York YCAL0043E Series Owner's manual

YCAL0043E_ - YCAL0377E_
R-22 & HFC-407C
STYLE C
(50 Hz)
Standard, Glycol & Metric Models, Combined
380-415-3-50
MODEL ONLY
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
New Release Form 150.62-NM7 (103)
YCAL0287 – YCAL0377 EPROM
031-02423-001
29224(R)A
YCAL0043 – YCAL0253 EPROM (031-02050-001 MICROBOARD)
031-02049-001
035-19330-000

YORK INTERNATIONAL
2
FORM 150.62-NM7 (103)
YORK INTERNATIONAL
2
GENERAL SAFETY GUIDELINES
Thisequipmentisarelativelycomplicatedapparatus.Duringinstallation,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
obligationandresponsibilityofoperating/servicepersonneltoidentify and recognize
these inherent hazards, protect themselves, and proceed safely in completing their
tasks. Failure to comply with any of these requirements could result in serious
damage to the equipment and the property in which it is situated, as well as severe
personal injury or death to themselves and people at the site.
Thisdocument isintendedforuse byowner-authorizedoperating/servicepersonnel.
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 un-
derstood this document and any referenced materials. This individual shall also be
familiarwithandcomply 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:
DANGERindicatesan imminentlyhazardoussituationwhich,ifnotavoided,
will result in death or serious injury.
WARNING indicatesapotentially hazardoussituationwhich,ifnot avoided,
could result in death or serious injury.
IMPORTANT!
READ BEFORE PROCEEDING!

YORK INTERNATIONAL 3
FORM 150.62-NM7 (103)
YORK INTERNATIONAL 3
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.
CHANGEABILITY OF THIS DOCUMENT
In complying with YORK’s policy for continuous product improvement, the infor-
mationcontainedinthis document is subject to change without notice. WhileYORK
makesno commitment to update orprovidecurrent 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
ofoperating/service personnel as to the applicabilityofthese documents, then prior
to working on the equipment, they should verify with the owner whether the equip-
ment has been modified and if current literature is available.

YORK INTERNATIONAL
4
FORM 150.62-NM7 (103)
TABLE OF CONTENTS AND LIST OF TABLES
PAGE
PRODUCT IDENTIFICATION NUMBER........................................................7-8
REFRIGERANT FLOW DIAGRAM ................................................................... 9
SECTION 1 INSTALLATION .......................................................................... 10
ELECTRICAL DATA........................................................................................ 20
OPERATIONAL LIMITATIONS........................................................................ 28
PHYSICAL DATA............................................................................................. 32
DIMENSIONS & CLEARANCES..................................................................... 36
PRE-STARTUP CHECKLIST.......................................................................... 60
INITIAL STARTUP........................................................................................... 61
UNIT OPERATING SEQUENCE..................................................................... 63
SECTION 2 UNIT CONTROLS ...................................................................... 64
STATUS KEY .................................................................................................. 66
DISPLAY/PRINT KEYS................................................................................... 72
ENTRY KEYS.................................................................................................. 82
SETPOINTS KEYS ......................................................................................... 83
UNIT KEYS ..................................................................................................... 90
UNIT OPERATION.......................................................................................... 95
SECTION 3 SERVICE AND TROUBLESHOOTING .................................... 109
SERVICE MODE – CHILLER CONFIGURATION..........................................110
OPTIONAL PRINTER INSTALLATION .........................................................118
TROUBLESHOOTING CHARTS ...................................................................119
MAINTENANCE............................................................................................ 122
ISN CONTROL.............................................................................................. 128
SECTION 4 WIRING DIAGRAMS ............................................................... 126
SECTION 5 APPENDIX 1 – ISOLATORS ...........................................174 - 181
TABLES
1 MICRO PANEL POWER SUPPLY............................................................ 18
2 STANDARD SINGLE-POINT POWER (YCAL0043E_ - YCAL0253E_)... 21
3 SINGLE-POINT / DUAL POINTPOWER SUPPLY CONNECTIONS
(YCAL0117E_ - YCAL0253E_ DUAL POINT) .................................. 22 – 23
4 SINGLE-POINT POWER SUPPLY CONNECTIONS W/
INDIVIDUAL CIRCUIT BREAKERS (YCAL0287E_ - YCAL0377E_)24 – 25
5 MUTIPLE POINT POWER SUPPLY CONNECTIONS
(YCAL0287E_ - YCAL0377E_)......................................................... 26 – 27
6 TEMPERATURES AND FLOWS (ENGLISH)........................................... 28
7 VOLTAGE LIMITATIONS .......................................................................... 28
8 COOLER PRESSURE DROP CURVES (ENGLISH) ............................... 29

YORK INTERNATIONAL 5
FORM 150.62-NM7 (103)
LIST OF TABLES
PAGE
TABLES
9 ETHYLENE GLYCOL CORRECTION FACTORS ...................................28
10 TEMPERATURES AND FLOWS (METRIC)............................................30
11 VOLTAGE LIMITATIONS (METRIC)........................................................30
12 COOLER PRESSURE DROP CURVES (METRIC) ................................31
13 ETHYLENE GLYCOL CORRECTION FACTORS ...................................31
14 PHYSICAL DATA (ENGLISH)..........................................................32 – 33
14 PHYSICAL DATA (METRIC)............................................................34 – 35
16 SETPOINTS ENTRY LIST.......................................................................61
17 STATUS KEY MESSAGES......................................................................71
18 OPERATOR DATA QUICK REFERENCE LIST.......................................76
19 COOLING SETPOINTS, PROGRAMMABLE LIMITS & DEFAULTS.......85
20 PROGRAM KEY LIMITS & DEFAULTS...................................................88
21 SETPOINTS KEY QUICK REFERENCE LIST........................................89
22 UNIT KEYS QUICK REFERENCE LIST..................................................94
23 COMPRESSOR STAGING FOR RETURN WATER CONTROL.............97
24 RETURN CHILLED LIQUID CONTROL – 5 & 6 COMPRESSORS ........97
25 RETURN CHILLED LIQUID CONTROL – 4 COMPRESSORS...............98
26 YCAL0043 - YCAL0253 CONDENSER FAN CONTROL USING
OUTDOOR AMBIENT TEMP. & DP.......................................................101
27 YCAL0043 - YCAL0253 CONDENSER FAN CONTROL USING
DP ONLY ...............................................................................................101
28 YCAL0043 - YCAL00253 LOW AMBIENT CONDENSER FAN
CONTROL + DISCHARGE PRESSURE CONTROL.............................102
29 YCAL0287 - YCAL0317 CONDENSER FAN CONTROL ......................103
30 YCAL0347 - YCAL0377 CONDENSER FAN CONTROL ......................104
31 COMPRESSOR OPERATION – LOAD LIMITING ................................106
32 MICROBOARD DIGITAL INPUTS.........................................................111
33 MICROBOARD ANALOG INPUTS........................................................111
34 MICROBOARD DIGITAL OUTPUTS.....................................................111
35 MICROBOARD ANALOG OUTPUTS....................................................111
36 OUTDOOR AIR SENSOR TEMP./VOLT./RESISTANCE .......................113
37 ENTERING & LEAVING CHILLED LIQUID TEMPERATURE
SENSOR, COOLER INLET TEMP. & SUCTION TEMP.........................114
38 KEYPAD PIN ASSIGNMENT MATRIX...................................................117
39 TROUBLESHOOTING CHARTS...........................................................119
40 ISN RECEIVED DATA............................................................................123
41 ISN TRANSMITTED DATA....................................................................123
42 ISN OPERATIONAL & FAULT CODES..................................................125

YORK INTERNATIONAL
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FORM 150.62-NM7 (103)
LIST OF FIGURES
1 REFRIGERANT FLOW DIAGRAM......................................................................................9
2 SINGLE-POINT SUPPLY CONNECTION .........................................................................14
3 MULTIPLE POINT POWER SUPPLY CONNECTION.......................................................15
4 MULTIPLE POINT POWER SUPPLY WIRING – TERMINAL BLOCK,
NON-FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER ...................................16
5 OPTIONAL SINGLE-POINT WIRING................................................................................17
6 CONTROL WIRING..........................................................................................................18
7 SETPOINTADJUST..........................................................................................................96
8 LEAVING WATER TEMPERATURE CONTROL – EXAMPLE ..........................................96
9 YCAL0043 - YCAL0253 FAN LOCATION (TYPICAL) .....................................................101
10 YCAL0287 - YCAL0317 FAN LOCATION........................................................................103
11 YCAL0347 - YCAL0377 FAN LOCATION........................................................................104
12 FIELD & FACTORY ELECTRICAL CONNECTIONS –
OPTIONAL REMOTE TEMPERATURE RESET BOARD..............................................108
13 MICROBOARD LAYOUT.................................................................................................112
14 MICROBOARD RELAY CONTACT ARCHITECTURE ....................................................116
15 PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS.......................................118
16 ELEMENTARY DIAGRAM – CONTROL CIRCUIT (YCAL0043E_ - YCAL0087E_)126 - 127
17 ELEMENTARY DIAGRAM – POWER CIRCUIT (YCAL0043E_ - YCAL0087E_)............128
18 CONNECTION DIAGRAM – (YCAL0043E_ - YCAL00687E_)...............................130 - 131
19 ELEMENTARY DIAGRAM – NOTES / DETAILS (YCAL0043E_ - YCAL0087E_)...........132
20 ELEMENTARY DIAGRAM – CONTROL CIRCUIT (YCAL0107E_) .......................134 - 135
21 ELEMENTARY DIAGRAM – POWER CIRCUIT (YCAL0107E_).....................................136
22 CONNECTION DIAGRAM – (YCAL0107E_)..........................................................138 - 140
23 ELEMENTARY DIAGRAM – NOTES / DETAILS (YCAL0107E_)....................................140
24 ELEMENTARY DIAGRAM – CONTROL CIRCUIT (YCAL0117E_ - YCAL0173E_)142 - 143
25 ELEMENTARY DIAGRAM – POWER CIRCUIT (YCAL0117E_ - YCAL0173E_)...144 - 145
26 CONNECTION DIAGRAM – (YCAL0117E_ - YCAL0173E_).................................146 - 147
27 ELEMENTARY DIAGRAM – NOTES / DETAILS (YCAL0117E_ - YCAL0173E_)...........148
28 ELEMENTARY DIAGRAM – CONTROL CIRCUIT (YCAL0197E_ - YCAL0253E_)150 - 151
29 CONNECTION DIAGRAM – (YCAL0197E_ - YCAL0253E_).................................152 - 153
30 ELEMENTARY DIAGRAM – NOTES / DETAILS (YCAL0197E_ - YCAL253E_).............154
31 ELEMENTARY DIAGRAM – POWER CIRCUIT (YCAL0197E_ - YCAL0253E_)...156 - 157
32 ELEMENTARY DIAGRAM – CONTROL CIRCUIT (YCAL0287E_ - YCAL0317E_)158 - 159
33 ELEMENTARY DIAGRAM – NOTES / DETAILS (YCAL0287E_ - YCAL0317E_)...........160
34 ELEMENTARY DIAGRAM – POWER CIRCUIT (YCAL0287E_ - YCAL0317E_)...162 - 163
35 CONNECTION DIAGRAM – (YCAL0287E_ - YCAL0317E_).................................164 - 165
36 ELEMENTARY DIAGRAM – CONTROL CIRCUIT (YCAL0347E_ - YCAL0377E_).166-167
37 ELEMENTARY DIAGRAM – NOTES / DETAILS (YCAL0347E_ - YCAL0377E_)...........168
38 ELEMENTARY DIAGRAM – POWER CIRCUIT (YCAL0347E_ - YCAL0377E_)...170 - 171
39 CONNECTION DIAGRAM – (YCAL0347E_ - YCAL0377E_)................................172 - 173
40 ISOLATORS, TYPE CP 1................................................................................................178
41 ISOLATORS, TYPE CP 2................................................................................................178
42 R SPRING SEISMIC ISOLATOR.....................................................................................179
43 TYPE CP MOUNTING ....................................................................................................180
44 “AEQM” SPRING-FLEX MOUNTING..............................................................................181

YORK INTERNATIONAL 7
FORM 150.62-NM7 (103)
PRODUCT IDENTIFICATION NUMBER (PIN)
BASIC MODEL NUMBER
: High Efficiency : R-22
: R-407C
: 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 13 14 15
BASE PRODUCT TYPE NOMINALCAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE/STARTER DESIGN/DEVELOPMENT LEVEL
Y 0 # # # E C C
C 1 # # # B A
A 5 0
U
L
X
: Design Series
: Engineering
Change
or PIN Level
: 380-415 / 3 / 50
: Across the Line
YCAL0080EC 50XCA

YORK INTERNATIONAL
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FORM 150.62-NM7 (103)
PRODUCT IDENTIFICATION NUMBER (PIN)
EXAMPLES: 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 X X X X X X X X L X X X X X X X X X X X X X X X X X A X X X X X X X X X X X X X S D T C A T S R L X P R S 2 5 C X 1 X X X X 3 D W S A R X B X X 4 B X X L X S D
OPTIONS MODEL NUMBER
: Aluminum
: Copper
: Black Fin
: Phenolic
: TEAO Fan
Motors
EVAP. FIELD CONDENSER FIELD CABINET FIELD
: Wire Condenser Headers Only (factory)
: Wire (Full Unit) Enc. Panels (factory)
: Wire (Full Unit) Enc. Panels (field)
: Wire/Louvered Enc. Panels (factory)
: Wire/Louvered Enc. Panels (field)
: Louvered (Cond. Only) Enc. Panels (factory)
: Louvered (Cond. Only) Enc. Panels (field)
: Louvered (Full Unit) Enc. Panels (factory)
: Louvered (Full Unit) Enc. Panels (field)
: Acoustic Sound Blanket
: Low Sound Fans
: 1" Deflection
: Seismic
: Neoprene Pads
55
EXTENDED FIELD
X
B
C
D
E
F
G
H
: 1st Year Parts Only
: 1st Year Parts & Labor
: 2nd Year Parts Only
: 2nd Year Parts & Labor
: 5 Year Compressor Parts Only
: 5 Year Compressor Parts & Labor Only
: 5 Year Units Parts Only
: 5 Year Unit Parts & Labor
NOTES:
1. Q :DENOTES SPECIAL/ S.Q.
2. # :DENOTES STANDARD
3. X :w/in OPTIONS FIELD, DENOTES NO OPTION SELECTED
4. Agency Files (i.e. U.L. / E.T.L.; CE; ARI; ETC.) will contain info. based on the first 14 characters only.
: Low Ambient Kit (factory)
: High Ambient Kit (factory)
: Both Low / High Ambient (factory)
: BAS/EMS Temp. Reset / Offset
: Spanish LCD & Keypad Display
: French LCD & Keypad Display
: German LCD & Keypad Display
: Discharge Pressure Transducers/
Readout Kit
: Suction Pressure Transducers /
Readout Kit
: Both Discharge & Suction Pressure
Transducers / Readout
: N. American Safety Code
(cU.L./cE.T.L.)
: No Listing (typically 50 HZ non-CE,
non-U.L.
: Remote Control Panel
: Sequence Control & Automatic
Lead Transfer
: 300 PSIG DWP Waterside
: Double Thick Insulation
: Weld Flange Kit
: Victaulic Flange Kit
: Flow Switch
: ASME Pressure Vessel &
Associated Codes
: Remote DX Cooler
: SP Supply TB
: MP Supply TB
: SP Supply TB
: SP NF Disconnect Switch
: SP Circuit Breaker w/ Lockable Handle
: Control Transformer (factory)
: Power Factor Capacitor
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
POWER FIELD CONTROLS FIELD COMPRESSOR / PIPING FIELD
X X L # #
X X H
S X A C
S D T S
B X S B
F E
G 1
T I
C R X
S X
B X
X
L
N
C
R
S
MP = Multiple Point
SP = Single-Point
NF = Non-Fused
TB = Terminal Block
Ser. = Service
Ind. Sys. Brkr. & L. Ext. Handles = Individual
System Breaker & Lockable
External Handle
38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 X X
D C 1
W B 2
V P 3
S X 4
A 5
6
R 7
8
B
L
1
S
N
: Leaving Supply Temp.
: Chicago Code Kit Req’d.
: Service Isolation Valves
: Both Chicago & Svc. Iso.
: Elec. Expansion Valve
: Hot Gas By-Pass req’d.
(1 circuit)
: X
: X
: X
: Crankcase Heater Std.

YORK INTERNATIONAL 9
FORM 150.62-NM7 (103)
LD07613-50HZ
REFRIGERANT FLOW DIAGRAM
FIG. 1 – REFRIGERANT FLOW DIAGRAM
2 OR 3 COMPRESSORS PER SYSTEM
OIL EQUALIZING
LINE
AIR COOLED CONDENSERS
DX COOLER
LEAVING CHILLED WATER
ENTERING CHILLED WATER
OPTIONAL
SERVICE VALVE
OPTIONAL DISCHARGE
PRESSURE TRANSDUCER
HIGH PRESSURE
CUTOUT SWITCH
OPTIONAL
SERVICE
VALVE
LOW PRESSURE SWITCH OR
SUCTION PRESSURE TRANSDUCER
LEAVING
CHILLED WATER
TEMP. SENSOR
RETURN WATER
TEMP. SENSOR
OPTIONAL
DISCHARGE LINE
BALL VALVE
HOT DISCHARGE
GAS LINE
LIQUID LINE
SERVICE VALVE
LIQUID LINE FILTER / DRIER
LIQUID LINE
SOLENOID VALVE
SIGHT GLASS /
MOISTURE INDICATOR
SOLENOID OPERATED
HOT GAS BY PASS VALVE
*
OPTIONAL
SUCTION LINE
BALL VALVE
EQUALIZER
LINE
TXV
OPTIONAL
RELIEF VALVE
300 PSIG
(20.68 BARG)
YCAL REFRIGERANT FLOW DIAGRAM
(INCLUDING TEMPERATURE SENSORS & PRESSURE TRANSDUCERS)
NOTE: YCAL0117-0377 HAVE TWO REFRIGERANT
SYSTEMS AND ONE DX COOLER.
* HOT GAS OPTION - SYSTEM 1 ONLY

YORK INTERNATIONAL
10
FORM 150.62-NM7 (103)
29224(RIG)A
To ensure warranty coverage, this
equipment must be commissioned
and serviced by an authorized YORK
servicemechanicora qualifiedservice
person experienced in chiller instal-
lation. Installation must comply with
all applicable codes, particularly in
regard to electrical wiring and other
safety elements such as relief valves,
HP cutout settings, design working
pressures, and ventilation require-
ments consistent with the amount and
type of refrigerant charge.
Lethalvoltagesexistwithin thecontrol
panels.Beforeservicing,openandtag
all disconnect switches.
INSTALLATION CHECK LIST
The following items, 1 through 5, must be checked be-
fore placing the units in operation.
1. Inspect the unit for shipping damage.
2. Rig unit using spreader bars.
3. Open the unit only to install water piping system.
Do not remove protective covers from water con-
nections until piping is ready for attachment. Check
water piping to ensure cleanliness.
4. Pipe unit using good piping practice (seeASHRAE
handbook section 215 and 195).
5. Check to see that the unit is installed and operated
within limitations (Refer to LIMITATIONS).
The following pages outline detailed procedures to be
followed to install and start-up the chiller.
HANDLING
Theseunitsare shippedas completely assembledunits
containing full operating charge, and care should be
taken to avoid damage due to rough handling.
INSTALLATION
INSPECTION
Immediately upon receiving the unit, it should be in-
spectedforpossible damagewhichmay haveoccurred
duringtransit. Ifdamageis evident,it shouldbenoted in
the carrier’s freight bill.A written request for inspection
by the carrier’s agent should be made at once. See
“Instruction” manual, Form 50.15-NM for more infor-
mation and details.
LOCATION AND CLEARANCES
These units are designed for outdoor installations on
ground level, rooftop, or beside a building. Location
should be selected for minimum sun exposure and to
insure adequate supply of fresh air for the condenser.
The units must be installed with sufficient clearances
for air entrance to the condenser coil, for air discharge
away from the condenser, and for servicing access.
In installations where winter operation is intended and
snow accumulations are expected, additional height
must be provided to ensure normal condenser air
flow.
Clearances are listed under “Notes” in the “DIMEN-
The unit should be lifted by inserting hooks through
the holes provided in unit base rails. Spreader bars
should be usedto avoid crushingthe unitframe rails
with the lifting chains. See below.
Installation

YORK INTERNATIONAL 11
FORM 150.62-NM7 (103)
FOUNDATION
The unit should be mounted on a flat and level foun-
dation, floor, or rooftop capable of supporting the entire
operating weight of the equipment. See PHYSICAL
DATAforoperatingweight. Ifthe unitiselevated beyond
thenormal reachofservicepersonnel,a suitablecatwalk
must be capable of supporting service personnel, their
equipment, and the compressors.
GROUND LEVEL LOCATIONS
Itisimportant that theunits be installedon a substantial
base that will not settle. A one piece concrete slab with
footers extended below the frost line is highly recom-
mended. Additionally, the slab should not be tied to
the main building foundations as noise and vibration
may be transmitted. Mountingholes areprovidedin the
steel channel for bolting the unit to its foundation. (See
DIMENSIONS.)
For ground level installations, precautions should be
taken to protect the unit from tampering by or injury to
unauthorizedpersons. Screwsand/or latcheson access
panels will prevent casual tampering. However, further
safety precautions such as a fenced-in enclosure or
locking devices on the panels may be advisable.
ROOFTOP LOCATIONS
Choosea spotwithadequate structuralstrengthtosafely
support the entire weight of the unit and service per-
sonnel. Care must be taken not to damage the roof.
Consult the building contractor or architect if the roof is
bonded. Roof installations should have wooden beams
(treated to reduce deterioration), cork, rubber, or vibra-
tion isolators under the base to minimize vibration.
NOISE SENSITIVE LOCATIONS
Efforts should be made to assure that the chiller is not
locatednext tooccupied spacesor noisesensitive areas
where chiller noise level would be a problem. Chiller
noise is a result of compressor and fan operation. Con-
siderations should be made utilizing noise levels pub-
lished in the YORK Engineering Guide for the specific
chiller model. Sound blankets for the compressors and
low sound fans are available.
SPRING ISOLATORS (OPTIONAL)
When ordered, four (4) isolators will be furnished.
Identifytheisolator,locateat thepropermounting point,
and adjust per instructions. See APPENDIX 1.
COMPRESSOR MOUNTING
The compressors are mounted on four (4) rubber iso-
lators. The mounting bolts should not be loosened or
adjusted at installation of the chiller.
REMOTE COOLER OPTION
Forunits usingremote cooleroption, referto instructions
included with miscellaneous cooler parts kit.
The unit and remote cooler is shipped with a 6 lb. (2.7
kg) nitrogen holding charge. The nitrogen charge must
beremoved,and systemevacuated, and therefrigerant
charge must be weighed-in according to the operating
chargelisted underPHYSICALDATA.Additionalcharge
must also be added for the refrigerant lines.
CHILLED WATER PIPING
General – When the unit has been located in its
final position, the unit water piping may be connected.
Normal installation precautions should be observed in
ordertoreceive maximumoperating efficiencies.Piping
shouldbekept freeofall foreignmatter.All chilledwater
evaporator piping must comply in all respects with local
plumbing codes and ordinances.
Sinceelbows, teesandvalves decreasepump capacity,
all piping should be kept as straight and as simple as
possible. All piping must be supported independent
of the chiller.
Consideration should be given to
compressor access when laying out
water piping. Routing the water pip-
ing too close to the unit could make
compressor servicing/replacement
difficult.
1

YORK INTERNATIONAL
12
FORM 150.62-NM7 (103)
Hand stop valves should be installed in all lines to fa-
cilitate servicing.
Piping to the inlet and outlet connections of the chiller
should include high-pressure rubber hose or piping
loops to ensure against transmission of water pump
vibration.The necessarycomponents mustbeobtained
in the field.
Drain connections should be provided at all low points
to permit complete drainage of the cooler and system
water piping.
Asmallvalveor valvesshould beinstalled atthe highest
point or points in the chilled water piping to allow any
trapped air to be purged. Vent and drain connections
shouldbe extendedbeyondthe insulationto makethem
accessible.
The piping to and from the cooler must be designed
to suit the individual installation. It is important that the
following considerations be observed:
1. The chilled liquid piping system should be laid out
so that the circulating pump discharges directly
into the cooler. The suction for this pump should
be taken from the piping system return line and not
the cooler. This piping scheme is recommended,
but is not mandatory.
2. The inlet and outlet cooler connection sizes are
3" (YCAL0043 - 0073), 4" (YCAL0087 - 0107), 6"
(YCAL0117 - 0253), or 8" (YCAL0287 - 0377) .
3. A strainer, preferably 40 mesh, must be installed
in the cooler inlet line just ahead of the cooler. This
is important to protect the cooler from entrance of
large particles which could cause damage to the
evaporator.
4. Allchilledliquid pipingshould be thoroughlyflushed
to free it from foreign material before the system
is placed into operation. Use care not to flush any
foreign material into or through the cooler.
5. As an aid to servicing, thermometers and pressure
gauges should be installed in the inlet and outlet
water lines.
6. The chilled water lines that are exposed to outdoor
ambients should be wrapped with supplemental
heater cable and insulated to protect against
freeze-up during low ambient periods, and to pre-
vent formation of condensation on lines in warm
humid locations.
7. Achilled water flow switch, (either by YORK or oth-
ers)MUSTbeinstalledintheleavingwaterpipingof
thecooler.There shouldbe a straighthorizontal run
of at least 5 diameters on each side of the switch.
Adjust the flow switch paddle to the size of the pipe
in which it is to be installed. (See manufacturer’s
instructions furnished with the switch.) The switch
is to be wired to terminals 13 - 14 of CTB1 located
in the control panel, as shown on the unit wiring
diagram.
WIRING
Liquid Chillers are shipped with all factory-mounted
controls wired for operation.
Field Wiring – Power wiringmustbe providedthrough
a fused disconnect switch to the unit terminals (or op-
tional molded disconnect switch) in accordance with
N.E.C. or local code requirements. Minimum circuit
ampacity and maximum dual element fuse size are
given in the Tables 2 – 6.
A 120-1-60, 15 amp source must be supplied for the
controlpanel throughafused disconnectwhen acontrol
panel transformer (optional) is not provided. Refer to
Table 1 and Figures 2 - 6.
See Figures 2 - 6 and unit wiring diagrams for field and
power wiring connections, chilled water pump starter
contacts, alarm contacts, compressor run status con-
tacts,PWMinput, andloadlimitinput. Refertosectionon
UNITOPERATIONforadetaileddescription ofoperation
concerning aforementioned contacts and inputs.
Installation
The Flow Switch MUST NOT be used
to start and stop the chiller (i.e. start-
ing and stopping the chilled water
pump). It is intended only as a safety
switch.

YORK INTERNATIONAL 13
FORM 150.62-NM7 (103)
EVAPORATOR PUMP START CONTACTS
Terminalblock CTB2 –terminals 23to24, arenormally-
open contacts that can be used to switch field supplied
power to provide a start signal to the evaporator pump
contactor. The contacts will be closed when any of the
following conditions occur:
1. Low Leaving Chilled Liquid Fault
2. Any compressor is running
3. Daily schedule is not programmed OFF and the
Unit Switch is ON
The pump will not run if the micro panel has been pow-
ered up for less than 30 seconds, or if the pump has
run in the last 30 seconds, to prevent pump motor over-
heating. Refer to Figure 6 and unit wiring diagram.
SYSTEM RUN CONTACTS
Contacts are available to monitor system status. Nor-
mally-open auxiliary contacts from each compressor
contactor are wired in parallel with CTB2 – terminals
25 to 26 for system 1, and CTB2 – terminals 27 to 28
for system 2 (YCAL0117 - YCAL0377). Refer to Figure
6 and unit wiring diagram.
ALARM STATUS CONTACTS
Normally-opencontactsareavailablefor eachrefrigerant
system. These normally-open contacts close when the
system is functioning normally. The respective contacts
will open when the unit is shut down on a unit fault, or
locked out on a system fault. Field connections are at
CTB2 terminals 29 to 30 (system 1), and terminals 31
to 32 (system 2 YCAL0117 - YCAL0377).
REMOTE START/STOP CONTACTS
Toremotelystartandstopthechiller,drycontactscanbe
wiredin serieswiththe flowswitch andCTB1 -terminals
13 to 14. Refer to Figure 6 and unit wiring diagram.
REMOTE EMERGENCY CUTOFF
Immediateshutdownof thechiller can beaccomplished
byopening afield-installed drycontact tobreak theelec-
trical circuit between terminals 5 to L on terminal block
CTB2.Theunitisshippedwith afactory jumperinstalled
between terminals 5 to L, which must be removed if
emergency shutdown contacts are installed. Refer to
Figure 6 and unit wiring diagram.
PWM INPUT
The PWM input allows reset of the chilled liquid set-
pointby supplyinga“timed” contactclosure. Fieldwiring
should be connected to CTB1 – terminals 13 to 20. A
detailed explanation is provided in the Unit Control sec-
tion. Refer to Figure 6 and unit wiring diagram.
LOAD LIMIT INPUT
Load limiting is a feature that prevents the unit from
loading beyond a desired value. The unit can be “load
limited”either33%, 40%,50%, 66% or80%, depending
on the number of compressors on unit. The field con-
nections are wired to CTB1 – terminals 13 to 21, and
work in conjunction with the PWM inputs. A detailed
explanationis providedin theUnit Controlsection. Refer
to Figure 6 and unit wiring diagram.
When using the Load Limit feature,
the PWM feature will not function
– SIMULTANEOUS OPERATION
OF LOAD LIMITING AND TEM-
PERATURE RESET (PWM INPUT)
CANNOT BE DONE.
FLOW SWITCH INPUT
The flow switch is field wired to CTB1 terminals 13 - 14.
See Figure 6 and unit wiring diagram.
COMPRESSOR HEATERS
Compressorheaters arestandard. IfpowerisOFF more
than two hours, the crankcase heaters must be ener-
gized for 18 - 24 hours prior to restarting a compressor.
This will assure that liquid slugging and oil dilution does
not damage the compressors on start.
1

YORK INTERNATIONAL
14
FORM 150.62-NM7 (103)
FIG. 2 – SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED DISCONNECT
SWITCH OR CIRCUIT BREAKER (0043 - 0253)
SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED
DISCONNECT SWITCH OR CIRCUIT BREAKER (0043 - 0253)
Electrical Notes and Legend located on page 19.
Installation
Itispossiblethatmultiple sources ofpowercanbesupplyingthe unit powerpanel.Toprevent
serious injury or death, the technician should verify that NO LETHAL VOLTAGES are
present inside the panel AFTER disconnecting power, PRIOR to working on equipment.
The unit evaporator heater uses 120VAC. Disconnecting 120VAC power from the unit, at
or below freezing temperatures, can result in damage to the evaporator and unit as a result
of the chilled liquid freezing.
* Models YCAL0040-0080 Only (Models YCAL0014-0034 are Single Point)
LD07719
Power Panel Control Panel
Terminal Block,
NF Disconnect SW
or Circuit Breaker
1L1 1L2 1L3
GRD
MICROPANEL
2
L
CTB2
13 14
CTB1
Field Provided Unit Power Supply
Field Provided 120-1-60
Micropanel Power Supply if Control
Transformer not Supplied
Flow Switch
See electrical note 9
Power Panel Control PanelPower Panel Control Panel
Terminal Block,
NF Disconnect SW
or Circuit Breaker
1L1 1L2 1L31L1 1L2 1L3
GRDGRDGRD
MICROPANEL
2
L
CTB2
2
L
CTB2
13 1413 14
CTB1
Field Provided Unit Power Supply
Field Provided 120-1-60
Micropanel Power Supply if Control
Transformer not Supplied
Flow Switch
See electrical note 9

YORK INTERNATIONAL 15
FORM 150.62-NM7 (103)
Electrical Notes and Legend located on page 19.
FIG. 3 – MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL BLOCK (0117 - 0253)
MULTIPLE POINT POWER SUPPLY CONNECTION –
TERMINAL BLOCK (0117 - 0253)
1
Itispossiblethat multiplesourcesofpowercan besupplyingtheunitpowerpanel. Toprevent
serious injury or death, the technician should verify that NO LETHAL VOLTAGES are
present inside the panel AFTER disconnecting power, PRIOR to working on equipment.
The unit evaporator heater uses 120VAC. Disconnecting 120VAC power from the unit, at
or below freezing temperatures, can result in damage to the evaporator and unit as a result
of the chilled liquid freezing.
Power Panel Control Panel
Terminal
Block1
Terminal
Block2
1L1 1L2 1L3 2L1 2L2 2L3
GRD GRD
MICROPANEL
2
L
CTB2
13 14
CTB1
Field Provided Unit Power Supply
Field Provided 120-1-60
Micropanel Power Supply if Control
Transformer not Supplied
Flow Switch
See electrical note 9
Power Panel Control PanelPower Panel Control Panel
Terminal
Block1
Terminal
Block2
1L1 1L2 1L31L1 1L2 1L3 2L1 2L2 2L32L1 2L2 2L3
GRDGRDGRD GRDGRDGRD
MICROPANEL
2
L
CTB2
2
L
CTB2
13 1413 14
CTB1
Field Provided Unit Power Supply
Field Provided 120-1-60
Micropanel Power Supply if Control
Transformer not Supplied
Flow Switch
See electrical note 9
LD07720

YORK INTERNATIONAL
16
FORM 150.62-NM7 (103)
Electrical Notes and Legend located on page 19.
FIG. 4 – MULTIPLE POINT POWER SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED
DISCONNECT SWITCHES OR CIRCUIT BREAKERS (0287 - 0377)
MULTIPLE POINT POWER SUPPLY CONNECTION –
TERMINAL BLOCK, NON-FUSED DISCONNECT SWITCHES OR
CIRCUIT BREAKERS (0287 - 0377)
Installation
Itispossiblethatmultiple sources ofpowercanbesupplyingthe unit powerpanel.Toprevent
serious injury or death, the technician should verify that NO LETHAL VOLTAGES are
present inside the panel AFTER disconnecting power, PRIOR to working on equipment.
The unit evaporator heater uses 120VAC. Disconnecting 120VAC power from the unit, at
or below freezing temperatures, can result in damage to the evaporator and unit as a result
of the chilled liquid freezing.
LD07721
Power Panel Control Panel
Terminal Block1,
NF Disconnect
SW1
or Circuit Breaker1
Terminal Block2,
NF Disconnect
SW2
or Circuit Breaker2
1L1 1L2 1L3 2L1 2L2 2L3
GRD GRD
MICROPANEL
2
L
CTB2
13 14
CTB1
Field Provided Unit Power Supply
Field Provided 120-1-60
Micropanel Power Supply if
Control Transformer not Supplied
Flow Switch
See electrical note 9
Power Panel Control PanelPower Panel Control Panel
Terminal Block1,
NF Disconnect
SW1
or Circuit Breaker1
Terminal Block2,
NF Disconnect
SW2
or Circuit Breaker2
1L1 1L2 1L31L1 1L2 1L3 2L1 2L2 2L32L1 2L2 2L3
GRDGRDGRD GRDGRDGRD
MICROPANEL
2
L
CTB2
2
L
CTB2
13 1413 14
CTB1
Field Provided Unit Power Supply
Field Provided 120-1-60
Micropanel Power Supply if
Control Transformer not Supplied
Flow Switch
See electrical note 9

YORK INTERNATIONAL 17
FORM 150.62-NM7 (103)
1
Electrical Notes and Legend located on page 19.
FIG. 5 – OPTIONAL SINGLE-POINT POWER WIRING
SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK
OR NON-FUSED DISCONNECT SWITCH TO INDIVIDUAL
SYSTEM CIRCUIT BREAKERS (0287 - 0377)
Itispossiblethatmultiple sources ofpowercanbesupplyingthe unit powerpanel.Toprevent
serious injury or death, the technician should verify that NO LETHAL VOLTAGES are
present inside the panel AFTER disconnecting power, PRIOR to working on equipment.
The unit evaporator heater uses 120VAC. Disconnecting 120VAC power from the unit, at
or below freezing temperatures, can result in damage to the evaporator and unit as a result
of the chilled liquid freezing.
Power Panel Control Panel
Terminal Block or
NF Disconnect SW
1L1 1L2 1L3
GRD
MICROPANEL
2
L
CTB2
13 14
CTB1
Field Provided Unit Power Supply
Field Provided 120-1-60
Micropanel Power Supply if Control
Transformer not Supplied
Flow Switch
See electrical note 9
Circuit
Breaker1
Circuit
Breaker2
Power Panel Control PanelPower Panel Control Panel
Terminal Block or
NF Disconnect SW
1L1 1L2 1L31L1 1L2 1L3
GRDGRDGRD
MICROPANEL
2
L
CTB2
2
L
CTB2
13 1413 14
CTB1
Field Provided Unit Power Supply
Field Provided 120-1-60
Micropanel Power Supply if Control
Transformer not Supplied
Flow Switch
See electrical note 9
Circuit
Breaker1
Circuit
Breaker2
LD07722

YORK INTERNATIONAL
18
FORM 150.62-NM7 (103)
Installation
CTB1
21
13
20
13
14
13
FLOW SW REMOTE START/STOP
PWM INPUT
LOAD LIMIT INPUT
FIG. 6 – CONTROL WIRING
CONTROL WIRING
*
* Factory wired with optional transformer.
LD07730
LD07725
Itispossiblethatmultiple sources ofpowercanbesupplyingthe unit powerpanel.Toprevent
serious injury or death, the technician should verify that NO LETHAL VOLTAGES are
present inside the panel AFTER disconnecting power, PRIOR to working on equipment.
The unit evaporator heater uses 120VAC. Disconnecting 120VAC power from the unit, at
or below freezing temperatures, can result in damage to the evaporator and unit as a result
of the chilled liquid freezing.
OVER CURRENT PROTECTION,
UNIT VOLTAGE UNIT VOLTAGE CONTROLPOWER MCA SEE NOTE B NF DISC SW
NOTEA MIN MAX
MODELS w/o
CONTROL TRANS 115-1-60/50 15A 10A 15A 30A / 240V
MODELS w/ -50 380/415-3-50 15A 10A 15A 30A/ 480V
CONTROL TRANS
A. Minimum #14AWG, 75°C, Copper Recommended
B. Minimum and Maximum Over Current Protection, Dual Element Fuse or Circuit Breaker
TABLE 1 – MICRO PANEL POWER SUPPLY

YORK INTERNATIONAL 19
FORM 150.62-NM7 (103)
ELECTRICAL NOTES AND LEGEND
1
NOTES:
1. Minimum Circuit Ampacity (MCA) is based on 125% of the rated load amps for the largest motor plus 100% of
the rated load amps for all other loads included in the circuit, per N.E.C.Article 430.33. If the Factory-mounted
Control Transformer is provided, add the following to the system MCA values in the electrical tables for the
system supplying power to the optional transformer. -50, add 1.75 amps.
2. The minimum recommended disconnect switch is based on 115% of the rated load amps for all loads included
in the circuit, per N.E.C. Article 440.12 (A) 1.
3. Minimum fuse size is based upon 150% of the rated load amps for the largest motor plus 100% of the rated load
amps for all other loads included in the circuit to avoid nuisance trips at start-up due to lock rotor amps. It is not
recommended in applications where brown outs, frequent starting and stopping of the unit, and/or operation at
ambient temperatures in excess of 95°F is anticipated.
4. Maximum fuse size is based upon 225% of the rated load amps for the largest motor plus 100% of the rated
load amps for all other loads included in the circuit, per N.E.C. Article 440.22.
5. Circuit breakers must be U.L. listed and CSA certified and maximum size is based on 225% of the rated load
ampsforthe largest motorplus100% of therated load ampsforall other loadsincludedin the circuit.Exception:
YCAL0043 and YCAL0057 must have the optional factory overloads installed to use a standard circuit breaker.
Otherwise, an HACR-type circuit breakers must be used. Maximum HACR circuit breaker rating is based on
225% of the rated load amps for the largest motor plus 100% of the rated load amps for all other loads included
in the circuit.
6. The “INCOMING WIRE RANGE” is the minimum and maximum wire size that can be accommodated by the
unitwiringlugs.The(2) preceding thewire range indicatesthenumber of terminationpoints available perphase
of the wire range specified. Actual wire size and number of wires per phase must be determined based on the
National Electrical Code, using copper connectors only. Field wiring must also comply with local codes.
7. A ground lug is provided for each compressor system to accommodate a field grounding conductor per N.E.C.
Table 250.122. A control circuit grounding lug is also supplied.
8. The supplied disconnect is a “Disconnecting Means” as defined in the N.E.C. 100.I, and is intended for isolating
the unit for the available power supply to perform maintenance and troubleshooting. This disconnect is not
intended to be a Load Break Device.
9. Field Wiring by others which complies to the National Electrical Code and Local Codes.
VOLTAGE CODE
-50 = 380/415-3-50
LEGEND
ACR-LINE ACROSS -THE-LINE START
C.B. CIRCUIT BREAKER
D.E. DUAL ELEMENT FUSE
DISC SW DISCONNECT SWITCH
FACT MOUNT CB FACTORY-MOUNTED CIRCUIT BREAKER
FLA FULL LOAD AMPS
HZ HERTZ
MAX MAXIMUM
MCA MINIMUM CIRCUIT AMPACITY
MIN MINIMUM
MIN NF MINIMUM NON FUSED
RLA RATED LOAD AMPS
S.P. WIRE SINGLE-POINT WIRING
UNIT MTD SERV SW UNIT MOUNTED SERVICE (NON-FUSED
DISCONNECT SWITCH)
LRA LOCKED ROTOR AMPS
Field Wiring
Factory Wiring
LEGEND:

YORK INTERNATIONAL
20
FORM 150.62-NM7 (103)
ELECTRICAL DATA
Installation
TABLE 2 – SINGLE-POINT POWER SUPPLY
See Notes and Legend on page 19
Itispossiblethatmultiple sources ofpowercanbesupplyingthe unit powerpanel.Toprevent
serious injury or death, the technician should verify that NO LETHAL VOLTAGES are
present inside the panel AFTER disconnecting power, PRIOR to working on equipment.
The unit evaporator heater uses 120VAC. Disconnecting 120VAC power from the unit, at
or below freezing temperatures, can result in damage to the evaporator and unit as a result
of the chilled liquid freezing.
SINGLE-POINT POWER SUPPLY CONNECTIONS – YCAL0043E_ - YCAL0253E_
(One Field Provided Power Supply to the chiller. Field connections to Factory Provided Power Terminal Block (standard), Non-Fused Discon-
nect Switch (optional) or Circuit Breaker (optional).)
MODEL
YCAL VOLT HZ
SINGLE POINT FIELD SUPPLIED WIRING
MCA1MIN N/F
DISC SW2
D.E. FUSE CKT. BKR.5INCOMING (LUGS) WIRE RANGE6
FACTORY SUPPLIED OPTIONAL
MIN3MAX4MIN MAX SINGLE
POINT DISCONNECT BREAKER
0043 380/415 50 35 60 40 45 40 45 # 10 - # 1 # 14 - 2 # 14 - 2
0057 380/415 50 46 60 50 60 50 60 # 10 - # 1 # 14 - 2 # 14 - 2
0073 380/415 50 53 60 60 70 60 70 # 10 - # 1 # 14 - 2 # 14 - 2
0087 380/415 50 62 100 70 70 70 70 # 10 - # 1 # 14 - 1/0 # 14 - 1/0
0107 380/415 50 73 100 80 90 80 90 # 10 - # 1 # 14 - 1/0 # 14 - 1/0
0117 380/415 50 87 100 100 100 100 100 # 10 - # 1 # 14 - 1/0 # 14 - 1/0
0133 380/415 50 94 150 100 110 100 110 # 10 - # 1 # 2 - 4/0 # 14 - 1/0
0147 380/415 50 101 150 110 110 110 110 # 10 - # 1 # 2 - 4/0 # 2 - 4/0
0157 380/415 50 110 150 125 125 125 125 # 10 - # 1 # 2 - 4/0 # 2 - 4/0
0173 380/415 50 118 150 125 125 125 125 # 10 - 3/0 # 2 - 4/0 # 2 - 4/0
0197 380/415 50 131 150 150 150 150 150 # 10 - 3/0 # 2 - 4/0 # 2 - 4/0
0217 380/415 50 141 200 150 150 150 150 # 10 - 3/0 # 6 - 350 # 2 - 4/0
0237 380/415 50 154 200 175 175 175 175 # 10 - 3/0 # 6 - 350 # 4 - 300
0253 380/415 50 166 200 175 175 175 175 # 10 - 3/0 # 6 - 350 # 4 - 300