York YLUA0248 Series Owner's manual

YLUA0248 – YLUA0498
AIR-COOLED SCROLL CONDENSING UNITS
STYLE A (50 Hz)
70 ton to 135 ton
245 kW to 475 kW
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED SCROLL CONDENSING UNITS
Supersedes: 150.73-NM2 (609) Form 150.73-NM2 (920)
R-410A
035-22868-100
Issue Date:
September 7, 2020

JOHNSON CONTROLS
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FORM 150.73-NM2
ISSUE DATE: 09/07/2020
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.

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FORM 150.73-NM2
ISSUE DATE: 09/07/2020
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.
ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
Installation and Start-up Checklist 150.73-CL2
Limited Warranty Engineered Systems Equipment 50.05-NM2
Shipping Damage Claims 50.15-NM
AFFECTED PAGES DESCRIPTION
3 Conditioned Based Maintenance program information added
18 Motor Current Module paragraph removed
79 Isolator locations updated in image and dimensions updated in table for YLUA0308 to YLUA0408
83 Isolator Locations section removed
91–93 Checklist updated to latest version
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.

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TABLE OF CONTENTS
SECTION 1 – GENERAL EQUIPMENT INFORMATION AND SAFETY .......................................................... 11
Introduction..................................................................................................................................................... 11
Compressors .................................................................................................................................................. 11
Condenser...................................................................................................................................................... 11
Refrigerant Circuit .......................................................................................................................................... 11
Warranty ......................................................................................................................................................... 11
Safety And Quality..........................................................................................................................................12
About This Manual..........................................................................................................................................12
Misuse Of Equipment .....................................................................................................................................13
SECTION 2 – PRODUCT DESCRIPTION...........................................................................................................15
Introduction.....................................................................................................................................................15
General System Description...........................................................................................................................15
Refrigerant Circuit ..........................................................................................................................................16
Microcomputer Control Center ....................................................................................................................... 16
High Ambient Kit.............................................................................................................................................17
Communications.............................................................................................................................................17
Power Panel ...................................................................................................................................................17
Accessories And Options ...............................................................................................................................18
Unit Components ...........................................................................................................................................20
Product Identification Number (Pin) ...............................................................................................................23
Refrigerant Flow Diagram .............................................................................................................................. 28
Process And Instrumentation Diagram...........................................................................................................29
SECTION 3 – HANDLING AND STORAGE........................................................................................................31
Delivery And Storage......................................................................................................................................31
Inspection .......................................................................................................................................................31
Unit Rigging....................................................................................................................................................31
SECTION 4 – INSTALLATION .............................................................................................................................33
Installation Checklist.......................................................................................................................................33
Handling .........................................................................................................................................................33
Location And Clearances ...............................................................................................................................33
Spring Isolators (Optional)..............................................................................................................................34
Compressor Mounting ....................................................................................................................................34
Pipework Arrangement ...................................................................................................................................34
Duct Work Connection ................................................................................................................................... 34
Wiring .............................................................................................................................................................34
Compressor Heaters ......................................................................................................................................35
Relief Valves...................................................................................................................................................35
High Pressure Cutout .....................................................................................................................................35
Electrical Wiring..............................................................................................................................................35
Compressor Heaters ......................................................................................................................................37
Refrigerant Piping...........................................................................................................................................37
Refrigerant Piping Reference .........................................................................................................................37
YCRL Line Sizing Notes .................................................................................................................................37
Refrigerant Line Sizing ...................................................................................................................................40
Oil Traps .......................................................................................................................................................40

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TABLE OF CONTENTS (CONT’D)
Refrigerant Charge.........................................................................................................................................40
Filter Driers/ Sight Glasses/ TXVs..................................................................................................................40
Refrigerant Piping Notes ................................................................................................................................ 41
Control Wiring.................................................................................................................................................43
SECTION 5 – TECHNICAL DATA........................................................................................................................45
Operational Limitations (English) ...................................................................................................................45
Physical Data (English) .................................................................................................................................. 46
Electrical Data ................................................................................................................................................47
Wiring Diagrams.............................................................................................................................................54
Dimensions (English) .....................................................................................................................................78
Clearances .....................................................................................................................................................81
Weight Distribution and Isolator Mounting Positions ......................................................................................82
Isolator Information.........................................................................................................................................83
SECTION 6 – COMMISSIONING.........................................................................................................................89
Commissioning...............................................................................................................................................89
Preparation – Power Off.................................................................................................................................89
Preparation – Power On.................................................................................................................................90
SECTION 7 – UNIT CONTROLS..........................................................................................................................95
Introduction.....................................................................................................................................................95
Microprocessor Board ....................................................................................................................................95
Unit Switch .....................................................................................................................................................96
Display............................................................................................................................................................96
Keypad ...........................................................................................................................................................96
Battery Back-Up .............................................................................................................................................96
Transformer ...................................................................................................................................................96
Single System Select And Programming Number Of Compressors...............................................................96
Status Key ......................................................................................................................................................97
Display/Print Keys ........................................................................................................................................102
Entry Keys .................................................................................................................................................... 110
Setpoints Keys ............................................................................................................................................. 111
Unit Keys ..................................................................................................................................................... 118
SECTION 8 – UNIT OPERATION ......................................................................................................................125
Capacity Control...........................................................................................................................................125
Suction Pressure Limit Controls ...................................................................................................................125
Discharge Pressure Limit Controls...............................................................................................................125
Discharge Air Temperature Control ..............................................................................................................125
Suction Pressure Control .............................................................................................................................127
System Lead/Lag .........................................................................................................................................128
Compressor Lead/Lag..................................................................................................................................128
Anti-Recycle Timer .......................................................................................................................................128
Anti-Coincidence Timer ................................................................................................................................128
Evaporator Blower Control ........................................................................................................................... 128
Pumpdown Control.......................................................................................................................................128
Condenser Fan Control ................................................................................................................................132
Load Limiting ................................................................................................................................................133

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TABLE OF CONTENTS (CONT’D)
Compressor Run Status ...............................................................................................................................133
Alarm Status.................................................................................................................................................133
BAS/EMS Discharge Air Temperature Reset Using A Voltage Or Current Signal .......................................134
SECTION 9 – SERVICE AND TROUBLESHOOTING .....................................................................................135
Clearing History Buffers................................................................................................................................ 135
Service Mode ...............................................................................................................................................135
Service Mode – Outputs...............................................................................................................................135
Service Mode – Condensing Unit Configuration ..........................................................................................136
Service Mode – Analog And Digital Inputs ...................................................................................................136
Control Inputs/Outputs .................................................................................................................................137
Checking Inputs And Outputs.......................................................................................................................139
Optional Printer Installation ..........................................................................................................................143
Troubleshooting............................................................................................................................................144
SECTION 10 – MAINTENANCE.........................................................................................................................147
Important ......................................................................................................................................................147
Compressors ................................................................................................................................................147
Condenser Fan Motors.................................................................................................................................147
Condenser Coils...........................................................................................................................................147
Operating Parameters ..................................................................................................................................147
On-Board Battery Back-Up...........................................................................................................................147
Overall Unit Inspection ................................................................................................................................. 147
ISN Control...................................................................................................................................................148
BACnet And Modbus Data Communication .................................................................................................151

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FORM 150.73-NM2
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LIST OF FIGURES
FIGURE 1 - Compressors.......................................................................................................................................15
FIGURE 2 - Unit Components Front.......................................................................................................................20
FIGURE 3 - Power Panel Components ..................................................................................................................21
FIGURE 4 - Power Panel / Control Components....................................................................................................22
FIGURE 5 - Refrigerant Flow Diagram ...................................................................................................................28
FIGURE 6 - Process And Instrumentation Diagram ...............................................................................................29
FIGURE 7 - Unit Rigging ........................................................................................................................................31
FIGURE 8 - Single-Point Supply Connection – Terminal Block, Non-Fused Disconnect Switch
Or Circuit Breaker ...............................................................................................................................42
FIGURE 9 - Discharge Air Sensor Field Wiring ......................................................................................................42
FIGURE 10 - Control Wiring ...................................................................................................................................43
FIGURE 11 - Elementary Wiring Diagram ..............................................................................................................54
FIGURE 12 - Elementary Wiring Diagram..............................................................................................................56
FIGURE 13 - Elementary Wiring Diagram..............................................................................................................58
FIGURE 14 - Elementary Wiring Diagram..............................................................................................................60
FIGURE 15 - Elementary Wiring Diagram..............................................................................................................62
FIGURE 16 - Power Options Connection Diagram.................................................................................................64
FIGURE 17 - Power Panel......................................................................................................................................66
FIGURE 18 - Single Point & Dual Point Wiring.......................................................................................................68
FIGURE 19 - Wiring................................................................................................................................................70
FIGURE 20 - Micro Panel Connections..................................................................................................................72
FIGURE 21 - Elementary Diagram .........................................................................................................................74
FIGURE 22 - Elementary Diagram .........................................................................................................................76
FIGURE 23 - Unit Clearances – All Models ............................................................................................................81
FIGURE 24 - Setpoints Quick Reference List....................................................................................................... 117
FIGURE 25 - Unit Keys Programming Quick Reference List................................................................................123
FIGURE 26 - Discharge Air Temperature Control.................................................................................................126
FIGURE 27 - Suction Pressure Control................................................................................................................127
FIGURE 28 - YLUA0248 – YLUA0298 Fan Location (Typical) ............................................................................129
FIGURE 29 - YLUA0308 – YLUA0408 Fan Location ..........................................................................................131
FIGURE 30 - YLUA0468 – YLUA0498 Fan Location ...........................................................................................132
FIGURE 31 - Microboard Layout ..........................................................................................................................138
FIGURE 32 - I/O Board Relay Contact Architecture ............................................................................................142
FIGURE 33 - Printer to Microboard Electrical Connections..................................................................................143

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LIST OF TABLES
TABLE 1 - Fitting Equivalent Lengths.....................................................................................................................38
TABLE 2 - Refrigerant Piping Charges...................................................................................................................38
TABLE 3 - Miscellaneous Liquid Line Pressure Drops...........................................................................................38
TABLE 4 - Refrigerant Line Connections ...............................................................................................................39
TABLE 5 - Refrigerant Line Pressure Drops (English) ...........................................................................................41
TABLE 6 - Voltage Limitations................................................................................................................................45
TABLE 7 - Physical Data (English).........................................................................................................................46
TABLE 8 - Micro Panel Power Supply....................................................................................................................47
TABLE 9 - Voltage Range ......................................................................................................................................47
TABLE 10 - Unit Electrical Data .............................................................................................................................48
TABLE 11 - Lug Sizing ...........................................................................................................................................49
TABLE 12 - Status Key Messages Quick Reference List.....................................................................................101
TABLE 13 - Operation Data..................................................................................................................................105
TABLE 14 - Cooling Setpoints Programmable Limits And Defaults ..................................................................... 116
TABLE 15 - Program Key Limits And Defaults ..................................................................................................... 116
TABLE 16 - Discharge Air Temperature Control For 5 And 6 Compressors (7 And 8 Steps)..................................126
TABLE 17 - Discharge Air Temperature Control For 4 Compressors (6 Steps) ................................................... 126
TABLE 18 - YLUA0248 – YLUA0298 Condenser Fan Control Using Outdoor Ambient Temperature
And Discharge Pressure .................................................................................................................129
TABLE 19 - YLUA0248 – YLUA0298 Condenser Fan Control Using Discharge Pressure Only..........................129
TABLE 20 - YLUA0248 – YLUA0298 Low Ambient Condenser Fan Control – Discharge Pressure Control .......130
TABLE 21 - YLUA0308 – YLUA0408 Condenser Fan Control ............................................................................131
TABLE 22 - YLUA0468 – YLUA0498 Condenser Fan Control ............................................................................132
TABLE 23 - Compressor Operation – Load Limiting ............................................................................................133
TABLE 24 - I/O Digital Inputs ...............................................................................................................................137
TABLE 25 - I/O Digital Outputs.............................................................................................................................137
TABLE 26 - I/O Analog Inputs ..............................................................................................................................137
TABLE 27 - I/O Analog Outputs............................................................................................................................137
TABLE 28 - Outdoor Air Sensor Temperature/Voltage/ Correlation...................................................................... 139
TABLE 29 - Discharge Air Temp. Sensor Temperature/Voltage/Resistance Correlation......................................140
TABLE 30 - Pressure Transducers.......................................................................................................................141
TABLE 31 - Troubleshooting ................................................................................................................................144
TABLE 32 - ISN Received Data ...........................................................................................................................148
TABLE 33 - ISN Transmitted Data........................................................................................................................148
TABLE 34 - ISN Operational And Fault Codes.....................................................................................................150
TABLE 35 - Minimum, Maximum And Default Values ..........................................................................................152
TABLE 36 - Real Time Error Numbers .................................................................................................................152
TABLE 37 - Serial Communication Analog Value Data ........................................................................................153
TABLE 38 - Serial Communication Binary Value Data .........................................................................................153
TABLE 39 - Serial Communication Analog Input Data .........................................................................................153
TABLE 40 - Serial Communication Binary Input Data ..........................................................................................155

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