ............34
Electrical Data – Single Point Power Supply Connections – YCAL0040E_ - YCAL0080E_ ............35
Electrical Data – Multiple Point Power Supply Connections – YCAL0090E_ - YCAL0134E_..........36
Electrical Data – Multiple Point Power Supply Connections – YCAL0090E_ - YCAL0134E_..........37
Electrical Data – Single Point Power Supply Connections With Individual
System Circuit Breakers – YCAL0090E_ - YCAL0134E_ ....................................................................38
Electrical Data – Single Point Power Supply Connections With Individual
System Circuit Breakers – YCAL0090E_ - YCAL0134E_ ....................................................................39
OPERATIONAL LIMITATIONS (ENGLISH)..............................................................................................40
Voltage Limitations ................................................................................................................................40
OPERATIONAL LIMITATIONS (METRIC) ................................................................................................42
Voltage Limitations ................................................................................................................................42
PHYSICAL DATA (ENGLISH) YCAL0014E_ - YCAL0134E_ ..................................................................44
PHYSICAL DATA (METRIC) YCAL0014E_ - YCAL0134E_.....................................................................46
DIMENSIONS AND CLEARANCES ..........................................................................................................48
Dimensions - YCAL0014-YCAL0020 (English) ....................................................................................48
Dimensions - YCAL0024-YCAL0034 (English) ....................................................................................50
Dimensions - YCAL0040-YCAL0060 (English) ....................................................................................52
Dimensions - YCAL0064-YCAL0080 (English) ....................................................................................54
Dimensions - YCAL0090-YCAL0094 (English) ....................................................................................56
Dimensions - YCAL0104 (English) .......................................................................................................58
Dimensions - YCAL0114 - YCAL0134 (English)..................................................................................60
Dimensions - YCAL0014-YCAL0020 (SI) ..............................................................................................62
Dimensions - YCAL0024-YCAL0034 (SI) ..............................................................................................64
Dimensions - YCAL0040-YCAL0060 (SI) ..............................................................................................66
Dimensions -YCAL0064-YCAL0080 (SI) ...............................................................................................68
Dimensions - YCAL0090-YCAL0094 (SI) ..............................................................................................70
Dimensions - YCAL0104 (SI) .................................................................................................................72
Dimensions - YCAL0114 - YCAL0134 (SI) ............................................................................................74
EQUIPMENT PRE-STARTUP AND STARTUP CHECKLIST..................................................................76
Pre-Startup..............................................................................................................................................76
Startup.....................................................................................................................................................77
Checking Superheat and Subcooling ..................................................................................................78
Leak Checking........................................................................................................................................79
UNIT OPERATING SEQUENCE................................................................................................................80

JOHNSON CONTROLS 7
FORM 150.62-NM8 (1020)
SECTION 2 - UNIT CONTROLS .....................................................................................................81
INTRODUCTION .........................................................................................................................................81
IPU II AND I/O BOARDS ............................................................................................................................81
UNIT SWITCH .............................................................................................................................................82
DISPLAY ......................................................................................................................................................82
KEYPAD.......................................................................................................................................................82
BATTERY BACK-UP...................................................................................................................................82
TRANSFORMER ........................................................................................................................................82
SINGLE SYSTEM SELECT AND PROGRAMMING # OF COMPRESSORS........................................82
STATUS KEY..............................................................................................................................................83
General Status Messages......................................................................................................................83
Fault Status Messages ..........................................................................................................................85
Unit Warning...........................................................................................................................................87
STATUS KEY MESSAGES.........................................................................................................................88
DISPLAY/PRINT KEYS ..............................................................................................................................89
Oper Data Key ........................................................................................................................................89
Oper Data Quick Reference List ...........................................................................................................92
Print Key .................................................................................................................................................93
Operating Data Printout.........................................................................................................................93
History Printout ......................................................................................................................................94
History Displays .....................................................................................................................................94
Software Version ....................................................................................................................................97
ENTRY KEYS ..............................................................................................................................................98
Up and Down Arrow Keys .....................................................................................................................98
Enter/Adv Key.........................................................................................................................................98
SETPOINTS KEYS......................................................................................................................................99
Cooling Setpoints ..................................................................................................................................99
Leaving Chilled Liquid Control .............................................................................................................99
Return Chilled Liquid Control .............................................................................................................100
Schedule/Advance Day Key ................................................................................................................100
Program Key.........................................................................................................................................102
UNIT KEYS ...............................................................................................................................................107
Options Key ..........................................................................................................................................107
CLOCK....................................................................................................................................................... 111
SECTION 3 - UNIT OPERATION ..................................................................................................113
CAPACITY CONTROL..............................................................................................................................113
SUCTION PRESSURE LIMIT CONTROLS ............................................................................................113
DISCHARGE PRESSURE LIMIT CONTROLS.......................................................................................113
LEAVING CHILLED LIQUID CONTROL.................................................................................................113
Leaving Chilled Liquid Control Override to Reduce Cycling...........................................................114
RETURN CHILLED LIQUID CONTROL..................................................................................................114
SYSTEM LEAD/LAG.................................................................................................................................116
COMPRESSOR LEAD/LAG.....................................................................................................................116
TABLE OF CONTENTS (CONT'D)

JOHNSON CONTROLS
8
FORM 150.62-NM8 (1020)
ANTI-RECYCLE TIMER ...........................................................................................................................116
ANTI-COINCIDENCE TIMER................................................................................................................... 116
EVAPORATOR PUMP CONTROL........................................................................................................... 117
EVAPORATOR HEATER CONTROL ......................................................................................................117
PUMPDOWN CONTROL..........................................................................................................................117
ELECTRONIC EXPANSION VALVE (EEV)............................................................................................. 117
General..................................................................................................................................................117
MOP Feature .........................................................................................................................................117
Valve Preheat........................................................................................................................................117
Inputs ....................................................................................................................................................117
Outputs .................................................................................................................................................118
Program ................................................................................................................................................118
Safeties .................................................................................................................................................118
CONDENSER FAN CONTROL (YCAL0014 THROUGH YCAL0080 CHILLERS)............................... 118
CONDENSER FAN CONTROL (YCAL0090 THROUGH YCAL0134) ................................................... 118
LOW AMBIENT CONDENSER FAN CONTROL (YCAL0014 THROUGH YCAL0080) ....................... 118
CONDENSER FAN CONTROL ................................................................................................................119
YCAL0014 - YCAL0080 ........................................................................................................................119
YCAL0090 – YCAL0104........................................................................................................................121
YCAL0114 – YCAL0134........................................................................................................................122
LOAD LIMITING........................................................................................................................................123
COMPRESSOR RUN STATUS ................................................................................................................123
ALARM STATUS .......................................................................................................................................123
EMS-PWM REMOTE TEMPERATURE RESET .....................................................................................124
BAS/EMS TEMPERATURE RESET OPTION ........................................................................................124
SECTION 4 - SERVICE AND TROUBLESHOOTING .................................................................127
CLEARING HISTORY BUFFERS ............................................................................................................127
SOFTWARE VERSION.............................................................................................................................127
SERVICE MODE .......................................................................................................................................127
Service Mode – Outputs ......................................................................................................................127
Service Mode – Chiller Conguration ................................................................................................127
Service Mode – Inputs .........................................................................................................................128
CONTROL INPUTS/OUTPUTS................................................................................................................129
Checking Inputs and Outputs .............................................................................................................131
KEYPAD.....................................................................................................................................................135
Parts ......................................................................................................................................................136
Assembly and Wiring...........................................................................................................................136
Obtaining a Printout.............................................................................................................................136
TROUBLESHOOTING CHARTS .............................................................................................................137
TABLE OF CONTENTS (CONT'D)

JOHNSON CONTROLS 9
FORM 150.62-NM8 (1020)
TABLE OF CONTENTS (CONT'D)
SECTION 5 - MAINTENANCE ......................................................................................................141
IMPORTANT ..............................................................................................................................................141
COMPRESSORS.......................................................................................................................................141
Oil Level check .....................................................................................................................................141
Oil Analysis...........................................................................................................................................141
CONDENSER FAN MOTORS ..................................................................................................................141
CONDENSER COILS................................................................................................................................141
OPERATING PARAMETERS...................................................................................................................141
ON-BOARD BATTERY BACK-UP...........................................................................................................141
OVERALL UNIT INSPECTION ................................................................................................................141
BACNET, MODBUS AND YORKTALK 2 COMMUNICATIONS ............................................................142
Micro Panel Connections ....................................................................................................................143
BACnet and Modbus Communications..............................................................................................145
Communications Data Map Notes ......................................................................................................145
Yorktalk 2 Communications ................................................................................................................149
SECTION 6 - WIRING DIAGRAMS...............................................................................................153
YCAL0014E_ – YCAL0030E_...................................................................................................................153
YCAL0034E_..............................................................................................................................................159
YCAL0040E_ – YCAL0060E_...................................................................................................................165
YCAL0064E_ – YCAL0080E_...................................................................................................................172
YCAL0090E_ – YCAL0094E_...................................................................................................................179
YCAL0104E_ .............................................................................................................................................186
YCAL0114E_ – YCAL0134E_ ...................................................................................................................193
SECTION 7 - ISOLATOR DATA ....................................................................................................201
WEIGHT DISTRIBUTION .........................................................................................................................201
Aluminum Fin Coils .............................................................................................................................201
Copper Fin Coils ..................................................................................................................................202
ISOLATOR SELECTIONS........................................................................................................................203
Aluminum Fin Coils .............................................................................................................................203
Copper Fin Coils ..................................................................................................................................205
ISOLATOR DIMENSIONS AND SPRINGS CP-1 AND CP-2................................................................207
Isolator Spring Identication Table ....................................................................................................207
SEISMIC ISOLATOR DIMENSIONS .......................................................................................................208
INSTALLATION AND ADJUSTING INSTALLATIONSTYPE CP MOUNTING.....................................209
AEQM SPRING-FLEX MOUNTING .........................................................................................................210
INSTALLATION AND ADJUSTMENT INSTRUCTIONS........................................................................210

JOHNSON CONTROLS
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FORM 150.62-NM8 (1020)
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JOHNSON CONTROLS 11
FORM 150.62-NM8 (1020)
LIST OF TABLES
TABLE 1 – MICRO PANEL POWER SUPPLY........................................................................................29
TABLE 2 – SINGLE-POINT POWER SUPPLY .......................................................................................30
TABLE 3 – DUAL POINT POWER SUPPLY CONNECTIONS..............................................................32
TABLE 4 – SINGLE POINT POWER SUPPLY CONNECTIONS ..........................................................34
TABLE 5 – MULTIPLE POINT POWER SUPPLY CONNECTIONS......................................................36
TABLE 6 – SINGLE POINT POWER SUPPLY CONNECTIONS WITH INDIVIDUAL
SYSTEM CIRCUIT BREAKERS ...........................................................................................38
TABLE 7 – TEMPERATURES AND FLOWS ..........................................................................................40
TABLE 8 – VOLTAGE LIMITATIONS ......................................................................................................40
TABLE 9 – COOLER PRESSURE DROP CURVES ..............................................................................41
TABLE 10 – ETHYLENE / PROPYLENE GLYCOL CORRECTION FACTORS....................................41
TABLE 11 – TEMPERATURES AND FLOWS ..........................................................................................42
TABLE 12 – VOLTAGE LIMITATIONS ......................................................................................................42
TABLE 13 – COOLER PRESSURE DROP CURVES ..............................................................................43
TABLE 14 – ETHYLENE / PROPYLENE GLYCOLCORRECTION FACTORS......................................43
TABLE 15 – PHYSICAL DATA (ENGLISH)...............................................................................................44
TABLE 16 – PHYSICAL DATA (METRIC).................................................................................................46
TABLE 17 - SETPOINTS ENTRY LIST .....................................................................................................77
TABLE 18 – STATUS KEY MESSAGES ...................................................................................................88
TABLE 19 – OPERATION DATA................................................................................................................92
TABLE 20 – COOLING SETPOINTS, PROGRAMMABLE LIMITS AND DEFAULTS ........................101
TABLE 21 – PROGRAM KEY LIMITS AND DEFAULTS .......................................................................105
TABLE 22 – SETPOINTS QUICK REFERENCE LIST...........................................................................106
TABLE 23 – UNIT KEYS PROGRAMMING QUICK REFERENCE LIST ............................................. 112
TABLE 24 – COMPRESSOR STAGING FOR RETURN WATER CONTROL ...................................... 115
TABLE 25 – RETURN CHILLED LIQUID CONTROL FOR 5 & 6 COMPRESSORS (7 & 8 STEPS) . 115
TABLE 26 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS)............... 116
TABLE 27 – YCAL0014 THROUGH YCAL0080 CONDENSER FAN CONTROL USING
OUTDOOR AMBIENT TEMPERATURE AND DISCHARGE PRESSURE. ....................119
TABLE 28 – YCAL0014 THROUGH YCAL0080 CONDENSER FAN CONTROL USING
DISCHARGE PRESSURE ONLY........................................................................................120
TABLE 29 – YCAL0014 - YCAL0080 LOW AMBIENT CONDENSER FAN CONTROL –
DISCHARGE PRESSURE CONTROL ...............................................................................120
TABLE 30 – YCAL0090 - YCAL0104 CONDENSER FAN CONTROL .................................................121
TABLE 31 – YCAL0114 - YCAL0134 CONDENSER FAN CONTROL .................................................122
TABLE 32 – COMPRESSOR OPERATION – LOAD LIMITING ............................................................123
TABLE 33 – I/O BOARD DIGITAL INPUTS ............................................................................................129
TABLE 34 – I/O BOARD ANALOG INPUTS...........................................................................................129
TABLE 35 – I/O BOARD DIGITAL OUTPUTS ........................................................................................129
TABLE 36 – I/O BOARD ANALOG OUTPUTS.......................................................................................129
TABLE 37 – OUTDOOR AIR SENSOR TEMPERATURE/VOLTAGE/ RESISTANCE CORRELATION131

JOHNSON CONTROLS
12
FORM 150.62-NM8 (1020)
LIST OF TABLES (CONT'D)
TABLE 38 – ENTERING/LEAVING CHILLED LIQUID TEMP. SENSOR, COOLER INLET
TEMPERATURE SENSOR, AND SUCTION TEMPERATURE SENSOR:
TEMPERATURE/VOLTAGE/RESISTANCE CORRELATION ..........................................132
TABLE 39 – KEYPAD PIN ASSIGNMENT MATRIX...............................................................................135
TABLE 40 – TROUBLESHOOTING ........................................................................................................137
TABLE 41 – MINIMUM, MAXIMUM AND DEFAULT VALUES ..............................................................143
TABLE 42 – VALUES REQUIRED FOR BAS COMMUNICATION .......................................................144
TABLE 43 – REAL TIME ERROR NUMBERS........................................................................................144
TABLE 44 - BACNET AND MODBUS COMMUNICATIONS DATA MAP.............................................146
TABLE 45 - YORKTALK 2 COMMUNICATIONS DATA MAP................................................................150

JOHNSON CONTROLS 13
FORM 150.62-NM8 (1020)
LIST OF FIGURES
FIG. 1 – REFRIGERANT FLOW DIAGRAM ...........................................................................................17
FIG. 2 – SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED
DISCONNECT SWITCH OR CIRCUIT BREAKER (0014 - 0080)............................................23
FIG. 3 – MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL BLOCK (0040 - 0080).24
FIG. 4 – MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL BLOCK,
NON-FUSED DISCONNECT SWITCHES OR CIRCUIT BREAKERS (0090 - 0134).............25
FIG. 5 – OPTIONAL SINGLE-POINT POWER WIRING ........................................................................26
FIG. 6 – CONTROL WIRING ...................................................................................................................27
FIG. 7 – SETPOINT ADJUST.................................................................................................................114
FIG. 8 – LEAVING WATER TEMPERATURE CONTROL EXAMPLE.................................................114
FIG. 9 – YCAL0014 THROUGH YCAL0080 FAN LOCATION (TYPICAL).......................................... 119
FIG. 10 – YCAL0090 THROUGH YCAL0104 FAN LOCATION .............................................................121
FIG. 11 – YCAL0114 – YCAL0134 FAN LOCATION...............................................................................122
FIG. 12 – FIELD AND FACTORY ELECTRICAL CONNECTIONSOPTIONAL REMOTE
TEMPERATURE RESET BOARD ............................................................................................125
FIG. 13 – I/O BOARD LAYOUT................................................................................................................130
FIG. 14 – I/O BOARD RELAY CONTACT ARCHITECTURE.................................................................134
FIG. 15 – PRINTER TO I/O BOARD ELECTRICAL CONNECTIONS ..................................................136
FIG. 16 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0014E_ - YCAL0030E_..................153
FIG. 17 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0014E_ - YCAL0030E_ .............154
FIG. 18 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0014E_ - YCAL0030E_.................156
FIG. 19 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0014E_ - YCAL0030E_.................158
FIG. 20 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0034E_............................................159
FIG. 21 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0034E_ ..........................................160
FIG. 22 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0034E_...........................................162
FIG. 23 – ELEMENTARY DIAGRAM, MIDLLE MARKET – YCAL0034E_ ...........................................164
FIG. 24 – ELEMENTARY DIAGRAM, MIDLLE MARKET – YCAL0040E_ - YCAL0060E_ .................165
FIG. 25 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0040E_ - YCAL0060E_ .............166
FIG. 26 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0040E_ - YCAL0060E_..................168
FIG. 27 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0040E_ - YCAL0060E_.................170
FIG. 28 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0064E_ - YCAL0080E_ .............172
FIG. 29 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0064E_ - YCAL0080E_..................174
FIG. 30 – CONNECTION DIAGRAM, MIDDLE MARKET – YCAL0064E_ - YCAL0080E_.................176
FIG. 31 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0064E_ - YCAL0080E_.................178
FIG. 32 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCAL0090E_ - YCAL0094E_.................179
FIG. 33 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0090E_ - YCAL0094E_ .............180
FIG. 34 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0090E_ - YCAL0094E_..................182
FIG. 35 – CONNECTION DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE –
YCAL0090E_ - YCAL0094E_....................................................................................................184
FIG. 36 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0104E_ .......................................186
FIG. 37 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0104E_............................................188
FIG. 38 – CONNECTION DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE – YCAL0104E_..190
FIG. 39 – ELEMENTARY DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE– YCAL0104E_...192

JOHNSON CONTROLS
14
FORM 150.62-NM8 (1020)
LIST OF FIGURES (CONT'D)
FIG. 40 – ELEMENTARY DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE –
YCAL0114E_ - YCAL0134E_.....................................................................................................193
FIG. 41 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCAL0114E_ - YCAL0134E_..............194
FIG. 42 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCAL0114E_ - YCAL0134E_..................196
FIG. 43 – CONNECTION DIAGRAM, MIDDLE MARKET HIGH PERFORMANCE –
YCAL0114E_ - YCAL0134E_.....................................................................................................198
FIG. 44 – TYPE CP 1.................................................................................................................................207
FIG. 45 – TYPE CP 2.................................................................................................................................207
FIG. 46 – R SPRING SEISMIC ISOLATOR.............................................................................................208
FIG. 47 – TYPE CP MOUNTING ..............................................................................................................209
FIG. 48 – AEQM SPRING-FLEX MOUNTING.........................................................................................210

JOHNSON CONTROLS 15
FORM 150.62-NM8 (1020)
PRODUCT IDENTIFICATION NUMBER (PIN)
BASIC MODEL NUMBER
: High E󰀩ciency : R-22
: R-407C
: YORK
: Chiller
: Air-Cooled
: Condensing
Unit
: Scroll
Even Number:
60 HZ Nominal Tons
Odd Number:
50 HZ Nominal kW
: 200 / 3/ 60
: 230 / 3 / 60
: 380 / 3 / 60
: 460 / 3 / 60
: 380-415 / 3 / 50
: 575 / 3 / 60
: Across the Line
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE/STARTER DESIGN/DEVELOPMENT LEVEL
Y 0 # # # E C 1 7 C
C 1 # # # B 2 8 A
A 4 0
U 4 6
5 0
L 5 8
X
: Design Series
: Engineering
Change
or PIN Level
YCAL0080EC46XCA

JOHNSON CONTROLS
16
FORM 150.62-NM8 (1020)
PRODUCT IDENTIFICATION NUMBER (PIN)
EXAMPLES:
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55
X X X X X X X X L X X X X X X X X X X X X X X X X X A X X X X X X X X X X X X X
S D T C A T S R L X P R S 2 5 C X 1 X X X X 3 D W S A R X B X X 4 B X X L X S D
OPTIONS MODEL NUMBER
: Aluminum : Copper : Black Fin : Phenolic : TEAO Fan Motors
EVAP. FIELD CONDENSER FIELD CABINET FIELD
: Wire Condenser Headers Only (factory) : Wire (Full Unit) Enc. Panels (factory) : Wire (Full Unit) Enc. Panels (eld) : Wire/Louvered Enc. Panels (factory) : Wire/Louvered Enc. Panels (eld) : Louvered (Cond. Only) Enc. Panels (factory) : Louvered (Cond. Only) Enc. Panels (eld) : Louvered (Full Unit) Enc. Panels (factory) : Louvered (Full Unit) Enc. Panels (eld) : Acoustic Sound Blanket : Low Sound Fans : 1" Deection : Seismic : Neoprene Pads
55 EXTENDED FIELD X B C D E F G H
: 1st Year Parts Only : 1st Year Parts & Labor : 2nd Year Parts Only : 2nd Year Parts & Labor : 5 Year Compressor Parts Only : 5 Year Compressor Parts & Labor Only : 5 Year Units Parts Only : 5 Year Unit Parts & Labor
NOTES: 1. Q :DENOTES SPECIAL / S.Q. 2. # :DENOTES STANDARD 3. X :w/in OPTIONS FIELD, DENOTES NO OPTION SELECTED 4. Agency Files (i.e. U.L. / E.T.L.; CE; ARI; ETC.) will contain info. based on the rst 14 characters only.
: Low Ambient Kit (factory) : High Ambient Kit (factory) : Both Low / High Ambient (factory) : BAS/EMS Temp. Reset / O󰀨set : Spanish LCD & Keypad Display : French LCD & Keypad Display : German LCD & Keypad Display : Discharge Pressure Transducers/ Readout Kit : Suction Pressure Transducers / Readout Kit : Both Discharge & Suction Pressure Transducers / Readout : N. American Safety Code (cU.L./cE.T.L.) : No Listing (typically 50 HZ non-CE, non-U.L. : Remote Control Panel : Sequence Control & Automatic Lead Transfer
: 300 PSIG DWP Waterside : Double Thick Insulation : Weld Flange Kit : Victaulic Flange Kit : Flow Switch : ASME Pressure Vessel & Associated Codes : Remote DX Cooler
: SP Supply TB : MP Supply TB : SP Supply TB : SP NF Disconnect Switch : SP Circuit Breaker w/ Lockable Handle : Control Transformer (factory) : Power Factor Capacitor
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 POWER FIELD CONTROLS FIELD COMPRESSOR / PIPING FIELD X X L # # X X H S X A C S D T S B X S B F E G 1 T I C R X S X B X X L N C R S
MP = Multiple Point SP = Single-Point NF = Non-Fused TB = Terminal Block Ser. = Service Ind. Sys. Brkr. & L. Ext. Handles = Individual System Breaker & Lockable External Handle
38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 3 X X D C 1 W B 2 V P 3 S X 4 A 5 6 R 7 8 B L 1 S N
: Leaving Supply Temp. : Chicago Code Kit Req’d. : Service Isolation Valves : Both Chicago & Svc. Iso. : Elec. Expansion Valve : Hot Gas By-Pass req’d. (1 circuit) : X : X : X : Crankcase Heater Std.

JOHNSON CONTROLS 17
FORM 150.62-NM8 (1020)
LD07613A
REFRIGERANT FLOW DIAGRAM
FIG. 1 – REFRIGERANT FLOW DIAGRAM
2 OR 3 COMPRESSORS PER SYSTEM
OIL EQUALIZING
LINE
AIR COOLED CONDENSERS
DX COOLER
LEAVING CHILLED WATER
ENTERING CHILLED WATER
OPTIONAL
SERVICE VALVE
OPTIONAL DISCHARGE
PRESSURE TRANSDUCER
HIGH PRESSURE
CUTOUT SWITCH
OPTIONAL
SERVICE
VALVE
LOW PRESSURE SWITCH OR
SUCTION PRESSURE TRANSDUCER
LEAVING
CHILLED WATER
TEMP. SENSOR
RETURN WATER
TEMP. SENSOR
OPTIONAL
DISCHARGE LINE
BALL VALVE
HOT DISCHARGE
GAS LINE
LIQUID LINE
SERVICE VALVE
LIQUID LINE FILTER / DRIER
LIQUID LINE
SOLENOID VALVE
SIGHT GLASS /
MOISTURE INDICATOR
SOLENOID OPERATED
HOT GAS BY PASS VALVE
*
OPTIONAL
SUCTION LINE
BALL VALVE
EQUALIZER
LINE
TXV
OPTIONAL
RELIEF VALVE
300 PSIG
(20.68 BARG)
YCAL REFRIGERANT FLOW DIAGRAM
(INCLUDING TEMPERATURE SENSORS & PRESSURE TRANSDUCERS)
NOTE: YCAL0040-0134 HAVE TWO REFRIGERANT
SYSTEMS AND ONE DX COOLER.
* HOT GAS OPTION - SYSTEM 1 ONLY
OPTIONAL

JOHNSON CONTROLS
18
FORM 150.62-NM8 (1020)
THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS 19
FORM 150.62-NM8 (1020)
1
29224(RIG)A
To ensure warranty coverage, this
equipment must be commissioned
and serviced by an authorized John-
son Controls service mechanic or a
qualied service person experienced in
chiller installation. Installation must
comply with all applicable codes, par-
ticularly in regard to electrical wiring
and other safety elements such as re-
lief valves, HP cutout settings, design
working pressures, and ventilation re-
quirements consistent with the amount
and type of refrigerant charge.
Lethal voltages exist within the control
panels. Before servicing, open and tag
all disconnect switches.
INSTALLATION CHECK LIST
The following items,must be checked before placing
the units in operation.
1. Inspect the unit for shipping damage.
2. Rig unit using spreader bars.
3. Open the unit only to install water piping system.
Do not remove protective covers from water
connections until piping is ready for attachment.
Check water piping to ensure cleanliness.
4. Pipe unit using good piping practice (see ASHRAE
handbook section 215 and 195).
5. Check to see that the unit is installed and operated
within limitations (Refer to Operational and Voltage
Limitations located in Section 1 of this IOM).
The following pages outline detailed procedures to be
followed to install and startup the chiller.
HANDLING
These units are shipped as completely assembled units
containing full operating charge, and care should be
taken to avoid damage due to rough handling.
The unit should be lifted by inserting
hooks through the holes provided in
unit base rails. Spreader bars should be
used to avoid crushing the unit frame
rails with the lifting chains.
SECTION 1 - INSTALLATION
INSPECTION
Immediately upon receiving the unit, it should be
inspected for possible damage which may have
occurred during transit. If damage is evident, it should
be noted in the carrier’s freight bill. A written request
for inspection by the carrier’s agent should be made at
once. See Instruction manual, Form 50.15-NM for more
information and details.
LOCATION AND CLEARANCES
These units are designed for outdoor installations on
ground level, rooftop, or beside a building. Location
should be selected for minimum sun exposure and to
insure adequate supply of fresh air for the condenser.
The units must be installed with sucient clearances
for air entrance to the condenser coil, for air discharge
away from the condenser, and for servicing access.
In installations where winter operation is intended and
snow accumulations are expected, additional height
must be provided to ensure normal condenser air ow.
Clearances are listed under Dimensions in Section 1
of this IOM.
EXAMPLE OF PROPER LIFITING

JOHNSON CONTROLS
20
FORM 150.62-NM8 (1020)
INSTALLATION
Foundation
The unit should be mounted on a flat and level
foundation, oor, or rooftop capable of supporting the
entire operating weight of the equipment. See Physical
Data in Section 1 of this IOM for operating weight.
If the unit is elevated beyond the normal reach of
service personnel, a suitable catwalk must be capable
of supporting service personnel, their equipment, and
the compressors.
Ground Level Locations
It is important that the units be installed on a substantial
base that will not settle. A one piece concrete slab
with footers extended below the frost line is highly
recommended. Additionally, the slab should not be tied
to the main building foundations as noise and vibration
may be transmitted. Mounting holes are provided in the
steel channel for bolting the unit to its foundation. (See
Dimensions in Section 1 of this IOM.)
For ground level installations, precautions should be
taken to protect the unit from tampering by or injury to
unauthorized persons. Screws and/or latches on access
panels will prevent casual tampering. However, further
safety precautions such as a fenced-in enclosure or
locking devices on the panels may be advisable.
Rooftop Locations
Choose a spot with adequate structural strength to
safely support the entire weight of the unit and service
personnel. Care must be taken not to damage the roof.
Consult the building contractor or architect if the roof
is bonded. Roof installations should have wooden
beams (treated to reduce deterioration), cork, rubber,
or vibration isolators under the base to minimize
vibration.
Noise Sensitive Locations
Eorts should be made to assure that the chiller is not
located next to occupied spaces or noise sensitive areas
where chiller noise level would be a problem. Chiller
noise is a result of compressor and fan operation.
Considerations should be made utilizing noise levels
published in the YORK Engineering Guide for
the specific chiller model. Sound blankets for the
compressors and low sound fans are available.
SPRING ISOLATORS (OPTIONAL)
When ordered, four (4) isolators will be furnished.
Identify the isolator, locate at the proper mounting point,
and adjust per instructions. See Isolator Data In Section
7 of this IOM.
COMPRESSOR MOUNTING
The compressors are mounted on four (4) rubber
isolators. The mounting bolts should not be loosened
or adjusted at installation of the chiller.
REMOTE COOLER OPTION
For units using remote cooler option, refer to instructions
included with miscellaneous cooler parts kit.
The unit and remote cooler are shipped with a 6 lb. (2.7
kg) nitrogen holding charge. The nitrogen charge must
be removed, and system evacuated, and the refrigerant
charge must be weighed-in according to the operating
charge listed in Table 15 “Physical Data”. Additional
charge must also be added for the refrigerant lines.
CHILLED WATER PIPING
General
When the unit has been located in its nal position, the
unit water piping may be connected. Normal installation
precautions should be observed in order to receive
maximum operating eciencies. Piping should be kept
free of all foreign matter. All chilled water evaporator
piping must comply in all respects with local plumbing
codes and ordinances.
Since elbows, tees and valves decrease pump capacity,
all piping should be kept as straight and as simple as
possible.
All piping must be supported indepen-
dent of the chiller.
Consideration should be given to com-
pressor access when laying out water
piping. Routing the water piping too
close to the unit could make compres-
sor servicing/replacement dicult.