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.

JOHNSON CONTROLS
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THIS PAGE INTENTIONALLY LEFT BLANK

FORM 150.72-NM1 (1020)
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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

FORM 150.72-NM1 (1020)
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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)

JOHNSON CONTROLS
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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)

FORM 150.72-NM1 (1020)
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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)

JOHNSON CONTROLS
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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)