Johnson Controls YORK Tempo YLAA Series Owner's manual

YLAA0070 - YLAA0175
AIR-COOLED SCROLL CHILLERS
WITH MICROCHANNEL CONDENSER COILS
STYLE A (60 Hz)
70 - 175 TON
246-613 KW
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Supersedes 150.72-NM1 (110) Form 150.72-NM1 (1020)
R-410A
035-21911-000
Interim
Products are produced at a
f a c i l i t y w h o s e q u a l i t y -
management systems are
ISO9001 certified.

JOHNSON CONTROLS
2
FORM 150.72-NM1 (1020)
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, materials under pressure, rotating components,
and both high and low voltage. Each of these items
has the potential, if misused or handled improperly, to
cause bodily injury or death. It is the obligation and
responsibility of operating/service personnel to identify
and recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to
comply with any of these requirements could result in
serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
individual possesses independent training that will
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 this document and any referenced
materials. This individual shall also be familiar with and
comply with all applicable 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 areas of potential hazard:
CAUTION identies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instruction will be given, together with
a brief explanation.
NOTE is used to highlight additional
information which may be helpful to
you.
DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or serious
injury.
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or seri-
ous injury.
External wiring, unless specied as an optional connection in the manufacturer’s product
line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the panel. NO external wiring is al-
lowed to be run through the micro panel. All wiring must be in accordance with Johnson
Controls published specications and must be performed ONLY by qualied Johnson Controls
personnel. Johnson Controls will not be responsible for damages/problems resulting from
improper connections to the controls or application of improper control signals. Failure to
follow this will void the manufacturer’s warranty and cause serious damage to property or
injury to persons.

FORM 150.72-NM1 (1020)
3
JOHNSON CONTROLS
In complying with Johnson Controls policy for
continuous product improvement, the information
contained in this document is subject to change without
notice. While Johnson Controls makes no commitment
to update or provide current information automatically
to the manual owner, that information, if applicable, can
be obtained by contacting the nearest Johnson Controls
Engineered Systems Service oce or accessing the
Johnson Controls Knowledge Exchange website at
https://docs.johnsoncontrols.com/chillers/
CHANGEABILITY OF THIS DOCUMENT
It is the responsibility of operating/service personnel
to verify the applicability of these documents to the
equipment in question. If there is any question in
the mind of operating/service personnel as to the
applicability of these documents, then prior to working
on the equipment, they should verify with the owner
whether the equipment has been modied and if current
literature is available.
REVISION NOTES
Revisions made to this document are indicated in the following table. These revisions are to technical information,
and any other changes in spelling, grammar, or formatting are not included.
AFFECTED PAGES DESCRIPTION
3 Conditioned Based Maintenance program information added
CONDITIONED BASED MAINTENANCE
Traditional chiller maintenance is based upon assumed
and generalized conditions. In lieu of the traditional
maintenance program, a Johnson Controls YORK
Conditioned Based Maintenance (CBM) program can
be substituted. This CBM service plan is built around
the specific needs for the chiller, operating conditions,
and annualized impact realized by the chiller. Your lo-
cal Johnson Controls Branch can propose a customized
Planned Service Agreement that leverages real time
and historical data, delivering performance reporting,
corrective actions required and data enabled guidance
for optimal operation and lifecycle assurance. The pro-
gram will include fault detection diagnostics, operation
code statistics, performance based algorithms and ad-
vance rules based rationale delivered by the Johnson
Controls Connected Equipment Portal.

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JOHNSON CONTROLS
TABLE OF CONTENTS
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY ...........................................................15
INTRODUCTION........................................................................................................................................15
WARRANTY ...............................................................................................................................................15
SAFETY AND QUALITY............................................................................................................................15
Standards for Safety and Quality.......................................................................................................15
Responsibility for Safety ....................................................................................................................16
ABOUT THIS MANUAL.............................................................................................................................16
MISUSE OF EQUIPMENT.........................................................................................................................16
Suitability for Application ...................................................................................................................16
Structural Support...............................................................................................................................16
Mechanical Strength ..........................................................................................................................16
General Access....................................................................................................................................16
Pressure Systems ...............................................................................................................................17
Electrical...............................................................................................................................................17
Rotating Parts ......................................................................................................................................17
Sharp Edges.........................................................................................................................................17
Refrigerants and Oils ..........................................................................................................................17
High Temperature and Pressure Cleaning ........................................................................................17
Emergency Shutdown.........................................................................................................................17
SECTION 2 – PRODUCT DESCRIPTION ......................................................................................................19
INTRODUCTION........................................................................................................................................19
GENERAL SYSTEM DESCRIPTION .......................................................................................................19
Compressors .......................................................................................................................................19
Cooler (Evaporator).............................................................................................................................19
Condenser............................................................................................................................................20
Millennium Control Center..................................................................................................................20
COMMUNICATIONS..................................................................................................................................21
HIGH AMBIENT KIT ..................................................................................................................................21
BUILDING AUTOMATION SYSTEM INTERFACE .................................................................................21
POWER PANEL .........................................................................................................................................21
ACCESSORIES AND OPTIONS ..............................................................................................................22
Power Options .....................................................................................................................................22
Control Options ...................................................................................................................................22
Compressor, Piping, Evaporator Options .........................................................................................22
Condenser and Cabinet Options........................................................................................................23
UNIT COMPONENTS ...............................................................................................................................25
CONTROL / POWER PANEL COMPONENTS .......................................................................................27
PRODUCT IDENTIFICATION NUMBER (PIN)........................................................................................29
BASIC UNIT NOMENCLATURE ..............................................................................................................29
PROCESS AND INSTRUMENTATION DIAGRAM .................................................................................35

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FORM 150.72-NM1 (1020)
TABLE OF CONTENTS (CONT’D)
SECTION 3 – HANDLING AND STORAGE...................................................................................................37
DELIVERY AND STORAGE......................................................................................................................37
INSPECTION..............................................................................................................................................37
MOVING THE CHILLER............................................................................................................................37
Lifting Weights.....................................................................................................................................37
Rigging Instructions............................................................................................................................38
SECTION 4 – INSTALLATION ........................................................................................................................39
INSTALLATION CHECKLIST...................................................................................................................39
HANDLING .................................................................................................................................................39
INSPECTION..............................................................................................................................................39
LOCATION AND CLEARANCES .............................................................................................................39
Foundation ...........................................................................................................................................39
Ground Level Locations .....................................................................................................................40
Rooftop Locations...............................................................................................................................40
Noise Sensitive Locations ..................................................................................................................40
SPRING ISOLATORS (OPTIONAL).........................................................................................................40
COMPRESSOR MOUNTING ....................................................................................................................40
REMOTE COOLER OPTION ....................................................................................................................40
CHILLED LIQUID PIPING.........................................................................................................................40
PIPEWORK ARRANGEMENT..................................................................................................................41
DUCT WORK CONNECTION ..................................................................................................................42
General Requirements .......................................................................................................................42
WIRING.......................................................................................................................................................42
Evaporator Pump Start Contacts .......................................................................................................42
System Run Contacts .........................................................................................................................42
Alarm Status Contacts ........................................................................................................................43
Remote Start/Stop Contacts...............................................................................................................43
Remote Emergency Cuto󰀨 .................................................................................................................43
Remote Temp Reset Input ..................................................................................................................43
Load Limit Input...................................................................................................................................43
Flow Switch Input ................................................................................................................................43
COMPRESSOR HEATERS .......................................................................................................................43
RELIEF VALVES........................................................................................................................................43
HIGH PRESSURE CUTOUT .....................................................................................................................43
SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED DISCONNECT
SWITCH OR CIRCUIT BREAKER ...........................................................................................................44
USER CONTROL WIRING INPUTS.........................................................................................................45
USER CONTROL WIRING OUTPUTS.....................................................................................................46

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JOHNSON CONTROLS
SECTION 5 – TECHNICAL DATA...................................................................................................................47
OPERATIONAL LIMITATIONS (ENGLISH).............................................................................................47
Temperatures and Flows ....................................................................................................................47
Voltage Limitations..............................................................................................................................47
HEAT EXCHANGER FLOW, GPM ...........................................................................................................48
Ethylene & Propylene Glycol Correction Factors ............................................................................48
PHYSICAL DATA (ENGLISH)...................................................................................................................50
ELECTRICAL DATA ..................................................................................................................................52
ELECTRICAL NOTES ...............................................................................................................................53
ELECTRICAL DATA W/O PUMPS ...........................................................................................................54
Wiring Lugs..........................................................................................................................................58
ELECTRICAL DATA W/ PUMPS ..............................................................................................................60
ELECTRICAL NOTES AND LEGEND .....................................................................................................68
WIRING DIAGRAMS .................................................................................................................................72
Elementary Wiring Diagrams..............................................................................................................72
Connection Diagrams .........................................................................................................................80
DIMENSIONS (ENGLISH).........................................................................................................................96
TECHNICAL DATA – CLEARANCES ....................................................................................................101
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS ...............................................102
General ...............................................................................................................................................102
Sample Isolator Location Drawing...................................................................................................102
Isolator Locations..............................................................................................................................103
ISOLATOR INFORMATION (For units shipped on or after June 15, 2008) .......................................106
One Inch Deection Spring Isolator Cross-reference....................................................................106
One Inch Deection Spring Isolators Installation Instructions.....................................................107
Seismic Isolator Cross-reference ....................................................................................................108
SEISMIC ISOLATOR INSTALLATION AND ADJUSTMENT..............................................................109
Duralene Isolator Cross-reference...................................................................................................110
Installation of Durulene Vibration Isolators .................................................................................... 111
ISOLATOR INFORMATION (For units shipped before June 15, 2008) .................................................. 112
SLRS Seismic Isolator Specications .............................................................................................112
SLRS Seismic Isolator Installation and Adjustment ......................................................................113
One Inch Deection Spring Isolator Cross-reference....................................................................114
Installation of 1” Deection Mounts ................................................................................................115
Neoprene Isolator Cross-reference .................................................................................................116
Two Inch Deection, Seismic Spring Isolator Cross-reference - SLRS .......................................117
SLRS Seismic Isolator Installation and Adjustment ......................................................................118
TABLE OF CONTENTS (CONT’D)

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FORM 150.72-NM1 (1020)
SECTION 6 – COMMISSIONING ..................................................................................................................119
PREPARATION – POWER OFF .............................................................................................................119
Inspection ..........................................................................................................................................119
Refrigerant Charge ............................................................................................................................119
Service and Oil Line Valves ..............................................................................................................119
Compressor Oil..................................................................................................................................119
Fans ...................................................................................................................................................119
Isolation / Protection .........................................................................................................................119
Control Panel .....................................................................................................................................119
Power Connections ........................................................................................................................... 119
Grounding ..........................................................................................................................................119
Supply Voltage...................................................................................................................................119
PREPARATION – POWER ON ...............................................................................................................120
Switch Settings..................................................................................................................................120
Compressor Heaters .........................................................................................................................120
Water System .....................................................................................................................................120
Flow Switch........................................................................................................................................120
Temperature Sensor(s) .....................................................................................................................120
EQUIPMENT PRE-STARTUP AND STARTUP CHECKLIST...............................................................121
Pre-Startup .........................................................................................................................................121
Startup ................................................................................................................................................121
SETPOINTS ENTRY LIST.......................................................................................................................122
CHECKING SUPERHEAT AND SUBCOOLING ...................................................................................123
LEAK CHECKING....................................................................................................................................123
UNIT OPERATING SEQUENCE.............................................................................................................124
SECTION 7 – UNIT CONTROLS...................................................................................................................125
INTRODUCTION......................................................................................................................................125
IPU II and I/O Boards .........................................................................................................................125
Unit Switch .........................................................................................................................................126
Display................................................................................................................................................126
Keypad................................................................................................................................................126
Battery Back-up .................................................................................................................................126
Transformer .......................................................................................................................................126
Programming # of Compressors......................................................................................................126
STATUS KEY...........................................................................................................................................127
Unit Status..........................................................................................................................................127
General Status Messages .................................................................................................................127
Fault Safety Status Messages ..........................................................................................................129
System Safeties .................................................................................................................................129
Unit Safeties.......................................................................................................................................131
Unit Warning ......................................................................................................................................131
Status Key Messages........................................................................................................................132
TABLE OF CONTENTS (CONT’D)

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9
JOHNSON CONTROLS
DISPLAY/PRINT KEYS ...........................................................................................................................133
Oper Data Key....................................................................................................................................133
Oper Data Quick Reference List.......................................................................................................136
Print Key.............................................................................................................................................137
Operating Data Printout ....................................................................................................................137
History Printout .................................................................................................................................138
History Displays ................................................................................................................................138
Software Version ...............................................................................................................................140
ENTRY KEYS ...........................................................................................................................................141
Up and Down Arrow Keys.................................................................................................................141
Enter/Adv Key ....................................................................................................................................141
SETPOINTS KEYS ..................................................................................................................................142
Cooling Setpoints..............................................................................................................................142
Leaving Chilled Liquid Control ........................................................................................................142
Return Chilled Liquid Control ..........................................................................................................143
Remote Setpoint Control ..................................................................................................................143
Schedule/Advance Day Key .............................................................................................................143
PROGRAM KEY.......................................................................................................................................145
PROGRAM KEY LIMITS AND DEFAULT..............................................................................................147
SETPOINTS QUICK REFERENCE LIST...............................................................................................148
UNIT KEYS ..............................................................................................................................................149
Options Key .......................................................................................................................................149
CLOCK......................................................................................................................................................153
UNIT KEYS OPTIONS PROGRAMMING QUICK REFERENCE LIST ...............................................154
SECTION 8 – UNIT OPERATION .................................................................................................................155
CAPACITY CONTROL ............................................................................................................................155
SUCTION PRESSURE LIMIT CONTROLS...........................................................................................155
DISCHARGE PRESSURE LIMIT CONTROLS .....................................................................................155
LEAVING CHILLED LIQUID CONTROL ...............................................................................................155
LEAVING CHILLED LIQUID CONTROLOVERRIDE TO REDUCE CYCLING ..................................156
LEAVING CHILLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING ..............156
RETURN CHILLED LIQUID CONTROL ................................................................................................157
RETURN CHILLLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING.............158
ANTI-RECYCLE TIMER ..........................................................................................................................159
ANTI-COINCIDENCE TIMER..................................................................................................................159
EVAPORATOR PUMP CONTROL AND YORK HYDRO KIT PUMP CONTROL ...............................159
EVAPORATOR HEATER CONTROL .....................................................................................................159
PUMPDOWN CONTROL.........................................................................................................................159
STANDARD CONDENSER FAN CONTROL.........................................................................................159
LOAD LIMITING.......................................................................................................................................163
COMPRESSOR RUN STATUS ...............................................................................................................163
ALARM STATUS......................................................................................................................................163
BAS/EMS TEMPERATURE RESET USINGA VOLTAGE OR CURRENT SIGNAL...........................164
TABLE OF CONTENTS (CONT’D)

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FORM 150.72-NM1 (1020)
SECTION 9 – SERVICE AND TROUBLESHOOTING ................................................................................165
CLEARING HISTORY BUFFERS...........................................................................................................165
SERVICE MODE ......................................................................................................................................165
SERVICE MODE – OUTPUTS ................................................................................................................165
SERVICE MODE – CHILLER CONFIGURATION.................................................................................166
SERVICE MODE – ANALOG AND DIGITAL INPUTS..........................................................................166
CONTROL INPUTS/OUTPUTS ..............................................................................................................167
MICROBOARD LAYOUT ........................................................................................................................168
CHECKING INPUTS AND OUTPUTS....................................................................................................169
Digital Inputs......................................................................................................................................169
Analog Inputs – Temperature ...........................................................................................................169
Outside Air Sensor ............................................................................................................................169
Liquid & Refrigerant Sensor Test Points ........................................................................................170
Analog Inputs – Pressure .................................................................................................................171
Digital Outputs...................................................................................................................................172
OPTIONAL PRINTER INSTALLATION .................................................................................................173
Parts....................................................................................................................................................173
Assembly and Wiring ........................................................................................................................173
Obtaining a Printout ..........................................................................................................................173
TROUBLESHOOTING.............................................................................................................................174
SECTION 10 – MAINTENANCE....................................................................................................................177
IMPORTANT.............................................................................................................................................177
COMPRESSORS .....................................................................................................................................177
Oil Level Check..................................................................................................................................177
Oil Analysis ........................................................................................................................................177
CONDENSER FAN MOTORS.................................................................................................................177
CONDENSER COILS ..............................................................................................................................177
OPERATING PARAMETERS..................................................................................................................177
ON-BOARD BATTERY BACK-UP..........................................................................................................177
EVAPORATOR HEATER.........................................................................................................................177
OVERALL UNIT INSPECTION...............................................................................................................177
BACNET, MODBUS AND YORKTALK 2 COMMUNICATIONS...........................................................178
BACnet and Modbus Communications ...........................................................................................181
Communications Data Map Notes ...................................................................................................181
Yorktalk 2 Communications .............................................................................................................185
TEMPERATURE CONVERSION CHART..............................................................................................189
R410A PRESSURE TEMPERATURE CHART ......................................................................................190
TABLE OF CONTENTS (CONT’D)

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JOHNSON CONTROLS
LIST OF FIGURES
FIG. 1 – UNIT COMPONENTS FRONT..................................................................................................25
FIG. 2 – UNIT COMPONENTS SIDE......................................................................................................26
FIG. 3 – POWER PANEL COMPONENTS.............................................................................................27
FIG. 4 – POWER PANEL / CONTROL COMPONENTS .......................................................................28
FIG. 5 – REFRIGERANT FLOW DIAGRAM ..........................................................................................34
FIG. 6 – PROCESS AND INSTRUMENTATION DIAGRAM.................................................................35
FIG. 7 – UNIT RIGGING/LIFTING .........................................................................................................38
FIG. 8 – CHILLED LIQUID SYSTEM......................................................................................................41
FIG. 9 – SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED
DISCONNECT SWITCH OR CIRCUIT BREAKER .................................................................44
FIG. 10 – CONTROL WIRING INPUTS....................................................................................................45
FIG. 11 – CONTROL WIRING OUTPUTS ................................................................................................46
FIG. 12 – ELEMENTARY WIRING DIAGRAM, SHT 1 ............................................................................72
FIG. 13 – ELEMENTARY WIRING DIAGRAM, SHT 2 ............................................................................74
FIG. 14 – ELEMENTARY WIRING DIAGRAM, SHT 3 ............................................................................76
FIG. 15 – ELEMENTARY WIRING DIAGRAM, SHT 4 ............................................................................78
FIG. 16 – CONNECTION DIAGRAM, SHT 1............................................................................................80
FIG. 17 – CONNECTION DIAGRAM, SHT 2............................................................................................82
FIG. 18 – CONNECTION DIAGRAM, SHT 3............................................................................................84
FIG. 19 – CONNECTION DIAGRAM, SHT 6............................................................................................86
FIG. 20 – CONNECTION DIAGRAM, SHT 7............................................................................................88
FIG. 21 – DUAL PUMP WIRING ...............................................................................................................90
FIG. 22 – WIRING.......................................................................................................................................92
FIG. 23 – WIRING DIAGRAM, SINGLE POINT WIRING OPTIONS .....................................................94
FIG. 24 – LAYOUT - POWER BLOCKS AND TRANSFORMERS .........................................................95
FIG. 25 – UNIT CLEARANCES – ALL MODELS ..................................................................................101
FIG. 26 – LEAVING WATER TEMPERATURECONTROL EXAMPLE ................................................155
FIG. 27 – SETPOINT ADJUST................................................................................................................156
FIG. 28 – CONDENSER FAN LOCATIONSWIRING DIAGRAMS .......................................................160
FIG. 29 – MICROBOARD LAYOUT ........................................................................................................168
FIG. 30 – I/O BOARD RELAY CONTACT ARCHITECTURE ...............................................................172
FIG. 31 – PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS ..........................................173
FIG. 32 - MICRO PANEL CONNECTIONS ............................................................................................179

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LIST OF TABLES
TABLE 1 – TEMPERATURES AND FLOWS .........................................................................................47
TABLE 2 – VOLTAGE LIMITATIONS .....................................................................................................47
TABLE 3 – ETHYLENE AND PROPYLENE GLYCOL CORRECTION FACTORS ............................48
TABLE 4 – PHYSICAL DATA (ENGLISH) .............................................................................................50
TABLE 5 – MICRO PANEL POWER SUPPLY.......................................................................................52
TABLE 6 – VOLTAGE RANGE ...............................................................................................................52
TABLE 7 – SETPOINTS ENTRY LIST .................................................................................................122
TABLE 8 – STATUS KEY MESSAGES QUICK REFERENCE LIST .................................................132
TABLE 9 – OPERATION DATA.............................................................................................................136
TABLE 10 – COOLING SETPOINTS, PROGRAMMABLE LIMITS AND DEFAULTS .......................144
TABLE 11 – PROGRAM KEY LIMITS AND DEFAULT.........................................................................147
TABLE 12 – SETPOINTS QUICK REFERENCE LIST .........................................................................148
TABLE 13 – UNIT KEYS OPTIONS PROGRAMMING QUICK REFERENCE LIST..........................154
TABLE 14 – SAMPLE COMPRESSOR STAGING FOR RETURN WATER CONTROL....................157
TABLE 15 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS) .............158
TABLE 16 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS) .............158
TABLE 17 – YLAA STANDARD CONDENSER FAN CONTROL USING DISCHARGE
PRESSURE ONLY (2, 3, OR 4 FANS PER SYSTEM)......................................................161
TABLE 18 – YLAA STANDARD CONDENSER FAN CONTROL USING DISCHARGE
PRESSURE ONLY (5 OR 6 FANS PER SYSTEM)...........................................................162
TABLE 19 – COMPRESSOR OPERATION – LOAD LIMITING...........................................................163
TABLE 20 – I/O DIGITAL INPUTS..........................................................................................................167
TABLE 21 – I/O DIGITAL OUTPUTS......................................................................................................167
TABLE 22 – I/O ANALOG INPUTS ........................................................................................................167
TABLE 23 – I/O ANALOG OUTPUTS ....................................................................................................167
TABLE 24 – OUTDOOR AIR SENSOR ..................................................................................................169
TABLE 25 – ENTERING/LEAVING CHILLED LIQUID TEMP. SENSOR,
TEMPERATURE/VOLTAGE CORRELATION ...................................................................170
TABLE 26 – PRESSURE TRANSDUCERS...........................................................................................171
TABLE 27 – TROUBLESHOOTING .......................................................................................................174
TABLE 28 – MINIMUM, MAXIMUM AND DEFAULT VALUES.............................................................179
TABLE 29 – VALUES REQUIRED FOR BAS COMMUNICATION......................................................180
TABLE 30 – REAL TIME ERROR NUMBERS.......................................................................................180
TABLE 31 - BACNET AND MODBUS COMMUNICATIONS DATA MAP ...........................................182
TABLE 32 - YORKTALK 2 COMMUNICATIONS DATA MAP ..............................................................186

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JOHNSON CONTROLS
1
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY
INTRODUCTION
YORK YLAA0070 - 0175 (70 -175 ton, 246 - 613kW)
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 specied
in this manual.
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 must
only be performed by suitably trained and qualied
personnel.
The manufacturer will not be liable for any injury or
damage caused by incorrect installation, 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, or 12
months from date of shipment, whichever occurs rst,
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
specied.
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cation plate.
The unit warranty will be void if any modication to the
unit is carried out without prior written approval from
Johnson Controls.
For warranty purposes, the following conditions must
be satised:
• The initial start of the unit must be carried out by
trained personnel from an Authorized Johnson
Controls Service Center (see Commissioning
Page 119).
• Only genuine YORK approved spare parts, oils,
coolants, and refrigerants must be used.
• All the scheduled maintenance operations detailed
in this manual must be performed at the specied
times by suitably trained and qualied personnel
(see Maintenance Section, Page 177).
• Failure to satisfy any of these conditions will
automatically void the warranty (see Warranty
Policy).
SAFETY AND QUALITY
Standards for Safety and Quality
YLAA chillers are designed and built within an ISO
9002 accredited design and manufacturing organization.
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 - Positive Displacement
Compressors and Air Cooled Rotary Screw Water
Chilling Packages.
• ASHRAE 90.1- Energy Eciency compliance.
• 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.

JOHNSON CONTROLS
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FORM 150.72-NM1 (1020)
General Chiller Introduction & Safety
In addition, the chillers conform to Underwriters
Laboratories (U.L.) for construction of chillers and
provide U.L./cU.L. Listing Label.
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.
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
explanation and the possible result of ignoring the
instruction.
A CAUTION identies a hazard which could lead to
damage to the machine, damage to other equipment
and/or environmental pollution. Usually an instruction
will be given, together with a brief explanation 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 those specied
in these instructions. Any use of the 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
parameters specied in this manual.
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
to suitably qualied persons who are familiar with the
potential hazards and precautions necessary for safe
operation and maintenance of equipment containing
high temperatures, pressures and voltages.

FORM 150.72-NM1 (1020)
17
JOHNSON CONTROLS
1
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 qualied
personnel.
Electrical
The unit must be grounded. No installation or
maintenance work should be attempted on the electrical
equipment without rst switching power OFF, isolating
and locking-off the power supply. Servicing and
maintenance on live equipment must only be performed
by suitably trained and qualied 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 tted at all times and not removed
unless the power supply has been isolated. If ductwork is
to be tted, requiring the wire fan guards to be removed,
alternative safety measures must be taken to protect
against the risk of injury from rotating fans.
Sharp Edges
The ns 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
nontoxic, non-ammable 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
example, does pose a risk of asphyxiation in conned or
enclosed spaces and attention should be 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
In case of emergency, the control panel is tted with
a Unit Switch to stop the unit in an emergency. When
operated, it removes the low voltage 120 VAC electrical
supply from the inverter system, thus shutting down
the unit.

JOHNSON CONTROLS
18
FORM 150.72-NM1 (1020)
THIS PAGE INTENTIONALLY LEFT BLANK

FORM 150.72-NM1 (1020)
19
JOHNSON CONTROLS
2
SECTION 2 – PRODUCT DESCRIPTION
INTRODUCTION
YORK YLAA 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 complete
packaged unit includes hermetic scroll compressors,
a liquid cooler, air cooled condenser, a charge of Zero
Ozone Depletion Potential Refrigerant R-410A and
a weather resistant microprocessor control center, all
mounted on a pressed steel base.
The units are completely assembled with all
interconnecting refrigerant piping and internal wiring,
ready for eld installation.
Prior to delivery, the packaged unit is pressure-tested,
evacuated, and fully charged with Refrigerant-R410A
and oil. After assembly, a complete operational test is
performed with water owing 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”. Units are designed in accordance with NFPA 70
(National Electric Code), ASHRAE/ANSI 15 Safety
code for mechanical refrigeration, ASME, and rated in
accordance with ARI Standard 550/590.
GENERAL SYSTEM DESCRIPTION
Compressors
The chiller has suction-gas cooled, hermetic, scroll
compressors. The YLAA 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.
Cooler (Evaporator)
The cooler is a direct expansion type with refrigerant
inside high eciency copper tubes. The liquid owing
through the cooler is forced over the tubes by water
baes.
The Water baes are constructed of brass to resist
corrosion. The removable heads allow access to the
internally enhanced, seamless copper tubes. Vent and
drain connections are included.
Water inlet and outlet connections are grooved for
compatibility with eld supplied ANSI/AWWA C-606
couplings.
The cooler is equipped with a heater controlled by
a separate thermostat. The heater provides freeze
protection for the cooler down to -20º F (-29º C) ambient.
The cooler is covered with ¾” exible, closed cell, foam
insulation (K = 0.25).
GS560418.JPG

JOHNSON CONTROLS
20
FORM 150.72-NM1 (1020)
Product Description
The evaporator is constructed, tested and stamped in
accordance with applicable sections of ASME pressure
vessel code for minimum 450 PSIG (3103 kPa)
refrigerant side design working pressure and 150 PSIG
(1034 kPa) water side design working pressure
A strainer with a mesh size between .5 and 1.5 mm (40
mesh) is recommended upstream of the heat exchanger
to prevent clogging from water system debris.
Condenser
Coils
Condenser coils are Microchannel type and made of
a single material to avoid galvanic corrosion due to
dissimilar metals. Coils and headers are brazed as one
piece. Integral sub cooling is included. The design
working pressure of the coil is 650 PSIG (45 bar).
Low Sound Fans
The condenser fans are composed of corrosion resistant
aluminum hub and glass-ber reinforced polypropylene
composite blades molded into a low noise airfoil section.
They are designed for maximum eciency and are
statically and dynamically balanced for vibration free
operation. They are directly driven by independent
motors, and positioned for vertical air discharge. The
fan guards are constructed of heavy gauge, rust resistant,
coated steel. All blades are statically and dynamically
balanced for vibration free operation.
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.
Ambient Kit (High)
Required if units are to operate when the ambient
temperature is above 115°F (46°C). Includes discharge
pressure transducers.
Millennium Control Center
All controls are contained in a NEMA 3R/12 cabinet
with hinged outer door and includes Liquid Crystal
Display with Light Emitting Diode backlighting for
outdoor viewing:
• Two display lines
• Twenty characters per line
Display/Print
Color coded 12-button non-tactile keypad with sections
for display and 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
This section is used 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
This section is used to:
• Set time
• Set unit options