York YCAZ88EE8 Installation, Operation And Maintenance Manual Download Page 4 | Manualshive

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YORK INTERNATIONAL

FIG. 1

UNIT COMPONENTS

LD02159

26175A

COOLER

OUTLET

CONDENSER

FANS

SHIPPING

BRACE

COOLER

INLET

COOLER, HEATER

& THERMOSTAT

26174A

UNIT DATA PLATE

(SIDE OF PANEL)

MICROPANEL

CONDENSER

FANS

CONDENSER

COIL(S)

POWER

PANEL

COMPRESSOR #2

COMPRESSOR #1

OPTIONAL SINGLE

POINT POWER CONNECT

COMPRESSOR

POWER SUPPLY

COOLER

SYSTEM #2

SIGHT

GLASS

TX

VALVE

>

SIGHT

GLASS

TXV

SYSTEM #1

>

25212A

25211A

SYSTEM #2

SOLENOID

VALVE

SYSTEM #1

LIQUID STOP

VALVE

SYSTEM #2

LIQUID STOP

VALVE

SYSTEM #2

FILTER/DRIER

SYSTEM #1

FILTER/DRIER

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Summary of Contents for YCAZ88EE8

Page 1: ... YCAJ55HE8 YCAJ65HE8 STYLE A 26174A With EPROM 031 01096 001 Standard Brine Metric Models Combined SHOWN WITH OPTIONAL SINGLEPOINTPOWERCONNECTION fi M A N U F A C T U R E R CERTI FI ED TO ARIAS C O M P L Y I N G W I T H ARISTA N D A R D 590 CERTI FI CATI O N SECTI O NS O F C E N T R I F U G A L A N D ROTARY SCREW W A T E R C H I L L I N G PACKAGES 200 230 460 3 60 ...

Page 2: ... 72 OPTIONS 74 TROUBLESHOOTINGCHART 87 GENERAL DESCRIPTION These packaged liquid chillers are completely self con tained outdoor units shipped ready for final job installa tion requiring only liquid connections power and control wiring They are designed primarily for central station air conditioning applications with normal installations being on roof tops or on ground level beside the building CO...

Page 3: ... 200 3 60 28 230 3 60 40 380 3 60 46 460 3 60 50 380 415 3 50 58 575 3 60 64 346 3 50 Fan Code 8 Compressor Series Compressor Style No of Active Cylinders 4 6 8 Stroke 3 4 Steps of unloading Motor Size M N P Q S T V Voltage Code 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 64 346 3 50 Motor Manufacturer A A O Smith L Leroy Somer J G 4 3 1 M 17 S Compressor Series No ...

Page 4: ...TA PLATE SIDE OF PANEL MICROPANEL CONDENSER FANS CONDENSER COIL S POWER PANEL COMPRESSOR 2 COMPRESSOR 1 OPTIONALSINGLE POINTPOWERCONNECT COMPRESSOR POWERSUPPLY COOLER SYSTEM 2 SIGHT GLASS TX VALVE SIGHT GLASS TXV SYSTEM 1 25212A 2521 1A SYSTEM 2 SOLENOID VALVE SYSTEM 1 LIQUIDSTOP VALVE SYSTEM 2 LIQUIDSTOP VALVE SYSTEM 2 FILTER DRIER SYSTEM 1 FILTER DRIER ...

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

Page 6: ...CITY CONTROL SOLENOIDS RAINTIGHT TERMINALBOX SUCTION STOP VALVE SIGHT GLASSES 2 OILCHARGING VALVE CRANKCASE HEATER OILPRESSURE ACCESS CONNECTION 27297A 27299 OIL CHARGING VALVE CRANKCASE HEATER DATA PLATE MOTOR TERMINALS SUPPRESSORS MOTORPROTECTOR MP 27298A DISCHARGE STOP VALVE TERMINAL BOX OIL LEVEL SIGHT GLASS OIL PRESSURE ACCESSCONN CAPACITY CONTROL SOLENOID ...

Page 7: ...etting standard controls 2 Operation below 25 F requires the Optional Low Ambient kit Minimum recommended operating temperature is 0 F 3 Operation above 115 F requires Optional High Ambient kit Maxi mum recommended operating temperature is 130 F 4 The evaporator is protected against freeze up to 20 F with an electrical heater cable standard CAUTION Excessive flow will cause damage to the cooler Do...

Page 8: ...n reduced system performance nuisance shutdowns and servicing problems The area within the clearances shown above and area under the unit must be kept clear of all obstructions that would impede free air flow to the unit In installations where winter operation is intended and snow accumulations are expected additional unit height must be provided to insure full air flow 2 Panel bottom to be punche...

Page 9: ...rest YORK Sales Office for detailed drawings PHYSICAL DATA MODELYCA 60 HZ Z88EE8 J44H38 J54HE8 J55HE8 Z65HE8 NOMINAL TONS 60 HZ 93 7 100 5 107 5 114 7 120 7 NO OFREFRIG CIRCUITS 2 2 2 2 2 COMPRESSOR ZB6W1 E JS43G M JS44G P JS44G P JS63G Q MODEL Sys 1 65 HP 60 HP 80 HP 80 HP 90 HP MOTOR Sys 2 ZB6W1 E JS43G M JS43G M JS44G P JS44G P HORSEPOWER 65 HP 60 HP 60 HP 80 HP 80 HP UNIT CAPACITY 60 HZ 5 Step...

Page 10: ...X MAX SIZE INCOMING COND MAX MAX SIZE INCOMING COND YCA MCA1 DUAL ELEM DIS CKT BKR WIRE RANGE6 CPR CPR FAN MCA1 DUAL ELEM DIS CKT BKR WIRE RANGE6 CPR CPR FAN FUSE MIN 4 HACR5 CU ONLY RLA LRA FLA FUSE MIN 4 HACR5 CU ONLY RLA LRA FLA MIN 2 MAX 3 TYPE EACH MIN 2 MAX 3 TYPE EACH Z88EE8 17 291 350 350 400 450 2 4 250MCM 207 858 16 291 350 450 400 450 2 4 250MCM 207 858 16 Z88EE8 28 258 350 400 400 400 ...

Page 11: ...MCM 186 225 225 200 250 1 6 350MCM 1 6 350MCM 582 700 800 800 800 1 3 6 350MCM 1 4 1 0 350MCM 516 600 700 600 700 1 3 6 350MCM 1 2 4 0 500MCM 258 300 350 400 350 1 6 350MCM 1 1 600MCM OR 2 1 250MCM 204 225 250 400 250 1 6 350MCM 1 6 350MCM 627 700 800 800 800 1 3 6 350MCM 1 4 1 0 350MCM 555 700 700 600 700 1 3 6 350MCM 1 2 4 0 500MCM 278 350 350 400 350 1 6 350MCM 1 1 600MCM OR 2 1 250MCM 219 250 ...

Page 12: ...ull operating charge and care should be taken to avoid damage due to rough handling The units are shipped without export crating unless it is specified by Sales Order A unit should be lifted by inserting hooks through the holes provided in unit base rails Spreader bars should be used to avoid crushing the unit with the rifling chains See Fig 3 WARNING To protect warranty this equipment must be ins...

Page 13: ...ted Mounting holes are provided in the steel channel for bolt ing the unit to its foundation See DIMENSIONS For ground level installations precautions should be taken to protect the unit from tampering by or injure to unautho rized persons Screws and or latches on access panels will prevent casual tampering However further safety pre cautions such as a fenced in enclosure or locking devices on the...

Page 14: ... D YCAZ88EE8 CP 2 32 CP 2 31 CP 2 32 CP 2 31 YCAJ44HE8 CP 4 27 CP 4 27 CP 4 27 CP 4 27 YCAJ54HE8 CP 4 27 CP 4 27 CP 4 27 CP 4 27 YCAJ55HE8 CP 4 27 CP 4 27 CP 4 27 CP 4 27 YCAJ65HE8 CP 4 27 CP 4 27 CP 4 27 CP 4 27 LD02164 MODEL YCA WEIGHT DISTRIBUTION LBS A B C D Z88EE6 2337 2059 2246 2031 J44HE8 2778 2500 2522 2307 J54HE8 2818 2514 2536 2312 J55HE8 2860 2561 2552 2321 J65HE8 2935 2588 2576 2530 CO...

Page 15: ...event formation of con densation on lines in warm humid climates 7 A chilled water flow switch either by YORK or others MUST be installed in the leaving water piping of the cooler There should be a straight horizontal run of at least 5 diameters on each side of the switch Adjust the flow switch paddle to the size of pipe in which it is to be installed See manufacturer s instructions fur nished wit...

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

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

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

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

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

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

Page 22: ... and loading unloading de cisions are performed by the Microprocessor to maintain leaving water temperatures These decisions are a func tion of temperature deviation from setpoint and rate of change of temperature MICROPROCESSOR BOARD The Microprocessor Board is the controller and decision maker in the control panel System inputs from pressure transducers temperature sensors and C T s are con nect...

Page 23: ...ential CURRENTTRANSFORMER C T A C T on the 3φ power wiring of each motor sends AC signals proportional to motor current to the Power Sup ply Board which rectifies and filters the signal to variable DC voltage analog This analog level is then fed to the Microprocessor Board to allow it to monitor motor current 40 CHARACTER DISPLAY The 40 Character Display 2 lines of 20 characters is a liquid crysta...

Page 24: ...XTERIOR 25999A MICROPROCESSOR BOARD KEYPAD TB3 26000A LCD DISPLAY BOARD MICROPROCESSOR BOARD UNITON OFF SWITCH 2TTRANSFORMER RELAY OUTPUT BOARD 1 TB3 CONNECTIONS FOR FLOW SWITCH LEAD LAG SELECTORAND EMS BAS CONTROLS LOCATION OF OPTIONAL RELAY OUTPUT BOARD 2 POWERSUPPLY BOARD ...

Page 25: ... which are being displayed If a message is required to be updated faster than every 2 seconds the appropriate key for the desired display may be pushed and held Updating will be at 4 second inter vals Each of the keys and an example of the typical corre sponding display messages will be discussed in the text which follows Chilled Liquid Temps A display indicating chiller leaving and return water t...

Page 26: ...ted by the user These options are se lected by the S1 Dip Switch on each Microprocessor Board Fig 12 Proper programming of the switch is important during commissioning of the chiller The OP TIONS display allows a means of verifying the Dip Switch positions without looking at or handling the Microproces sor Board It also eliminates visual inspection of the sometimes difficult to determine Dip Switc...

Page 27: ...L I S H U N I T S R E A D O U T M E T R I C U N I T S R E A D O U T R E T U R N W A T E R C O N T R O L L E A V I N G W A T E R C O N T R O L L O C A L C O N T R O L M O D E R E M O T E C O N T R O L M O D E S T A N D A R D A M B I E N T L O W A M B I E N T C O N T R O L C O M F O R T C O O L I N G B R I N E P R O C E S S D U T Y TABLE 1 SWITCH POSITION AND DISPLAY 26001A EPROM RTC S1 031 01096C00...

Page 28: ...EN Display messages will show units of measure in English units F PSI etc CLOSED Display messages will show units of measure in Metric units C kPa etc SWITCH 6 OPEN This MUST be selected for chillers with 4 or more fans where each refrigerant system will have fans of its own CLOSED This must be selected for 2 fan chillers where fans are shared by both refrigerant circuits C O M F O R T C O O L I N...

Page 29: ...n In this mode maximum chiller efficiency will be achieved If the Low Ambient option is installed the fan control will automatically change to pressure control at tempera tures below 25 F See page 66 for fan control sequence CLOSED Fan control is by discharge pressure only This mode of fan control will increase discharge pressure It should be used if nuisance low suction pressure faults are experi...

Page 30: ...the CLOCK SET SCHEDULE HOLIDAY is keeping the chiller from running Run Permissive is an indicator that an external cycling contact i e flow switch connected to terminals 13 and 14 is open or a system switch es on the Microproces sor Board is in the OFF position Whenever the contact is open or a switch is OFF the NO RUN PERM will be displayed This message informs the operator that the chilled liqui...

Page 31: ...er programmable threshold and the micro is unloading the affected system to pre vent shutdown on a manual high pressure cut out Re loading will take place when discharge pressure has dropped 60 PSIG below the threshold Optional discharge pressure transducers must be in stalled for this feature to operate This is accomplished by adding the Discharge Pressure Read out option If the MANUAL OVERRIDE k...

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

Page 33: ...lable data after any one of the following keys is pressed PROGRAM SET SCHEDULE HOLIDAY OPER DATA HISTORY Cancel Key The CANCEL key allows the user to change errors in the data being programmed into memory When the CANCEL key is pressed any data which has been keyed in but not entered will be erased The origi nal values will re appear on the display and the cursor will return to the first character...

Page 34: ...Y PROGRAM 26572A PROGRAM KEY PROGRAMMINGUSERPROGRAMMABLESAFETIES LIMITS O U T O F R A N G E T R Y A G A I N D I S C H A R G E C U T O U T 3 9 5 P S I G PROGRAM KEY THESE VALUES MAY CAUSE DAMAGE TO THE CHILLER OR OPERATION PROBLEMS DISCHARGE CUT OUT The DISCHARGE CUT OUT is a microprocessor back up for the mechanical high pressure cut out located in each refrigerant circuit Typically chillers with ...

Page 35: ...50 0 F for this cut out if S1 Dip Switch 2 on the Micro Logic Board is in the CLOSED position In the OPEN position a fixed 25 F cut out is recognized OUTSIDE AIR TMP HIGH CUT OUT The OUTSIDE AIR TMP HIGH CUT OUT is selectable to establish the high ambient cut out point If the ambient rises above this point the chiller will shut down Restart can occur when temperature drops below the cut out This o...

Page 36: ...reduced loader and compressor cycling Typically this value should be programmed for 00 1 F When program ming values like 00 1 F it is first required to key in 00 Example 00 1 F Additional details for program ming this control will be discussed in the SELECTION OF RETURN OR LEAVING CHILLED LIQUID CONTROL Section Page 40 ANTI RECYCLE TIME The ANTI RECYCLE TIME selection allows the user to select the...

Page 37: ...establishes the rate of change of return or leaving water temperature where the micro will override the normal 30 150 seconds per stage load ing rate which is based on error between setpoint and actual temperature The RATE SENSITIVITY is active when the leaving chilled liquid temperature is in the RATE CONROL TEMP RANGE In this range if water temperature is dropping faster than the RATE SENSITIVIT...

Page 38: ...is played when the SET TIME key is pressed To program the day time and date first press the AD VANCE DAY key until the appropriate day of the week is displayed The day will advance each time the key is pressed The cursor will already be below the first digit of the time Key in the new time if required Be sure to key in a 0 before the other digits for times before 10 o clock i e 08 01 After the tim...

Page 39: ... days to view times programmed use the ADVANCE DAY KEY not the ENTER KEY This will assure that after viewing MONDAY that the ENTER KEY is not pressed changing times programmed for the rest of the week If the chiller is not cycled by the DAILY SCHEDULE but is required to run whenever the system switches are on all 00 00 s should be programmed into the daily sched ule This can be done manually for e...

Page 40: ...y of compressor and loader cycling that is critical to precisely controlling temperature MANUAL OVERRIDE M A N U A L O V E R R I D E RETURN WATER CONTROL may also be used on batch and process application and should provide ad equate control However it will prove to be less respon sive with slightly more leaving chilled liquid temperature variation RETURN WATER CONTROL may become necessary to use i...

Page 41: ...still timing out The effects can be reduced by programming the anti recycle timer Page 36 for a minimum of 300 seconds if it isn t already pro grammed for 300 seconds If problems still arise switch to RWT CONTROL Once the dip switch 4 on the Microprocessor Board is properly positioned the user will be able to view the ap propriate display when the CHILLED LIQUID TEMP RANGE is pressed This display ...

Page 42: ...he CHILLED LIQUID TEMP RANGE key The display will first exhibit a message that RETURN WATER TEMP CONTROL is selected and 3 seconds later automat ically scroll to the next display of LWT and CR The cur sor will stop at the first digit of LWT Key in the Design Leaving Water Temperature LWT that is required in the system See the following Design Leaving Water Temperature After the Design Leaving Wate...

Page 43: ...op and a wide control loading unloading range com pressor loader cycling is reduced wear and tear on me chanical parts is reduced and pulldown demand is auto matically limited This makes the selection of RATE CONTROL TEMP and RATE SENSITIVITY values less critical unless short water loops are encountered Before programming the RATE CONTROL TEMP the user should first determine if typically the norma...

Page 44: ...e entered into memory and the display will advance to the next user programmable limit The micro will accept a range of programmable values between 0 5 5 0 F min PROGRAMMING LEAVING WATER CONTROL Chilled Liquid Temp Range When the CHILLED LIQUID TEMP RANGE key is pressed the following message will be displayed for 3 seconds indicating Dip Switch S1 Switch 4 on the Mi croprocessor Board is programm...

Page 45: ...rs leaving water temperature may vary considerably as a result of a compressor that cannot restart due to the anti recycle timer To eliminate this increase the T temperature differential of the CR and or program the anti recycle timer for a mini mum of 300 seconds if it isn t already pro grammed for 300 seconds NOTE Whenever reprogramming the LWT CR keep in mind that the desired leaving water temp...

Page 46: ...pull temperature down select 0 1 F To program the RATE CONTROL TEMP first press line PROGRAM key Repetitively press the ENTER key until the display below appears Key in the desired value and press the ENTER key The new value will be entered into memory and the display will advance to the next user programmable limit The micro will accept a range of programmable values between 0 1 20 F NOTE When pr...

Page 47: ...le values between 0 5 5 0 F min LOADING AND UNLOADING RETURN WATER TEMPERATURE CONTROL In return water temperature control loading and unload ing will take place according to the difference between the leaving water temperature setpoint and the actual re turn water temperature By programming the CONTROL RANGE equal to the actual temperature drop across the evaporator fully loaded the microprocesso...

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

Page 49: ... CONTROL RANGE which is below the programmed Low Limit WATER TEMPERA TURE the microprocessor will unload the chiller in 20 sec intervals until water temperature rises back into the CONTROL RANGE If temperature is in the upper half of CONTROL RANGE or in the RATE CONTROL RANGE the microprocessor will continue loading the chiller as needed in 150 sec intervals until temperatures pass into the lower ...

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

Page 51: ...or current is exceeding 120 FLA at the 3 second point the compressor will shut down After 4 seconds of operation motor current must be greater than 15 FLA but less than 115 FLA as long as the compressor continues to run NOTE Do not confuse FLA and RLA FLA full load amps is approximately 1 2 x RLA RLA running load amps specified on the motor nameplate is typical current demand under rated operating...

Page 52: ...tator These sensors are wired into the motor protec tor module located inside the Motor terminal box As the motor windings heat and cool the resistance of the mo tor temperature sensors will change If the windings overheat the change in resistance in the sensors will be sensed by the Motor protector module The module will open it s MP contacts breaking the 115VAC fed to the motor contactor When th...

Page 53: ...is shown below High Ambient Temperature Safety The High Ambient Temperature Safety assures that the chiller does not run in ambients above 130 F where po tential malfunction of system mechanical and electrical components may result Whenever the outdoor ambient exceeds 130 F non programmable the chiller will shut down Restart will not occur until temperature drops to 2 F below the cut out point loa...

Page 54: ...ce of tripping the relief valve due to a very high rate of rise in pressure resulting from a controls problem which would cause condenser water flow to be interrupted In this case the pressure rise is so fast refrigerant loss may occur through the relief valve even though the high pres sure cut out has opened and the compressor is in the midst of stopping An example of the message displayed when d...

Page 55: ...on of the use of the keys for remote printer or local data retrieval will follow An optional printer Page 77 will be required for remote printout REMOTE PRINTOUT Oper Data The OPER DATA key allows the operator to remotely obtain a printout of current system operating parame ters When the key is pressed a snapshot will be taken of system operating conditions and panel programming selections This da...

Page 56: ...orage area for data related to each of the last 3 safety shutdowns The printout will begin with the most recent fault which occurred The most recent fault will always be stored as SAFETY SHUTDOWN NO 1 See printout Fig 21 Identically formatted fault information will then be printed for SAFETY SHUTDOWN NO 2 and SAFETY SHUT DOWN NO 3 Information contained in the SAFETY SHUTDOWN Buff ers is very impor...

Page 57: ...noid status run time etc A total of 20 different displays are offered When the OPER DATA key is pressed the following message will appear Repetitively pressing the ENTER key allows the operator to scroll through the 20 available displays In the information that follows a sample message along with an explanation of it s meaning is provided for all 20 messages OFF SYS 1 Liquid Line Solenoid De energ...

Page 58: ...d Compr Loaded Lag Compr Loaded On some STEPS actual Loading will NOT change S Y S 2 R U N T I M E 0 S E C S 7 STAGE STEP 0 Both Compressors OFF 1 Lead Compr Unloaded Lag Compr OFF 2 Lead Compr 1 Stage Loading Lag Compr OFF 3 Lead Compr 1 Stage Loading Lag Compr OFF 4 Lead Compr 2 Stages Loading Lag Compr OFF 5 Lead Compr 1 Stage Loading Lag Compr Unloaded 6 Lead Compr 1 Stage Loading Lag Compr 1 ...

Page 59: ...etitively pressing the ENTER key will allow the operator to scroll through the informa tion available in the SAFETY SHUTDOWN Buffer In the information that follows a sample message along with an explanation is provided for all available mes sages This message informs the operator of the time and date of the fault This message informs the operator of the nature of the fault which occurred This mess...

Page 60: ...essure Readout is installed This display shows the oil pressure at the time of the fault This display informs the operator whether SYS 1 liquid line solenoid was energized ON or de energized OFF at the time of the fault This message informs the operator if SYS 1 Run Per missive flow switch remote START STOP was in the RUN mode ON or STOP mode OFF This message indicates the number of stages which w...

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

Page 62: ...ted to terminals 23 and 24 Fig 23 are supplied which will transition to function as a warning whenever a fault shutdown occurs on any sys tem or if power is lost to the control panel The dry con tacts are normally open N O and will close when con trol power is applied to the panel if no fault conditions are present If power is not lost or a fault lockout occurs the contact will open A 28VDC or 120...

Page 63: ...ll automatically become the lead anytime the system switch on the Microprocessor Board of the compressor currently in the lead is placed in the OFF position This is also done to maintain water temperature as close to setpoint as possible If MANUAL Lead Lag is selected an external dry con tact switch must be wired into the chiller This contact is supplied by others When the contact is closed SYS 2 ...

Page 64: ...ME KEEPING WILL BE MAINTAINED IN MEMORY REGARDLESS OF WHETHER THE CLOCK IS ON OR OFF AND REGARDLESS OF THE LENGTH OF THE POWER FAILURE To disable the clock place the jumper Fig 25 in the OFF positions To activate it place the jumper in the ON position On power up the microprocessor will check the Real Time Clock RTC Chip battery to assure that the internal battery is still operational This is acco...

Page 65: ...itch 5 of Dip Switch S1 on the Microprocessor Board must be placed in the OPEN position Page 28 The positioning of this switch can then be verified by pushing the OPTIONS key and verifying that METRIC UNITS READOUT is pro grammed Page 26 EMS BAS CONTROLS The microprocessor is capable of REMOTE START STOP REMOTE UNLOADING Pulldown demand limit ing and REMOTE SETPOINT RESET These functions can be ea...

Page 66: ... of the device must be suppressed with a user supplied YORK P N 031 00808 suppressor NOTE Remote Setpoint Reset will not operate when a Remote Control Center Option Kit is connected to the Micro Panel The Remote Control Center will always determine the setpoint REMOTE UNLOADING The microprocessor is capable of remote unloading or pulldown demand limiting in two steps The first step shuts down the ...

Page 67: ...control system is to automatically adjust the compressor pumping ca pacity to balance with the cooling load at a pre deter mined return water temperature and to permit the com pressor to start under partial load The compressor ca pacity control system is actuated by means of gas pres sure from the discharge side of the compressor Control of the gas pressure to the unloader elements is the func tio...

Page 68: ...t the recessed opening to the suction plenum effectively blocking the flow of suction gas into the cylinders blocked suction unloading The cylinders are now unloaded LOADING When the solenoid valve is de energized gas pressure on top of the unloader piston is relieved to the suction plenum The coil spring forces the piston up uncovering the recessed opening which allows the suction gas to flow thr...

Page 69: ... cooler 7 Check panel to see that it is free of foreign mate rial wires metal chips etc 8 Visually inspect wiring power control Must meet NEC and all local codes See Figs 9 11 9 Check for proper size fuses in main and control power circuits 10 Verify that field wiring matches the 3 phase power requirements of the compressor See nameplate See Fig 9 11 Assure 115VAC Control Power to TB1 has 30A mini...

Page 70: ...lumn of liquid when the unit is operating normally On start up foaming of the oil may be evi dent in the compressor oil sight glass After the wa ter temperature has been pulled down to operating conditions the oil should be clear Normal operation of the unit is evidenced by a hot discharge line dis charge superheat should not drop below 50 F clear oil in the compressor crankcase solid liquid refri...

Page 71: ...l sequence and timing previously described When a compressor starts internal timers limit minimum time before another compressor can start to 1 minute Time between stages of loading is also limited by in ternal timers to a minimum of 1 minute al though the micro would like to load at 30 sec onds intervals which may cause the lag com pressor to start before the lead system fully loads optional step...

Page 72: ... will load if cooling demand tem perature and rate control requires 12 After 3 minutes of run time the lead compressor will load if cooling demand temperature and rate control requires and extra steps of capacity are present 13 After 3 minutes and 30 seconds of run time the lag compressor will load if optional stages of loading are present and cooling demand requires 14 After 4 minutes or runtime ...

Page 73: ...p any part of the hermetic compres sor F Open the coil drain valve slowly and drain as much oil from the compressor as possible G Examine the oil for any metal particles which would indicate wear on the bearings crankshaft or connecting rods If metal particles are found the need for closer examination by factory ser vice personnel is indicated H If the oil is clean and free of metal particles refi...

Page 74: ...r pump contact will transition as soon as a System Switch on the micro processor board is placed in the ON position If a daily schedule is programmed the evaporator water pump contacts will transition when the daily schedule dictates If MANUAL OVERRIDE is selected the evaporator water pump contacts will immediately transition Connections to this contact can be made on Terminals 25 and 26 of TB1 in...

Page 75: ...YCAJ44HE8 17P 471 01262 102 YCAJ44HE8 28P 471 01262 102 YCAJ44HE8 46P 471 01262 102 YCAJ44HE8 58P 471 01262 102 YCAJ54HE8 17P 471 01262 102 YCAJ54HE8 28P 471 01262 102 YCAJ54HE8 46P 471 01262 102 YCAJ54HE8 58P 471 01262 102 YCAJ55HE8 17P 471 01262 101 YCAJ55HE8 28P 471 01262 101 YCAJ55HE8 46P 471 01262 102 YCAJ55HE8 58P 471 01262 102 YCAJ65HE8 17P 471 01262 101 YCAJ65HE8 28P 471 01262 101 YCAJ65HE...

Page 76: ...m whenever discharge pressure exceeds 340 PSIG These fans will stay on until discharge pressure drops below 120 PSIG NOTE The corresponding compressor must be on for 4 seconds before these fans are permit t e dt os t a r t 4 The fourth stage of fan control will energize fan 1 SYS 1 5M or fan 3 SYS 2 8M and will operate the corresponding fans in the forward direction when ever discharge pressure ex...

Page 77: ...o the cooler which keeps the compressor on the line The option will provide hot gas bypass on both compressors enabling hot gas to be ac tive regardless of which compressor is in the lead NOTE The microprocessor will only activate the hot gas on the lead compressor The hot gas bypass consists of a pilot operated regu lating valve with an integral solenoid The pilot operated solenoid is controlled ...

Page 78: ...2 F The hot gas solenoid will be activated at 45 1 2 F in the example above and hot gas may then be fed according to the suction pressure and the pressure regulated valve setting Once activated the micro will keep the solenoid energized until the return water temperature rises above the temperature designated by the formula ULCR CR CR 10 Where UCLR Upper Limit of Control Range CR Control Range Dif...

Page 79: ...med for DISCHARGE PRES SURE FAN CONTROL See Page 29 Fan cycling will operate as indicated in Table 3 The kit consists of discharge pressure transducers for each system wire harnesses and associated mounting hardware HIGH AMBIENT OPTION The High Ambient Option consists of two kits P N s 471 01262 111 and 475 04250 000 The option allows operation of the chiller in ambients up to 115 F Typi cally sta...

Page 80: ...er is in the form of a compact roll and is easily handled compared to larger printers using wider busi ness form style paper The paper is 2 25 wide desk top calculator paper that can be easily and inexpensively purchased at most stationary stores Shown in Fig 32 and 33 is the WEIGH TRONIX printer and a typical sample print out The WEIGH TRONIX IMP 24 Model 2600 printer can be purchased for approxi...

Page 81: ... The printer may be left connected to the micro panel Parts The following parts are required 1 Weigh Tronix IMP 24 Model 2600 printer 2 2 25 wide desk top calculator paper 3 25 ft Twisted Pair Shielded Cable minimum 3 con ductor 18 AWG Stranded 300V min insulation 4 1 ea 25 pin Cannon connector and shell Connec tor Cannon P N DB 25P or equivalent Shell Can non P N DB C2 J9 Assembly and Wiring All ...

Page 82: ...uts down on a fault regardless of whether the fault causes a system or the entire chiller to lockout or whether restart is permitted This is the same print out that is obtained when the OPER DATA Key is pressed however it will be a snap shot of system operat ing conditions at the instant fault occurred Additionally the Status indication that is noted in the print out will note the specific fault t...

Page 83: ...Refer to Fig 36 and the Parts List for place ment of the grilles and the proper hardware required 4 Notch grilles to suit water connection and wiring har nesses as needed 5 If the High Ambient Sunshield Kit or Disconnect Op tion is installed field adaption will be required where parts of the kits interfere Touch up exposed metal parts to prevent rust Parts List PART ITEM QUAN DESCRIPTION 075 02501...

Page 84: ...Notch grilles to suit water connections and wiring harnesses 2 Discard existing grilles to attach louver panels where necessary FIG 37 LOUVERED AND WIRE GRILLE INSTALLATION Parts List PART ITEM QUAN DESCRIPTION 075 02563 037 1 2 Panel Louvers Side Top R H 075 02563 036 2 1 Panel Louvers Rear Top R H 075 02563 015 3 1 Panel Louvers Front Top R H 075 02563 016 4 1 Panel Louvers Front Top L H 075 025...

Page 85: ...tion Shown ASSEMBLY INSTRUCTIONS 1 Condensing and remote DX evaporator arrangement shown 2 Standard units with cooler discard items 20 21 FIG 39 LOUVERED INSTALLATION Parts List PART ITEM QUAN DESCRIPTION 075 02563 001 1 2 Panel Louvers Side Btm 075 02563 037 2 2 Panel Louvers Side Top R H 075 02563 016 3 1 Panel Louvers Front Top L H 075 02563 015 4 1 Panel Louvers Front Top R H 075 02563 036 5 1...

Page 86: ...nal should be connected to the and terminals on the TB3 Terminal Block at the right of the Microprocessor Board Be sure polarity is correct CAUTION THE 0 10VDC INPUT SIGNAL WIRING MUST NOT BE EARTH GROUNDED 4 20mA Jumpers JU3 and JU5 must be IN All other jumpers should be OUT Program the REMOTE TEMP SET POINT RANGE page 65 for 40 F which will allow a 20 F offset with an input of 20mA There will be...

Page 87: ... may not Energize be up 2 External motor protector tripped 2 Check for defective External motor protector wiring and motor problems Assure that motor protector is not tripped due to external high pressure switch 3 Defective relay output board 3 Replace relay output board CONTACTORENERGIZES 1 Improper system high voltage 1 Check system high voltage supply 2 Defective contactor contacts and 2 Check ...

Page 88: ...ernal H P correctly set restart unit Cut out Switch opens 6 Assure OAT sensor is reading properly 6 Place a thermometer next to the sensor a Motor Current Fault and compare reading to the display w i l lr e s u l t Operation should not suffer if thermometer is 10 F Chiller Fault High 1 Temperature sensed incorrectly by 1 Verify actual ambient temperature at Ambient Temp thermistor probe 10 F with ...

Page 89: ... thermometer located in 33 0 F 2 09 waterpiping 36 0 F 2 22 38 0 F 2 28 41 0 F 2 37 43 0 F 2 43 46 0 F 2 54 48 0 F 2 60 50 0 F 2 67 53 0 F 2 77 55 0 F 2 83 57 0 F 2 89 59 0 F 2 95 61 0 F 3 02 63 0 F 3 08 65 0 F 3 14 67 0 F 3 20 70 0 F 3 28 Check voltage on microprocessor board LWT J11 7 to J11 1 RWT J11 8 to J11 1 Low Compressor 1 Low oil charge 1 Oil level should be visible in sight glass Oil Lev...

Page 90: ...nd not great enough 3 OK Become familiar with control operating 4 Defective loading solenoid 4 Replace compressor loading solenoid 5 Faulty wiring to loading solenoid 5 Check wiring 6 Defective water temperature sensor 6 Compare sensor with a thermometer Variation of sensor vs thermometer of 2 F is not unusual Replace if necessary 7 Defective evaporator or optional 7 Replace transducer after verif...

Page 91: ...0 43 9 111 231 8 44 4 112 233 6 45 0 113 235 4 45 6 114 237 2 46 1 115 239 0 46 7 116 240 8 47 2 117 242 6 47 8 118 244 4 48 3 119 246 2 48 9 120 248 0 49 4 121 249 8 50 0 122 251 6 50 6 123 253 4 51 1 124 255 2 51 7 125 257 0 52 2 126 258 8 52 8 127 260 6 53 3 128 262 4 53 9 129 264 2 54 4 130 266 0 55 0 131 267 8 55 6 132 269 6 56 1 133 271 4 56 7 134 273 2 57 2 135 275 0 57 8 136 276 8 58 3 137...

Page 92: ...mpic Team 36USC380 P O Box 1592 YORK Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by YORK International Corporation 1997 ALL RIGHTS RESERVED Form 150 60 NM3 595 Supersedes 150 60 NM2 in ERR only ...

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