York YLAA0041 User manual

YLAA0041 – YLAA0230
Air-Cooled Scroll Chillers
With Brazed Plate Heat Exchanger
Style B (60 HZ) 4–12 Fan
40 ton to 230 ton
140 kW to 800 kW
R-410A
Issue Date:
August 3, 2022
Air-Cooled Scroll Chiller
Installation, Operation,
Maintenance Supersedes: 150.72-ICOM6 (221) Form 150.72-ICOM6 (822)
Products are produced at a
f a c i l i t y w h o s e q u a l i t y -
management systems are
ISO9001 certified.
035-23572-100

JOHNSON CONTROLS
2
FORM 150.72-ICOM6
ISSUE DATE: 08/03/2022
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 150.72-ICOM6
ISSUE DATE: 08/03/2022
ASSOCIATED LITERATURE
Manual Description Form Number
Start-Up Checklist - Style A and B, 60 Hz 150.72-CL1
Limited Warranty Engineered Systems Equipment 50.05-NM2
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.
AFFECTED PAGES DESCRIPTION
19 Flow switch section updated
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.
CONDITIONED BASED MAINTENANCE
Traditional chiller maintenance is based upon assumed
and generalized conditions. In lieu of the traditional
maintenance program, a Johnson Controls YORK
Conditioned Based Maintenance (CBM) program can
be substituted. This CBM service plan is built around
the specific needs for the chiller, operating conditions,
and annualized impact realized by the chiller. Your lo-
cal Johnson Controls Branch can propose a customized
Planned Service Agreement that leverages real time
and historical data, delivering performance reporting,
corrective actions required and data enabled guidance
for optimal operation and lifecycle assurance. The pro-
gram will include fault detection diagnostics, operation
code statistics, performance based algorithms and ad-
vance rules based rationale delivered by the Johnson
Controls Connected Equipment Portal.

JOHNSON CONTROLS
4
FORM 150.72-ICOM6
ISSUE DATE: 08/03/2022
NOMENCLATURE
YL A A 0125 H 46 X C B
YL = YORK CHILLER
A = AIR COOLED
S = STANDARD EFFICIENCY
H = HIGH EFFICIENCY
REFRIGERANT = R-410A
DESIGN SERIES
A = DESIGN SERIES
FOUR DIGIT UNIT
NUMBER
VOLTAGE CODE:
17 = 200-3-60
28 = 230-3-60
40 = 380-3-60
46 = 460-3-60
58 = 575-3-60
DEVELOPMENT
LEVEL = B (BPHX)

JOHNSON CONTROLS 5
FORM 150.72-ICOM6
ISSUE DATE: 08/03/2022
TABLE OF CONTENTS
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY ................................................................ 11
Introduction..................................................................................................................................................... 11
Warranty ......................................................................................................................................................... 11
Handling ......................................................................................................................................................... 11
Safety and Quality .......................................................................................................................................... 11
About this Manual........................................................................................................................................... 12
Misuse of Equipment......................................................................................................................................12
SECTION 2 – PRODUCT DESCRIPTION...........................................................................................................15
Introduction..................................................................................................................................................... 15
General System Description........................................................................................................................... 15
Communications............................................................................................................................................. 18
Building Automation System Interface............................................................................................................18
Power Panel ...................................................................................................................................................18
Accessories and Options................................................................................................................................ 18
SECTION 3 – HANDLING AND STORAGE ........................................................................................................33
Delivery and Storage......................................................................................................................................34
Inspection .......................................................................................................................................................34
Moving the Chiller........................................................................................................................................... 34
Lifting Weights................................................................................................................................................36
Lifting Using Lugs...........................................................................................................................................36
Lifting Using Shackles ....................................................................................................................................36
SECTION 4 – INSTALLATION .............................................................................................................................37
Installation Checklist....................................................................................................................................... 37
Startup/Commissioning ..................................................................................................................................37
Location and Clearances................................................................................................................................ 37
Spring Isolators (Optional).............................................................................................................................. 38
Compressor Mounting ....................................................................................................................................38
Chilled Liquid Piping.......................................................................................................................................38
Pipework Arrangement ...................................................................................................................................39
Wiring .............................................................................................................................................................39
Relief Valves...................................................................................................................................................40
High Pressure Cutout .....................................................................................................................................40
Single-Point Supply Connection – Terminal Block, Non-Fused
Disconnect Switch or Circuit Breaker .............................................................................................................41
SECTION 5 – TECHNICAL DATA........................................................................................................................47
Physical Data YLAA0041 – YLAA0230 60 Hz................................................................................................50
Electrical Data ................................................................................................................................................54
Compressor Heaters ......................................................................................................................................54
Electrical Notes ..............................................................................................................................................65
Weight Distribution and Isolator Mounting Positions ......................................................................................99
Clearances ...................................................................................................................................................100
Isolator Locations .........................................................................................................................................101
Isolator Information....................................................................................................................................... 104

JOHNSON CONTROLS
6
FORM 150.72-ICOM6
ISSUE DATE: 08/03/2022
TABLE OF CONTENTS (CONT’D)
SECTION 6 – COMMISSIONING ....................................................................................................................... 111
Preparation – Power Off............................................................................................................................... 111
Commissioning the Pump VFD .................................................................................................................... 114
Preparation – Power On............................................................................................................................... 114
Determining Proper Oil Levels ..................................................................................................................... 118
SECTION 7 – UNIT CONTROLS........................................................................................................................123
Introduction................................................................................................................................................... 123
IPU II and I/O Boards ...................................................................................................................................123
Transformer .................................................................................................................................................124
Display.......................................................................................................................................................... 124
Keypad .........................................................................................................................................................124
Unit Switch ...................................................................................................................................................124
Battery Backup .............................................................................................................................................124
Programming the Number of Compressors.................................................................................................. 124
Status Key ....................................................................................................................................................125
Display/Print Keys ........................................................................................................................................133
Entry Keys ....................................................................................................................................................141
Setpoints Keys .............................................................................................................................................142
Schedule/Advance Day Key.........................................................................................................................143
Program Key ................................................................................................................................................145
Unit Keys .....................................................................................................................................................151
BACnet, Modbus, N2, and Yorktalk 2 Communications ...............................................................................159
SECTION 8 – UNIT OPERATION ......................................................................................................................175
Capacity Control...........................................................................................................................................175
Suction Pressure Limit Controls ...................................................................................................................176
Discharge Pressure Limit Controls...............................................................................................................176
Leaving Chilled Liquid Control...................................................................................................................... 176
Leaving Chilled Liquid Control Override to Reduce Cycling.........................................................................177
Leaving Chilled Liquid System Lead/Lag and Compressor Sequencing......................................................178
Return Chilled Liquid System Lead/Lag and Compressor Sequencing .......................................................178
Anti-Recycle Timer ....................................................................................................................................... 178
Anti-Coincidence Timer ................................................................................................................................ 178
Evaporator Pump Control and YORK Hydro Kit Pump Control....................................................................178
Evaporator Heater Control ...........................................................................................................................179
Pumpdown Control.......................................................................................................................................179
Standard Condenser Fan Control ................................................................................................................ 179
VSD Fan.......................................................................................................................................................179
Changing the Switch Point of the Thermal Dispersion Flow Switch.............................................................179
Load Limiting ................................................................................................................................................183
Compressor Run Status ...............................................................................................................................183
Alarm Status.................................................................................................................................................183
Remote BAS/EMS Temperature Reset Using a Voltage or Current Signal ..................................................184

JOHNSON CONTROLS 7
FORM 150.72-ICOM6
ISSUE DATE: 08/03/2022
TABLE OF CONTENTS (CONT’D)
SECTION 9 – SERVICE AND TROUBLESHOOTING .....................................................................................185
Clearing History Buffers................................................................................................................................ 185
Resetting System Lockout Faults.................................................................................................................185
Service Mode ...............................................................................................................................................185
Service Mode – Outputs...............................................................................................................................185
Service Mode – Chiller Configuration...........................................................................................................186
Service Mode – Analog and Digital Inputs....................................................................................................186
Control Inputs/Outputs .................................................................................................................................187
Checking Inputs and Outputs .......................................................................................................................189
Optional Printer Installation ..........................................................................................................................195
Troubleshooting............................................................................................................................................197
SECTION 10 – MAINTENANCE.........................................................................................................................199
Compressors ................................................................................................................................................199
Condenser Fan Motors................................................................................................................................. 199
Condenser MCHX Cleaning .........................................................................................................................199
Operating Parameters ..................................................................................................................................201
On-Board Battery Backup ............................................................................................................................203
Thermal Dispersion Flow Switch ..................................................................................................................203
Brazed Plate Heat Exchanger (Evaporator) Heater .....................................................................................203
Overall Unit Inspection .................................................................................................................................203

JOHNSON CONTROLS
8
FORM 150.72-ICOM6
ISSUE DATE: 08/03/2022
LIST OF FIGURES
FIGURE 1 - Compressor Enclosure for YLAA0041HE ...........................................................................................16
FIGURE 2 - Unit Components (Front) ....................................................................................................................21
FIGURE 3 - Unit Components (Side)......................................................................................................................22
FIGURE 4 - Power Panel Components ..................................................................................................................23
FIGURE 5 - Power Panel / Control Components....................................................................................................24
FIGURE 6 - Process and Instrumentation Diagram................................................................................................31
FIGURE 7 - Rigging and Lifting Label ....................................................................................................................33
FIGURE 8 - Unit Rigging/Lifting .............................................................................................................................35
FIGURE 9 - Lifting lugs...........................................................................................................................................36
FIGURE 10 - Chilled Liquid System ......................................................................................................................39
FIGURE 11 - Single-Point Supply Connection – Terminal Block, Non-Fused Disconnect Switch
or Circuit Breaker ..............................................................................................................................41
FIGURE 12 - Control Wiring Inputs ........................................................................................................................42
FIGURE 13 - Thermal Dispersion Flow Switch.......................................................................................................44
FIGURE 14 - Wiring of Thermal Dispersion Flow Switch .......................................................................................44
FIGURE 15 - Control Wiring Outputs......................................................................................................................46
FIGURE 16 - Elementary Wiring Diagram..............................................................................................................70
FIGURE 17 - Elementary Wiring Diagram..............................................................................................................72
FIGURE 18 - Fan Wiring, Standard Air Flow ..........................................................................................................74
FIGURE 19 - Fan Wiring, High Air Flow .................................................................................................................76
FIGURE 20 - Single and Dual Point Wiring Options...............................................................................................78
FIGURE 21 - Pump Wiring .....................................................................................................................................80
FIGURE 22 - EEV Controller Elementary Diagram ................................................................................................82
FIGURE 23 - Compressor Wiring ...........................................................................................................................84
FIGURE 24 - Power Options Connection Diagram.................................................................................................86
FIGURE 25 - Power Panel......................................................................................................................................88
FIGURE 26 - Micro Panel Connections..................................................................................................................90
FIGURE 27 - Four Fan Units Dimensions – YLAA0041HE, YLAA0048HE, YLAA0058HE, YLAA0065HE,
YLAA0081HE, YLAA0082HE............................................................................................................92
FIGURE 28 - Four Fan Units Dimensions – YLAA0070SE, YLAA0080SE, YLAA0089SE.....................................93
FIGURE 29 - Five Fan Units Dimensions – YLAA0100SE .....................................................................................94
FIGURE 30 - Six Fan Units Dimensions – YLAA0092HE, YLAA0101HE, YLAA0115SE, YLAA0120SE............... 95
FIGURE 31 - Eight Fan Units Dimensions – YLAA0125HE, YLAA0136SE, YLAA0139HE, YLAA0142HE,
YLAA150SE, YLAA0155SE .............................................................................................................96
FIGURE 32 - Ten Fan Units Dimensions – YLAA0170SE, YLAA0156HE, YLAA0175HE......................................97
FIGURE 33 - Twelve Fan Units Dimensions - YLAA200HE, YLAA0230HE ........................................................... 98
FIGURE 34 - Sample Printout Supplied in the Isolator Package and in the Chiller Panel Literature Packet .........99
FIGURE 35 - Unit Clearances – All Models ..........................................................................................................100
FIGURE 36 - EEV IB-G Interface Board............................................................................................................... 113
FIGURE 37 - Drive Display................................................................................................................................... 116
FIGURE 38 - Circuit Breaker Panel...................................................................................................................... 117
FIGURE 39 - Tandem Set..................................................................................................................................... 118
FIGURE 40 - Trio Set............................................................................................................................................ 118
FIGURE 41 - Status Key Messages Quick Reference List...................................................................................132
FIGURE 42 - Operation Data................................................................................................................................136
FIGURE 43 - Setpoints Quick Reference List.......................................................................................................148
FIGURE 44 - Unit Keys Options Programming Quick Reference List ..................................................................158
FIGURE 45 - Micro Panel Connections................................................................................................................160
FIGURE 46 - Leaving Water Temperature Control Example ................................................................................176
FIGURE 47 - Setpoint Adjust ................................................................................................................................177
FIGURE 48 - Condenser Fan Locations...............................................................................................................180
FIGURE 49 - Microboard Layout ..........................................................................................................................188
FIGURE 50 - I/O Board Relay Contact Architecture .............................................................................................192
FIGURE 51 - Printer to Microboard Electrical Connections..................................................................................196

JOHNSON CONTROLS 9
FORM 150.72-ICOM6
ISSUE DATE: 08/03/2022
LIST OF TABLES
TABLE 1 - Canadian Registration Numbers........................................................................................................... 16
TABLE 2 - Complete Pin Number Description........................................................................................................25
TABLE 3 - Chemical Specification of Water ...........................................................................................................43
TABLE 4 - Temperatures and Flows.......................................................................................................................47
TABLE 5 - Ethylene and Propylene Glycol Correction Factors ..............................................................................49
TABLE 6 - Physical Data (English) 60 Hz ..............................................................................................................50
TABLE 7 - Micropanel Power Supply .....................................................................................................................54
TABLE 8 - Voltage Range ......................................................................................................................................54
TABLE 9 - Pump Electrical Data 60 Hz ..................................................................................................................55
TABLE 10 - Transformer Load................................................................................................................................55
TABLE 11 - Electrical Data Without Pumps............................................................................................................56
TABLE 12 - Wiring Lugs.........................................................................................................................................62
TABLE 13 - Drive Programming Parameters ....................................................................................................... 116
TABLE 14 - YLAA Fault and Inhibit Codes ...........................................................................................................131
TABLE 15 - Legend ..............................................................................................................................................131
TABLE 16 - Cooling Setpoint, Programmable Limits, and Defaults .....................................................................144
TABLE 17 - Program Key Limits and Default .......................................................................................................147
TABLE 18 - Program Key Limits and Default .......................................................................................................149
TABLE 19 - Minimum, Maximum and Default Values...........................................................................................160
TABLE 20 - Values Required for BAS Communication ........................................................................................161
TABLE 21 - Real Time Error Numbers .................................................................................................................162
TABLE 22 - Native BACnet, Modbus and N2 Communications Data Map...........................................................163
TABLE 23 - YorkTalk 2 Communications Data Map .............................................................................................168
TABLE 24 - Sample Compressor Staging for Return Water Control....................................................................177
TABLE 25 - YLAA Standard Condenser Fan Control Using Discharge Pressure Only
(2, 3, or 4 Fans per System) .............................................................................................................181
TABLE 26 - YLAA Standard Condenser Fan Control Using Discharge Pressure Only
(5 or 6 Fans per System) ..................................................................................................................182
TABLE 27 - Compressor Operation Load Limiting ...............................................................................................183
TABLE 28 - I/O Digital Inputs ...............................................................................................................................187
TABLE 29 - I/O Digital Outputs.............................................................................................................................187
TABLE 30 - I/O Analog Inputs ..............................................................................................................................187
TABLE 31 - I/O Analog Outputs............................................................................................................................187
TABLE 32 - Outdoor Air Sensor Temperature/Voltage/Correlation.......................................................................189
TABLE 33 - Entering/Leaving Chilled Liquid Temp. Sensor, Temperature/Voltage Correlation............................190
TABLE 34 - Pressure Transducers.......................................................................................................................191
TABLE 35 - Data Logging to Flash.......................................................................................................................193
TABLE 36 - Troubleshooting ................................................................................................................................197
TABLE 37 - SI Metric Conversion.........................................................................................................................203

JOHNSON CONTROLS
10
FORM 150.72-ICOM6
ISSUE DATE: 08/03/2022
THIS PAGE IS INTENTIONALLY LEFT BLANK