York YS User Manual
FORM 160.80-EG1 (808)
Rated in Accordance
with the latest edition of ARI
STANDARD 550/590
Model YS Rotary Screw Liquid Chillers
Design Level E
100 thru 675 tons
(315 thru 2375 KW)
r-22 and r-134a
TABLE OF CONTENTS
PAGE
INTRODUCTION ........................................................... 3
RATINGS ....................................................................... 4
OPTIVIEW CONTROL CENTER ................................... 5
MECHANICAL SPECIFICATIONS ................................ 13
ACCESSORIES & MODIFICATIONS ............................ 17
UNIT COMPONENTS ................................................... 19
APPLICATION DATA ..................................................... 20
DIMENSIONS – STD ..................................................... 28
S0-S3 Compressor .................................................... 28
S4 & S5 Compressor ............................................... 29
Compact Water Box Nozzle Arrangements ............... 30
Floor Layout .............................................................. 31
Cooler Nozzle Arrangements .................................... 32
Condenser Nozzle Arrangements ............................. 34
WEIGHTS – STD ........................................................... 36
DIMENSIONS – METRIC .............................................. 38
S0-S3 Compressor .................................................... 38
S4 & S5 Compressor ............................................... 39
Compact Water Box Nozzle Arrangements ............... 40
Floor Layout .............................................................. 41
Cooler Nozzle Arrangements .................................... 42
Condenser Nozzle Arrangements ............................. 44
WEIGHTS – METRIC .................................................... 46
GUIDE SPECIFICATIONS ............................................ 48
METRIC CONVERSION TABLES ................................. 53
LIST OF TABLES
TABLE
NO.
1 Water Flow Rate Limits.................. 20
2 Motor Voltage Variations ................ 23
3 60 Hz Electrical Data ..................... 25
4 Motor Starters ................................ 25
5 50 Hz Electrical Data ..................... 26
6 Available Compressor/Shell/
Motor Combinations
(R-22 & R-134a) ............................ 26
7 Available Compressor/Shell/
Motor Combinations
(50 Hz, R-134a Only) ..................... 27
PAGE
NOMENCLATURE
The model number denotes the following characteristics of the unit:
YS BB BA S0 – CF E S
Model
Cooler Code
Condenser Code
Compressor Code
Power Supply:
– for 60 Hz
5 for 50 Hz
2 JOHNSON CONTROLS
Special Features
Design Level
Motor Code
Introduction
FORM 160.80-EG1 (808)
The YORK Millennium YS Chiller offers a complete com-
bination of features for total owner satisfaction.
MATCHED COMPONENTS MAXIMIZE EFFICIENCY
Actual chiller efciency cannot be determined by analyzing
the theoretical efciency of any one chiller component.
It requires a specic combination of heat exchanger,
compressor, and motor performance to achieve the lowest system kW/Ton. YORK Millennium chiller technology
matches chiller system components to provide maximum
chiller efciency under actual – not just theoretical – operating conditions.
REAL-WORLD ENERGY PERFORMANCE
Johnson Controls pioneered the term “Real-World Energy”
to illustrate the energy-saving potential of focusing on
chiller performance during off-design conditions. Off-design is not only part load, but full load operation as well,
with reduced entering condenser water temperatures
(ECWTs). This is where chillers operate 99% of the time,
and where operating costs add up.
The YS Millennium chillers are the only chillers designed
to operate on a continuous basis with cold ECWT and full
condenser ow at all load points, taking full advantage of
Real-World conditions. This type of operation benets the
cooling tower as well; reducing cycling of the fan motor
and ensuring good coverage of the cooling ll.
YORK Millennium chillers offer the most efcient Real-
World operation of any chiller, meaning lower operating
costs and an excellent return on your chiller investment.
Insurance companies that offer policies on large air conditioning equipment often consider air-cooled motors a sig-
nicant advantage over hermetic refrigerant cooled units.
HIGH-EFFICIENCY HEAT EXCHANGERS
Millennium chiller heat exchangers offer the latest technology in heat transfer surface design to give you maxi-
mum efciency and compact design. Water-side and
refrigerant-side design enhancements minimize both
energy consumption and tube fouling.
FACTORY PACKAGING REDUCES FIELD LABOR
COSTS
YORK Millennium screw chillers are designed to keep
installation costs low. Where installation access is not a
problem, the unit can be shipped completely packaged,
requiring minimal piping and wiring to complete the installation.
For those units utilizing a factory installed Solid-State
Starter, the three power leads provide all power to the
chiller and its auxiliaries.
TAKE ADVANTAGE OF COLDER COOLING TOWER
WATER TEMPERATURES
YORK Millennium screw chillers are designed to take full
advantage of colder cooling tower water temperatures,
which are naturally available during most operating hours.
Considerable energy savings are available by letting tower
water temperature drop, rather than articially holding it
above 75°F (23.9°C), especially at low load, as some
chillers require.
OPEN DRIVE DESIGN
Hermetic-motor burnout can cause catastrophic damage
to a chiller. The entire chiller must be cleaned, and the
refrigerant replaced. YORK Millennium screw chillers
eliminate this risk by utilizing air-cooled motors. Refrigerant never comes in contact with the motor, preventing
contamination of the rest of the chiller.
U.L. ACCEPTANCE – YOUR ASSURANCE OF RELIABILITY
YORK Millennium screw chillers are approved for listing
by Underwriter’s Laboratories for the United States and
Canada. Recognition of safety and reliability is your assurance of trouble-free performance in day-to-day building
operation.
3JOHNSON CONTROLS
Ratings
Rated in accordance with the latest
issue of ARI Standard 550/590.
ARI CERTIFICATION PROGRAM
The performance of YORK Millennium chillers is certied
to the Air Conditioning and Refrigeration Institute (ARI)
complying with the certication sections of the latest issue
of ARI Standard 550/590. Under this Certication Pro-
gram, chillers are regularly tested in strict compliance with
this Standard. This provides an independent, third-party
verication of chiller performance.
COMPUTERIZED PERFORMANCE RATINGS
Each chiller is custom-matched to meet the individual
building load and energy requirements. A large number
of standard heat exchangers and pass arrangements are
available to provide the best possible match.
It is not practical to provide tabulated performance for
each combination, as the energy requirements at both full
and part- load vary signicantly with each heat exchanger
and pass arrangement. Computerized ratings are avail-
able through each Johnson Controls sales ofce. These
ratings can be tailored to specic job requirements, and
are part of the ARI Certication Program.
OFF-DESIGN PERFORMANCE
Since the vast majority of its operating hours are spent
at off-design conditions, a chiller should be chosen not
only to meet the full-load design, but also for its ability to
perform efciently at lower loads and lower tower water
temperatures. It is not uncommon for chillers with the
same full-load KW/TON to have an operating cost difference of over 10% due to part-load operation.
Part-load information can be easily and accurately generated by computer. And because it is so important to an
owner’s operating budget, this information is now stan-
dard within the ARI Certication Program in the form of
an Integrated Part-Load Value (IPLV), and Non-Standard
Part-Load Value (NPLV).
The IPLV / NPLV formulas from ARI Standard 550/590
closely track chiller operations, and provide a more accurate indication of chiller performance than the previous IPLV / APLV formula. A more detailed analysis must
take into account actual building load proles, and local
weather data. Part-load performance data should be ob-
tained for each job using its own design criteria.
4 JOHNSON CONTROLS
OptiView Control Center
FORM 160.80-EG1 (808)
OPTIVIEW CONTROL CENTER
The YORK OptiView Control Center, furnished as standard
on each chiller, provides the ultimate in efciency, monitoring, data recording, chiller protection and operating ease.
The control center is a factory mounted, wired, and tested
state-of-the-art microprocessor based control system for
R-134a or R-22 screw chillers. The panel is congured
with a 10.4 inch diagonal color Liquid Crystal Display
(LCD) surrounded by “soft” keys, which are redened with
one keystroke based on the screen display at that time.
This revolutionary development makes chiller operation
quicker and easier than ever before. Instead of requiring
keystroke after keystroke to hunt for information on a small
monochrome LCD screen, a single button reveals a wide
array of information on a large, full-color illustration of the
appropriate component, which makes information easier
to interpret. This is all mounted in the middle of a keypad
interface and installed in a locked enclosure.
The LCD display allows graphic animated display of the
chiller, chiller sub-systems and system parameters; this
allows the presentation of several operating parameters
at once. In addition, the operator may view a graphical
representation of the historical operation of the chiller as
well as the present operation. A Status Bar is displayed
at all times on all screens. It contains the System - Status
Line and Details Line, the Control Source, Access Level,
Date and Time. All date representations and calculations
use four digits for the year to provide Year 2000 compliance.
During the Start Sequence and System Lockout Delay, the
system status will include a countdown timer indicating the
time remaining. The control panel is compatible with the
YORK Solid State Starter (optional), Electro-mechanical
(E-M) starter, or any customer supplied E-M starter that
complies with the YORK R-1051 standard. The locations
of various chiller parameters are clearly marked and in-
structions for specic operations are provided. The panel
verbiage is available in other languages as an option, with
English always available. Data can be displayed in either
English or Metric units, plus keypad entry setpoints of 0.1
increments.
Security access is provided to prevent unauthorized access and/or a change of setpoints. This is accomplished
with three different levels of access and passwords for
each level. There are screens, displayed values, programmable setpoints and manual controls not shown available
to service the chiller. They are only displayed when logged
in at the service access level. The Advanced Diagnostics
and troubleshooting information for the chiller and the
panel is also included.
The panel is fused through a 1-1/2 or 2 KVA transformer
in the compressor motor starter to provide individual
over-current protected power for all controls. Numbered
terminal strips for wiring such as Remote Start/Stop,
Flow Switch, Chilled Water Pump and Local or Remote
Cycling Device are provided. The Panel also provides
eld interlocks that indicate the chiller status. These contacts include a Remote Mode Ready To Start, a Cycling
5JOHNSON CONTROLS
OptiView Control Center - continued
Shutdown, a Safety Shutdown and a chiller Run Contact.
Pressure transducers sense system pressures and thermistors sense system temperatures. The output of each
transducer is a DC voltage that is analogous to the pressure input. The output of each thermistor is a DC voltage
that is analogous to the temperature it is sensing.
Setpoints can be changed from a remote location via
0-10VDC, 4-20mA, contact closures or through serial
communications. The adjustable remote reset range [up
to 20°F (11.1°C)] provides exible, efcient use of remote
signal depending on reset needs. Serial data interface
to the YORK ISN Building Automation System (BAS) is
through the General Protocol Interface Card (GPIC), which
can be mounted inside the Control Center.
This printed circuit board requests the required data from
the Micro Board and makes it available for the YORK
ISN network. This optional board is available through the
Johnson Controls BAS group. The operating program
is stored in non-volatile memory (EPROM) to eliminate
chiller failure due to AC power failure/battery discharge.
Programmed setpoints are retained in lithium batterybacked RTC memory for 11 years minimum.
Smart Freeze Point Protection can operate the chiller as
low as 36°F (2.22°C) leaving chilled water temperature,
without nuisance trips on Low Water Temperature. The
sophisticated program and sensor monitors the chiller water temperature to prevent freeze-up. Each programmable
point has a pop-up screen with the allowable ranges, so
the chiller cannot be programmed to operate outside of
its design limits.
When power is applied to the chiller, the HOME screen
is displayed. This screen displays a visual representation
of the chiller and a collection of data detailing important
operations and parameters. When the chiller is running,
the ow of chilled liquid is animated by the alternating
shades of color moving in and out of the pipe nozzles. The
primary values that need to be monitored and controlled
are shown on this screen. They are as follows:
Display Only:
• Chilled Liquid Temperature – Leaving
• Chilled Liquid Temperature – Return
• Condenser Liquid Temperature – Return
• Condenser Liquid Temperature – Leaving
• Motor Run (LED)
• % Full Load Amps
• Operating Hours
With the “soft” keys the operator is only one touch away
from the 8 main screens that allow access to the major
information and components of the chiller. The 8 screens
are the SYSTEM, EVAPORATOR, CONDENSER, COM-
PRESSOR, OIL SUMP, MOTOR, SETPOINTS, and the
HISTORY. Also on the Home Screen is the ability to LOG
IN, LOG OUT and PRINT. Log In and Log Out is the means
by which different security levels are accessed.
The SYSTEM screen gives a general overview of common
chiller parameters for both shells. This is an end view of
the chiller with a 3-D cutaway of both the shells. The following can be viewed from this screen:
Thermal ice storage systems are based on the concept
of using off-peak, lower cost electricity to build ice for
handling the cooling load during peak hours. The most
efcient way to build ice is to maximize chiller load and
minimize run time. Standard chiller control systems are not
designed for this operating mode. In a typical application,
chillers will load and unload to maintain a leaving chilled
liquid setpoint. When the YORK YS chiller operates in the
thermal storage control mode, the unit will remain at 100%
load until the setpoint shutdown temperature is reached.
To add greater operating exibility and eliminate unnecessary chiller cycling, two different Low Water (Liquid)
Temperature Restart Thresholds can be programmed, one
for the ice mode and one for the standard cooling mode.
This control enhancement is standard on all YS chillers.
The chiller can also be left in the standard control mode
for temperatures ranging between 20 and 70°F (-6.7 and
21.1°C), for applications involving a process cooling duty
that requires leaving chilled liquid temperature setpoint
control.
6 JOHNSON CONTROLS
Display Only:
• Discharge Temperature
• Chilled Liquid Temperature – Leaving
• Chilled Liquid Temperature – Return
• Chilled Liquid Temperature – Setpoint
• Evaporator Pressure
• Evaporator Saturation Temperature
• Condenser Liquid Temperature – Leaving
• Condenser Liquid Temperature – Return
• Condenser Pressure
• Condenser Saturation Temperature
• Oil Temperature
• Differential Oil Pressure
• % Full Load Amps
• Current Limit
• Slide Valve Position
FORM 160.80-EG1 (808)
The EVAPORATOR screen displays a cutaway view of
the chiller evaporator. All setpoints relating to the evaporator side of the chiller are maintained on this screen.
Animation of the evaporation process indicates whether
the chiller is presently in RUN condition (bubbling) and
liquid ow in the pipes is indicated by alternating shades
of color moving in and out of the pipes. Adjustable limits
on the low water temperature setpoints allow the chiller
to cycle on and off for greater efciency and less chiller
cycling. The chiller cycles off when the leaving chilled
water temperature is below setpoint and is adjustable
from 1°F (0.55°C) below to a minimum of 36°F (2.22°C).
Restart is adjustable from setpoint up to a max of 80°F
(44.4°C). The Panel will check for ow to avoid freezeup of the tubes. If ow is interrupted, shutdown will occur
after a minimum of two seconds. The following can also
be performed through this screen:
Display Only:
• Chilled Liquid Flow Switch (Open/Closed)
• Chilled Liquid Pump (Run/Stop)
• Evaporator Pressure
• Evaporator Saturation Temperature
• Return Chilled Liquid Temperature
• Leaving Chilled Liquid Temperature
• Evaporator Refrigerant Temperature
• Small Temperature Difference
• Leaving Chilled Liquid Temperature Setpoints –
Setpoint
• Leaving Chilled Liquid Temperature Setpoints –
Remote Range
• Leaving Chilled Liquid Temperature Setpoints –
Shutdown
• Leaving Chilled Liquid Temperature Setpoints –
Shutdown Offset
• Leaving Chilled Liquid Temperature Setpoints –
Restart
• Leaving Chilled Liquid Temperature Setpoints –
Restart Offset
• Ice Storage Active (LED)
Programmable:
• Local Leaving Chilled Liquid Temperature – Range
• Local Leaving Chilled Liquid Temperature – Setpoint
• Leaving Chilled Liquid Temperature Cycling Offset –
Shutdown
• Leaving Chilled Liquid Temperature Cycling Offset –
Restart
The CONDENSER screen displays a cutaway view of the
chiller condenser. The liquid ow is animated to indicate
ow through the condenser. All setpoints relating to the
condenser side of the chiller are maintained on this screen.
With the proper access level this screen also serves as a
gateway to controlling the Refrigerant Level. The following
can also be viewed through this screen:
Display Only:
• Leaving Condenser Liquid Temperature
• Return Condenser Liquid Temperature
• Condenser Pressure
• Condenser Saturation Temperature
• Small Temperature Difference
• High Pressure Switch (Open/Closed)
• Condenser Liquid Flow Switch
• Condenser Liquid Pump (Run/Stop)
Programmable:
• High Pressure Warning Threshold
• Freeze Warning (Enabled/Disabled)
• Freeze Time
The VARIABLE ORIFICE CONTROL screen, accessed
from the CONDENSER screen in SERVICE access level,
displays all of the applicable Variable Orice control
parameters and allows a Service Technician to program
the Delta P setpoint. The Low Evaporator Pressure and
Superheat Override LED’s are located on this screen.
A view of the liquid ow piping to the chiller condenser,
along with the solenoid ow control valve, is shown. The
following can also be performed through this screen:
Display Only:
• Condenser Pressure
• Evaporator Pressure
• Delta P (Condenser – Evaporator)
• Discharge Temperature
• Condenser Saturation Temperature
• Superheat Temperature
• Low Evaporator Override (LED)
• Superheat Override (LED)
Programmable:
• Delta P Setpoint
7JOHNSON CONTROLS
OptiView Control Center - continued
The COMPRESSOR screen displays a cutaway view of
the chiller compressor, revealing the rotary screw, and
shows all conditions associated with the compressor. The
slide valve positioning is animated and with the proper
Access level, it can be manually controlled. Animation
of the compressor rotors indicates whether the chiller is
presently in a RUN condition. This screen also serves as
a gateway to sub-screens for calibrating the slide valve
or conguring the optional Hot Gas Bypass. From this
screen you can view the following:
Display Only:
• Differential Oil Pressure
• Oil Temperature
• Discharge Temperature
• Discharge Superheat
• Slide Valve Position
• Oil Return Solenoid (LED)
• Full Load Amps (E.M. Starter Only)
• Phase A, B, C Current (SSS Only)
Programmable:
• Slide Valve Load (Manual)
• Slide Valve Hold (Manual)
• Slide Valve Unload (Manual)
• Slide Valve Auto
• Max. Load Temperature
• Minimum Load FLA
• Minimum Load Control Source
The HOT GAS BYPASS screen, accessed from the COM-
PRESSOR screen, displays a pictorial of the bypass line
and solenoid valve location on the chiller. The Hot Gas
ON and OFF Setpoints are programmed on this screen
and system parameters pertinent to Hot Gas Bypass
operation are displayed. An LED illuminates when the
Hot Gas solenoid is ON. If the chiller is equipped with
the Hot Gas Bypass option, operation must be enabled
on the OPERATIONS screen. From this screen you can
perform the following:
Display Only:
• Slide Valve Position
• Return Chilled Liquid Temperature
• Leaving Chilled Liquid Temperature
• Hot Gas Solenoid (LED)
Programmable:
• On Setpoint
• Off Setpoint
The SLIDE VALVE CALIBRATION screen displays a
cutaway view of the chiller compressor, revealing the
rotary screw and slide valve and provides the capability
of calibrating the slide valve. From this screen, you can
perform the following:
Display Only:
• Slide Valve Loading (LED)
• Slide Valve Unloading (LED)
• Calibration Message
Programmable:
• Start Calibration
• Cancel Calibration
The OIL SEPARATOR screen displays a close-up view
of the chiller oil separator/sump and provides all the necessary setpoints for maintaining the Variable Speed Oil
Pump (VSOP). This screen also allows manual control
of the Frequency Command sent to the VSOP. From this
screen you can perform the following:
Display Only:
• Discharge Temperature
• Oil Sump Temperature
• Discharge Superheat
• Oil Pressure
• Filter Pressure
• Seal Pressure
• Differential Oil Pressure
• Differential Filter Pressure
• Differential Seal Pressure
• Offset Pressure
• Oil Return Solenoid (LED)
• Low Separator Oil Level (LED)
1. The MOTOR “soft” key on the HOME screen, when
pressed, shows a picture of either a YORK ElectroMechanical Starter or a Solid State Starter, depending
on chiller conguration. The Programmable pulldown
demand to automatically limit motor loading can be
used to minimize building demand charges. Pulldown
8 JOHNSON CONTROLS
FORM 160.80-EG1 (808)
time period control over four hours, and verication of
time remaining in pulldown cycle from display readout.
Separate digital setpoint for current limiting between
30 and 100%.
The ELECTRO-MECHANICAL STARTER (E–M) screen
displays a picture of the starter and the following values.
The ones below are common among both offerings and the
values will be displayed on both types of starter screens.
From this screen you can perform the following:
Display Only:
• Motor Run (LED)
• Motor Current % Full Load Amps
• Current Limit Setpoints
• Pulldown Demand Time Left
Programmable:
• Local Motor Current Limit
• Pulldown Demand Limit
• Pulldown Demand Time
The SOLID STATE STARTER (SSS) screen displays a
picture of the starter and the following values, which are
displayed in addition to the common ones listed above.
From this screen, you can perform the following:
Display Only:
• Input Power
• kW Hours
• Starter Model
• Voltage – Phase A, B, C
• Current – Phase A, B, C
• Temperature – Phase A, B, C
ing, they can all be found on this screen. This screen also
serves as a gateway to a sub-screen for dening the setup
of general system parameters. From this screen you can
perform the following:
Display Only:
• Leaving Chilled Liquid Temperature – Setpoint
• Leaving Chilled Liquid Temperature Cycling –
Shutdown
• Leaving Chilled Liquid Temperature Cycling –
Restart
• Current Limit Setpoint
Programmable:
• Local Leaving Chilled Liquid Temperature – Range
• Local Leaving Chilled Liquid Temperature – Setpoint
• Leaving Chilled Liquid Temperature Cycling Offset –
Shutdown
• Leaving Chilled Liquid Temperature Cycling Offset –
Restart
• Remote Analog Input Range
• Local Motor Current Limit
• Pulldown Demand Limit
• Pulldown Demand Time
• Print
The SETUP is the top level of the general conguration parameters. It allows programming of the time and
date, along with specications as to how the time will be
displayed. In addition, the chiller conguration as determined by the micro board program jumpers and program
switches is displayed. From this screen you can perform
the following:
Programmable:
• Full Load Amps
• Voltage Range
• Starting Current
• Open SCR
• Shorted SCR
• kWH Reset
The SETPOINTS screen provides a convenient location
for programming the most common setpoints involved
in the chiller control. The Setpoints are shown on other
individual screens, but to cut down on needless search-
Display Only:
• Chilled Liquid Pump Operation (Displays Standard or
Enhanced)
• Refrigerant Selection (Displays R-22 or R-134a)
• Anti-Recycle (Displays Disabled or Enabled)
• Power Failure Restart (Displays Manual or Auto-
matic)
• Liquid Type (Displays Water or Brine)
Programmable:
• Set Date
• Set Time
• Clock (Enabled/Disabled)
• 12/24 Hour
9JOHNSON CONTROLS
OptiView Control Center - continued
The following six subscreens can be accessed from
the SETUP screen:
The SCHEDULE screen contains more programmable
values than a normal display screen. Each programmable
value is not linked to a specic button; instead, the select
key is used to enable the cursor arrows and check key to
program the Start/Stop times for any day of the week up
to 6 weeks in advance. The user has the ability to dene
a standard set of Start/Stop times that are utilized every
week or specify exceptions to create a special week.
Programmable:
• Exception Start/Stop Times
• Schedule (Enable/Disable)
• Repeat Sunday Schedule
• Standard Week Start/Stop Times
• Reset All Exception Days
• Select
• Print
The USER screen allows denition of the language for the
chiller to display and denes the unit of measure.
Programmable:
• System Language
• English/Metric Units
• Output Interval
• Automatic Printer Logging (Enabled/Disabled)
• Print Type
• Print Report
• Print All Histories
The SALES ORDER screen allows denition of the order
parameters. Note: This information is loaded at the factory
or by the installation service technician.
Display Only
• Model Number
• Panel Serial Number
• Chiller Serial Number
• YORK Order Number
• System Information
• Condenser and Evaporator Design Load Information
• Nameplate Information
The OPERATIONS screen permits denition of param-
eters pertaining to operation of the chiller. What is dened
is whether the control of the chiller will be Local, Digital Remote, Analog Remote, Modem Remote or ISN Remote.
Programmable
• Control Source
The COMMS screen allows the user to dene communications parameters.
Programmable:
• Chiller ID
• COM 2 Baud Rate
• COM 2 Data Bit(s)
• COM 2 Parity Bit(s)
• COM 2 Stop Bit(s)
• Printer Baud Rate
• Printer Data Bit(s)
• Printer Parity Bit(s)
• Printer Stop Bit(s)
The PRINTER screen permits the user to dene communications Parameters for the Printer.
Display Only
• Time Remaining Until Next Print
Programmable
• Log Start Time
The HISTORY screen allows the user to browse through
the last ten faults; either safety or cycling shutdowns with
the conditions, while the chiller is running or stopped.
The faults are color coded for ease in determining
the severity at a glance, recording the date, time and
description. (See Display Messages for Color Code
meanings.)
Display Only
• Last Normal Shutdown
• Last Fault While Running
• Last Ten Faults
Programmable:
• Print History
• Print All Histories
By pressing the VIEW DETAILS key you will move to the
HISTORY DETAILS screen. From these screens you
are able to see an on-screen printout of all the system
parameters at the time of the selected shutdown.
10 JOHNSON CONTROLS
FORM 160.80-EG1 (808)
Display Only:
• History Printout
Programmable:
• Page Up
• Page Down
• Print History
Also under the HISTORY screen is the TRENDING
screen, accessible by the key marked the same. On this
screen, up to six operator-selected parameters, selected
from a list of over 140, can be plotted in an X/Y graph
format. The graph can be customized to record points
once every second up to once every hour. There are
two types of charts that can be created: single screen,
or continuous screen. The single screen collects data for
one screen width (450 data points across the X-axis), then
stops. The continuous screen keeps collecting the data,
but the oldest data drops off the graph from left to right
at the next data collection interval. For ease of identication, each plotted parameter, title and associated Y-axis
labeling is color coordinated.
Display Only:
• This screen allows the user to view the graphical
trending of the selected parameters and is a gateway
to the graph setup screens.
• Data Point Min (1 - 6)
• Data Point Max (1 - 6)
The TREND COMMON SLOTS screen displays the Mas-
ter Slot Numbers List of the monitored parameters.
Display Only:
• Slot Numbers
Programmable:
• Page Up
• Page Down
• Print
DISPLAY MESSAGES
The Control Center continuously monitors the operating
system, displaying and recording the cause of any shutdowns (Safety, Cycling or Normal). The condition of the
chiller is displayed at the System Status line that contains
a message describing the operating state of the chiller;
whether it is stopped, running, starting or shutting down.
A System Details Line displays Warning, Cycling, Safety,
Start Inhibit and other messages that provide further
details of the Status Bar messages. Messages are colorcoded: Green – Normal Operations; Yellow – Warnings;
Orange – Cycling Shutdowns; and Red – Safety Shutdowns to aid in identifying problems quickly.
Programmable:
• Start
• Stop
• Y-axis
• X-axis
The TREND SETUP screen is used to congure the trend-
ing screen. The parameters to be trended are selected
from the Trend Common Slots screen, accessed from
the Slot Numbers button or the Master Slot Numbers
List found in the Operating Manual. The interval at which
all the parameters are sampled is selected under the
Collection Interval button. The data point minimum and
maximum values may be adjusted closer to increase
viewing resolution.
Programmable:
• Chart Type (select continuous or one screen)
• Collection Interval
• Select
• Data Point Slot Number (1 - 6)
Status messages include:
• System Ready To Start
• Cycling Shutdown – Auto Restart
• Safety Shutdown – Manual Restart
• Start Sequence Initiated
• System Run (with countdown timers)
• Start Inhibit
• Slide Valve Closing Before Shutdown
• System Lockout Delay
Run Messages include:
• Leaving Chilled Liquid Control
• Motor Pulldown Limit
• Motor – High Current Limit
Start Inhibit Messages include:
• Anti-Recycle XX min/sec.
• Slide Valve – Position >30%
• Motor Current >15% FLA
• LCSSS – High-Temperature Phase X - Stopped
11JOHNSON CONTROLS
OptiView Control Center - continued
Warning Messages include:
• Real Time Clock Failure
• Setpoint Override
• Condenser – High Pressure Limit
• Evaporator – Low Pressure Limit
• Freeze Threat From Operating Chiller
• Freeze Threat, Condenser Flow Switch Open
• Low Discharge Superheat Limit
• Low Discharge Superheat Detected
• Maximum Load – Load Limit
• Minimum Load – Load Limit
• Oil – Dirty Filter
• Oil – High Temperature
• Slide Valve Uncalibrated
Routine Shutdown Messages Include:
• Remote Stop
• Local Stop
• Place Compressor Switch In Run Position
Cycling Shutdown Messages Include:
• Multiunit Cycling – Contacts Open
• System Cycling – Contacts Open
• Control Panel – Power Failure
• Leaving Chilled Liquid – Low Temperature
• Leaving Chilled Liquid – Flow Switch Open
• Condenser – Flow Switch Open
• Motor Controller – Contacts Open
• Motor Controller – Loss of Current
• Power Fault
• Control Panel – Schedule
Solid State Starter Only (LCSSS)
• Initialization Failed
• Serial Communications
• Requesting Fault Data
• Stop Contacts Open
• Power Fault
• Low Phase (X) Temperature Sensor
• Run Signal
• Invalid Current Scale Selection
• Phase Locked Loop
• Low Supply Line Voltage
• High Supply Line Voltage
• Logic Board Processor
• Logic Board Power Supply
• Phase Loss
Safety Shutdown Messages include:
• Evaporator – Low Pressure
• Evaporator – Low Pressure – Smart Freeze
• Evaporator – Transducer or Leaving Liquid Probe
• Evaporator – Transducer or Temperature Sensor
• Condenser – High Pressure Contacts Open
• Condenser – High Pressure
• Condenser – Pressure Transducer Out of Range
• Auxiliary Safety – Contacts Closed
• Discharge – High Temperature
• Discharge – Low Temperature
• Oil – High Temperature
• Oil – Low Differential Pressure
• Oil – Low Differential Seal Pressure
• Oil or Condenser Transducer Error
• Oil – Clogged Filter
• Oil – High Pressure
• Oil – Separator – Low Level
• Control Panel – Power Failure
• Watchdog – Software Reboot
Solid State Starter Only (LCSSS)
• Shutdown – Requesting Fault Data . . .
• High Instantaneous Current
• High Phase (X) Heatsink Temperature – Running
• 105% Motor Current Overload
• Motor or Starter – Current Imbalance
• Open SCR
• Phase Rotation
12 JOHNSON CONTROLS
Mechanical Specications
FORM 160.80-EG1 (808)
STANDARD UNIT
General
The YORK Millennium YS Rotary Screw Chiller is completely factory-packaged, including evaporator, condenser,
sub-cooler, oil separator, compressor, motor, lubrication
system, control center and refrigerant isolation valves.
The factory package consists of a “leak tight” design. All
units ship as standard with a full charge of refrigerant
and oil. Units can also be shipped in sections (optional)
to accommodate job site requirements.
The services of a Johnson Controls factory-trained, eld
service representative are incurred to supervise or perform
the nal leak testing, charging, the initial start-up, and
concurrent operator instructions.
Compressor
The Frick Rotary Twin Screw Compressor is engineered
and constructed to meet the exact requirements of the
industrial refrigeration market. It utilizes state-of-the-art
technology to provide the most reliable and energy-ef-
cient compressor available at all operating conditions.
The compressor operates at 3750 RPM for 60 Hertz and
2975 RPM for 50 Hertz. The compressor housing is made
of cast iron, precision-machined to provide minimal clearance for the rotors. Compressor housing has a design
working pressure (DWP) of 300 PSIG (2068 kPa) minimum, and hydro-tested at 544 PSIG (3751 kPa).
provides fully modulating capacity control from 100% to
10% of full load. The slide valve is actuated by oil pressure,
controlled by external solenoid valves via the OptiView
Control Center.
Oil Separator
The oil separator is a horizontal design without moving
parts. Effective oil separation is achieved by gravity dropout of oil from the refrigerant gas as velocity decreases
upon entering the separator, and by mesh pads to provide
nal gas/oil separation before gas enters the condenser.
The oil separator is designed for 345 PSIG (2378 kPa)
design working pressure, tested at 517 PSIG (3565 kPa),
and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section VIII - Division 1.
Each vessel has a refrigerant relief device(s) set at 300
PSIG (2068 kPa). In addition to the spring-loaded, re-seating-type relief valves sized for pressure vessel volume,
each unit is equipped with a rupture disk. This rupture
disk is able to relieve the entire pumping capacity of the
compressor if electronic safeties fail, providing protection for property and personnel. This device is set for
345 PSIG (2378 kPa). Alternatively, the shell side may
be designed to European Pressure Vessel Codes and
stamped in accordance with A.D. Merkblatter or other
European Pressure Vessel design code. When required
by the refrigeration safety code, each vessel has a dual
refrigerant relief device(s).
The rotors are manufactured from forged steel and use
asymmetric proles. The compressor incorporates a
complete anti-friction bearing design for reduced power
and increased reliability. Four separate cylindrical roller
bearings handle radial loads. Two 4-point angular contact
ball bearings handle axial loads. Together, they maintain
accurate rotor positioning at all pressure ratios, thereby
minimizing blow-by and maintaining efciency.
A check valve is installed in the compressor discharge
housing (suction housing for S4 and S5 compressor) to
prevent compressor rotor back spin because of system
refrigerant pressure gradients during shutdown.
The open-drive compressor shaft seal consists of precision ceramic seal faces, metallic bellows, rotating member,
PTFE ‘C’-Ring static seal, and multi-port oil injection ring.
The seal cavity is maintained at intermediate pressure
with its oil discharged to the oil drain from the compressor.
Combining intermediate pressure with direct oil injection
provides cool, non-foaming lubricant to the seal assuring
a longer lifespan.
Capacity Control
Capacity control is achieved by use of a slide valve which
Lubrication
The main unit oil reservoir is located in the oil separator.
The compressor also has an oil reservoir located at the
rotor bearings to provide lubrication during start-up, coat
down, and in the event of a power failure. During opera-
tion, system pressure differential provides proper oil ow
without the need of an auxiliary oil pump. This minimizes
energy consumption.
The chiller is shipped with a 3 Micron absolute oil lter,
ensuring a clean oil system and superior compressor
life. An external, replaceable cartridge oil lter is supplied
with manual isolation stop valves for ease of servicing.
An optional dual oil lter housing with isolation valves is
available on all units. This allows immediate switching
from one lter to the other, eliminating downtime during
lter changes. The off-line oil lter can be changed during
chiller operation.
A 500 watt (115 volt - 1-phase - 60/50Hz) immersion
oil heater is located in the oil separator reservoir, tem-
perature actuated to efciently remove refrigerant from
the oil. Oil heater power supply is factory wired from
the control panel. A factory-piped refrigerant-cooled oil
13JOHNSON CONTROLS
Mechanical Specications - continued
cooler is provided as standard. No auxiliary water piping is required. An oil eductor automatically removes oil
which may have migrated to the evaporator and returns
it to the compressor.
MOTOR DRIVELINE
The compressor motor is an open drip-proof, squirrel
cage, induction type constructed to Johnson Controls
design specications. 60 Hertz motors operate at 3750
RPM; 50 Hertz motors operate at 2975 RPM. The open
motor is provided with a D-Flange and is factory-mounted
to a cast-iron adaptor mounted on the compressor. This
unique design allows the motor to be rigidly coupled to
the compressor to provide factory alignment of motor and
compressor shafts.
Motor drive shaft is directly connected to the compressor
shaft with a exible disc coupling. Coupling has all metal
construction with no wearing parts to assure long life.
Additionally, no lubrication is required – providing low
maintenance.
For units utilizing remote electro-mechanical starters,
a large steel terminal box with gasketed front access
cover is provided for eld connected conduit. There are
six terminals (three for medium voltage) brought through
the motor casing into the terminal box. Jumpers are furnished for three-lead type of starting. Motor terminal lugs
are not furnished. Overload/overcurrent transformers are
furnished with all units. For units furnished with factorypackaged Solid State Starters, refer to the Accessories
and Modications section (page 17).
HEAT EXCHANGERS
Shells
Evaporator and condenser shells are fabricated from
rolled carbon steel plates with fusion welded seams.
Carbon steel tube sheets, drilled and reamed to accommodate the tubes, are welded to the end of each shell.
Intermediate tube supports are fabricated from carbon
steel plates, drilled and reamed to eliminate sharp edges,
and spaced no more than four feet apart. The refrigerant
side of each shell is designed, tested, and stamped in
accordance with ASME Boiler and Pressure Vessel Code,
Section VIII – Division I, or other pressure vessel code
as appropriate.
Tubes
Heat exchanger tubes are state-of-the-art, high efciency,
externally and internally enhanced type to provide optimum performance. Tubes in both the evaporator and
condenser are 3/4” O.D. copper alloy and utilize the
“skip-n” design, providing a smooth internal and external
surface at each intermediate tube support. This provides
extra wall thickness (up to twice as thick) and non-work
hardened copper at the support location, extending the
life of the heat exchangers. Each tube is roller expanded
into the tube sheets providing a leak-proof seal, and is
individually replaceable.
Evaporator
The evaporator is a shell and tube, ooded type heat exchanger. A distributor trough provides uniform distribution
of refrigerant over the entire shell length to yield optimum
heat transfer. A suction bafe or aluminum mesh eliminators are located above the tube bundle to prevent liquid
refrigerant carryover into the compressor. A 1-1/2” liquid
level sight glass is conveniently located on the side of the
shell to aid in determining proper refrigerant charge. The
evaporator shell contains a dual refrigerant relief valve
arrangement set at 180 PSIG (1241 kPa); or single-relief
valve arrangement, if the chiller is supplied with the optional refrigerant isolation valves. A 1” refrigerant charging
valve is provided.
Condenser
The condenser is a shell and tube type, with a discharge
gas bafe to prevent direct high velocity impingement on
the tubes. The bafe is also used to distribute the refrigerant gas ow properly for most efcient heat transfer.
An integral sub-cooler is located at the bottom of the
condenser shell providing highly effective liquid refriger-
ant subcooling to provide the highest cycle efciency. The
condenser contains dual refrigerant relief valves set at
235 PSIG (1620 kPa).
Water Boxes
The removable water boxes are fabricated of steel. The
design working pressure is 150 PSIG (1034 kPa) and the
boxes are tested at 225 PSIG (1551 kPa). Integral steel
water bafes are located and welded within the water box
to provide the required pass arrangements. Stub-out water
nozzle connections with ANSI/AWWA C-606 grooves are
welded to the water boxes. These nozzle connections
are suitable for ANSI/AWWA C-606 couplings welding or
anges, and are capped for shipment. Plugged 3/4” drain
and vent connections are provided in each water box.
REFRIGERANT FLOW CONTROL
The YS Chiller is equipped with a refrigerant metering
device consisting of a xed orice and bypass solenoid
valve, which automatically adjusts to all real-world operating conditions. This control ensures proper refrigerant ow
to the evaporator over a wide range of operating conditions, including thermal storage applications and chilled
water reset. Valve operation is programmable and can
be customized for a specic application via the control
panel keyboard.
14 JOHNSON CONTROLS
FORM 160.80-EG1 (808)
REFRIGERANT ISOLATION
The condenser shell serves as a refrigerant receiver
to store the system charge during servicing. Manually
operated isolation valves are located at the inlet and
outlet of the condenser. Valves are also provided to facilitate removal of the refrigerant from the system when
necessary.
OPTIVIEW CONTROL CENTER
General
The chiller is controlled by a stand-alone microprocessorbased control center. The chiller control panel provides
control of chiller operation and monitoring of chiller sensors, actuators, relays and switches.
Control Panel
The control panel includes a 10.4 inch diagonal color liquid
crystal display (LCD) surrounded by “soft” keys, which
are redened based on the screen displayed at that time,
mounted in the middle of a keypad interface and installed
in a locked enclosure. The screen details all operations
and parameters, using a graphical representation of the
chiller and its major components. Panel verbiage is available in other languages as an option with English always
available. Data can be displayed in either English or Metric
units. Smart Freeze Point Protection will run the chiller at
36°F (2.22°C) leaving chilled water temperature and not
experience nuisance trips on low water temperature. The
sophisticated program and sensor monitors the chiller water temperature to prevent freeze-up. When needed, Hot
Gas Bypass is available as an option. The panel displays
countdown timer messages so the operator knows when
functions are starting and stopping. Every programmable
point has a pop-up screen with the ranges included, so
the chiller can not be programmed to operate outside of
its design limits.
The control panel includes a thermal ice storage control
mode which enhances system performance during ice
building operation when compared to standard cooling
logic. In thermal storage control mode, the chiller will
operate at 100% load until the setpoint shutdown tem-
perature is reached. To add greater operating exibility
and eliminate unnecessary chiller cycling, two different
Low Water (Liquid) Temperature Restart Thresholds are
programmable, one for the ice mode and one for the standard cooling mode. The chiller has the capability to remain
in the standard control mode for temperatures between
20°F to 70°F (–6.7°C to 21.1°C) for applications involving
a process cooling duty that requires leaving chilled liquid
temperature setpoint control.
The chiller control panel also provides:
1. System operating information including:
• Return and Leaving Chilled Water Temperature
• Return and Leaving Condenser Water Tem
perature
• Evaporator and Condenser Saturation Tem
perature
• Oil Pressure at Compressor and Oil Filter
Differential
• Percent Motor Current
• Evaporator and Condenser Saturation Tem
perature
• Compressor Discharge Temperature
• Oil Temperature
• Percent Slide Valve Position
• Operating Hours
• Number of Unit Starts
2. Digital Programming of Setpoints Through The Universal Keypad Including:
• Leaving Chilled Water Temperature
• Percent Current Limit
• Pull-Down Demand Limiting
• Six-Week Schedule For Starting and Stopping
The Chiller, Pumps and Tower
• Remote Reset Temperature Range
3. Status Messages Indicating:
• System Ready To Start
• System Running
• System Coastdown
• System Safety Shutdown – Manual Restart
• System Cycling Shutdown – Auto Restart
• System Prelube
• Start Inhibit
4. The text displayed within the system status and sys-
tem details eld is displayed as a color-coded message to indicate severity: red for safety fault; orange
for cycling faults; yellow for warnings; and green for
normal messages.
5. Safety shutdowns are enunciated through the display
and the status bar, and consist of system status, system details, day, time, cause of shutdown, and type of
restart required. Safety shutdowns with a xed speed
drive include:
• Evaporator – Low Pressure
• Evaporator – Low Pressure - Smart Freeze
• Evaporator – Transducer or Leaving Liquid
Probe
15JOHNSON CONTROLS
Mechanical Specications - continued
• Evaporator – Transducer or Temperature Sen sor
• Condenser – High Pressure Contacts Open
• Condenser – High Pressure
• Condenser – Pressure Transducer Out Of
Range
• Auxiliary Safety – Contacts Closed
• Discharge – High Temperature
• Discharge – Low Temperature
• Oil – High Temperature
• Oil – Low Differential Pressure
• Oil – Low Differential Seal Pressure
• Oil Or Condenser Transducer Error
• Oil – Clogged Filter
• Oil – High Pressure
• Oil – Separator – Low Level
• Control Panel – Power Failure
• Watchdog – Software Reboot
5.1 Safety shutdowns with a Solid State Starter (LCSSS)
include:
• Shutdown - Requesting Fault Data...
• High Instantaneous Current
• High Phase (X) Heatsink Temperature - Run
ning
• 105% Motor Current Overload
• Motor Or Starter – Current Imbalance
• Phase (X) Shorted SCR
• Open SCR
• Phase Rotation
6. Cycling shutdowns enunciated through the display
and the status bar, and consists of system status,
system details, day, time, cause of shutdown, and
type of restart required.
Cycling shutdowns with a fixed speed drive in-
clude:
• Multiunit Cycling - Contacts Open
• System Cycling - Contacts Open
• Control Panel - Power Failure
• Leaving Chilled Liquid – Low Temperature
• Leaving Chilled Liquid – Flow Switch Open
• Condenser - Flow Switch Open
• Motor Controller – Contacts Open
• Motor Controller – Loss Of Current
• Power Fault
• Control Panel – Schedule
6.1 Cycling shutdowns with a Solid State Starter (LCSSS)
include:
• Initialization Failed
• Serial Communications
• Requesting Fault Data
• Stop Contacts Open
• Power Fault
• Low Phase (X) Temperature Sensor
• Run Signal
• Invalid Current Scale Selection
• Phase Locked Loop
• Low Supply Line Voltage
• High Supply Line Voltage
• Logic Board Processor
• Logic Board Power Supply
• Phase Loss
7. Security access to prevent unauthorized change of
setpoints, to permit local or remote control of the
chiller, and to allow manual operation of the prerotation vanes and oil pump. Access is through ID and
password recognition, which is dened by three
different levels of user competence: view, operator,
and service.
8. Trending data with the ability to customize points of
once every second to once every hour. The panel
will trend up to 6 different parameters from a list of
over 140, without the need of an external monitoring
system.
9. The operating program is stored in non-volatile
memory (EPROM) to eliminate reprogramming the
chiller due to AC power failure or battery discharge.
Programmed setpoints are retained in lithium battery-backed RTC memory for a minimum of 11 years
with power removed from the system.
10. A fused connection through a transformer in the
compressor motor starter to provide individual
over-current protected power for all controls.
11. A numbered terminal strip for all required eld interlock wiring.
12. An RS-232 port to output all system operating data,
shutdown/cycling message, and a record of the last
10 cycling or safety shutdowns to a eld-supplied
printer. Data logs to a printer at a set programmable
interval. This data can be pre-prograrnmed to print
from 1 minute to 1 day.
13. The capability to interface with a building automation
16 JOHNSON CONTROLS
FORM 160.80-EG1 (808)
system to provide:
• remote chiller start and stop
• remote leaving chilled liquid temperature adjust
• remote current limit setpoint adjust
• remote ready to start contacts
• safety shutdown contacts
• cycling shutdown contacts
• run contacts
CODES AND STANDARDS
• ASME Boiler and Pressure Vessel Code – Section
Vlll Division 1.
• ARI Standard 550/590
• c/U.L. – Underwriters Laboratory
• ASHRAE 15 – Safety Code for Mechanical Refrigeration
• ASHRAE Guideline 3 – Reducing Emission of Halogenated Refrigerants in Refrigeration and Air-Conditioning Equipment and Systems
• NEC – National Electrical Code
• OSHA – Occupational Safety and Health Act
• A.D. Merkblatter
ISOLATION MOUNTING
The unit is provided with four vibration isolation mounts
consisting of 1” (25.4 mm) thick neoprene isolation pads
for eld mounting under the steel mounting pads located
on the tube sheets.
REFRIGERANT CONTAINMENT
The standard unit has been designed as a complete and
compact factory packaged chiller. As such, it has mini-
mum joints from which refrigerant can leak. The entire
assembly has been thoroughly leak tested at the factory
prior to shipment. The YORK chiller includes service
valves conveniently located to facilitate transfer of refrigerant to a remote refrigerant storage/recycling system.
Optional condenser isolation valves permit storage of the
charge in the condenser.
PAINT
Exterior surfaces are protected with one coat of Carib-
bean blue, durable alkyd-modied, vinyl enamel, ma-
chinery paint.
17JOHNSON CONTROLS
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