Johnson Controls YORK YLAA0180SE Installation, Operation And Maintenance Manual
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Johnson Controls YORK YLAA0180SE Installation, Operation And Maintenance Manual

Air cooled liquid chillers with scroll compressors
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YLAA0180SE-YLAA0485SE & YLAA0195HE-YLAA0516HE
Installation, Comissioning, Operation
Supercedes: 150.72-ICOM8.EN.CE (0912)
Form 150.72-ICOM8.EN.CE (0713)
and Maintenance
035-23574-100
AIR COOLED LIQUID CHILLERS
WITH SCROLL COMPRESSORS
STYLE B
(Cooling Capacities: 187 kW to 520 kW)
R410A

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Summary of Contents for Johnson Controls YORK YLAA0180SE

  • Page 1 YLAA0180SE-YLAA0485SE & YLAA0195HE-YLAA0516HE Installation, Comissioning, Operation Supercedes: 150.72-ICOM8.EN.CE (0912) Form 150.72-ICOM8.EN.CE (0713) and Maintenance 035-23574-100 AIR COOLED LIQUID CHILLERS WITH SCROLL COMPRESSORS STYLE B (Cooling Capacities: 187 kW to 520 kW) R410A...
  • Page 3 Form 150.72-ICOM8.EN.CE (0713) Table of Contents Transportation, Handling and Storage ..3-1 General Chiller Information and Safety ..1-1 Delivery and Storage Introduction Inspection Warranty Moving the unit Standards for Safety Typical Lifting Arrangement Fluorinated Greenhouse Gases Lifting Weights Responsibility for Safety About this manual...

  • Page 4: Table Of Contents

    Form 150.72-ICOM8.EN.CE (0713) Commissioning ......5-1 Preparation 6. Unit Operation......6-1 General Description Start-up Normal running and cycling Shutdown Maintenance ....... 7-1 General Requirements Daily Maintenance Scheduled Maintenance...
  • Page 5 ISO 9614 – Determination of sound power levels Warranty of noise sources using sound intensity Johnson Controls warrants all equipment and materials Conform to CE Testing Services for construction of against defects in workmanship and materials for a chillers and provide CE Listed Mark...
  • Page 6 Electrical This manual and any other document supplied with the unit are the property of Johnson Controls which The unit must be earthed. No installation or maintenance reserves all rights. They may not be reproduced, in work should be attempted on the electrical equipment whole or in part, without prior written authorization from an authorized Johnson Controls representative.
  • Page 7 Form 150.72-ICOM8.EN.CE (0713) Refrigerants and Oils Safety Labels Refrigerants and oils used in the unit are generally instruction, or to indicate potential hazards which may no special safety hazards. Use of gloves and safety exist. glasses is, however, recommended when working White symbol on blue background on the unit.
  • Page 8 Form 150.72-ICOM8.EN.CE (0713) Material Safety Data Refrigerant Safety Data R410A: COMPOSITION/INFORMATION ON INGREDIENTS Components Material PENTAFLUOROETHANE (HFC-125) DIFLUOROMETHANE (HFC-32) CAS Number 354-33-6 75-10-5 HAZARDS IDENTIFICATION Potential Health Effects Inhalation of high concentrations of vapour is harmful and may cause heart irregularities, unconsciousness, or death.
  • Page 9 Form 150.72-ICOM8.EN.CE (0713) Refrigerant Safety Data R410A: Extinguishing Media As appropriate for combustibles in area. Fire Fighting Instructions Cool cylinder with water spray or fog. Self-contained breathing apparatus (SCBA) is required if cylinders rupture and contents are released under fire conditions. Water runoff should be contained and neutralized prior to release.
  • Page 10 Form 150.72-ICOM8.EN.CE (0713) Refrigerant Safety Data R410A: Polymerization Polymerization will not occur. Other Hazards Decomposition : Decomposition products are hazardous. This material can be decomposed by high temperatures (open flames, glowing metal surfaces, etc.) forming hydrofluoric acid, and possibly carbonyl halides.
  • Page 11 Form 150.72-ICOM8.EN.CE (0713) Oil Safety Data YORK 'V' Oil: Section 1 Substance Product Information Product Trade Name: YORK "V" Oil. Chemical Name: Carboxylic Ester. Section 2 Components and Hazard Statement This product is non-hazardous. This material has no known hazards under applicable laws. Section 3 Safe Handling and Storage Handling: Keep containers closed when not in use.
  • Page 12 Form 150.72-ICOM8.EN.CE (0713) Page Left Intentionally Blank...
  • Page 13 Form 150.72-ICOM8.EN.CE (0713) each unit. Each circuit uses copper refrigerant pipe formed on computer controlled bending machines to reduce the number of brazed joints resulting in a YLAA air-cooled chillers are completely factory reliable and leak resistant system. assembled with all interconnecting refrigerant piping Liquid line components include: a service valve with pressure tested, evacuated, and fully factory charged with refrigerant R410A and oil in each of the independent...
  • Page 14 Form 150.72-ICOM8.EN.CE (0713) and dynamically balanced for vibration free operation. Programmable setpoints: They are directly driven by independent motors, and Chilled liquid temperature setpoint and range positioned for vertical air discharge. The fan guards Remote reset temperature range are constructed from heavy-gauge, corrosion resistant, Set daily schedule/holiday for start/stop coated steel.
  • Page 15 Form 150.72-ICOM8.EN.CE (0713) Alarm Contacts: Thermal Dispersion Flow Switch Low leaving chilled liquid temperature Low voltage included as standard. It is factory wired and installed Low battery in the extension pipe between evaporator outlet and High discharge pressure (per system) edge of chiller.
  • Page 16 Form 150.72-ICOM8.EN.CE (0713) Condenser Coil Louvred Panels and Unit Wire Coil End Hail Guard Guards Louvred panel attached to exposed coil end. Louvred panels mounted over the condenser coils, and Neoprene Pads Isolators welded wire mesh guards mounted around the bottom of the unit.
  • Page 17 Form 150.72-ICOM8.EN.CE (0713) Component Location Diagram BRAZED PLATE EVAPORATOR Hydrokit Components Outlet coupling with port. Used to read pressure Inlet to evaporator before the evaporator (optional). Customer inlet Coupling with drain port (optional). Customer outlet Outlet coupling with drain port Coupling with port for field provided expansion 1/4”...
  • Page 18 Form 150.72-ICOM8.EN.CE (0713) Nomenclature YLAA 0390H E 50XAA 1 2 3 4 5 6 7 8 11 12 13 14 15 BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATION REFRIGERANT VOLTAGE / STARTER DESIGN / DEVELOPMENT LEVEL : York : Standard Unit : R-410A : 380-415 / 3 / 50 : Design Series...
  • Page 19 Major damage must be reported immediately to your local Johnson Controls representative.
  • Page 20 Form 150.72-ICOM8.EN.CE (0713) Typical Lifting Arrangement...
  • Page 21 Form 150.72-ICOM8.EN.CE (0713) Lifting Weights For details of weights and weight distribution, refer to the technical data section of this manual.
  • Page 22 Form 150.72-ICOM8.EN.CE (0713) Page Left Intentionally Blank...
  • Page 23 Form 150.72-ICOM8.EN.CE (0713) 4. Installation Indoor installations The unit can be installed in an enclosed plant room, Location Requirements to support the full operating weight of the unit. It is To achieve optimum performance and trouble-free service, it is essential that the proposed installation site to the unit.
  • Page 24 Form 150.72-ICOM8.EN.CE (0713) Where cross-winds may occur, any ductwork must be Location Clearances supported to prevent side loading on the unit. If the Adequate clearances around the unit(s) are required ducts from two or more fans are to be combined into coils and to prevent re-circulation of warm discharge the individual fan ducts.
  • Page 25 Form 150.72-ICOM8.EN.CE (0713)
  • Page 26 Form 150.72-ICOM8.EN.CE (0713) Location Clearances - SE & SELS Models YLAA-SE YLAA-SE-LS Dim. YLAA 0180 0210 0180 0210 0360 0435 0360 0435 0240 0285 0320 0240 0285 0320 0400 0485 0400 0485 Arrangement Solid Walls Arrangement Solid Walls Arrangement Louvres on 2 walls Arrangement Solid Walls...
  • Page 27 Form 150.72-ICOM8.EN.CE (0713) Pipework Connection pumps must also be used to ensure liquid is circulated when the ambient temperature approaches freezing The following piping recommendations are intended point. Insulation should also be installed around the to ensure satisfactory operation of the unit. Failure to heat exchanger nozzles.
  • Page 28 Form 150.72-ICOM8.EN.CE (0713) Chilled Liquid System with Standard Hydrokit Option Single or Dual Pump Press./Temp. Ports on Pump Inlet and Outlet Flow Regulating Valve Port for Venting Device Strainer Customer Inlet Pressure Measurement (2) Pump Drain Ports Flow Switch Evap. Victaulic Connection Customer Outlet ¼”...
  • Page 29 Form 150.72-ICOM8.EN.CE (0713) Heat Recovery System Pressure Tapping Air vent Drain Isolating Valve – Normally Open 3 Way Control Valve Flow Regulating Valve Strainer Closed Loop Heat Recovery System If heat recovery is being used to heat potable water, the potable water must be isolated from the heat recovery condenser by using a secondary heat exchanger as shown below.
  • Page 30 Form 150.72-ICOM8.EN.CE (0713) Water Treatment D5=1.447 x L The unit performance given in the Design Guide is Where: based on a fouling factor of 0.018 m² °C/kW . Dirt, D = minimum pipe internal diameter (cm) scale, grease and certain types of water treatment will adversely affect the heat exchanger surfaces and L = length of pipe (m).
  • Page 31 Form 150.72-ICOM8.EN.CE (0713) Single Point Power Supply Wiring Chilled Liquid Pump Starter Terminals 23 and 24 close to start the liquid pump. + PE (Protected Earth) supply to the unit with circuit This contact is closed if there is a ‘Leaving Liquid protection.
  • Page 32 Form 150.72-ICOM8.EN.CE (0713) Flow Switch Fan Full Speed Inhibit The fan full speed inhibit input is 30 Vdc and as standard. It is factory wired and installed in the the customer voltage free contact and wiring extension pipe between evaporator outlet and edge must be suitable for 30 Vdc.

  • Page 33: Commissioning

    Control panel: Check the panel to see that it is free of has been set to the On position before commissioning foreign materials (wire, metal chips, etc.) and clean out then it must be reported to Johnson Controls otherwise if required. the warranty may be invalidated.
  • Page 34 Form 150.72-ICOM8.EN.CE (0713) Switch Settings: Ensure that the unit On/Off toggle Programmed options: Verify that the options switch beneath the key pad in the electronic section factory programmed into the Microprocessor Control of the control panel is set to OFF. Set the non-fused Centre are in accordance with the customers order disconnect switch to ON.
  • Page 35 Form 150.72-ICOM8.EN.CE (0713) First Time Start-Up System Operation: Use the ‘OPER DATA’ key to check the system pressures and temperatures. During the commissioning period there should Suction Superheat: Check suction superheat at stable full load operation to enable the unit steady full system load only.
  • Page 36 Form 150.72-ICOM8.EN.CE (0713) Page Left Intentionally Blank...

  • Page 37: Unit Operation

    Form 150.72-ICOM8.EN.CE (0713) 6. Unit Operation Normal running and cycling Once the unit has been started, all operations are fully General Description automatic. After an initial period of operation with the lead compressor, the control system will adjust the unit The units are designed to work independently, or load depending on the chilled liquid temperature and in conjunction with other equipment via a Johnson...
  • Page 38 Form 150.72-ICOM8.EN.CE (0713) Page Left Intentionally Blank...

  • Page 39: Maintenance

    If damage or a system failure occurs due limit of the oil sight glass. to improper maintenance during the warranty period, Johnson Controls shall not be liable for costs incurred to return the unit to satisfactory condition. This maintenance section applies to the basic...

  • Page 40: Scheduled Maintenance

    In the design of the vessels used in the unit, a 1 mm corrosion allowance has been used to consider slight corrosion Johnson Controls believes that periodic in service proof testing (e.g.; hydro tests) is not required. However, Johnson Controls recognises that national regulations may require such testing to be conducted.

  • Page 41: Trouble Shooting

    Form 150.72-ICOM8.EN.CE (0713) 8. Trouble Shooting Competent Persons Trouble Shooting Guide PROBLEM POSSIBLE CAUSE ACTION No display on panel — Unit will not Mains supply to unit off. Switch on mains supply if safe to do so. operate Emergency stop device off. Check if remote emergency stop device is in the ‘OFF’...
  • Page 42 Replace defective part. Compressor failure. Diagnose cause of failure and replace. Lack of cooling effect Fouled cooler surface. (Low suction Contact the local Johnson Controls pressure will be observed). service representative. Improper flow through the cooler Reduce flow to within unit design specification.

  • Page 43: Sensor Calibration Charts

    Form 150.72-ICOM8.EN.CE (0713) Sensor Calibration Charts Discharge and Suction Pressure Transducers (-BDP & -BSP) Chilled Liquid Temperature Sensors (-BLCT & -BECT) -BSP 0 - 27.58 Barg -BDP 0 - 44.83Barg Pressure Barg Volts Pressure Volts Temperature Resistance Microboard Sensor Barg °C ohms Voltage...
  • Page 44 Form 150.72-ICOM8.EN.CE (0713) Page Left Intentionally Blank...

  • Page 45: Technical Data

    Form 150.72-ICOM8.EN.CE (0713) 9. Technical Data Evaporator pressure drop graph 1000 1000 ¡ ¢ £ ¤ ¥ ¦ § ¨ © Line YLAA Model 0180SE, 0210SE, 0240SE 0285SE, 0195HE, 0220HE 0320SE, 0360SE, 0260HE, 0300HE 0400SE, 0435SE, 0350HE, 0456HE 0485SE, 0390HE, 0441HE 0516HE Operating Limitations - SE Models 0180...

  • Page 46: Operating Limitations - He Models

    Form 150.72-ICOM8.EN.CE (0713) Operating Limitations - HE Models 0195 0220 0260 0300 0350 0390 YLAA HE Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. 5 to 15 Liquid Outlet Temperature (Water) °C Liquid Outlet Temperature (Glycol) ºC -12 to 15* Chilled...

  • Page 47: Physical Data - Se Models

    Form 150.72-ICOM8.EN.CE (0713) Physical Data - SE Models YLAA - SE 0180SE 0210SE 0240SE 0285SE 0320SE Number of refrigerant circuits Circuit 1 / Circuit 2 21.3/15.4 25.4/15.4 24.0/23.1 25.9/24.0 25.9/25.9 Refrigerant Charge 12.0/6.0 12.0/6.0 10.0/10.0 12.0/10.0 12.0/12.0 Oil Charge Circuit 1 / Circuit 2 Number of compressors 3 / 2 2 / 2...

  • Page 48: Physical Data - He Models

    Form 150.72-ICOM8.EN.CE (0713) Physical Data - HE Models YLAA - HE 0195HE 220HE 260HE 0300HE 0350HE 0390HE Number of refrigerant circuits Circuit 1 / Circuit 2 24.0/16.8 24.5/22.7 24.5/24.5 28.1/24.5 28.6/26.8 32.7/27.7 Refrigerant Charge 12.0/6.0 10.0/8.0 10.0/10.0 12.0/10.0 12.0/12.0 18.0/10.0 Oil Charge Circuit 1 / Circuit 2 Number of compressors...

  • Page 49: Electrical Data Se Models

    Form 150.72-ICOM8.EN.CE (0713) Electrical Data SE Models YLAA - SE Nominal Nominal Current (A) Start up Amps Maximum Nominal YLAA Direct on Optional Soft Current (A) (with Power Factor Correction) Power (kW) Current (2&3) @ 400 V @ 400 V Line Start 0180SE...

  • Page 50: Dimensions - Ylaa0180Se, 0210Se & 0195He

    Form 150.72-ICOM8.EN.CE (0713) Dimensions - YLAA0180SE, 0210SE, 0195HE & 0220HE...

  • Page 51: Dimensions - Ylaa0240Se, 0285Se

    Form 150.72-ICOM8.EN.CE (0713) Dimensions - YLAA0240SE, 0285SE, 0320SE & 0260HE...

  • Page 52: Dimensions - Ylaa0360Se, 0400Se & 0300He

    Form 150.72-ICOM8.EN.CE (0713) Dimensions - YLAA0360SE, 0400SE & 0300HE...

  • Page 53: Dimensions - Ylaa0435Se, 0485Se, 0350He & 0390He

    Form 150.72-ICOM8.EN.CE (0713) Dimensions - YLAA0435SE, 0485SE, 0350HE & 0390HE...
  • Page 54 Form 150.72-ICOM8.EN.CE (0713) Dimensions - YLAA0441HE 9-10...
  • Page 55 Form 150.72-ICOM8.EN.CE (0713) Dimensions - YLAA0456HE 9-11...
  • Page 56 Form 150.72-ICOM8.EN.CE (0713) Dimensions - YLAA00516HE 9-12...

  • Page 57: Isolator Location

    Form 150.72-ICOM8.EN.CE (0713) Isolator Location All dimensions in mm 4 Fan Units (YLAA0180SE, 0210SE, 0240SE, 0285SE, 0320SE, 0195HE, 0220HE & 0260HE) 35.3 Control Panel End 2169.2 1920.8 495.8 495.8 36.9 Top View of Base Frame 5 & 6 Fan Units (YLAA0360SE, 0400SE, 0435SE, 0485SE, 0300HE, 0350HE & 0390HE) 35.3 Control Panel End...
  • Page 58 Form 150.72-ICOM8.EN.CE (0713) 7 & 8 Fan Units (YLAA0441HE, 0456HE & 0516HE) 36.4 Control Panel End 2169.2 36.4 865.6 1917.9 1753.2 194.6 Top View of Base Frame 9-14...

  • Page 59: Anti Vibration Isolators Data - Neoprene Isolators

    Form 150.72-ICOM8.EN.CE (0713) Anti Vibration Isolators Data - Neoprene Isolators Mount Dimensions (mm) Type CD (inch) RD1-WR 5/16-18 UNC X 3/4 RD2-WR 3/8-16 UNC X 1 RD3-WR 1/2-13 UNC X 1 RD4-WR 1/2-13 UNC X 1 Weight Range (kg) Mount Type Colour JCI Part Number Up to 375...
  • Page 60 Form 150.72-ICOM8.EN.CE (0713) Mount Dimensions (mm) Type Weight Range (kg) Mount Type Colour JCI Part Number Up to 197 Black 029-25334-002 197 to 347 Dark Green 029-25334-003 347 to 463 Gray 029-25334-004 463 to 525 White 029-25334-005 525 to 810 Gray / Red 029-25334-006 Up to 521...

  • Page 61: Spare Parts

    Form 150.72-ICOM8.EN.CE (0713) 10. Spare Parts Recommended Spares Details of unit spare parts are given in the Renewal Parts List 035-22290-000. Contact your local Johnson Controls Sales and Service Centre for information and please quote the unit model number and serial number. Recommended Compressor Oil The correct type of oil must be used in the unit as shown on the unit data plate and labels.
  • Page 62 Form 150.72-ICOM8.EN.CE (0713) Page Left Intentionally Blank 10-2...

  • Page 63: Decommissioning, Dismantling And Disposal

    Form 150.72-ICOM8.EN.CE (0713) 11. Decommissioning, Dismantling If glycol or similar solutions have been used in the water system, or chemical and Disposal additives are contained, the solution MUST be disposed of in a suitable and safe Never release refrigerant to the atmosphere manner.
  • Page 64 Form 150.72-ICOM8.EN.CE (0713) Page Left Intentionally Blank 11-2...
  • Page 66 www.johnsoncontrols.com Form 150.72-ICOM8.EN.CE (0713) Supercedes: Form 150.72-ICOM8.EN.CE (0912) Subject to change without notice. ALL RIGHTS RESERVED...

This manual is also suitable for:

York ylaa0485seYork ylaa0195heYork ylaa0516he

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