York YCUL0045E Owner's manual

Standard, Glycol & Metric Models, Combined
380-415/5
MODELS ONLY
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED CONDENSING UNITS
HERMETIC SCROLL
Supersedes 150.63-NM8 (209) Form 150.63-NM8 (1020)
035-22319-000
YCUL0045E_ - YCUL0275E_
R22 & HFC - 407C
STYLE C
(50 Hz.)
WITH IPU II AND I/O BOARDS

JOHNSON CONTROLS
2
FORM 150.63-NM8 (1020)
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, materials under pressure, rotating components, and
both high and low voltage. Each of these items has the
potential, if misused or handled improperly, to cause
bodily injury or death. It is the obligation and respon-
sibility of operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure
to comply with any of these requirements could result
in serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
individual possesses independent training that will en-
able them to perform their assigned tasks properly and
safely. It is essential that, prior to performing any task
on this equipment, this individual will have read and
understood this document and any referenced materials.
This individual will also be familiar with and comply
with all applicable governmental standards and regula-
tions pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
CAUTION identies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instruction will be given, together with
a brief explanation.
NOTE is used to highlight additional
information which may be helpful to
you.
DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or seri-
ous injury.
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or seri-
ous injury.
External wiring, unless specied as an optional connection in the manufacturer’s product
line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the micro panel. NO external wiring
is allowed to be run through the micro panel. All wiring must be in accordance with John-
son Controls published specications and must be performed ONLY by qualied Johnson
Controls personnel. Johnson Controls will not be responsible for damages/problems result-
ing from improper connections to the controls or application of improper control signals.
Failure to follow this will void the manufacturer’s warranty and cause serious damage to
property or injury to persons.

JOHNSON CONTROLS 3
FORM 150.63-NM8 (1020)
3
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the John-
son Controls Knowledge Exchange website at https://
docs.johnsoncontrols.com/chillers/.
It is the responsibility of rigging, lifting, and operating/
service personnel to verify the applicability of these
documents to the equipment. If there is any question
regarding the applicability of these documents, rig-
ging, lifting, and operating/service personnel should
verify whether the equipment has been modified and
if current literature is available from the owner of the
equipment prior to performing any work on the chiller.
REVISION NOTES
Revisions made to this document are indicated in the following table. These revisions are to technical information,
and any other changes in spelling, grammar, or formatting are not included.
AFFECTED PAGES DESCRIPTION
3 Conditioned Based Maintenance program information added
CONDITIONED BASED MAINTENANCE
Traditional chiller maintenance is based upon assumed
and generalized conditions. In lieu of the traditional
maintenance program, a Johnson Controls YORK
Conditioned Based Maintenance (CBM) program can
be substituted. This CBM service plan is built around
the specific needs for the chiller, operating conditions,
and annualized impact realized by the chiller. Your lo-
cal Johnson Controls Branch can propose a customized
Planned Service Agreement that leverages real time
and historical data, delivering performance reporting,
corrective actions required and data enabled guidance
for optimal operation and lifecycle assurance. The pro-
gram will include fault detection diagnostics, operation
code statistics, performance based algorithms and ad-
vance rules based rationale delivered by the Johnson
Controls Connected Equipment Portal.

JOHNSON CONTROLS
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FORM 150.63-NM8 (1020)
PRODUCT IDENTIFICATION NUMBER (PIN)............................................................................................10
REFRIGERANT FLOW DIAGRAM .............................................................................................................11
SPECIFICATIONS .......................................................................................................................................12
SECTION 1 - INSTALLATION .........................................................................................................13
CONTROL WIRING.....................................................................................................................................25
ELECTRICAL DATA....................................................................................................................................28
PHYSICAL DATA (ENGLISH) .....................................................................................................................34
DIMENSIONS AND CLEARANCES............................................................................................................36
WEIGHT DISTRIBUTION ............................................................................................................................46
ISOLATOR SELECTIONS...........................................................................................................................48
PRE-STARTUP CHECKLIST ......................................................................................................................53
INITIAL START-UP......................................................................................................................................54
SECTION 2 - UNIT CONTROLS .....................................................................................................56
“STATUS” KEY ...........................................................................................................................................58
DISPLAY/PRINT KEYS ...............................................................................................................................64
“ENTRY” KEYS...........................................................................................................................................72
“SETPOINTS” KEYS ..................................................................................................................................73
“UNIT” KEYS .............................................................................................................................................80
UNIT OPERATION.......................................................................................................................................85
SECTION 3 - SERVICE AND TROUBLESHOOTING ...................................................................96
SERVICE MODE – CHILLER CONFIGURATION.......................................................................................97
OPTIONAL PRINTER INSTALLATION.....................................................................................................105
TROUBLESHOOTING ..............................................................................................................................106
MAINTENANCE ........................................................................................................................................109
ISN CONTROL ..........................................................................................................................................110
SECTION 4 - WIRING DIAGRAMS...............................................................................................114
TABLE OF CONTENTS

JOHNSON CONTROLS 5
FORM 150.63-NM8 (1020)
LIST OF TABLES
TABLE 1 – FITTING EQUIVALENT LENGTHS............................................................................17
TABLE 2 – REFRIGERANT PIPING CHARGES .........................................................................17
TABLE 3 – MISCELLANEOUS LIQUID LINE PRESSURE DROPS ..........................................17
TABLE 4 – REFRIGERANT LINE CONNECTIONS.....................................................................18
TABLE 5 – REFRIGERANT LINE PRESSURE DROPS (ENGLISH) .........................................18
TABLE 6 – REFRIGERANT LINE PRESSURE DROPS (METRIC) ...........................................20
TABLE 7 – DUAL POINT POWER SUPPLY CONNECTIONS....................................................28
TABLE 8 – SINGLE POINT POWER SUPPLY CONNECTIONS................................................30
TABLE 9 – MICROPANEL POWER SUPPLY...............................................................................33
TABLE 10 – VOLTAGES ..................................................................................................................33
TABLE 11 – PHYSICAL DATA (METRIC) .......................................................................................34
TABLE 12 – SETPOINTS ENTRY LIST..........................................................................................54
TABLE 13 – STATUS KEY MESSAGES .........................................................................................63
TABLE 14 – OPERATION DATA......................................................................................................67
TABLE 15 – COOLING SETPOINTS PROGRAMMABLE LIMITS AND DEFAULTS ..................76
TABLE 16 –PROGRAM KEY LIMITS AND DEFAULTS................................................................78
TABLE 17 – SETPOINTS QUICK REFERENCE LIST ..................................................................79
TABLE 18 –UNIT KEYS PROGRAMMING QUICK REFERENCE LIST .....................................84
TABLE 19 – DISCHARGE AIR TEMPERATURE CONTROL FOR 5 AND 6 COMPRESSORS
(7 AND 8 STEPS)..........................................................................................................86
TABLE 20 – DISCHARGE AIR TEMPERATURE CONTROL FOR 4 COMPRESORS (6 STEPS)86
TABLE 21 – DISCHARGE AIR TEMPERATURE CONTROL FOR 3 COMPRESSORS
(SINGLE SYSTEM)......................................................................................................87
TABLE 22 – DISCHARGE AIR TEMPERATURE CONTROL FOR 2 COMPRESSORS
(SINGLE SYSTEM)......................................................................................................87
TABLE 23 –YCUL0045 – YCUL0275 CONDENSER FAN CONTROL USING OUTDOOR
AMBIENT TEMPERATURE AND DISCHARGE PRESSURE...................................91
TABLE 23A – YCUL0045 – YCUL0275 CONDENSER FAN CONTROL USING DISCHARGE
PRESSURE ONLY.......................................................................................................91
TABLE 24 –YCUL0045 - YCUL0275 LOW AMBIENT CONDENSER FAN CONTROL –
DISCHARGE PRESSURE CONTROL.......................................................................92
TABLE 25 –COMPRESSOR OPERATION – LOAD LIMITING....................................................93
TABLE 26 – I/O BOARD DIGITAL INPUTS ....................................................................................98
TABLE 27 – I/O BOARD ANALOG INPUTS ...................................................................................98
TABLE 28 – I/O BOARD DIGITAL OUTPUTS ................................................................................98
TABLE 29 – OUTDOOR AIR SENSORTEMPERATURE/VOLTAGE/RESISTANCE
CORRELATION .........................................................................................................100
TABLE 30 – DISCHARGE AIR TEMP. SENSOR TEMPERATURE/VOLTAGE/
RESISTANCE CORRELATION ................................................................................101

JOHNSON CONTROLS
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FORM 150.63-NM8 (1020)
TABLE 31 – SUCTION TEMP. SENSOR TEMPERATURE/VOLTAGE/RESISTANCE
CORRELATION ..........................................................................................................102
TABLE 32 – TROUBLESHOOTING ..............................................................................................106
TABLE 33 –ISN RECEIVED DATA............................................................................................... 110
TABLE 34 –ISN TRANSMITTED DATA .......................................................................................110
TABLE 35 – ISN OPERATIONAL AND FAULT CODES .............................................................. 112
LIST OF TABLES (CONT.)

JOHNSON CONTROLS 7
FORM 150.63-NM8 (1020)
LIST OF FIGURES
FIG. 1 – REFRIGERANT FLOW DIAGRAM.................................................................................11
FIG. 2 – SINGLE POINT POWER SUPPLY WIRING ..................................................................23
FIG. 3 – MULTI POINT POWER SUPPLY WIRING.....................................................................23
FIG. 4 – SINGLE POINT POWER SUPPLY WIRING ..................................................................24
FIG. 5 – MULTI POINT POWER SUPPLY WIRING.....................................................................24
FIG. 6 – CTB1 FIELD CONTROL WIRING (CTB1 LOCATED BELOW
MICROPROCESSOR BOARD).......................................................................................25
FIG. 7 – CTB2 POWER PANEL FIELD WIRING .........................................................................26
FIG. 8 – CTB3 POWER PANEL FIELD WIRING ........................................................................26
FIG. 9 – DISCHARGE AIR SENSOR FIELD WIRING.................................................................27
FIG. 10 – OPTIONAL SUCTION TEMPERATURE SENSOR FIELD WIRING............................27
FIG. 11 – DISCHARGE AIR TEMPERATURE CONTROL ............................................................85
FIG. 12 – SUCTION PRESSURE CONTROL.................................................................................88
FIG. 13 – YCUL0045 – YCUL0275 FAN LOCATION (TYPICAL)..................................................91
FIG. 14 – FIELD AND FACTORY ELECTRICAL CONNECTIONSOPTIONAL REMOTE
TEMPERATURE RESET BOARD...................................................................................95
FIG. 15 – I/O BOARD LAYOUT .......................................................................................................99
FIG. 16 – I/O BOARD RELAY CONTACTARCHITECTURE .......................................................104
FIG. 17 – PRINTER TO I/O BOARD ELECTRICAL CONNECTIONS .......................................105
FIG. 18 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCUL0045E_ - YCUL0095E_...114
FIG. 19 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCUL0045E_ - YCUL0095E_....... 116
FIG. 20 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCUL0045E_ - YCUL0095E_...... 117
FIG. 21 – CONNECTION DIAGRAM, MIDDLE MARKET – YCUL0045E_ - YCUL0095E_ ....118
FIG. 22 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT - YCUL0121E_ .............................120
FIG. 23 – ELEMENTARY DIAGRAM, POWER CIRCUIT - YCUL0121E_..................................122
FIG. 24 – ELEMENTARY DIAGRAM, MIDDLE MARKET - YCUL0121E_.................................123
FIG. 25 – CONNECTION DIAGRAM, MIDDLE MARKET - YCUL0121E_.................................124
FIG. 26 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCUL0125E_ - YCUL0185E_...126
FIG. 27 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCUL0125E_ - YCUL0185E_.......128
FIG. 28 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCUL0125E_ - YCUL0185E_......130
FIG. 29 – CONNECTION DIAGRAM, MIDDLE MARKET – YCUL0125E_ - YCUL0185E_ ......132
FIG. 30 – ELEMENTARY DIAGRAM, CONTROL CIRCUIT – YCUL0211E_ - YCUL0275E_...134
FIG. 31 – ELEMENTARY DIAGRAM, POWER CIRCUIT – YCUL0211E_ - YCUL0275E_ .......136
FIG. 32 – ELEMENTARY DIAGRAM, MIDDLE MARKET – YCUL0211E_ - YCUL0275E_ ......138
FIG. 33 – CONNECTION DIAGRAM, MIDDLE MARKET – YCUL0211E_ - YCUL0275E_ ......140

JOHNSON CONTROLS
8
FORM 150.63-NM8 (1020)
THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS 9
FORM 150.63-NM8 (1020)
PRODUCT IDENTIFICATION NUMBER (PIN)
BASIC MODEL NUMBER
: High E󰀩ciency : Design Series A
: Engineering
Change
or PIN Level
: R-22
: R-407C
Even Number:
60 HZ Nominal Tons
Odd Number:
50 HZ Nominal kW
: 200 / 3/ 60
: 230 / 3 / 60
: 380 / 3 / 60
: 460 / 3 / 60
: 380-415 / 3 / 50
: 575 / 3 / 60
: Across the Line
YCUL0025EC 50XCA
: YORK
: Chiller
: Air-Cooled
: Condensing
Unit
: Scroll
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE/STARTER DESIGN/DEVELOPMENT LEVEL
Y 0 # # # E C 1 7 C
C 1 # # # B 2 8 A
A 4 0
U 4 6
5 0
L 5 8
X
U
Condensing
Unit
:380-415/3/50
5 0 C

JOHNSON CONTROLS
10
FORM 150.63-NM8 (1020)
PRODUCT IDENTIFICATION NUMBER (PIN)
EXAMPLES:
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55
X X X X X X X X L X X X X X X X X X X X X X X X X X A X X X X X X X X X X X X X
S D T C A T S R L X P R S 2 5 C X 1 X X X X 3 D W S A R X B X X 4 B X X L X S D
: Aluminum : Copper : Black Fin : Phenolic : TEAO Fan Motors
EVAP. FIELD CONDENSER FIELD CABINET FIELD
: Wire Condenser Headers Only (factory) : Wire (Full Unit) Enc. Panels (factory) : Wire (Full Unit) Enc. Panels (eld) : Wire/Louvered Enc. Panels (factory) : Wire/Louvered Enc. Panels (eld) : Louvered (Cond. Only) Enc. Panels (factory) : Louvered (Cond. Only) Enc. Panels (eld) : Louvered (Full Unit) Enc. Panels (factory) : Louvered (Full Unit) Enc. Panels (eld) : Acoustic Sound Blanket : Low Sound Fans : 1" Deection : Seismic : Neoprene Pads
55 EXTENDED FIELD X B C D E F G H
: 1st Year Parts Only : 1st Year Parts & Labor : 2nd Year Parts Only : 2nd Year Parts & Labor : 5 Year Compressor Parts Only : 5 Year Compressor Parts & Labor Only : 5 Year Units Parts Only : 5 Year Unit Parts & Labor
NOTES: 1. Q :DENOTES SPECIAL / S.Q. 2. # :DENOTES STANDARD 3. X :w/in OPTIONS FIELD, DENOTES NO OPTION SELECTED 4. Agency Files (i.e. U.L. / E.T.L.; CE; ARI; ETC.) will contain info. based on the rst 14 characters only.
: ASME Pressure Vessel Code
38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 X X X X C 1 X B 2 P 3 X X 4 A 5 6 X 7 X 8 B L 1 S N
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 # # M D H M B A C S D T S S X S B B X F X S B G 1 D B I R X S X B X X L N T C R O X
OPTIONS MODEL NUMBER
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
: Standard Power Option : MP NF Disconnects : MP Circuit Breakers : SP NF Disconnects : SP TB : SP Circuit Breaker : SP TB w/ Separate System Circuit Breakers : SP NF Disconnect w/ Separate System Circuit Breakers : Control Transformer (factory) : Power Factor Capacitor
: Leaving Supply Temp. : Chicago Code Kit Req’d. : Service Isolation Valves : Both Chicago & Svc. Iso. : Hot Gas By-Pass req’d. (1 circuit) : X : X : X : Crankcase Heater Std.
: Low Ambient Kit (factory) : High Ambient Kit (factory) : Both Low / High Ambient (factory) : BAS/EMS Temp. Reset / O󰀨set : Spanish LCD & Keypad Display : French LCD & Keypad Display : German LCD & Keypad Display : Italian LCD & Keypad Display : Discharge Pressure readout required : Suction Pressure readout required : Discharge & Suction readouts required : N. American Safety Code : No Listing (typically 50 HZ non-CE,non-U.L. : Suction Temp Sensor required : Motor Current Module required : Remote Control Panel required : OptiView Remote Panel