York YCAV1039 Owner's manual

MODELS YCAV1039-1909, 50 HZ
STYLE A
(960-1815KW)
E/V HIGH EFFICIENCY AND S/P STANDARD EFFICIENCY
AIR-COOLED SCREW LIQUID CHILLERS
R-134a
Issue Date:
October 2, 2020
AIR-COOLED SCREW
LIQUID CHILLERS
INSTALLATION, OPERATION, MAINTENANCE Supersedes 201.21-NM4 (616) Form 201.21-NM4 (1020)
035-20995-000

2JOHNSON CONTROLS
FORM 201.21-NM4 (1020)
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-NM4 (1020)
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 Knowledge Exchange website at https://
docs.johnsoncontrols.com/chillers/
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.
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 o, after AC power is removed.
Always check the DC Bus Voltage with a Voltmeter to assure the capacitor charge has bled o 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 o.
WARNING!
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.
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.
AFFECTED PAGES DESCRIPTION
3 Conditioned Based Maintenance program information added
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.

4JOHNSON CONTROLS
FORM 201.21-NM4 (1020)
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 AND
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
PIPEWORK ARRANGEMENTS..........................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
POWER SUPPLY WIRING...................................34
115 VAC CONTROL SUPPLY TRANSFORMER34
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
Remote Print.........................................................35
Optional Remote Setpoint Oset Temp................35
Optional Remote Setpoint Oset Current ............35
Optional Remote Setpoint Oset Sound Limit.....35

5
JOHNSON CONTROLS
FORM 201.21-NM4 (1020)
SECTION 5 - COMMISSIONING
PREPARATION ......................................................36
PREPARATION - GENERAL ...............................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
Grounding.............................................................37
Water System ........................................................37
Flow Switch..........................................................37
Temperature Sensor(s)..........................................37
Programmed Options............................................38
Programmed Settings............................................38
Date & Time .........................................................38
Start / Stop ............................................................38
Setpoint & Remote Oset.....................................38
FIRST TIME STARTUP.........................................38
Interlocks ..............................................................38
Unit Switch...........................................................38
Start-Up ................................................................38
Oil Pressure...........................................................38
Refrigerant Flow...................................................39
Loading.................................................................39
Condensor & Fan Rotation...................................39
Suction Super Heat ...............................................39
Sub-Cooling..........................................................39
General Operation.................................................39
SECTION 6 - TECHNICAL DATA
WATER PRESSURE DROP CHARTS .................40
GLYCOL CORRECTION FACTORS ..................41
WATER TEMP. AND FLOWS...............................42
PHYSICAL DATA ..................................................44
OPERATING LIMITATIONS AND
SOUND POWER ................................................46
ELECTRICAL DATA - COMPR. WIRING .........47
ELECTRICAL NOTES ..........................................54
WIRING DIAGRAMS - 3 COMPRESSOR .........56
WIRING DIAGRAMS - 4 COMPRESSOR .........68
DIMENSIONS ........................................................84
TECHNICAL DATA (CLEARANCES).............. 116
WEIGHT DISTRIBUTION &
ISOLATOR MOUNTING ............................... 117
ISOLATOR MOUNTING POSITIONS.............. 118
SEISMIC ISOLATOR INSTALLATION ...........123
NEOPRENE ISOLATOR POSITION.................124
1" DEFLECTION ISOLATOR INSTALLATION125
REFRIGERANT FLOW DIAGRAM..................127
PROCESS & INSTRUMENTATION
DIAGRAM ........................................................128
COMPONENT LOCATIONS..............................129
EQUIPMENT START-UP CHECK SHEET.......148
Unit Checks (NO power)....................................148
Panel Checks
(Power ON-both system switches OFF).............150
Programmed Values............................................151
Chilled Liquid Setpoint ......................................151
Date/Time, Daily Schedule, & Clock Jumper ....151
Initial Start-Up....................................................152
Check Subcooling & Superheat..........................152
Leak Checking....................................................153
CHILLER ELECTRONIC COMPONENTS......154
Keypad................................................................154
Display................................................................155
Chiller Control Board .........................................156
Relay Output Boards ..........................................157
VSD (Variable Speed Drive) ..............................157
AC to DC Rectier .............................................157
SCR Trigger Board .............................................158
DC Link Filter ....................................................158
1L Line Inductor .................................................159
AC to DC Inverter ..............................................159
Laminated Bus Structure ....................................159
VSD Logic Board ...............................................160
Control Panel to VSD Communications.............160
IGBT Gate Driver Boards...................................161
Current Transformers..........................................161
DV/DT Output Suppression Network ................162
Flash Tank Feed/Drain Valve Controller ............162
DC Bus Voltage Isolation Board.........................163
Chiller Circuit Breaker .......................................163
Autotransformer..................................................163
CHILLER CONFIGURATION JUMPERS........164
Number of Compr. Conguration Jumpers ........164
VSD LOGIC TO CHILLER MICROPROCESSOR
BOARD RS-485 COMMUNICATION
CONFIGURATION JUMPERS ......................164
MAX VSD FREQUENCY ...................................165
TABLE OF CONTENTS (CONT’D)

6JOHNSON CONTROLS
FORM 201.21-NM4 (1020)
SECTION 7 - OPERATION
OPERATING CONTROLS..................................166
BASIC OPERATING SEQUENCE.....................168
NUMBER OF COMPRESSORS TO START.....169
General................................................................169
Standard IPLV.....................................................169
Optional Optimized IPLV...................................169
MINIMUM VSD COMPRESSOR
START/STOP FREQUENCY..........................170
Minimum VSD Start Frequency.........................170
Minimum VSD Run Frequency..........................170
ACCELERATION/DECELERATION RATE
WHEN STARTING & STOPPING
COMPRESSORS..............................................171
VSD Acceleration/ Deceleration Rates...............171
STANDARD IPLV CAPACITY CONTROL......172
Fuzzy Logic Control...........................................173
Hot Water Starts..................................................174
Lag Compressor Operation in Load Limiting ....174
OPTIONAL IPLV CAPACITY CONTROL .......175
Fuzzy Logic ........................................................176
Hot Water Starts..................................................177
LOAD LIMITING CONTROL............................178
FLASH TANK DRAIN/FEED VALVE
CONTROLLER ................................................181
Valve Controller & Control Algorithm ..............181
ECONOMIZER CONTROL................................184
CONDENSER FAN CONTROL .........................184
VSD TEMPERATURE CONTROL/FAN
CONTROL OPERATION ................................187
REMOTE TEMPERATURE RESET CONTROL189
Local Current Limit Control..............................189
Pulldown Current Limit Setpoint .......................189
REMOTE CURRENT LIMIT RESET ...............190
Sound Limit Controls .........................................192
SECTION 8 - MICROPANEL
VSD OPERATION & CONTROLS ....................194
VSD Cooling and Cooling Loop ........................196
VSD SAFETIES....................................................200
IGBT Gate Driver (Hardware) Fault ..................203
Power Supply (Hardware) Fault.........................205
UNIT WARNINGS ...............................................208
UNIT SAFETIES ..................................................212
SYSTEM SAFETIES............................................214
STATUS KEY........................................................220
UNIT DATA KEY .................................................224
SYSTEM DATA KEY...........................................226
VSD DATA KEY...................................................230
OPERATING HOURS & START KEYS............232
HISTORY KEY .....................................................233
Unit Data.............................................................234
VSD Data............................................................235
System Data........................................................236
Compressor Operating Hours & Starts...............238
Chilled Liquid & Cooling Setpoints..................238
Options................................................................238
Program Values...................................................239
SETPOINTS KEY.................................................241
PROGRAM KEY ..................................................243
OPTIONS KEY.....................................................246
DATE/TIME & SCHEDULE KEY......................250
Date/Time Key....................................................250
Schedule Key......................................................251
Unit Operating Schedule ....................................252
Sound Limit Schedule ........................................253
MANUAL OVERRIDE KEY ..............................254
PRINT KEY...........................................................255
Operating Data Printout......................................256
History Data Printout..........................................257
SERVICE KEY......................................................258
SYSTEM SWITCHES KEY ................................264
SERIAL NUMBER PROGRAMMING..............265
ENABLING OPTIMIZED HIGH IPLV MODE 267
UNIT SETUP MODE ...........................................268
DEFAULT PROGRAMMABLE VALUES.........270
SERIAL PORT CONNECTIONS........................271
ANALOG INPUT CONNECTIONS...................272
DIGITAL INPUT CONNECTIONS....................274
ANALOG OUTPUT CONNECTIONS ..............276
DIGITAL OUTPUT CONNECTIONS ...............278
ISN COMMUNICATIONS
& TRANSMITTED DATA...................................280
SECTION 9 - MAINTENANCE
R-134A CONVERSION TABLES.......................288
MAINTENANCE..................................................289
General Requirements ........................................289
MAINTENANCE REQUIREMENTS ................290
TROUBLESHOOTING GUIDE .........................292
EVACUATING A SYSTEM.................................294
WARRANTY POLICY.........................................295
New Equipment ..................................................295
Reconditioned or Replacement Materials...........295
All Warranties are VIOD if.................................295
TABLE OF CONTENTS (CONT’D)

7
JOHNSON CONTROLS
FORM 201.21-NM4 (1020)
CHILLED LIQUID & SUCTION TEMP
SENSOR INPUT VOLTAGE TABLE.................296
OUTSIDE AIR TEMP SENSOR INPUT
VOLTAGE TABLE ...............................................297
PRESSURE TRANSDUCER OUTPUT
VOLTAGE TABLE ...............................................297
MOTOR TEMPERATURE SENSOR
RESISTANCE TABLE.........................................299
COMPRESSOR MOTOR OVERLOAD SETTINGS
& MAXIMUM VSD FREQUENCY ...................300
PRINTER WIRING ..............................................301
Okidata 184.........................................................302
Weigh-Tronix IMP Model 2600 .........................302
Seiko ...................................................................302
OPERATING LOG ...............................................303
Site and Chiller Info ...........................................303
Programmed Values............................................303
Unit Operating Temperature, Pressures,
& Currents ..........................................................304
System Operating Conditions.............................305
Water System Conditions ...................................306
Condensor Conditions ........................................306
RECOMMENDED SPARE PARTS ....................307
LIST OF TABLES
Table 1 - Compressors and the Appropriate Jumper
Positions ..................................................164
Table 2 - VSD Logic Board Address Jumper..........164
Table 3 - Maximum Frequency Jumper ..................165
Table 4 - Fuzzy Logic Loading/Unloading
vs. Error...................................................174
Table 5 - Fuzzy Logic Loading/Unloading
vs. Error...................................................177
Table 6 - Current Load Limiting/Unloading...........178
Table 7 - Discharge Pressure Load Limiting/
Unloading ................................................178
Table 8 - Suction Pressure Load Limiting/
Unloading ................................................179
Table 9 - VSD Internal Ambient Load Limiting/
Unloading ................................................179
Table 10 - VSD Baseplate Temperature Load
Limiting/Unloading...............................180
Table 11 - Fan Stages & Corresponding Outputs....185
Table 12 - VSD Operating Display Parameters ......199
Table 13 - Low Dierential Oil Pressure Cutout ...216
Table 14 - Start Inhibit Sensor Thresholds..............218
Table 15 - Sensor Min./Max. Outputs.....................228
Table 16 - Setpoint Limits.......................................242
Table 17 - Programmable Operating Parameters ....245
Table 18 - Printout Types ........................................255
Table 19 - Unit Setup Programmable Values ..........268
Table 20 - Serial Port Connections .........................271
Table 21 - Analog Input Connections .....................272
Table 22 - Digital Input Connections......................274
Table 23 - Analog Output Connections...................276
Table 24 - Digital Output Connections ...................278
Table 25 - Mustang Chiller YORK Talk
Control Data ...........................................280
Table 26 - DXST/ISN Transmitted Data.................281
Table 27 - Fault Inhibit Codes ................................285
Table 28 - Operational Status Codes.......................287
Table 29 - R-134a Pressure to Saturated
Temperature Conversion .......................288
Table 30 - Temperature Input Voltage Sensor.........296
Table 31 - Outside Air Temperature Input Voltage .297
Table 32 - Pressure Transducer Input Voltage.........298
Table 33 - Motor Temperature Sensor Resistance ..299
Table 34 - Compressor Motor Overload Settings &
Max. VSD Frequency............................300

8JOHNSON CONTROLS
FORM 201.21-NM4 (1020)
Fig 1 - PWM Current Waveform ..............................18
Fig 2 - PWM Voltage Waveform...............................18
Fig 3 - Pipework Arrangement..................................32
Fig 4 - Victaulic Groove............................................32
Fig 5 - Flange Attachment.........................................32
Fig 6 - Single Point Power Supply Connection
W/Circuit Breaker Protection (3 Compr) ......47
Fig 7 - Single Point Power Supply Connection
W/Terminal Block (3 Compr) ....................47
Fig 8 - Single Point Power Supply Connection
W/Circuit Breaker Protection (4 Compr) ......48
Fig 9 - Single Point Power Supply Connection
W/Terminal Block (4 Compr) .......................48
Fig 10 - Multi-Point Power Supply Connection
W/Circuit Breaker Protection (4 Compr) ....49
Fig 11 - Multi-Point Power Supply Connection
W/Terminal Block (4 Compr) .....................49
Fig 12 - Sample Printout Supplied in the Isolator
Package & Chiller Panel Literature Packet 117
Fig 13 - Refrigerant Flow Diagram ........................127
Fig 14 - Processes and Instrumentation ..................128
Fig 15 - Component Locations ...............................129
Fig 16 - Control and VSD Cabinet Locations.........130
Fig 17 - Chiller Control Board, Relay Boards,
Microgateway, and Optional
Circuit Breaker ..........................................131
Fig 18 - Chiller Control Board, Relay Boards, and
Microgateway............................................132
Fig 19 - VSD Logic Board......................................133
Fig 20 - VSD Logic Board......................................134
Fig 21 - Power Components ...................................135
Fig 22 - Power Components ...................................136
Fig 23 - Fan Contactors...........................................137
Fig 24 - VSD Components......................................138
Fig 25 - VSD Components......................................139
Fig 26 - VSD Components......................................140
Fig 27 - VSD Components......................................141
Fig 28 - Inverter Power Components......................142
Fig 29 - Inverter Power Components......................143
Fig 30 - Inverter Power Components......................144
Fig 31 - Inverter Power Components......................144
Fig 32 - Glycol Pump & Fill Tube Locations .........145
Fig 33 - Glycol Piping & Fill Tube Locations ........146
Fig 34 - Compressor Components ..........................147
Fig 35 - Chiller Control (Cooling) Range...............168
Fig 36 - Number of Compressors to Start...............169
Fig 37 - Minimum VSD Start Frequency ...............170
Fig 38 - Minimum VSD Run ..................................170
Fig 39 - LED Locations ..........................................182
Fig 40 - Power, Comms LED's ...............................183
Fig 41 - Power, Comms & System Open/Close
LED's.........................................................183
Fig 42 - Standard IPLV Fan Control.......................186
Fig 43 - High IPLV Fan Control .............................187
Fig 44 - Print Cable Chiller to Serial Printer ..........301
LIST OF FIGURES

9
JOHNSON CONTROLS
FORM 201.21-NM4 (1020)
9
JOHNSON CONTROLS
1
GENERAL CHILLER INFORMATION & SAFETY
INTRODUCTION
YORK YCAV1039-1909 chillers are manufactured to
the highest design and construction standards to ensure
high performance, reliability and adaptability to all types
of air conditioning installations.
The unit is intended for cooling water or glycol solu-
tions and is not suitable for purposes other than those
specied in this manual.
Rigging and lifting should only be done by a profes-
sional rigger in accordance with a written rigging and
lifting plan. The most appropriate rigging and lifting
method will depend on job specific factors, such as the
rigging equipment available and site needs. Therefore,
a professional rigger must determine the rigging and
lifting method to be used, and it is beyond the scope of
this manual to specify rigging and lifting details.
This manual contains all the information required for
correct installation and commissioning of the unit, to-
gether with operating and maintenance instructions. The
manuals should be read thoroughly before attempting
to operate or service the unit.
All procedures detailed in the manuals, including in-
stallation, commissioning and maintenance tasks must
only be performed by suitably trained and qualied
personnel.
The manufacturer will not be liable for any injury or
damage caused by incorrect installation, commission-
ing, operation or maintenance resulting from a failure
to follow the procedures and instructions detailed in
the manuals.
WARRANTY
YORK warrants all equipment and materials against
defects in workmanship and materials for a period of
eighteen months from date of shipment, unless labor
or extended warranty has been purchased as part of the
contract.
The warranty is limited to parts only replacement and
shipping of any faulty part, or sub-assembly, which has
failed due to poor quality or manufacturing errors. All
claims must be supported by evidence that the failure
has occurred within the warranty period, and that the
unit has been operated within the designed parameters
specied.
All warranty claims must specify the unit model, serial
number, order number and run hours/starts. Model and
serial number information is printed on the unit identi-
cation plate.
The unit warranty will be void if any modication to the
unit is carried out without prior written approval from
YORK.
For warranty purposes, the following conditions must
be satised:
• The initial start of the unit must be carried out by
trained personnel from an Authorized YORK Ser-
vice Center. See Commissioning (Page 36).
• Only genuine YORK approved spare parts, oils,
coolants, and refrigerants must be used. Recom-
mendations on spare parts stocking can be found
on Page 305.
• All the scheduled maintenance operations detailed
in this manual must be performed at the specied
times by suitably trained and qualied personnel.
See Maintenance Section, Page 287-304.
• Failure to satisfy any of these conditions will auto-
matically void the warranty.
SAFETY
Standards for Safety
YCAV chillers are designed and built within an ISO
9002 accredited design and manufacturing organization.
The chillers comply with the applicable sections of the
following Standards and Codes:
• ANSI/ASHRAE Standard 15, Safety Code for Me-
chanical Refrigeration.
• ANSI/NFPA Standard 70, National Electrical Code
(N.E.C.).
• ASME Boiler and Pressure Vessel Code, Section
VIII Division 1.
• ARI Standard 550/590-98, Water Chilling Packages
Using the Vapor Compression Cycle.
• ASHRAE 90.1 Energy Standard for Building Except
Low-Rise Residential Buildings.
• ARI 370 Sound Rating of Large Outdoor Refrigera-
tion and Air Conditioning Equipment.
In addition, the chillers conform to Underwriters Labo-
ratories (U.L.) for construction of chillers and provide
U.L./cU.L. Listing Label.

10 JOHNSON CONTROLS
FORM 201.21-NM4 (1020)
10 JOHNSON CONTROLS
General Chiller Information & Safety
RESPONSIBILITY FOR SAFETY
Every care has been taken in the design and manufac-
ture of the unit to ensure compliance with the safety
requirements listed above. However, the individual
rigging, lifting, maintaining, operating or working on
any machinery is primarily responsible for:
• Personal safety, safety of other personnel, and
the machinery.
• Correct utilization of the machinery in ac-
cordance with the procedures detailed in the
manuals.
ABOUT THIS MANUAL
The following terms are used in this document to alert
the reader to areas of potential hazard.
A WARNING is given in this document to identify a
hazard, which could lead to personal injury. Usually an
instruction will be given, together with a brief explana-
tion and the possible result of ignoring the instruction.
A CAUTION identies a hazard which could lead to
damage to the machine, damage to other equipment
and/or environmental pollution. Usually an instruction
will be given, together with a brief explanation and the
possible result of ignoring the instruction.
A NOTE is used to highlight additional information,
which may be helpful to you but where there are no
special safety implications.
The contents of this manual include suggested best
working practices and procedures. These are issued for
guidance only, and they do not take precedence over
the above stated individual responsibility and/or local
safety regulations.
This manual and any other document supplied with the
unit are the property of YORK which reserves all rights.
They may not be reproduced, in whole or in part, without
prior written authorization from an authorized YORK
representative.
MISUSE OF EQUIPMENT
Suitability for Application
The unit is intended for cooling water or glycol solu-
tions and is not suitable for purposes other than those
specied in these instructions. Any use of the equipment
other than its intended use, or operation of the equipment
contrary to the relevant procedures may result in injury
to the operator, or damage to the equipment.
The unit must not be operated outside the design param-
eters specied in this manual.
Structural Support
Structural support of the unit must be provided as in-
dicated in these instructions. Failure to provide proper
support may result in injury to the operator, or damage
to the equipment and/or building.
Mechanical Strength
The unit is not designed to withstand loads or stresses
from adjacent equipment, pipework or structures. Ad-
ditional components must not be mounted on the unit.
Any such extraneous loads may cause structural failure
and may result in injury to the operator, or damage to
the equipment.
General Access
There are a number of areas and features, which may
be a hazard and potentially cause injury when working
on the unit unless suitable safety precautions are taken.
It is important to ensure access to the unit is restricted
to suitably qualied persons who are familiar with the
potential hazards and precautions necessary for safe
operation and maintenance of equipment containing
high temperatures, pressures and voltages.