York YCAL0019 Owner's manual

YCAL0019, 0022, 0028, 0033, 0043, 0046, 0052, 0056, 0066
AIR-COOLED SCROLL CHILLERS
STYLE E (50 Hz)
15-65 TON
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Supersedes 150.67-NM2 (1007) Form 150.67-NM2 (209)
LD10950
R-410A
035-21456-100
DUAL CIRCUIT
SINGLE CIRCUIT

JOHNSON CONTROLS
2
FORM 150.67-NM2 (209)
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
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
enable them to perform their assigned tasks properly
and safely. It is essential that, prior to performing any
task on this equipment, this individual shall have read
and understood this document and any referenced
materials. This individual shall also be familiar with and
comply with all applicable governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
CAUTION identifies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instructionwillbegiven,togetherwith
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,isNOTto be connected inside the micropanelcabinet. 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
publishedspecificationsand must be performed ONLYbyqualifiedYORKpersonnel.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.

FORM 150.67-NM2 (209)
3
JOHNSON CONTROLS
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 equipment in
question. If there is any question in the mind of operating/service personnel as to the applicability of these documents,
then prior to working on the equipment, they should verify with the owner whether the equipment has been modified
and if current literature is available.
SINGLE CIRCUIT AND DUAL CIRCUIT MODELS
This manual contains installation, operation and maintenance instructions for both single and dual refriger-
ant circuit models. If your unit is a single circuit model (YCAL0019-0033) , disregard references to “System
2” which may appear in this manual.Any references to Sys 2 are applicable to YCAL0043-0066 models.

JOHNSON CONTROLS
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FORM 150.67-NM2 (209)
TABLE OF CONTENTS
SECTION 1 – GENERAL CHILLER INFORMATION & SAFETY......................................................................10
INTRODUCTION .........................................................................................................................................10
WARRANTY ................................................................................................................................................10
SAFETY.......................................................................................................................................................10
Standards for Safety ...........................................................................................................................10
Responsibility for Safety ....................................................................................................................11
ABOUT THIS MANUAL...............................................................................................................................11
MISUSE OF EQUIPMENT...........................................................................................................................11
Suitability for Application...................................................................................................................11
Structural Support...............................................................................................................................11
Mechanical Strength ..........................................................................................................................11
General Access....................................................................................................................................11
Pressure Systems ...............................................................................................................................12
Electrical...............................................................................................................................................12
Rotating Parts......................................................................................................................................12
Sharp Edges.........................................................................................................................................12
Refrigerants and Oils..........................................................................................................................12
High Temperature and Pressure Cleaning........................................................................................12
Emergency Shutdown.........................................................................................................................12
SECTION 2 – PRODUCT DESCRIPTION.........................................................................................................13
INTRODUCTION .........................................................................................................................................13
GENERAL SYSTEM DESCRIPTION..........................................................................................................13
Compressors .......................................................................................................................................13
Evaporator (Heat Exchanger).............................................................................................................13
Condenser............................................................................................................................................14
MILLENIUM CONTROL CENTER...............................................................................................................14
POWER PANEL...........................................................................................................................................15
ACCESSORIES AND OPTIONS.................................................................................................................16
Power Options.....................................................................................................................................16
Control Options...................................................................................................................................16
Compressor, Piping, Evaporator Options.........................................................................................17
Condenser and Cabinet Options........................................................................................................17
Sound Reduction Options..................................................................................................................17
UNIT COMPONENTS YCAL0019 - 0033....................................................................................................19
CONTROL - POWER PANEL COMPONENTS YCAL0019-0033...............................................................20
UNIT COMPONENTS - YCAL0043 – 0066.................................................................................................21
CONTROL / POWER PANEL COMPONENTS - YCAL0043 – 0066..........................................................22
PRODUCT IDENTIFICATION NUMBER (PIN)............................................................................................23
BASIC UNIT NOMENCLATURE.................................................................................................................23
REFRIGERANT FLOW DIAGRAM .............................................................................................................28
SECTION 3 – HANDLING AND STORAGE......................................................................................................29
DELIVERY AND STORAGE........................................................................................................................29
INSPECTION...............................................................................................................................................29

FORM 150.67-NM2 (209)
5
JOHNSON CONTROLS
TABLE OF CONTENTS (CONT’D)
MOVING THE CHILLER..............................................................................................................................29
Lifting Weights.....................................................................................................................................29
UNIT RIGGING............................................................................................................................................31
SECTION 4 – INSTALLATION...........................................................................................................................33
INSTALLATION CHECKLIST......................................................................................................................33
HANDLING..................................................................................................................................................33
INSPECTION...............................................................................................................................................33
LOCATION AND CLEARANCES................................................................................................................33
Foundation...........................................................................................................................................33
SPRING ISOLATORS (OPTIONAL)............................................................................................................34
COMPRESSOR MOUNTING ......................................................................................................................34
REMOTE COOLER OPTION ......................................................................................................................34
CHILLED LIQUID PIPING...........................................................................................................................34
Ground Level Locations .....................................................................................................................34
Rooftop Locations...............................................................................................................................34
Noise Sensitive Locations..................................................................................................................34
PIPEWORK ARRANGEMENT....................................................................................................................35
DUCT WORK CONNECTION ....................................................................................................................36
General Requirements .......................................................................................................................36
WIRING........................................................................................................................................................36
Evaporator Pump Start Contacts.......................................................................................................36
System Run Contacts .........................................................................................................................36
Alarm Status Contacts........................................................................................................................37
Remote Start/Stop Contacts...............................................................................................................37
Remote Emergency Cutoff .................................................................................................................37
Remote Temp Reset Input ..................................................................................................................37
Load Limit Input...................................................................................................................................37
Flow Switch Input................................................................................................................................37
COMPRESSOR HEATERS.........................................................................................................................37
RELIEF VALVES .........................................................................................................................................37
HIGH PRESSURE CUTOUT .......................................................................................................................37
SINGLE-POINT SUPPLY CONNECTION ...................................................................................................38
CONTROL WIRING.....................................................................................................................................39
SECTION 5 – TECHNICAL DATA .....................................................................................................................40
OPERATIONAL LIMITATIONS (ENGLISH) ................................................................................................40
Voltage Limitations..............................................................................................................................40
Temperatures and Flows ....................................................................................................................40
OPERATIONAL LIMITATIONS (SI).............................................................................................................43
Voltage Limitations..............................................................................................................................43
Temperatures and Flows (Si)..............................................................................................................43
Ethylene & Propolyne Glycol Correction Factors ............................................................................43
PHYSICAL DATA (ENGLISH) .....................................................................................................................46
SOUND DATA (ENGLISH) ..........................................................................................................................48
ELECTRICAL DATA (ENGLISH).................................................................................................................50

JOHNSON CONTROLS
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FORM 150.67-NM2 (209)
ELECTRICAL NOTES AND LEGEND ........................................................................................................53
ELEMENTARY WIRING DIAGRAM............................................................................................................54
CONNECTION WIRING DIAGRAM ............................................................................................................64
ELEMENTARY WIRING DIAGRAM DETAILS............................................................................................68
DIMENSIONS (ENGLISH)...........................................................................................................................70
TECHNICAL DATA – CLEARANCES.......................................................................................................106
ISOLATORS ..............................................................................................................................................107
Weight Distribution and Isolator Mounting PositionsYCAL0019 – 0033
(Without Pump Package Option).....................................................................................................107
Weight Distribution and Isolator Mounting PositionsYCAL0043 – 0066......................................109
Isolator Details - Units Shipped On Or After June 15, 2008...........................................................110
Isolator Details - Units Shipped Before June 15, 2008...................................................................116
SECTION 6 – COMMISSIONING.....................................................................................................................121
COMMISSIONING.....................................................................................................................................121
PREPARATION – POWER OFF................................................................................................................121
Inspection ..........................................................................................................................................121
Refrigerant Charge............................................................................................................................121
Service and Oil Line Valves..............................................................................................................121
Compressor Oil..................................................................................................................................121
Fans ...................................................................................................................................................121
Isolation / Protection.........................................................................................................................121
Control Panel.....................................................................................................................................121
Power Connections...........................................................................................................................121
Grounding..........................................................................................................................................121
Supply Voltage...................................................................................................................................122
PREPARATION – POWER ON .................................................................................................................122
Switch Settings..................................................................................................................................122
Compressor Heaters.........................................................................................................................122
Water System.....................................................................................................................................122
Flow Switch........................................................................................................................................122
Temperature Sensor(s) .....................................................................................................................122
EQUIPMENT STARTUP CHECKLIST ......................................................................................................123
Checking The System Prior To Initial Start (No Power).................................................................123
Unit Checks........................................................................................................................................123
Compressor Heaters(Power On – 24 Hours Prior To Start)...........................................................123
Panel Checks(Power On – Both Unit Switch Off).........................................................................123
SETPOINTS ENTRY LIST.........................................................................................................................124
CHECKING SUPERHEAT AND SUBCOOLING.......................................................................................125
LEAK CHECKING.....................................................................................................................................125
UNIT OPERATING SEQUENCE ...............................................................................................................126
TABLE OF CONTENTS (CONT’D)

FORM 150.67-NM2 (209)
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JOHNSON CONTROLS
SECTION 7 – UNIT CONTROLS.....................................................................................................................127
INTRODUCTION .......................................................................................................................................127
IPU II and I/O Boards.........................................................................................................................127
Unit Switch.........................................................................................................................................128
Display................................................................................................................................................128
Keypad................................................................................................................................................128
Battery Back-up.................................................................................................................................128
Transformer .......................................................................................................................................128
Single System Select and Programming # of Compressors........................................................128
“STATUS” KEY.........................................................................................................................................129
Unit Status..........................................................................................................................................129
General Status Messages.................................................................................................................129
Fault Safety Status Messages..........................................................................................................131
Unit Warning ......................................................................................................................................133
Status Key Messages........................................................................................................................134
Status Key Messages Quick Reference List...................................................................................134
DISPLAY/PRINT KEYS.............................................................................................................................135
Oper Data Key....................................................................................................................................135
Oper Data Quick Reference List.......................................................................................................138
Print Key.............................................................................................................................................139
Operating Data Printout....................................................................................................................139
History Printout .................................................................................................................................140
History Displays ................................................................................................................................140
Software Version ...............................................................................................................................142
“ENTRY” KEYS.........................................................................................................................................143
Up and Down Arrow Keys.................................................................................................................143
Enter/adv Key.....................................................................................................................................143
“SETPOINTS” KEYS ................................................................................................................................144
Cooling Setpoints..............................................................................................................................144
Leaving Chilled Liquid Control ........................................................................................................144
Return Chilled Liquid Control ..........................................................................................................145
Remote Setpoint Control..................................................................................................................145
SCHEDULE/ADVANCE DAY KEY............................................................................................................145
PROGRAM KEY........................................................................................................................................147
System Trip Volts...............................................................................................................................148
Unit Trip Volts ....................................................................................................................................149
PROGRAM KEY LIMITS AND DEFAULT.................................................................................................149
SETPOINTS QUICK REFERENCE LIST..................................................................................................150
“UNIT” KEYS ...........................................................................................................................................151
Options Key .......................................................................................................................................151
CLOCK ......................................................................................................................................................155
UNIT KEYS OPTIONS PROGRAMMING QUICK REFERENCE LIST.....................................................156
TABLE OF CONTENTS (CONT’D)

JOHNSON CONTROLS
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FORM 150.67-NM2 (209)
SECTION 8 – UNIT OPERATION....................................................................................................................157
CAPACITY CONTROL ..............................................................................................................................157
SUCTION PRESSURE LIMIT CONTROLS ..............................................................................................157
DISCHARGE PRESSURE LIMIT CONTROLS.........................................................................................157
LEAVING CHILLED LIQUID CONTROL...................................................................................................157
LEAVING CHILLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING .....................158
LEAVING CHILLED LIQUID CONTROLOVERRIDE TO REDUCE CYCLING.........................................158
RETURN CHILLED LIQUID CONTROL....................................................................................................159
RETURN CHILLLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING....................160
ANTI-RECYCLE TIMER............................................................................................................................161
ANTI-COINCIDENCE TIMER....................................................................................................................161
EVAPORATOR PUMP CONTROL & YORK HYDRO KIT PUMP CONTROL ..........................................161
EVAPORATOR HEATER CONTROL........................................................................................................161
PUMPDOWN CONTROL...........................................................................................................................161
STANDARD CONDENSER FAN CONTROL............................................................................................161
YCAL0019 - 0028 LOW AMBIENT FAN CONTROL OPTION..................................................................165
General......................................................................................................................................................165
Potentiometer Configuration............................................................................................................165
Wiring .................................................................................................................................................166
Programming.....................................................................................................................................167
YCAL0033 LOW AMBIENT FAN CONTROL OPTION.............................................................................168
General...............................................................................................................................................168
Configuration (Jumpers and Potentiometers)................................................................................169
Wiring .................................................................................................................................................169
Programming.....................................................................................................................................169
YCAL0043 - 0066 LOW AMBIENT FAN CONTROL OPTION..................................................................171
General...............................................................................................................................................171
Configuration (Jumpers and Potentiometers)................................................................................172
Wiring .................................................................................................................................................173
Programming ....................................................................................................................................173
LOAD LIMITING........................................................................................................................................175
COMPRESSOR RUN STATUS .................................................................................................................175
ALARM STATUS.......................................................................................................................................175
BAS/EMS TEMPERATURE RESET USINGA VOLTAGE OR CURRENT SIGNAL.................................176
SECTION 9 – SERVICE AND TROUBLESHOOTING.....................................................................................177
CLEARING HISTORY BUFFERS..............................................................................................................177
SERVICE MODE........................................................................................................................................177
SERVICE MODE – OUTPUTS ..................................................................................................................177
SERVICE MODE – CHILLER CONFIGURATION.....................................................................................178
SERVICE MODE – ANALOG & DIGITAL INPUTS...................................................................................178
CONTROL INPUTS/OUTPUTS.................................................................................................................179
MICROBOARD LAYOUT ..........................................................................................................................180
TABLE OF CONTENTS (CONT’D)

FORM 150.67-NM2 (209)
9
JOHNSON CONTROLS
CHECKING INPUTS AND OUTPUTS.......................................................................................................181
Digital Inputs......................................................................................................................................181
Analog Inputs – Temperature...........................................................................................................181
Outside Air Sensor............................................................................................................................181
Liquid & Refrigerant Sensor Test Points ........................................................................................182
Analog Inputs – Pressure.................................................................................................................183
Digital Outputs...................................................................................................................................184
OPTIONAL PRINTER INSTALLATION.....................................................................................................185
Parts....................................................................................................................................................185
The following parts are required:.....................................................................................................185
Assembly and Wiring........................................................................................................................185
Obtaining a Printout..........................................................................................................................185
TROUBLESHOOTING ..............................................................................................................................186
SECTION 10 – MAINTENANCE......................................................................................................................189
IMPORTANT..............................................................................................................................................189
COMPRESSORS.......................................................................................................................................189
Oil Level check ..................................................................................................................................189
Oil Analysis........................................................................................................................................189
CONDENSER FAN MOTORS...................................................................................................................189
CONDENSER COILS................................................................................................................................189
OPERATING PARAMETERS....................................................................................................................189
ON-BOARD BATTERY BACK-UP............................................................................................................189
PLATE AND FRAME HEAT EXCHANGER (EVAPORATOR) HEATER...................................................189
OVERALL UNIT INSPECTION..................................................................................................................189
ISN CONTROL ..........................................................................................................................................190
Received Data (Control Data)...........................................................................................................190
Transmitted Data ...............................................................................................................................190
ISN Operational and Fault Codes.....................................................................................................192
BACNET AND MODBUS DATA COMMUNICATION................................................................................193
Serial Communication Analog Value Data ......................................................................................196
Serial Communication Binary Value Data.......................................................................................196
Serial Communication Analog Input Data.......................................................................................196
Serial Communication Binary Input Data........................................................................................198
TEMPERATURE CONVERSION CHART.................................................................................................199
R410-APRESSURE TEMPERATURE CHART.........................................................................................200
TABLE OF CONTENTS (CONT’D)

JOHNSON CONTROLS
10
FORM 150.67-NM2 (209)
General Chiller Introduction & Safety
SECTION 1 – GENERAL CHILLER INFORMATION & SAFETY
INTRODUCTION
YORK YCAL0019-0066 (15-65 ton, 53-218Kw)
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
solutions and is not suitable for purposes other than
those specified in this manual.
This manual contains all the information required for
correct installation and commissioning of the unit,
together with operating and maintenance instructions.
The manuals should be read thoroughly before
attempting to operate or service the unit.
All procedures detailed in the manuals, including
installation, commissioning and maintenance tasks
must only be performed by suitably trained and
qualified personnel.
The manufacturer will not be liable for any
injury or damage caused by incorrect installation,
commissioning, operation or maintenance resulting
from a failure to follow the procedures and
instructions detailed in the manuals.
WARRANTY
Johnson Controls warrants all equipment and
materials against defects in workmanship and
materials for a period of eighteen months from date of
shipment, unless 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 identification plate.
The unit warranty will be void if any modification to
the unit is carried out without prior written approval
from Johnson Controls.
For warranty purposes, the following conditions must
be satisfied:
• The initial start of the unit must be carried out by
trained personnel from an Authorized Johnson
Controls Service Center (see Commissioning
Page 121).
• 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 189).
• Failure to satisfy any of these conditions will
automatically 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
Mechanical 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
Refrigeration and Air Conditioning Equipment.
• Conform to Intertek Testing Services, formerly
ETL, for construction of chillers and provide
ETL/cETL listing label.
• Manufactured in facility registered to ISO 9002.
• OSHA – Occupational Safety and Health Act.
In addition, the chillers conform to Underwriters
Laboratories (U.L.) for construction of chillers and
provide U.L./cU.L. Listing Label.

FORM 150.67-NM2 (209)
11
JOHNSON CONTROLS
1
Responsibility for Safety
Every care has been taken in the design and
manufacture of the unit to ensure compliance with
the safety requirements listed above. However, the
individual operating or working on any machinery is
primarily responsible for:
• Personal safety, safety of other personnel, and
the machinery.
• Correct utilization of the machinery in
accordance with the procedures detailed in the
manuals.
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
explanation 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 forApplication
The unit is intended for cooling water or glycol
solutions and is not suitable for purposes other than
those specified in these instructions. Any use of the
equipment other than its intended use, or operation
of the equipment contrary to the relevant procedures
may result in injury to the operator, or damage to the
equipment.
The unit must not be operated outside the design
parameters specified in this manual.
Structural Support
Structural support of the unit must be provided as
indicated in these instructions. Failure to provide
proper support may result in injury to the operator, or
damage to the equipment and/or building.
Mechanical Strength
The unit is not designed to withstand loads or stresses
from adjacent equipment, pipework or structures.
Additional components must not be mounted on the
unit. Any such extraneous loads may cause structural
failure and may result in injury to the operator, or
damage to the equipment.
General Access
There are a number of areas and features, which
may be a hazard and potentially cause injury when
working on the unit unless suitable safety precautions
are taken. It is important to ensure access to the unit
is restricted to suitably qualified persons who are
familiar with the potential hazards and precautions
necessary for safe operation and maintenance of
equipment containing high temperatures, pressures
and voltages.

JOHNSON CONTROLS
12
FORM 150.67-NM2 (209)
General Chiller Introduction & Safety
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 damage to the pressure system. No attempt
should be made to gain access to the component parts
of the pressure system other than by suitably trained
and qualified personnel.
Electrical
The unit must be grounded. No installation or
maintenance work should be attempted on the
electrical equipment without first switching power
OFF, isolating and locking-off the power supply.
Servicing and maintenance on live equipment must
only be performed by suitably trained and qualified
personnel. No attempt should be made to gain access
to the control panel or electrical enclosures during
normal operation of the unit.
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
nontoxic, non-flammable and non-corrosive, and pose
no special safety hazards. Use of gloves and safety
glasses is, however, recommended when working on
the unit. The build up of refrigerant vapor, from a
leak for example, does pose a risk of asphyxiation in
confined or enclosed spaces and attention should be
given to good ventilation.
High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods
(e.g. steam cleaning) should not be used on any part
of the pressure system as this may cause operation of
the pressure relief device(s). Detergents and solvents,
which may cause corrosion, should also be avoided.
Emergency Shutdown
In case of emergency, the control panel is fitted
with a Unit Switch to stop the unit in an emergency.
When operated, it removes the low voltage 120
VAC electrical supply from the inverter system, thus
shutting down the unit.

FORM 150.67-NM2 (209)
13
JOHNSON CONTROLS
2
SECTION 2 – 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 complete
packaged unit includes hermetic scroll compressors, a
liquid cooler, air cooled condenser, a charge of refrigerant
R-410A and a weather resistant microprocessor control
center, all mounted on a pressed steel base.
The units are completely assembled with all
interconnecting refrigerant piping and internal wiring,
ready for field installation.
Prior to delivery, the packaged unit is pressure-tested,
evacuated, and fully charged with Refrigerant-R410A
and oil. After assembly, a complete operational test is
performed with water flowing through the cooler to
assure that the refrigeration circuit operates 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
(National Electric Code), ASHRAE/ANSI 15 Safety
code for mechanical refrigeration, ASME, Listed and
labeled with Intertek Testing Services (ETL) and rated
in accordance 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
dynamically balanced. A large internal volume and oil
reservoir provides greater liquid tolerance. Compressor
crankcase heaters are also included for extra protection
against liquid migration.
Evaporator (Heat Exchanger)
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
proper drainage and venting of the heat exchanger. Water
inlet and outlet connections are grooved for compatibility
with factory supplied victaulic connections.
LD10950
DUAL CIRCUIT

JOHNSON CONTROLS
14
FORM 150.67-NM2 (209)
Product Description
The heat exchanger is a brazed plate stainless steel
construction, single or dual circuit heat exchanger
capable of refrigerant working pressure of 650 PSIG
(3103 kPa) and liquid side pressure of 150 PSIG (1034
kPa) (Option for 300 PSIG [2068 kPa] available). Each
heat exchanger is covered in 3/4” (19mm) flexible,
closed cell insulation, thermal conductivity of 0.26k
(BTU/HR-FT2– °F] /in) maximum.
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,
internally-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 650 PSIG (45 bar).
Low Sound Fans – The condenser fans are composed
of corrosion resistant aluminum hub and glass-fiber
reinforced 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 vibration-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 (TEAO), direct drive, 6 pole, 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
displaying 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

FORM 150.67-NM2 (209)
15
JOHNSON CONTROLS
2
• 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.
 -a4-20milliampor0-10VDCinput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denition
• 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
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.
* IntensityofProtectionEuropeanStandard
**InternationalElectrotechnicalCommission
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.

JOHNSON CONTROLS
16
FORM 150.67-NM2 (209)
Product Description
ACCESSORIES AND OPTIONS
POWER OPTIONS
COMPRESSORPOWER CONNECTION –Single-
point (YCAL0019-0066) 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 YCAL0019 – 0066 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 Non-fused 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).
CONTROLTRANSFORMER–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).
POWERFACTORCORRECTIONCAPACITORS
–Will correct unit compressor power factors to a 0.90-
0.95 (Factory-Mounted).
CONTROL OPTIONS
AMBIENTKIT(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 110 °F
(43 °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).
LANGUAGELCDANDKEYPADDISPLAY–Span-
ish, French, and German unit LCD controls and keypad
displays are available. Standard language is English.
DISCHARGE PRESSURE TRANSDUCERS AND
READOUTCAPABILITY– 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 on YCAL0019-0066 models.
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).
MULTI-UNITSEQUENCING–A separate Sequenc-
ing Control Center can be 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 ControSl Panel or Multi-unit
Sequence Control) (Factory-Mounted).

FORM 150.67-NM2 (209)
17
JOHNSON CONTROLS
2
COMPRESSOR, PIPING, EVAPORATOR
OPTIONS
LOWTEMPERATURE BRINE – Required for brine
chilling below 30 °F (-1 °C) leaving brine temperature
for YCAL0019 – 0066 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).
HEAT EXCHANGER 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 Heat Exchanger
nozzles (Factory-Mounted). The companion flanges
will be field-supplied by others.
FLANGES (ANSI/AWWA C-606 COUPLINGS
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).
300PSIG (21BAR) 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.
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 applicable for any outdoor design ambient temperature
up to 115 °F (46 °C) (Factory-Mounted).
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:

JOHNSON CONTROLS
18
FORM 150.67-NM2 (209)
Product Description
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).

FORM 150.67-NM2 (209)
19
JOHNSON CONTROLS
2
COMPRESSORS
FAN ASSEMBLIES
CONDENSER
COILS
CONTROL / POWER PANEL
HEAT EXCHANGER
FIG. 1 – UNIT COMPONENTS SINGLE SYSTEM UNITS
UNIT COMPONENTS YCAL0019 - 0033

JOHNSON CONTROLS
20
FORM 150.67-NM2 (209)
Product Description
LD11463
KEYPAD & DISPLAY UNIT SWITCH
COMPRESSOR CONTACTORS USER TERMINAL BLOCK
CIRCUIT BREAKER
FIG. 2 – CONTROL/POWER PANEL COMPONENTS SINGLE SYSTEM UNITS
CONTROL - POWER PANEL COMPONENTS YCAL0019-0033