Johnson Controls York YCIV A Series Owner's manual

R134A
YCIV STYLE A
MODELS
YCIV0157-0397, 60 HZ
(150-260 TONS)
AIR-COOLED SCREW LIQUID CHILLERS
E/V HIGH EFFICIENCY AND S/P STANDARD EFFICIENCY
AIR-COOLED SCREW LIQUID CHILLERS
INSTALLATION, OPERATION, MAINTENANCE Supersedes: 201.23-NM2 (610) Form 201.23-NM2 (315)
035-21506-101
Issue Date:
March 9, 2015

JOHNSON CONTROLS
2
FORM 201.23-NM2
ISSUE DATE: 3/9/2015
This equipment is a relatively complicated apparatus.
During rigging, installation, operation, maintenance,
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to:
heavy objects, refrigerants, 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 rigging, instal-
lation, and 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
rigging, installation, and operating/service personnel. It
is expected that these individuals possess 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 the on-product labels,
this document and any referenced materials. This in-
dividual shall also be familiar with and comply with
all applicable industry and 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 specific situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Indicates a potentially hazardous situa-
tion which will result in possible injuries
or damage to equipment if proper care is
not taken.
Identies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
External wiring, unless specied as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accor-
dance with Johnson Controls’ published specications and must be performed only by a qualied
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3
FORM 201.23-NM2
ISSUE DATE: 3/9/2015
The Control/VSD Cabinet contains lethal
high AC and DC voltages. Before per-
forming service inside the cabinet, remove
the AC supply feeding the chiller and
verify using a non-contact voltage sensor.
The DC voltage on the VSD DC Bus will
take 5 minutes to bleed off, after AC
power is removed. Always check the DC
Bus Voltage with a Voltmeter to assure
the capacitor charge has bled off before
working on the system.
NEVER short out the DC Bus to dis-
charge the lter capacitors.
NEVER place loose tools, debris, or any
objects inside the Control Panel/VSD
Cabinet.
NEVER allow the Control Panel VSD
Cabinet doors to remain open if there is
a potential for rain to enter the panel.
Keep doors closed and assure all latch-
es are engaged on each door unless the
unit is being serviced.
ALWAYS lockout the disconnect supply-
ing AC to the chiller.
The 1L Line Inductor will reach operating
temperatures of over 300° F. DO NOT
open panel doors during operation. As-
sure the inductor is cool whenever work-
ing near the inductor with power OFF.
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the John-
son Controls QuickLIT website at http://cgproducts.
johnsoncontrols.com.
It is the responsibility of rigging, lifting, and operating/
service personnel to verify the applicability of these
documents to the equipment. If there is any question
regarding the applicability of these documents, rig-
ging, lifting, and operating/service personnel should
verify whether the equipment has been modified and
if current literature is available from the owner of the
equipment prior to performing any work on the chiller.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
formation and any other changes in spelling, grammar
or formatting are not included.

JOHNSON CONTROLS
4
FORM 201.23-NM2
ISSUE DATE: 3/9/2015
MANUAL DESCRIPTION FORM NUMBER
Centrifugal Chiller Long Term Storage 50.20-NM5
Equipment Pre-Startup and Startup Checklist 201.23-CL2
Installation, Operation and Maintenance, 50hz 201.23-NM1
Unit Replacement Parts, Style A, 50 hz 201.23-RP1
Unit Replacement Parts, Style A, 60 hz 201.23-RP2
Unit Replacement Parts, Style A, 50 and 60 hz 201.23-RP3
All Products - Replacement Parts Electrical Connectors 50.20-RP1
All Products - Replacement Parts Fittings 50.20-RP2
ASSOCIATED LITERATURE
NOMENCLATURE
The model number denotes the following characteristics of the unit.
YCIV - 0187 - S - A - 46 - V A A
YORK
CHILLER
AIR COOLED
VSD DRIVEN
SCREW COMPRESSOR
MODEL NUMBER UNIT DESIGNATOR
REFRIGERANT - R134A
VOLTAGE CODE
STARTER - VSD
DESIGN SERIES
DEVELOPMENT CODE
VOLTAGE CODE
17=200-3-60
28=230-3-60
40=380-3-60
46=460-3-60
50=380/400/415-3-50
58=575-3-60
UNIT DESIGNATOR
E- High Efficiency with Standard IPLV
S- Standard Efficiency with Standard IPLV
P- Standard Efficiency with Optimized IPLV
V- High Efficiency with Optimized IPLV

JOHNSON CONTROLS 5
FORM 201.23-NM2
ISSUE DATE: 3/9/2015
TABLE OF CONTENTS
SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY ......................................................................19
Introduction.....................................................................................................................................................19
Warranty .........................................................................................................................................................19
Safety .............................................................................................................................................................19
Standards for Safety..............................................................................................................................19
Responsibility for Safety........................................................................................................................20
About this Manual...........................................................................................................................................20
Misuse of Equipment......................................................................................................................................20
Suitability for Application .......................................................................................................................20
Structural Support .................................................................................................................................20
Mechanical Strength .............................................................................................................................20
General Access .....................................................................................................................................20
Pressure Systems .................................................................................................................................21
Electrical................................................................................................................................................21
Rotating Parts........................................................................................................................................21
Sharp Edges..........................................................................................................................................21
Refrigerants and Oils.............................................................................................................................21
High Temperature and Pressure Cleaning ............................................................................................21
Emergency Shutdown ...........................................................................................................................21
SECTION 2 - PRODUCT DESCRIPTION...............................................................................................................23
Introduction.....................................................................................................................................................23
General System Description..................................................................................................................23
Compressor...........................................................................................................................................24
Evaporator.............................................................................................................................................25
Condenser.............................................................................................................................................25
Flash Tank Feed Valve/Drain Valves .....................................................................................................26
Oil Separator/Oil System.......................................................................................................................26
Relief Valves..........................................................................................................................................26
Oil Cooling.............................................................................................................................................27
Capacity Control....................................................................................................................................27
Power and Control Panel ......................................................................................................................27
Each Power Compartment Contains .....................................................................................................27
Microprocessor and VSD Controls ........................................................................................................27
Display...................................................................................................................................................27
Keypad ..................................................................................................................................................28
Unit Switch ............................................................................................................................................28
Variable Speed Drive (VSD)..................................................................................................................29
Accessories and Options................................................................................................................................ 30
Sound Reduction Options .....................................................................................................................30
Condenser Coil Protection ....................................................................................................................31
Protective Chiller Panels .......................................................................................................................31
Evaporator Options ...............................................................................................................................32
General Options ....................................................................................................................................32
Vibration Isolation..................................................................................................................................32
Complete Pin Number Description .................................................................................................................34

JOHNSON CONTROLS
6
FORM 201.23-NM2
ISSUE DATE: 3/9/2015
TABLE OF CONTENTS (CONT'D)
SECTION 3 - RIGGING, HANDLING AND STORAGE ..........................................................................................39
Lifting Weights................................................................................................................................................39
Delivery and Storage......................................................................................................................................39
Inspection .......................................................................................................................................................39
Moving the Chiller........................................................................................................................................... 40
Unit Removal from Shipping Container ..........................................................................................................40
Lifting Using Lugs...........................................................................................................................................40
Lifting Using Shackles ....................................................................................................................................40
SECTION 4 - INSTALLATION ................................................................................................................................43
Location Requirements ..................................................................................................................................43
Outdoor Installations ......................................................................................................................................43
Indoor Installations .........................................................................................................................................43
Location Clearances....................................................................................................................................... 43
Vibration Isolators........................................................................................................................................... 44
Installation .............................................................................................................................................44
Shipping Braces .............................................................................................................................................44
Chilled Liquid Piping.......................................................................................................................................44
General Requirements ..........................................................................................................................44
Water Treatment.............................................................................................................................................45
Pipework Arrangement ...................................................................................................................................46
Connection Types and Sizes..........................................................................................................................46
Cooler Connections........................................................................................................................................46
Option Flanges ......................................................................................................................................46
Refrigerant Relief Valve Piping.......................................................................................................................46
Ductwork Connection ....................................................................................................................................47
General Requirements .........................................................................................................................47
Electrical Connection...................................................................................................................................... 47
Power Wiring ..................................................................................................................................................48
Power Supply Wiring ......................................................................................................................................48
115VAC Control Supply Transformer.............................................................................................................. 48
Control Panel Wiring ......................................................................................................................................48
Volts Free Contacts ........................................................................................................................................49
Chilled Liquid Pump Starter...................................................................................................................49
Run Contact ..........................................................................................................................................49
Alarm Contacts......................................................................................................................................49
System Inputs.................................................................................................................................................49
Flow Switch ...........................................................................................................................................49
Remote Run / Stop................................................................................................................................49
Remote Print .........................................................................................................................................49
Optional Remote Setpoint Offset – Temperature...................................................................................49
Optional Remote Setpoint Offset – Current...........................................................................................49
Optional Remote Setpoint Offset – Sound Limiting...............................................................................49

JOHNSON CONTROLS 7
FORM 201.23-NM2
ISSUE DATE: 3/9/2015
TABLE OF CONTENTS (CONT'D)
SECTION 5 - COMMISSIONING ............................................................................................................................51
Preparation.....................................................................................................................................................51
Preparation – General ....................................................................................................................................51
Inspection .............................................................................................................................................51
Refrigerant Charge................................................................................................................................51
Service and Oil Line Valves................................................................................................................... 51
Compressor Oil .....................................................................................................................................51
Fans .....................................................................................................................................................51
Isolation / Protection..............................................................................................................................51
Control Panel.........................................................................................................................................51
Power Connections ...............................................................................................................................51
Grounding..............................................................................................................................................52
Water System........................................................................................................................................52
Flow Switch ...........................................................................................................................................52
Temperature Sensor(s)..........................................................................................................................52
Programmed Options ............................................................................................................................52
Programmed Settings ...........................................................................................................................52
Date and Time .......................................................................................................................................52
Start/Stop Schedule ..............................................................................................................................52
Setpoint and Remote Offset ..................................................................................................................52
First Time Start-Up ......................................................................................................................................... 52
Interlocks ...............................................................................................................................................52
Unit Switch ............................................................................................................................................53
Start-up..................................................................................................................................................53
Oil Pressure...........................................................................................................................................53
Refrigerant Flow ....................................................................................................................................53
Loading..................................................................................................................................................53
Condenser and Fan Rotation ................................................................................................................53
Suction Superheat.................................................................................................................................53
Subcooling.............................................................................................................................................53
General Operation ................................................................................................................................53
Operation in Sub-freezing Conditions ...................................................................................................54
Unit Maintenance and Shutdown in Sub-freezing Conditions .............................................................. 54

JOHNSON CONTROLS
8
FORM 201.23-NM2
ISSUE DATE: 3/9/2015
SECTION 6 - TECHNICAL DATA ...........................................................................................................................61
Water Pressure Drop Charts ..........................................................................................................................61
Glycol Correction Factors...............................................................................................................................65
Water Temperature and Flows .......................................................................................................................66
Physical Data (English - Standard Efficiency) ................................................................................................68
Physical Data (English - High Efficiency) .......................................................................................................70
Physical Data (Si - Standard Efficiency)......................................................................................................... 72
Physical Data (Si - High Efficiency)................................................................................................................74
Electrical Data ................................................................................................................................................76
2 Compressor Power Wiring Connections ............................................................................................76
3 Compressor Power Wiring Connections ............................................................................................77
Standard Efficiency 2-Compressor Units........................................................................................................78
High Efficiency 2-Compressor Units............................................................................................................... 82
Standard Efficiency 3-Compressor Units........................................................................................................86
High Efficiency 3-Compressor Units............................................................................................................... 88
Electrical Notes ..............................................................................................................................................90
Electrical Wiring Diagrams - 2 Compressor Models.......................................................................................92
Elementary Power Wiring Diagram .......................................................................................................94
Power Wiring Connection Diagram .......................................................................................................96
Control Wiring Connection Diagram......................................................................................................98
Power Elementary Wiring Diagram .....................................................................................................101
Location Label - 2 Compressor Models...............................................................................................103
Panel Layout - 2 Compressor Models .................................................................................................104
Electrical Wiring Diagrams - 3 Compressor Models.....................................................................................106
Power Elementary Diagram ................................................................................................................ 110
Control Wiring Connection Diagram.................................................................................................... 112
Power Wiring Connection Diagram ..................................................................................................... 116
Power Elementary Diagram ................................................................................................................120
Location Label - 3 Compressor Models...............................................................................................122
Panel Layout - 3 Compressor Models .................................................................................................123
Dimensions - 2 and 3 Compressor SI ..........................................................................................................124
Technical Data - Clearances ........................................................................................................................144
Isolator Selection and Mounting ..........................................................................................................145
Isolator Information for Units Shipped on or After June 15, 2008.................................................................145
One Inch Deection Spring Isolators Cross-Reference.......................................................................162
One Inch Deection Spring Isolators Installation Instructions .............................................................163
Durulene Isolator Cross-Reference..................................................................................................... 164
Installation of Durulene Vibration Isolators..........................................................................................165
Seismic Isolator Cross-reference ........................................................................................................166
Seismic Isolator Installation and Adjustment .......................................................................................167
Isolator Information for Units Shipped Before June 15, 2008.......................................................................168
SLRS Seismic Isolator Specications .................................................................................................168
SLRS Seismic Isolator Installation and Adjustment.............................................................................169
To Install and Adjust Mounts................................................................................................................169
ND-X Neoprene Isolator Specications............................................................................................... 170
Installation of Neoprene Mounts..........................................................................................................170
CIP 1" Deection Restrained Mounting Specications........................................................................171
Installation of 1" Deection Mounts .....................................................................................................172
Refrigerant Flow Diagram ............................................................................................................................173
Process and Instrumentation Diagram .........................................................................................................174
TABLE OF CONTENTS (CONT'D)

JOHNSON CONTROLS 9
FORM 201.23-NM2
ISSUE DATE: 3/9/2015
Component Locations ..................................................................................................................................175
Glycol System Components .........................................................................................................................196
Compressor Components ............................................................................................................................198
Chiller Electronic Components .....................................................................................................................199
Keypad ................................................................................................................................................199
Keypad Data Entry Mode ....................................................................................................................200
Display.................................................................................................................................................200
Relay Output Boards ...........................................................................................................................201
VSD (Variable Speed Drive) ...............................................................................................................202
AC to DC Rectier ...............................................................................................................................202
SCR Trigger Board ..............................................................................................................................202
DC Link Filter.......................................................................................................................................202
1L Line Inductor ..................................................................................................................................203
DC to AC Inverter ................................................................................................................................203
Laminated Bus Structure.....................................................................................................................204
VSD Logic Board.................................................................................................................................204
Control Panel to VSD Communications ..............................................................................................205
IGBT Gate Driver Boards ....................................................................................................................205
Current Transformers ..........................................................................................................................206
DV/DT Output Suppression Network...................................................................................................206
Flash Tank Feed and Drain Valve Controller....................................................................................... 206
DC Bus Voltage Isolation Board ..........................................................................................................207
Chiller Circuit Breaker .........................................................................................................................207
Chiller Configuration Jumpers ......................................................................................................................207
Number of Compressors Conguration Jumper.................................................................................. 207
VSD Logic to Chiller Microprocessor Board RS-485 Communication Configuration Jumpers.....................208
Maximum VSD Frequency/Model designator...............................................................................................208
SECTION 7 - OPERATION ...................................................................................................................................209
Operating Controls .......................................................................................................................................209
Anti-recycle Timer................................................................................................................................209
Evaporator Pump Control....................................................................................................................209
Evaporator Heater Control ..................................................................................................................209
Pumpdown Control..............................................................................................................................209
Compressor Heater Control ................................................................................................................209
Alarms .................................................................................................................................................209
Chiller Run Contact .............................................................................................................................209
Unit Switch ..........................................................................................................................................210
Basic Operating Sequence........................................................................................................................... 210
Start Sequence and Loading...............................................................................................................210
Number of Compressors to Start.................................................................................................................. 211
General................................................................................................................................................ 211
Standard IPLV ..................................................................................................................................... 211
Optional Optimized High IPLV............................................................................................................. 211
Minimum VSD Compressor Start / Run Frequency......................................................................................212
Minimum VSD Start Frequency...........................................................................................................212
Minimum VSD Run Frequency............................................................................................................ 212
Acceleration / Deceleration Rate when Starting / Stopping Compressors ................................................... 213
VSD Acceleration and Deceleration Rates..........................................................................................213
TABLE OF CONTENTS (CONT'D)

JOHNSON CONTROLS
10
FORM 201.23-NM2
ISSUE DATE: 3/9/2015
Standard IPLV Capacity Control...................................................................................................................213
Fuzzy Logic Control.............................................................................................................................214
Hot Water Starts..................................................................................................................................215
Lag Compressor Operation in Load Limiting....................................................................................... 215
Optional High IPLV Capacity Control ........................................................................................................... 215
Fuzzy Logic Control.............................................................................................................................217
Hot Water Starts..................................................................................................................................218
Load Limiting Control ...................................................................................................................................218
Load Limiting ......................................................................................................................................218
Motor Current Load Limiting/Unloading...............................................................................................218
Discharge Pressure Load Limiting/Unloading .....................................................................................218
Suction Pressure Load Limiting/Unloading .........................................................................................219
VSD Internal Ambient Temperature Load Limiting ..............................................................................219
VSD Baseplate Temperature Load Limiting ........................................................................................219
Flash Tank Drain and Feed Valve Controller ................................................................................................220
Valve Controller and Control Algorithm Operation...............................................................................220
MOP Setpoint Control for Hot Water Starts.........................................................................................221
Moderate To High Ambient MOP Setpoint Control. .............................................................................221
Low Ambient MOP Setpoint Control....................................................................................................221
Actual MOP Setpoint ...........................................................................................................................221
Valve Controller LED’s.........................................................................................................................222
Economizer Control......................................................................................................................................223
Condenser Fan Control ................................................................................................................................224
Standard IPLV Fan Control ................................................................................................................225
Optimized IPLV Fan Control ...............................................................................................................225
High VSD Cabinet Ambient Temperature Fan Operation ....................................................................225
VSD Temperature Control, Operation of the Coolant Pump, and VSD Cabinet Cooling Fans.....................225
Remote Temperature Reset Control.............................................................................................................226
Temperature Reset Control .................................................................................................................226
Remote ISN Setpoint Control ..............................................................................................................226
Remote Temperature Reset ................................................................................................................226
Local Current Limit Control..................................................................................................................227
Pulldown Current Limit Setpoint ..........................................................................................................227
Remote Current Limit Reset Control ............................................................................................................227
Remote ISN Current Limit Setpoint .....................................................................................................228
Remote Current Limit Reset................................................................................................................228
Sound Limit Control......................................................................................................................................229
Sound Limiting and Local Sound Limit Setpoint..................................................................................229
ISN Sound Limit Setpoint ....................................................................................................................229
Remote Sound Limit............................................................................................................................229
TABLE OF CONTENTS (CONT'D)