York YVAA Guide

AIR-COOLED SCREW
LIQUID CHILLERS
INSTALLATION, OPERATION, MAINTENANCE Supersedes: 201.28-NM1.1 (1117) Form 201.28-NM1.1 (118)
HFC-134A OR R-513A
LD15045
150 - 500 TONS
525 - 1750 KW
2 COMPRESSOR
50 AND 60 HZ
MODEL YVAA STYLE A
AIR-COOLED SCREW LIQUID CHILLERS WITH
VARIABLE SPEED DRIVE
FRAME SIZES 015 - 052
035-23219-100
Issue Date:
January 31, 2018

JOHNSON CONTROLS
2
FORM 201.28-NM1.1
ISSUE DATE: 1/31/2018
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: 1/31/2018
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 automatical-
ly to the manual or product owner. Updated manu-
als, if applicable, can be obtained by contacting
the nearest Johnson Controls Service office or ac-
cessing the Johnson Controls QuickLIT website at
http://cgproducts.johnsoncontrols.com.
The Control/VSD Cabinet contains lethal
high AC and DC voltages. Before per-
forming service inside the cabinet, remove
the AC supply feeding the chiller and
verify using a non-contact voltage sensor.
The DC voltage on the VSD DC Bus will
take 5 minutes to bleed off, after AC
power is removed. Always check the DC
Bus Voltage with a Voltmeter to assure
the capacitor charge has bled off before
working on the system.
NEVER short out the DC Bus to dis-
charge the lter capacitors.
NEVER place loose tools, debris, or any
objects inside the Control Panel/VSD
Cabinet.
NEVER allow the Control Panel VSD
Cabinet doors to remain open if there is
a potential for rain to enter the panel.
Keep doors closed and assure all 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.
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.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
formation and any other changes in spelling, grammar
or formatting are not included.
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

JOHNSON CONTROLS
4
FORM 201.28-NM1.1
ISSUE DATE: 10/12/2017
THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS 5
FORM 201.28-NM1.1
ISSUE DATE: 1/31/2018
TABLE OF CONTENTS
SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY ......................................................................13
Introduction.....................................................................................................................................................13
Warranty .........................................................................................................................................................13
Quality Assurance and Safety ........................................................................................................................14
Fluorinated Greenhouse Gases .....................................................................................................................14
Responsibility for Safety.................................................................................................................................14
About This Manual..........................................................................................................................................14
Misuse of Equipment......................................................................................................................................14
Suitability for Application .......................................................................................................................14
Structural Support .................................................................................................................................15
Mechanical Strength .............................................................................................................................15
General Access .....................................................................................................................................15
Pressure Systems .................................................................................................................................15
Electrical................................................................................................................................................15
Rotating Parts........................................................................................................................................15
Sharp Edges..........................................................................................................................................15
Refrigerants and Oils.............................................................................................................................16
High Temperature and Pressure Cleaning ............................................................................................16
Emergency Shutdown ...........................................................................................................................16
Safety Labels.........................................................................................................................................16
SECTION 2 - PRODUCT DESCRIPTION...............................................................................................................17
General System Description...........................................................................................................................17
Semi-Hermetic YORK Twin-Screw Compressors...........................................................................................19
Evaporator......................................................................................................................................................19
Condenser......................................................................................................................................................19
Refrigerant Circuit ..........................................................................................................................................19
Electrical.........................................................................................................................................................19
Building Automation System Capabilities .......................................................................................................20
Microcomputer Control Center .......................................................................................................................20
Display Data ..........................................................................................................................................20
Programmable Setpoints ......................................................................................................................20
Accessories and Options................................................................................................................................ 21
Sound Attenuation .................................................................................................................................21
Fan Options....................................................................................................................................................21
Condenser Coils.............................................................................................................................................21
Condenser Coil Protection ....................................................................................................................21
Protective Chiller Panels .......................................................................................................................21
Evaporator Options ...............................................................................................................................22
Controls Options....................................................................................................................................22
General Options ....................................................................................................................................22
Vibration Isolation..................................................................................................................................23
SECTION 3 - RIGGING, HANDLING AND STORAGE ..........................................................................................25
Lifting Weights................................................................................................................................................25
Delivery and Storage......................................................................................................................................25
Inspection .......................................................................................................................................................26
Moving the Chiller...........................................................................................................................................26
Unit Removal From Shipping Container.........................................................................................................26
Lifting Using Lugs...........................................................................................................................................26
Lifting Using Shackles ....................................................................................................................................26

JOHNSON CONTROLS
6
FORM 201.28-NM1.1
ISSUE DATE: 1/31/2018
TABLE OF CONTENTS (CONT'D)
SECTION 4 - INSTALLATION ................................................................................................................................37
Location Requirements ..................................................................................................................................37
Outdoor Installations ......................................................................................................................................37
Location Clearances....................................................................................................................................... 37
Recommended Minimum Clearances ...................................................................................................38
Vibration Isolators........................................................................................................................................... 39
Installation .............................................................................................................................................39
Shipping Braces .............................................................................................................................................39
Chilled Liquid Piping.......................................................................................................................................39
General Requirements ..........................................................................................................................39
Evaporator Pressure Drop.............................................................................................................................. 40
Water Treatment.............................................................................................................................................41
Pipework Arrangement ...................................................................................................................................41
Minimum Water Volume .................................................................................................................................42
Leaving Water Temperature Out of Range.....................................................................................................42
Thermal Storage............................................................................................................................................. 43
Variable Primary Flow ....................................................................................................................................43
Connection Types and Sizes..........................................................................................................................43
Evaporator Connections.................................................................................................................................43
Option Flanges ......................................................................................................................................45
Refrigerant Relief Valve Piping.......................................................................................................................45
Electrical Connection...................................................................................................................................... 45
Power Wiring ..................................................................................................................................................46
Power Supply Wiring ......................................................................................................................................46
115VAC Control Supply Transformer..............................................................................................................46
Control Wiring.................................................................................................................................................46
Volts Free Contacts ........................................................................................................................................47
Chilled Liquid Pump Starter...................................................................................................................47
Run Contact ..........................................................................................................................................47
Alarm Contacts......................................................................................................................................47
System Inputs................................................................................................................................................. 47
Flow Switch ...........................................................................................................................................47
Remote Run / Stop................................................................................................................................47
Remote Print .........................................................................................................................................47
Optional Remote Setpoint Offset – Temperature...................................................................................47
Optional Remote Setpoint Offset – Current...........................................................................................47
Optional Remote Setpoint Offset – Sound Limiting............................................................................... 47
Power Supply Wiring ......................................................................................................................................48
Single Point Wiring ................................................................................................................................48
Voltage Utilization Range ......................................................................................................................48
Dual Point Wiring...................................................................................................................................49
Customer Control Wiring ................................................................................................................................50
SECTION 5 - TECHNICAL DATA ...........................................................................................................................63
Nomenclature .................................................................................................................................................63
Elastomeric Isolator Installation...................................................................................................................... 90
Elastomeric Isolator Specifications................................................................................................................. 91
One Inch Deflection Isolator Installation.........................................................................................................92
One Inch Deflection Spring Isolator Specifications ........................................................................................93
CPX-xx-xxx............................................................................................................................................93

JOHNSON CONTROLS 7
FORM 201.28-NM1.1
ISSUE DATE: 1/31/2018
TABLE OF CONTENTS (CONT'D)
Two Inch Deflection Isolator Installation And Adjustment ............................................................................... 94
Two Inch Deflection, Restrained Spring Isolator Specifications .....................................................................95
Y2RSI-xx-xxx.........................................................................................................................................95
SECTION 6 - COMMISSIONING ............................................................................................................................97
Preparation.....................................................................................................................................................97
Inspection .............................................................................................................................................97
Refrigerant Charge................................................................................................................................97
Correct System Refrigerant Charge ......................................................................................................97
Service and Oil Line Valves...................................................................................................................97
Compressor Oil .....................................................................................................................................97
Fans .....................................................................................................................................................98
Isolation / Protection..............................................................................................................................98
Control Panel.........................................................................................................................................98
Power Connections ...............................................................................................................................98
Grounding..............................................................................................................................................98
Water System........................................................................................................................................98
Flow Switch ...........................................................................................................................................98
Temperature Sensor(s)..........................................................................................................................98
Programmed Options ............................................................................................................................98
Programmed Settings ...........................................................................................................................98
Date and Time .......................................................................................................................................98
Start/Stop Schedule ..............................................................................................................................98
Setpoint and Remote Offset ..................................................................................................................99
First Time Start Up .........................................................................................................................................99
Interlocks ...............................................................................................................................................99
Unit Switch ............................................................................................................................................99
Startup...................................................................................................................................................99
Oil Pressure...........................................................................................................................................99
Loading..................................................................................................................................................99
Condenser and Fan Rotation ................................................................................................................99
System Charge......................................................................................................................................99
General Operation .......................................................................................................................................100
Operation in Sub-freezing Conditions .................................................................................................100
Unit Maintenance and Shutdown in Sub-freezing Conditions ............................................................100
SECTION 7 - OPERATION ...................................................................................................................................101
Operating Controls .......................................................................................................................................101
Unit Switch ..........................................................................................................................................101
Keypad ................................................................................................................................................101
Keypad Data Entry Mode ....................................................................................................................102
Display.................................................................................................................................................102
Anti-recycle Timer................................................................................................................................102
Evaporator Pump Control....................................................................................................................102
Evaporator Heater Control ..................................................................................................................103
Alarms .................................................................................................................................................103
Chiller Run Contact .............................................................................................................................103
Flow Switch Control.............................................................................................................................103
Remote Run / Stop..............................................................................................................................103

JOHNSON CONTROLS
8
FORM 201.28-NM1.1
ISSUE DATE: 1/31/2018
TABLE OF CONTENTS (CONT'D)
Basic Operating Sequence........................................................................................................................... 103
Start Sequence and Loading...............................................................................................................103
Unit Warning.................................................................................................................................................103
Unit Warning Operation.......................................................................................................................103
Low Battery Warning ...........................................................................................................................103
Microboard (331-03478-xxx) ........................................................................................................................104
Power Supplies and LEDs...................................................................................................................104
Power Supply Test Points....................................................................................................................104
Conguration Jumpers .......................................................................................................................104
Building Automation System (BAS) Communications .................................................................................. 106
Using Communications Protocol .........................................................................................................106
E-Link or SC-EQ Interface............................................................................................................................ 107
SC-EQ or E-Link BAS Communications Card.............................................................................................. 110
VSD ..................................................................................................................................................... 118
Program Update ........................................................................................................................................... 118
Data Logging ................................................................................................................................................ 118
Invalid Number of Compressors Warning............................................................................................ 119
Invalid Serial Number Warning............................................................................................................ 119
Unit Safeties .................................................................................................................................................120
Unit Safety Operation ..........................................................................................................................120
High Ambient Temp Fault ....................................................................................................................120
Low Ambient Temp Fault .....................................................................................................................120
Low Leaving Chilled Liquid Temp Fault...............................................................................................120
VSD Communications Failure Fault ....................................................................................................120
System Safeties (Faults) ..............................................................................................................................121
System Safety (Fault) Operation .........................................................................................................121
High Discharge Pressure Cutout (Software) Fault ..............................................................................121
High Discharge Pressure Cutout (HPCO) (Hardware) Fault ..............................................................121
Low Suction Pressure Cutout (Software) Fault ...................................................................................122
Low Motor Current Cutout Fault ..........................................................................................................122
High Differential Oil Pressure Cutout Fault .........................................................................................122
Low Differential Oil Pressure Cutout Fault ..........................................................................................122
High Discharge Temperature Cutout Fault ..........................................................................................123
Low Discharge Superheat Cutout Fault ..............................................................................................123
Discharge Pressure Load Limiting/Unloading .....................................................................................123
Suction Pressure Load Limiting/Unloading .........................................................................................124
Sensor Failure Cutout Fault ................................................................................................................124
High Motor Temperature Cutout Fault .................................................................................................125
System Control Voltage Cutout Fault ..................................................................................................125
Eductor Clog Fault...............................................................................................................................125

JOHNSON CONTROLS 9
FORM 201.28-NM1.1
ISSUE DATE: 1/31/2018
TABLE OF CONTENTS (CONT'D)
SECTION 8 - MICROPANEL ................................................................................................................................127
SECTION 9 - MAINTENANCE..............................................................................................................................161
General Requirements .................................................................................................................................161
Weekly Maintenance ...........................................................................................................................161
Unit Status...........................................................................................................................................161
Refrigerant Leaks ................................................................................................................................161
Operating Conditions...........................................................................................................................161
Compressor Oil Level..........................................................................................................................161
Refrigerant Charge..............................................................................................................................161
Adding Charge to a System ................................................................................................................161
Refrigerant Removal, Evacuation and Charging a YVAA Chiller .................................................................162
Refrigerant Removal ...........................................................................................................................162
Evacuating a System...........................................................................................................................162
Charging Refrigerant into a System ....................................................................................................163
Microchannel Coil Cleaning.......................................................................................................................... 163
Scheduled Maintenance......................................................................................................................163
Maintenance Requirements for YVAA Chillers .............................................................................................164
R-513A Conversion Table ............................................................................................................................168
R-513A Conversion Table ............................................................................................................................169
SECTION 10 - DECOMMISSIONING, DISMANTLING AND DISPOSAL ............................................................175

JOHNSON CONTROLS
10
FORM 201.28-NM1.1
ISSUE DATE: 1/31/2018
LIST OF FIGURES
FIGURE 1 - YVAA Air-Cooled Screw Liquid Chiller with Variable Speed Drive.......................................................17
FIGURE 2 - Chiller Control System.........................................................................................................................18
FIGURE 3 - View of York Control Center User Interface .........................................................................................20
FIGURE 4 - Acceptable Minimum Clearances Around/Between Unit(s) .................................................................38
FIGURE 5 - Three Pass Water Pressure Drop, english units.................................................................................. 40
FIGURE 6 - Two Pass Water Pressure Drop, SI Units ............................................................................................41
FIGURE 7 - Pipework Arrangement ........................................................................................................................41
FIGURE 8 - Leaving Water Temperature Out of Range Suggested Layout ............................................................42
FIGURE 9 - Suggested Layout For Applications With A Flow Rate Less Than The Evaporator
Minimum Allowable Flow Rate.............................................................................................................42
FIGURE 10 - Suggested Layout For Applications With A Flow Rate Greater Than The Evaporator
Maximum Allowable Flow Rate..........................................................................................................42
FIGURE 11 - Victaulic Groove.................................................................................................................................43
FIGURE 12 - Flange For GB Vessels......................................................................................................................45
FIGURE 13 - Flange Attachment.............................................................................................................................45
FIGURE 14 - Single Point Power Wiring .................................................................................................................48
FIGURE 15 - Dual Point Power Wiring....................................................................................................................49
FIGURE 16 - Customer Control Connections .........................................................................................................50
FIGURE 17 - YVAA Dimensions..............................................................................................................................82
FIGURE 18 - Keyboard and Display......................................................................................................................101
FIGURE 19 - New 331-03478-xxx Microboard......................................................................................................105
FIGURE 20 - LON E-Link Gateway Option ........................................................................................................... 110