York YCAV0157-0267 Installation Operation & Maintenance Download Page 5

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JOHNSON CONTROLS

FORM 201.21-NM1 (616)

TABLE OF CONTENTS

SECTION 1 - GENERAL CHILLER

INFORMATION & SAFETY

INTRODUCTION ......................................................9

WARRANTY ..............................................................9

SAFETY ......................................................................9

Standards for Safety................................................9

RESPONSIBILITY FOR SAFETY ..........................10

ABOUT THIS MANUAL .........................................10

MISUSE OF EQUIPMENT ......................................10

Suitability for Application ....................................10

Structural Support .................................................10

Mechanical Strength .............................................10

General Access .....................................................10

Pressure Systems ..................................................11

Electrical ...............................................................11

Rotating Parts .......................................................11

Sharp Edges ..........................................................11

Refrigerant & Oils ................................................11

High Temperature & Pressure Cleaning ...............11

Emergency Shutdown ...........................................11

SECTION 2 - PRODUCT DESCRIPTION

INTRODUCTION ....................................................12

General System Description .................................12

Compressor ...........................................................13

Evaporator ............................................................14

Condensor .............................................................14

Flash Tank Feed / Drain Valve ..............................15

Oil Separator / Oil System ....................................15

Relief Valves .........................................................15

Oil Cooling ...........................................................16

Capacity Controls .................................................16

Power and Control Panel ......................................16

Microprocessor & VSD Controls .........................16

Display ..................................................................17

Keypad ..................................................................17

Unit Switch ...........................................................17

Variable Speed Drive (VSD) ................................18

ACCESSORIES & OPTIONS ..................................19

Single Point Circuit Breaker .................................19

Building Automation System (BAS) Interface .....19

Condensor Coil Protection....................................19

DX COOLER OPTIONS ..........................................20

SERVICE VALVE OPTION .....................................20

UNIT ENCLOSURES ..............................................20

FANS .........................................................................20

SOUND REDUCTION OPTIONS ...........................20

VIBRATION ISOLATION .......................................20

UNIT NOMENCLATURE .......................................21

PRODUCT IDENTIFICATION NUMBER .............22

SECTION 3 - RIGGING, HANDLING & STORAGE

DELIVERY AND STORAGE ...................................26

INSPECTION ............................................................26

MOVING THE CHILLER.........................................26

Lifting Weights ......................................................26

UNIT RIGGING ........................................................27

SECTION 4 - INSTALLATION

LOCATION REQUIREMENTS ................................29

OUTDOOR INSTALLATION ...................................29

INDOOR INSTALLATION .......................................29

LOCATION CLEARANCES ....................................30

VIBRATION ISOLATORS .......................................30

Installation .............................................................30

SHIPPING BRACES .................................................30

CHILLED LIQUID PIPING ......................................30

General Requirements ...........................................30

WATER TREATMENT ..............................................32

CONNECTION TYPES & SIZES .............................32

COOLER CONNECTIONS ......................................32

Option Flanges .......................................................32

REFRIGERANT RELIEF VALVE PIPING ..............33

DUCTWORK CONNECTION .................................33

General Requirements ...........................................33

ELECTRICAL CONNECTION ................................33

POWER WIRING ......................................................34

115 VAC CONTROL SUPPLY TRANSFORMER ...34

CONTROL PANEL WIRING ....................................34

VOLTS FREE CONTACTS ......................................35

Chilled Liquid Pump Starter ..................................35

Run Contact ...........................................................35

Alarm Contact........................................................35

SYSTEM INPUTS .....................................................35

Flow Switch ...........................................................35

Remote Run/Stop ...................................................35

Optional Remote Setpoint Offset Temp. ...............35

Optional Remote Setpoint Offset Sound Limit .....35

SECTION 5 - COMMISSIONING

PREPARATION .........................................................36

PREPARATION - POWER OFF ...............................36

Inspection...............................................................36

Refrigerant Charge ................................................36

Service and Oil Line Valves ..................................36

Compressor Oil ......................................................36

Fans ........................................................................36

Isolation / Protection ..............................................36

Control Panel .........................................................36

Power Connections ................................................37

Summary of Contents for YCAV0157-0267

Page 1: ...57 0267 60 HZ 150 260 TONS E V HIGH EFFICIENCY AND S P STANDARD EFFICIENCY LD10477 AIR COOLED SCREW LIQUID CHILLERS INSTALLATION OPERATION MAINTENANCE Supersedes 201 21 NM1 315 Form 201 21 NM1 616 Issue Date June 30 2016 035 20552 000 ...

Page 2: ...ument 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 ...

Page 3: ...gproducts johnsoncontrols com 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 o...

Page 4: ... working on the system NEVER short out the DC Bus to discharge 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 th...

Page 5: ... UNIT ENCLOSURES 20 FANS 20 SOUND REDUCTION OPTIONS 20 VIBRATION ISOLATION 20 UNIT NOMENCLATURE 21 PRODUCT IDENTIFICATION NUMBER 22 SECTION 3 RIGGING HANDLING STORAGE DELIVERY AND STORAGE 26 INSPECTION 26 MOVING THE CHILLER 26 Lifting Weights 26 UNIT RIGGING 27 SECTION 4 INSTALLATION LOCATION REQUIREMENTS 29 OUTDOOR INSTALLATION 29 INDOOR INSTALLATION 29 LOCATION CLEARANCES 30 VIBRATION ISOLATORS ...

Page 6: ...l Start Up 156 Check Subcooling Superheat 156 Leak Checking 157 CHILLER ELECTRONIC COMPONENTS 158 Keypad 158 Display 159 Chiller Control Board 160 Relay Output Boards 161 VSD Variable Speed Drive 161 AC to DC Rectifier 161 SCR Trigger Board 162 DC Link Filter 162 1L Line Inductor 163 AC to DC Inverter 163 Laminated Bus Structure 163 VSD Logic Board 164 Control Panel to VSD Communications 164 IBGT ...

Page 7: ...Operating Data Printout 260 History Data Printout 261 SERVICE KEY 262 SYSTEM SWITCHES KEY 268 SERIAL NUMBER PROGRAMMING 269 ENABLING OPTIMIZED HIGH IPLV MODE 271 UNIT SETUP MODE 272 DEFAULT PROGRAMMABLE VALUES 274 SERIAL PORT CONNECTIONS 275 ANALOG INPUT CONNECTIONS 276 DIGITAL INPUT CONNECTIONS 278 ANALOG OUTPUT CONNECTIONS 280 DIGITAL OUTPUT CONNECTIONS 282 ISN COMMUNICATIONS TRANSMITTED DATA 28...

Page 8: ... 32 Pressure Transducer Input Voltage 300 Table 33 Motor Temperature Sensor Resistance 301 Table 34 Compressor Motor Overload Settings Max VSD Frequency 302 Fig 1 PWM Current Waveform 18 Fig 2 PWM Voltage Waveform 18 Fig 3 Pipework Arrangement 32 Fig 4 Victaulic Groove 32 Fig 5 Flange Attatchment 32 Fig 6 Single Point Power Supply Connection W Field Supplied Circuit Protection 49 Fig 7 Single Poin...

Page 9: ...ny faulty part or sub assembly which has failed due to poor quality or manufacturing errors All claims must be supported by evidence that the failure has occurred within the warranty period and that the unit has been operated within the designed parameters specified All warranty claims must specify the unit model serial number order number and run hours starts Model and serial number information i...

Page 10: ...s manual and any other document supplied with the unit are the property ofYORK which reserves all rights They may not be reproduced in whole or in part without prior written authorization from an authorized YORK representative MISUSE OF EQUIPMENT Suitability for Application The unit is intended for cooling water or glycol solu tions and is not suitable for purposes other than those specified in th...

Page 11: ...e taken when working in contact with the coils to avoid the risk of minor abrasions and lacerations The use of gloves is recommended Frame rails brakes and other components may also have sharp edges Reasonable care should be taken when working in contact with any components to avoid risk of minor abrasions and lacerations Refrigerants and Oils Refrigerants and oils used in the unit are generally n...

Page 12: ...neral System Description The Latitude YCAV Air Cooled Chiller line combines the best of modern screw compressor design with the latest technology in variable speed drives The result is superior control and efficiency in real world conditions TheVSD enables slowing the speed of the compressor to match the load on the system resulting in precise chilled liquid control minimized sound maximum energy ...

Page 13: ...CONTROL SYSTEM INPUTS COMMUNICATIONS OUTPUTS VSD MOTOR CONTROL PANEL Pressure Transducers Temperature Sensors Level Sensor Switches Liquid Flow High Pressure Start Stop Customer Supplied Contacts Chiller Control Board Microprocessor User Interface Display Keypad Building Automation Printer Modem VSD Logic Board SCR Trigger Board Power Components PWM Speed Control Relay Output Board Solenoids Conta...

Page 14: ...nd insulated with 3 4 19 mm flexible closed cell insulation The water nozzles are provided with grooves for mechanical couplings and should be insulated by the contractor after pipe installation A 300 PSIG 20 7 bar waterside design working pres sure option is available 2 compressor chillers utilize a typical 2 pass E type evaporator with liquid inlets and suction outlets at the same end Entering c...

Page 15: ...r solenoid valve will typically be on most of the time When the economizer solenoid is OFF the liquid level will vary greatly as the Drain and Feed Valves directly affect the level as they open and close Oil Separator Oil System The external oil separators with no moving parts and designed for minimum oil carry over are mounted in the discharge line of the compressor The high pressure discharge ga...

Page 16: ...lectrical cabinet Each Power Compartment Contains Incoming single point power is standard utilizing either a lockable circuit breaker or terminal block 115VAC control transformer VSD fan contactors ON OFF unit switch microcomputer keypad and display Chiller Control and VSD Logic boards and relay boards Current transformers sense each phase of motor current and send corresponding signals to the Chi...

Page 17: ...er pump Out of range message Up to 10 fault shutdown histories Keypad An operator keypad allows complete control of the system from a central location The keypad utilizes an overlay to allow use in 5 languages The keypad is a color coded 36 button sealed keypad with keys for Display Entry Setpoints Clock Print Program Unit ON OFF and other functions Details on a few of the keys follow Status Allow...

Page 18: ...while simultaneously providing a large energy reservoir for use by the DC to AC inverter section of the drive In order to achieve the required voltage capability for the capacitor portion of the filter filter capacitor banks are formed by connecting two groups of parallel capacitors in series to form a capaci tor bank In order to assure an equal sharing of the voltage between the series connected ...

Page 19: ...gic board Each IGBT Power Module within the DC toAC inverter section con tains a thermistor heatsink temperature sensor to provide temperature information to the VSD logic board The Bus Isolator board utilizes three resistors on the board to provide a safe impedance resistance between the DC link filter capacitors located on the output phase bank assemblies and the VSD logic board It provides the ...

Page 20: ...rior condenser coil faces and heavy gauge welded wire mesh guards mounted around the bottom of the unit Factory or field mounted Louvered Panels Condenser Coils Only Louvered panels are mounted over the exterior condenser coil faces on the sides of the unit to visually screen and protect the coils Factory or field mounted Louvered Panels Full Unit enclosure Louvered panels over condenser coils and...

Page 21: ...R COOLED VSD DRIVEN SCREW COMPRESSOR MODEL NUMBER UNIT DESIGNATOR E High Efficiency with Standard IPLV S Standard Efficiency with Standard IPLV P Standard Efficiency with High IPLV V High Efficiency with High IPLV REFRIGERANT R134a VOLTAGE CODE STARTER VSD DESIGN SERIES DEVELOPMENT CODE VOLTAGE CODE UNIT DESIGNATOR 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 ...

Page 22: ... E High Efficiency High Ambient Unit Standard IPLV V High Efficiency High Ambient Unit Optimized IPLV REF Refrigerant PIN 10 A R 134a VOLTS Voltage PIN 11 12 17 200 3 60 28 230 3 60 40 380 3 60 46 460 3 60 50 380 415 3 50 58 575 3 60 STARTER Starter PIN 13 V Variable Speed Drive DESIGN Design Series PIN 14 A Design Series A DEV Modification Level PIN 15 A Mod Level A POWER Power Fld PIN 16 17 SX S...

Page 23: ... X No Pump Control required Q Special Pump Control required REMOTE Remote Ctrl Panel PIN 27 X No Remote Control Panel required O Optiview Remote Control Panel required Q Special Remote Control Panel required SEQ Sequence Kit PIN 28 X No Sequence Kit required S Sequence Control Automatic Lead Transfer seq Q Special Sequence Kit required TEMP Water Temp PIN 29 30 NUM Leaving Water Temp temp degrees ...

Page 24: ...s PIN 45 X Aluminum Coils COILS C Copper Fin Coils B Pre Coated Fin Coils P Post Coated Dipped Coils Q Special Coils HEAT Heat Recovery PIN 46 X Partial Heat Recovery not required H Partial Heat Recovery required Q Special quote FANMOTORS Fan Motors PIN 47 X TEAO Fan Motors Q Special Fan Motors PANEL Enclosure Panels PIN 48 X No Enclosure Panels required 1 Wire Full Unit Encl Panels factory 2 Wire...

Page 25: ...s Labor G 5 Year Unit Parts Only H 5 Year Unit Parts Labor Q Special Warranty REFRIGERANT WTY Refrigerant Wty PIN 56 X No Refrigerant Warranty required 1 1 Year Refrigerant Warranty 2 2 Year Refrigerant Warranty 5 5 Year Refrigerant Warranty SHIP Ship Instructions PIN 57 X No option required A Buy American Act Compliance C Container Shipping Kit B Both Buy American Act Compliance and Container Shi...

Page 26: ...coils and fins from potential damage and corrosion particularly where building work is in progress The unit should be stored in a location where there is minimal activity in order to limit the risk of ac cidental physical damage To prevent inadvertent operation of the pressure relief devices the unit must not be steam cleaned It is recommended that the unit is periodically in spected during storag...

Page 27: ... locations are outside of the container Place 4 X 4 blocks of wood un der the base rails of the unit Gently rest the unit on the blocks and remove the chains and lift truck 5 Attach lifting rigging from the crane and slowly complete the removal from the container then lift up and away LD19197a LIFTING USING LUGS Units are provided with lifting holes in the base frame which accept the accessory lif...

Page 28: ...imate center of gravity location shown for base unit Any options selected may add weight to the unit and affect the center of gravity Locate the center of gravity through trial lifts to account for possible variations in unit configuration Contact your nearest Johnson Controls Sales Office for weight data ...

Page 29: ...ending below the frost line is recommended To avoid noise and vibration transmission the unit should not be secured to the building foundation On rooftop locations choose a place with adequate structural strength to safely support the entire operating weight of the unit and service personnel The unit can be mounted on a concrete slab similar to ground floor locations or on steel channels of suitab...

Page 30: ... of large components may require larger clearances than those given in the Technical Data Section Page 122 INSTALLATION OF VIBRATION ISOLATORS Optional sets of vibration isolators can be supplied loose with each unit Using the Isolator tables shipped with the unit in the information pack refer to the Dimension Section Pages 66 121 Weight Distribution and Isolator Mounting Position Section Pages 12...

Page 31: ...es which can cause oxidation of steel parts within the cooler A flow switch must be installed in the customer pip ing at the outlet of the cooler and wired back to the control panel using shielded cable There should be a straight run of piping of at least 5 pipe diameters on either side The flow switch should be wired to Terminals 2 and 13 on the 1TB terminal block See FIG 17 Page 141 A flow switc...

Page 32: ... a range between 7 and 8 5 PIPEWORK ARRANGEMENT The following is a suggested piping arrangement for single unit installations For multiple unit installations each unit should be piped as shown in FIG 3 Isolating Valve Normally Open Isolating Valve Normally Closed Flow Regulating Valve Flow Measurement Device Strainer Pressure Tapping Flow Switch Flanged Connection Pipework FIG 3 PIPEWORK ARRANGEME...

Page 33: ... the fan outlet and straight for at least three feet 1 meter to obtain static regain from the fan Ductwork should be suspended with flexible hangers to prevent noise and vibration being transmitted to the structure Aflexible joint is also recommended between the duct attached to the fan and the next section for the same reason Flexible connectors should not be allowed to concertina The unit is not...

Page 34: ...chiller 115VAC CONTROL SUPPLY TRANSFORMER A3 wire high voltage to 115VAC supply transformer is standard in the chiller This transformer is mounted in the Cabinet and steps down the high voltage supply to 115VAC to be used by the Controls VSD Feed Drain Valve Controller valves solenoids heaters etc The high voltage for the transformer primary is taken from the chiller input Fusing is provided for t...

Page 35: ... each pair of systems 1 3 2 4 These inputs require a dry contact to start and stop the system System 1 3 remote dry contacts are connected between Terminals 2 and 15 of 1TB FIG 17 Page 141 and System 2 4 dry contacts are connected between Terminals 2 and 16 of 1TB FIG 17 Page 141 If remote start stop is not utilized a jumper must be paced across the terminals to allow the system to run The remote ...

Page 36: ...lves are of the back seat type open them fully counterclockwise then close one turn of the stem to ensure operating pressure is fed to pressure transducers Open the liquid line service valve and oil return line ball valve fully in each system Compressor Oil To add oil to a circuit connect a YORK hand oil pump Part No 470 10654 000 to the 1 4 oil charging valve on the oil separator piping with a le...

Page 37: ...hielded cable There should be a straight run of at least 5 pipe diam eters on either side of the flow switch The flow switch should be connected to terminals 2 and 13 in the panel Temperature Sensor s Ensure the leaving liquid temperature sensor is coated with heat conductive compound Part No 013 00890 000 and is inserted to the bottom of the water outlet sensor well in the evaporator This sensor ...

Page 38: ...t the controller will increase the speed of the compressor s Condenser and Fan Rotation Once a compressor is running discharge pressure rises as refrigerant is pumped into the air cooled condenser coils This pressure is controlled by stages of fans to ensure maximum unit efficiency while maintaining suf ficient pressure for correct operation of the condensers and the lubrication system As discharg...

Page 39: ...SYS 1 switch on the keypad and repeat the process for each subsequent system When all run correctly stop the unit switch all applicable switches to the ON position and restart the unit Assure all checks are completed in the EQUIPMENT START UP CHECK SHEET Pages 152 157 The chiller is then ready to be placed into operation 5 ...

Page 40: ...800 900 1000 Water Flow Rate GPM Pressure Drop ft H2O A B C D English Units Pressure Drop Through YCAV Evaporators 0 20 40 60 80 100 120 140 160 180 200 0 5 10 15 20 25 30 35 40 45 50 Water Flow Rate l s Pressure Drop kPa A B C D SI Units LD10497 LD10498 MODEL NUMBER YCAV COOLER 0157 S P A 0157 E V 0177 0187 B 0207 0227 C 0247 0267 D TECHNICAL DATA ...

Page 41: ...are higher than with water see correction factors to be applied when using glycol solutions Special care must be taken not to exceed the maximum flow rate allowed A Correction Factor B Mean Temperature through Cooler C Concentration W W Excessive flow above the max GPM will damage the evaporator PROPYLENE GLYCOL ETHYLENE GLYCOL GLYCOL CORRECTION FACTORS A A B B 18 17 16 15 14 13 12 11 10 1 45 1 40...

Page 42: ...750 0 125 0207 40 60 160 750 0 125 0227 40 60 160 750 0 125 0247 40 60 180 750 0 125 0267 40 60 180 800 0 125 NOTES 1 For leaving brine temperature below 40 F 4 4 C contact your nearest YORK office for application requirements 2 For leaving water temperature higher than 60 F 15 6 C contact the nearest YORK office for application guidelines TEMPERATURE AND FLOWS SI UNITS MODEL NUMBER YCAV LEAVING W...

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Page 44: ...2 2 2 Fan Motor Speed revs min 1140 1140 1140 1140 1140 1140 1140 Fan Diameter inches 35 4 35 4 35 4 35 4 35 4 35 4 35 4 Fan Tip Speed ft min 10575 10575 10575 10575 10575 10575 10575 Total Chiller Airflow cfm 104000 117000 130000 130000 143000 156000 156000 Ultra Quiet Fans Fan Motor HP 2 2 2 2 2 2 2 Fan Motor Speed revs min 838 838 838 838 838 838 838 Fan Diameter inches 35 4 35 4 35 4 35 4 35 4...

Page 45: ... 2 2 2 Fan Motor Speed revs sec 19 0 19 0 19 0 19 0 19 0 19 0 19 0 Fan Diameter mm 899 899 899 899 899 899 899 Fan Tip Speed m sec 53 7 53 7 53 7 53 7 53 7 53 7 53 7 Total Chiller Airflow l sec 49082 55218 61353 61353 67488 73624 73624 Low Noise Fans Fan Motor HP 2 2 2 2 2 2 2 Fan Motor Speed revs sec 14 0 14 0 14 0 14 0 14 0 14 0 14 0 Fan Diameter mm 899 899 899 899 899 899 899 Fan Tip Speed m se...

Page 46: ...6 5 6 6 Low Sound Fans Fan Motor HP 2 2 2 2 2 2 2 Fan Motor Speed revs min 1140 1140 1140 1140 1140 1140 1140 Fan Diameter inches 35 4 35 4 35 4 35 4 35 4 35 4 35 4 Fan Tip Speed ft min 10575 10575 10575 10575 10575 10575 10575 Total Chiller Airflow cfm 104000 104000 117000 117000 130000 143000 156000 Ultra Quiet Fans Fan Motor HP 2 2 2 2 2 2 2 Fan Motor Speed revs min 838 838 838 838 838 838 838 ...

Page 47: ... Low Sound Fans Fan Motor HP 2 2 2 2 2 2 2 Fan Motor Speed revs sec 19 0 19 0 19 0 19 0 19 0 19 0 19 0 Fan Diameter mm 899 899 899 899 899 899 899 Fan Tip Speed m sec 53 7 53 7 53 7 53 7 53 7 53 7 53 7 Total Chiller Airflow l sec 49082 49082 55218 55218 61353 67488 73624 Ultra Quiet Fans Fan Motor HP 2 2 2 2 2 2 2 Fan Motor Speed revs sec 14 0 14 0 14 0 14 0 14 0 14 0 14 0 Fan Diameter mm 899 899 ...

Page 48: ...48 JOHNSON CONTROLS FORM 201 21 NM1 616 OPERATING LIMITATIONS AND SOUND DATA Contact Product Application Marketing for Sound Power Data TECHNICAL DATA ...

Page 49: ...PLY CONNECTION WITH OPTIONAL FACTORY CIRCUIT BREAKER LD10598a LD10599a ELECTRICAL DATA 2 COMPRESSOR POWER WIRING CONNECTIONS VSD CONTROL PANEL 6 VSD SYSTEM TERMINAL BLOCK FAN CONTACTORS STANDARD CONTROL TRANSFORMERS UNIT CONTROLS EVAPORATOR HEATER VSD SYSTEM CIRCUIT BREAKER FAN CONTACTORS STANDARD CONTROL TRANSFORMERS UNIT CONTROLS EVAPORATOR HEATER ...

Page 50: ... 84 5 2 2 1 8 30KA 42KA 0197 200 60 326 5 6 5 326 5 6 5 1 8 30KA 100KA 230 60 283 5 5 6 283 5 5 6 1 8 30KA 100KA 380 60 178 5 3 5 178 5 3 5 1 8 30KA 65KA 460 60 141 5 2 8 141 5 2 8 1 8 30KA 65KA 575 60 113 5 2 2 113 5 2 2 1 8 30KA 42KA 0207 200 60 327 6 6 5 353 5 6 5 1 8 30KA 100KA 230 60 283 6 5 6 306 5 5 6 1 8 30KA 100KA 380 60 178 6 3 5 193 5 3 5 1 8 30KA 65KA 460 60 141 6 2 8 152 5 2 8 1 8 30K...

Page 51: ...0AWG 500 kcmil 260 300 600 450 2 2AWG 600 kcmil 2 2 0AWG 500 kcmil 0197 799 1000 1600 1600 4 2AWG 600 kcmil 4 4 0AWG 500 kcmil 692 800 1600 1200 4 2AWG 600 kcmil 4 4 0AWG 500 kcmil 437 500 1000 700 3 2AWG 600 kcmil 3 3 0AWG 400 kcmil 345 400 800 600 2 2AWG 600 kcmil 2 2 0AWG 500 kcmil 277 350 700 450 2 2AWG 600 kcmil 2 2 0AWG 500 kcmil 0207 832 1000 1600 1600 4 2AWG 600 kcmil 4 4 0AWG 500 kcmil 72...

Page 52: ... 96 4 2 2 1 8 30KA 42KA 0207 200 60 336 5 6 5 379 4 6 5 1 8 30KA 100KA 230 60 291 5 5 6 328 4 5 6 1 8 30KA 100KA 380 60 184 5 3 5 207 4 3 5 1 8 30KA 65KA 460 60 145 5 2 8 163 4 2 8 1 8 30KA 65KA 575 60 116 5 2 2 131 4 2 2 1 8 30KA 42KA 0227 200 60 375 5 6 5 375 5 6 5 1 8 30KA 100KA 230 60 325 5 5 6 325 5 5 6 1 8 30KA 100KA 380 60 205 5 3 5 205 5 3 5 1 8 30KA 65KA 460 60 162 5 2 8 162 5 2 8 1 8 30K...

Page 53: ...l 698 800 1600 1200 4 2AWG 600 kcmil 4 4 0AWG 500 kcmil 440 500 1000 700 3 2AWG 600 kcmil 3 3 0AWG 400 kcmil 348 400 800 600 2 2AWG 600 kcmil 2 2 0AWG 500 kcmil 279 350 700 450 2 2AWG 600 kcmil 2 2 0AWG 500 kcmil 0207 857 1000 2000 1600 4 2AWG 600 kcmil 4 4 0AWG 500 kcmil 742 1000 2000 1200 4 2AWG 600 kcmil 4 4 0AWG 500 kcmil 468 600 1200 800 3 2AWG 600 kcmil 3 3 0AWG 400 kcmil 370 450 1000 600 2 ...

Page 54: ...the use of YORK Variable Speed Drive technology Typical Compressor Starting Current rst four seconds of startup Rated Voltage Typical Starting Current per Compressor 200 60 3 53A 230 60 3 46A 380 60 3 29A 460 60 3 23A 575 60 3 18A 10 Optional Compressor Service Disconnect switch is available on all units 11 Voltage Utilization Range Rated Voltage Utilization Range 200 60 3 180 220 230 60 3 208 254...

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Page 56: ...56 JOHNSON CONTROLS FORM 201 21 NM1 616 ELECTRICAL WIRING LD12518 ELEMENTARY CONTROL WIRING DIAGRAM TECHNICAL DATA ...

Page 57: ...57 JOHNSON CONTROLS FORM 201 21 NM1 616 ELEMENTARY CONTROL WIRING DIAGRAM CON T 6 LD12519 ...

Page 58: ...58 JOHNSON CONTROLS FORM 201 21 NM1 616 ELEMENTARY POWER WIRING DIAGRAM 2 COMPRESSOR YCAV CHILLER TECHNICAL DATA LD12516 T 115VAC T RUN RUN ...

Page 59: ...59 JOHNSON CONTROLS FORM 201 21 NM1 616 ELEMENTARY POWER WIRING DIAGRAM 2 COMPRESSOR YCAV CHILLER CON T 6 LD12517 ...

Page 60: ...60 JOHNSON CONTROLS FORM 201 21 NM1 616 LD12514 CONNECTION WIRING DIAGRAM 2 COMPRESSOR YCAV CHILLER TECHNICAL DATA ...

Page 61: ...61 JOHNSON CONTROLS FORM 201 21 NM1 616 CONNECTION WIRING DIAGRAM 2 COMPRESSOR YCAV CHILLER CON T 6 LD12515 ...

Page 62: ...62 JOHNSON CONTROLS FORM 201 21 NM1 616 CONNECTION WIRING DIAGRAM 2 COMPRESSOR YCAV CHILLER TECHNICAL DATA LD12512 ...

Page 63: ...63 JOHNSON CONTROLS FORM 201 21 NM1 616 CONNECTION WIRING DIAGRAM 2 COMPRESSOR YCAV CHILLER CON T 6 LD12513 ...

Page 64: ...64 JOHNSON CONTROLS FORM 201 21 NM1 616 LOCATION LABEL LD10519 TECHNICAL DATA ...

Page 65: ...65 JOHNSON CONTROLS FORM 201 21 NM1 616 This page intentionally left blank 6 ...

Page 66: ...optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances side to wall 6 rear to wall 6 control panel end to wall 4 top no obstructions allowed distance between adjacent units 10 No more than one ad...

Page 67: ...88 1 8 96 40 14 1 16 87 3 8 1 933 2 098 1 435 1 301 1 984 1 666 5 8 MOUNTING HOLES TYP APPROX OPERATING WEIGHT DISTRIBUTION LB X G C Y G C X Z D D VIEW D D CONTROL PANEL 8 WATER OUTLET 8 WATER INLET 1 1 48 1 2 64 108 1 2 A A 3 RIGGING HOLES EACH SIDE 4 5 X 2 SYS 2 SYS 1 11 1 2 85 7 16 100 7 8 ORIGIN 6 3 3 4 10 1 091 1 055 68 60 ...

Page 68: ...timize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances side to wall 6 rear to wall 6 control panel end to wall 4 top no obstructions allowed distance between adjacent units 10 No more than one adja...

Page 69: ...14 1 16 87 3 8 2 052 2 282 1 586 1 499 2 267 1 796 5 8 MOUNTING HOLES TYP APPROX OPERATING WEIGHT DISTRIBUTION LB X G C Y G C X Z Z D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 1 1 48 1 2 64 108 1 2 A A 3 RIGGING HOLES EACH SIDE 4 5 X 2 SYS 2 SYS 1 11 1 2 85 7 16 100 7 8 ORIGIN 6 3 3 4 10 1 182 1 140 68 60 LD10523A ...

Page 70: ... without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances side to wall 6 rear to wall 6 control panel end to wall 4 top no obstructions allowed distance between adjacent units 10 No more than one adjacent wall may be...

Page 71: ...87 3 8 2 062 2 304 1 592 1 504 2 276 1 804 5 8 MOUNTING HOLES TYP APPROX OPERATING WEIGHT DISTRIBUTION LB X G C Y G C X Z D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 1 1 48 1 2 64 108 1 2 A A 3 RIGGING HOLES EACH SIDE 4 5 X 2 SYS 2 SYS 1 11 1 2 85 7 16 100 7 8 POWER SINGLE POINT WITH TERMINAL BLOCK ORIGIN 6 3 3 4 10 1 187 1 145 68 60 ...

Page 72: ...tion and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no...

Page 73: ...6 87 3 8 L2 L3 L4 L5 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 1 1 48 1 2 64 85 67 1 2 A A 3 RIGGING HOLES EACH SIDE SYS 2 SYS 1 11 1 2 85 7 16 123 11 16 ORIGIN 6 3 3 4 10 R1 L1 68 10 10 LD10527 DIMENSIONS YCAV0177E V High Efficiency English Con t ...

Page 74: ...ration and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is ...

Page 75: ...ncy English Con t 60 274 3 8 112 7 8 84 1 2 88 1 8 96 40 14 1 16 87 3 8 L2 L3 L4 L5 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 1 1 48 1 2 64 85 67 1 2 A A 3 RIGGING HOLES EACH SIDE SYS 2 SYS 1 11 1 2 85 7 16 123 11 16 ORIGIN 6 3 3 4 10 R1 L1 68 10 10 ...

Page 76: ...tion and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no...

Page 77: ...y English Con t 60 274 3 8 112 7 8 84 1 2 88 1 8 96 40 14 1 16 87 3 8 L2 L3 L4 L5 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 1 1 48 1 2 64 85 67 1 2 A A 3 RIGGING HOLES EACH SIDE SYS 2 SYS 1 11 1 2 85 7 16 123 11 16 ORIGIN 6 3 3 4 10 R1 L1 68 10 10 ...

Page 78: ...tion and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no...

Page 79: ...y English Con t 60 274 3 8 112 1 4 85 5 8 88 1 8 96 40 14 1 16 87 3 8 L2 L3 L4 L5 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 1 1 48 1 2 64 85 67 1 2 A A 3 RIGGING HOLES EACH SIDE SYS 2 SYS 1 11 1 2 85 7 16 123 11 16 ORIGIN 6 3 3 4 10 R1 L1 68 10 10 ...

Page 80: ...eration and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is...

Page 81: ...English Con t 60 274 3 8 114 5 8 79 3 16 88 1 8 96 40 14 1 16 87 3 8 L2 L3 L4 L5 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 1 1 48 1 2 65 3 8 80 5 8 70 1 2 A A 3 RIGGING HOLES EACH SIDE SYS 2 SYS 1 12 1 2 84 7 16 123 11 16 ORIGIN 6 3 3 4 10 R1 L1 68 10 10 ...

Page 82: ...tion and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no...

Page 83: ...sh Con t 60 318 3 8 112 1 4 85 5 8 88 1 8 96 40 14 1 16 87 3 8 L2 L3 L4 L6 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 1 1 48 1 2 64 85 54 7 8 A A 4 RIGGING HOLES EACH SIDE SYS 2 SYS 1 11 1 2 85 7 16 79 11 16 88 ORIGIN 6 R6 R1 3 3 4 68 10 L5 L1 56 5 8 10 10 ...

Page 84: ...eration and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is...

Page 85: ...English Con t 60 274 3 8 114 5 8 79 3 16 88 1 8 96 40 14 1 16 87 3 8 L2 L3 L4 L5 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 1 1 48 1 2 65 3 8 80 5 8 70 1 2 A A 3 RIGGING HOLES EACH SIDE SYS 2 SYS 1 12 1 2 84 7 16 123 11 16 ORIGIN 6 3 3 4 10 R1 L1 68 10 10 ...

Page 86: ...ation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is n...

Page 87: ...n t 60 318 3 8 114 5 8 79 3 16 88 1 8 96 40 14 1 16 87 3 8 L2 L3 L4 L6 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 1 1 48 1 2 65 3 8 80 5 8 57 7 8 A A 4 RIGGING HOLES EACH SIDE SYS 2 SYS 1 12 1 2 84 7 16 79 11 16 88 ORIGIN 6 R6 R1 3 3 4 68 10 L5 L1 56 5 8 10 10 ...

Page 88: ...eration and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is...

Page 89: ...Con t 60 318 3 8 114 5 8 79 3 16 88 1 8 96 40 14 1 16 87 3 8 L2 L3 L4 L6 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 1 1 48 1 2 65 3 8 80 5 8 57 7 8 A A 4 RIGGING HOLES EACH SIDE SYS 2 SYS 1 12 1 2 84 7 16 79 11 16 88 ORIGIN 6 R6 R1 3 3 4 68 10 L5 L1 56 5 8 10 10 ...

Page 90: ...timize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances side to wall 6 rear to wall 6 control panel end to wall 4 top no obstructions allowed distance between adjacent units 10 No more than one adja...

Page 91: ...n t 60 318 3 8 114 5 8 79 3 16 88 1 8 96 40 14 1 16 87 3 8 L2 L3 L4 L6 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 1 1 48 1 2 65 3 8 80 5 8 57 7 8 A A 4 RIGGING HOLES EACH SIDE SYS 2 SYS 1 12 1 2 85 7 16 79 11 16 88 ORIGIN 6 R6 R1 3 3 4 68 10 L5 L1 56 5 8 10 10 ...

Page 92: ...eration and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is...

Page 93: ...Con t 60 318 3 8 114 5 8 79 3 16 88 1 8 96 40 14 1 16 87 3 8 L2 L3 L4 L6 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 1 1 48 1 2 65 3 8 80 5 8 57 7 8 A A 4 RIGGING HOLES EACH SIDE SYS 2 SYS 1 12 1 2 84 7 16 79 11 16 88 ORIGIN 6 R6 R1 3 3 4 68 10 L5 L1 56 5 8 10 10 ...

Page 94: ...e system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances side to wall 2m rear to wall 2m control panel end to wall 1 2m top no obstructions allowed distance between adjacent units 3m No more than one adjacent wall may be higher than the unit DIMENSIONS YCAV0157S P Standa...

Page 95: ...219 1 933 2 098 1 435 1 301 1 984 1 666 16 MOUNTING HOLES TYP APPROX OPERATING WEIGHT DISTRIBUTION KG X G C Y G C X Z Z D D VIEW D D CONTROL PANEL 8 WATER OUTLET 8 WATER INLET 26 26 1232 1626 2756 A A 3 RIGGING HOLES EACH SIDE 114 X 51 SYS 2 SYS 1 292 2169 2562 POWER SINGLE POINT WITH TERMINAL BLOCK ORIGIN 152 95 254 1 091 1 055 1727 1524 ...

Page 96: ...ithout nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances side to wall 2m rear to wall 2m control panel end to wall 1 2m top no obstructions allowed distance between adjacent units 3m No more than one adjacent wall may...

Page 97: ...2 052 2 282 1 586 1 499 2 267 1 796 16 MOUNTING HOLES TYP APPROX OPERATING WEIGHT DISTRIBUTION KG X G C Y G C X Z Z D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1232 1626 2756 A A 3 RIGGING HOLES EACH SIDE 114 X 51 SYS 2 SYS 1 292 2169 2562 POWER SINGLE POINT WITH TERMINAL BLOCK ORIGIN 152 95 254 1 182 1 140 1727 1524 ...

Page 98: ...tion and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no...

Page 99: ...177E V High Efficiency SI Con t 1524 6970 2867 2146 2239 2438 1016 357 2219 L2 L3 L4 L5 R5 R4 R3 R2 MOUNTING HOLES TYP IE ONTROL P NEL TER OUTLET TER INLET 26 26 1232 1626 2160 1714 3 RIGGING HOLES E H SI E SYS 2 SYS 1 292 2169 3141 ORIGIN 152 95 254 R1 L1 68 10 10 ...

Page 100: ... without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spring isolators Recommended minimum clearances side to wall 2m rear to wall 2m control panel end to wall 1 2m top no obstructions allowed distance between adjacent units 3m No more than one adjacent wall m...

Page 101: ...9 2 062 2 304 1 592 1 504 2 276 1 804 16 MOUNTING HOLES TYP APPROX OPERATING WEIGHT DISTRIBUTION KG X G C Y G C X X Z Z D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1232 1626 2756 A A 3 RIGGING HOLES EACH SIDE 114 X 51 SYS 2 SYS 1 292 2169 2562 POWER SINGLE POINT WITH TERMINAL BLOCK ORIGIN 152 95 254 1 187 1 145 1727 1524 ...

Page 102: ... ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher ...

Page 103: ...187S P Standard Efficiency SI Con t 1524 6970 2867 2146 2239 2438 1016 357 2219 L2 L3 L4 L5 R5 R4 R3 R2 MOUNTING HOLES TYP IE ONTROL P NEL TER OUTLET TER INLET 26 26 1232 1626 2160 1714 3 RIGGING HOLES E H SI E SYS 2 SYS 1 292 2169 3141 ORIGIN 152 95 254 R1 L1 68 10 10 ...

Page 104: ...ase of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher th...

Page 105: ...igh Efficiency SI Con t 1524 6970 2867 2146 2239 2438 1016 357 2219 L2 L3 L4 L5 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 26 26 1232 1626 2160 1714 A A 3 RIGGING HOLES EACH SIDE SYS 2 SYS 1 292 2169 3141 ORIGIN 152 95 254 R1 L1 68 10 10 ...

Page 106: ...ase of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher th...

Page 107: ...ciency SI Con t LD10559 1524 6970 2851 2174 2239 2438 1016 357 2219 L2 L3 L4 L5 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 26 26 1232 1626 2160 1714 A A 3 RIGGING HOLES EACH SIDE SYS 2 SYS 1 292 2169 3141 ORIGIN 152 95 254 R1 L1 68 10 10 ...

Page 108: ... ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher ...

Page 109: ...ndard Efficiency SI Con t 1524 6970 2912 2011 2239 2438 1016 357 2219 L2 L3 L4 L5 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 26 26 1232 1661 2048 1791 A A 3 RIGGING HOLES EACH SIDE SYS 2 SYS 1 318 2145 3141 ORIGIN 152 95 254 R1 L1 68 10 10 ...

Page 110: ...ase of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher th...

Page 111: ...ciency SI Con t 1524 8087 2851 2174 2239 2438 1016 357 2219 L2 L3 L4 L6 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL WATER OUTLET WATER INLET 26 26 1232 1626 2160 1393 A A 4 RIGGING HOLES EACH SIDE SYS 2 SYS 1 292 2169 2024 2235 ORIGIN 152 R6 R1 95 68 254 L5 L1 1438 10 10 ...

Page 112: ... ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher ...

Page 113: ...ndard Efficiency SI Con t 1524 6970 2912 2011 2239 2438 1016 357 2219 L2 L3 L4 L5 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1232 1661 2048 1791 A A 3 RIGGING HOLES EACH SIDE SYS 2 SYS 1 318 2145 3141 ORIGIN 152 95 254 R1 L1 68 ...

Page 114: ...ase of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher th...

Page 115: ...ciency SI Con t 1524 8087 2851 2174 2239 2438 1016 357 2219 L2 L3 L4 L6 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1232 1626 2160 1393 A A 4 RIGGING HOLES EACH SIDE SYS 2 SYS 1 292 2169 2024 2235 ORIGIN 152 R6 R1 95 68 254 L5 L1 1438 ...

Page 116: ... ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher ...

Page 117: ...ficiency SI Con t 1524 8087 2912 2011 2239 2438 1016 357 2219 L2 L3 L4 L6 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1232 1661 2048 1470 A A 4 RIGGING HOLES EACH SIDE SYS 2 SYS 1 318 2144 2024 2235 ORIGIN 152 R6 R1 95 68 254 L5 L1 1438 ...

Page 118: ...ase of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher th...

Page 119: ...ciency SI Con t 1524 8087 2912 2011 2239 2438 1016 357 2219 L2 L3 L4 L6 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1232 1661 2048 1470 A A 4 RIGGING HOLES EACH SIDE SYS 2 SYS 1 318 2169 2024 2235 ORIGIN 152 R6 R1 95 68 254 L5 L1 1438 ...

Page 120: ... ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher ...

Page 121: ...ficiency SI Con t 1524 8087 2912 2011 2239 2438 1016 357 2219 L2 L3 L4 L6 R5 R4 R3 R2 MOUNTING HOLES TYP D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1232 1661 2048 1470 A A 4 RIGGING HOLES EACH SIDE SYS 2 SYS 1 318 2144 2024 2235 ORIGIN 152 R6 R1 95 68 254 L5 L1 1438 ...

Page 122: ...1 21 NM1 616 TECHNICAL DATA CLEARANCES 1 3 m 2 m 2 m 2 m NOTES 1 No obstructions allowed above the unit 2 Only one adjacent wall may be higher than the unit 3 Adjacent units should be 10 feet 3 Meters apart LD10506 TECHNICAL DATA ...

Page 123: ...123 JOHNSON CONTROLS FORM 201 21 NM1 616 This page intentionally left blank 6 ...

Page 124: ...ll be similar to Figure 8 below The drawing will show the isolator locations along with weight in pounds and kilograms at the specific location isolator position and location measurements for each isolator Location X Distance inches mm Y Distance inches mm Vendor Number Weight R1 3 75 95 78 0 1981 2 CIP C 1350 Yellow 895 0 405 97 L1 3 75 95 10 0 254 0 CIP C 1350 Yellow 895 0 405 97 R2 48 5 1231 9 ...

Page 125: ...ignated as X in FIG 8 YCAV0157S P YCAV0157E V and YCAV0177S P YCAV0177E V YCAV0187S P YCAV0187E V and YCAV0197E V L1 L2 L3 L4 R1 R2 R3 R4 3 75 95mm 48 5 1231 9mm 112 5 2857 5mm 224 75 5708 7mm Control Panel LD10501 L1 L2 L3 L4 R1 R2 R3 R4 L5 R5 3 75 95mm 48 5 1231 9mm 112 5 2857 5mm 197 53 5017 3mm 265 6731mm Control Panel LD10502 ...

Page 126: ... and YCAV0227S P YCAV0207E V and YCAV0227E V LD10504 LD10503 L1 L2 L3 L4 R1 R2 R3 R4 L6 R6 3 75 95mm 48 5 1231 9mm 112 5 2857 5mm 197 53 5017 3mm 309 7848 6mm L5 R5 252 38 6410 5mm Control Panel L1 L2 L3 L4 R1 R2 R3 R4 3 75 95mm 48 5 1231 9mm 113 875 2892 4mm 194 5 4940mm L5 R5 265 6731mm Control Panel ...

Page 127: ...1 21 NM1 616 6 YCAV0247S P YCAV0247E V and YCAV0267S P LD10508 L1 L2 L3 L4 R1 R2 R3 R4 L6 R6 3 75 95mm 48 5 1231 9mm 113 875 2892 4mm 194 5 4940mm 309 7848 6mm L5 R5 252 375 6410 3mm Control Panel ISOLATOR MOUNTING POSITIONS CON T ...

Page 128: ...ngs SLRS 6 C2 has six springs and SLRS 9 C2 has nine springs Value is de rated by 15 PIN 54 S Weight Range lbs Weight Range kg Vendor P N COLOR YORK P N UP TO 358 LBS Up to 162 kg SLRS 2 C2 420 Red 029 24585 006 358 442 LBS 162 to 201 kg SLRS 2 C2 520 White 029 24585 007 443 581 LBS 201 to 264 kg SLRS 2 C2 660 Black 029 24585 008 582 782 LBS 264 to 335 kg SLRS 2 C2 920 Blue 029 24585 009 783 1037 ...

Page 129: ...sher 8 Turn adjustment bolt 8 turns on each mount 9 Take one additional complete turn on each adjustment bolt in sequence until the top plate lifts off of the lower restraining nuts Take no additional turns on that mount Continue with equal turns on the other mounts until the top plates lift off of the lower restraining nuts of all mounts 10 Hold the limit stop bolt in place and turn the lower res...

Page 130: ...olt the mountings to a concrete pad in most cases Mountings should always be bolted to the chiller rails When mountings and the chiller are installed on steel framing above the ground the mountings should be bolted to the steel framework Lower the chiller on to the mountings evenly to avoid placing excessive weight on individual isolators LD10569 TECHNICAL DATA ENGLISH SIZE D H L T W BC CS MBD ND ...

Page 131: ...386 to 483 kg CIP B 1250 Gray 029 24583 005 1064 1404 LBS 483 to 637 kg CIP B 1650 Black 029 24583 006 For Units With Any Load Point Above 1404 LBS 637 KG UP TO 851 LBS Up to 386 kg CIP C 1000 Black 029 24583 007 851 1149 LBS 386 to 521 kg CIP C 1350 Yellow 029 24583 008 1149 1489 LBS 521 to 675 kg CIP C 1750 Black 029 24583 009 1489 1786 LBS 675 to 810 kg CIP C 2100 Yellow w Red 029 24583 010 178...

Page 132: ...equip ment is raised free of the spacer blocks or shims Remove the blocks or shims 8 Turn the leveling bolt of all mountings in either direction in order to level the installation 9 Tighten the nuts on hold down bolts to permit a clearance of 2mm 1 8 between resilient washer and underside of channel cap plate 10 Installation is now complete Illustration shows single spring CIP B or CIP C mount HCL...

Page 133: ...133 JOHNSON CONTROLS FORM 201 21 NM1 616 RC2 C R R C R 22 R C R R R R R C R C C R C FIG 9 REFRIGERANT FLOW DIAGRAM REFRIGERANT FLOW DIAGRAM 6 LD10505 ...

Page 134: ...MPERATURE CUTOUT LOW PRESSURE CUTOUT CHT DP DFP DV HPL HTC LPC LOW TEMPERATURE CUTOUT HIGH PRESSURE CUTOUT HEATER LTC HPC HTR SOLENOID VALVE BALL VALVE RELIEF VALVE STOP VALVE ANGLE ACCESS PRESSURE SENSOR TEMPERATURE SENSOR REPLACEABLE CORE FILTER DRYER SIGHT GLASS FLOW SWITCH optional PRESSURE SWITCH ELECTRIC HEATER PLUG MICROPROCESSOR CONTROL FUNCTIONS MAJOR COMPONENTS P T T T P P T T P S SMV FS...

Page 135: ... CONTROLS FORM 201 21 NM1 616 COMPONENT LOCATIONS FIG 11 COMPONENT LOCATIONS LD10477 CHILLER VSD ELECTRICAL PANEL FANS CONDENSOR COIL COMPRESSOR FILTER DRIER OIL SEPARATORS GLYCOL PUMP KEYPAD DISPLAY PANEL DOOR 6 ...

Page 136: ...136 JOHNSON CONTROLS FORM 201 21 NM1 616 FIG 12 CONTROL AND VSD CABINET COMPONENTS COMPONENT LOCATIONS CON T LD10578 TECHNICAL DATA ...

Page 137: ...LER CONTROL BOARD RELAY BOARDS MICROGATEWAY AND OPTIONAL CIRCUIT BREAKER LD10579 MICROGATEWAY OPTIONAL CHILLER CONTROL BOARD RELAY BOARD 1 RELAY BOARD 2 OPTIONAL CIRCUIT BREAKER Standard Unit will have terminal blocks Input power to the chiller will be connected here see FIG 17 6 ...

Page 138: ...14 CHILLER CONTROL BOARD RELAY BOARDS AND MICROGATEWAY LD10580 COMPONENT LOCATIONS CON T TECHNICAL DATA CHILLER CONTROL BOARD MICROGATEWAY OPTIONAL RELAY BOARD 1 RELAY BOARD 2 RS 232 485 JUMPER CLOCK JUMPER CLK JP2 JP4 JP5 JP6 mA V JUMPER POSITION ...

Page 139: ...139 JOHNSON CONTROLS FORM 201 21 NM1 616 FIG 15 VSD LOGIC BOARD LD10582 COMPONENT LOCATIONS CON T 6 VSD LOGIC BOARD ...

Page 140: ...M 201 21 NM1 616 FIG 16 VSD LOGIC BOARD LD10590 COMPONENT LOCATIONS CON T TECHNICAL DATA MADE IN THE USA YORK R86 COMPR 4 Over Load Adjust R42 COMPR 3 Over Load Adjust R64 COMPR 2 Over Load Adjust R19 COMPR 1 Over Load Adjust ...

Page 141: ...will have terminal blocks FLASH TANK FEED AND DRAIN VALVE CONTROLLER CONTROL AND VSD CABINET COOLING COIL CONTROL AND VSD CABINET COOLING FAN 1TB TERMINAL BLOCK 10T TRANSFORMER INCOMING POWER GROUND LUGS INPUT POWER TO THE CHILLER CONNECTS HERE 17 21 FU FUSES 4 9FU FUSES 14 16FU FUSES TRANSIENT SUPPRESSOR 10CR FAN PUMP CONTROL RELAY 1L AC LINE INDUCTOR 6 ...

Page 142: ...ON CONTROLS FORM 201 21 NM1 616 FIG 18 FAN CONTACTORS AND 3T TRANSFORMER COMPONENT LOCATIONS CON T LD10584 FAN CONTACTORS 4CR 9CR 3T TRANSFORMER 24VAC to SCR Gate Driver Board and VSD Logic Board TECHNICAL DATA ...

Page 143: ...lay Board 1 21 FU Relay Board 2 COOLING FAN 4 9 FU FUSES 14 16 FU FUSES 4 6 FU TB 1 3 SCR Trigger Board 7 9 FU Sys 1 Fans 14 16 FU Sys 2 Fans TRANSIENT SUPPRESSOR BOARD 3 Phase Input 1L AC LINE INDUCTOR 4 6 CT CURRENT TRANSFORMERS 10 CR FAN PUMP CONTROL RELAY CAPACITORS C15 C17 Motor output RC DV DT Network 3 8 RES RESISTORS Motor Output RC DV DT Network 3 8 RES RESISTORS Motor Output RC DV DT Net...

Page 144: ...d SCR Trigger Board 24 VAC Supply Transformer CURRENT TRANSFORMERS SNUBBER CAPS C7 C12 BUS ISOLATOR BOARD Feeds VSD Logic Board SCR TRIGGER BOARD IGBT MODULES SCR DIODE MODULES 1RES 2RES BUS CAPACITOR BANK EQUALIZING BLEEDER RESISTORS IGBT GATE DRIVER BOARDS HEATSINK Water Cooled BUS FILTER CAPACITORS Behind Panel 1L LINE INDUCTOR COMPONENT LOCATIONS CON T ...

Page 145: ... 6 FIG 21 VSD COMPONENTS LD10587 FAN RELAYS CURRENT TRANSFORMERS C13 C17 COOLING FANS 1L LINE INDUCTOR CABINET COOLING COIL TRANSIENT SUPPRESSOR BOARD W 11FU 12FU 13 FU FUSES 3 Phase Input 10CR FAN PUMP CONTROL RELAY COMPONENT LOCATIONS CON T ...

Page 146: ...TA FIG 22 INVERTER POWER COMPONENTS LD10588 COMPONENT LOCATIONS CON T THE LINE INDUCTOR WILL REACH OPERATING TEMPERATURES OF OVER 300 F DO NOT OPEN PANEL DOORS DURING OPERATION ASSURE THE INDUCTOR IS COOL WHENEVER WORKING NEAR THE INDUCTOR WITH POWER OFF ...

Page 147: ...ENTS LD10592 COMPONENT LOCATIONS CON T LD10591 IGBT S IGBT S IGBT S WATER COOLED HEAT SINK SCR DIODE MODULE SCR DIODE MODULES 1RES 2RES BUS CAPACITORS BANK EQUALIZING BLEEDER RESISTORS LAMINATED BUS STRUCTURE IGBT S IGBT S IGBT GATE DRIVER BOARD 1 IGBT GATE DRIVER BOARD 2 ...

Page 148: ... BUS STRUCTURE BUS FILTER CAPACITORS IGBT GATE DRIVER BOARD IGBT WATER COOLED HEAT SINK IGBT S IGBT S SCR DIODE MODULES SCR DIODE MODULES 1RES 2RES BUS CAPACITORS BANK EQUALIZING BLEEDER RESISTORS FIG 24 INVERTER POWER COMPONENTS LD10593 LD10594 TECHNICAL DATA COMPONENT LOCATIONS CON T ...

Page 149: ...SEE DETAIL B SEE DETAIL C SEE DETAIL B SEE DETAIL A REAR OF VSD PANEL GLYCOL SYSTEM COMPONENTS GLYCOL FILL TUBE GLYCOL PUMP DETAIL A DETAIL C DETAIL B TYPICAL 4 PLACES SEE DETAIL A SEE DETAIL C SEE DETAIL B SEE DETAIL C SEE DETAIL B SEE DETAIL A REAR OF VSD PANEL LD10595 FIG 25 GLYCOL PUMP FILL TUBE LOCATIONS 6 ...

Page 150: ...150 JOHNSON CONTROLS FORM 201 21 NM1 616 TECHNICAL DATA LD10597 FIG 26 GLYCOL PIPING AND FILL TUBE LOCATION GLYCOL FILL TUBE GLYCOL SYSTEM COMPONENTS CON T ...

Page 151: ...21 NM1 616 6 COMPRESSOR COMPONENTS LD10596 FIG 27 COMPRESSOR COMPONENTS SUCTION STRAINER STATOR KEY ROTOR MOTOR ROTOR HOUSING MALE ROTOR FEMALE ROTOR BEARINGS SHIMS SHIMS BEARINGS DISCHARGE HOUSING OIL FILTER MOTOR TERMINALS STATOR ...

Page 152: ...ly charged and there are no piping leaks 4 Open each system suction service valve discharge service valve economizer service valve liquid line stop valve and oil line ball valve 5 The oil separator oil level s should be maintained so that an oil level is visible in either of the oil separator sight glasses when a compressor is running at high speeds for 10 to 15 minutes An oil level may not be vis...

Page 153: ... drop across the cooler Excessive flow may cause catastrophic damage to the evaporator 6 EQUIPMENT START UP CHECK SHEET CON T 7 Check the control panel to ensure it is free of foreign material wires metal chips tools documents etc 8 Visually inspect wiring power and control Wiring MUST meet N E C and local codes See FIG 13 and 17 Pages 137 and 141 9 Check tightness of the incoming power wiring ins...

Page 154: ...gic Board are set correctly correct settings are provided on Page 300 Press the VSD DATA key and using the arrow keys scroll to the compressor overload settings Verify the Factory Set overload potentiometer s on the VSD logic board see FIG 16 are set correctly In the un likely event that they are not set correctly adjust the potentiometers until the desired values are achieved The VSD is powered u...

Page 155: ...ogram the required operating values into the micro for cutouts safeties etc and record them in the chart below See Page 245 for details Record these values in the chart below Suction Press Cutout ________________________ PSIG kPa Low Ambient Cutout ________________________ F C Leaving Chilled Liquid Temp Cutout ________________________ F C Motor Current Limit ________________________ FLA Pulldown ...

Page 156: ...liquid line temp 87 F 30 6 C SUBCOOLING 6 F 3 3 C The subcooling should be adjusted to 5 7 F 2 77 3 78 C 14 Place the panel in Service mode and turn on each fan stage one by one Assure the fans rotate in the correct direction so air flow exits the top of the chiller 15 Remove the cap on the fill tube and run the glycol pump to verify the level in the fill tube Assure the glycol level in the VSD co...

Page 157: ...n pressure as shown in a standard pressure temperature chart SUPERHEAT Example Suction Temp 46 F 8 C minus Suction Press 30 PSIG converted to Temp 35 F 1 C 11 F 6 C The suction temperature should be taken 6 13 mm before the compressor suction service valve and the suction pressure is taken at the compressor suction service valve No superheat adjustments are necessary and the electronically control...

Page 158: ...y operation and returns the programmed value to the original value before any programming changes were made when an error is made The UP ARROW and DOWN ARROW keys allow scrolling backward and forward through items to be programmed under keys such as the PROGRAM or OPTIONS key The UP ARROW and DOWN ARROW keys also allow scrolling forward or backwards through data display keys that have multiple dis...

Page 159: ...store the programmed value the ENTER key must be pressed When the ENTER key is pressed the cursor will disappear The data entry mode may also be exited by pressing the X CANCEL key The programmed data will be returned to it s original value when the X CANCEL key is pressed When the data entry mode is exited the cursor will disappear If any other key is pressed while in the Data Entry Mode the foll...

Page 160: ... analog signals to digital signals which can be read by the onboard microprocessor On a 2 system chiller approximately half of these inputs are utilized Three integrated circuits on the microprocessor can be configured for digital inputs or outputs Digital I O As inputs they can read digital 2 level on off inputs like keypad keys unit switch high pressure cut out flow switch etc As outputs they ar...

Page 161: ...theAC to DC rectifier section with precharge circuit a DC link filter section a three phase DC to AC inverter section and an output RC suppression network AC TO DC RECTIFIER TheAC to DC Rectifier circuit utilizes a semi converter made of three SCR diode modules in a three phase bridge configuration Each SCR Diode module contains 1 SCR and 1 diode The modules are mounted on a liquid cooled heatsink...

Page 162: ...ductor forms a low pass LC Filter and provides further smoothing filters ripple to the rectified DC Equalizing Bleeder resistors connected across the banks equalize the voltage between the top and bottom capacitors to avoid damaging the capacitors from over voltage The Equalizing Bleeder resistors also provide a path for discharge of the capacitors when the drive is switched off This safely discha...

Page 163: ...cific speed Although a common DC Bus links the compressor drive outputs each compressor has it s own inverter output module Each inverter output module consists of 6 IGBT s 3 modules and an IGBT Gate Driver Board which converts DC to a 3 phaseAC output The IGBT s are mounted to the liquid cooled heatsink designed to take the heat away from the devices and remove it in the condenser The IGBT Gate D...

Page 164: ...n and Control section Page 198 CONTROL PANEL TO VSD COMMUNICATIONS Communication between the VSD Logic Board and the Chiller Control Board is made via a three wire RS 485 opto coupled data link Communications between the two boards occurs at the rate of 9600 baud UART2 of the dual UART located on the Chiller Control Board is dedi cated to internal communications and has a higher prior ity interrup...

Page 165: ...originate from the VSD Logic Board and are changed in level by the IGBT Gate Driver Board The IGBT s in the inverter section of the VSD change the DC Link voltage to a variable Voltage and Frequency output to the motor to control the compressor motor speed The IGBT Gate Driver Boards also provides VCE SAT detection short circuit detection to safely turn off the IGBT s during a short circuit condit...

Page 166: ... opens and closes the feed valve to control the liquid level of the refrigerant in the Flash Tank based on commands from the Chiller Control Board Superheat is controlled by sequencing a stepper motor valve Drain Valve on the outlet of the Flash Tank The controller opens and closes the drain valve to control flow to the evaporator and ultimately superheat to the compressor based on commands from t...

Page 167: ...gned to operate at 460VAC on all voltage units Whenever a 208VAC 60 Hz 230VAC 60 Hz 380VAC 60 Hz 400VAC 50 Hz or 575VAC 60 Hz supply is utilized an autotransformer is used to convert the voltage to 460VAC On 50 Hz units a frequency converter also converts the fan voltage from 50 Hz to 60 Hz The DC Bus Isolation Board allows the VSD Logic Board to read the voltage on the DC BUS without expos ing th...

Page 168: ...arning message will be displayed in the Status display TABLE 1 shows the chiller number of compressors and the associated location of the jumpers to program the appropriate compressor configuration TABLE 1 COMPRESSORS AND THE APPROPRIATE JUMPER POSITIONS of COMPRESSORS VSD LOGIC BOARD JUMPER POSITION 2 J1 10 to J1 9 3 J1 11 to J1 9 4 J1 12 to J1 9 VSD LOGIC TO CHILLER MICROPROCESSOR BOARD RS 485 C...

Page 169: ...jumper is out or a 1 or high when the wire jumper is inserted between the two pins The jumpers will only be checked once by the Chiller Control Board on power up TABLE 3 shows the Chiller configuration and the associated location of the jumpers TABLE 3 MAXIMUM FREQUENCY MODEL DESIGNATOR JUMPER CHILLER CONTROL BOARD MAX VSD FREQUENCY J7 1 to J7 2 J7 3 to J7 4 J7 5 to J7 6 YCAV 200 Hz 1 1 0 0157 SA ...

Page 170: ...ambient air temperature If no systems are running and the ambient temperature drops below 40 F the heater is turned on If no systems are running and the temperature rises above 45 F the heater is turned off Whenever a system is running the evaporator heater is turned off Both evaporator heater outputs will always be turned on and off together An under voltage condition will keep the heater off unt...

Page 171: ... in series with each set of UNIT Switch contacts If either fuse is pulled or blown only the system with the good fuse Input is high will run When both inputs are high the entire chiller will be enabled to run When both inputs are low the chiller will be disabled as a Unit Switch OFF Shutdown LD10605 UNIT SWITCH The Unit Switch should never be used to shut down the chiller except in an emergency Wh...

Page 172: ...sor starts the Feed and Drain Valves on the system will immediately begin to control superheat and the liquid level in the Flash Tank and the Chiller Control Board micro will begin to regulate the speed on the VSD to bring the chilled liquid temperature to within the Control Range CR The micro will regu late the speed of the compressor s primarily based on temperature offset as the loading timer p...

Page 173: ...m the all compressors stopped state This routine will try to run all the compressors unless it is determined that less will be needed due to light load The first step in the sequence is for the micro to set the number of compressors to start equal to the number of compressors in the chiller The micro will look at two prior conditions relating to the compressor operating time the previous time it r...

Page 174: ...ove also illustrates the scaled frequency FIG 30 MINIMUM VSD START FREQUENCY LD10627 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 Ambient Temperature F Minimum VSD Frequency Hz NOTE The graph above also illustrates the scaled frequency FIG 31 MINIMUM VSD RUN FREQUENCY LD10628 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 Ambient Temperature F Minimum VSD Freque...

Page 175: ...ible up to 200 Hz the frequency speed is limited by the minimum start frequency and the add a compressor frequency calculation performed by the micro when bringing on an additional compressor When decelerating the deceleration rate changes with frequency and follows the guidelines below Between 200 and 100 Hz the deceleration time is 30 4 Hz sec Between 100 and 0 Hz the deceleration time is 10 Hz ...

Page 176: ...temperature to within Setpoint CR 2 the chiller control will make a decision to start another compressor At this point the first compressor will decelerate to a frequency of 5 Hz Reducing the frequency of the running compressor to 5 Hz enables the differential between discharge and suction pres sure to be reduced to a point where it will not affect motor current when the running compressor is ramp...

Page 177: ...own 1 FUZZY LOGIC CONTROL The fuzzy logic control in software makes decisions to increase or decrease speed according to the error or deviation from Setpoint and the rate of change of chilled liquid temperature Before making a change in speed the Chiller Control Board microprocessor will look at the load and unload timers to assure they are timed out It also looks to assure there is no load limiti...

Page 178: ...hiller Control Board microprocessor may also elect to hold capacity when error is negative temperature is below Setpoint because the rate of change of chilled liquid is positive rising Table 4 illustrates these conditions and the loading response from the Chiller Control Board microprocessor TABLE 4 FUZZY LOGIC LOADING UNLOADING VS ERROR NEGATIVE ERROR ZERO ERROR POSITIVE ERROR NEGATIVE RATE UNLOA...

Page 179: ...long as leaving chilled liquid temperature is above the Setpoint CR The chiller control board will be make decisions regard ing speed changes under conditions where the error and rate conflict Under these conditions loading un loading follows the guidelines described in the Fuzzy Logic Control Section Page 177 If chilled liquid temperature is not satisfied and above Setpoint CR the microprocessor ...

Page 180: ...ompressors running 1 Minimum VSD Freq 50 Hz In the example above one compressor will restart at 100 Hz as indicated in the formula below 50Hz x 1 1 100 Hz 1 The load timer will also be set to 30 seconds and the unload timer will be set to 10 seconds On 3 and 4 compressor chillers if temperature stays below the Setpoint minus the Control Range 2 another lag compressor will be shut down using the sa...

Page 181: ...onds As the temperature rises toward Setpoint CR the Chiller Control Board microprocessor s fuzzy logic will begin factoring in the rate of change before continuing to unload If the rate of change is rising too fast and there is potential for overshoot the Chiller Control Board microprocessor may elect not to decrease speed In cases where temperature is rising too fast when tem perature is within ...

Page 182: ... Current Limit Setpoint and the Current Limit Setpoint 5 the system will unload every 2 seconds according to the amount current is ex ceeding the Current Limit Setpoint At the Current limit Setpoint 0 Hz reduction in speed will take place and at the Current Limit Setpoint 5 a 10 Hz speed reduction will take place Between the Current Limit Setpoint and Current Limit Setpoint 5 unloading will occur ...

Page 183: ...ssure Cutout 9 PSIG 9 Hz Suction Pressure Cutout 10 PSIG 10 Hz Suction pressure load limiting is active at start up to only prevent loading of the compressors Suction pres sure limit unloading will not occur until the system run time reaches 5 minutes of operation to allow the system to stabilize VSD Internal Ambient Temperature Load Limiting VSD Internal Ambient temperature limiting helps pre ven...

Page 184: ...en though increased loading is required Between the VSD Base plate Temperature Cutout 4 F and the cutout forced unloading is performed every 2 seconds according to TABLE 10 below TABLE 10 VSD BASEPLATE TEMPERATURE LOAD LIMITING UNLOADING VSD BASEPLATE TEMPERATURE UN LOADING Baseplate Temp is between Cutout 8ºF Cutout 4ºF 0 Hz Baseplate Temp Cutout 3 6ºF 1 Hz Baseplate Temp Cutout 3 2ºF 2 Hz Basepl...

Page 185: ...uid flow from the condenser to assure the liquid level in the Flash Tank is maintained at a proper level The Level Sensor is a rod inserted into the reservoir connected to the side of the Flash Tank The sensing rod has an active range of about 12 The control algorithm looks at feedback from the Level Sensor and compares it to the fixed level setpoint in the control algorithm This control strategy ...

Page 186: ...tion line may be warmed by the ambient contributing to inaccurate suc tion superheat measurement at start up To avoid this situation the MOP control utilizes suction pressure control at start up which overrides superheat control For the first minute of run time the MOP Setpoint is set to RCHLT Superheat Setpoint 1 0 F Run Time in Seconds FLASH TANK DRAIN AND FEED VALVE CONTROLLER After the first m...

Page 187: ...stem 1 or 3 Feed Valve Close 6 Close System 1 or 3 Drain Valve Close 7 Close System 2 or 4 Feed Valve Close 8 Close System 2 or 4 Drain Valve Close On 3 and 4 compressor chillers a second module will control systems 3 and 4 Due to the short duration of the open and close stepper pulses LED lighting will be difficult to observe In rare cases where validation of the controller output and valve movem...

Page 188: ...uction pressure and low oil differential faults by increasing the load At ambients above 40 F once on the Economizer So lenoid will remain energized until the VSD frequency drops below 90 Hz Below 90 Hz the solenoid will be turned off regardless of the time remaining on the economizer timers Under these conditions the econo mizer timers will be set to 0 when the solenoids are de energized Below 10...

Page 189: ...s discharge pressure rises and falls is 5 seconds The controller increments or decrements the fan stage by one stage based on discharge pressure and fan delay time TABLE 11 shows the fan staging and the outputs for each fan stage on 4 5 and 6 fan systems The microproces sor fan outputs and the fan contactors will be the same regardless of the number of fans The fan wiring will change to permit ope...

Page 190: ...ssure PSIG Fan On Press Fan Off Press LD10633 FIG 35 STANDARD IPLV FAN CONTROL Optimized IPLV Fan Control Fan staging on and off points will be determined by the ambient temperature The fan stage will be incremented unless the 5 second timer between fan stages is still timing when the discharge pressure rises above the Fan ON Press The fan stage is decremented unless the 5 second timer between fan...

Page 191: ...out a time delay Pre charge Enable 1 from the Chiller Logic Board is ON Pre charge Enable 2 from the Chiller Logic Board is ON VSD Internal Ambient Temp 158 F Cutout 10 F 148 F When the Internal Ambient Temp falls 158 F Cutout 15 F 143 F the VSD cooling fans and glycol pump will turn off Condenser Fans as needed andVSD coolant pump fans will run whenever a compressor is running Under these conditi...

Page 192: ...fset is linear and may be adjusted anywhere between the 0 and 100 points The maximum setpoint allowed is the maximum programmable Local Cooling Setpoint and will be capped at this value if the calculated setpoint with temperature offset exceeds this value This input may be used either in Local or Remote Con trol Mode This feature will only operate if enabled under the UNIT SETUP and the OPTIONS Ke...

Page 193: ...quid tempera tures on hot water starts and maintaining chilled liquid setpoints REMOTE TEMPERATURE RESET CONTROL CON T 7 0 20 mA Reset Input A 0 mA signal produces a 0 F reset A 20 mA signal produces the maximum remote temp reset program mable under the SETPOINTS key The setpoint reset is ramped linearly between these limits as the input varies between 0 mA and 20 mA In order for this input to wor...

Page 194: ...rent Limit Setpoint A full scale signal input 100 input equates to the minimum current limit setpoint as defined under the PROGRAM key Current Limit Setpoint The current limit value is linear and may be adjusted any where between the maximum and minimum points of 0 no offset and 100 max current limiting This input may be used either in Local or Remote Con trol Mode This input will be ignored if th...

Page 195: ... programmed for 2 10 VDC input OPTIONS key and Chiller Control Board jumper JP5 placed in the V position 0 20 mA Reset Input A 0 mA signal sets the current limit to the maximum value A 20 mA signal sets the current limit to the minimum value The current limit is ramped linearly between these limits as the input varies between 0 mA and 20 mA In order for this input to work properly the Remote Curre...

Page 196: ...aximum value will be used Contact a local YORK ISN Representative for details on ISN controls and capabilities Remote Sound Limit The Sound Limit Setpoint can be set via the Remote Sound Limit analog input Azero signal input 0 input equates to the minimum sound limit setpoint as defined under the PROGRAM key Sound Limit Setpoint Afull scale signal input 100 input equates to the maximum sound limit...

Page 197: ... to work properly the Remote Sound Limit must be programmed for 2 10 VDC input OPTIONS key and Chiller Control Board jumper JP6 placed in the V position 0 20 mA Reset Input A 0 mA signal produces a 0 sound limit no change to max VSD freq A 20 mA signal produces a 100 sound limit max VSD freq min VSD freq The sound limit reset is ramped linearly between these limits as the input varies between 0 mA...

Page 198: ...tput frequency required based on the operating frequency command from the Chiller Control Board This information will then be sent to the PWM generator located on the VSD Logic Board On start up the output frequency from the VSD to the motor s will be increased from 0 Hz to the operating frequency commanded by the Chiller Control Board The rate of change of the frequency will also be con trolled b...

Page 199: ...ltage sinusoidal waveform To change the speed of an AC motor the frequency of the AC voltage must be changed When ever frequency is changed the voltage is changed in a linear ratio Maintaining a relatively constant V F ratio as speed changes assures motor losses and overheating do not occur The output voltage of the VSD is not a sinusoidal wave form Instead the PWM generator provides an output tha...

Page 200: ...ool the electronics in the cabinet Never run the glycol pump without coolant Running the glycol pump without coolant may damage the pump seals Always fill the system with approved coolant to avoid damage to the pump seals and other components Heat transfer characteristics of the coolant are very critical Substituting coolant or adding water will result in cooling loop performance loss and chiller ...

Page 201: ...o compressors are running Service Mode Fan Pump is disabled In some cases the condenser fans may be turned on by the micro when no compressors are running to keep the power components and Control VSD Cabinet from overheating IGBT Module Baseplate Temperature Sensing Each IGBT module has an internal 5Kohm thermistor built in to measure the temperature of the module Up to 4 thermistors are connected...

Page 202: ...itions are true otherwise it is disabled Daily Schedule is ON Unit Switch is ON System Switch es are ON Run Permissive s are Enabled Flow Switch indicates flow LCHLT Setpoint High Limit Unit not faulted locked out Run Mode Unit Restart In order to initiate a system run two conditions must be met At least 1 of the 2 systems run signals from the control panel must be present and at least 1 of the 4 ...

Page 203: ...the Chiller Control Board for both display purposes and for current limiting control This parameter is the 105 FLA value VSD OPERATION AND CONTROLS CON T TABLE 12 VSD OPERATING DISPLAY PARAMETERS DATA DISPLAY FORMAT Highest Phase of Compressor Motor Current in Amperes RMS per Compressor XXX Amps VSD Output Frequency XXX X Hz Motor Overload Setting 105 FLA potentiometer setting in amperes RMS per C...

Page 204: ...croproces sor to save a snapshot of system data The VSD Logic Board then transmits the fault data to the Chiller Control Board microprocessor on the next comms between the two boards If the Chiller Control Board receives the comms fault indication before the Fault Relay signal it will immediately save a snapshot of system data when the comms fault is recognized This also enables the micro to captu...

Page 205: ... unit fault for 2 or 3 compressor units The Status display fault message is shown below The fault will be a system 1 3 or 2 4 fault for 4 com SYS X YYYYYYYY PRECHARGE LOW DC BUS VOLT UNIT YYYYYYYY PRECHARGE DC BUS VOLTAGE IMBALANCE pressor units Two key presses of the STATUS key are required to show the fault on both systems The Status display fault message is displayed below X indicates the syste...

Page 206: ...or 3 compressor units Below is the Status display fault message The fault will be a system 1 3 or 2 4 fault on 4 com pressor units Two key presses of the STATUS key are required to show the fault on both systems Below is a sample Status display fault message X indicates the system and YYYYYYY indicates the system is in a LOCKOUT condition and will not restart until the operator clears the fault us...

Page 207: ... boards monitor the saturation voltage drop across each of the six IGBT s while gated on If the IGBT s saturation voltage exceeds the prescribed limit the gate driver will make the determination that a short circuit is present This in turn will cause the system to trip During normal operation the voltage drop across a saturated IGBT is low When a short or shoot occurs the extremely high current ca...

Page 208: ...e system will be allowed to restart when the inverter power module base plate temperatures drop below this value It is possible for an internal sensor to fail and not sense temperature without causing a high baseplate sensor fault SYS X YYYYYYYY HIGH VSD BASEPLATE TEMP High VSD Internal Ambient Temperature Software Fault The VSD Logic board contains a temperature sensor which monitors the unit s i...

Page 209: ...YY VSD LOGIC BOARD POWER SUPPLY X indicates the system and YYYYYYY indicates the system is in a FAULT condition and will restart when the fault clears or LOCKOUT and will not restart until the operator clears the fault using the keypad SYS X YYYYYYYY VSD RUN RELAY VSD Logic Board Failure Software Fault Upon receipt of the voltage and frequency commands the PWM generator will acknowledge receipt of...

Page 210: ...ory and are transmitted to the panel as the fault data Fault Relay Fault Acknowledge Bit Control of the Fault Relay is from the VSD Logic Board The Fault Relay on the VSD will be closed during a non fault condition When a running or pre charge fault occurs on the VSD the fault relay will immediately open The relay will not open for non running faults that occur When the Chiller Control Board sees ...

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Page 212: ...dasadirect replacement for the 031 02478 xxx line of microboards No adapter harness is required when replacing a 02478 with the new 03478 The 03478 uses the IPUII processor card and provides some new features for the chillers that the 02478 did not have The 03478 program resides in flash memory instead of EPROM Program updates are accomplished by loading the new program from an SD card inserted in...

Page 213: ... 6VDC powers the analog out puts to the EEV valves CONFIGURATION JUMPERS The same configuration jumpers that existed on the 02478 are provided on the 03478 JP4 Remote Temp Reset jumper position Pins 1 to 2 left 4 20 mA Pins 2 to 3 right 0 10 VDC JP5 Remote Current Limit jumper position Pins 1 to 2 left 4 20 mA Pins 2 to 3 right 0 10 VDC JP6 Remote Sound Limit jumper position Pins 1 to 2 left 4 20 ...

Page 214: ...or Code FLASH CARD UPDATE ERROR XXXXX FLASH CARD UPDATE ERROR CODE DEFINITION 0 Okay 10 Flash card not found 11 SOFTWARE BIN file not found 14 SOFTWARE BIN file larger than expected 15 RAM to IPU Flash transfer of DATABASE BIN failed 16 RAM to IPU Flash transfer of SOFTWARE BIN failed 17 Could not allocate sufficient memory to read or write file 99 Internal software error 10 After the update is co...

Page 215: ...essage may mean the chiller has lost important factory programmed infor mation The serial number can be entered using the Service Key UNIT WARNING INVALID SERIAL NUMBER ENTER UNIT SERIAL NUMBER Additionally when this appears an Optimized IPLV chiller will only run in Standard IPLV control mode Optimized IPLV cannot be enabled unless the serial number is programmed into the unit using the special p...

Page 216: ...wn or while the systems were shut down All faults do not store operating data at the time of the fault LD10605 STATUS KEY If a VSD fault occurs during the fault rampdown or while the systems are shut down the VSD fault will be registered as a new fault The reason for this is the belief any VSD fault should be registered with a full account of the systems data at the time of the fault High Ambient ...

Page 217: ...ped shutdown if the Chiller Control Board loses communications with the VSD Logic Board while the chiller is operating On power up the Chiller Microprocessor Board will attempt to initialize communications with the VSD Logic Board The control panel will request data from the VSD which includes the number of compressors and the VSD software version Once these data points have been received by the C...

Page 218: ...ALL FAULT and these faults will be recorded as such under the HIS TORY information stored at the instant of the primary fault In some cases this information may be valuable in troubleshooting the primary fault An example of the ALL FAULT history message is shown on Page 236 under the HISTORY Key When an ALL FAULT oc curs associated history information will not be stored If an additional fault does...

Page 219: ...e keypad Typically the cutout will be set at 24 PSIG for chilled water applications The cutout is ignored for the first 30 seconds of system run time During the next 3 minutes of run time the cutout point is linearly ramped from 10 of the cutout value up to the programmed cutout point If at any time during the first 3 minutes of operation the suction pres SYS X YYYYYYYY LOW SUCTION PRESSURE sure f...

Page 220: ...e 120 second anti recycle timer times out or LOCK OUT and will not restart until the operator clears the fault using the keypad The safety is ignored for the first 60 seconds of run time After the first 60 seconds of operation the cutout is lin early ramped from 0 PSID to 30 PSID in 5 to 10 minutes based on ambient temperature See TABLE 13 for the ramp times for the given ambient temperatures TABL...

Page 221: ... shutdown If the suction superheat 2 F the discharge super heat 15 F for 10 seconds and the run time is or 5 minutes the system will fault and shutdown with a controlled ramped shutdown If the suction superheat 0 5 F and discharge superheat is 15 F for 60 seconds and run time or 5 minutes the system will fault and shutdown with a controlled ramped shutdown If suction superheat 5 F for 10 minutes t...

Page 222: ...otor temperature sensor to be ignored if it fails The start inhibit thresholds for each sensor are shown in TABLE 14 SYS X YYYYYYYY SENSOR FAILURE ZZZZZZZZZZZZ TABLE 14 START INHIBIT SENSOR THRESHOLDS SENSOR LOW THRESHOLD HIGH THRESHOLD SUCTION TRANSDUCER 0 3VDC 4 7VDC OIL TRANSDUCER 0 3VDC 4 7VDC DISCHARGE TRANSDUCER 0 3VDC 4 7VDC LEVEL SENSOR 3 0ma 21 0ma MOTOR TEMP SENSOR 0ºF 240ºF High Motor T...

Page 223: ...pad System Control Voltage Cutout Fault The System Control Voltage Cutout alerts the operator the 115VAC Control voltage to one of the systems is missing This could be due to a system fuse that has been removed or is blown The affected system will fault and shut down immediately when the 115VAC supply is lost The safety will not shut down a system if the Unit Switch is OFF which electrically remov...

Page 224: ...stem 3 4 data There are three types of status data which may appear on the display General Status mes sages Unit Safeties and System Safeties When power is first applied to the control panel the following message displaying YORK International Corporation the EPROM version date and time will be displayed for 2 seconds followed by the appropriate general status message Unit status messages occupy 2 ...

Page 225: ...he chiller to run There is a 1 second delay on this safety to assure the flow switch did not momentarily open UNIT STATUS FLOW SWITCH SHUTDOWN This message indicates the chiller is shutdown but running all the condenser fans VSD glycol pump and VSD fan in an effort to bring the internal VSD ambient temperature down to an acceptable level before allowing the chiller to start UNIT STATUS VSD COOLING...

Page 226: ...YS X PULLDOWN MOTOR CURRENT LIMITING SYS X VSD INTERNAL AMBIENT TEMP LIMITING The pulldown motor current limiting message indicates the pulldown motor current load limit or pulldown motor current unloading is in effect based on the programmed setpoint SYS X SOUND LIMITING SYS X ISN SOUND LIMITING The ISN Current Limiting message indicates the motor current load limit or motor current unloading is ...

Page 227: ... complete listing of the unit safeties and the corre sponding status messages is provided on Page 216 System Safety Fault Status Messages A complete listing of the system safeties and the cor responding status messages is provided on Page 218 VSD Safety Fault Status Messages A complete listing of VSD safeties and the correspond ing status messages is provided on Page 204 Unit Warning Messages A co...

Page 228: ...the UNIT DATA key or the ARROW key displays the ambient air temperature UNIT LOAD TIMER XXX SEC UNLOAD TIMER XXX SEC UNIT OUTSIDE AMBIENT AIR TEMP XXX X F UNIT TEMP ERROR XXX X F RATE XXX X F M The next key press will display the time remaining on the load and unload timers UNIT LEAD SYSTEM NUMBER X FLOW SWITCH XXX The next key press displays the error in temperature between the actual leaving chi...

Page 229: ...ve items will be blanked out The types of remote control are listed below NONE No remote control is actively controlling the chiller however remote monitoring by a remote device may still be active RCC ARemote Control Center is providing remote control The chiller is in remote mode ISN YorkTalk via ISN The chiller in remote mode CURR Remote Current Limiting is enabled TEMP Remote Temperature Reset...

Page 230: ...ays all of the measured system pressures oil suction and discharge The second key press of the SYSTEM DATAKey or the DOWN ARROW key displays all of the measured system temperatures oil suction and discharge SYS 1 PRESSURES OIL XXXX PSIG SUCTION XXXX DISCHARGE XXXX PSIG The next key press displays the suction temperature and all of the calculated suction temperatures saturated suction and system su...

Page 231: ...zer solenoid is either ON or OFF The next key press displays the liquid level in the flash tank and an indicator of the the Flash Tank Feed Valve is open The next key press displays the system suction superheat and an indicator of the the Flash Tank Drain Valve is open The next key press displays the system fan stage and the status of the compressor heater X the number of fans ON XXX indicates eit...

Page 232: ...ressure Transducer 0 0 PSIG 275 0 PSIG Discharge Pressure Transducer 0 0 PSIG 275 0 PSIG Flash Tank Level Capacitance 0 0 100 Leaving Chilled Liquid Temp 3Kohm Thermistor 19 1ºF 110 2ºF Return Chilled Liquid Temp 3Kohm Thermistor 19 1ºF 110 2ºF Ambient Air Temp 10Kohm Thermistor 4 6ºF 137 9ºF Suction Temp 3Kohm Thermistor 4 1ºF 132 8ºF Oil Temp 50Kohm Thermistor 40 3ºF 302 6ºF Discharge Temp 50Koh...

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Page 234: ...essor FLA and calculated currents in amps for systems 1 and 2 The calculated currents are approximate and some error can be expected Also keep in mind that measuring inverter PWM current is difficult and meter error can be significant VSD FREQUENCY ACTUAL XXX X HZ COMMAND XXX X HZ For 3 and 4 compressor units only the second key press will display the following message for systems 1 and 3 VSD COMP...

Page 235: ...OMP 3 MOTOR OVERLOAD XXX AMPS COMP 4 MOTOR OVERLOAD XXX AMPS VSD COMP 1 MOTOR OVERLOAD XXX AMPS COMP 2 MOTOR OVERLOAD XXX AMPS VSD INTERNAL AMBIENT TEMP XXX X F COOLING SYSTEM STATUS YYY VSD IGBT BASEPLATE TEMPS T1 XXX F T2 XXX F The next key press displays the state of the Precharge signal where XXX is either ON or OFF The first dis play is for 2 and 3 compressor units the second display shown is...

Page 236: ... starts are displayed with a single key press The maximum value for both hours and starts is 99 999 at which point they will roll over to 0 A single display is available under this key and is displayed below On 2 and 3 compressor units the data and compressor designators for compres sors not present are blanked out HOURS 1 XXXXX 2 XXXXX 3 XXXXX 4 XXXXX START 1 XXXXX 2 XXXXX 3 XXXXX 4 XXXXX MICRO P...

Page 237: ... selection HISTORY CHOOSE HISTORY TYPE XXXXXXXXXXXXXXXXXXXXXXXXXXXX NORM HIST XX 18 JUN 20004 10 34 58 AM SYS X COOLING DEMAND SHUTDOWN NORM HIST XX 18 JUN 20004 10 34 58 AM YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY Normal Shutdowns History If the NORMAL SHUTDOWNS History is selected the following screen will be displayed XX is the normal shutdown number The display will provide date and time of the s...

Page 238: ...play Listed below is a description of the fault data displays and their meaning Data will be displayed in a specific order starting with the Status Display System Faults only Fault Display All Fault Display Unit Data VSD Data System Data Operating Hours Starts Setpoints Options and Program Values at the time of the fault FAULT HIST XX 18 JUN 20004 10 34 58 AM YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY ...

Page 239: ...m Selection and Flow Switch Status This message indicates the designated lead system at the time of the fault and whether the flow switch was ON Closed or OFF Open at the time of the fault Evaporator Pump and Evaporator Heater UNIT LEAD SYSTEM NUMBER X FLOW SWITCH XXX Status This message indicates the status of the evaporator pump and the evaporator heater at the time of the fault XXX indicates ON...

Page 240: ...e of the fault IGBT Baseplate Temperature VSD INTERNAL AMBIENT TEMP XXX X F COOLING SYSTEM STATUS YYY VSD COMP 1 MOTOR OVERLOAD XXX AMPS COMP 2 MOTOR OVERLOAD XXX AMPS VSD IGBT BASEPLATE TEMPS T1 XXX F T2 XXX F This message displays the IGBT highest baseplate tem perature for 2 and 3 compressor units at the time of the fault 4 compressor units display temperatures for 1 3 T1 and 2 4 T2 Precharge S...

Page 241: ...ime of the fault The economizer status will be indicated as either ON or OFF System 1 Flash Tank Level and Feed Valve Open HISTORY KEY CON T SYS 1 FLASH TANK LEVEL XXX X FEED VALVE PERCENT OPEN XXX X This message displays the liquid level in the Flash Tank and indicates the the Flash Tank Feed Valve is open at the time of the fault System 1 Suction Superheat and Flash Tank Drain Valve open This me...

Page 242: ...ING MODE WATER COOLING SETPOINTS REMOTE SETPOINT XXX X F REMOTE CONTROL RANGE X X F This message displays the remote setpoint and control range at the time of the fault Maximum Remote Temperature Setpoint This message displays the maximum remote reset pro grammed at the time of the fault SETPOINTS MAXIMUM REMOTE TEMP RESET XXX X F OPTIONS Display Language This message displays the language selecte...

Page 243: ... OPTIONS REMOTE CURRENT LIMIT INPUT 4 0 TO 20 0 MILLIAMPS OPTIONS REMOTE CURRENT LIMIT INPUT 0 0 TO 20 0 MILLIAMPS OPTIONS REMOTE CURRENT LIMIT INPUT 2 0 TO 10 0 VOLTS DC OPTIONS REMOTE CURRENT LIMIT INPUT 0 0 TO 10 0 VOLTS DC OPTIONS REMOTE CURRENT LIMIT INPUT DISABLED This message indicates whether remote current reset was active or disabled at the chiller keypad at the time of the fault and if ...

Page 244: ...e time of the fault Suction Superheat Setpoint PROGRAM SUCTION SUPERHEAT SETPOINT XXX X F This message indicates the suction superheat setpoint programmed at the time of the fault Unit ID Number PROGRAM REMOTE UNIT ID NUMBER X This indicates the unit ID programmed at the time of the fault Sound Limit Setpoint This indicates the sound limit setpoint programmed at the time of the fault if the sound ...

Page 245: ...ressing the SETPOINTS key a second time or the ARROW key will display the leaving chilled liquid control range default and low high limits SETPOINTS DEF XXXXX LO XXXXX HI XXXXX LOCAL CONTROL RANGE X X F Pressing the SETPOINTS key or the ARROW key a third time will display the remote setpoint and cooling range This display automatically updates about every 2 seconds This remote setpoint message is ...

Page 246: ...lue in the display to store the data into memory The ARROW key allows scrolling back through the setpoints displays The minimum maximum and default values allowed under the SETPOINTS key are provided in TABLE 16 below SETPOINTS KEY CON T TABLE 16 SETPOINT LIMITS PROGRAM VALUE MODE LOW LIMIT HIGH LIMIT DEFAULT Leaving Chilled Liquid Setpoint Water Cooling 40 0 F 60 0 F 44 0 F 4 4 C 15 6 C 6 7 C Gly...

Page 247: ...HI The user programmable value is programmed on in the second line of the message When the PROGRAM Key is first pressed the fol lowing display will appear indicating the user is in the program mode Pressing the ENTER key again will display the first programmable selection Suction Pressure Cutout PROGRAM MODE XXXX PRESS ENTER KEY TO CONTINUE The suction pressure cutout is protects the chiller from ...

Page 248: ... Pulldown Current Limit The pulldown current limit FLA is programmable This allows the micro to limit a system on pulldown limiting for the purpose of peak time energy savings Typically the limit point is set at 100 The pulldown limit point is programmable from 30 100 with a default of 100 Be aware when using pulldown mo tor current limit the chiller may not be able to load to satisfy temperature ...

Page 249: ...oise during night time hours The sound limit display will only be present if the sound limit option is programmed at the factory Default Values Alisting of the low limits high limits and default values for each of the programmable values is noted in each display and can be found in TABLE 17 Note that the Imperial units are exact values while the Metric units are only approximate PROGRAM KEY CON T ...

Page 250: ...on of each option message is provided below Display Language Selection The display language can be selected for English Dutch German Italian and Chinese The default language will be English OPTIONS DISPLAY LANGUAGE XXXXXXXXXXXXXXXXXX OPTIONS CHILLED LIQUID COOLING MODE XXXXXXXXXXXXXXXXXX Chilled Liquid Cooling Mode Selection The Chilled liquid cooling mode can be selected for Water Cooling or low ...

Page 251: ...r Imperial units F PSIG OPTIONS DISPLAY UNITS IMPERIAL OPTIONS LEAD LAG CONTROL MODE AUTOMATIC OPTIONS DISPLAY UNITS SI OPTIONS LEAD LAG CONTROL MODE MANUAL SYS 1 LEAD The default mode is IMPERIAL OPTIONS LEAD LAG CONTROL MODE MANUAL SYS 2 LEAD System Lead Lag Control Mode Selection The operator may select the type of lead lag control desired In most cases automatic lead lag will be selected When ...

Page 252: ...only appear if the remote temp limit option is enabled at the factory Remote Current Limit Input Selection Remote current limit from an external source may be tied directly into the chiller microprocessor board OPTIONS REMOTE CURRENT LIMIT INPUT XXXXXXXXXXXXXXXXXXXXX Selections may be made for DISABLED no signal 0 10VDC 2 10VDC 0 20ma and 4 20ma OPTIONS REMOTE CURRENT LIMIT INPUT DISABLED OPTIONS ...

Page 253: ...253 JOHNSON CONTROLS FORM 201 21 NM1 616 8 This page intentionally left blank ...

Page 254: ...OW keys allows scrolling to the next programmed item Pressing the DOWN ARROW key scrolls to the next item that can be pro grammed and the UP ARROW key scrolls to the previous item The day of the week is the first display and can be changed by pressing either the or LEFT OR RIGHT ARROW key to select the day After the day is selected the ENTER key must be pressed to store the data Pressing the DOWN ...

Page 255: ...ust be keyed in for minutes 00 09 CLOCK FRI 18 JUN 2004 10 15 33 AM AM PM XX CLOCK FRI 18 JUN 2004 10 15 33 AM TIME FORMAT XXXXXXX CLOCK FRI 18 JUN 2004 10 15 33 AM MINUTE XX Pressing the DOWN ARROW key again scrolls to AM PM AM PM can be selected by pressing the or AR ROW keys After the meridian is selected the EN TER key must be pressed to store the data Pressing the DOWN ARROW key again scrolls...

Page 256: ... 00 PM The line under the 0 is the cursor If the start time is wrong it can be changed by keying in the new time from the numeric keypad Once the correct values for the START hour and minute are entered press the ENTER key The cursor will then move to the AM PM selection The meridian AM PM value may be changed by the LEFT ARROW or RIGHT ARROW keys and entered by pressing ENTER key Repeat this proc...

Page 257: ...Limit Setpoint programmed under the PROGRAM key 0 will cause no speed reduction while 100 only allows running at minimum speed The START Time for a specific day hour and min ute is entered using the same guidelines used for the start stop schedules and press the ENTER key to store it into memory The cursor will then move to the AM PM selection The AM PM selection may be chosen using the LEFT ARROW...

Page 258: ...dule is being ignored and the chiller will start when chilled liquid temperature allows Remote Contacts UNIT switch and SYSTEM switches permitting This is a pri ority message and cannot be overridden by anti recycle messages fault messages etc when in the STATUS display mode Therefore do not expect to see any other STATUS messages when in the MANUALOVERRIDE mode MANUAL OVERRIDE is to only be used ...

Page 259: ...CEL PRINTING option The following message is displayed when the PRINT key is pressed PRINT CHOOSE PRINT REPORT XXXXXXXXXXXXXXXXXXXXX After pressing the PRINT key the printout type is select ed by pressing the LEFT ARROW or RIGHT ARROW keys until the desired printout is displayed TABLE 18 shows the available printout types TABLE 18 PRINTOUT TYPES PRINTOUT TYPES Operating Data Default Selection All ...

Page 260: ...R PUMP RUN O N EVAPORATOR HEATER O F F ACTIVE REMOTE CONTROL N O N E O P E R A T I N G H O U R S 1 X X X X X 2 X X X X X 3 XXXXX 3 circuit 3 XXXXX 4 XXXXX START COUNTER 1 XXXXX 2 XXXXX 3 XXXXX 3 circuit 3 XXXXX 4 XXXXX 4 circuit SOFTWARE VERSION C A C S X X 0 0 VSD DATA ACTUAL FREQUENCY X X X X H Z COMMAND FREQUENCY X X X X H Z DC BUS VOLTAGE X X X V D C 2 circuit 3 circuit DC BUS VOLTAGES XXX XXX...

Page 261: ... DATA PRINTOUT History printouts when selected provide stored data relating to all specific system and chiller operating conditions at the time of the fault regardless of whether a lockout occurred History information is stored in battery backed memory on the Chiller Control Board and is not affected by power failures or resetting of faults Whenever a fault of any type occurs all system operating ...

Page 262: ... the ENTER key allows view only Service Mode operation All control board I O will be view able in this mode No outputs can be changed For troubleshooting or start up commissioning purposes the Chiller Micro Board and some VSD outputs can be toggled or changed by turning off the UNIT SWITCH pressing the SERVICE Key entering password 9675 and pressing the ENTER key Once the password is entered the D...

Page 263: ...ut This will cause the voltage read on the display to be less than the voltage on the board header inputs between TB1 17 and 18 TB1 19 and 20 or TB1 40 and 41 To correct for this when measuring voltage at the remote device supplying voltage to the board header while trouble shooting use the following calculation Voltage 10 x ADC volts 4 5 If the input is programmed for a current input the voltage ...

Page 264: ...E TEMP X X VDC XXX X F SERVICE AI J22 20 SYS2 SUCTION PRESS X X VDC XXX X PSIG SERVICE AI J22 22 SYS2 OIL PRESS X X VDC XXX X PSIG SERVICE AI J22 24 SYS2 DISCHARGE PRESS X X VDC XXX X PSIG SERVICE AI J23 3 SYS3 OIL TEMP X X VDC XXX X F SERVICE AI J23 6 SYS3 FL TANK LEVEL X X VDC XXX X SERVICE AI J23 13 SYS3 SUCTION TEMP X X VDC XXX X F SERVICE AI J23 16 SYS3 DISCHARGE TEMP X X VDC XXX X F SERVICE ...

Page 265: ...DI J6 3 PRINT STATUS XXX SERVICE DI J6 5 SYS 2 4 RUN PERM STATUS XXX SERVICE DI J6 6 SPARE DIGITAL INPUT 1 STATUS XXX SERVICE DI J7 2 CONFIG INPUT 0 STATUS XXX SERVICE DI J7 4 CONFIG INPUT 1 STATUS XXX SERVICE DI J7 6 CONFIG INPUT 2 STATUS XXX SERVICE DI J7 8 CONFIG INPUT 3 STATUS XXX SERVICE DI J7 10 CONFIG SPARE INPUT 0 STATUS XXX SERVICE DI J7 12 CONFIG SPARE INPUT 1 STATUS XXX SERVICE DO J9 1 ...

Page 266: ...UT 1 RB1 TB1 6 STATUS XXX SERVICE DO J11 9 SYS 3 COND FAN OUT 2 RB1 TB1 5 STATUS XXX SERVICE DO J11 10 SYS 3 COND FAN OUT 3 RB1 TB1 4 STATUS XXX SERVICE DO J11 11 SYS 3 COMP HEATER RB1 TB1 3 STATUS XXX SERVICE DO J11 12 SYS 3 ECON SOL VALVE RB1 TB1 2 STATUS XXX The fifth data section displays the Analog Outputs AO that can be viewed from the Service Mode The Analog Output signals are typically ref...

Page 267: ... XX X VDC SERVICE AO J25 1 SYS 1 SPARE XXX X XX X VDC SERVICE AO J25 2 SYS 2 SPARE XXX X XX X VDC SERVICE AO J25 3 SYS 3 SPARE XXX X XX X VDC SERVICE AO J25 4 SYS 4 SPARE XXX X XX X VDC The sixth data section displays the VSD digital outputs DO that can be viewed from the service mode The Digital Output signals indicate the status of the output The 0 120VAC digital outputs are referenced to neutra...

Page 268: ...or 4 SYSTEM SWITCHES SYS 1 ON OFF RESET XXXXXXXXXXXXXXX SYSTEM SWITCHES SYS 2 ON OFF RESET XXXXXXXXXXXXXXX SYSTEM SWITCHES SYS 3 ON OFF RESET XXXXXXXXXXXXXXX SYSTEM SWITCHES SYS 4 ON OFF RESET XXXXXXXXXXXXXXX The LEFTARROW or RIGHTARROW keys allow scrolling through the choices of SYSTEM OFF default SYSTEM ON RESET LOCKOUT The switch selection is accepted into memory by press ing the ENTER key When...

Page 269: ... Factory Technical Support with the version of the Chiller Control Board EPROM The version will be written on the EPROM label and typically will be in the format Version C ACS XX XX After obtaining the password the following steps will need to be followed to input the serial number As the serial number is input the characters keyed in will ap pear in the display indicating the panel has recognized...

Page 270: ... PROGRAMMING CON T At this point the letters entered for theYYYYand XXX inputs should now appear in the top line of the display and should match the first 7 characters of the serial number on the unit Data Plate The next three digits of the serial number should now be keyed in Press the ENTER key to store the input The full serial number should now be displayed across the top of the display and th...

Page 271: ...he following STATUS message If the message above appears immediately contact YORK Product Technical Support or YORK ES Com mercial for a password to enable the High IPLV mode You will need to provide YORK Product Technical Support or YORK ES Commercial with the Unit Serial Number located on the chiller nameplate The date and time will also need to be current on the chiller and will need to be prov...

Page 272: ...puts Service Time 5 Min 60 Min 15 Min Sys 1 Motor Sensor to Ignore See Below None Sys 2 Motor Sensor to Ignore See Below None Sys 3 Motor Sensor to Ignore See Below None Sys 4 Motor Sensor to Ignore See Below None The following messages will be displayed for the Unit Setup Mode in the order they appear The first group of displays relates to setup parameters that relate to unit configuration and fa...

Page 273: ...LIMIT OPTION XXXXXXXXXXXXXXXXXXXXXXXX SETUP MODE SOUND LIMIT OPTION XXXXXXXXXXXXXXXXXXXXXXXX The following setup OPTION display is selectable as ENABLED or DISABLED using the and AR ROW keys SETUP MODE DEF XXXXX LO XXXXX HI XXXXX REMOTE INPUTS SERVICE TIME XX MIN The following OPTION displays are selectable as EN ABLED or DISABLED using the and ARROW keys The choices are NONE default TEMP SENSOR 1...

Page 274: ...rs to their default values YES or NO may be selected for XXX using the and ARROW keys to change the selection Following is a list of the operating parameters that will be reset to their default values Suction Pressure Cutout 24 0 PSIG Low Ambient Air Temp Cutout 25 F Leaving Chilled Liquid Temp Cutout 36 F High Motor Current Limit 100 Pulldown Current Limit 100 Pulldown Current Limit Time 0 Min Su...

Page 275: ...ntrol panel TABLE 20 SERIAL PORT CONNECTIONS BOARD HEADER PORT TYPE PORT USE Chiller Control Board TB1 TB2 RS 232 RS 485 Printer RCC and ISN Chiller Control Board J2 J1 RS 485 Control Panel VSD 1 2 VSD Logic Board J12 Opto Coupled RS 485 VSD Control Panel TB2 allows connectiong to a remote OptiView RCC or Microgateway The OptiView RCC option is not yet available The OptiView RCC and Microgateway o...

Page 276: ...ature 1 Chiller Control Board J19 2 Comp 1 Motor Temperature 2 Chiller Control Board J19 3 Comp 1 Motor Temperature 3 Chiller Control Board J19 6 Comp 2 Motor Temperature 1 Chiller Control Board J19 7 Comp 2 Motor Temperature 2 Chiller Control Board J19 8 Comp 2 Motor Temperature 3 Chiller Control Board J21 13 Sys 1 Suction Temperature Chiller Control Board J21 3 Sys 1 Oil Temperature Chiller Cont...

Page 277: ...ogic Board J1 5 to J1 6 Comp 1 Phase C Motor Current VSD Logic Board J1 13 to J1 14 Comp 3 Phase A Motor Current VSD Logic Board J1 15 to J1 16 Comp 3 Phase B Motor Current VSD Logic Board J1 17 to J1 18 Comp 3 Phase C Motor Current VSD Logic Board J2 1 to J2 2 Comp 2 Phase A Motor Current VSD Logic Board J2 3 to J2 4 Comp 2 Phase B Motor Current VSD Logic Board J2 5 to J2 6 Comp 2 Phase C Motor C...

Page 278: ...ssor Select VSD Logic Board J1 11 3 Compressor Select VSD Logic Board J1 12 4 Compressor Select VSD Logic Board J5 1 to J5 2 VSD Logic Board J5 3 to J5 4 VSD Logic Board J6 2 Comp 1 Phase A Gate Driver Fault VSD Logic Board J6 5 Comp 1 Phase C Gate Driver Fault VSD Logic Board J6 12 Comp 1 Phase B Gate Driver Fault VSD Logic Board J7 2 Comp 3 Phase A Gate Driver Fault VSD Logic Board J7 5 Comp 3 P...

Page 279: ...HEADER ANALOG OUTPUT VSD Logic Board J11 2 Phase Loss Fault 1 VSD Logic Board J11 6 Phase Loss Fault 2 VSD Logic Board SW1 Test Pushbutton VSD Logic Board J10 5 to J10 6 Comp 1 3 Run from control panel VSD Logic Board J10 7 to J10 8 Comp 2 4 from control panel DIGITAL INPUT CONNECTIONS CON T ...

Page 280: ...rd J15 5 to J15 6 Sys 2 flash Tank Feed Valve Chiller Control Board J15 7 to J15 8 Sys 2 Flash Tank Drain Valve Chiller Control Board J14 1 to J14 6 Sys 3 Flash Tank Feed Valve Chiller Control Board J14 2 to J14 7 Sys 3 Flash Tank Drain Valve Chiller Control Board J14 3 to J14 8 Sys 4 Flash Tank Feed Valve Chiller Control Board J14 4 to J14 9 Sys 4 Flash Tank Feed Valve Chiller Control Board J25 1...

Page 281: ...281 JOHNSON CONTROLS FORM 201 21 NM1 616 8 This page intentionally left blank ...

Page 282: ...elay Board 1 J9 5 TB1 12 and 11 Sys 1 SPARE Chiller Control Relay Board 1 J9 6 TB1 10 and 9 SPARE Chiller Control Relay Board 1 J9 7 TB1 8 and 7 SPARE Chiller Control Relay Board 1 J9 8 TB1 6 Sys 1 Condensor Fans Output 1 Chiller Control Relay Board 1 J9 9 TB1 5 Sys 1 Condensor Fans Output 2 Chiller Control Relay Board 1 J9 10 TB1 4 Sys 1 Condensor Fans Output 3 Chiller Control Relay Board 1 J9 11...

Page 283: ... Board J7 4 Comp 3 Phase C IGBT Gating Signal VSD Logic Board J7 10 Comp 3 Phase A IGBT Gating Signal VSD Logic Board J7 11 Comp 3 Phase B IGBT Gating Signal VSD Logic Board J7 13 Comp 3 Phase C IGBT Gating Signal VSD Logic Board J7 14 Comp 3 Enable VSD Logic Board J8 1 Comp 2 Phase A IGBT Gating Signal VSD Logic Board J8 3 Comp 2 Phase B IGBT Gating Signal VSD Logic Board J8 4 Comp 2 Phase C IGBT...

Page 284: ... munications with a 3 or 4 compressor chiller involves 2 sections of feature 54 to get all the data Control pa rameters from the ISN as well system 1 2 and unit data are handled in the first section The second section will not be able to do any control but only receive system 3 and 4 if applicable data Received Data Control Data The chiller control panel receives 8 data values from the ISN The fir...

Page 285: ...3 Analog Sys 2 Discharge Pressure P30 84 87 Analog Sys 2 Compressor Full Load Amps P31 88 91 Analog Sys 2 Total Run Hours P32 92 95 Analog Sys 2 Total Number of Starts P33 96 99 Analog VSD Output Frequency P34 100 103 Analog Sys 1 Flash Tank Feed Valve Open P35 104 107 Analog Sys 2 Flash Tank Feed Valve Open P36 108 Digital Chiller Run P37 109 Digital Chiller Alarm P38 110 Digital Evaporator Heate...

Page 286: ...ondensor Fan Stage 0 6 P64 136 Coded Lead System Number P65 137 Coded Sys 1 2 Debug Code P66 138 141 Analog Local Leaving Chilled Liquid Setpoint P67 142 145 Analog Low Leaving Chilled Liquid Temp Cutout P68 146 149 Analog Sys 1 Flash Tank Drain Valve Open P69 150 153 Analog Sys 2 Flash Tank Drain Valve Open P70 154 157 Analog Low Suction Pressure Cutout P71 158 161 Analog VSD DC Bus Voltage P72 1...

Page 287: ...Failure 8 Unit VSD Pre charge Low DC Bus Voltage 9 Unit VSD Pre charge DC Bus Voltage Imbalance 10 Unit VSD High DC Bus Voltage 11 Unit VSD Low DC Bus Voltage 12 Unit VSD DC Bus Voltage Imbalance 13 Unit VSD High VSD Ambient Temp 14 Unit VSD Single Phase Input 15 Unit VSD VSD Power Supply Fault 16 Unit VSD VSD Logic Board Fault 17 Unit VSD Motor Current Overload Hardware 18 Unit VSD CT Plug Fault ...

Page 288: ...otor Current 43 System VSD Motor Current Overload Software 44 System VSD IGBT Gate Driver Fault 45 System VSD High Baseplate Temp 46 System VSD Single Phase Input 47 System VSD VSD Run Signal Fault 48 System Panel High Discharge Press Hardware HPCO 49 System Panel High Flash Tank Level 50 System Panel Control Voltage Fault 51 System Panel Low Discharge Superheat 52 System SPARE 2 53 System SPARE 3...

Page 289: ...ling Shutdown 70 Unit SPARE 1 71 Unit SPARE 2 72 Unit SPARE 3 73 Unit SPARE 4 74 System Panel No Run Permissive 75 System Panel Anti Recycle Timer Active 76 System Panel System Switch OFF 77 System Panel System Not Running 78 System Panel System Running 79 System Panel Discharge Pressure Limiting 80 System Panel Suction Pressure Limiting 81 System Panel Motor Current Limiting 82 System Panel Motor...

Page 290: ...0 0 34 6 165 0 117 6 300 0 160 0 35 0 40 0 170 0 119 6 305 0 161 3 40 0 45 0 175 0 131 5 310 0 162 5 45 0 49 6 180 0 123 3 315 0 163 8 50 0 54 0 185 0 125 2 320 0 165 0 55 0 58 1 190 0 126 9 325 0 166 2 60 0 62 0 195 0 128 7 330 0 167 4 65 0 65 7 200 0 130 4 335 0 168 6 70 0 69 2 205 0 132 1 340 0 169 8 75 0 72 6 210 0 133 8 345 0 171 0 80 0 75 9 215 0 135 5 350 0 172 1 85 0 79 0 220 0 137 1 355 0...

Page 291: ...ipped to do so If in any doubt contact your local YORK Service Agent Unit Status Press the STATUS key on the keypad and ensure no fault messages are displayed Refrigerant Leaks Visually check the heat exchangers compressors and pipework for damage and gas leaks Operating Conditions Read the operating pressures and temperatures at the control panel using the display keys and check that these are wi...

Page 292: ...ris and clean as necessary X Check Programmable Operating Setpoints and Safety Cutouts Assure they are correct for the application X Check Compressor and Evaporator Heater operation X Check for dirt in the Panel Check Door Gasket sealing integrity X Check Superheat on the Evaporator and the Economizer feed to the Compressor X Check Condensor Subcooling X Leak check the Chiller X Sample Compressor ...

Page 293: ...lem X VSD Glycol Change X MAINTENANCE REQUIREMENTS FOR YCAV CHILLERS CON T Reserved for customer use for any special site requirements This procedure must be performed at the specific time by an industry certified technician who has been trained and qualified to work on this type of equipment Arecord of this procedure be successfuly carried out should be maintained on file by the equipment owner s...

Page 294: ...mometer reading of ambient temperature Chiller Fault HIGH AMBIENT TEMPERATURE Ambient Temperature is above the maximum operating limit Check outside air temperature Ambient Sensor is defective Check the Panel Display against Thermometer reading of Ambient Temperature at the sensor Chiller Fault LOW LEAVING CHILLED LIQUID Leaving chilled liquid temperature drops faster than the unit can unload Chec...

Page 295: ...ng High Superheat Drain Feed Valves NOT controlling Isolate cause Motor Sensor reading incorrectly Program panel to ignore a single sensor Economizer Solenoid energized at low speeds Valve is leaking through System Fault LOW SUCTION PRESSURE Low charge Check subcooling Transducer reads incorrectly Check transducer against a guage Suction Temp Sensor reads incorrectly Check sensor against a thermoc...

Page 296: ...rrent limiting Ambient temperature is high normal response from controller Remore or panel limiting is in effect Normal response Excess charge in system adjust charge Condensor coils dirty Clean condensor Fans NOT operating Check fans VSD Fault High Baseplate Temperature Coolant level low Add coolant Glycol Pump is defective Replace Glycol Pump VSD Board is defective Replace VSD Logic Board IBGT M...

Page 297: ...nses 1 Labor to remove or reinstall any equipment mate rials or components 2 Shipping handling or transportation charges 3 Cost of refrigerant No warranty repairs or replacements will be made until payment for all equipment materials or components has been received by YORK ALL WARRANTIES AND GUARANTEES ARE VOID IF 1 Equipment is used with refrigerants oil or antifreeze agents other than those auth...

Page 298: ...3 3 1 76 42 7 2 42 63 2 3 09 23 9 1 78 43 3 2 44 63 8 3 11 24 5 1 80 43 9 2 46 64 5 3 13 25 0 1 82 44 4 2 48 65 1 3 14 25 6 1 84 45 0 2 50 65 8 3 16 26 2 1 86 45 6 2 52 66 5 3 18 26 8 1 88 46 2 2 54 67 1 3 20 27 3 1 90 46 7 2 56 67 8 3 22 27 9 1 91 47 3 2 58 68 5 3 24 28 5 1 93 47 9 2 60 69 2 3 26 29 0 1 95 48 5 2 62 69 9 3 28 29 6 1 97 49 1 2 64 70 6 3 30 30 2 1 99 49 7 2 66 71 3 3 32 30 8 2 01 5...

Page 299: ... 2 44 112 3 3 75 21 2 1 15 64 4 2 47 113 8 3 78 22 3 1 18 65 3 2 50 115 2 3 81 23 4 1 21 66 3 2 52 116 7 3 84 24 4 1 24 67 2 2 55 118 3 3 87 25 5 1 26 68 1 2 58 119 9 3 90 26 6 1 26 69 1 2 61 121 5 3 93 27 6 1 32 70 0 2 64 123 2 3 96 28 7 1 35 70 9 2 67 124 9 3 98 29 7 1 38 71 9 2 70 126 6 4 01 30 7 1 41 72 8 2 73 128 4 4 04 31 7 1 44 73 8 2 76 130 3 4 07 32 7 1 47 74 8 2 76 33 7 1 50 75 8 2 82 34...

Page 300: ... 62 35 1 01 175 3 05 40 1 78 40 1 08 180 3 12 45 1 94 45 1 15 185 3 19 50 2 10 50 1 23 190 3 26 55 2 26 55 1 30 195 3 34 60 2 42 60 1 37 200 3 41 65 2 58 65 1 45 205 3 48 70 2 74 70 1 52 210 3 55 75 2 90 75 1 59 215 3 63 80 3 06 80 1 66 220 3 70 85 3 22 85 1 74 225 3 77 90 3 38 90 1 81 230 3 85 95 3 54 95 1 88 235 3 92 100 3 70 100 1 95 240 3 99 105 3 86 105 2 03 245 4 06 110 4 02 110 2 10 250 4 1...

Page 301: ...26 3 00 5 166 5 485 45 4 368 3 25 4 226 4 510 50 3 602 3 50 3 476 3 728 55 2 986 3 75 2 874 3 098 60 2 488 4 00 2 389 2 588 65 2 083 4 25 1 995 2 172 70 1 753 4 50 1 674 1 832 75 1 481 4 75 1 411 1 551 80 1 257 5 00 1 194 1 321 85 1 071 5 20 1 016 1 127 90 916 9 5 40 867 4 966 4 95 787 7 5 60 743 6 831 9 100 679 3 5 80 639 9 718 7 105 587 9 6 00 552 6 623 2 110 510 6 6 20 479 9 542 3 115 445 0 6 4...

Page 302: ...80 460 575 192 192 186 YCAV0157SA PA 200 230 380 460 575 196 196 200 YCAV0177EA VA 200 230 380 460 575 184 197 200 YCAV0177SA PA 200 230 380 460 575 270 191 182 YCAV0187EA VA 200 230 380 460 575 250 183 192 YCAV0187SA PA 200 230 380 460 575 254 198 200 YCAV0197EA VA 200 230 380 460 575 244 244 182 YCAV0207EA VA 200 230 380 460 575 234 250 192 YCAV0207SA PA 200 230 380 460 575 247 273 186 YCAV0227E...

Page 303: ...r manual for the respective printer for set up and wiring Data from the chiller is transmitted at 1200 baud Wir ing diagrams for cables are shown below OKIDATA MICROLINE 184 25 pin RS 232 DB 25P 25 pin RS 232 DB 25P TB1 Chiller Control Board 11 CTS RD GND DSR RS 232 TXD GND TB1 2 TB1 3 TB1 5 3 7 SEIKO DPU 414 9 pin RS 232 DB 9 TB1 Chiller Control Board 8 CTS RD GND DSR TXD GND TB1 2 TB1 3 TB1 5 3 ...

Page 304: ...nt mode 1 7 off SDD pin 11 1 8 on SDD pin 11 2 1 on 1200 baud 2 2 on 1200 baud 2 3 off 1200 baud 2 4 off DSR active 2 5 on Buffer threshold 32 bytes 2 6 on Busy signal 200ms 2 7 on DTR space after power on 2 8 not used With SUPER SPEED Serial Board SW1 off Low when busy 2 off 1200 baud 3 off 1200 baud 4 on 1200 baud 5 not used 6 off no parity 7 off Pin 20 pin 11 act as busy line WEIGH TRONIX IMP 2...

Page 305: ...ODEL COMPRESSOR 3 MODEL COMPRESSOR 4 MODEL SERIAL PROGRAMMED VALUES CHILLED LIQUID SETPOINT Setpoint ºF ºC Range ºF ºC Display Language Chilled Liquid Mode Local Remote Mode Display Units Lead Lag Control Remote Temperature Reset Remote Current Reset PROGRAMMED CUTOUTS Suction Pressure Cutout PSIG kPa Low Ambient Cutout ºF ºC Leaving Chilled Liquid Temp Cutout ºF ºC High Motor Current Unload FLA 9...

Page 306: ...EPLATE TEMPS T1 ºF ºC T2 ºF ºC SYSTEM OPERATING TEMPERATURES PRESSURES CURRENTS SYSTEM PRESSURES SYS 1 SYS 2 SYS 3 SYS 4 Oil PSIG kPa Suction PSIG kPa Discharge PSIG kPa SYSTEM TEMPERATURES SYS 1 SYS 2 SYS 3 SYS 4 Oil ºF ºC Suction ºF ºC Discharge ºF ºC Sat Suction ºF ºC Sat Superht ºF ºC Sat Discharge ºF ºC Dsch Superht ºF ºC MOTOR TEMPERATURES SYS 1 SYS 2 SYS 3 SYS 4 T1 ºF ºC T2 ºF ºC T3 ºF ºC C...

Page 307: ...SYS 4 Fan Stage COMPRESSOR HEATER ON OFF SYS 1 SYS 2 SYS 3 SYS 4 Comp Heater SYSTEM RUN TIME Days Hours Mins Sec System 1 System 2 System 3 System 4 SYSTEM STARTS STARTS SYSTEM 1 SYSTEM 2 SYSTEM 3 SYSTEM 4 OIL SEPARATOR LEVEL Check Oil Separator Oil Levels SYS 1 SYS 2 Separator 1 2 3 4 Oil Level Top Glass Oil Level Bot Glass SYS 3 SYS 4 Separator 1 2 3 4 Oil Level Top Glass Oil Level Bot Glass Oil...

Page 308: ...1 NM1 616 WATER SYSTEM CONDITIONS EVAPORATOR FLOW Flow Rate GPM Evap Pressure Drop FT LBS Circle One Glycol Freeze Point ºF ºC CONDENSOR CONDITIONS AIR TEMPERATURE Air ON Temperature ºF ºC Air OFF Temperature ºF ºC MAINTENANCE NOTES ...

Page 309: ...or Type L R 134a 011 00592 000 VSD Logic Board ALL 031 02477 000 EPROM U36 ALL 031 02521 001 EPROM U39 ALL 031 02522 001 Sensor Outside Air Temperature ALL 025 28663 001 Transducer Pressure 0 275 psig ALL 025 29139 003 High Pressure Cutout 297 psig ALL 025 39456 000 Transducer Suction Pressure 0 125 psig ALL 025 29583 001 Sensor EWT LWT ALL 025 40334 000 Relay Output Board ALL 031 02479 002 VSD Lo...

Page 310: ...nia USA 17405 1592 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2016 www johnsoncontrols com ALL RIGHTS RESERVED Form 201 21 NM1 616 Issue Date June 30 2016 Supersedes 201 21 NM1 315 ...

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