York YCAL0012EC Owner's manual

YCAL0012EC - YCAL0032EC
AIR-COOLED
SCROLL CHILLERS
STYLE D
(60 Hz)
9-1/2 - 28 TON
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
New Release Form 150.66-NM2 (906)
R-22
035-21552-000
50091

JOHNSON CONTROLS
2
FORM 150.66-NM2 (906)
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 respon-
sibility 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
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
individual possesses independent training that will en-
able 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 regula-
tions 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.
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or se-
rious 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 al-
lowed to be run through the micro panel. All wiring must be in accordance with YORK’s
published specifications and must be performed ONLY by qualified YORK personnel. YORK
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.

JOHNSON CONTROLS 3
FORM 150.66-NM2 (906)
CHANGEABILITY OF THIS DOCUMENT
In complying with YORK’s policy for continuous product improvement, the information contained in this document
is subject to change without notice. While YORK makes no commitment to update or provide current information
automatically to the manual owner, that information, if applicable, can be obtained by contacting the nearest YORK
Engineered Systems Service office.
It is the responsibility of operating/service personnel to verify the applicability of these documents to the equip-
ment 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.

JOHNSON CONTROLS
4
FORM 150.66-NM2 (906)
TABLE OF CONTENTS
SECTION 1 - GENERAL CHILLER
INFORMATION & SAFETY
INTRODUCTION ......................................................7
WARRANTY ..............................................................7
SAFETY ......................................................................7
Standards for Safety ...............................................7
RESPONSIBILITY FOR SAFETY ............................8
ABOUT THIS MANUAL ...........................................8
MISUSE OF EQUIPMENT ........................................8
Suitability for Application ......................................8
Structural Support ...................................................8
Mechanical Strength ...............................................8
General Access .......................................................8
Pressure Systems ....................................................9
Electrical .................................................................9
Rotating Parts .........................................................9
Sharp Edges ............................................................9
Refrigerant & Oils ..................................................9
High Temperature & Pressure Cleaning .................9
Emergency Shutdown .............................................9
SECTION 2 - PRODUCT DESCRIPTION
INTRODUCTION ....................................................10
General System Description .................................10
Compressor ...........................................................10
Cooler ...................................................................10
Condenser .............................................................11
Millenuim Control Center .................................... 11
Power Panel ..........................................................12
ACCESSORIES & OPTIONS ..................................13
Power Options ......................................................13
Control Options ....................................................13
Compressor, Piping, Evaporator Options .............14
Condenser Cabinet Options ..................................14
Sound Reduction Options .....................................15
UNIT COMPONENTS .............................................16
CONTROL / POWER PANEL COMPONENTS .....17
UNIT NOMENCLATURE .......................................18
PRODUCT IDENTIFICATION NUMBER .............18
REFRIGERANT FLOW DIAGRAM .......................23
SECTION 3 -HANDLING AND STORAGE
DELIVERY AND STORAGE ..................................24
INSPECTION ...........................................................24
MOVING THE CHILLER .......................................24
Lifting Weights .....................................................24
UNIT RIGGING .......................................................25
SECTION 4 - INSTALLATION
INSTALLATION CHECKLIST ...............................26
HANDLING .............................................................26
INSPECTION ...........................................................26
LOCATION CLEARANCES ...................................26
Foundation ............................................................27
Ground Level Locations .......................................27
Rooftop Locations ................................................27
Noise Sensitive Locations ....................................27
SPRING ISOLATORS ..............................................27
COMPRESSOR MOUNTING .................................27
REMOTE COOLER OPTION .................................27
CHILLED LIQUID PIPING .....................................27
General Requirements ..........................................27
DUCTWORK CONNECTION ................................28
WIRING ....................................................................28
Evaporator Pump Start Contacts ..........................29
System Run Contacts ............................................29
Alarm Status .........................................................29
Remote Start/Stop Contacts ..................................29
Remote Emergency Cutoff ...................................29
PWM Input ...........................................................29
Load Limit input ...................................................29
Flow Switch Input ................................................29
COMPRESSOR HEATERS .....................................29
SINGLE POINT SUPPLY CONNECTION .............30
CONTROL WIRING ................................................31
SECTION 5 - COMMISSIONING
COMMISSIONING ..................................................32
PREPARATION - POWER OFF ..............................32
Inspection .............................................................32
Refrigerant Charge ...............................................32
Service and Oil Line Valves .................................32
Compressor Oil .....................................................32
Fans .......................................................................32
Isolator Protection ................................................32
Control Panel ........................................................32
Power Connections ...............................................32
Grounding .............................................................32
Supply Voltage ......................................................32
PREPARATION - POWER ON ................................33
Switch Settings .....................................................33
Compressor Heaters ..............................................33
Water System ........................................................33
Flow Switch ..........................................................33
Temperature Sensor(s) ..........................................33

JOHNSON CONTROLS 5
FORM 150.66-NM2 (906)
TABLE OF CONTENTS (CONT’D)
EQUIPMENT START-UP CHECKLIST .................34
Checking The System Prior To Initial Start-up
(No Power) ...........................................................34
Unit Checks ..........................................................34
Compressor Heaters
(Power On 24 Hrs. Prior To Start) ........................34
Panel Checks
(Power On - Both Unit Switch Off) ......................34
SETPOINTS ENTRY LIST ......................................35
CHECKING SUPERHEAT & SUBCOOLING .......36
LEAK CHECKING ..................................................36
UNIT OPERATING SEQUENCE ............................37
SECTION 6 - TECHNICAL DATA
OPERATIONAL LIMITATIONS (ENGLISH) ........38
Temperatures and Flows .......................................38
Voltage Limitations ...............................................38
Ethylene Glycol Correction Factors .....................39
OPERATIONAL LIMITATIONS (SI) ......................40
Temperatures and Flows .......................................40
Voltage Limitations ...............................................40
Ethylene Glycol Correction Factors .....................41
PHYSICAL DATA (ENGLISH) ...............................42
SOUND DATA (ENGLISH) .....................................44
ELECTRICAL DATA ..............................................45
ELECTRICAL NOTES ............................................47
WIRING DIAGRAMS .............................................48
DIMENSIONS ..........................................................60
TECHNICAL DATA (CLEARANCES) ...................84
ISOLATORS .............................................................85
SECTION 7 - UNIT CONTROLS
INTRODUCTION ....................................................92
MICROPROCESSOR BOARD ...........................92
UNIT SWITCH ....................................................93
DISPLAY ..............................................................93
KEYPAD ..............................................................93
BATTERY BACK-UP ..........................................93
TRANSFORMER STATUS .................................93
SINGLE SYSTEM SELECT PROGRAMMING #
OF COMPRESSORS ...........................................93
STATUS KEY ...........................................................94
UNIT STATUS .....................................................94
GENERAL STATUS MESSAGE .........................94
FAULT SAFETY STATUS MESSAGES .............96
System Safties ...................................................96
Unit Safeties ......................................................98
UNIT WARNING .................................................98
STATUS KEY MESSAGES
QUICK REFERENCE LIST ................................99
DISPLAY/PRINT KEYS ........................................100
OPER DATA KEY ..............................................100
OPER DATA QUICK REFERENCE LIST ........103
PRINT KEY ........................................................104
OPERATING DATA PRINTOUT ......................104
HISTORY PRINTOUT .......................................105
HISTORY DISPLAYS .......................................105
SOFTWARE VERSION .....................................107
ENTRY KEYS ........................................................108
UP & DOWN ARROW KEYS ..........................108
ENTER/ADV KEY ............................................108
SETPOINTS KEY ..................................................109
COOLING SETPOINTS ....................................109
LEAVING CHILLED LIQUID CONTROL ......109
RETURN CHILLED LIQUID CONTROL ........ 110
REMOTE SETPOINT CONTROL .................... 110
SCHEDULE/ADVANCE DAY KEY .....................110
PROGRAM KEY ....................................................112
SYSTEM TRIP VOLTS .....................................113
UNIT TRIP VOLTS ............................................114
PROGRAM KEY LIMITS AND DEFAULTS ....... 114
SETPOINTS QUICK REFERENCE LIST ............115
UNIT KEYS ............................................................116
OPTIONS KEY .................................................. 116
CLOCK ...................................................................119
UNIT KEYS PROGRAMMING
QUICK REFERENCE LIST ...................................120
SECTION 8 - UNIT OPERATION
CAPACITY CONTROL .........................................121
SUCTION PRESSURE LIMIT CONTROLS ........121
DISCHARGE PRESSURE LIMIT CONTROLS ...121
LEAVING CHILLED LIQUID CONTROL ...........121
OVERRIDE TO REDUCE CYCLING ..................122
LEAVING CHILLED LIQUID SYSTEM AND
COMPRESSOR SEQUENCING ...........................122
RETURN LIQUID CONTROL ..............................122
ANTI-RECYCLE TIMER ......................................123
ANTI-COINCIDENCE TIMER .............................123
EVAPORATOR PUMP CONTROL .......................123
EVAPORATOR HEATER CONTROL ...................123
PUMPDOWN CONTROL .....................................123
ELECTRONIC EXPANSION VALVE (EEV) .......123
MOP Feature .......................................................123
Valve Preheat ......................................................123
Inputs ..................................................................124
Outputs ...............................................................124
Program ..............................................................124
Safeties ...............................................................124
CONDENSER FAN CONTROL (STD) .................124

JOHNSON CONTROLS
6
FORM 150.66-NM2 (906)
LOW AMBIENT CONTROL OPTION
0012 - 0021 UNITS ...............................................126
General ................................................................l26
Potentiometers Configuration .............................125
Wiring .................................................................127
PROGRAMMING ..................................................128
LOW AMBIENT CONTROL OPTION
0025 - 0032 UNITS ...............................................129
General ................................................................l29
Potentiometers Configuration .............................130
Wiring .................................................................130
PROGRAMMING ..................................................130
LOAD LIMITING ..................................................132
COMPRESSOR RUN STATUS .............................132
ALARM STATUS ...................................................132
EMS-PWM REMOTE TEMPERATURE RESET .133
BAS/EMS TEMPERATURE RESET OPTION .....133
SECTION 9 -
SERVICE AND TROUBLESHOOTING
CLEARING HISTORY BUFFERS ........................136
SERVICE MODE ...................................................136
SERVICE MODE - OUTPUTS ..............................136
SERVICE MODE -
CHILLER CONFIGURATION ..............................136
SERVICE MODE - INPUTS ..................................137
CONTROL INPUTS/OUTPUTS ............................138
MICROBOARD LAYOUT ....................................139
CHECKING INPUTS AND OUTPUTS ................140
DIGITAL INPUTS ..................................................140
TABLE OF CONTENTS (CONT’D)
ANALOG INPUTS - TEMPERATURE .................140
OUTSIDE AIR SENSOR .......................................140
LIQUID & REFRIGERANT SENSOR
TEST POINTS ........................................................141
ANALOG INPUTS - PRESSURE .........................142
DIGITAL OUTPUTS ..............................................143
KEYPAD .................................................................144
OPTIONAL PRINTER INSTALLATION ..............145
Parts ....................................................................145
Assembly And Wiring ........................................145
Obtaining A Printout ...........................................145
TROUBLESHOOTING ..........................................146
SECTION 10 - MAINTENANCE
IMPORTANT ..........................................................150
COMPRESSORS ....................................................150
Oil Level Check ..................................................150
Oil Analysis ........................................................150
CONDENSER FAN MOTORS ..............................150
CONDENSER COILS ............................................150
OPERATING PARAMETERS ...............................150
ON-BOARD BATTERY BACK-UP ......................150
OVERALL UNIT INSPECTION ...........................150
ISN CONTROL ......................................................151
RECEIVED DATA (CONTROL DATA) ................151
TRANSMITTED DATA .........................................151
ISN CONTROL ......................................................151
RECEIVED DATA (CONTROL DATA) ................151
TRANSMITTED DATA .........................................151
ISN OPERATIONAL & FAULT CODES ..............153
RECOMMENDED SPARE PARTS .......................154

JOHNSON CONTROLS 7
FORM 150.66-NM2 (906)
GENERAL CHILLER INFORMATION & SAFETY
INTRODUCTION
YORK YCAL0012-0032 chillers are 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 solu-
tions and is not suitable for purposes other than those
specified in this manual.
This manual contains all the information required for
correct installation and commissioning of the unit, to-
gether with operating and maintenance instructions. The
manuals should be read thoroughly before attempting
to operate or service the unit.
All procedures detailed in the manuals, including in-
stallation, commissioning and maintenance tasks must
only be performed by suitably trained and qualified
personnel.
The manufacturer will not be liable for any injury or
damage caused by incorrect installation, commission-
ing, operation or maintenance resulting from a failure
to follow the procedures and instructions detailed in
the manuals.
WARRANTY
YORK warrants all equipment and materials against
defects in workmanship and materials for a period of
eighteen months from date of shipment, unless labor
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.
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 identi-
fication plate.
The unit warranty will be void if any modification to the
unit is carried out without prior written approval from
YORK.
For warranty purposes, the following conditions must
be satisfied:
• The initial start of the unit must be carried out by
trained personnel from an Authorized YORK Ser-
vice Center (see Commissioning Page 32).
• Only genuine YORK 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 Maintenance Section, Page 150).
• Failure to satisfy any of these conditions will auto-
matically void the warranty (see Warranty Policy).
SAFETY
Standards for Safety
YCAL chillers are designed and built within an ISO
9002 accredited design and manufacturing organization.
The chillers comply with the applicable sections of the
following Standards and Codes:
• ANSI/ASHRAE Standard 15- Safety Code for Me-
chanical Refrigeration.
• ANSI/NFPA Standard 70- National Electrical Code
(N.E.C.).
• ASME Boiler and Pressure Vessel Code- Section
VIII Division 1.
• ARI Standard 550/590-98- Water Chilling Packages
Using the Vapor Compression Cycle.
• ASHRAE 90.1- Energy Efficiency compliance.
• ARI 370- Sound Rating of Large Outdoor Refrigera-
tion and Air Conditioning Equipment.
In addition, the chillers conform to Underwriters Labo-
ratories (U.L.) for construction of chillers and provide
U.L./cU.L. Listing Label.
1

JOHNSON CONTROLS
8
FORM 150.66-NM2 (906)
RESPONSIBILITY FOR SAFETY
Every care has been taken in the design and manufac-
ture of the unit to ensure compliance with the safety
requirements listed above. However, the individual
operating or working on any machinery is primarily
responsible for:
• Personal safety, safety of other personnel, and
the machinery.
• Correct utilization of the machinery in ac-
cordance with the procedures detailed in the
manuals.
ABOUT THIS MANUAL
The following terms are used in this document to alert
the reader to areas of potential hazard.
A WARNING is given in this document to identify a
hazard, which could lead to personal injury. Usually an
instruction will be given, together with a brief explana-
tion and the possible result of ignoring the instruction.
A 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 and the
possible result of ignoring the instruction.
A NOTE is used to highlight additional information,
which may be helpful to you but where there are no
special safety implications.
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 YORK which reserves all
rights. They may not be reproduced, in whole or in part,
without prior written authorization from an authorized
YORK representative.
MISUSE OF EQUIPMENT
Suitability for Application
The unit is intended for cooling water or glycol solu-
tions and is not suitable for purposes other than those
specified in these instructions. Any use of the 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 param-
eters specified in this manual.
Structural Support
Structural support of the unit must be provided as in-
dicated in these instructions. Failure to provide proper
support may result in injury to the operator, or damage
to the equipment and/or building.
Mechanical Strength
The unit is not designed to withstand loads or stresses
from adjacent equipment, pipework or structures. Ad-
ditional components must not be mounted on the unit.
Any such extraneous loads may cause structural failure
and may result in injury to the operator, or damage to
the equipment.
General Access
There are a number of areas and features, which may
be a hazard and potentially cause injury when working
on the unit unless suitable safety precautions are taken.
It is important to ensure access to the unit is restricted
to suitably qualified persons who are familiar with the
potential hazards and precautions necessary for safe
operation and maintenance of equipment containing
high temperatures, pressures and voltages.
General Chiller Information & Safety

JOHNSON CONTROLS 9
FORM 150.66-NM2 (906)
1
Pressure Systems
The unit contains refrigerant vapor and liquid under
pressure, release of which can be a danger and cause
injury. The user should ensure that care is taken during
installation, operation and maintenance to avoid dam-
age to the pressure system. No attempt should be made
to gain access to the component parts of the pressure
system other than by suitably trained and qualified
personnel.
Electrical
The unit must be grounded. No installation or main-
tenance work should be attempted on the electrical
equipment without first switching power OFF, isolating
and locking-off the power supply. Servicing and mainte-
nance on live equipment must only be performed by suit-
ably trained and qualified personnel. No attempt should
be made to gain access to the control panel or electrical
enclosures during normal operation of the unit.
Rotating Parts
Fan guards must be fitted at all times and not removed
unless the power supply has been isolated. If ductwork is
to be fitted, requiring the wire fan guards to be removed,
alternative safety measures must be taken to protect
against the risk of injury from rotating fans.
Sharp Edges
The fins on the air-cooled condenser coils have sharp
metal edges. Reasonable care should be taken when
working in contact with the coils to avoid the risk of
minor abrasions and lacerations. The use of gloves is
recommended.
Frame rails, brakes, and other components may also have
sharp edges. Reasonable care should be taken when
working in contact with any components to avoid risk
of minor abrasions and lacerations.
Refrigerants and Oils
Refrigerants and oils used in the unit are generally non-
toxic, 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 vapor, from a leak for ex-
ample, 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 pres-
sure relief device(s). Detergents and solvents, which may
cause corrosion, should also be avoided.
Emergency Shutdown
In case of emergency, the control panel is fitted with
a Unit Switch to stop the unit in an emergency. When
operated, it removes the low voltage 120 VAC electri-
cal supply from the inverter system, thus shutting down
the unit.

JOHNSON CONTROLS
10
FORM 150.66-NM2 (906)
Product Description
PRODUCT DESCRIPTION
INTRODUCTION
YORK Millennium® Air-Cooled Scroll Chillers provide
chilled water for all air conditioning applications using
central station air handling or terminal units. They are
completely self-contained and are designed for outdoor
(roof or ground level) installation. Each unit includes
hermetic scroll compressors, a liquid cooler, air cooled
condenser, and a weather resistant microprocessor con-
trol center, all mounted on a pressed steel base.
The units are completely assembled with all intercon-
necting refrigerant piping and internal wiring, ready for
field installation.
Prior to delivery, the unit is pressure-tested, evacuated,
and fully charged with Refrigerant-22 (HCFC-22) and
includes an initial oil charge. After assembly, a complete
operational test is performed with water flowing through
the cooler to assure that the refrigeration circuit oper-
ates correctly.
The unit structure is heavy-gauge, galvanized steel. This
galvanized steel is coated with baked-on powder paint,
which, when subjected to ASTM B117 1000 hour, salt
spray testing, yields a minimum ASTM 1654 rating of
“6”. Corrosion resistant wire mesh panels are added to
protect the condenser coil from incidental damage and
restrict unauthorized access to internal components.
Units are designed in accordance with NFPA 70 (Na-
tional Electric Code), ASHRAE/ANSI 15 Safety code
for mechanical refrigeration, ASME, Listed and labeled
with Intertek Testing Services (ETL) and rated in ac-
cordance with ARI Standard 550/590-2003.
All exposed power wiring is routed through liquid-tight,
non-metallic conduit.
GENERAL SYSTEM DESCRIPTION
Compressors
The chiller has suction-gas cooled, hermetic, scroll
compressors. The YCAL compressors incorporate a
compliant scroll design in both the axial and radial
direction. All rotating parts are statically and dynami-
cally balanced. A large internal volume and oil reservoir
provides greater liquid tolerance. Compressor crankcase
heaters are also included for extra protection against
liquid migration.
Cooler
The Brazed Plate Heat Exchanger is equipped with a
heater controlled by the microprocessor. The heater
provides freeze protection for the cooler down to -20°F (-
29°C) ambient. The cooler is covered with 3/4” (19mm)
flexible, closed-cell, foam insulation (K~0.25).
Brazed plate heat exchangers shall be UL (Underwriters
Laboratories) listed. Installing contractor must include
accommodations in the chilled water piping to allow
50091

JOHNSON CONTROLS 11
FORM 150.66-NM2 (906)
proper drainage and venting of the heat exchanger. Water
inlet and outlet connections are grooved for compatibil-
ity with factory supplied victaulic connections.
A strainer with a mesh size between .5 and 1.5 mm (40
mesh) is recommended upstream of the heat exchanger
to prevent clogging.
Condenser
Coils – Fin and tube condenser coils of seamless, inter-
nally-enhanced, high-condensing-coefficient, corrosion
resistant copper tubes are arranged in staggered rows,
mechanically expanded into aluminum fins. Integral
subcooling is included. The design working pressure
of the coil is 450 PSIG (31 bar).
Low Sound Fans – The condenser fans are composed
of corrosion resistant aluminum hub and glass-fiberrein-
forced composite blades molded into a low noise airfoil
section. They are designed for maximum efficiency and
are statically and dynamically balanced for vibration
free operation. They are directly driven by independent
motors, and positioned for vertical air discharge. All
blades are statically and dynamically balanced for vibra-
tion-free operation. The fan guards are constructed of
heavy-gauge, rust-resistant, PVC coated steel wire.
Motors – The fan motors are Totally Enclosed Air-
Over, squirrel-cage type, current protected. They feature
ball bearings that are double-sealed and permanently
lubricated.
MILLENIUM CONTROL CENTER
All controls are contained in a NEMA 3R/12 (and
equivalent to IP55*) cabinet with hinged outer door
and includes:
Liquid Crystal Display with Light Emitting Diode back-
lighting for outdoor viewing:
• Two display lines
• Twenty characters per line
Color coded 12-button non-tactile keypad with sections
for:
DISPLAY/PRINT of typical information:
• Chilled liquid temperatures
• Ambient temperature
• System pressures (each circuit)
• Operating hours and starts (each compressor)
• Print calls up to the liquid crystal display
• Operating data for the systems
• History of fault shutdown data for up to
the last six fault shutdown conditions.
• An RS-232 port, in conjunction with this
press-to-print button, is provided to permit
the capability of hard copy print-outs via a
separate printer (by others).
ENTRY section to:
ENTER setpoints or modify system values.
SETPOINTS: Updating can be performed to:
• Chilled liquid temperature setpoint and range
• Remote reset temperature range
• Set daily schedule/holiday for start/stop
• Manual override for servicing
• Low and high ambient cutouts
• Number of compressors
• 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)
UNIT section to:
• Set time
• Set unit options
UNIT ON/OFF switch
The microprocessor control center is capable of dis-
playing the following:
• Return and leaving liquid temperature
• Low leaving liquid temperature cutout setting
• Low ambient temperature cutout setting
• Outdoor air temperature
• English or Metric data
• Suction pressure cutout setting
• Each system suction pressure
• Discharge pressure (optional)
• Liquid Temperature Reset via a YORK ISN DDC
or Building Automation System (by others) via:
- a pulse width modulated (PWM) input as stan-
dard.
2

JOHNSON CONTROLS
12
FORM 150.66-NM2 (906)
- a 4-20 milliamp or 0 -10 VDC input, or contact
closure with the optional B.A.S. interface option.
• Anti-recycle timer status for each system
• 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)
• Status of hot gas valves, evaporator heater
and fan operation
• Run permissive status
• Number of compressors running
• Liquid solenoid valve status
• Load & unload timer status
• Water pump status
* Intensity of Protection European Standard
** International Electrotechnical Commission
Provisions are included for: pumpdown at shutdown;
optional remote chilled water temperature reset and two
steps of demand load limiting from an external building
automation system. Unit alarm contacts are standard.
The operating program is stored in non-volatile memory
(EPROM) to eliminate chiller failure due to AC powered
failure/battery discharge. Programmed setpoints are
retained in lithium battery-backed RTC memory for 5
years minimum.
POWER PANEL
Each panel contains:
• Compressor power terminals
• Compressor motor starting contactors per l.E.C.**
• Control power terminals to accept incoming for
115-1-60 control power
• Fan contactors & overload current protection
The power wiring is routed through liquid-tight conduit
to the compressors and fans.
Product Description

JOHNSON CONTROLS 13
FORM 150.66-NM2 (906)
2
ACCESSORIES AND OPTIONS
POWER OPTIONS:
COMPRESSOR POWER CONNECTION – Single-
point (YCAL0012-0032) terminal block connection is
provided as standard. The following power connections
are available as options. (See electrical data for specific
voltage and options availability) (Factory-Mounted).
SINGLE-POINT SUPPLY TERMINAL BLOCK
– (standard on YCAL0012 - 0032 models) Includes
enclosure, terminal-block and interconnecting wiring to
the compressors. Separate external protection must be
supplied, by others, in the incoming compressor-power
wiring. (Do not include this option if either the Single-
Point NonFused Disconnect Switch or Single-Point
Circuit Breaker options have been included).
SINGLE-POINT NON-FUSED DISCONNECT
SWITCH – Unit-mounted disconnect switch with
external, lockable handle (in compliance with Article
440-14 of N.E.C.), can be supplied to isolate the unit
power voltage for servicing. Separate external fusing
must be supplied, by others in the power wiring, which
must comply with the National Electrical Code and/or
local codes.
SINGLE-POINT CIRCUIT BREAKER – A unit
mounted circuit breaker with external, lockable handle
(in compliance with N.E.C. Article 440-14), can be
supplied to isolate the power voltage for servicing (this
option includes the Single-Point Power connection).
CONTROL TRANSFORMER – Converts unit power
voltage to 115-1-60 (0.5 or 1.0 KVA capacity). Fac-
tory mounting includes primary and secondary wiring
between the transformer and the control panel (Fac-
tory-Mounted).
POWER FACTOR CORRECTION CAPACITORS
– Will correct unit compressor power factors to a 0.90-
0.95 (Factory-Mounted).
CONTROL OPTIONS:
AMBIENT KIT (LOW) – Units will operate to 25°F (-
4°C). This accessory includes all necessary components
to permit chiller operation to 0°F (-18°C). (This option
includes the Discharge Pressure Transducer / Readout
Capability option). For proper head pressure control
in applications below 25°F (-4°C), where wind gusts
may exceed five mph, it is recommended that Optional
Condenser Louvered Enclosure Panels also be included
(Factory-Mounted).
AMBIENT KIT (HIGH) – Required if units are to
operate when the ambient temperature is above 115°F
(46°C). Includes discharge pressure transducers. (This
option includes the Discharge Pressure Transducer /
Readout Capability option) (Field-Mounted).
BUILDING AUTOMATION SYSTEM INTER-
FACE – The factory addition of a Printed Circuit Board
to accept a 4-20 milliamp, 0-10VDC or contact closure
input to reset the leaving chiller liquid temperature from
a Building Automation System. (Only one of following
options can be offered on a unit at a time: BAS, Remote
Control Panel or Multi-unit Sequence Control) (Fac-
tory-Mounted). (The standard unit capabilities include
remote startstop, remote water temperature reset via a
PWM input signal or up to two steps of demand (load)
limiting depending on model). (The standard control
panel can be directly connected to a YORK Building
Automated System via the standard onboard RS485
communication port).
LANGUAGE LCD AND KEYPAD DISPLAY – Span-
ish, French, and German unit LCD controls and keypad
displays are available. Standard language is English.
DISCHARGE PRESSURE TRANSDUCERS AND
READOUT CAPABILITY – The addition of pressure
transducers allows models to sense and display discharge
pressure. This is recommended for brine chilling appli-
cations. (This option is included with either the low or
high ambient kits) (Factory-Mounted).
• Suction Pressure Transducers: Permits unit to
sense and display suction pressure. This capability
is standard.
MOTOR CURRENT MODULE – Capable of moni-
toring compressor motor current. Provides extra protec-
tion against compressor reverse rotation, phase-loss and
phase imbalance. Option consists of one module per
electrical system (Factory-Mounted).
OPTIVIEW REMOTE CONTROL PANEL - Graphi-
cal interface panel to remotely control and monitor up to
8 different units. (Refer to form 201.18-SG4 for detailed
information).
MULTI-UNIT SEQUENCING – A separate Sequenc-
ing Control Center is provided to handle sequencing
control of up to eight chillers in parallel based on mixed
liquid temperature (interconnecting wiring by others).
(Only one of following options can be offered on a unit
at a time: BAS, Remote Control Panel or Multi-unit
Sequence Control) (Factory-Mounted).

JOHNSON CONTROLS
14
FORM 150.66-NM2 (906)
Product Description
COMPRESSOR, PIPING, EVAPORATOR OP-
TIONS:
LOW TEMPERATURE BRINE – Required for brine
chilling below 30°F (-1°C) leaving brine temperature
for YCAL0012 - 0065 models. Option includes resized
thermal expansion valve (Factory-Mounted).
CHICAGO CODE RELIEF VALVES – Unit will
be provided with relief valves to meet Chicago code
requirements (Factory-Mounted).
SERVICE ISOLATION VALVE – Service suction
and discharge (ball type) isolation valves are added to
unit per system. This option also includes a system high
pressure relief valve in compliance with ASHRAE 15
(Factory-Mounted).
HOT GAS BY-PASS – Permits continuous, stable
operation at capacities below the minimum step of com-
pressor unloading to as low as 5% capacity (depending
on both the unit and operating conditions) by introduc-
ing an artificial load on the cooler. Hot gas by-pass is
installed on only refrigerant system #1 on two-circuited
units (Factory-Mounted).
DX COOLER 300 PSIG (21 bar) DWP WATERSIDE
– The waterside will be of 300 PSIG (21 bar) instead of
the standard 150 PSIG DWP. 300 PSIG R.F. flanges are
included on the DX cooler nozzles (Factory-Mounted).
The companion flanges will be field-supplied by oth-
ers.
FLANGES (VICTAULIC TYPE) – Consists of two
(2) Flange adapters for grooved end pipe (standard 150
psi [10.5 bar] cooler).
FLOW SWITCH – The flow switch or its equivalent
must be furnished with each unit.
150 PSIG (10.5 bar) DWP – For standard units. Johnson
Controls model F61MG-1C Vapor-proof SPDT, NEMA
4X switch (150 PSIG [10.5 bar] DWP), -20°F to 250°F
(-29°C to 121°C), with 1” NPT connection for upright
mounting in horizontal pipe (Field-Mounted).
300 psig (21 bar) DWP – For units with optional 300
PSIG (21 bar) DX cooler. McDonnell & Miller model
FS74W Vapor-proof SPDT, NEMA 4X switch (300
PSIG (21 bar) DWP), -20°F to 300°F (-29°C to 149°C),
with 1¼ inch MPT connection for upright mounting in
horizontal pipe (Field-Mounted).
DIFFERENTIAL PRESSURE SWITCH – Alterna-
tive to an above mentioned flow switch. Pretempco
model DPS300AP40PF-82582-5 (300 psi max. working
pressure), SPDT 5 amp 125/250VAC switch, Range
0 - 40 PSID, deadband 0.5 - 0.8 psi, with 1/4” NPTE
Pressure Connections.
REMOTE DX COOLER – A split system arrangement
with the cooler, leaving & return water sensors, liquid
line solenoid valves, filter driers, sightglasses & TXVs
shipped loose for field connection to the air-cooled con-
densing section. The DX cooler and outdoor section will
have a nitrogen holding charge. Interconnecting rigid
piping, wiring and refrigerant are by others. Includes
YORK Service startup. See Form 150.62-NM1.1 (200)
for other application information (this option includes
the Crankcase Heater option) (Field-Mounted).
CONDENSER AND CABINET OPTIONS:
Condenser coil protection against corrosive environ-
ments is available by choosing any of the following
options. For additional application recommendations,
refer to FORM 150.12-ES1 (Factory-Mounted).
PRE-COATED FIN CONDENSER COILS – The
unit's coils are constructed with black epoxy coated
aluminum fins. This can provide corrosion resistance
comparable to copper-fin coils in typical seashore loca-
tions. Either these or the post-coated coils (below), are
recommended for units being installed at the seashore
or where salt spray may hit the unit.
POST-COATED DIPPED CONDENSER COILS
– The unit's coils are constructed with dipped-cured
condenser coils. This is another choice for seashore
and other corrosive applications (with the exception of
strong alkalies, oxidizers and wet bromine, chlorine and
fluorine in concentrations greater than 100 ppm).
COPPER FIN CONDENSER COILS – The unit's
coils are constructed with copper fins. (This is not
recommended for units in areas where they may be
exposed to acid rain).
ENCLOSURE PANELS (UNIT) – Tamperproof
Enclosure Panels prevent unauthorized access to units.
Enclosure Panels can provide an aesthetically pleas-
ing alternative to expensive fencing. Additionally, for
proper head pressure control, YORK recommends the
use of :
LOUVERED PANELS (Full Unit) – Louvered panels
surround the front, back, and sides of the unit. They
prevent unauthorized access and visually screen unit
components. Unrestricted air flow is permitted through
generously sized louvered openings. This option is ap-
plicable for any outdoor design ambient temperature up
to 115°F (46°C) (Factory-Mounted).

JOHNSON CONTROLS 15
FORM 150.66-NM2 (906)
2
SOUND REDUCTION OPTIONS:
SOUND ATTENUATION – One or both of the fol-
lowing sound attenuation options are recommended for
residential or other similar sound-sensitive locations.
Louvered Panels can be ordered for winter applications
where wind gusts may exceed five miles per hour. The
following types of enclosure options are available:
COMPRESSOR ACOUSTIC SOUND BLANKET
– Each compressor is individually enclosed by an acous-
tic sound blanket. The sound blankets are made with
one layer of acoustical absorbent textile fiber of 5/8”
(15mm) thickness; one layer of anti-vibrating heavy
material thickness of 1/8” (3mm). Both are closed by
two sheets of welded PVC, reinforced for temperature
and UV resistance (Factory-Mounted).
ULTRA QUIET FANS – Lower RPM, 8-pole fan
motors are used with steeper-pitch fans (Factory-
Mounted).
VIBRATION ISOLATORS – Level adjusting, spring
type 1” (25.4mm) or seismic deflection or neoprene
pad isolators for mounting under unit base rails (Field-
Mounted).

JOHNSON CONTROLS
16
FORM 150.66-NM2 (906)
COMPRESSORS
Product Description
UNIT COMPONENTS
FAN ASSEMBLIES
CONDENSER
COILS
CONTROL / POWER PANEL
HEAT EXCHANGER
FIG. 1 – UNIT COMPONENTS

JOHNSON CONTROLS 17
FORM 150.66-NM2 (906)
KEYPAD & DISPLAY UNIT SWITCH
COMPRESSOR CONTACTORS USER TERMINAL BLOCK
2
CONTROL / POWER PANEL COMPONENTS
CIRCUIT BREAKER
FIG. 2 – CONTROL/POWER PANEL COMPONENTS

JOHNSON CONTROLS
18
FORM 150.66-NM2 (906)
PRODUCT IDENTIFICATION NUMBER (PIN)
FEATURE DESCRIPTION OPTION DESCRIPTION
MODEL Model (PIN 1-4) YCAL YCAL
CAP Capacity (PIN 5-8)
0012 0012
0018 0018
0021 0021
0025 0025
0027 0027
0032 0032
UNIT Unit Designator (PIN 9) E High Efficiency
REF Refrigerant (PIN 10) C R-22
VOLTS Voltage (PIN 11 & 12)
17 200/3/60
28 230/3/60
40 380/3/60
46 460/3/60
58 575/3/60
STARTER Starter (PIN 13) X Across The Line Starter
DESIGN Design Series (PIN 14) D Design Series D
DEV Developement Level (PIN 15) A Development Level A
POWER Power Field (PIN 16 & 17)
SX Single Point Terminal Block
SD Single Point Non-Fused Disconnect
BX Single Point Circuit Breaker
QQ Special Power Option Required
YCAL0021EC 46XBA
BASIC UNIT NOMENCLATURE
: High Efficiency : Design Series A
: Engineering
Change
or PIN Level
: YORK
: Chiller
: Air-Cooled
: Condensing
Unit
: Scroll
Even Number:
60 HZ Nominal Tons
Odd Number:
50 HZ Nominal kW
1 2 3 4 5 6 7 8 9 10 11 12 17 14 15
BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE/STARTER DESIGN/DEVELOPMENT LEVEL
Y 0 # # # E C 1 7 B
C 1 # # # 2 8 A
A 4 0
U 4 6
5 8
L
X
: R-22 : 200 / 3/ 60
: 230 / 3 / 60
: 380 / 3 / 60
: 460 / 3 / 60
: 575 / 3 / 60
: Across the Line
Product Description

JOHNSON CONTROLS 19
FORM 150.66-NM2 (906)
FEATURE DESCRIPTION OPTION DESCRIPTION
TRANS Cntrl Transformer (PIN 18)
X No Control Transformer Required
T Control Transformer Required
Q Special Control Transformer Required
PFC Power Factor Capacitor (PIN 19)
X No Power Capacitor Required
C Power Capacitor Required
Q Special Power Capacitor Required
AMB Ambient Kits (PIN 20)
X No Ambient Kits Required
L Low Ambient Kits Required
H High Ambient Kits Required
A High/Low Ambient Kits Required
Q Special Ambient Kits Required
BAS BAS Reset/Offset (PIN 21)
X No BAS Reset/Offset Required
M ISN Microgateway Required
T BAS Reset/Offset Required
Q Special BAS Reset/Offset Required
LCD Language (PIN 22)
X English
S Spanish
F French
G German
Q Special Language Required
RDOUT Readout Kits (PIN 23)
X No Readout Kit Required
R Discharge Readout Kit Required
Q Special Pressure Readout Required
SAFETY Safety Codes (PIN 24) L N American Safety Code(Cul/Cet)
SENSOR Sensor (PIN 25) X No Option Required
Q Special Quote
PUMP Pump Control (PIN 26)
X No Motor Current
C Motor Current Readout
Q Special Quote
REMOTE Remote Panel (PIN 27)
X No Remote Panel Required
O OptiView Remote Panel Required
Q Special Remote Panel Required
SEQ Sequence Kit (PIN 28)
X No Sequence Kit Required
S Sequence Kit Required= {SEQ/S}
Q Special Sequence Required
TEMP Leaving Water Temp
(PIN 29, 30)
NUM Leaving Water Temp=
{TEMP/NUM} Degrees
QQ Special LWT Requirements
PRODUCT IDENTIFICATION NUMBER (PIN) (CON’T)
2

JOHNSON CONTROLS
20
FORM 150.66-NM2 (906)
FEATURE DESCRIPTION OPTION DESCRIPTION
CHICAGO Chicago Code Kit (PIN 31)
X No Chicago Code Kit Required
C Chicago Code Kit Required
S Service Isolation Valves
B Both Chicago Code & Serv Isolation
Q Special Chicago Code Kit Required
VALVES Valves (PIN 32) X Standard Valves Required
Q Special Optional Valves Required
HGBP Hot Gas Bypass (PIN 33)
X No Hot Gas Bypass Required
1 Hot Gas Bypass Required-1 Circuit
2 Hot Gas Bypass Required-2 Circuit
Q Special Hot Gas Required
GAUGE Mech Gauge Kit (PIN 34) X No Option Required
Q Special Quote
OVERLOAD Overload (PIN 35) X No Option Required
Q Special Quote
PIN 36 (PIN 36) X No Option Required
Q Special Quote
HTR Crankcase Heater (PIN 37) X Crankcase Heater Standard
Q Special Crankcase Heater Required
DWP DWP (PIN 38)
X 150 psig DWP Waterside
3 300 psig DWP Waterside
Q Special DWP
INS Insulation (PIN 39)
X Standard Insulation
D Double Thick Insulation
Q Special Insulation Required
FLANGES Flanges (PIN 40)
X Standard Victaulic
V Victaulic to Flange Adapter
Q Special Flanges Required
FLOW Flow Switch (PIN 41)
X No Flow Switch Required
S One Flow Switch Required
T Two Flow Switches Required
U Three Flow Switches Required
D One Differential Pressure Switch
Required
E Two Differential Pressure Switches
Required
F Three Differential Pressure Switches
Required
Q Special Flow Switch Required
PRODUCT IDENTIFICATION NUMBER (PIN) (CON’T)
Product Description