York YVAA Style A Owner's manual

Air-Cooled Screw Liquid Chillers
Installation, Operation, Maintenance Supersedes: 201.28-NM1.1 (321) Form 201.28-NM1.1 (821)
HFC-134A or R-513A
525 kW to 1750 kW
2 Compressor
50 Hz and 60 Hz
Model YVAA Style A
Air-Cooled Screw Liquid Chillers with Variable Speed Drive
Frame Sizes 015 – 052
150 ton to 500 ton
035-23219-100
Issue Date:
August 6, 2021

JOHNSON CONTROLS
2
Form 201.28-NM1.1
Issue date: 08/06/2021
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 201.28-NM1.1
Issue date: 08/06/2021
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 operat-
ing/ service personnel to verify the applicability of
these documents to the equipment. If there is any ques-
tion regarding the applicability of these documents,
rigging, 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.
Changeability of this document
Associated literature
Manual description Form number
Equipment Pre-Startup and Startup Checklist 201.28-CL2
YVAA Style A Frame Size 015 - 027, 2 Compressor 60 Hz (150-350 Tons)
YVAA Style A Frame Size 054 - 098, 2 Compressor 50 Hz (525-950 KW) Manufactured before April 2012 201.28-RP1
YVAA Style A Frame Size 015 - 052, 2 Compressor 50 & 60 Hz (150-500 Tons)
(Manufactured after April 2012 to before September 2014) 201.28-RP2
YVAA Style B Frame Size 015 - 052, 2 Compressor 50 & 60 Hz (150-500 Tons)
(Manufactured after September 2014) 201.28-RP3
Affected pages Description
20 Water box heater text updated
37 Chilled liquid requirements text updated
100,101 Freeze damage protection text 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 201.28-NM1.1
Issue date: 08/06/2021
ASHRAE 90.1 Compliant
Products are produced at a
facility whose quality-
management systems are
ISO9001 certified.
LD23523a
UNIT NOMENCLATURE
Base Product Type
YVAA 3AXX 46 A
Level / Refrigerant
A = Refrigerant R-134a
B = Refrigerant R-513A
Voltage
17 = 200 / 3 / 60
28 = 230 / 3 / 60
40 = 380 / 3 / 60
42 = 400 / 3 / 60
46 = 460 / 3 / 60
50 = 380-415 / 3 / 50
58 = 575 / 3 / 60
021 A
Y = YORK
V= Variable Speed Screw
AA = Air Cooled Design Series
Configuration
3 = Condenser Code
X = Evaporator Code
X = Compressor Code
X = Condenser Fan & Sound Kit Code
Development Level
(Engineering Change
or PIN)
Frame Size
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 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 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 latches
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 150°C (300°F.) DO
NOT open panel doors during operation.
Assure the inductor is cool whenever
working near the inductor with power
OFF.

JOHNSON CONTROLS 5
Form 201.28-NM1.1
Issue date: 08/06/2021
Table of contents
Section 1 - General chiller information and safety ............................................................................................ 11
Introduction..................................................................................................................................................... 11
Warranty ......................................................................................................................................................... 11
Quality assurance and safety .........................................................................................................................12
Fluorinated greenhouse gases.......................................................................................................................12
Responsibility for safety .................................................................................................................................12
About this manual...........................................................................................................................................12
Misuse of equipment ......................................................................................................................................12
Section 2 - Product description ...........................................................................................................................15
General system description............................................................................................................................15
Semi-hermetic YORK twin-screw compressors.............................................................................................. 17
Evaporator......................................................................................................................................................17
Condenser......................................................................................................................................................17
Refrigerant circuit ...........................................................................................................................................17
Electrical.........................................................................................................................................................17
Building automation system capabilities......................................................................................................... 18
Microcomputer control center.........................................................................................................................18
Accessories and options ................................................................................................................................19
Fan options.....................................................................................................................................................19
Condenser coils..............................................................................................................................................19
Section 3 - Rigging, handling, and storage ........................................................................................................23
Lifting weights.................................................................................................................................................23
Delivery and storage ......................................................................................................................................23
Inspection .......................................................................................................................................................24
Moving the chiller ...........................................................................................................................................24
Unit removal from shipping container.............................................................................................................24
Lifting using lugs.............................................................................................................................................24
Lifting using shackles .....................................................................................................................................24
Section 4 - Installation ..........................................................................................................................................35
Location requirements....................................................................................................................................35
Outdoor installations.......................................................................................................................................35
Location clearances .......................................................................................................................................35
Vibration isolators...........................................................................................................................................37
Shipping braces..............................................................................................................................................37
Chilled liquid piping ........................................................................................................................................37
Evaporator pressure drop...............................................................................................................................38
Water treatment..............................................................................................................................................40
Pipework arrangement ...................................................................................................................................40
Minimum water volume ..................................................................................................................................40
Leaving water temperature out of range ........................................................................................................40
Thermal storage .............................................................................................................................................41
Variable primary flow .....................................................................................................................................41
Connection types and sizes ...........................................................................................................................41
Evaporator connections..................................................................................................................................41
Refrigerant relief valve piping.........................................................................................................................43
Electrical connection ......................................................................................................................................43
Power wiring...................................................................................................................................................44

JOHNSON CONTROLS
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Form 201.28-NM1.1
Issue date: 08/06/2021
Table of contents (cont'd)
Power supply wiring .......................................................................................................................................44
115 VAC control supply transformer ............................................................................................................... 44
Control wiring .................................................................................................................................................44
Volts free contacts ..........................................................................................................................................45
System inputs.................................................................................................................................................45
Power supply wiring .......................................................................................................................................46
Customer control wiring.................................................................................................................................. 48
Thermal dispersion flow switch connections ..................................................................................................49
Section 5 - Technical data ....................................................................................................................................63
Elastomeric isolator installation ......................................................................................................................90
Elastomeric isolator specifications .................................................................................................................91
One inch deflection isolator installation ..........................................................................................................92
One inch deflection spring isolator specifications...........................................................................................93
Two inch deflection isolator installation and adjustment.................................................................................94
Two inch deflection, restrained spring isolator specifications.........................................................................95
Section 6 - Commissioning ..................................................................................................................................97
Preparation.....................................................................................................................................................97
First time startup...........................................................................................................................................100
General operation ........................................................................................................................................100
Section 7 - Operation ..........................................................................................................................................103
Operating controls ........................................................................................................................................103
Basic operating sequence ............................................................................................................................105
Unit warning .................................................................................................................................................106
Microboard (331-03478-xxx) ........................................................................................................................106
Building automation system (BAS) communications....................................................................................109
E-Link or SC-EQ interface............................................................................................................................ 110
SC-EQ or E-Link BAS communications card ............................................................................................... 113
Program update............................................................................................................................................123
Data logging .................................................................................................................................................123
Unit safeties..................................................................................................................................................125
System safeties (faults) ................................................................................................................................126
Section 8 - Micropanel ........................................................................................................................................131
Unit data key ................................................................................................................................................134
System data keys 1 through 4......................................................................................................................136
VSD data key ...............................................................................................................................................139
Operating hours / Start counter key .............................................................................................................141
History key....................................................................................................................................................142
Setpoints key................................................................................................................................................149
Program key .................................................................................................................................................151
Options key ..................................................................................................................................................154
Date/time and schedule keys .......................................................................................................................157
Manual override key .....................................................................................................................................160
Print key .......................................................................................................................................................161
System switches key ....................................................................................................................................164

JOHNSON CONTROLS 7
Form 201.28-NM1.1
Issue date: 08/06/2021
Table of contents (cont'd)
Section 9 - Maintenance .....................................................................................................................................165
General requirements...................................................................................................................................165
Refrigerant removal, evacuation and charging a YVAA chiller ....................................................................166
Microchannel coil cleaning ...........................................................................................................................167
Thermal dispersion flow switch ....................................................................................................................169
Maintenance requirements for YVAA chillers ...............................................................................................170
R-134a conversion table...............................................................................................................................174
R-513A conversion table .............................................................................................................................175
R-513A conversion table .............................................................................................................................176
Section 10 - Decommissioning, dismantling, and disposal............................................................................181
Temperature .................................................................................................................................................182
Notes ............................................................................................................................................................183

JOHNSON CONTROLS
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Form 201.28-NM1.1
Issue date: 08/06/2021
List of figures
Figure 1 - YVAA air-cooled screw liquid chiller with variable speed drives............................................................. 15
Figure 2 - Chiller control system.............................................................................................................................16
Figure 3 - View of YORK control center user interface...........................................................................................18
Figure 4 - Lifting using lugs ....................................................................................................................................24
Figure 5 - Acceptable minimum clearances around and between units .................................................................36
Figure 6 - Two pass water pressure drop, English units.........................................................................................39
Figure 7 - Three pass water pressure drop, English units......................................................................................39
Figure 8 - Pipework arrangement ...........................................................................................................................40
Figure 9 - Leaving water temperature out of range suggested layout ....................................................................40
Figure 10 - Suggested layout for applications with a ow rate less than the evaporator minimum
allowable ow rate................................................................................................................................41
Figure 11 - Suggested layout for applications with a ow rate greater than the evaporator maximum
allowable ow rate................................................................................................................................41
Figure 12 - Grooved nozzle ....................................................................................................................................41
Figure 13 - Flange for GB vessels..........................................................................................................................43
Figure 14 - Flange attachment ...............................................................................................................................43
Figure 15 - Single point power wiring .....................................................................................................................46
Figure 16 - Dual point power wiring........................................................................................................................47
Figure 17 - Customer control connections .............................................................................................................48
Figure 18 - Thermal dispersion ow switch connections ........................................................................................49
Figure 19 - Reserved customer wiring entry ..........................................................................................................50
Figure 20 - Water box heater wiring box.................................................................................................................50
Figure 21 - YVAA dimensions .................................................................................................................................82
Figure 22 - LED indicator buttons...........................................................................................................................98
Figure 23 - Flow switch set.....................................................................................................................................99
Figure 24 - Flow below the representation range ...................................................................................................99
Figure 25 - Flow exceeds the representation range ...............................................................................................99
Figure 26 - Keyboard and display.........................................................................................................................103
Figure 27 - New 331-03478-xxx microboard ........................................................................................................108
Figure 28 - LON E-Link gateway option ............................................................................................................... 113

JOHNSON CONTROLS 9
Form 201.28-NM1.1
Issue date: 08/06/2021
List of tables
Table 1 - Unit rigging...............................................................................................................................................26
Table 2 - Minimum evaporator tube removal clearance..........................................................................................36
Table 3 - Evaporator connections dimensions ........................................................................................................42
Table 4 - Electrical lug data.....................................................................................................................................52
Table 5 - Physical data - Microchannel coil.............................................................................................................64
Table 6 - Physical data - Round tube coil ...............................................................................................................68
Table 7 - Optional one-pass evaporator..................................................................................................................70
Table 8 - Standard two-pass, rear inlet/outlet evaporator ....................................................................................... 74
Table 9 - Optional three-pass rear inlet/front outlet evaporator ..............................................................................78
Table 10 - Isolator selection and mounting locations ..............................................................................................84
Table 11 - Freeze damage protection requirements...............................................................................................101
Table 12 - Values required for BAS communication.............................................................................................. 111
Table 13 - Real time error numbers for BAS, SC-EQ or E-Link communications card ......................................... 112
Table 14 - YVAA native communications data map .............................................................................................. 114
Table 15 - YVAA operational and fault/inhibit codes ............................................................................................. 117
Table 16 - YVAA E-Link communications data map.............................................................................................. 118
Table 17 - Flash card update error XXXXX...........................................................................................................123
Table 18 - Low differential oil pressure cutout.......................................................................................................128
Table 19 - Discharge pressure load limiting/unloading .........................................................................................129
Table 20 - Suction pressure load limiting/unloading .............................................................................................129
Table 21 - Start inhibit sensor thresholds..............................................................................................................130
Table 22 - Sensor min/max outputs ......................................................................................................................138
Table 23 - Compressor motor overload settings ................................................................................................... 140
Table 24 - Setpoint limits.......................................................................................................................................150
Table 25 - Programmable operating parameters ..................................................................................................153
Table 26 - Printout types .......................................................................................................................................161
Table 27 - Troubleshooting guide..........................................................................................................................169
Table 28 - R-134a pressure to saturated temperature conversion.........................................................................172
Table 29 - R-513A refrigerant pressure to saturated temperature ........................................................................173
Table 30 - R-513A refrigerant temperature to pressure ........................................................................................174
Table 31 - Temperature input voltage sensor (measured signal to shield at the sensor)......................................175
Table 32 - Outside air temperature sensor input voltage (measured signal to shield at the sensor) .................... 176
Table 33 - Pressure transducer output voltage (measured signal to return at the transducer).............................177
Table 34 - Motor temperature sensor resistance (check at the motor) .................................................................178
Table 35 - SI metric conversion ............................................................................................................................181

JOHNSON CONTROLS
10
FORM 201.28-NM1.1
ISSUE DATE: 12/18/2020
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