York YCAV0157-0267 Owner's manual

R134a
YCAV STYLE A
MODELS YCAV0157-0267, 60 HZ
(150-260 TONS)
E/V HIGH EFFICIENCY AND S/P STANDARD EFFICIENCY
LD10477
AIR-COOLED SCREW
LIQUID CHILLERS
INSTALLATION, OPERATION, MAINTENANCE Supersedes 201.21-NM1 (315) Form 201.21-NM1 (616)
Issue Date:
June 30, 2016
035-20552-000

2JOHNSON CONTROLS
FORM 201.21-NM1 (616)
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.

3
JOHNSON CONTROLS
FORM 201.21-NM1 (616)
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.

4JOHNSON CONTROLS
FORM 201.21-NM1 (616)
The Control/VSD Cabinet contains lethal High AC and DC voltages. Before
performing 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 discharge 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 latches
are engaged on each door unless the unit is being serviced.
• ALWAYS lockout the disconnect supplying AC to the chiller.
• The 1L Line Inductor will reach operating temperatures of over 300° F. DO
NOT open panel doors during operation. Assure the inductor is cool whenever
working near the inductor with power off.

5
JOHNSON CONTROLS
FORM 201.21-NM1 (616)
TABLE OF CONTENTS
SECTION 1 - GENERAL CHILLER
INFORMATION & SAFETY
INTRODUCTION ......................................................9
WARRANTY..............................................................9
SAFETY......................................................................9
Standards for Safety................................................9
RESPONSIBILITY FOR SAFETY..........................10
ABOUT THIS MANUAL.........................................10
MISUSE OF EQUIPMENT......................................10
Suitability for Application ....................................10
Structural Support.................................................10
Mechanical Strength.............................................10
General Access .....................................................10
Pressure Systems ..................................................11
Electrical...............................................................11
Rotating Parts .......................................................11
Sharp Edges ..........................................................11
Refrigerant & Oils ................................................11
High Temperature & Pressure Cleaning ............... 11
Emergency Shutdown...........................................11
SECTION 2 - PRODUCT DESCRIPTION
INTRODUCTION ....................................................12
General System Description .................................12
Compressor...........................................................13
Evaporator ............................................................14
Condensor.............................................................14
Flash Tank Feed / Drain Valve..............................15
Oil Separator / Oil System....................................15
Relief Valves.........................................................15
Oil Cooling ...........................................................16
Capacity Controls .................................................16
Power and Control Panel ......................................16
Microprocessor & VSD Controls .........................16
Display..................................................................17
Keypad..................................................................17
Unit Switch...........................................................17
Variable Speed Drive (VSD) ................................18
ACCESSORIES & OPTIONS..................................19
Single Point Circuit Breaker.................................19
Building Automation System (BAS) Interface.....19
Condensor Coil Protection....................................19
DX COOLER OPTIONS..........................................20
SERVICE VALVE OPTION .....................................20
UNIT ENCLOSURES ..............................................20
FANS.........................................................................20
SOUND REDUCTION OPTIONS...........................20
VIBRATION ISOLATION .......................................20
UNIT NOMENCLATURE .......................................21
PRODUCT IDENTIFICATION NUMBER .............22
SECTION 3 - RIGGING, HANDLING & STORAGE
DELIVERY AND STORAGE ...................................26
INSPECTION ............................................................26
MOVING THE CHILLER.........................................26
Lifting Weights ......................................................26
UNIT RIGGING ........................................................27
SECTION 4 - INSTALLATION
LOCATION REQUIREMENTS................................29
OUTDOOR INSTALLATION...................................29
INDOOR INSTALLATION.......................................29
LOCATION CLEARANCES ....................................30
VIBRATION ISOLATORS .......................................30
Installation .............................................................30
SHIPPING BRACES.................................................30
CHILLED LIQUID PIPING......................................30
General Requirements ...........................................30
WATER TREATMENT..............................................32
CONNECTION TYPES & SIZES.............................32
COOLER CONNECTIONS ......................................32
Option Flanges.......................................................32
REFRIGERANT RELIEF VALVE PIPING ..............33
DUCTWORK CONNECTION .................................33
General Requirements ...........................................33
ELECTRICAL CONNECTION ................................33
POWER WIRING......................................................34
115 VAC CONTROL SUPPLY TRANSFORMER ...34
CONTROL PANEL WIRING....................................34
VOLTS FREE CONTACTS ......................................35
Chilled Liquid Pump Starter..................................35
Run Contact ...........................................................35
Alarm Contact........................................................35
SYSTEM INPUTS.....................................................35
Flow Switch...........................................................35
Remote Run/Stop...................................................35
Optional Remote Setpoint Offset Temp. ...............35
Optional Remote Setpoint Offset Sound Limit .....35
SECTION 5 - COMMISSIONING
PREPARATION.........................................................36
PREPARATION - POWER OFF ...............................36
Inspection...............................................................36
Refrigerant Charge ................................................36
Service and Oil Line Valves ..................................36
Compressor Oil......................................................36
Fans........................................................................36
Isolation / Protection..............................................36
Control Panel .........................................................36
Power Connections................................................37