APPENDIX F - Haverhill District Court - YORK Chiller O M Manual.pdf

PDF 12 MB Posted Sep 11, 2026

Attached to: Trial Court - Region 3 - Chiller PM Service Contract
Solicitation number: BD-27-1107-FREG5-ACCOU-133133
Issued by: Massachusetts

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Written by GovTribe AI · Sep 18, 2026

This is an Operation and Maintenance Manual for YORK YCAL Air-Cooled Scroll Chillers (15 to 65 ton capacity) supplied by Johnson Controls as Appendix F to the Massachusetts Trial Court Region 3 Chiller Service Agreement Request for Proposals. The manual provides comprehensive technical documentation for chiller installation, operation, and maintenance covering single-circuit models (YCAL0019-0033) and dual-circuit models (YCAL0043-0066) operating on R-410A refrigerant. The document includes detailed safety guidelines, product descriptions, handling and storage procedures, installation requirements, technical specifications, commissioning protocols, unit controls and operation instructions, and maintenance procedures. Key components addressed include hermetic scroll compressors with crankcase heaters, brazed plate heat exchangers with freeze protection to -20°F, air-cooled condenser coils with integral subcooling, corrosion-resistant aluminum fans with low-noise design, and a microprocessor control center with LCD display. The manual specifies operational limitations, electrical requirements, wiring diagrams, and control inputs including options for building automation system integration, remote temperature reset, load limiting, and emergency shutdown capabilities. Installation requirements mandate outdoor placement with adequate clearances, proper structural support, independent piping systems with isolation valves and strainers, and compliance with ASHRAE, ANSI, ASME, NFPA, and local electrical codes.

The manual establishes an 18-month warranty covering parts only from shipment date, contingent upon commissioning by authorized Johnson Controls service personnel, use of genuine YORK parts and refrigerants, and adherence to specified maintenance schedules. Maintenance protocols require regular compressor inspection, condenser fan motor and coil cleaning, monitoring of operating parameters, battery backup verification for the microprocessor, and heat exchanger maintenance. Standard control features include capacity control through suction pressure limits, discharge pressure limits, and leaving chilled liquid temperature control with anti-recycle and anti-coincidence timers. The unit supports multiple communication protocols including BACnet (MS/TP) and Modbus as standard, with optional N2 and LON communication available through eLink accessory. Optional enhancements available include low and high ambient operation kits, discharge pressure transducers, building automation system interfaces, multi-unit sequencing capability, acoustic sound blankets, vibration isolators, and various condenser coil protection options for corrosive environments. The manual specifies that all installation, commissioning, and service work must be performed by trained, qualified personnel, with particular emphasis on refrigerant handling, electrical safety, and compliance with pressure system protocols.

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MASSACHUSETTS TRIAL COURT | REGION 3 CHILLER

SERVICE AGREEMENT

Region 3 Chiller Service Agreement RFP | Page 16 of 30

COMMONWEALTH OF MASSACHUSETTS

MASSACHUSETTS TRIAL COURT

REQUEST FOR PROPOSALS

Region 3 Chiller and Associated HVAC Equipment Preventive Maintenance and Repair Service Agreement

APPENDIX F

Haverhill District Court - YORK Chiller O&M Manual

This appendix is incorporated by reference into the Region 3 Chiller Service Agreement Request for Proposals.

Facilities Management & Capital Planning

R-410A

035-21456-000

DUAL CIRCUIT

SINGLE CIRCUIT

YCAL0019, 0022, 0028, 0033, 0043, 0046, 0052, 0056, 0066

AIR-COOLED SCROLL CHILLERS

STYLE E (60 HZ)

15 TON TO 65 TON

Products are produced at a f ac i l i t y whose qua l i t y -management systems are ISO9001 certified.

Issue Date:

March 12, 2021

AIR-COOLED LIQUID CHILLERS

HERMETIC SCROLL

INSTALLATION, OPERATION, MAINTENANCE Supersedes 150.67-NM1 (1220) Form 150.67-NM1 (321)

JOHNSON CONTROLS2

FORM 150.67-NM1

ISSUE DATE: 03/12/2021

This equipment is a relatively complicated apparatus.

During rigging, installation, operation, maintenance, or service, individuals may be exposed to certain com-ponents or conditions including, but not limited to:

heavy objects, refrigerants, 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 rigging, instal-lation, and 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 rigging, installation, and operating/service personnel. It is expected that these individuals possess 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 the on-product labels, this document and any referenced materials. This in-dividual shall also be familiar with and comply with all applicable industry and 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 specific situations:

Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken.

Indicates a potentially hazardous situa-tion which will result in possible injuries or damage to equipment if proper care is not taken.

Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollu-tion if proper care is not taken or instruc-tions and are not followed.

Highlights additional information useful to the technician in completing the work being performed properly.

External wiring, unless specified as an optional connection in the manufacturer’s product line, is not to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls and any external wiring must not be installed inside the micro panel. All wiring must be in accor-dance with Johnson Controls’ published specifications and must be performed only by a qualified electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of improper control signals. Failure to follow this warn-ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

3JOHNSON CONTROLS

ISSUE DATE: 03/12/2021

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.

AFFECTED PAGES DESCRIPTION

49 Physical data table units updated

132-136 Isolator data updated

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.

MANUAL DESCRIPTION FORM NUMBER

Replacement Parts 150.67-RP1

Air Cooled Liquid Chillers Condenser Corrosion Protection 150.12-ES1

Shipping Damage Claims 50.15-NM

Start-Up Checklist 150.67-CL1

ASSOCIATED LITERATURE

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.

https://docs.johnsoncontrols.com/chillers/ https://docs.johnsoncontrols.com/chillers/

JOHNSON CONTROLS4

ISSUE DATE: 03/12/2021

This manual contains installation, op-eration and maintenance instructions for both single and dual refrigerant 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.

SINGLE CIRCUIT AND DUAL CIRCUIT MODELS

5JOHNSON CONTROLS

ISSUE DATE: 03/12/2021

TABLE OF CONTENTS

SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY

Introduction Warranty Safety About This Manual Misuse Of Equipment

SECTION 2 – PRODUCT DESCRIPTION

Introduction General System Description Millennium Control Center Communications Power Panel Accessories And Options Unit Components YCAL0019-0033 Control - Power Panel Components YCAL0019-0033 Unit Components - YCAL0043 – 0066 Control / Power Panel Components - YCAL0043-0066 Product Identification Number (PIN) Basic Unit Nomenclature Refrigerant Flow Diagram

SECTION 3 – HANDLING AND STORAGE

Delivery And Storage Inspection Moving The Chiller (YCAL0043–0066 Dual System Only) Moving The Chiller (YCAL0019–0033 Single Circuit Only) Unit Rigging

SECTION 4 – INSTALLATION

Installation Checklist Handling Inspection Location And Clearances Spring Isolators (Optional) Compressor Mounting Remote Cooler Option Chilled Liquid Piping Pipework Arrangement Duct Work Connection Wiring Compressor Heaters Relief Valves High Pressure Cutout Control Wiring

JOHNSON CONTROLS6

ISSUE DATE: 03/12/2021

TABLE OF CONTENTS (CONT’D)

SECTION 5 – TECHNICAL DATA

Operational Limitations (English) Operational Limitations (SI) Physical Data (English) Electrical Data (English) Electrical Notes And Legend

SECTION 6 – COMMISSIONING

Commissioning Preparation – Power Off Preparation – Power On Equipment Start-Up Checklist Unit Operating Sequence

SECTION 7 – UNIT CONTROLS

Introduction Ipu Ii And I/O Boards Status Key Display/Print Keys Entry Keys Setpoints Keys Schedule/Advance Day Key Program Key Unit Keys Clock

SECTION 8 – UNIT OPERATION

Capacity Control Suction Pressure Limit Controls Discharge Pressure Limit Controls Leaving Chilled Liquid Control Leaving Chilled Liquid Control Override To Reduce Cycling Leaving Chilled Liquid System Lead/Lag And Compressor Sequencing Return Chilled Liquid System Lead/Lag And Compressor Sequencing Anti-Recycle Timer Anti-Coincidence Timer Evaporator Pump Control And YORK Hydro Kit Pump Control Evaporator Heater Control Pumpdown Control Standard Condenser Fan Control YCAL0019-0028 Low Ambient Fan Control Option Programming - YCAL0019 – 0028 Configuration (Jumpers And Potentiometers) YCAL0033 Programming YCAL0043 – 0066 Low Ambient Fan Control Option Configuration (Jumpers And Potentiometers)

7JOHNSON CONTROLS

ISSUE DATE: 03/12/2021

TABLE OF CONTENTS (CONT’D)

Programming Load Limiting Compressor Run Status Alarm Status BAS/EMS Temperature Reset Using A Voltage Or Current Signal

SECTION 9 – SERVICE AND TROUBLESHOOTING

Clearing History Buffers Service Mode Service Mode – Outputs Service Mode – Chiller Configuration Service Mode – Analog And Digital Inputs Control Inputs/Outputs Checking Inputs And Outputs

SECTION 10 – MAINTENANCE

Important Compressors Condenser Fan Motors Condenser Coils Operating Parameters On-Board Battery Back-Up Plate And Frame Heat Exchanger (Evaporator) Heater Overall Unit Inspection BACnet, Modbus And Yorktalk 2 Communications Temperature Conversion Chart R410-A Pressure Temperature Chart Adding Refrigerant Charge After Commissioning

JOHNSON CONTROLS8

ISSUE DATE: 03/12/2021

LIST OF FIGURES

FIGURE 1 - YCAL Air-Cooled Scroll Chillers��15 FIGURE 2 - Unit Components Single System Units��21 FIGURE 3 - Control/Power Panel Components Single System Units��22 FIGURE 4 - Unit Components Dual System Units��23 FIGURE 5 - Control/Power Panel Components Dual System Units��24 FIGURE 6 - Refrigerant Flow Diagram��29 FIGURE 7 - Unit Rigging/Lifting (YCAL0019–0033 Single Circuit Models Only)��32 FIGURE 8 - Unit Rigging/Lifting (YCAL0043–0066 Dual Circuit Models)��33 FIGURE 9 - Chilled Liquid System��37 FIGURE 10 - �Single-Point Supply Connection – Terminal Block, Non-Fused Disconnect Switch

Or Circuit Breaker (0043–0066)��40 FIGURE 11 - Control Wiring��41 FIGURE 12 - Control Wiring Diagram, Single Circuit, Ipu Ii��56 FIGURE 13 - Control Wiring Diagram, Single Circuit, Ipu Ii��59 FIGURE 14 - Control Wiring Diagram, Dual Circuit, Ipu Ii��60 FIGURE 15 - Control Wiring Diagram, Dual Circuit, Ipu Ii��62 FIGURE 16 - Control Wiring Diagram, Details, Single Circuit��65 FIGURE 17 - Control Wiring Diagram, Details, Dual Circuit��66 FIGURE 18 - Power Wiring, Single Circuit��68 FIGURE 19 - Power Wiring, Single Circuit��70 FIGURE 20 - Power Wiring, Single Circuit��72 FIGURE 21 - Power Wiring, Single Circuit��74 FIGURE 22 - Power Wiring, Dual Circuit��77 FIGURE 23 - Power Wiring, Dual Circuit��78 FIGURE 24 - Connection Wiring, Single Circuit��80 FIGURE 25 - Connection Wiring, Single Circuit��82 FIGURE 26 - Connection Wiring, Single Circuit��84 FIGURE 27 - Connection Wiring, Single Circuit��86 FIGURE 28 - Connection Wiring, Dual Circuit��89 FIGURE 29 - Connection Wiring, Dual Circuit��90 FIGURE 30 - Unit Clearances – All Models��128 FIGURE 31 - One Inch Deflection Spring Isolator Cross-Reference��132 FIGURE 32 - One Inch Deflection Spring Isolators Installation Instructions��133 FIGURE 33 - Durulene Isolator Cross-Reference��134 FIGURE 34 - Installation Of Durulene Vibration Isolators��135 FIGURE 35 - Two Inch Deflection Seismic Isolator Cross-Reference��136 FIGURE 36 - Seismic Isolator Installation And Adjustment��137 FIGURE 37 - One Inch Deflection Spring Isolator Cross-Reference (Cip-X)��138 FIGURE 38 - Neoprene Isolator Cross-Reference��140 FIGURE 39 - Two Inch Deflection, Seismic Spring Isolator Cross-Reference��141 FIGURE 40 - Slrs Seismic Isolator Installation And Adjustment��142 FIGURE 41 - Leaving Water Temperature Control Example��180 FIGURE 42 - Setpoint Adjust��180 FIGURE 43 - YCAL0019–YCAL0033 Fan Location (Typical)��183 FIGURE 44 - YCAL0043–YCAL0066 Fan Location (Typical)��184 FIGURE 45 - Typical VFD Location��185 FIGURE 46 - Liquid Line Sensing Bulb Location��185 FIGURE 47 - Potentiometer Settings��185 FIGURE 48 - Wiring��186 FIGURE 49 - �Typical VFD Enclosure Locations��187 FIGURE 50 - �Typical VFD Enclosure Configurations��188

9JOHNSON CONTROLS

ISSUE DATE: 03/12/2021

LIST OF FIGURES (CONT’D)

FIGURE 51 - Potentiometer Settings��189 FIGURE 52 - Inverter Power Wiring Schematic��189 FIGURE 53 - Inverter Wiring��190 FIGURE 54 - �Typical VFD Enclosure Locations��191 FIGURE 55 - Typical VFD Enclosure Configurations��192 FIGURE 56 - Inverter Power Wiring Sc��193 FIGURE 57 - Potentiometer Settings��193 FIGURE 58 - Inverter Wiring ��194 FIGURE 59 - Microboard Layout��200 FIGURE 60 - I/O Board Relay Contact Architecture��204 FIGURE 61 - Printer To Microboard Electrical Connections��205 FIGURE 62 - Micro Panel Connections�� 211

JOHNSON CONTROLS10

ISSUE DATE: 03/12/2021

LIST OF TABLES

TABLE 1 - Temperatures And Flows��43 TABLE 2 - Voltage Limitations��43 TABLE 3 - Temperatures And Flows (SI)��46 TABLE 4 - Voltage Limitations��46 TABLE 5 - Ethylene And Propolyne Glycol Correction Factors��46 TABLE 6 - Physical Data (English)��49 TABLE 7 - Electrical Data (English)��50 TABLE 8 - Micro Panel Power Supply��54 TABLE 9 - Voltage Range��54 TABLE 10 - Status Key Messages Quick Reference List��156 TABLE 11 - Operation Data��160 TABLE 12 - Cooling Setpoints, Programmable Limits And Defaults��167 TABLE 13 - Program Key Limits And Default��169 TABLE 14 - Setpoints Quick Reference List��172 TABLE 15 - Unit Keys Options Programming Quick Reference List��178 TABLE 16 - Return Chilled Liquid Control For 4 Compressors (6 Steps)��181 TABLE 17 - Return Chilled Liquid Control For 4 Compressors (6 Steps)��181 TABLE 18 - YCAL0019–YCAL0033 Condenser Fan Control Using Discharge Pressure��183 TABLE 19 - YCAL0019–YCAL0033 Condenser Fan Control Using Discharge Pressure Only��183 TABLE 20 - YCAL0043–YCAL0066 Condenser Fan Control Using Discharge Pressure��184 TABLE 21 - YCAL0043–YCAL0066 Condenser Fan Control Using Discharge Pressure Only��184 TABLE 22 - YCAL0019–0028 VFD Low Ambient Option – Condenser Fan Control Operation��187 TABLE 23 - VFD Jumpers��188 TABLE 24 - YCAL033 VFD Low Ambient Option – Condenser Fan Control Operation��190 TABLE 25 - VFD Jumpers��192 TABLE 26 - YCAL0043-0066 VFD Low Ambient Option – Condenser Fan Control Operation��194 TABLE 27 - �Compressor Operation –Load Limiting��195 TABLE 28 - I/O Digital Inputs��199 TABLE 29 - I/O Digital Outputs��199 TABLE 30 - I/O Analog Inputs��199 TABLE 31 - I/O Analog Outputs��199 TABLE 32 - �Outdoor Air Sensor Temperature/Voltage / Correlation��201 TABLE 33 - �Entering/Leaving Chilled Liquid Temperature Sensor��202 TABLE 34 - Pressure Transducers��203 TABLE 35 - Troubleshooting��206 TABLE 36 - Minimum, Maximum And Default Values�� 211 TABLE 37 - Values Required For Bas Communication��212 TABLE 38 - Real Time Error Numbers��212 TABLE 39 - Bacnet And Modbus Communications Data Map��214 TABLE 40 - Yorktalk 2 Communications Data Map��219 TABLE 41 - SI Metric Conversion��227

11JOHNSON CONTROLS

ISSUE DATE: 03/12/2021

SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY

INTRODUCTION

YORK YCAL0019-0066 (15 ton to 65 ton, 53 kW to 218 kW) chillers are manufactured to the highest de-sign and construction standards to ensure high perfor-mance, reliability and adaptability to all types of air conditioning installations.

The unit is intended for cooling water or glycol solu-tions and is not suitable for purposes other than those specified in this manual.

This manual contains all the information required for correct installation and commissioning of the unit, to-gether with operating and maintenance instructions.

The manuals should be read thoroughly before at-tempting to operate or service the unit.

All procedures detailed in the manuals, including in-stallation, commissioning and maintenance tasks must only be performed by suitably trained and qualified personnel.

The manufacturer will not be liable for any injury or damage caused by incorrect installation, commission-ing, operation or maintenance resulting from a failure to follow the procedures and instructions detailed in the manuals.

WARRANTY

Johnson Controls warrants all equipment and materials against defects in workmanship and materials for a pe-riod of eighteen months from date of shipment, unless labor or extended warranty has been purchased as part of the contract.

The warranty is limited to parts only replacement and shipping of any faulty part, or sub-assembly, which has failed due to poor quality or manufacturing errors. All claims must be supported by evidence that the failure has occurred within the warranty period, and that the unit has been operated within the designed parameters specified.

All warranty claims must specify the unit model, serial number, order number and run hours/starts. Model and serial number information is printed on the unit identi-fication plate.

The unit warranty will be void if any modification to the unit is carried out without prior written approval from 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 on page 143).

• Only genuine YORK approved spare parts, oils, coolants, and refrigerants must be used.

• All the scheduled maintenance operations de-tailed in this manual must be performed at the specified times by suitably trained and qualified personnel (see SECTION 10 – MAINTENANCE on page 209).

• Failure to satisfy any of these conditions will au-tomatically void the warranty (refer to the War-ranty Policy).

SAFETY

Standards For Safety YCAL chillers are designed and built within an ISO 9002 accredited design and manufacturing organiza-tion. 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 Pack-ages Using the Vapor Compression Cycle.

• ASHRAE 90.1- Energy Efficiency Compliance.

• ARI 370- Sound Rating of Large Outdoor Refrig-eration 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 Labo-ratories (U.L.) for construction of chillers and provide U.L./cU.L. Listing Label.

JOHNSON CONTROLS12

ISSUE DATE: 03/12/2021SECTION 1 – GENERAL CHILLER INFORMATION and SAFETY

Responsibility For Safety Every care has been taken in the design and manufac-ture of the unit to ensure compliance with the safety requirements listed above. However, the individual operating or working on any machinery is primarily responsible for:

• Personal safety, safety of other personnel, and the machinery.

• Correct utilization of the machinery in 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 explana-tion and the possible result of ignoring the instruction.

A CAUTION identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution. Usually an instruction will be given, together with a brief explanation and the possible result of ignoring the instruction.

A NOTE is used to highlight additional information, which may be helpful to you but where there are no special safety implications.

The contents of this manual include suggested best working practices and procedures. These are issued for guidance only, and they do not take precedence over the above stated individual responsibility and/or local safety regulations.

This manual and any other document supplied with the unit are the property of Johnson Controls which reserves all rights. They may not be reproduced, in whole or in part, without prior written authorization from an authorized Johnson Controls representative.

MISUSE OF EQUIPMENT

Suitability for Application The unit is intended for cooling water or glycol solu-tions and is not suitable for purposes other than those specified in these instructions. Any use of the equipment other than its intended use, or operation of the equip-ment 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 pa-rameters specified in this manual.

Structural Support Structural support of the unit must be provided as in-dicated in these instructions. Failure to provide proper support may result in injury to the operator, or damage to the equipment and/or building.

Mechanical Strength The unit is not designed to withstand loads or stresses from adjacent equipment, pipework or structures. Ad-ditional components must not be mounted on the unit.

Any such extraneous loads may cause structural failure and may result in injury to the operator, or damage to the equipment.

General Access There are a number of areas and features, which may be a hazard and potentially cause injury when working on the unit unless suitable safety precautions are taken.

It is important to ensure access to the unit is restricted to suitably qualified persons who are familiar with the potential hazards and precautions necessary for safe operation and maintenance of equipment containing high temperatures, pressures and voltages.

13JOHNSON CONTROLS

SECTION 1 – GENERAL CHILLER INFORMATION and SAFETYFORM 150.67-NM1

ISSUE DATE: 03/12/2021

Pressure Systems The unit contains refrigerant vapor and liquid under pres-sure, release of which can be a danger and cause injury.

The user should ensure that care is taken during installa-tion, operation and maintenance to avoid damage to the pressure system. No attempt should be made to gain ac-cess to the component parts of the pressure system other than by suitably trained and qualified personnel.

Electrical The unit must be grounded. No installation or main-tenance work should be attempted on the electrical equipment without first switching power OFF, isolat-ing and locking-off the power supply. Servicing and maintenance on live equipment must only be per-formed 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 re-moved, alternative safety measures must be taken to protect against the risk of injury from rotating fans.

Sharp Edges The fins on the air-cooled condenser coils have sharp metal edges. Reasonable care should be taken when working in contact with the coils to avoid the risk of minor abrasions and lacerations. The use of gloves is recommended.

Frame rails, brakes, and other components may also have sharp edges. Reasonable care should be taken when working in contact with any components to avoid risk of minor abrasions and lacerations.

Refrigerants and Oils Refrigerants and oils used in the unit are generally non-toxic, non-flammable and non-corrosive, and pose no special safety hazards. Use of gloves and safety glasses is, however, recommended when working on the unit.

The build up of refrigerant vapor, from a leak for ex-ample, does pose a risk of asphyxiation in confined or enclosed spaces and attention should be given to good ventilation.

High Temperature and Pressure Cleaning High temperature and pressure cleaning methods (for example, steam cleaning) should not be used on any part of the pressure system as this may cause opera-tion 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 op-erated, it removes the low voltage 120 VAC electrical supply from the inverter system, thus shutting down the unit.

JOHNSON CONTROLS14

ISSUE DATE: 03/12/2021

THIS PAGE IS INTENTIONALLY LEFT BLANK

15JOHNSON CONTROLS

ISSUE DATE: 03/12/2021

SECTION 2 – PRODUCT DESCRIPTION

INTRODUCTION

YORK Millennium® Air-Cooled Scroll Chillers pro-vide chilled water for all air conditioning applications using central station air handling or terminal units. They are completely self-contained and are designed for out-door (roof or ground level) installation. Each complete packaged unit includes hermetic scroll compressors, a liquid cooler, air cooled condenser, a charge of refriger-ant R-410A and a weather resistant microprocessor con-trol center, all mounted on a pressed steel base.

The units are completely assembled with all intercon-necting refrigerant piping and internal wiring, ready for field installation.

Prior to delivery, the packaged unit is pressure-tested, evacuated, and fully charged with R-410A refrigerant and oil. After assembly, a complete operational test is performed with water flowing through the cooler to en-sure 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 (Na-tional Electric Code), ASHRAE/ANSI 15 Safety code for mechanical refrigeration, ASME, Listed and labeled with Intertek Testing Services (ETL) and rated in accor-dance with ARI Standard 550/590-2003.

All exposed power wiring is routed through liquid-tight, non-metallic conduit.

GENERAL SYSTEM DESCRIPTION

Compressors The chiller has suction-gas cooled, hermetic, scroll compressors. The YCAL compressors incorporate a compliant scroll design in both the axial and radial direction. All rotating parts are statically and dynami-cally balanced. A large internal volume and oil res-ervoir 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 heat-er provides freeze protection for the cooler down to -20°F (-29°C) ambient. The cooler is covered with 3/4 in. (19 mm) flexible, closed-cell, foam insulation (K~0.25).

Brazed plate heat exchangers must 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. Wa-ter inlet and outlet connections are grooved for compat-ibility with factory supplied grooved connections.

LD10950

Dual Circuit

Figure 1 - YCAL AIR-COOLED SCROLL CHILLERS

JOHNSON CONTROLS16

ISSUE DATE: 03/12/2021SECTION 2 – PRODUCT DESCRIPTION

The heat exchanger is a brazed plate stainless steel con-struction, 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). An op-tion for 300 psig (2068 kPa) is available. Each heat ex-changer is covered in 3/4 in. (19 mm) flexible, closed cell insulation, thermal conductivity of 0.26k ([BTU/ HR-FT2 –°F] /in) maximum.

A strainer with a mesh size between 0.5 mm 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 re-sistant 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 resis-tant aluminum hub and glass-fiber reinforced compos-ite 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 lubri-cated.

MILLENNIUM CONTROL CENTER

All controls are contained in a NEMA 3R/12 cabi-net equivalent to IP55*. They include a Liquid Crys-tal Display (LCD) with Light Emitting Diode (LED) backlighting for outdoor viewing and includes the fol-lowing features:

• Two display lines

• Twenty characters for each line

Display/Print Color coded 12-button non-tactile keypad with sections for the display and print of the following information:

• Chilled liquid temperatures

• Ambient temperature

• System pressures for each circuit

• Operating hours and starts for each compressor

• Print calls up to the liquid crystal display

• Operating data for the systems

• Fault shutdown data of up to six of the most recent 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 through a separate printer (not supplied).

Entry Use this section to enter setpoints or modify system values.

Setpoints You can update the following setpoints:

• 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 Use unit to set the following features

• Time

• Unit options

* Intensity of Protection European Standard

** International Electrotechnical Commission

17JOHNSON CONTROLS

SECTION 2 – PRODUCT DESCRIPTIONFORM 150.67-NM1

ISSUE DATE: 03/12/2021

Unit On/Off Switch The microprocessor control center is capable of dis-playing the following:

• Return and leaving liquid temperature

• Low leaving liquid temperature cutout setting

• Low ambient temperature cutout setting

• Outdoor air temperature

• English or Metric data

• Suction pressure cutout setting

• Each system suction pressure

• Optional: Discharge pressure

• Liquid Temperature Reset using a YORK ISN DDC or a third part supplied Building Automa-tion System using one of the following:

• Pulse width modulated (PWM) input as stan-dard

• 4 mA to 20 mA or 0 VDC to 10 VDC input with the optional BAS 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 and stop times

• Holiday status

• Automatic or manual system lead and lag control

• Lead system definition

• Compressor starts and operating hours for each compressor

• Status of the hot gas valves, evaporator heater and fan operation

* Intensity of Protection European Standard

** International Electrotechnical Commission

• Run permissive status

• Number of compressors running

• Liquid solenoid valve status

• Load and unload timer status

• Water pump status

Provisions are included for the following features:

• Pumpdown at shutdown

• Optional remote chilled water temperature reset

• Two steps of demand load limiting from an exter-nal BAS.

Unit alarm contacts are standard

The operating program is stored in non-volatile mem-ory (EPROM) to eliminate chiller failure due to AC powered failure or battery discharge. Programmed setpoints are retained in lithium battery-backed RTC memory for 5 years minimum.

COMMUNICATIONS

• Native communication capability for BACnet

(MS/TP) and Modbus

• Optional communication available for N2 and LON via eLink option

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 and overload current protection

The power wiring is routed through liquid-tight con-duit to the compressors and fans.

JOHNSON CONTROLS18

ISSUE DATE: 03/12/2021SECTION 2 – PRODUCT DESCRIPTION

ACCESSORIES AND OPTIONS

Power Options

Compressor Power Connection Single-point (YCAL0019-0066) terminal block con-nection 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 interconnect-ing wiring to the compressors. Separate external pro-tection 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 in-cluded).

Single-Point Non-Fused Disconnect Switch Unit-mounted disconnect switch with external, lock-able handle (in compliance with Article 440-14 of N.E.C.), can be supplied to isolate the unit power volt-age for servicing. Separate external fusing must be supplied, by others in the power wiring, which must comply with the National Electrical Code and/or local codes.

Single-Point Circuit Breaker A unit mounted circuit breaker with external, lockable handle (in compliance with N.E.C. Article 440-14), can be supplied to isolate the power voltage for servicing (this option includes the Single-Point Power connection).

Control Transformer Converts unit power voltage to 115-1-60 (0.5 KVA or

1.0 KVA capacity). Factory mounting includes primary

and secondary wiring between the transformer and the control panel (Factory-Mounted).

Power Factor Correction Capacitors Will correct unit compressor power factors to a 0.90-

0.95 (Factory-Mounted).

Control Options

Ambient Kit (Low) Units will operate to 25°F (-4°C). This accessory in-cludes 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 applica-tions 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 tem-perature is above 110°F (43°C). Includes discharge pressure transducers. This option includes the Dis-charge Pressure Transducer / Readout Capability op-tion (Field-Mounted).

Building Automation System Interface The factory addition of a Printed Circuit Board to ac-cept a 4 mA to 20 mA, 0 VDC to 10 VDC or contact closure input to reset the leaving chiller liquid temper-ature 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 (Factory-Mounted)

The standard unit capabilities include remote start/stop, remote water temperature reset via a PWM input signal or up to two steps of demand (load) limiting depending on model. The standard control panel can be directly connected to a YORK Building Automated System via the standard onboard RS485 communication port.

Language LCD And Keypad Display Spanish, French, and German unit LCD controls and keypad displays are available. Standard language is English.

Discharge Pressure Transducers And Readout Capability The addition of pressure transducers allows models to sense and display discharge pressure. This is recom-mended for brine chilling applications. This option is included with either the low or high ambient kits (Fac-tory-Mounted).

19JOHNSON CONTROLS

ISSUE DATE: 03/12/2021

Suction Pressure Transducers Permits unit to sense and display suction pressure.

This capability is standard on YCAL0019 through YCAL0066 models.

Multi-Unit Sequencing A separate Sequencing Control Center can be provided to handle sequencing control of up to eight chillers in parallel based on mixed liquid temperature (intercon-necting wiring by others). Only one of following op-tions can be offered on a unit at a time:

• BAS

• Remote Control Panel or

• Multi-unit Sequence Control) (Factory-Mount-ed)

Compressor, Piping, Evaporator Options

Low Temperature Brine Required for brine chilling below 30°F (-1°C) leaving brine temperature for YCAL0019 through YCAL0066 models. Option includes resized thermal expansion valve (Factory-Mounted).

Chicago Code Relief Valves Unit will be provided with relief valves to meet Chi-cago 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 compli-ance with ASHRAE 15 (Factory-Mounted).

Hot Gas By-Pass Permits continuous, stable operation at capacities be-low the minimum step of compressor unloading to as low as 5% capacity (depending on both the unit and operating conditions) by introducing an artificial load on the cooler. Hot gas by-pass is installed on only re-frigerant system #1 on two-circuited units (Factory- Mounted).

Heat Exchanger 300 psig (21 barg) DWP Waterside The waterside will be of 300 psig (21 barg) instead of the standard 150 psig DWP. Included on the Heat Ex-changer nozzles are 300 psig R.F. flanges. (Factory- Mounted). The companion flanges will be field-sup-plied by others.

Flanges (ANSI/AWWA C-606 Couplings Type) Consists of two flange adapters for grooved end pipe (standard 150 psi [10.5 barg] cooler).

Flow Switch The flow switch or its equivalent must be furnished with each unit. A description of the standard and op-tional flow switch is as follows:

150 psig (10.5 barg) DWP For standard units. Johnson Controls model F61MG- 1C Vapor-proof SPDT, NEMA 4X switch (150 psig [10.5 barg] DWP), -20°F to 250°F (-29°C to 121°C), with 1 in. NPT connection for upright mounting in hor-izontal pipe (Field-Mounted).

300 psig (21 BARG) DWP For units with optional 300 psig (21 barg) DX cool-

er. McDonnell and Miller model FS74W Vapor-proof SPDT, NEMA 4X switch (300 psig (21 barg) DWP), -20°F to 300°F (-29°C to 149°C), with 1 1/4 in. MPT connection for upright mounting in horizontal pipe (Field-Mounted).

Differential Pressure Switch Alternatives to an above mentioned flow switch are:

Pretempco model DPS300AP40PF-82582-5 (300 psi max. [21 barg] working pressure), SPDT 5 amp 125/250 VAC switch, Range 3 psig to 45 psig (0.2 barg to 3 barg), deadband 0.5 psi to 0.8 psi (0.003 bar to

0.005 bar) , with 1/4 in. 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).

JOHNSON CONTROLS20

ISSUE DATE: 03/12/2021SECTION 2 – PRODUCT DESCRIPTION

Pre-Coated Fin Condenser Coils The unit's coils are constructed with black epoxy coated aluminum fins. This can provide corrosion re-sistance comparable to copper-fin coils in typical sea-shore locations. 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,…

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