APPENDIX H - Newburyport District Court - YORK Chiller O M Manual.Rev.pdf

PDF 11 MB Posted Sep 11, 2026

Attached to: Trial Court - Region 3 - Chiller PM Service Contract
Solicitation number: BD-27-1107-FREG5-ACCOU-133133
Issued by: Massachusetts

About this file

Written by GovTribe AI · Sep 18, 2026

This is an Operation and Maintenance Manual for a YORK YCIV0157 through YCIV0397 air-cooled chiller serving the Massachusetts Trial Court, Region 3 facilities. The manual is incorporated by reference as Appendix H into the Region 3 Chiller Service Agreement Request for Proposals and provides comprehensive technical documentation for the YORK screw compressor chillers installed at the Newburyport District Court and other Region 3 court locations. The YCIV chillers are R-134a refrigerant-based, air-cooled units designed for water or glycol cooling applications, available in 2 or 3 compressor configurations with capacities ranging from 150 to 260 tons at 60 Hz. Each unit features variable speed drive (VSD) technology enabling capacity control from 10% to 100% of full load without requiring hot gas bypass, with operating ambient temperature ranges from 0°F to 125°F and soft-start capability allowing 2-minute off-time intervals between starts.

The manual contains detailed specifications across nine major sections covering general safety information, product description, rigging and handling procedures, installation requirements, commissioning protocols, technical performance data, operational controls, micropanel functions, and comprehensive maintenance procedures. Key technical components include semi-hermetic rotary twin-screw MTS compressors operating at speeds up to 6,000 RPM, high-efficiency shell-and-tube direct expansion evaporators with 150 psig shell-side design working pressure, air-cooled fin-and-tube condensers with 450 psig design working pressure, flash tank feed and drain valve controllers for system efficiency optimization, and external oil separators utilizing YORK "L" POE oil for lubrication. The documentation specifies recommended spare parts, sensor input voltage specifications, troubleshooting guides, electrical wiring diagrams for both 2 and 3 compressor configurations, dimensional drawings, isolator specifications, and maintenance requirements. Warranty coverage extends eighteen months from shipment for parts and materials only, conditioned on initial startup by authorized Johnson Controls Service Centers, use of genuine YORK-approved spare parts and refrigerants, and compliance with scheduled maintenance procedures as detailed in the manual.

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MASSACHUSETTS TRIAL COURT | REGION 3 CHILLER

SERVICE AGREEMENT

Region 3 Chiller Service Agreement RFP | Page 18 of 30

COMMONWEALTH OF MASSACHUSETTS

MASSACHUSETTS TRIAL COURT

REQUEST FOR PROPOSALS

Region 3 Chiller and Associated HVAC Equipment Preventive Maintenance and Repair Service Agreement

APPENDIX H

Newburyport District Court - YORK Chiller O&M Manual

This appendix is incorporated by reference into the Region 3 Chiller Service Agreement Request for Proposals.

Facilities Management & Capital Planning

Manualslib.com - The Global Manuals Library

Manuals / Brands / York Manuals / Chiller / YCIV0157 / Installation operation & maintenance / PDF

YORK YCIV0157 INSTALLATION OPERATION &

MAINTENANCE

Quick Links Section 1 - General Chiller Information and Safety Figure 1 - Yciv Chiller https://www.manualslib.com/ https://www.manualslib.com/ https://www.manualslib.com/brand/ https://www.manualslib.com/brand/york/ https://www.manualslib.com/brand/york/chiller.html https://www.manualslib.com/products/York-Yciv0157-13913257.html https://www.manualslib.com/manual/3417113/York-Yciv0157.html https://static-data2.manualslib.com/product-images/9ca/3417113/york-yciv0157-chiller.jpg

Table of Contents Table of Contents Section 1 - General chiller information and safety Introduction Warranty Safety About this manual Misuse of equipment Section 2 - Product description Introduction Figure 1 - YCIV chiller Figure 2 - Chiller control system Figure 3 - Compressor Figure 4 - PWM current waveform Figure 5 - PWM voltage waveform Accessories and options Complete PIN number description Table 1 - Complete PIN number description Section 3 - Rigging, handling, and storage Lifting weights Delivery and storage Inspection Moving the chiller Unit removal from shipping container Lifting using lugs Lifting using shackles Figure 6 - Lifting lugs Figure 7 - Lifting using lugs Figure 8 - Unit rigging

Table 2 - Lifting points dimensions Section 4 - Installation Location requirements Outdoor installations Indoor installations Location clearances Vibration isolators Shipping braces Chilled liquid piping Water treatment Pipework arrangement Connection types and sizes Cooler connections Refrigerant relief valve piping Figure 9 - Pipework arrangement Figure 10 - Grooved nozzle Figure 11 - Flange attachment Ductwork connection Electrical connection Power wiring Power supply wiring 115 VAC control supply transformer Control panel wiring Volts free contacts System inputs Section 5 - Commissioning Preparation Preparation - general First time start-up Section 6 - Technical data

Figure 12 - Pressure drop through two circuit YCIV evaporators ft H Figure 13 - Pressure drop through two circuit YCIV evaporators kPa Figure 14 - Pressure drop through three circuit YCIV evaporators ft H Figure 15 - Pressure drop through three circuit YCIV evaporators kPa Glycol correction factors Figure 16 - Glycol correction factors Table 3 - Water temperature and flows Table 4 - Physical data, English - standard efficiency Table 5 - Physical data (English - high efficiency) Table 6 - Physical data, SI - standard efficiency Table 7 - Physical data (SI - high efficiency) Figure 17 - Two compressor wiring diagram with circuit breaker Figure 18 - Two compressor wiring diagram with terminal block Figure 19 - Three compressor wiring diagram with circuit breaker -single point Figure 20 - Three compressor wiring diagram with terminal block -single point Table 8 - Standard efficiency 2-compressor units Table 9 - High efficiency 2-compressor units Table 10 - Standard efficiency 3-compressor units Table 11 - High efficiency 3-compressor units Electrical notes Table 12 - Typical Compressor Starting Current (First Four Seconds Of Start-Up) Table 13 - Voltage Utilization Range Electrical wiring diagrams - 2 compressor models Figure 21 - Elementary control wiring diagram 2 compressor models Figure 22 - Elementary power wiring diagram - YCIV0157-0267 2 compressor models Figure 23 - Power wiring connection diagram - YCIV0157-0267 2 Compressor Models

Figure 24 - Control wiring connection diagram - YCIV0157-0267 2 compressor models Figure 25 - Power elementary wiring diagram - YCIV0157-0267 2 compressor models Figure 26 - Location label - 2 compressor models Figure 27 - Panel layout - 2 compressor models Electrical wiring diagrams - 3 compressor models Figure 28 - Control elementary diagram - YCIV0257-0397 3 compressor models Figure 29 - Power elementary diagram - YCIV0257-0397 3 compressor models Figure 30 - Control wiring connection diagram - YCIV0257-0397 3 compressor models Figure 31 - Power wiring connection diagram - YCIV1050-1500 3 compressor models Figure 32 - Power elementary diagram - YCIV0257-0397 3 compressor models Figure 33 - Location label - 3 compressor models Figure 34 - Panel layout - 3 compressor models Dimensions - 2 and 3 compressor SI Figure 35 - Dimensions, 2 and 3 compressor SI, YCIV0157E/V and

YCIV0157S/P/H

Figure 36 - Dimensions, 2 and 3 compressor English, YCIV0157E/V and YCIV0157S/P/H Figure 37 - Dimensions, 2 and 3 compressor English, YCIV0177E/V, YCIV0177S/P/H, YCIV0187E/V, and Figure 38 - Dimensions, 2 and 3 compressor English, YCIV0197E/V, YCIV0207S/P/H, and YCIV0227S/P/H Figure 39 - Dimensions, 2 and 3 compressor English, YCIV0207E/V and YCIV0227E/V Figure 40 - Dimensions, 2 and 3 compressor English, YCIV0247S/P/H, YCIV0247E/V, and YCIV0267S/P/H

Figure 41 - Dimensions, 2 and 3 compressor English, YCIV0267E/V, and YCIV0287S/P/H Figure 42 - Dimensions, 2 and 3 compressor English, YCIV0287E/V Figure 43 - Dimensions, 2 and 3 compressor English, YCIV0307S/P/H Figure 44 - Dimensions, 2 and 3 compressor English, YCIV0327E/V and YCIV0357S/P/H Figure 45 - Dimensions, 2 and 3 compressor English, YCIV0357E/V and YCIV0397S/P/H Clearances Figure 46 - Clearances Isolator information for units shipped on or after June 15, 2008 Figure 47 - Isolator selection and mounting locations Figure 55 - Isolator selection and mounting locations Table 14 - Isolator locations and point loads Figure 48 - Isolator selection and mounting locations Figure 49 - Isolator selection and mounting locations Figure 50 - Isolator selection and mounting locations Figure 51 - Isolator selection and mounting locations Figure 52 - Isolator selection and mounting locations Figure 53 - Isolator selection and mounting locations Figure 54 - Isolator selection and mounting locations Figure 56 - Isolator selection and mounting locations Figure 57 - Isolator selection and mounting locations Figure 58 - Isolator selection and mounting locations Figure 59 - Isolator selection and mounting locations Figure 60 - Isolator selection and mounting locations Figure 61 - Isolator selection and mounting locations Figure 62 - Isolator selection and mounting locations Table 15 - Isolator cross reference Figure 63 - One inch deflection isolator specifications

Table 16 - One inch deflection isolator dimensions Table 17 - One inch deflection isolator weights Figure 64 - One inch deflection isolator Figure 65 - Durulene isolator specifications Table 18 - Durulene isolator dimensions Table 19 - Durulene isolator weights Figure 66 - Durulene isolator Figure 67 - Seismic isolator specifications Table 20 - Seismic isolator weights Figure 68 - Seismic isolator Isolator information for units shipped before June 15, 2008 Figure 69 - SLRS seismic isolator specifications Figure 70 - SLRS seismic isolator Table 21 - SLRS seismic isolator weights Figure 71 - ND-X neoprene isolator specifications Table 22 - ND-X Neoprene specifications Figure 72 - CIP 1 in. delfection restrained mounting specifications Table 23 - CIP 1 in. deflection restrained mounting specifications Figure 73 - 1 in. delfection mounts Refrigerant flow diagram Figure 74 - Refrigerant flow diagram Process and instrumentation diagram Figure 75 - Process and instrumentation diagram Component locations Figure 76 - Component locations Figure 77 - Control and VSD cabinet components Figure 78 - Chiller control board, relay boards, microgateway, and optional circuit breaker Figure 79 - Chiller control board, relay boards, and microgateway, 2 compressor

Figure 80 - Chiller control board, relay boards, and microgateway, 3 compressor Figure 81 - VSD logic board Figure 82 - VSD logic board (original - obsolete), P/N 031-02477-000 Figure 83 - VSD logic board (new), P/N 031-02507-XXX Figure 84 - Power components, 2 compressor Figure 85 - Power components, 3 compressor Figure 86 - Fan contactors and 3T transformer, 2 compressor Figure 87 - Fan contactors, 3 compressor Figure 88 - VSD components Figure 89 - VSD components, 2 compressor Figure 90 - VSD components, 3 compressor Figure 91 - VSD components, 2 compressor Figure 92 - VSD components, 3 compressor Figure 93 - Inverter power components, 2 compressor Figure 94 - Inverter power components, 3 compressor Figure 95 - Inverter power components Glycol system components Figure 96 - Glycol pump and fill tube locations Figure 97 - Glycol piping and fill tube location Compressor components Figure 98 - Compressor components Chiller electronic components Figure 99 - Keyboard and display Figure 100 - Cller control board Figure 101 - Relay output boards Figure 102 - AC to DC rectifier Figure 103 - SCR trigger board Figure 104 - DC link filter capciators Figure 105 - Equalizing/bleeder resistors

Figure 106 - 1L line inductor Figure 107 - IGBT gate driver board Figure 108 - Laminated bus structure Figure 109 - New board P/N 031-02507-000 Figure 110 - Obsolete board P/N 031-02477-000 Figure 111 - Current transformers Figure 112 - DV/DT output suppression network Figure 113 - Flash tank feed and drain valve controller Chiller configuration jumpers Figure 114 - DC bus voltage isolation board Figure 115 - Chiller circuit breaker Table 24 - Compressors and the appropriate jumper positions VSD logic to chiller microprocessor board RS-485 communication configuration jumpers Maximum VSD frequency/model designator Table 25 - VSD logic board address jumper Table 26 - Maximum frequency / model designator jumper Section 7 - Operation Operating controls Basic operating sequence Figure 116 - Unit switch Number of compressors to start Figure 117 - Chiller control (cooling) range Minimum VSD compressor start / run frequency Figure 118 - Number of compressors to start Figure 119 - Minimum VSD start frequency Acceleration / deceleration rate when starting / stopping compressors Standard IPLV capacity control Figure 120 - Minimum VSD run frequency Optional high IPLV capacity control

Table 27 - Fuzzy logic loading/unloading vs. Error Table 28 - Fuzzy logic loading/unloading vs. Error Load limiting control Table 29 - Current limit load limiting/unloading Table 30 - Discharge pressure load limiting/unloading Table 31 - Suction pressure load limiting/unloading Table 32 - VSD internal ambient load limiting/unloading Flash tank drain and feed valve controller Figure 121 - Flash tank drain and feed valve controller Table 33 - VSD baseplate temperature load limiting/unloading Figure 122 - LED locations Figure 123 - Power and comms LED's Figure 124 - Power, comms and system open/close LED's Economizer control Condenser fan control Figure 125 - Condenser fan locations Table 34 - Fan stages and corresponding outputs VSD temperature control, operation of the coolant pump, and VSD cabinet cooling fans Figure 126 - Standard IPLV fan control Figure 127 - High IPLV fan control Remote temperature reset control Remote current limit reset control Figure 139 - Program key Sound limit control Section 8 - Micropanel VSD operation and controls Figure 128 - VSD glycol pump Figure 129 - Original - obsolete P/N 031-02477-000 Figure 130 - New board - P/N 031-02507-XXX

VSD safeties (faults) Table 35 - VSD operating display parameters Unit warnings Microboard (331-03478-xxx) Figure 131 - Microboard 331-03478-xxx Program update Data logging Table 36 - Flash card update error XXXXX Table 37 - Data logging Unit safeties System safeties (faults) Table 38 - Low differential oil pressure cutout Table 39 - Start inhibit sensor thresholds Status key Figure 132 - Status key Unit data key Figure 133 - Unit data key System data keys 1 through 4 Figure 134 - System data keys 1 through 4 Table 40 - Sensor min./max. outputs VSD data key Figure 135 - VSD data key Operating hours / start counter key Figure 136 - Operating hours / start counter key History key Figure 137 - History key Setpoints key Figure 138 - Setpoints key Table 41 - Setpoint limits Program key

Table 42 - Programmable operating parameters Options key Figure 140 - Options key Date / time and schedule keys Figure 141 - Date / time and schedule keys Manual override key Figure 142 - Manual override key Print key Figure 143 - Print key Table 43 - Printout types Service key Figure 144 - Service key System switches key Figure 145 - System switches key Serial number programming Enabling optimized high IPLV mode Unit setup mode Table 44 - Unit setup programmable values Default programmable values Serial port connections Analog input connections Table 45 - Serial port connections Table 46 - Analog input connections Digital intput connections Table 47 - Digital input connections Analog output connections Table 48 - Analog output connections Digital output connections Table 49 - Digital output connections BACNET, MODBUS and YORKTALK 2 communications

Figure 146 - Control board connections Table 50 - Minimum, maximum and default values Table 51 - Values required for BAS communication Table 52 - Real time error numbers Table 53 - BACnet and Modbus Communications Data Map Section 9 - Maintenance General requirements Figure 147 - Service connections Figure 148 - Service connection view showing evaporator inlet Figure 149 - Leak test hold times Figure 150 - Evacuation of chiller operation Table 54 - System pressures Figure 151 - Saturation curve Table 55 - R-134a Pressure to Saturated Temperature Conversion Maintenance Requirements for YCIV Chillers Table 56 - Troubleshooting guide Limited warranty Chilled liquid and suction temperature sensor input voltage Table 57 - Temperature input voltage sensor (measured signal to shield at the sensor) Table 58 - Outside air temperature sensor input voltage (measured signal to shield at the sensor) Table 59 - Pressure transducer output voltage (measured signal to return at the transducer) Table 60 - Motor temperature sensor resistance (check at the motor) Table 61 - Compressor motor overload settings and maximum VSD frequency Printer wiring Figure 152 - Print cable - chiller to serial printer Operating log sheet Recommended spare parts

Table 62 - Recommended spare parts Other ManualsLib Projects

R-134a

YCIV Style A Models YCIV0157 to YCIV0397, 60 Hz

(150 to 260 tons) Air-Cooled Screw Liquid Chillers

E/V High Efficiency and S/P Standard Efficiency

Air-Cooled Screw Liquid Chillers

Installation, Operation, Maintenance Supersedes: 201.23-NM2 (623) Form 201.23-NM2 (1223)

035-21506-101

Issue Date:

December 19, 2023

Johnson Controls2

Form 201.23-NM2 Issue date: 12/19/2023

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.

Identifies 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 specified 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 specifications and must be performed only by a qualified electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of improper control signals. Failure to follow this warn-ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

Johnson Controls 3

Issue date: 12/19/2023

The Control/VSD Cabinet contains lethal high AC and DC voltages. Before per-forming service inside the cabinet, remove the AC supply feeding the chiller and verify using a non-contact voltage sensor.

The DC voltage on the VSD DC Bus will take 5 minutes to bleed off, after AC power is removed. Always check the DC Bus Voltage with a Voltmeter to assure the capacitor charge has bled off before working on the system.

NEVER short out the DC Bus to dis-charge the filter capacitors.

NEVER place loose tools, debris, or any objects inside the Control Panel/VSD Cabinet.

NEVER allow the Control Panel VSD Cabinet doors to remain open if there is a potential for rain to enter the panel.

Keep doors closed and assure all latches are engaged on each door unless the unit is being serviced.

ALWAYS lockout the disconnect supply-ing AC to the chiller.

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.

Changeability of this document

The 1L Line Inductor will reach operating temperatures of over 150°C (300°F.). DO NOT open panel doors during operation.

Assure the inductor is cool whenever working near the inductor with power

OFF.

Working with chiller vessels which are designed to contain contents under pressure must only be conducted by fully qualified technicians who have been certified in accordance with EPA Section 608 of the Clean Air Act requirements for the US or equivalently the Federal Halocarbon Regulations and the Refrigerant Code of Practice for Canada. This equipment is only intended for installation in locations that are not accessible to the general public. Further, this equipment is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge. Failure to meet this requirement can result in damage to equipment, release of refrigerant into the environment, contamination of the operating space for the equipment and pose a risk of personal injury or death. It is the responsibility of any service technician or opera-tor to adhere to these requirements.

Johnson Controls4

Issue date: 12/19/2023

MANUAL DESCRIPTION FORM NUMBER

Centrifugal Chiller Long Term Storage 50.20-NM5

Equipment Pre-Startup and Startup Checklist 201.23-CL2

Installation, Operation and Maintenance, 50 Hz 201.23-NM1

Unit Replacement Parts, Style A, 50 Hz 201.23-RP1

Unit Replacement Parts, Style A, 60 Hz 201.23-RP2

Unit Replacement Parts, Style A, 50 Hz and 60 Hz 201.23-RP3

All Products - Replacement Parts Electrical Connectors 50.20-RP1

All Products - Replacement Parts Fittings 50.20-RP2

Chiller A2L Refrigerant Application Data 160.00-AD10

Associated literature

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.

AFFECTED PAGES DESCRIPTION

3 Refrigerant warning added to General safety guidelines

Conditioned-based maintenance Traditional chiller maintenance is based upon assumed and generalized conditions. In lieu of the traditional maintenance program, a Johnson Controls YORK Conditioned Based Maintenance (CBM) program can be substituted. This CBM service plan is built around the specific needs for the chiller, operating conditions, and annualized impact realized by the chiller. Your lo-cal Johnson Controls Branch can propose a customized

Planned Service Agreement that leverages real time and historical data, delivering performance reporting, corrective actions required and data enabled guidance for optimal operation and lifecycle assurance. The pro-gram will include fault detection diagnostics, operation code statistics, performance based algorithms and ad-vance rules based rationale delivered by the Johnson Controls Connected Equipment Portal.

Johnson Controls 5

Issue date: 12/19/2023

LD26906

SYSTEM NOMENCLATURE

YORK

Air Cooled Chiller

Development Code

VSD Driven Screw Compressor Starter - VSD

A = Refrigerant R-134a B = Refrigerant R-513a

Y C I V 0187 S A- 46 V A A- - - - - -

Model Number

Unit Designator E = High Efficiency with Standard IPLV S = Standard Efficiency with Standard IPLV P = Standard Efficiency with Optimized IPLV V = High Efficiency with Optimized IPLV

Voltage Code 17 = 200-3-60 28 = 230-3-60 40 = 380-3-60 46 = 460-3-60 50 = 380/400/415-3-50 58 = 575-3-60

Design Series

Johnson Controls6

Issue date: 12/19/2023

Table of contents

Section 1 - General chiller information and safety Introduction Warranty Safety About this manual Misuse of equipment

Section 2 - Product description Introduction Accessories and options Complete PIN number description

Section 3 - Rigging, handling, and storage Lifting weights Delivery and storage Inspection Moving the chiller Unit removal from shipping container Lifting using lugs Lifting using shackles

Section 4 - Installation Location requirements Outdoor installations Indoor installations Location clearances Vibration isolators Shipping braces Chilled liquid piping Water treatment Pipework arrangement Connection types and sizes Cooler connections Refrigerant relief valve piping Ductwork connection Electrical connection Power wiring Power supply wiring 115 VAC control supply transformer Control panel wiring Volts free contacts System inputs

Section 5 - Commissioning Preparation Preparation – general First time start-up

Johnson Controls 7

Issue date: 12/19/2023

Table of contents (cont'd)

Section 6 - Technical data Glycol correction factors Electrical notes Electrical wiring diagrams - 2 compressor models Electrical wiring diagrams - 3 compressor models Dimensions - 2 and 3 compressor SI Clearances Isolator information for units shipped on or after June 15, 2008 Isolator information for units shipped before June 15, 2008 Refrigerant flow diagram Process and instrumentation diagram Component locations Glycol system components Compressor components Chiller electronic components Chiller configuration jumpers VSD logic to chiller microprocessor board RS-485 communication configuration jumpers Maximum VSD frequency/model designator

Section 7 - Operation Operating controls Basic operating sequence Number of compressors to start Minimum VSD compressor start / run frequency Acceleration / deceleration rate when starting / stopping compressors Standard IPLV capacity control Optional high IPLV capacity control Load limiting control Flash tank drain and feed valve controller Economizer control Condenser fan control VSD temperature control, operation of the coolant pump, and VSD cabinet cooling fans Remote temperature reset control Remote current limit reset control Sound limit control

Section 8 - Micropanel VSD operation and controls VSD safeties (faults) Unit warnings Microboard (331-03478-xxx) Program update Data logging Unit safeties System safeties (faults) Status key Unit data key System data keys 1 through 4

Johnson Controls8

Issue date: 12/19/2023

Table of contents (cont'd)

VSD data key Operating hours / start counter key History key Setpoints key Program key Options key Date / time and schedule keys Manual override key Print key Service key System switches key Serial number programming Enabling optimized high IPLV mode Unit setup mode Default programmable values Serial port connections Analog input connections Digital intput connections Analog output connections Digital output connections BACNET, MODBUS and YORKTALK 2 communications

Section 9 - Maintenance General requirements Maintenance Requirements for YCIV Chillers Limited warranty Chilled liquid and suction temperature sensor input voltage Printer wiring Operating log sheet Recommended spare parts

Johnson Controls 9

Issue date: 12/19/2023

List of figures Figure 1 - YCIV chiller��19 Figure 2 - Chiller control system��20 Figure 3 - Compressor��20 Figure 4 - PWM current waveform��25 Figure 5 - PWM voltage waveform��25 Figure 6 - Lifting lugs��34 Figure 7 - Lifting using lugs��34 Figure 8 - Unit rigging��35 Figure 9 - Pipework arrangement��40 Figure 10 - Grooved nozzle��40 Figure 11 - Flange attachment��40 Figure 12 - Pressure drop through two circuit YCIV evaporators ft H20��55 Figure 13 - Pressure drop through two circuit YCIV evaporators kPa��56 Figure 14 - Pressure drop through three circuit YCIV evaporators ft H20��57 Figure 15 - Pressure drop through three circuit YCIV evaporators kPa��58 Figure 16 - Glycol correction factors��59 Figure 17 - Two compressor wiring diagram with circuit breaker��70 Figure 18 - Two compressor wiring diagram with terminal block��70 Figure 19 - Three compressor wiring diagram with circuit breaker – single point��71 Figure 20 - Three compressor wiring diagram with terminal block – single point��71 Figure 21 - Elementary control wiring diagram 2 compressor models��86 Figure 22 - Elementary power wiring diagram - YCIV0157-0267 2 compressor models��88 Figure 23 - Power wiring connection diagram - YCIV0157-0267 2 Compressor Models��90 Figure 24 - Control wiring connection diagram - YCIV0157-0267 2 compressor models ��92 Figure 25 - Power elementary wiring diagram - YCIV0157-0267 2 compressor models��95 Figure 26 - Location label - 2 compressor models��97 Figure 27 - Panel layout - 2 compressor models��98 Figure 28 - Control elementary diagram - YCIV0257-0397 3 compressor models��100 Figure 29 - Power elementary diagram - YCIV0257-0397 3 compressor models��104 Figure 30 - Control wiring connection diagram - YCIV0257-0397 3 compressor models��106 Figure 31 - Power wiring connection diagram - YCIV1050-1500 3 compressor models�� 110 Figure 32 - Power elementary diagram - YCIV0257-0397 3 compressor models�� 112 Figure 33 - Location label - 3 compressor models�� 114 Figure 34 - Panel layout - 3 compressor models�� 115 Figure 35 - Dimensions, 2 and 3 compressor SI, YCIV0157E/V and YCIV0157S/P/H�� 116 Figure 36 - Dimensions, 2 and 3 compressor English, YCIV0157E/V and YCIV0157S/P/H�� 117 Figure 37 - �Dimensions, 2 and 3 compressor English, YCIV0177E/V, YCIV0177S/P/H, YCIV0187E/V, and

YCIV0187S/P/H�� 118 Figure 38 - Dimensions, 2 and 3 compressor English, YCIV0197E/V, YCIV0207S/P/H, and YCIV0227S/P/H��120 Figure 39 - Dimensions, 2 and 3 compressor English, YCIV0207E/V and YCIV0227E/V��122 Figure 40 - Dimensions, 2 and 3 compressor English, YCIV0247S/P/H, YCIV0247E/V, and YCIV0267S/P/H��124 Figure 41 - Dimensions, 2 and 3 compressor English, YCIV0267E/V, and YCIV0287S/P/H��126 Figure 42 - Dimensions, 2 and 3 compressor English, YCIV0287E/V��128 Figure 43 - Dimensions, 2 and 3 compressor English, YCIV0307S/P/H��130 Figure 44 - Dimensions, 2 and 3 compressor English, YCIV0327E/V and YCIV0357S/P/H��132 Figure 45 - Dimensions, 2 and 3 compressor English, YCIV0357E/V and YCIV0397S/P/H��134 Figure 46 - Clearances��136 Figure 47 - Isolator selection and mounting locations��137 Figure 48 - Isolator selection and mounting locations��138 Figure 49 - Isolator selection and mounting locations��139 Figure 50 - Isolator selection and mounting locations��140 Figure 51 - Isolator selection and mounting locations��141 Figure 52 - Isolator selection and mounting locations��142 Figure 53 - Isolator selection and mounting locations��143 Figure 54 - Isolator selection and mounting locations��144

Johnson Controls10

Issue date: 12/19/2023

Figure 55 - Isolator selection and mounting locations��145 Figure 56 - Isolator selection and mounting locations��146 Figure 57 - Isolator selection and mounting locations��147 Figure 58 - Isolator selection and mounting locations��148 Figure 59 - Isolator selection and mounting locations��149 Figure 60 - Isolator selection and mounting locations��150 Figure 61 - Isolator selection and mounting locations��151 Figure 62 - Isolator selection and mounting locations��152 Figure 63 - One inch deflection isolator specifications��154 Figure 64 - One inch deflection isolator��155 Figure 65 - Durulene isolator specifications��156 Figure 66 - Durulene isolator��157 Figure 67 - Seismic isolator specifications��158 Figure 68 - Seismic isolator��159 Figure 69 - SLRS seismic isolator specifications��160 Figure 70 - SLRS seismic isolator��161 Figure 71 - ND-X neoprene isolator specifications��162 Figure 72 - CIP 1 in. delfection restrained mounting specifications��163 Figure 73 - 1 in. delfection mounts��164 Figure 74 - Refrigerant flow diagram��165 Figure 75 - Process and instrumentation diagram��166 Figure 76 - Component locations��167 Figure 77 - Control and VSD cabinet components��168 Figure 78 - Chiller control board, relay boards, microgateway, and optional circuit breaker��169 Figure 79 - Chiller control board, relay boards, and microgateway, 2 compressor ��170 Figure 80 - Chiller control board, relay boards, and microgateway, 3 compressor ��171 Figure 81 - VSD logic board��172 Figure 82 - VSD logic board (original - obsolete), P/N 031-02477-000��173 Figure 83 - VSD logic board (new), P/N 031-02507-XXX ��174 Figure 84 - Power components, 2 compressor��175 Figure 85 - Power components, 3 compressor��176 Figure 86 - Fan contactors and 3T transformer, 2 compressor��177 Figure 87 - Fan contactors, 3 compressor��178 Figure 88 - VSD components��179 Figure 89 - VSD components, 2 compressor��180 Figure 90 - VSD components, 3 compressor��181 Figure 91 - VSD components, 2 compressor��182 Figure 92 - VSD components, 3 compressor��183 Figure 93 - Inverter power components, 2 compressor��184 Figure 94 - Inverter power components, 3 compressor��185 Figure 95 - Inverter power components��186 Figure 96 - Glycol pump and fill tube locations��188 Figure 97 - Glycol piping and fill tube location��189 Figure 98 - Compressor components��190 Figure 99 - Keyboard and display��191 Figure 100 - Cller control board��192 Figure 101 - Relay output boards��193 Figure 102 - AC to DC rectifier��194 Figure 103 - SCR trigger board��194 Figure 104 - DC link filter capciators��194 Figure 105 - Equalizing/bleeder resistors��195 Figure 106 - 1L line inductor��195 Figure 107 - IGBT gate driver board��196 Figure 108 - Laminated bus structure��196 Figure 109 - New board P/N 031-02507-000��196

List of figures (cont'd)

Johnson Controls 11

Conditioned-based maintenance Form 201.23-NM2 Issue date: 12/19/2023

List of figures (cont'd) Figure 110 - Obsolete board P/N 031-02477-000��197 Figure 111 - Current transformers��198 Figure 112 - DV/DT output suppression network��198 Figure 113 - Flash tank feed and drain valve controller��198 Figure 114 - DC bus voltage isolation board��199 Figure 115 - Chiller circuit breaker��199 Figure 116 - Unit switch��202 Figure 117 - Chiller control (cooling) range��203 Figure 118 - Number of compressors to start��204 Figure 119 - Minimum VSD start frequency��204 Figure 120 - Minimum VSD run frequency��205 Figure 121 - Flash tank drain and feed valve controller��212 Figure 122 - LED locations��214 Figure 123 - Power and comms LED's ��214 Figure 124 - Power, comms and system open/close LED's��214 Figure 125 - Condenser fan locations��216 Figure 126 - Standard IPLV fan control��217 Figure 127 - High IPLV fan control��217 Figure 128 - VSD glycol pump��225 Figure 129 - Original - obsolete P/N 031-02477-000��225 Figure 130 - New board - P/N 031-02507-XXX��226 Figure 131 - Microboard 331-03478-xxx��234 Figure 132 - Status key��244 Figure 133 - Unit data key��247 Figure 134 - System data keys 1 through 4��249 Figure 135 - VSD data key��252 Figure 136 - Operating hours / start counter key��254 Figure 137 - History key��255 Figure 138 - Setpoints key��262 Figure 139 - Program key��264 Figure 140 - Options key��267 Figure 141 - Date / time and schedule keys��270 Figure 142 - Manual override key��274 Figure 143 - Print key��275 Figure 144 - Service key��278 Figure 145 - System switches key��284 Figure 146 - Control board connections��296 Figure 147 - Service connections��306 Figure 148 - Service connection view showing evaporator inlet��306 Figure 149 - Leak test hold times��307 Figure 150 - Evacuation of chiller operation��310 Figure 151 - Saturation curve��311 Figure 152 - Print cable - chiller to serial printer��327

Johnson Controls12

Issue date: 12/19/2023Conditioned-based maintenance

List of tables Table 1 - Complete PIN number description��29 Table 2 - Lifting points dimensions��35 Table 3 - Water temperature and flows��60 Table 4 - Physical data, English - standard efficiency��62 Table 5 - Physical data (English - high…

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