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AIR-COOLED  MODULAR  CHILLER  AND 
HEAT PUMP

 

I

NSTALLATION, 

COMMISSIONING, 

OPERATION & MAINTENANCE

 

Supersedes: NOTHING 

FORM NO.: 6U6H-B01C-NB-EN 

 

 

YCAE065/100/130-X 

AIR-COOLED MODULAR CHILLER AND HEAT PUMP 

50Hz 

   

 

 

 

 

 

R410A

 

 

 

 

Issue Date: 

October 31, 2018 

Cooke Industries - Phone: +64 9 579 2185    Email: [email protected]    Web: www.cookeindustries.co.nz

Summary of Contents for YCAE065

Page 1: ...NG OPERATION MAINTENANCE Supersedes NOTHING FORM NO 6U6H B01C NB EN YCAE065 100 130 X AIR COOLED MODULAR CHILLER AND HEAT PUMP 50Hz R410A Issue Date October 31 2018 Cooke Industries Phone 64 9 579 218...

Page 2: ...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...

Page 3: ...hes transducers and controls and any external wiring must not be installed inside the micro panel All wiring must be in accordance with Johnson Controls published specifications and must be performed...

Page 4: ...t has been modified and if current literature is available from the owner of the equipment prior to performing any work on the chiller CHANGE BARS Revisions made to this document are indicated with a...

Page 5: ...ller 3 A Air cooled 4 E Scroll Compressor 5 6 7 Rated Cooling Capacity 65 65kW 100 100kW 130 130kW 8 X Product Series 9 R R Heat Pump 10 M Modular 11 E Refrigerant R410A 12 13 50 Power Supply 380V 3N...

Page 6: ...STALLATION CHECKLIST 18 HANDLING 18 INSPECTION 18 LOCATION AND CLEARANCES 18 ISOLATORS OPTIONAL 20 COMPRESSOR MOUNTING 20 CHILLED LIQUID PIPING 20 PIPEWORK ARRANGEMENT 22 WIRING 23 POWER SUPPLY CONNEC...

Page 7: ...ORS 48 CONDENSER COILS 48 OPERATING PARAMETERS 48 CONDENSER FAN MOTORS 48 OVERALL UNIT INSPECTION 48 EXPANSION TANK 49 ModBus Protocol 50 PRESSURE TRANSDUCER DIAGRAM 59 R410A PRESSURE TEMPERATURE CHAR...

Page 8: ...n Controls warrants all equipment and materials against defects in workmanship and materials for a period of one year from date of initial start up or eighteen 18 months from date of shipment whicheve...

Page 9: ...e suggested best working practices and procedures These are issued for guidance only and they do not take precedence over the above stated individual responsibility and or local safety regulations Thi...

Page 10: ...power OFF isolating and locking off the power supply Servicing and maintenance on live equipment must only be performed by suitably trained and qualified personnel No attempt should be made to gain ac...

Page 11: ...be given to good ventilation High Temperature and Pressure Cleaning High temperature and pressure cleaning methods e g steam cleaning should not be used on any part of the pressure system as this may...

Page 12: ...iring is routed through liquid tight UV stabilized non metallic conduit GENERAL SYSTEM DESCRIPTION Compressor The unit has fixed speed hermetic scroll compressors High efficiency is achieved through a...

Page 13: ...s internally enhanced high condensing coefficient corrosion resistant copper tubes are arranged in staggered rows mechanically expanded into hydrophilic aluminum fins The design working pressure of th...

Page 14: ...neously Field Mounted FLOW SWITCH Vapor proof paddle type with 1 NPT connection for upright mounting in horizontal pipe This flow switch or its equivalent must be supplied with each unit to protect th...

Page 15: ...ails Factory Mounted VIBRATION ISOLATORS Level adjusting spring type 1 25 4mm or seismic deflection or neoprene pad isolators for mounting under unit base rails Field Mounted WATER TEMPERATURE SENSOR...

Page 16: ...eight Note that weight may vary depending on unit configuration at the time of lifting Refer to the Physical Data tables within this manual for further information regarding shipping and operating wei...

Page 17: ...GE CONDITIONS Standard leaving chilled water temp 5 20 C Standard ambient at cooling mode 10 48 C Standard leaving hot water temp 25 55 C Ambient temp at heating mode 15 25 C Unit storage ambient temp...

Page 18: ...Operational Limitations The following pages outline detailed procedures to be followed to install and start up the unit HANDLING These units are shipped as completely assembled units containing full...

Page 19: ...s panels will prevent casual tampering However further safety precautions such as a fenced in enclosure or locking devices on the panels may be advisable This will help to prevent the possibility of v...

Page 20: ...he unit is installed without pump kit Two 2 additional isolators will be required if pump kit is picked Identify the isolator locate at the proper mounting point and adjust per instructions COMPRESSOR...

Page 21: ...YCAE065X 4 All chilled liquid piping should be thoroughly flushed to free it from foreign material before the system is placed into operation Use care not to flush any foreign material into or throug...

Page 22: ...ance reliable operation and ease of maintenance 2 Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance Y...

Page 23: ...minum to copper This transition should be done in an external box separate to the power panel Copper conductors can then be run from the box to the unit See unit wiring diagrams for field and power wi...

Page 24: ...is connected It is used to link external facilities like fire alarms in case there s an emergency cutoff It is wired to terminals 80H 88 on block XTB2 Make sure External Interlock is short circuited o...

Page 25: ...of the communication protocols used by York equipment exposing the data in a consistent organized and defined fashion The SC EQ Communication Card is available as a card that is already fitted directl...

Page 26: ...N Electrical Legends ABBREVIATIONS OF ELECTRICAL COMPONENTS YCAE065X ABBREVIATIONS OF ELECTRICAL COMPONENTS YCAE100 130X Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www...

Page 27: ...Power Supply Connection Single Unit Power Supply Connection Modular Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz...

Page 28: ...The maximum quantity of modules above 130 kW combined should be 16 The quantity of modules in the same communication network is based on the sum total of control boards in the network Disconnecting 23...

Page 29: ...ication network should be 32 and different control boards should use different ID addresses If not the control board will be broken 4 The control boards should not be energized while setting the addre...

Page 30: ...DI switch is 12VDC when DI switch signal opens 5 For output signals the output from the control board is active signal with 230VAC and the accepted Amps capacity is 1A For pump alarm output a relay K...

Page 31: ...1 65 1 65 2 Cooler Type BPHE BPHE BPHE Flow Rate m3 h 11 18 17 2 22 36 Connection Type Thread Victaulic Victaulic Diameter DN50 DN65 DN65 Water Pressure Drop kPa 61 50 60 Dimension L mm 1650 2250 225...

Page 32: ...se refer to IEC standards to select cables ELECTRICAL DIAGRAM All electrical wiring should be carried out in accordance with local regulations Route properly sized cables to the cable entries in the b...

Page 33: ...Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz...

Page 34: ...YCAE100 130X Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz...

Page 35: ...Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz...

Page 36: ...01 3 SW301 4 SW301 5 1 ON OFF OFF OFF OFF 2 OFF ON OFF OFF OFF 3 ON ON OFF OFF OFF 4 OFF OFF ON OFF OFF 5 ON OFF ON OFF OFF 6 OFF ON ON OFF OFF 7 ON ON ON OFF OFF 8 OFF OFF OFF ON OFF 9 ON OFF OFF ON...

Page 37: ...is already finished before unit delivery SW302 1 OFF SW302 2 OFF SW302 3 OFF Only available for 1 unit SW302 4 ON Only available for 1 unit SW302 5 OFF Cooling Only ON Heat Pump SW302 6 ON Only avail...

Page 38: ...AE100 130X All dimensions are in mm unless specified otherwise The enclosure panels of YCAE100 130X as shown are optional Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www...

Page 39: ...hout nuisance high pressure safety cutouts however the system designer must consider potential performance degradation CLEARANCES YCAE065X YCAE100 130X Recommended minimum clearances front to wall 2m...

Page 40: ...leak test must be undertaken the leak s located and repaired Repaired systems must be evacuated with a suitable vacuum pump recovery unit as appropriate to below 100 microns before charging Do not li...

Page 41: ...in the Technical Data section has not been exceeded Control Panel Check the panel to see that it is free of foreign materials wire metal chips etc and clean out if required Power Connections Check th...

Page 42: ...plied such as start up commissioning When a compressor starts internal timers limit the minimum time before another compressor can start to 40 seconds 20 120 seconds adjustable 1 When power is applied...

Page 43: ...emperature as compared to setpoint and the rate of temperature change See the section on Liquid Temp Control for a detailed explanation 9 When the last compressor in a system one or two compressors pe...

Page 44: ...nges in hue INTRODUCTION The touch screen wire controller is standard for remote controls of YCAE units The functions of parameter setting operating status viewing and fault recording are available In...

Page 45: ...setting Liquid Temperature Setpoint Press UP or DOWN key in daily display screen to set target liquid temperatures Press CONFIRM to finish the setting or the controller will autosave if there s no op...

Page 46: ...r setting the weekdays are able to be switched over by pressing FUNCTION key Press UP to CONFIRM the weekday timer activation and move on to the next weekday Press DOWN to cancel the activation of the...

Page 47: ...ted Press TIMER and DOWN again to terminate the function Pump Circulation Press COOLING key for 5 seconds in daily display to enter Pump Circulation function The PUMP icon will appear The pump will op...

Page 48: ...nt system Never use the scroll compressor to pump the refrigerant system down into a vacuum Doing so will cause internal arcing of the compressor motor which will result in failure of compressor CONDE...

Page 49: ...least once every year the expansion tank must be checked to verify that the pre charge is within the value indicated on the label with a tolerance of 20 Cooke Industries Phone 64 9 579 2185 Email sale...

Page 50: ...ep Actual EEV Opening Degree Register value 7 Fan Speed Unit RPM Actual Fan Speed Register value 8 Compressor Speed Unit 0 1 RPS Actual Compressor Speed Register value 10 9 Access Mechanism BAS parame...

Page 51: ...6 16 4 10 20 6 Heat LT Setpoint 3 6 16 5 20 55 7 Low Sound Mode 3 6 16 7 1 Enabled 8 Fault Reset 3 6 16 8 1 Reset 9 Cooling Control Select 3 6 16 9 0 Fixed RT 1 Fixed LT 3 Variable LT 10 Heating Cont...

Page 52: ...unication status 3 103 1 ON 0 OFF 5 Unit Networks status 3 104 bit0 16 Unit1 16 1 ON 0 OFF 6 Unit fault status 3 109 bit0 16 Unit1 16 1 Fault 7 Chiller EWT 3 110 8 Chiller LWT 3 111 9 3 112 10 Ambient...

Page 53: ...Ckt1 fan motor fault 3 Bit1 1 Fault 21 Ckt2 fan motor fault 3 Bit2 1 Fault 22 Ckt1 HPS and Comp1 2 overload 3 Bit3 1 Fault 23 Ckt1 LPS 3 Bit4 1 Fault 24 Chiller WFS 3 Bit5 1 Fault 25 Cooling Heating...

Page 54: ...1 OFF 48 Ckt2 Comp2 3 bit13 1 ON 1 OFF 49 Ckt1 FWV 3 bit14 1 ON 1 OFF 50 Ckt2 FWV 3 bit15 1 ON 1 OFF 51 Ckt1 EEV 3 1057 52 Ckt2 EEV 3 1058 53 Ckt1 Fan Speed 3 1065 54 Ckt2 Fan Speed 3 1066 55 Dial sw...

Page 55: ...sensor fault 8A Bit7 1 Fault Unit Bit8 Ckt1 Comp1 DLT sensor fault 9A Bit8 1 Fault Unit Bit9 Ckt1 Comp2 DLT sensor fault 10A Bit9 1 Fault Unit Bit10 Ckt2 Comp1 DLT sensor fault 11A Bit10 1 Fault Unit...

Page 56: ...7d Bit6 1 Fault Bit7 External interlock fault 8d Bit7 1 Fault System Bit8 Power fault 9d Bit8 1 Fault Unit Bit9 Ckt2 HPS fault Comp 1 or 2 overload fault 10d Bit9 1 Fault Unit Bit10 Ckt2 LPS fault 11...

Page 57: ...0 1 Fault Unit Bit11 12E Unit Bit12 Unit high LWT in heating 13E Bit12 1 Fault Unit Bit13 14E Unit Bit14 Unit low LWT in heating 15E Bit14 1 Fault Unit Bit15 16E Unit Fault Word 6 Bit0 Ckt1 comp1 High...

Page 58: ...9p Bit9 10p Bit10 11p Bit11 12p Bit12 13p Bit13 14p Bit14 15p Bit15 16p Fault Word 8 Bit0 1q Bit1 2q Bit2 Ckt1 High pressure alarm 3q Bit2 1 Fault Unit Bit3 Ckt2 High pressure alarm 4q Bit3 1 Fault U...

Page 59: ...PRESSURE TRANSDUCER DIAGRAM Low Pressure Transducer High Pressure Transducer Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz...

Page 60: ...50 24 240 1260 18 180 260 23 230 1300 19 190 270 22 220 1340 20 200 290 21 210 1380 21 210 300 20 200 1420 22 220 320 19 190 1460 23 230 340 18 180 1510 24 240 350 17 170 1550 25 250 370 16 160 1600 2...

Page 61: ...490 2980 50 500 3050 51 510 3120 52 520 3200 53 530 3270 54 540 3350 55 550 3430 56 560 3510 57 570 3590 58 580 3670 59 590 3750 60 600 3840 61 610 3920 62 620 4010 63 630 4100 64 640 4190 65 650 428...

Page 62: ...HING Johnson Controls is committed to the continuous product improvement Please note the product design may change without notification This manual is for reference only For the specific product speci...

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