FORM 150.64-EG1 (405) ....................................................................................................................................................................................... 1
Options and Accessories .................................................................................................................................................................................... 7
Selection Data ......................................................................................................................................................................................................11
Water Pressure Drop ..........................................................................................................................................................................................
Ratings - R-22 (60Hz - English Units) ............................................................................................................................................................... 16
Ratings - R-22 (50Hz - SI Units) ......................................................................................................................................................................... 26
Part Load Ratings - R-22 (English Units) ......................................................................................................................................................... 28
Part Load Ratings - R-22 (SI) ............................................................................................................................................................................. 29
Physical Data ..................................................................................................................................................................................................... 30
Sound Data .......................................................................................................................................................................................................... 32
Electrical Data ..................................................................................................................................................................................................... 62
Electrical Data - 60Hz ......................................................................................................................................................................................... 64
Electrical Data - 50Hz ......................................................................................................................................................................................... 66
Power Wiring ....................................................................................................................................................................................................... 68
Control Wiring ..................................................................................................................................................................................................... 71
Application Data ................................................................................................................................................................................................. 72
YORK Air-Cooled Scroll Chillers provide chilled water for all air conditioning applications using
central station air handling or terminal units. They are completely self-contained and are designed
for outdoor (roof or ground level) installation. Each unit includes hermetic scroll compressors,
a liquid cooler, air cooled condenser, and a weather resistant microprocessor control center, all
mounted on a pressed steel base.
YORK INTERNATIONAL
3
Specification
GENERAL
The 47 - 60 Ton (165 - 210 kW) YCAL models are
shipped complete from the factory ready for installation
and use.
The unit is pressure-tested, evacuated, and fully charged
with Refrigerant-22 (HCFC-22) and includes an initial
oil charge. After assembly, a complete operational test
is performed with water flowing through the cooler to
assure that the refrigeration circuit 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 accordance
with ARI Standard 550/590-2003.
COMPRESSORS
The chiller has suction-gas cooled, hermetic, scroll com
pressors. The YCAL compressors incorporate a compliant scroll design in both the axial and radial direction. All
rotating parts are statically and dynamically balanced. A
large internal volume and oil reservoir provides greater
liquid tolerance. Compressor crankcase heaters are also
included for extra protection against liquid migration.
tion for the cooler down to -20°F (-29°C) ambient. The
cooler is covered with 3/4” (19mm) flexible, closed-cell,
foam insulation (K~0.25).
Brazed plate heat exchangers shall be UL (Underwriters
Laboratories) listed. Installing contractor must include
accommodations in the chilled water piping to allow
proper drainage and venting of the heat exchanger.
Water inlet and outlet connections are grooved for com
patibility with factory supplied victaulic connections.
A strainer with a mesh size between .5 and 1.5 mm (40
mesh) is recommended upstream of the heat exchanger
to prevent clogging.
CONDENSER
Coils – Fin and tube condenser coils of seamless, inter
resistant copper tubes are arranged in staggered rows,
mechanically expanded into aluminum fins. Integral
subcooling is included. The design working pressure of
the coil is 450 PSIG (31 bar).
Low Sound Fans – The condenser fans are composed
of corrosion resistant aluminum hub and glass-fiberrein
forced composite blades molded into a low noise airfoil
-
section. They are designed for maximum efficiency and
are statically and dynamically balanced for vibration free
operation. They are directly driven by independent motors, and positioned for vertical air discharge. All blades
are statically and dynamically balanced for vibration-free
operation. The fan guards are constructed of heavygauge, rust-resistant, PVCcoated steel wire.
-
-
-
COOLER
The cooler is equipped with a heater controlled by a
separate thermostat. The heater provides freeze protec
4
Motors – The fan motors are Totally Enclosed Air-Over,
squirrel-cage type, current protected. They feature
ball bearings that are double-sealed and permanently
-
lubricated.
YORK INTERNATIONAL
MILLENNIUM CONTROL CENTER
All controls are contained in a NEMA 3R/12 (and
equivalent to IP55*) cabinet with hinged outer door and
includes:
FORM 150.64-EG1
UNIT ON/OFF switch
Liquid Crystal Display with Light Emitting Diode back
lighting for outdoor viewing:
Two display lines
Twenty characters per line
Color coded 12-button non-tactile keypad with sections
for:
DISPLAY/PRINT of typical information:
Chilled liquid temperatures
Ambient temperature
System pressures (each circuit)
Operating hours and starts (each compressor)
Print calls up to the liquid crystal display:
Operating data for the systems
History of fault shutdown data for up to
the last six fault shutdown conditions
An RS-232 port, in conjunction with this press-to-print button, is provided to permit
the capability of hard copy print-outs via a
separate printer (by others).
ENTRY section to:
ENTER setpoints or modify system values
SETPOINTS updating can be performed to:
Chilled liquid temperature setpoint and range
Remote reset temperature range
Set daily schedule/holiday for start/stop
Manual override for servicing
Low and high ambient cutouts
Number of compressors
Low liquid temperature cutout
Low suction pressure cutout
High discharge pressure cutout
Anti-recycle timer (compressor start cycle
time)
Anti-coincident timer (delay compressor starts)
UNIT section to:
Set time
Set unit options
The microprocessor control center is capable of dis
playing the following:
• Return and leaving liquid temperature
• Low leaving liquid temperature cutout setting
• Low ambient temperature cutout setting
• Outdoor air temperature
• English or Metric data
• Suction pressure cutout setting
• Each system suction pressure
• Discharge pressure (optional)
• Liquid Temperature Reset via a YORK ISN DDC or
Building Automation System (by others) via:
- a pulse width modulated (PWM) input as stan-
dard
- a 4-20 milliamp or 0 -10 VDC input, or contact
closure with the optional B.A.S. interface option
• Anti-recycle timer status for each system
• Anti-coincident system start timer condition
• Compressor run status
• No cooling load condition
• Day, date and time
• Daily start/stop times
• Holiday status
• Automatic or manual system lead/lag control
• Lead system definition
• Compressor starts & operating hours
(each compressor)
• Status of hot gas valves, evaporator heater
and fan operation
• Run permissive status
• Number of compressors running
• Liquid solenoid valve status
• Load & unload timer status
• Water pump status
-
* Intensity of Protection European Standard
YORK INTERNATIONAL
5
Provisions are included for: pumpdown at shutdown;
optional remote chilled water temperature reset and two
steps of demand load limiting from an external building
automation system. Unit alarm contacts are standard.
The operating program is stored in non-volatile memory
(EPROM) to eliminate chiller failure due to AC powered
failure/battery discharge. Programmed setpoints are
retained in lithium battery-backed RTC memory for 5
years minimum.
POWER PANEL
Each panel contains:
• Compressor power terminals
• Compressor motor starting contactors per l.E.C.**
• Control power terminals to accept incoming for
115-1-60 control power
• Fan contactors & overload current protection
The power wiring is routed through liquid-tight conduit
to the compressors and fans.
** International Electrotechnical Commission
6
YORK INTERNATIONAL
Options and Accessories
FORM 150.64-EG1
POWER OPTIONS:
COMPRESSOR POWER CONNECTIONS – Single-
point (YCAL0041-0065) terminal block connection(s) are
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 – (stan
dard on YCAL0041 - 0065 models). Includes enclosure,
terminal-block and interconnecting wiring to the compressors. Separate external protection must be supplied,
by others, in the incoming compressor-power wiring. (Do
not include this option if either the SinglePoint NonFused
Disconnect Switch or Single-Point Circuit Breaker options have been included.)
handle (in compliance with Article 440-14 of N.E.C.),
can be supplied to isolate the unit power voltage for
servicing. Separate external fusing must be supplied,
by others in the power wiring, which must comply with
the National Electrical Code and/or local codes.
SINGLE-POINT CIRCUIT BREAKER – A unit mounted
circuit breaker with external, lockable handle (in com
pliance with N.E.C. Article 440-14), can be supplied
to isolate the power voltage for servicing. (This option
includes the Single-Point Power connection.)
CONTROL TRANSFORMER – Converts unit power
voltage to 115-1-60 (0.5 or 1.0 KVA capacity). Fac
tory mounting includes primary and secondary wiring
between the transformer and the control panel. (Fac-
tory-Mounted.)
POWER FACTOR CORRECTION CAPACITORS – Will
correct unit compressor power factors to a 0.90-0.95.
(Factory-Mounted.)
CONTROL OPTIONS:
AMBIENT KIT (LOW) – Units will operate to 25°F (-4°C).
This accessory includes all necessary components to
permit chiller operation to 0°F (-18°C). (This option includes the Discharge Pressure Transducer / Readout
Capability option.) For proper head pressure control in
applications below 25°F (-4°C), where wind gusts may
exceed five mph, it is recommended that Optional Condenser Louvered Enclosure Panels also be included.
(Factory-Mounted.)
AMBIENT KIT (HIGH) – Required if units are to operate
when the ambient temperature is above 115°F (46°C).
Includes discharge pressure transducers. (This option
includes the Discharge Pressure Transducer / Readout
Capability option.) (Field-Mounted.)
BUILDING AUTOMATION SYSTEM INTERFACE – The
factory addition of a Printed Circuit Board to accept a
4-20 milliamp, 0-10VDC or contact closure input to reset
the leaving chiller liquid temperature from a Building Au
tomation System. (Only one of following options can be
offered on a unit at a time: BAS, Remote Control Panel
(The standard unit capabilities include remote startstop,
remote water temperature reset via a PWM input signal
or up to two steps of demand (load) limiting depending
on model.) (The standard control panel can be directly
connected to a YORK Building Automated System via
the standard onboard RS485 communication port.)
LANGUAGE LCD AND KEYPAD DISPLAY – Spanish,
French, and German unit LCD controls and keypad
display available. Standard language is English.
DISCHARGE PRESSURE TRANSDUCERS AND
READOUT CAPABILITY – The addition of pressure
transducers allows models to sense and display dis
charge pressure. This is recommended for brine chilling
applications. (This option is included with either the low
or high ambient kits.) (Factory-Mounted.)
-
• Suction Pressure Transducers: Permits unit to
sense and display suction pressure. This capability
is standard on YCAL0041-0065 models.
MOTOR CURRENT MODULE – Capable of monitoring
compressor motor current. Provides extra protection
against compressor reverse rotation, phase-loss and
phase imbalance. Option consists of one module per
electrical system. (Factory-Mounted.)
OPTIVIEW REMOTE CONTROL PANEL - Graphical
interface panel to remotely control and monitor up to 8
different units. (Refer to form 201.18-SG4 for detailed
information)
MULTI-UNIT SEQUENCING – A separate Sequencing
Control Center is provided to handle sequencing control
of up to eight chillers in parallel based on mixed liquid
temperature (interconnecting wiring by others). (Only
one of following options can be offered on a unit at a
time: BAS, Remote Control Panel or Multi-unit Sequence
Control.) (Factory-Mounted.)
COMPRESSOR, PIPING, EVAPORATOR
OPTIONS:
LOW TEMPERATURE BRINE – Required for brine
-
-
-
YORK INTERNATIONAL
7
chilling below 30°F (-1°C) leaving brine temperature
for YCAL0041 - 0065 models. Option includes resized
thermal expansion valve. (Factory-Mounted)
CHICAGO CODE RELIEF VALVES – Unit will be pro
vided with relief valves to meet Chicago code requirements. (Factory-Mounted)
SERVICE ISOLATION VALVE – Service suction and
discharge (ball type) isolation valves are added to unit
per system. This option also includes a system high
pressure relief valve in compliance with ASHRAE 15.
(Factory-Mounted)
HOT GAS BY-PASS – Permits continuous, stable opera
tion at capacities below 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 refrigerant system #1 on two-circuited units.
(Factory-Mounted)
DX COOLER 300 PSIG (21 bar) DWP WATERSIDE
– The waterside will be of 300 PSIG (21 bar) instead of
the standard 150 PSIG DWP. 300 PSIG R.F. flanges are
included on the DX cooler nozzles. (Factory-Mounted.)
The companion flanges will be field-supplied by others.
FLANGES (VICTAULIC TYPE) – Consists of two (2)
Flange adapters for grooved end pipe (standard 150
psi [10.5 bar] cooler).
REMOTE DX COOLER – A split system arrangement
with the cooler, leaving & return water sensors, liquid
line solenoid valves, filter driers, sightglasses & TXVs
shipped loose for field connection to the air-cooled con-
-
densing section. The DX cooler and outdoor section will
have a nitrogen holding charge. Interconnecting rigid
piping, wiring and refrigerant are by others. Includes
YORK Service startup. See Form 150.62-NM1.1 (200)
for other application information. (This option includes
the Crankcase Heater option.)(Field-Mounted.)
CONDENSER AND CABINET OPTIONS:
Condenser coil protection against corrosive environ-
-
ments is available by choosing any of the following options. For additional application recommendations, refer
to FORM 150.12-ES1. (Factory-Mounted.)
PRE-COATED FIN CONDENSER COILS – The unit's
coils are constructed with black epoxy coated aluminum
fins. This can provide corrosion resistance comparable
to copper-fin coils in typical seashore locations. Either
these or the post-coated coils (below), are recommend
ed 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 al
kalies, oxidizers and wet bromine, chlorine and fluorine
in concentrations greater than 100 ppm).
-
-
FLOW SWITCH – The flow switch or its equivalent must
be furnished with each unit.
150 PSIG (10.5 bar) DWP – For standard units. Johnson
Controls model F61MG-1C Vapor-proof SPDT, NEMA
4X switch (150 PSIG [10.5 bar] DWP), -20°F to 250°F
(-29°C to 121°C), with 1” NPT connection for upright
mounting in horizontal pipe. (Field-Mounted.)
300 psig (21 bar) DWP – For units with optional 300
PSIG (21 bar) DX cooler. McDonnell & Miller model
FS74W Vapor-proof SPDT, NEMA 4X switch (300 PSIG
(21 bar) DWP), -20°F to 300°F (-29°C to 149°C), with 1¼
inch MPT connection for upright mounting in horizontal
pipe. (Field-Mounted.)
DIFFERENTIAL PRESSURE SWITCH – Alternative
to an above mentioned flow switch. Pretempco model
DPS300AP40PF-82582-5 (300 psi max. working pres
sure), SPDT 5 amp 125/250VAC switch, Range 0 - 40
PSID, deadband 0.5 - 0.8 psi, with 1/4” NPTE Pressure
Connections.
COPPER FIN CONDENSER COILS – The unit's coils
are constructed with copper fins. (This is not recom
mended for units in areas where they may be exposed
to acid rain.)
ENCLOSURE PANELS (UNIT) – Tamperproof En
closure Panels prevent unauthorized access to units.
Enclosure Panels can provide an aesthetically pleasing alternative to expensive fencing. Additionally, for
proper head pressure control, YORK recommends the
use of :
LOUVERED PANELS (Full Unit) – Louvered panels
surround the front, back, and sides of the unit. They
prevent unauthorized access and visually screen unit
components. Unrestricted air flow is permitted through
generously sized louvered openings. This option is ap
plicable for any outdoor design ambient temperature up
-
to 115°F (46°C). (Factory-Mounted.)
SOUND ATTENUATION – One or both of the follow
ing sound attenuation options are recommended for
-
-
-
-
8
YORK INTERNATIONAL
FORM 150.64-EG1
residential or other similar sound-sensitive locations.
Louvered Panels can be ordered for winter applications
where wind gusts may exceed five miles per hour. The
following types of enclosure options are available:
COMPRESSOR ACOUSTIC SOUND BLANKET – Each
compressor is individually enclosed by an acoustic
sound blanket. The sound blankets are made with one
layer of acoustical absorbent textile fiber of 5/8” (15mm)
thickness; one layer of anti-vibrating heavy material
thickness of 1/8” (3mm). Both are closed by two sheets
of welded PVC, reinforced for temperature and UV
resistance. (Factory-Mounted.)
ULTRA QUIET FANS – Lower RPM, 8-pole fan motors
are used with steeper-pitch fans. (Factory-Mounted.)
VIBRATION ISOLATORS – Level adjusting, spring
type 1” (25.4mm) or seismic deflection or neoprene
pad isolators for mounting under unit base rails. (
Field-
Mounted.)
YORK INTERNATIONAL
9
This page intentionally left blank.
10
YORK INTERNATIONAL
Selection Data
FORM 150.64-EG1
GUIDE TO SELECTION
Capacity ratings for YORK YCAL Packaged Air-Cooled
Liquid Chillers, shown on pages 16 through 39 cover
the majority of design applications for these units. For
unusual applications or uses beyond the scope of this
catalog, please consult your nearest YORK Office or
representative.
SELECTION RULES
1. Ratings – Ratings may be interpolated, but must
not be extrapolated. The Ratings given on pages 16
through 39 and the DESIGN PARAMETERS given
on page 11 indicate the limits of application for these
chillers.
2. Cooler Water – Ratings are based upon 2.4 GPM
per ton which is equal to a 10°F chilled water range
and a 0.0001 fouling factor for the cooler at sea level.
Tables on pages 16 through 39 give capacity, compressor kW required, cooler GPM and unit EER.
3. Condenser – Ratings are given in terms of air on
condenser in degrees Fahrenheit.
4. Copper Fin Condenser Ratings – Since the thermal conductivity of copper is slightly higher than
aluminum, apply the following corrections to the
standard ratings. Tons x 0.97 and compressor kW
x 0.99.
5. Performance Data Correction Factors – Ratings
are based on 0.0001 cooler fouling factor, 10°F
chilled water range and at sea level. For operation at
different conditions, apply the appropriate correction
factor from the following table.
6. Ethylene Glycol Correction Factors – The following factors are to be applied to the standard
ratings for units cooling ethylene glycol.
ETHYLENE GLYCOL
%
WEIGHT
100.9960.99924.31.04926.2
200.9910.99825.11.12417.9
300.9840.99725.91.2586.7
400.9760.99526.91.430-8.1
500.9680.99428.01.650-28.9
TONS
COMPR KWGPM
°F/TON
PRESS
DROP
FREEZE
PT
7. Propylene Glycol Correction Factors – The following factors are to be applied to the standard
ratings for units cooling propylene glycol.
PROPYLENE GLYCOL
%
WEIGHT
100.9950.99924.01.01426
200.9840.99724.31.10419
300.9730.99424.91.2349
400.9600.99225.61.399-6
500.9430.98926.61.599-28
TONS
COMPR KWGPM
°F/TON
PRESS
DROP
FREEZE
PT
METHOD OF SELECTION
To select of YORK Packaged Air-Cooled Liquid Chiller,
the following data must be known:
1. Design Capacity in tons refrigeration (TR).
2. Entering and Leaving Liquid Temperatures.
3. Outside ambient air temperature in degrees F.
4. GPM of chilled liquid.
Determine capacity requirements from the following
formula:
GPM =
RANGE (°F)
TR x 24
EXAMPLE – WATER CHILLING
1. Given: Provide a capacity of 50 tons at 42 F leav
ing water at 10 F range. 0.0001FF, 85 F air on the
condenser, at sea level and 60 Hz.
2. Find: Unit Size, Compressor KW Output
3. From the ratings on page 18.
Select: YCAL0061 (English Units)
-
YORK INTERNATIONAL
11
a. 56.1 Tons
kWkWxkW8.499.55
1.56
50
==
GPM
FRang
e
Tons
GP
M120
10
24
)50(
=
°
×
=
kWCompressorx
tons
tons
93
.41)77.41(
87
.33
34
=
Range
Tonfacto
rFGalTons
GP
M
min/
/.°×
=
)(7.88
10
1.260.34
GP
MGPM=
×
=
b. 55.9 Compressor KW
c. 10.7 Unit EER
4. Calculate Compressor kW at 50 Tons:
5. Calculate GPM:
6. From page ____, read 6 ft of water cooler pressure
drop from GPM:
7. A YCAL0061 is suitable.
EXAMPLE - BRINE CHILLING
Example - Brine Chilling
1. Given: Provide a capacity of 34 tons cooling 30% by
weight Ethylene Glycol from 50 F to 40 F, 0.00025FF,
95 F air on the condenser, 60 Hz and 4000 ft. altitude.
2. Determine:
a. Unit Size
b. KW Input
c. Ethylene Glycol GPM
d. Cooler Pressure Drop
3. See E.G. correction factors, for 30% by weight
E.G.
READ: 0.984 Tons Factor
0.997 Compr. KW factor
26.1 Gal,/ F/Tons Factor
4. See Performance Data Correction Factors for
0.00025 fouling factor and 4,000 ft. altitude.
READ: 0.975 Tons factor
1.012 kW factor
5. From RATINGS on page 16.
SELECT: YCAL0045 (English Units)
35.3 Tons
41.1 Compressor kW
6. Determine YCAL0045 brine cooling capacity and
Compressor kW requirement from pg 14:
a. TONS: = 35.3 x 0.984 x 0.975 = 33.87
b. Compr. KW = 41.1 x 0.997 x 1.012 = 41.77
7. Determine average full load Compressor kW at 34
tons
8. Determine E.G. GPM:
9. Determine Cooler Pressure Drop:
a. See E.G. correction factors for 30% by weight
E.G.
READ: 1.258 Pressure Drop factor
b. See page 14 at 88.7 GPM for YCAL0045
READ: 6.5_Water H2O PD
c. Cooler Pressure Drop = 6.5 x 1.258 or 8.17
A YCAL0045 is suitable.
12
YORK INTERNATIONAL
Design Parameters
ENGLISH
YCAL
00414055402000125
00454055402000125
00514055402000125
00554055603000125
00614055603000125
00654055603000125
YCAL
00414.412.82.512.6-17.751.7
00454.412.82.512.6-17.751.7
00514.412.82.512.6-17.751.7
00554.412.83.818.9-17.751.7
00614.412.83.818.9-17.751.7
00654.412.83.818.9-17.751.7
LEAVING WATER
TEMPERATURE (
°F)
COOLER FLOW (GPM)AIR ON CONDENSER (°F)
MINMAXMINMAXMINMAX
SI UNITS
LEAVING WATER
TEMPERATURE (
°DC)
COOLER FLOW (L/S)AIR ON CONDENSER (°C)
MINMAXMINMAXMINMAX
FORM 150.64-EG1
NOTES:
1. For leaving brine temperature below 40°F (4.4°C), contact your nearest YORK Office for application requirements.
2. For leaving water temperature higher than 55°F (12.8°C), contact the nearest YORK Office for application guidelines.
3. The evaporator is protected against freezing to -20°F (-28.8°C) with an electric heater as standard.
4. For operation at temperatures below 25°F (-3.9°C), the optional Low Ambient Kit will need to be installed on the system (for YCAL0041-0065
models only).
5. For operation at temperatures above 115°F (46.1°C), the optional High Ambient Kit will need to be installed on the system.
YORK INTERNATIONAL
13
Water Pressure Drop
ENGLISH
1
10
100
10100100
0
FLOW, GP
M
Press Drop, Ft H
2
O
A
B
C
D
Note: Water Pressure Drop Curves may extend past the minimum and maximum water flow ranges. See page 13 for minimum and maximum
flow points.
14
YORK INTERNATIONAL
FORM 150.64-EG1
SI
1
10
100
1000
11
0100
FLOW, L/
S
Press Drop, kPA
B
AC
D
Note: Water Pressure Drop Curves may extend past the minimum and maximum water flow ranges. See page 13 for minimum and maximum
flow points.