SB0005 0900

File In: N/A

Affected
ESG SERVICE BULLETIN Equipment:
YCAL and YCUL

Subject: Safety Retrofit, TXV Control Improvement, and Suppressor Additions

Issue Date: 9/28/00 Withdrawal Date: 9/28/01 Data Control Level: C

Materials Needed: Refer to “Parts Requirements”
Tools Required: Refer to “Installation Instructions”
Estimated Time Required: • Installation of relief valve – Maximum two (2) hours per refrigerant circuit
• Installation of EPROM, programming modifications, TXV bulb relocation,
subcooling check, superheat check, system operation check, and
suppressor installation – Maximum two (2) hours per circuit
Warranty? Yes
Revision Notes: N/A

GENERAL

Safety Retrofit
A safety retrofit is required on all 50 Hz and 60Hz YCAL/YCUL chillers shipped prior to July 25, 2000. This
retrofit requires the addition of a relief valve in the discharge line of each circuit for safety purposes. The relief
valve is needed to relieve pressure in the compressor and discharge line, if the discharge shutoff valve is closed
and the compressor is started. It is extremely important that this retrofit is performed quickly on all
YCAL/YCUL chillers in your area.
TXV Control Improvement
While on site, a number of changes are required to insure improved TXV control; some require additional parts
and control modifications. The outcome, after the improvements, will be a reduced risk of liquid refrigerant being
fed to the compressor.
Suppressor Additions
Suppressors must be added to the liquid line solenoid wiring connections and optional hot gas solenoid
connections in the junction box located between the condenser coil sections. A suppressor also needs to be added
to the evaporator heater wiring connections in the evaporator heater junction box. Addition of the suppressors
will assure that de-energizing the solenoids will not cause an electrical spike that could affect the operation of the
micro panel.
PARTS REQUIREMENTS

Safety Retrofit
Kits are available to retrofit a single circuit on a chiller. Refer to Table 1 for a list of the chiller model numbers

Work on this equipment should only be done by properly trained personnel who are qualified to work on this type of equipment.
Failure to comply with this requirement could expose the worker, the equipment and the building and its inhabitants to the risk of
personal injury or property damage.
The instructions on this service bulletin are written assuming the individual who will perform this work is a fully trained HVAC &
R journeyman or equivalent, certified in refrigerant handling and recovery techniques, and knowledgeable with regard to electrical lock
out/tag out procedures. The individual performing this work should be aware of and comply with all national, state and local safety and
environmental regulations while carrying out this work. Before attempting to work on any equipment, the individual should be
thoroughly familiar with the equipment by reading and understanding the associated service literature applicable to the equipment. If you
do not have this literature, you may obtain it by contacting a York Service Office.
Should there be any question concerning any aspect of the tasks outlined in this bulletin, please consult a York Service Office prior
to attempting the work. Please be aware that this information may be time sensitive and that York International reserves the right to
revise this information at any time. Be certain you are working with the latest information. The York Service office nearest you may be
found on the Internet at www.york.com.
SB0005

and the part number of the kit for each individual circuit. Table 2 shows a bill of material for each kit. Order the
appropriate kit(s) for each chiller.
TXV Control Improvement Parts
A number of parts are required to improve TXV control. All parts are field supplied except for the EPROM and
TXV bulb straps, which must be ordered from Baltimore RPC. A list of the parts follows:
Baltimore RPC Supplied Parts:
• A new EPROM should be ordered for each chiller. The part numbers have remained the same. The
EPROM required will vary according to the microboard part number installed in the chiller. See
below.
NOTE: Virtually all YCAL/YCUL chillers to be modified in this retrofit use the 031-01314-000
microboard, which should be assumed when ordering parts. If a chiller is found to have a 031-02050-
000 microboard, the EPROM may be replaced at a later date. An alternative would be to keep a few
EPROMs for the 031-02050-000 microboard in stock and use as needed.
! Microboard 031-01314-000: Uses EPROM 031-02011-001, but the version has changed to
C.MMC.01.04, checksum (8D4B).
! Microboard 031-02050-000: Uses EPROM 031-02049-001, but the version has changed to
C.MMC.03.01, checksum (964B).
• Order one (1) TXV bulb strap kit (part number 021-30186-000) for single circuit chillers and two (2)
TXV bulb strap kits (part number 021-30186-000) for dual circuit (system) chillers. NOTE: Straps
come in pairs. Refer to Table 1 to determine the number of systems in a specific chiller model.
Field Supplied Parts:
• Additional refrigerant may need to be added after subcooling is checked. Add R22 or R407C as
required.
• Insulation (suction line) and tape will be needed to relocate the TXV. Sandpaper may also be
required to clean the piping.
Suppressor Parts
• Order one (1) suppressor kit per chiller--part number 375-40468-101 for 60 Hz and 50 Hz non-CE model
chillers or 375-40468-102 for 50 Hz CE model chillers. Suppressors, adhesive cable mounts, cable
straps, and wire nuts are contained in each 60/50 Hz non-CE kit, and only suppressors are in the 50 Hz
CE kit. The suppressors connect to the liquid line solenoids, evaporator heater, and optional hot gas
solenoid on a two-circuit (system) chiller. Unused parts from single-circuit (system) chillers may be used
sometime in the future for other applications.
INSTALLATION INSTRUCTIONS

Safety Retrofit
Follow the instructions provided in Figure 1. This drawing is also provided in the kit. Note that the relief valve is
not always installed in the same location and is dependent upon the kit number. NOTES 2 and 3 of Figure 1
provide specifics on which kits may be installed in the two possible locations.
Before making any modifications to the piping, run each system and pump the charge into the condenser and
valve off the compressors. Use proper refrigerant handling practices when removing the remaining charge in the
compressors and when performing all work. Be sure to use nitrogen when brazing to avoid contaminating the
system. After installing the relief valve(s), evacuate the valved off portion of the system to 500 microns.
TXV Control Improvement Modifications
TXV control will be improved by making a number of changes to each refrigerant system. Changes in the
location of the equalizing line are not necessary.

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YCAL ONLY – TXV BULB RELOCATION:

Relocate the TXV bulb according to the appropriate chiller drawing shown in Figures 2 through 7. Drawings are
shown for each model. This assures that the TXV is moved away from the side of the chiller where it may be
directly exposed to sun, wind, etc. It also assures that the bulb is not located on the outside of the pipe after a 90-
degree bend where it can be affected by liquid refrigerant or oil flowing on the outside of the pipe. Assure that
the bulb is located at the 4 or 8 o’clock position (see the appropriate chiller drawing shown in Figures 2 through
7), on a clean pipe, the bulb must be tightly clamped using two (2) copper straps, and the bulb must be properly
insulated and taped after relocation. NOTE: All models require the TXV bulb to be located at either the 4 or the
8 o’clock position, but not both. DO NOT use ty-wraps to clamp a TXV bulb. Some chillers may have ty-wraps
installed from the factory. Also remove any tape that may be on the TXV bulb or the piping.
YCUL ONLY – TXV BULB RELOCATION:
Assure the TXV bulb is located at the 4 or 8 o’clock position on a straight run of pipe as far from an elbow as
possible and near the compressors. This is to assure that the bulb is not located where liquid refrigerant and oil
flowing on the outside of a pipe after an elbow can affect it. The pipe must be clean, the bulb should be tightly
clamped using two (2) copper straps, and the bulb must be properly insulated and taped.
Be sure the TXV is properly sized for part loads and that multiple TXVs and liquid line solenoids are used when
required. Piping design (sizing, sloping, trapping) for proper oil return is a MUST, and good design practices
must be adhered to. Accumulators and crankcase heaters must also be used when needed. This is necessary to
assure that oil slugging and refrigerant overfeed do not damage compressors. Typically, no more than a quart of
oil should be added in a remotely piped system. Oil levels will routinely run at the bottom of the sight glass or
slightly below. Adding oil may not appreciably raise levels in the site glass and will often cause excess oil
pumping. Excess oil in the system will cause the TXV to control poorly, which will lead to compressor failure.
Legitimate requirements for more oil indicate a piping design problem. When in doubt, measure the percentage
of oil in the system. Percentages should not exceed 3 to 4%.
Hot gas piping, if used, must be designed to assure that refrigerant/oil cannot drain or condense in the lines
causing a liquid slug when the valve is energized.
YCAL AND YCUL EPROM INSTALLATION:
Remove power and install the new EPROM. Be sure the notch in the EPROM is located in the same position as
the original EPROM. Make certain that the original programmed values have not changed after the EPROM is
installed. The new EPROM assures that a compressor does not short cycle by automatically changing the chilled
liquid control range to increase compressor-operating time. The increased run time assures that the TXV has a
chance to stabilize control, which minimizes liquid carry over and allows good quality oil to lubricate the
compressor. Each time a compressor cycles off, the micro will look at the run time and extend the “control range
upper limit” if the last operating period was below 5 minutes. By raising the “upper limit” of the “control range”,
a compressor will remain off for a longer period of time before another compressor starts. Since a compressor
will not start until chilled liquid temperature rises to the new “micro reset” higher “control range upper limit
temperature”, the next compressor to run will remain on for a longer period of time before chilled liquid demand
is satisfied, which reduces short cycling.
The new EPROM will also minimize fan cycling by changing the temperature control points for fan start and stop,
reducing TXV hunting in the “AMBIENT & DSCH PRESS” mode. “DISCHARGE PRESSURE” mode control
of the fans may also need to be reprogrammed. Details of operation for each mode are outlined below:
“AMBIENT & DSCH PRESS” fan control mode ON/OFF points on will automatically be changed to:
1st fan ON at 45° F
2nd fan ON at 65° F
2nd fan OFF at 60° F
1st fan OFF at 40° F
Fan control in the “AMBIENT & DSCH PRESS” mode is also changed by switching the fan
outputs to cause the first forward fan to come on closest to the liquid header of the condenser

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coils. The outputs are switched in software, which in turn switches the microboard outputs and
the relay board outputs without the need for rewiring. The fan control in Low Ambient mode
remains unchanged since the first forward fan is already the fan closest to the liquid header.
“DISCHARGE PRESSURE” control mode fan ON/OFF points must be checked and re-programmed as
needed to assure that the FAN CONTROL ON PRESSURE – FAN DIFFERENTIAL OFF PRESSURE is
equal to or greater than 150 PSIG.
YCAL AND YCUL TXV OPERATIONAL CHECK:
Refrigerant should be added to each circuit to adjust the subcooling between 15 and 20° F, fully loaded.
Subcooling closer to 20° F is preferred. This will assure that the liquid seal in the sight glass is maintained
although the seal may temporarily be lost when fans or compressors cycle.
Run the system with all compressors in a system operating. Superheat, fully loaded, should be adjusted between
15 and 20° F to assure that the liquid seal in the sight glass is maintained during all periods of operation except
immediately after fan or compressor cycling. A final superheat check must be made to assure that superheat
is maintained above 10°° F when only a single compressor is running. Additional superheat adjustments may
be required to assure that 10° F is maintained with a single compressor operating. This is especially important on
three (3) compressor chillers.
During operation, severe foaming in the compressor sight glass should not last for more than a few seconds. This
typically occurs after compressors or fans cycle. The TXV should gain control in 15 to 20 seconds, and the sight
glass should be relatively free of foam although some agitation is normal. Oil levels may run at the bottom or
slightly below the bottom of the sight glass, which is normal. Oil levels should never run above the top of the
compressor sight glass. Adding excess oil to the compressors will cause excessive oil pumping, poor TXV
control, and possible failure of the compressor.
YCUL systems are especially susceptible to problems due to refrigerant overfeed and poor oil return resulting
from piping design problems (sizing, sloping, trapping, routing, improper TXV selection, poor controls, poor
liquid line solenoid selection to adjust for load changes, lack of crankcase heaters, and lack of accumulators).
These problems must be resolved or compressor failures will occur.
Suppressor Installation
Suppressors should be installed where each of the liquid line solenoids and optional hot gas solenoid wiring is
connected in the junction box located between the condenser coils and where the evaporator heater is connected in
the evaporator heater terminal box on the cooler. Follow the installation instructions in Figure 8 for the 60/50 Hz
non-CE models. Make sure that wire nuts are taped with electrical tape after the connection is made on 60/50 Hz
non-CE models. Follow the installation instructions shown in Figure 9 for 50 Hz CE models.
WARRANTY
Costs should be submitted under warranty. One warranty claim per chiller retrofit please. When completing the
warranty information, provide typical equipment information with a simple description such as “Relief Valve
Safety Retrofit and TXV Control Modifications”. Recommended maximum time spent performing these
modifications should be limited according to the following guidelines:
• It is our desire to limit time of installation of the relief valve to a maximum of 2 hours per refrigerant circuit.
• We also would like to limit the time spent on the installation of the EPROM, programming modifications,
TXV bulb relocation, subcooling check, superheat check, system operation check, and suppressor installation
to a maximum of 2 hours per circuit.
Complete the Retrofit Completion Record in Figure 10 and fax it to 717-771-6844. Fill out one form for
each chiller retrofitted. This form will be used to track completion of the retrofits by corporate auditing.

4 YORK INTERNATIONAL
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TABLE 1 - CHILLER MODEL NUMBERS AND RELIEF VALVE KIT PART NUMBERS
SYSTEM 1 SYSTEM 2
YCAL (60Hz) MODEL YCAL (50Hz) MODEL KIT PART NO. KIT PART NO.
0014 0043 375-40468-001 Not Applicable
0020 0057 375-40468-002 Not Applicable
0024 0073 375-40468-003 Not Applicable
0030 0087 375-40468-005 Not Applicable
0034 0107 375-40468-005 Not Applicable
0040 0117 375-40468-002 375-40468-002
----- 0133 375-40468-003 375-40468-002
0044 0147 375-40468-003 375-40468-003
0050 0157 375-40468-005 375-40468-005
0060 0173 375-40468-005 375-40468-005
0064 0197 375-40468-005 375-40468-004
0070 0217 375-40468-005 375-40468-005
0074 0237 375-40468-005 375-40468-005
0080 0253 375-40468-005 375-40468-005

SYSTEM 1 SYSTEM 2
YCUL (60Hz) MODEL YCUL (50Hz) MODEL KIT PART NO. KIT PART NO.
0016 0045 375-40468-001 Not Applicable
0026 0061 375-40468-002 Not Applicable
0030 0081 375-40468-003 Not Applicable
0036 0095 375-40468-005 Not Applicable
0040 0121 375-40468-005 Not Applicable
0046 0125 375-40468-002 375-40468-002
----- 0145 375-40468-003 375-40468-002
0056 0161 375-40468-003 375-40468-003
0060 0171 375-40468-005 375-40468-005
0066 0185 375-40468-005 375-40468-005
0076 0211 375-40468-005 375-40468-004
0080 0235 375-40468-005 375-40468-005
0086 0255 375-40468-005 375-40468-005
0090 0275 375-40468-005 375-40468-005

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TABLE 2 - BILLS OF MATERIAL OF KITS

KIT
ITEM PART NO. DESCRIPTION QTY.
PART NO.
1. 023-20229-000 TEE. 3/4 X 3/4 X 5/8 1
2. 023-00221-000 ADAPTER 5/8 FTG X 1/2 F 1
3. 022-10049-000 RELIEF VALVE 1
375-40468-001 4. 023-00124-000 ADAPTER 7/8 C X 3/4 M 1
5. 023-06065-000 ELBOW 7/8 2
6. 035-16209-000 LABEL 1
7. 075-40468-000 DWG-DISCHARGE RELIEF 1
1. 023-09718-000 TEE. 7/8 X 7/8 X 5/8 1
2. 023-00221-000 ADAPTER 5/8 FTG X 1/2 F 1
3. 022-10049-000 RELIEF VALVE 1
375-40468-002 4. 023-00124-000 ADAPTER 7/8 C X 3/4 M 1
5. 023-06065-000 ELBOW 7/8 2
6. 035-16209-000 LABEL 1
7. 075-40468-000 DWG-DISCHARGE RELIEF 1
1. 023-00286-000 TEE. 1-1/8 X 1-1/8 X 5/8 1
2. 023-00221-000 ADAPTER 5/8 FTG X 1/2 F 1
3. 022-10049-000 RELIEF VALVE 1
375-40468-003 4. 023-00124-000 ADAPTER 3/4 C X 7/8 M 1
5. 023-06065-000 ELBOW 7/8 2
6. 035-16209-000 LABEL 1
7. 075-40468-000 DWG-DISCHARGE RELIEF 1
1. 023-02678-000 TEE. 1-5/8 X 1-5/8 X 1-1/8 1
2. 023-10548-000 ADAPTER 1-1/8 FTG X 1 F 1
3. 022-10050-000 RELIEF VALVE 1
375-40468-004 4. 023-00129-000 ADAPTER 1-1/8 C X 1 M 1
5. 023-09725-000 ELBOW 1-1/8 2
6. 035-16209-000 LABEL 1
7. 075-40468-000 DWG-DISCHARGE RELIEF 1
1. 023-00247-000 TEE. 1-1/8 X 1-1/8 X 1-1/8 1
2. 023-10548-000 ADAPTER 1-1/8 FTG X 1 F 1
3. 022-10050-000 RELIEF VALVE 1
375-40468-005 4. 023-00129-000 ADAPTER 1-1/8 C X 1 M 1
5. 023-09725-000 ELBOW 1-1/8 2
6. 035-16209-000 LABEL 1
7. 075-40468-000 DWG-DISCHARGE RELIEF 1

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Common
Discharge
Line

075-40468-000

FIGURE 1 – INSTALLATION INSTRUCTIONS FOR RELIEF VALVE

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YCAL0014, 0020, 0024 (60 Hz)

YCAL0043, 0057, 0073 (50 Hz)

Mount TXV bulb

on inside of pipe
at SECTION A-A.
See Note.

NOTE: TXV BULB LOCATION AT 8 O'CLOCK

075-30678-100 Rev. E

FIGURE 2 – TXV LOCATION FOR YCAL0014, 0020, 0024, 0043, 0057, 0073

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YCAL0030 (60 Hz)

YCAL0087 (50 Hz)

Mount TXV bulb

on inside of pipe
at SECTION A-A.
See Note.

NOTE: TXV BULB LOCATION AT 8 O'CLOCK 075-30679-100 Rev. G

FIGURE 3 – TXV LOCATION FOR YCAL0030, 0087

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YCAL0034 (60 Hz)

YCAL0107 (50 Hz)

Mount TXV bulb

on inside of pipe
at SECTION A-A.
See Note.

NOTE: TXV BULB LOCATION AT 8 O'CLOCK

075-30605-100 Rev. H

FIGURE 4 – TXV LOCATION FOR YCAL0034, 0107

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YCAL0040, 0044 (60 Hz)

YCAL0117, 0133, 0147 (50 Hz)

Mount TXV bulb on

inside (evaporator
side) of pipe at
SECTION A-A.
See Note.

NOTE: TXV BULB LOCATION AT 4 O'CLOCK

Mount TXV bulb on

inside (evaporator
side) of pipe at
SECTION A-A.
See Note.
NOTE: TXV BULB LOCATION AT 8 O'CLOCK 075-30637-100 Rev. J

FIGURE 5 – TXV LOCATION FOR YCAL0040, 0044, 0117, 0133, 0147

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YCAL0050, 0060 (60 Hz)

YCAL0157, 0173 (50 Hz)

Mount TXV bulb on

inside (evaporator
side) of pipe at
SECTION A-A.
NOTE: TXV BULB LOCATION AT 4 O'CLOCK See Note.

Mount TXV bulb on

inside (evaporator
side) of pipe at
SECTION A-A.
NOTE: TXV BULB LOCATION AT 8 O'CLOCK See Note. 075-30616-100 Rev. K

FIGURE 6 – TXV LOCATION FOR YCAL0050, 0060, 0157, 0173

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YCAL0064, 0070, 0074, 0080 (60 Hz)

YCAL0197, 0217, 0237, 0253 (50 Hz) Mount TXV bulb on
inside (evaporator
side) of pipe at
SECTION A-A.
See Note.

NOTE: TXV BULB LOCATION AT 4 O'CLOCK

Mount TXV bulb on

inside (evaporator
side) of pipe at
SECTION A-A.
See Note.

NOTE: TXV BULB LOCATION AT 8 O'CLOCK

075-30657-100 Rev. J

FIGURE 7 – TXV LOCATION FOR YCAL0064, 0070, 0074, 0080, 0197, 0217, 0237, 0253

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CHILLER JUNCTION BOX

(ALL NON-CE UNITS)

EVAPORATOR HEATER JUNCTION BOX PROCEDURES FOR NON-CE UNITS:

(ALL NON-CE UNITS ONLY) 1. TURN POWER OFF TO MAKE MODIFICATIONS.
2. REMOVE EXISTING WIRE NUT CONNECTIONS FROM WIRES
120, 123, AND 220 IN CHILLER JUNCTION BOX AND
WIRES 139 AND 2 IN EVAPORATOR HEATER JUNCTION
BOX. RE-ATTACH WITH WIRE NUT (ITEM 102) TO
INCLUDE 1 LEAD OF SUPPRESSOR (ITEM 101).
3. CUT EXISTING WIRE #2 IN CHILLER JUNCTION BOX
WHERE SHOWN AND CONNECT THE REMAINING LEAD OF
SUPPRESSOR (ITEM 101) WITH WIRE NUT (ITEM 105).
4. SECURE EACH SUPPRESSOR TO INSIDE WALLS OF
JUNCTION BOX WITH CABLE MOUNT (ITEM 103) AND WIRE
STRAP (ITEM 104).
5. WRAP ALL NEW CONNECTIONS WITH ELECTRICAL TAPE
WHEN COMPLETE.

075-40468-000_2a

FIGURE 8 – 60/50 HZ NON-CE SUPPRESSOR INSTALLATION

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CHILLER JUNCTION BOX

(ALL 50 HZ CE UNITS)

PROCEDURES FOR CE UNITS:

1. TURN POWER OFF TO MAKE MODIFICATIONS.
2. INSTALL SUPPRESSORS (101) ON THE TERMINALS SHOWN.

075-40468-000_2b

FIGURE 9 – 50 HZ CE SUPPRESSOR INSTALLATION

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RETROFIT COMPLETION RECORD

(Fax to DX Product Team at 717-771-6844)

DATE RETROFIT COMPLETED: _______________________

WARRANTY NUMBER: _______________________________

CHILLER MODEL #: _________________________________

CHILLER SERIAL #: _________________________________

SUBCOOLING SYSTEM #1: ___________________________ (FULL LOAD)

SUBCOOLING SYSTEM #1: ___________________________ (ONLY ONE COMPRESSOR ON)

SUPERHEAT SYSTEM #1: ____________________________ (FULL LOAD)

SUPERHEAT SYSTEM #1: ____________________________ (ONLY ONE COMPRESSOR ON)

SUBCOOLING SYSTEM #2: ___________________________(FULL LOAD)

SUBCOOLING SYSTEM #2: ___________________________ (ONLY ONE COMPRESSOR ON)

SUPERHEAT SYSTEM #2: ____________________________(FULL LOAD)

SUPERHEAT SYSTEM #2: ____________________________ (ONLY ONE COMPRESSOR ON)

GENERAL OBSERVATION NOTES:

YCUL PIPING DISCREPANCIES:

FIGURE 10 – RETROFIT COMPLETION RECORD

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