York YCAJ44HE8 Installation, Operation And Maintenance Manual Download | Manualshive

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YORK INTERNATIONAL

6 CYLINDER

MODEL J G COMPRESSOR

6 CYLINDER

MODEL Z COMPRESSOR

COMPRESSOR TERMINAL BOX

FIG. 1A

COMPRESSOR COMPONENTS

DISCHARGE

STOP VALVE

CAPACITY CONTROL

SOLENOIDS

RAINTIGHT

TERMINAL BOX

SUCTION

STOP VALVE

SIGHT GLASSES (2)

OIL CHARGING

VALVE

CRANKCASE

HEATER

OIL PRESSURE

ACCESS

CONNECTION

27297A

27299

OIL

CHARGING

VALVE

CRANKCASE

HEATER

DATA

PLATE

MOTOR

TERMINALS

SUPPRESSORS

MOTOR PROTECTOR (MP)

27298A

DISCHARGE

STOP VALVE

TERMINAL

BOX

OIL LEVEL

SIGHT GLASS

OIL

PRESSURE

ACCESS CONN.

CAPACITY

CONTROL

SOLENOID

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Summary of Contents for YCAJ44HE8

Page 1: ...YCAJ55HE8 YCAJ65HE8 STYLE A 26174A With EPROM 031 01096 001 Standard Brine Metric Models Combined SHOWN WITH OPTIONAL SINGLEPOINTPOWERCONNECTION fi M A N U F A C T U R E R CERTI FI ED TO ARIAS C O M P...

Page 2: ...72 OPTIONS 74 TROUBLESHOOTINGCHART 87 GENERAL DESCRIPTION These packaged liquid chillers are completely self con tained outdoor units shipped ready for final job installa tion requiring only liquid co...

Page 3: ...200 3 60 28 230 3 60 40 380 3 60 46 460 3 60 50 380 415 3 50 58 575 3 60 64 346 3 50 Fan Code 8 Compressor Series Compressor Style No of Active Cylinders 4 6 8 Stroke 3 4 Steps of unloading Motor Size...

Page 4: ...A PLATE SIDE OF PANEL MICROPANEL CONDENSER FANS CONDENSER COIL S POWER PANEL COMPRESSOR 2 COMPRESSOR 1 OPTIONALSINGLE POINTPOWERCONNECT COMPRESSOR POWERSUPPLY COOLER SYSTEM 2 SIGHT GLASS TX VALVE SIGH...

Page 5: ...FORM 150 60 NM3 5 YORK INTERNATIONAL OPTIONAL SINGLE POINT POWER CONNECTION 26068A 26069A FIG 1 UNIT COMPONENTS Cont d INTERIOR VIEW POWER PANEL SINGLEPOINT CONNECTION TERMINALS GROUND LUGS...

Page 6: ...ITY CONTROL SOLENOIDS RAINTIGHT TERMINALBOX SUCTION STOP VALVE SIGHT GLASSES 2 OILCHARGING VALVE CRANKCASE HEATER OILPRESSURE ACCESS CONNECTION 27297A 27299 OIL CHARGING VALVE CRANKCASE HEATER DATA PL...

Page 7: ...tting standard controls 2 Operation below 25 F requires the Optional Low Ambient kit Minimum recommended operating temperature is 0 F 3 Operation above 115 F requires Optional High Ambient kit Maxi mu...

Page 8: ...reduced system performance nuisance shutdowns and servicing problems The area within the clearances shown above and area under the unit must be kept clear of all obstructions that would impede free a...

Page 9: ...est YORK Sales Office for detailed drawings PHYSICAL DATA MODELYCA 60 HZ Z88EE8 J44H38 J54HE8 J55HE8 Z65HE8 NOMINAL TONS 60 HZ 93 7 100 5 107 5 114 7 120 7 NO OFREFRIG CIRCUITS 2 2 2 2 2 COMPRESSOR ZB...

Page 10: ...MAX SIZE INCOMING COND MAX MAX SIZE INCOMING COND YCA MCA1 DUAL ELEM DIS CKT BKR WIRE RANGE6 CPR CPR FAN MCA1 DUAL ELEM DIS CKT BKR WIRE RANGE6 CPR CPR FAN FUSE MIN 4 HACR5 CU ONLY RLA LRA FLA FUSE M...

Page 11: ...CM 186 225 225 200 250 1 6 350MCM 1 6 350MCM 582 700 800 800 800 1 3 6 350MCM 1 4 1 0 350MCM 516 600 700 600 700 1 3 6 350MCM 1 2 4 0 500MCM 258 300 350 400 350 1 6 350MCM 1 1 600MCM OR 2 1 250MCM 204...

Page 12: ...ll operating charge and care should be taken to avoid damage due to rough handling The units are shipped without export crating unless it is specified by Sales Order A unit should be lifted by inserti...

Page 13: ...ed Mounting holes are provided in the steel channel for bolt ing the unit to its foundation See DIMENSIONS For ground level installations precautions should be taken to protect the unit from tampering...

Page 14: ...D YCAZ88EE8 CP 2 32 CP 2 31 CP 2 32 CP 2 31 YCAJ44HE8 CP 4 27 CP 4 27 CP 4 27 CP 4 27 YCAJ54HE8 CP 4 27 CP 4 27 CP 4 27 CP 4 27 YCAJ55HE8 CP 4 27 CP 4 27 CP 4 27 CP 4 27 YCAJ65HE8 CP 4 27 CP 4 27 CP 4...

Page 15: ...vent formation of con densation on lines in warm humid climates 7 A chilled water flow switch either by YORK or others MUST be installed in the leaving water piping of the cooler There should be a str...

Page 16: ...16 YORK INTERNATIONAL WIRING DIAGRAMS LD02165 FIG 5 ELEMENTARY DIAGRAM...

Page 17: ...FORM 150 60 NM3 17 YORK INTERNATIONAL FIG 5 ELEMENTARY DIAGRAM Cont d LD02166...

Page 18: ...18 YORK INTERNATIONAL CONNECTION DIAGRAM SYSTEM WIRING YCA 95 130 ARI LD02167 LD02168 LD02169 FIG 6 SYSTEM WIRING 6 CYL Z COMPRESSOR 4 6 CYL J COMPRESSOR COOLER CONDENSERFANS...

Page 19: ...FORM 150 60 NM3 19 YORK INTERNATIONAL COMPRESSOR TERMINAL BOX SYSTEM NO 1 COMPRESSOR TERMINAL BOX SYSTEM NO 2 FIG 6 SYSTEM WIRING Cont d LD02170...

Page 20: ...20 YORK INTERNATIONAL CONNECTION DIAGRAM ELECTRICAL BOX FIG 7 CONNECTION DIAGRAM LD02171...

Page 21: ...FORM 150 60 NM3 21 YORK INTERNATIONAL FIG 7 CONNECTION DIAGRAM Cont d LD02172...

Page 22: ...and loading unloading de cisions are performed by the Microprocessor to maintain leaving water temperatures These decisions are a func tion of temperature deviation from setpoint and rate of change of...

Page 23: ...ntial CURRENTTRANSFORMER C T A C T on the 3 power wiring of each motor sends AC signals proportional to motor current to the Power Sup ply Board which rectifies and filters the signal to variable DC v...

Page 24: ...TERIOR 25999A MICROPROCESSOR BOARD KEYPAD TB3 26000A LCD DISPLAY BOARD MICROPROCESSOR BOARD UNITON OFF SWITCH 2TTRANSFORMER RELAY OUTPUT BOARD 1 TB3 CONNECTIONS FOR FLOW SWITCH LEAD LAG SELECTORAND EM...

Page 25: ...which are being displayed If a message is required to be updated faster than every 2 seconds the appropriate key for the desired display may be pushed and held Updating will be at 4 second inter vals...

Page 26: ...ed by the user These options are se lected by the S1 Dip Switch on each Microprocessor Board Fig 12 Proper programming of the switch is important during commissioning of the chiller The OP TIONS displ...

Page 27: ...I S H U N I T S R E A D O U T M E T R I C U N I T S R E A D O U T R E T U R N W A T E R C O N T R O L L E A V I N G W A T E R C O N T R O L L O C A L C O N T R O L M O D E R E M O T E C O N T R O L M...

Page 28: ...N Display messages will show units of measure in English units F PSI etc CLOSED Display messages will show units of measure in Metric units C kPa etc SWITCH 6 OPEN This MUST be selected for chillers w...

Page 29: ...In this mode maximum chiller efficiency will be achieved If the Low Ambient option is installed the fan control will automatically change to pressure control at tempera tures below 25 F See page 66 f...

Page 30: ...he CLOCK SET SCHEDULE HOLIDAY is keeping the chiller from running Run Permissive is an indicator that an external cycling contact i e flow switch connected to terminals 13 and 14 is open or a system s...

Page 31: ...r programmable threshold and the micro is unloading the affected system to pre vent shutdown on a manual high pressure cut out Re loading will take place when discharge pressure has dropped 60 PSIG be...

Page 32: ...P S Y S 2 H I G H D S C H C H I L L E R F A U L T H I G H A M B I E N T T E M P S Y S 1 L O W O I L P R E S S C H I L L E R F A U L T 1 1 5 V A C U N D E R V O L T A G E S Y S 2 L O W O I L P R E S S...

Page 33: ...able data after any one of the following keys is pressed PROGRAM SET SCHEDULE HOLIDAY OPER DATA HISTORY Cancel Key The CANCEL key allows the user to change errors in the data being programmed into mem...

Page 34: ...PROGRAM 26572A PROGRAM KEY PROGRAMMINGUSERPROGRAMMABLESAFETIES LIMITS O U T O F R A N G E T R Y A G A I N D I S C H A R G E C U T O U T 3 9 5 P S I G PROGRAM KEY THESE VALUES MAY CAUSE DAMAGE TO THE...

Page 35: ...0 0 F for this cut out if S1 Dip Switch 2 on the Micro Logic Board is in the CLOSED position In the OPEN position a fixed 25 F cut out is recognized OUTSIDE AIR TMP HIGH CUT OUT The OUTSIDE AIR TMP HI...

Page 36: ...educed loader and compressor cycling Typically this value should be programmed for 00 1 F When program ming values like 00 1 F it is first required to key in 00 Example 00 1 F Additional details for p...

Page 37: ...stablishes the rate of change of return or leaving water temperature where the micro will override the normal 30 150 seconds per stage load ing rate which is based on error between setpoint and actual...

Page 38: ...s played when the SET TIME key is pressed To program the day time and date first press the AD VANCE DAY key until the appropriate day of the week is displayed The day will advance each time the key is...

Page 39: ...days to view times programmed use the ADVANCE DAY KEY not the ENTER KEY This will assure that after viewing MONDAY that the ENTER KEY is not pressed changing times programmed for the rest of the week...

Page 40: ...of compressor and loader cycling that is critical to precisely controlling temperature MANUAL OVERRIDE M A N U A L O V E R R I D E RETURN WATER CONTROL may also be used on batch and process applicati...

Page 41: ...till timing out The effects can be reduced by programming the anti recycle timer Page 36 for a minimum of 300 seconds if it isn t already pro grammed for 300 seconds If problems still arise switch to...

Page 42: ...e CHILLED LIQUID TEMP RANGE key The display will first exhibit a message that RETURN WATER TEMP CONTROL is selected and 3 seconds later automat ically scroll to the next display of LWT and CR The cur...

Page 43: ...p and a wide control loading unloading range com pressor loader cycling is reduced wear and tear on me chanical parts is reduced and pulldown demand is auto matically limited This makes the selection...

Page 44: ...entered into memory and the display will advance to the next user programmable limit The micro will accept a range of programmable values between 0 5 5 0 F min PROGRAMMING LEAVING WATER CONTROL Chill...

Page 45: ...s leaving water temperature may vary considerably as a result of a compressor that cannot restart due to the anti recycle timer To eliminate this increase the T temperature differential of the CR and...

Page 46: ...ull temperature down select 0 1 F To program the RATE CONTROL TEMP first press line PROGRAM key Repetitively press the ENTER key until the display below appears Key in the desired value and press the...

Page 47: ...e values between 0 5 5 0 F min LOADING AND UNLOADING RETURN WATER TEMPERATURE CONTROL In return water temperature control loading and unload ing will take place according to the difference between the...

Page 48: ...48 YORK INTERNATIONAL FIG 15 5 STEP LOADING UNLOADING RETURN WATER CONTROL LD02174 FIG 16 7 STEP LOADING UNLOADING RETURN WATER CONTROL NOTE 7 Step Loading Unloading is Not Presently Available LD02175...

Page 49: ...CONTROL RANGE which is below the programmed Low Limit WATER TEMPERA TURE the microprocessor will unload the chiller in 20 sec intervals until water temperature rises back into the CONTROL RANGE If tem...

Page 50: ...50 YORK INTERNATIONAL LD02176 FIG 19 LEAVING WATER CONTROL LOADING UNLOADING 7 STEP NOTE 7 Steps Loading Unloading is not presently available...

Page 51: ...r current is exceeding 120 FLA at the 3 second point the compressor will shut down After 4 seconds of operation motor current must be greater than 15 FLA but less than 115 FLA as long as the compresso...

Page 52: ...ator These sensors are wired into the motor protec tor module located inside the Motor terminal box As the motor windings heat and cool the resistance of the mo tor temperature sensors will change If...

Page 53: ...s shown below High Ambient Temperature Safety The High Ambient Temperature Safety assures that the chiller does not run in ambients above 130 F where po tential malfunction of system mechanical and el...

Page 54: ...e of tripping the relief valve due to a very high rate of rise in pressure resulting from a controls problem which would cause condenser water flow to be interrupted In this case the pressure rise is...

Page 55: ...n of the use of the keys for remote printer or local data retrieval will follow An optional printer Page 77 will be required for remote printout REMOTE PRINTOUT Oper Data The OPER DATA key allows the...

Page 56: ...rage area for data related to each of the last 3 safety shutdowns The printout will begin with the most recent fault which occurred The most recent fault will always be stored as SAFETY SHUTDOWN NO 1...

Page 57: ...oid status run time etc A total of 20 different displays are offered When the OPER DATA key is pressed the following message will appear Repetitively pressing the ENTER key allows the operator to scro...

Page 58: ...Compr Loaded Lag Compr Loaded On some STEPS actual Loading will NOT change S Y S 2 R U N T I M E 0 S E C S 7 STAGE STEP 0 Both Compressors OFF 1 Lead Compr Unloaded Lag Compr OFF 2 Lead Compr 1 Stage...

Page 59: ...titively pressing the ENTER key will allow the operator to scroll through the informa tion available in the SAFETY SHUTDOWN Buffer In the information that follows a sample message along with an explan...

Page 60: ...ssure Readout is installed This display shows the oil pressure at the time of the fault This display informs the operator whether SYS 1 liquid line solenoid was energized ON or de energized OFF at the...

Page 61: ...START STOP was in the RUN mode ON or STOP mode OFF This message indicates the number of stages which were loaded on SYS 2 at the time of the fault This display indicates the number of fans on SYS 2 w...

Page 62: ...ed to terminals 23 and 24 Fig 23 are supplied which will transition to function as a warning whenever a fault shutdown occurs on any sys tem or if power is lost to the control panel The dry con tacts...

Page 63: ...l automatically become the lead anytime the system switch on the Microprocessor Board of the compressor currently in the lead is placed in the OFF position This is also done to maintain water temperat...

Page 64: ...E KEEPING WILL BE MAINTAINED IN MEMORY REGARDLESS OF WHETHER THE CLOCK IS ON OR OFF AND REGARDLESS OF THE LENGTH OF THE POWER FAILURE To disable the clock place the jumper Fig 25 in the OFF positions...

Page 65: ...tch 5 of Dip Switch S1 on the Microprocessor Board must be placed in the OPEN position Page 28 The positioning of this switch can then be verified by pushing the OPTIONS key and verifying that METRIC...

Page 66: ...of the device must be suppressed with a user supplied YORK P N 031 00808 suppressor NOTE Remote Setpoint Reset will not operate when a Remote Control Center Option Kit is connected to the Micro Panel...

Page 67: ...ontrol system is to automatically adjust the compressor pumping ca pacity to balance with the cooling load at a pre deter mined return water temperature and to permit the com pressor to start under pa...

Page 68: ...the recessed opening to the suction plenum effectively blocking the flow of suction gas into the cylinders blocked suction unloading The cylinders are now unloaded LOADING When the solenoid valve is...

Page 69: ...cooler 7 Check panel to see that it is free of foreign mate rial wires metal chips etc 8 Visually inspect wiring power control Must meet NEC and all local codes See Figs 9 11 9 Check for proper size f...

Page 70: ...umn of liquid when the unit is operating normally On start up foaming of the oil may be evi dent in the compressor oil sight glass After the wa ter temperature has been pulled down to operating condit...

Page 71: ...sequence and timing previously described When a compressor starts internal timers limit minimum time before another compressor can start to 1 minute Time between stages of loading is also limited by...

Page 72: ...will load if cooling demand tem perature and rate control requires 12 After 3 minutes of run time the lead compressor will load if cooling demand temperature and rate control requires and extra steps...

Page 73: ...any part of the hermetic compres sor F Open the coil drain valve slowly and drain as much oil from the compressor as possible G Examine the oil for any metal particles which would indicate wear on th...

Page 74: ...pump contact will transition as soon as a System Switch on the micro processor board is placed in the ON position If a daily schedule is programmed the evaporator water pump contacts will transition...

Page 75: ...CAJ44HE8 17P 471 01262 102 YCAJ44HE8 28P 471 01262 102 YCAJ44HE8 46P 471 01262 102 YCAJ44HE8 58P 471 01262 102 YCAJ54HE8 17P 471 01262 102 YCAJ54HE8 28P 471 01262 102 YCAJ54HE8 46P 471 01262 102 YCAJ5...

Page 76: ...whenever discharge pressure exceeds 340 PSIG These fans will stay on until discharge pressure drops below 120 PSIG NOTE The corresponding compressor must be on for 4 seconds before these fans are per...

Page 77: ...the cooler which keeps the compressor on the line The option will provide hot gas bypass on both compressors enabling hot gas to be ac tive regardless of which compressor is in the lead NOTE The micr...

Page 78: ...F The hot gas solenoid will be activated at 45 1 2 F in the example above and hot gas may then be fed according to the suction pressure and the pressure regulated valve setting Once activated the mic...

Page 79: ...ed for DISCHARGE PRES SURE FAN CONTROL See Page 29 Fan cycling will operate as indicated in Table 3 The kit consists of discharge pressure transducers for each system wire harnesses and associated mou...

Page 80: ...r is in the form of a compact roll and is easily handled compared to larger printers using wider busi ness form style paper The paper is 2 25 wide desk top calculator paper that can be easily and inex...

Page 81: ...The printer may be left connected to the micro panel Parts The following parts are required 1 Weigh Tronix IMP 24 Model 2600 printer 2 2 25 wide desk top calculator paper 3 25 ft Twisted Pair Shielded...

Page 82: ...ts down on a fault regardless of whether the fault causes a system or the entire chiller to lockout or whether restart is permitted This is the same print out that is obtained when the OPER DATA Key i...

Page 83: ...efer to Fig 36 and the Parts List for place ment of the grilles and the proper hardware required 4 Notch grilles to suit water connection and wiring har nesses as needed 5 If the High Ambient Sunshiel...

Page 84: ...otch grilles to suit water connections and wiring harnesses 2 Discard existing grilles to attach louver panels where necessary FIG 37 LOUVERED AND WIRE GRILLE INSTALLATION Parts List PART ITEM QUAN DE...

Page 85: ...ion Shown ASSEMBLY INSTRUCTIONS 1 Condensing and remote DX evaporator arrangement shown 2 Standard units with cooler discard items 20 21 FIG 39 LOUVERED INSTALLATION Parts List PART ITEM QUAN DESCRIPT...

Page 86: ...al should be connected to the and terminals on the TB3 Terminal Block at the right of the Microprocessor Board Be sure polarity is correct CAUTION THE 0 10VDC INPUT SIGNAL WIRING MUST NOT BE EARTH GRO...

Page 87: ...may not Energize be up 2 External motor protector tripped 2 Check for defective External motor protector wiring and motor problems Assure that motor protector is not tripped due to external high pres...

Page 88: ...rnal H P correctly set restart unit Cut out Switch opens 6 Assure OAT sensor is reading properly 6 Place a thermometer next to the sensor a Motor Current Fault and compare reading to the display w i l...

Page 89: ...thermometer located in 33 0 F 2 09 waterpiping 36 0 F 2 22 38 0 F 2 28 41 0 F 2 37 43 0 F 2 43 46 0 F 2 54 48 0 F 2 60 50 0 F 2 67 53 0 F 2 77 55 0 F 2 83 57 0 F 2 89 59 0 F 2 95 61 0 F 3 02 63 0 F 3...

Page 90: ...d not great enough 3 OK Become familiar with control operating 4 Defective loading solenoid 4 Replace compressor loading solenoid 5 Faulty wiring to loading solenoid 5 Check wiring 6 Defective water t...

Page 91: ...43 9 111 231 8 44 4 112 233 6 45 0 113 235 4 45 6 114 237 2 46 1 115 239 0 46 7 116 240 8 47 2 117 242 6 47 8 118 244 4 48 3 119 246 2 48 9 120 248 0 49 4 121 249 8 50 0 122 251 6 50 6 123 253 4 51 1...

Page 92: ...pic Team 36USC380 P O Box 1592 YORK Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by YORK International Corporation 1997 ALL RIGHTS RESERVED Form 150 60 NM3 595...

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