Johnson Controls YORK YLAA0180SE Installation and operating instructions

Installation, Comissioning, Operation
and Maintenance
YLAA0180SE-YLAA0485SE & YLAA0195HE-YLAA0516HE
Supercedes: 150.72-ICOM8.EN.CE (0912) Form 150.72-ICOM8.EN.CE (0713)
AIR COOLED LIQUID CHILLERS
WITH SCROLL COMPRESSORS
STYLE B
(Cooling Capacities: 187 kW to 520 kW)
R410A
035-23574-100

I
Form 150.72-ICOM8.EN.CE (0713)
EN
Table of Contents
1. General Chiller Information and Safety ... ... . 1-1
Introduction 1-1
Warranty 1-1
Standards for Safety 1-1
Fluorinated Greenhouse Gases 1-1
Responsibility for Safety 1-1
About this manual 1-2
Misuse of Equipment 1-2
Safety Labels 1-3
Material Safety Data 1-4
 6SHFL¿FDWLRQ ... ... ... ... ... ... ... ... ... ... . 2-1
Compressors 2-1
Refrigerant Circuits 2-1
Brazed Plate Evaporator 2-1
Air Cooled Condensers 2-1
Power and Controls Panels 2-2
Microprocessor Controls 2-2
Accessories and Options 2-3
Power Factor Correction 2-3
Soft Starters 2-3
Language LCD and Keypad 2-3
Heat Recovery 2-3
Hydrokit 2-3
Victaulic Flange Kit 2-3
38 mm Evaporator Insulation 2-3
Thermal Dispersion Flow Switch 2-3
Dual Pressure Relief Valves 2-3
Low Sound (LS) Unit 2-3
Compressor Acoustic Enclosure 2-3
Dual speed fans 2-3
High Pressure Fans 2-3
High Ambient Kit 2-3
Low Ambient Kit 2-3
Condenser Coil Louvred Panels 2-3
Condenser Coil Louvred Panels and
Unit Wire Guards 2-3
Unit Wire Enclosure 2-3
Aesthetic Vee Panels 2-3
Coil End Hail Guard 2-4
Neoprene Pads Isolators 2-4
25 mm Spring Isolators 2-4
Lifting Lug Kit 2-4
Component Location Diagram 2-5
Hydrokit Components 2-5
Nomenclature 2-6
3. Transportation, Handling and Storage ... ... . 3-1
Delivery and Storage 3-1
Inspection 3-1
Moving the unit 3-1
Typical Lifting Arrangement 3-2
Lifting Weights 3-3
4. Installation... ... ... ... ... ... ... ... ... ... ... . 4-1
Location Requirements 4-1
Outdoor installations 4-1
Indoor installations 4-1
Operating in low ambient conditions 4-1
High static fan ductwork connection 4-1
Location Clearances 4-2
Installation of Vibration Isolators 4-2
Location Clearances - SE & SELS Models 4-4
Location Clearances - HE & HELS Models 4-4
Pipework Connection 4-5
Pipework Arrangement 4-5
Chilled Liquid System 4-5
Chilled Liquid System with Standard Hydrokit
Option 4-6
Chilled Liquid System with Full Feature
Hydrokit Option 4-6
Connection Types and Sizes 4-6
Heat Recovery System 4-7
Closed Loop Heat Recovery System 4-7
Water Treatment 4-8
Refrigerant Relief Valve Piping 4-8
Electrical Connection 4-8
Power Wiring 4-8
Single Point Power Supply Wiring 4-9
Control Circuit Transformer 4-9
Remote Emergency Stop Device 4-9
Control Wiring - Voltage Free Contact 4-9
Chilled Liquid Pump Starter 4-9
Run Contacts 4-9
Alarm Contacts 4-9
Control Wiring - System Inputs 4-9
Flow Switch 4-10
Remote Start/Stop 4-10
Remote Reset of Chilled Liquid Setpoint 4-10
Remote Load Limiting 4-10
Fan Full Speed Inhibit 4-10
EMS Analogue Input 4-10
Modbus and BACnet MS/TP 4-10
Connection Diagram 4-10

II
Form 150.72-ICOM8.EN.CE (0713)
EN
5. Commissioning ... ... ... ... ... ... ... ... ... . 5-1
Preparation 5-1
6. Unit Operation.. ... ... ... ... ... ... ... ... ... . 6-1
General Description 6-1
Start-up 6-1
Normal running and cycling 6-1
Shutdown 6-1
7. Maintenance ... ... ... ... ... ... ... ... ... ... . 7-1
General Requirements 7-1
Daily Maintenance 7-1
Scheduled Maintenance 7-2
Evaporator In-Service Inspection 7-2
8. Trouble Shooting... ... ... ... ... ... ... ... ... . 8-1
Competent Persons Trouble Shooting Guide 8-1
Sensor Calibration Charts 8-3
9. Technical Data . ... ... ... ... ... ... ... ... ... . 9-1
Evaporator pressure drop graph 9-1
Operating Limitations - SE Models 9-1
Operating Limitations - HE Models 9-2
Fan Power Data 9-2
Physical Data - SE Models 9-3
Physical Data - HE Models 9-4
Electrical Data SE Models 9-5
Electrical Data HE Models 9-5
Dimensions - YLAA0180SE, 0210SE &
0195HE 9-6
Dimensions - YLAA0240SE, 0285SE,
0320SE, 0220HE & 0260HE 9-7
Dimensions - YLAA0360SE, 0400SE &
0300HE 9-8
Dimensions - YLAA0435SE, 0485SE,
0350HE & 0390HE 9-9
Isolator Location 9-10
Anti Vibration Isolators Data -
Neoprene Isolators 9-11
Anti Vibration Isolators Data -
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10. Spare Parts. ... ... ... ... ... ... ... ... ... ... 10-1
Recommended Spares 10-1
Recommended Compressor Oil 10-1
Associated Drawings 10-1
11. Decommissioning, Dismantling
and Disposal ... ... ... ... ... ... ... ... ... ... 11-1
General 11-1

1-1
Form 150.72-ICOM8.EN.CE (0713)
EN
1. General Chiller Information and Safety
Introduction
YORK YLAA chillers are manufactured to the highest
design and construction standards to ensure high
performance, reliability and adaptability to all types of
air conditioning installations.
The unit is intended for cooling water or glycol solutions
and is not suitable for purposes other than those
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This manual contains all the information required for
correct installation and commissioning of the unit,
together with operating and maintenance instructions.
The manuals should be read thoroughly before
attempting to operate or service the unit.
All procedures detailed in the manuals, including
installation, commissioning and maintenance tasks
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personnel.
The manufacturer will not be liable for any injury or
damagecausedbyincorrectinstallation,commissioning,
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
period 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
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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
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unit is carried out without prior written approval from
Johnson Controls.
For warranty purposes, the following conditions must
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The initial start of the unit must be carried out by trained
personnel from anAuthorized Johnson Controls Service
Centre.
Only genuine Johnson Controls approved spare parts,
oils, coolants, and refrigerants must be used.
All the scheduled maintenance operations detailed in
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Failure to satisfy any of these conditions will
automatically void the warranty.
Standards for Safety
YLAA chillers are designed and manufactured within an
EN ISO 9001 accredited organisation and in conformity
with the following European Directives:
xMachinery Directive (2006/42/EC)
xEMC Directive (2004/108/EC)
xPressure Equipment Directive (97/23/EC)
xSafety Code for Mechanical Refrigeration
EN378-2 (2008)/A2 (2012) [Safety accessories
according to essential requirementsin PED
paragraph 2.11.1 have been calculated according
to EN13136:2001/A1:2005 and are not following
the requirements in EN378-2:2008 paragraph
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xSafety of machinery - Electrical Equipment of
Machine EN 60204-1 (2006)
xGeneric emissions and immunity standards for
industrial environment EN61000-6-4:2007 &
61000-6-2:2005
xISO 9614 – Determination of sound power levels
of noise sources using sound intensity
xConform to CE Testing Services for construction of
chillers and provide CE Listed Mark
Fluorinated Greenhouse Gases
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gases covered by the Kyoto Protocol.
xThe global warming potential of the refrigerant
(R410A) used in this unit is 1720.
xThe refrigerant quantity is stated in the Physical
Data table of this document.
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may not be vented to the atmosphere.
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technicians.
Responsibility for Safety
Every care has been taken in the design and
manufacture 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.

1-2
Form 150.72-ICOM8.EN.CE (0713)
EN
About this manual
The following symbols 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 explanation and the
possible result of ignoring the instruction.
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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
solutions and is not suitable for purposes other than
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equipment other than its intended use, or operation
of the equipment 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
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Structural Support
Structural support of the unit must be provided as
indicated 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.
Additional 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
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potential hazards and precautions necessary for safe
operation and maintenance of equipment containing
high temperatures, pressures and voltages.
Pressure Systems
The unit contains refrigerant vapor and liquid under
pressure, release of which can be a danger and cause
injury. The user should ensure that care is taken
during installation, operation and maintenance to avoid
damage to the pressure system. No attempt should
be made to gain access to the component parts of the
pressure system other than by suitably trained and
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Electrical
The unit must be earthed. No installation or maintenance
work should be attempted on the electrical equipment
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lockingoff the power supply. Servicing and maintenance
on live equipment must only be performed by suitably
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made to gain access to the control panel or electrical
enclosures during normal operation of the unit.
Rotating Parts
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unless the main power supply has been isolated. If
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to be removed, alternative safety mesaures must be
taken to protect against the risk of injury from rotating
fans.

1-3
Form 150.72-ICOM8.EN.CE (0713)
EN
Refrigerants and Oils
Refrigerants and oils used in the unit are generally
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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 example, does pose a risk of asphyxiation in
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given to good ventilation.
High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods (e.g.
steam cleaning) should not be used on any part of the
pressure system as this may cause operation of the
pressure relief device(s). Detergents and solvents,
which may cause corrosion, should also be avoided.
Emergency Shutdown
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a incoming supply non-fused disconnect switch which
can be used as the emergency stop device. When
operated it removes the electrical supply to the control
circuit thus shutting down the unit.
Safety Labels
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instruction, or to indicate potential hazards which may
exist.
White symbol on blue background
For safe operation, read the instructions
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Black symbol on yellow background
Warning: This machine may start
automatically without prior warning
Black symbol on yellow background
Warning: Hot surface
Black symbol on yellow background
Warning: Safety relief valve may discharge
gas or liquid without prior warning
Black symbol on yellow background
Warning: Isolate all electrical sources of
supply before opening or removing the
cover, as lethal voltages may exist
Black symbol on yellow background
General attention symbol
Black symbol on yellow background
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On isolating the supply it may take up to
60 seconds for the capacitor voltage to fall
below 60 volts

1-4
Form 150.72-ICOM8.EN.CE (0713)
EN
Material Safety Data
Components Material PENTAFLUOROETHANE (HFC-125) DIFLUOROMETHANE (HFC-32)
CAS Number 354-33-6 75-10-5
% 50 50
Inhalation of high concentrations of vapour is harmful and may cause heart irregularities, unconsciousness,
or death. Intentional misuse or deliberate inhalation may cause death without warning. Vapour reduces
oxygen available for breathing and is heavier than air. Liquid contact can cause frostbite.
At flame temperatures, this material can decompose to hydrogen fluoride which can be lethal at much lower
concentrations.
Overexposure to the vapours by inhalation may include temporary nervous system depression with
anaesthetic effects such as dizziness, headache, confusion, incoordination, and loss of consciousness.
Higher exposures to the vapours may cause temporary alteration of the heart's electrical activity with
irregular pulse, palpitations, or inadequate circulation. Gross overexposure may be fatal. Skin contact with
the liquid may cause frostbite.
Individuals with preexisting diseases of the central nervous or cardiovascular system may have increased
susceptibility to the toxicity of increased exposures.
Carcinogenicity Information
None of the components present in this material at concentrations equal to or greater than 0.1% are listed
by IARC, NTP, OSHA or ACGIH as a carcinogen.
If inhaled, immediately remove to fresh air. Keep person calm.
If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Call a physician.
Skin Contact Flush area with lukewarm water. Do not use hot water. If frostbite has occurred, call a physician.
Eye Contact In case of contact, immediately flush eyes with plenty of water for at least 15 minutes. Call a physician.
Ingestion Do not induce vomiting. Give plenty of water in sips
Notes to Physicians
THIS MATERIAL MAY MAKE THE HEART MORE SUSCEPTIBLE TO ARRHYTHMIAS. Catecholamines
such as adrenaline, and other compounds having similar effects, should be reserved for emergencies and
then used only with special caution.
Flash Point : No flash point
Flammable Limits in Air, % by Volume:
LEL : None per ASTM E681
UEL : None per ASTM E681
Autoignition: Not determined
Cylinders may rupture under fire conditions. Decomposition may occur.
Contact of welding or soldering torch flame with high concentrations of refrigerant can result in visible
changes in the size and colour of torch flames. This flame effect will only occur in concentrations of product
well above the recommended exposure limit, therefore stop all work and ventilate to disperse refrigerant
vapours from the work area before using any open flames.
R-410A is not flammable in air at temperatures up to 100 deg C (212 deg F) at atmospheric pressure.
However, mixtures of R-410A with high concentrations of air at elevated pressure and/or temperature can
become combustible in the presence of an ignition source. R-410A can also become combustible in an
oxygen enriched environment (oxygen concentrations greater than that in air). Whether a mixture
containing R-410A and air, or R-410A in an oxygen enriched atmosphere becomes combustible depends
on the inter-relationship of 1) the temperature 2) the pressure, and 3) the proportion of oxygen in the
mixture. In general, R-410A should not be allowed to exist with air above atmospheric pressure or at high
temperatures; or in an oxygen enriched environment. For example: R-410A should NOT be mixed with air
under pressure for leak testing or other purposes.
Human Health Effects
FIRST AID MEASURES
Inhalation
FIRE FIGHTING MEASURES
Refrigerant Safety Data R410A:
COMPOSITION/INFORMATION ON INGREDIENTS
HAZARDS IDENTIFICATION
Potential Health Effects
Flammable Properties
Fire and Explosion Hazards

1-5
Form 150.72-ICOM8.EN.CE (0713)
EN
Extinguishing Media As appropriate for combustibles in area.
Fire Fighting Instructions
Cool cylinder with water spray or fog. Self-contained breathing apparatus (SCBA) is required if cylinders
rupture and contents are released under fire conditions. Water runoff should be contained and neutralized
prior to release.
NOTE: Review FIRE FIGHTING MEASURES and HANDLING (PERSONNEL)
sections before proceeding with clean-up. Use appropriate PERSONAL PROTECTIVE EQUIPMENT during
clean-up.
Accidental Release Measures
Ventilate area, especially low or enclosed places where heavy vapours might collect. Extinguish open
flames. Use self-contained breathing apparatus (SCBA) for large spills or releases. Eliminate electrical
sources.
Handling (Personnel)
Avoid breathing vapour. Avoid liquid contact with eyes and skin. Use with sufficient ventilation to keep
employee exposure below recommended limits. See Fire and Explosion Data section.
Storage Clean, dry area. Do not heat above 52 deg C (125 deg F).
Engineering Controls
Avoid breathing vapours. Avoid contact with skin or eyes. Use with sufficient ventilation to keep employee
exposure below the recommended exposure limit. Local exhaust should be used if large amounts are
released. Mechanical ventilation should be used in low or enclosed places.
Personal Protective Equipment
Impervious gloves should be used to avoid prolonged or repeated exposure. Chemical splash goggles
should be available for use as needed to prevent eye contact. Under normal manufacturing conditions, no
respiratory protection is required when using this product provided exposure is maintained at or below
occupational limits. Self-contained breathing apparatus (SCBA) is required if a large release occurs.
Applicable Exposure Limits
PENTAFLUOROETHANE (HFC-125)
PEL (OSHA) : None Established
TLV (ACGIH) : None Established
AEL * (DuPont) : 1000 ppm, 8 & 12 Hr. TWA
WEEL (AIHA) : 1000 ppm, 4900 mg/m
3
, 8 Hr. TWA
DIFLUOROMETHANE (HFC-32)
AEL * (DuPont) : 1000 ppm, 8 & 12 Hr. TWA
WEEL (AIHA) : 1000 ppm, 8 Hr. TWA
* AEL is DuPont's Acceptable Exposure Limit. Where governmentally imposed occupational exposure limits
which are lower than the AEL are in effect, such limits shall take precedence.
Boiling Point : - 60.8 F (-51.6 C) @ 1 atm
Vapour Pressure : 239.7 psia 25 C (77 F)
% Volatiles : 100 WT%
Evaporation Rate : (Cl4 = 1) Greater than 1
Solubility in Water : Not determined
Odour : Slight ethereal
Form : Liquefied gas
Colour : Clear, colourless
Specific Gravity : 1.066 @ 25 C (77 F)
Chemical Stability Material is stable. However, avoid open flames and high temperatures.
Incompatibility with Other Materials Incompatible with active metals, alkali or alkaline earth metals--powdered Al, Zn, Be, etc.
Decomposition
Decomposition products are hazardous. This material can be decomposed by high temperatures (open
flames, glowing metal surfaces, etc.) forming hydrofluoric acid and possibly carbonyl fluoride. These
materials are toxic and irritating. Contact should be avoided.
Safeguards (Personnel)
HANDLING AND STORAGE
EXPOSURE CONTROLS/PERSONAL PROTECTION
Exposure Guidelines
Refrigerant Safety Data R410A:
ACCIDENTAL RELEASE MEASURES
PHYSICAL AND CHEMICAL PROPERTIES
Physical Data
STABILITY AND REACTIVITY

1-6
Form 150.72-ICOM8.EN.CE (0713)
EN
Polymerization Polymerization will not occur.
Other Hazards
Decomposition : Decomposition products are hazardous. This material can be decomposed by high
temperatures (open flames, glowing metal surfaces, etc.) forming hydrofluoric acid, and possibly carbonyl
halides.
The blend is untested.
HFC-125
Inhalation 4-hour ALC: >709,000 ppm in rats
Single exposure to high doses caused: Lethargy. Laboured breathing. Weak cardiac sensitization, a
potentially fatal disturbance of heart rhythm caused by a heightened
sensitivity to the action of epinephrine. Lowest-Observed-Adverse-Effect-Level for cardiac sensitization:
100,000 ppm.
Repeated exposure caused: No significant toxicological effects. No-Observed-Adverse-Effect-
Level(NOAEL): 50,000 ppm
ADDITIONAL TOXICOLOGICAL EFFECTS:
No animal data are available to define the following effects of this material: carcinogenicity, reproductive
toxicity. In animal testing this material has not caused developmental toxicity. Tests have shown that this
material does not cause genetic damage in bacterial or mammalian cell cultures, or in animals. This
material has not been tested for its ability to cause permanent genetic damage in reproductive cells of
mammals (not tested for heritable genetic damage).
HFC-32
Inhalation 4 hour-ALC: > 520,000 ppm in rats
Single exposure caused: Lethargy. Spasms. Loss of mobility in the hind limbs. Other effects include weak
cardiac sensitization, a potentially fatal disturbance of heart rhythm caused by a heightened sensitivity to
the action of epinephrine. 250,000 ppm.
Repeated exposure caused pathological changes of the lungs, liver, spleen, kidneys. In more recent
studies repeated exposure caused: No significant toxicological effects.
No-Observed-Effect-Level (NOEL): 49,100 ppm.
No animal data are available to define the following effects of this material: carcinogenicity, reproductive
toxicity. Animal data show slight fetotoxicity but only at exposure levels producing other toxic effects in the
adult animal. Tests have shown that this material does not cause genetic damage in bacterial or
mammalian cell cultures, or in animals. This material has not been tested for its ability to cause permanent
genetic damage in reproductive cells of mammals (not tested for heritable genetic damage).
Waste Disposal
Comply with Federal, State, and local regulations. Reclaim by distillation or remove to a permitted waste
disposal facility.
DOT/IMO/IATA
Proper Shipping Name : Liquefied Gas, N.O.S. (Pentafluoroethane and Difluoromethane)
Hazard Class : 2.2
UN No. : 3163
Label(s) : Nonflammable Gas
Shipping Containers : Tank Cars. Cylinders. Ton Tanks
Shipping Information
TOXICOLOGICAL INFORMATION
Animal Data
DISPOSAL CONSIDERATIONS
TRANSPORTATION INFORMATION
Refrigerant Safety Data R410A: