York YCRJ45E00 Installation Operation & Maintenance Download Page 29

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FORM 150.24-NM27

YORK INTERNATIONAL

CONTROL CIRCUIT (With I/O Expansion Board)

LD02106

Summary of Contents for YCRJ45E00

Page 1: ...55HE0 YCRJ55H00 YCWJ56HF0 YCRJ56H00 YCWJ66KH0 YCRJ66K00 YCWJ67KH0 YCRJ67K00 YCWJ77KH0 YCRJ77K00 YCWJ88MH0 YCRJ88M00 YCWJ99MJ0 YCRJ99M00 STYLE A 50 HZ YCWJ56EE0 YCRJ56E00 YCWJ66HE0 YCRJ66H00 YCWJ67HF0 YCRJ67H00 YCWJ77KH0 YCRJ77K00 YCWJ78KH0 YCRJ78K00 YCWJ88KH0 YCRJ88K00 YCWJ99MH0 YCRJ99M00 STYLE A 26214A With EPROM Standard Brine Metric Models Combined 031 01652 001 or 031 01096 001 ...

Page 2: ... 9 MOUNTING DETAIL FOR SPRING ISOLATORS 9 CONTROL PANEL 9 WATER COOLED 10 REMOTE CONDENSER 11 ELECTRICAL DATA 12 INSTALLATION 18 WIRING DIAGRAM 27 UNIT CONTROLS AND OPERATION 38 COMPRESSOR CAPACITY CONTROL 86 START UP CHECKLIST REPORT 87 PREVENTATIVE MAINTENANCE 92 OPTIONS 93 TROUBLESHOOTINGCHART 100 TEMPERATURE CONVERSION TABLE 106 WARNING HIGH VOLTAGE is used in the operation of this equipment D...

Page 3: ...OR NOMENCLATURE J MODELS UNIT NOMENCLATURE The model number denotes the following characteristics of the unit Y C W J 6 7 H F 0 46 P A YORK S Special Blank if not used Chiller Design Level W Water Cooled R Remote Condenser Type Start P Part Wind Compressor Type J or Z Voltage Code System 1Compressor Code 17 200 3 60 4 thru 9 See PHYSICAL DATA 28 230 3 60 40 380 3 60 System 2 Compressor Code 46 460...

Page 4: ...OR COOLER INLET LIQUIDSTOP VALVE LIQUID SOLENOID VALVES FILTERDRIERS LIQUID STOP VALVE CONDENSER 1 2 RELIEF VALVE COOLER OUTLET COOLER 26125A REAR VIEW OPTIONALSINGLE POINTPOWER CONNECTION POWERPANEL CONTROLPANELWITH KEYBOARD CONDENSER INLET CONDENSER OUTLET 26124A FRONT VIEW ...

Page 5: ...X 8 CYLINDER MODEL J G COMPRESSOR DISCHARGE STOP VALVE SUCTIONPRESSURE CONNECTION CAPACITY CONTROL SOLENOIDS RAINTIGHT TERMINALBOX SUCTION STOP VALVE SIGHT GLASSES 2 OILCHARGING VALVE CRANKCASE HEATER OILPRESSURE ACCESSCONNECTION MOTOR TERMINALS SUPPRESSORS MOTORPROTECTOR MP 27299A 27599A ...

Page 6: ...i Oll Temperature Max 1 160 F Maximum Sat Discharge Temp 2 150 F Maximum Ambient 115 F Minimum Ambient 40 F Minimum Leaving Liquid Temp 3 40 F Maximum Leaving Liquid Temp 50 F YCWJ YCRJ Models YCWJ 60 HZ 45EE0 55HE0 56HF0 66KH0 67KH0 77KH0 88MH0 99MJ0 YCWJ 50 HZ 56HE0 66HE0 67HF0 77KH0 78KH0 88KH0 99MH0 DESCRIPTION YCRJ 60 HZ 45E00 55H00 56H00 66K00 67K00 77K00 88M00 99M00 YCRJ 50 HZ 56E00 66H00 6...

Page 7: ... CAUTION Excessive flow will cause damage to the cooler Do not exceed max cooler GPM Special care should be taken when multiple chillers are fed by a single pump FIG 2 COOLER WATER PRESSURE DROP PRESSURE DROP KEY MODEL YCWJ56EE0 LETTER FOR COOLER LETTER FOR CONDENSER LD02345 LD02346 ...

Page 8: ...160HP YCRJ 50 HZ SYS 1 G44 P 67HP G63 Q 75HP G63 Q 75HP G64 S 96HP G64 S 96HP G83 T 113HP G83 T 113HP SYS 2 G63 Q 75HP G63 Q 75HP G64 S 96HP G64 S 96HP G83 T 113HP G83 T 113HP G83 T 113HP UNIT 60 HZ 5 Steps 5 Steps 6 Steps 7 Steps 7 Steps 7 Steps 10 Steps 10 Steps CAPACITY CONTROL 50HZ 6 Steps 7 Steps 7 Steps 7 Steps 7 Steps 10 Steps 10 Steps COOLER DUAL CIRCUIT DWP REF SIDE PSIG 235 235 235 235 2...

Page 9: ... 1600 1600 1600 1600 6 000 6 400 Isolator AWCB 1600 YCWJ55H00 60 1625 1625 1625 1625 5 950 6 500 Isolator AWCB 1625 YCWJ56H00 60 1650 1650 1650 1650 6 100 6 600 Isolator AWCB 1625 YCWJ66K00 60 1688 1688 1688 1688 6 150 6 750 Isolator AWCB 1625 YCWJ67K00 60 1750 1750 1750 1750 6 350 7 000 Isolator AWCB 1625 YCWJ77K00 60 1688 1688 1688 1688 6 150 6 750 Isolator AWCB 1625 YCWJ88M00 60 2263 2263 2263 ...

Page 10: ...6 MODEL 60HZ A B C D E F G H J K L M N P YCWJ45EE0 10 0 3 8 6 1 7 16 2 11 2 9 1 8 4 7 3 16 8 1 4 8 1 4 3 6 1 2 7 5 8 1 7 3 4 1 3 1 2 5 6 4 11 11 16 YCWJ55HE0 10 0 3 8 6 3 7 16 2 11 2 10 1 8 4 7 3 16 8 1 4 8 1 4 3 5 1 2 9 5 8 1 7 3 4 1 3 1 8 5 8 4 11 11 16 YCWJ56HF0 10 0 3 8 6 7 3 16 2 11 2 10 1 8 4 7 3 16 8 1 4 8 1 4 3 5 1 2 9 5 8 1 7 3 4 1 3 1 8 5 8 4 11 11 16 YCWJ66KH0 10 0 3 8 6 10 7 8 3 1 3 2 ...

Page 11: ...0 1 8 3 1 8 2 5 8 1 5 8 2 4 2 5 8 3 6 1 2 1 5 1 2 2 1 2 3 5 1 2 YCRJ88M00 1 8 7 8 3 2 3 4 8 3 1 8 1 5 8 3 0 3 1 8 3 6 1 2 1 5 1 2 2 2 1 2 3 5 1 2 YCRJ99M00 1 8 7 8 3 2 3 4 8 3 1 8 1 5 8 3 0 3 1 8 3 6 1 2 1 5 1 2 2 2 1 2 3 5 1 2 MODEL 50 HZ A B C D E F G H J K L YCRJ56E00 9 11 7 8 6 0 5 8 3 1 3 16 2 9 7 16 2 8 3 8 3 9 5 16 2 6 9 4 11 11 16 1 3 1 2 3 3 4 YCRJ66H00 9 11 7 8 6 2 5 8 3 2 3 16 3 2 3 16 ...

Page 12: ...0 412 56HF0 17 200 3 60 251 300 450 400 2 4 250MCM 450 200 731 56HF0 28 230 3 60 226 300 400 400 2 4 250MCM 400 180 636 56HF0 40 380 3 60 132 175 225 200 2 4 250MCM 225 105 385 56HF0 46 460 3 60 113 150 200 200 2 4 250MCM 200 90 318 67HF0 50 380 415 3 50 126 150 225 200 2 4 250MCM 225 100 410 56HF0 58 575 3 60 88 110 150 100 2 4 250MCM 150 70 254 67HF0 64 346 3 50 138 175 225 200 2 4 250MCM 225 11...

Page 13: ... 800 375 1101 408 500 700 400 2 4 250MCM 700 326 976 241 300 400 400 2 4 250MCM 400 192 591 204 250 350 200 2 4 250MCM 350 163 488 236 300 400 400 2 4 250MCM 400 188 760 159 200 250 200 2 4 250MCM 250 127 390 258 350 450 400 2 4 250MCM 450 206 917 296 400 500 400 2 4 250MCM 500 236 997 244 300 400 400 2 4 250MCM 400 195 830 196 250 350 200 2 4 250MCM 350 156 664 LEGEND VOLT Voltage MCA Minimum Cir...

Page 14: ... 3 60 301 400 500 400 2 4 250MCM 500 240 826 66K00 40 380 3 60 174 225 300 200 2 4 250MCM 300 139 467 66K00 46 460 3 60 151 200 250 200 2 4 250MCM 250 120 413 77K00 50 380 415 3 50 177 225 300 200 2 4 250MCM 300 141 585 66K00 58 575 3 60 116 150 200 200 2 4 250MCM 200 92 330 77K00 64 346 3 50 194 250 300 200 2 4 250MCM 300 155 668 67K00 17 200 3 60 346 450 600 400 2 4 250MCM 600 276 950 67K00 28 2...

Page 15: ...00 400 2 4 250MCM 600 276 950 301 400 500 400 2 4 250MCM 500 240 826 174 225 300 200 2 4 250MCM 300 139 467 151 200 250 200 2 4 250MCM 250 120 413 177 225 300 200 2 4 250MCM 300 141 585 116 150 200 200 2 4 250MCM 200 92 330 194 250 300 200 2 4 250MCM 300 155 668 428 600 700 400 2 1 0 500MCM 700 342 1322 368 450 600 400 2 1 0 500MCM 600 294 1150 219 300 350 400 2 4 250MCM 350 175 696 184 225 300 20...

Page 16: ... 60 271 300 350 400 350 1 6 350MCM 1 1 600MCM OR 2 1 250MCM 66KH0 46 460 3 60 232 300 300 400 300 1 6 350MCM 1 1 600MCM OR 2 1 250MCM 77KH0 50 380 415 3 50 268 300 350 400 350 1 6 350MCM 1 1 600MCM OR 2 1 250MCM 66KH0 58 575 3 60 178 200 250 200 250 1 6 350MCM 1 6 350MCM 77KH0 64 346 3 50 295 350 400 400 400 1 6 350MCM 1 1 600MCM OR 2 1 250MCM 67KH0 17 200 3 60 608 700 800 800 800 1 3 6 350MCM 1 4...

Page 17: ...0 350MCM 66K00 28 230 3 60 541 600 700 600 700 1 3 6 350MCM 1 4 1 0 350MCM 66K00 40 380 3 60 313 350 450 400 450 1 3 6 350MCM 1 2 4 0 500MCM 66K00 46 460 3 60 271 300 350 400 350 1 6 350MCM 1 1 600MCM OR 2 1 250MCM 77K00 50 380 415 3 50 318 400 450 400 450 1 3 6 350MCM 1 2 4 0 500MCM 66K00 58 575 3 60 208 250 250 400 250 1 6 350MCM 1 6 350MCM 77K00 64 346 3 50 349 400 500 400 500 1 3 6 350MCM 1 2 ...

Page 18: ...on page 6 The following paragraphs outline procedures to be fol lowed INSPECTION As soon as it is received the unit should be inspected for any damage done in transit If damage is evident it should be noted on the carrier s freight bill A separate request for inspection by the carrier s agent should be made in writing at once See YORK Service Policy and Procedures Shipping Damage Claims Form 50 15...

Page 19: ...tor mounting bracket underneath the unit base It will be necessary to raise the unit to do this Note that the bolt should be inserted from the bottom of the mounting bracket FIG 4 FOUNDATIONS The isolator should be fastened to the mounting bracket by the cap screw inserted through the hole in the mount ing bracket into the tapped hole in the top of the isolator leveling bolt Leveling of the unit i...

Page 20: ... mini mum leaving water temperature of 65 F The regulator should be installed in the entering water line however the outlet piping leaving the condenser should contain a vertical rise approximately 3 higher than the top of the condenser before an elbow is in stalled to continue the piping to an open drain The reason for the vertical riser is to create a trap which will prevent water from draining ...

Page 21: ...ngement provides a liquid column which raises the pressure of the refrigerant above the saturation pressure and thus assures proper subcooling at the expansion valve 7 The condenser must provide liquid subcooling of 10 F measured at the condenser outlet 8 Remote air cooled condensers with reciprocating wa ter chillers require the proper design of intercon necting piping using accepted refrigeratio...

Page 22: ...Mechanical Engineers United Engineer ing Center 345 East 47th Street New York NY 10017 Since YCR chillers are shipped containing Refriger ant 22 as a holding charge the compressor discharge valve and the liquid stop valve should be kept closed until the remote condenser and all refrigerant piping are installed tested and properly evacuated for removal of moisture as explained under FIELD REFRIGERA...

Page 23: ...d in the discharge line as close to the unit as possible They can be mounted vertically or horizontally but should never be installed in a riser One side of the muffler is stamped TOP for horizontal mounting The mufflers should always be pitched toward the condenser YCR models with optional Hot Gas Bypass Loadmin der require field piping to be completed to the discharge side of the system piping L...

Page 24: ...ld be noted that under unusual circumstances a possibility exists for freezing water inside the system Such moisture or free water may be removed by the Double Evacuation procedure as explained in Paragraph 4 of EVACUATING PROCEDURE STANDARDS To be considered dry and free of mois ture a refrigerant system must be capable of sustaining a pressure of 019 lb per sq in absolute or 1000 mi crons absolu...

Page 25: ...onnected to the sys tem charging port in the refrigerant liquid stop valve Allow the dry nitrogen to flow into the system until the pressure reaches zero pound or slightly above Stop the dry nitrogen flow open valve B and con tinue the evacuating procedure Since dry nitrogen can hold a large quantity of mois ture before becoming saturated it becomes an effec tive vehicle for carrying in vapor form...

Page 26: ...rn However if it is undesirable it is the responsibility of the installer to make provisions to field insulate the com pressor or install a factory insulation kit when they be come available Contact YORK Factory Marketing for availability ELECTRICAL WIRING Liquid Chillers are shipped with all factory mounted con trols wired for operation Field Wiring Power wiring must be provided through a fused d...

Page 27: ...FORM 150 24 NM27 YORK INTERNATIONAL 27 FIG 8 ELEMENTARY DIAGRAM WIRING DIAGRAM With or Without I O Expansion Board ...

Page 28: ...ctor auxiliary contacts must be suppressed with YORK P N 031 00808 000 sup pressor across the relay contactor coil Any contacts connected to flow switch inputs or BAS inputs on terminals 13 19 of TB3 or in any other input terminals must be supplied with a YORK P N 031 00808 000 suppressor across the relay contactor coil which activates the con tacts CAUTION Control wiring connected to the control ...

Page 29: ...FORM 150 24 NM27 YORK INTERNATIONAL 29 CONTROL CIRCUIT With I O Expansion Board LD02106 ...

Page 30: ...30 YORK INTERNATIONAL FIG 9 SYSTEM WIRING ...

Page 31: ...FORM 150 24 NM27 YORK INTERNATIONAL 31 LD02678 ...

Page 32: ...32 YORK INTERNATIONAL FIG 9 SYSTEM WIRING Cont d LD02110 MOTOR TERMINAL BOX WIRING WITH MODEL 15AA MOTOR PROTECTOR ...

Page 33: ...FORM 150 24 NM27 YORK INTERNATIONAL 33 LD02357 MOTOR TERMINAL BOX WIRING WITH MODEL 31AA MOTOR PROTECTOR ...

Page 34: ...34 YORK INTERNATIONAL FIG 10 CONNECTION DIAGRAM LD02358 MICROPANEL CONNECTION DIAGRAM WITHOUT EXPANSION BOARD ...

Page 35: ...FORM 150 24 NM27 YORK INTERNATIONAL 35 LD02679 ...

Page 36: ...36 YORK INTERNATIONAL MICROPANEL CONNECTION DIAGRAM With I O Expansion Board LD02107 ...

Page 37: ...FORM 150 24 NM27 YORK INTERNATIONAL 37 LD02108 ...

Page 38: ...pping and loading unloading de cisions are performed by the Microprocessor to main tain leaving water temperatures These decisions are a function 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 pres sure transducers temperature sensors and C T s are co...

Page 39: ...ential I O EXPANSION BOARD Introduced in the latter part of 1997 the I O Expansion Board allows the Micro to receive additional analog in puts from Oil Temperature Sensors and optional Dis charge Temperature Sensors These inputs are multiplexed and sent to the micropro cessor board to allow the micro to monitor these inputs for display and as safeties CURRENT TRANSFORMER C T A C T on the 3φ power ...

Page 40: ...6216A MICROPROCESSOR BOARD 2TTRANSFORMER RELAY OUTPUT BOARD 1 TB3 CONNECTIONS FOR FLOW SWITCH LEAD LAG SELECTERAND EMS BAS CONTROLS LOCATION OF OPTIONAL RELAY OUTPUT BOARD 2 POWERSUPPLY BOARD 28697A POWER SUPPLY BOARD 2T TRANSFORMER RELAY OUTPUT BOARD 1 RELAY OUTPUT BOARD OPTIONAL 2 TB3CONNECTIONS I O EXPANSION PLAN MICROPROCESSORBOARD ...

Page 41: ...ng potential future problems troubleshooting and commissioning the chiller Displayed data will be real time data displayed on a 40 character display consisting of 2 lines of 20 characters The display will update all information at a rate of about 2 seconds When a DISPLAY pushbutton is pressed the corre sponding message will be displayed and will remain on the display until another pushbutton is pr...

Page 42: ...een selected by the user These options are se lected by the S1 Dip Switch on the Microprocessor Board Fig 15 Proper programming of the switch is important during commissioning of the chiller The OPTIONS dis play allows a means of verifying the Dip Switch posi tions without looking at or handling the Microprocessor Board It also eliminates visual inspection of the some times difficult to determine ...

Page 43: ...L D I S C H A R G E P R E S S U R E F A N C O N T R O L M A N U A L L E A D L A G A U T O M A T I C L E A D L A G S T A N D A R D C O N D E N S E R F A N C O N T R O L S H A R E D C O N D E N S E R F A N C O N T R O L E N G 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 ...

Page 44: ...l will be from leaving water temperature SWITCH 5 OPEN 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 Switch 6 positioning on YCW YCR water cooled chill ers does not affect operation CLOSED Switch 6 positioning on YCW YCR water cooled chill ers does not affect operation Positioning of...

Page 45: ...sign ment is made whenever both compressors shut down The micro will then assign the lead to the compressor with the shortest anti recycle time SWITCH 8 OPEN Switch 8 positioning on YCW YCR water cooled chill ers does not affect operation CLOSED Switch 8 positioning on YCW YCR water cooled chill ers does not affect operation M A N U A L L E A D L A G A M B I E N T D I S C H P R F A N C O N T R O L...

Page 46: ...he STATUS key will enable the operator to determine current chiller operating status as a whole and as individual systems The messages displayed will in clude running status cooling demand fault status exter nal cycling device status and anti recycle timer status The display will be a single message relating to the high est priority message as determined by the micro Sta tus messages fall into the...

Page 47: ...ng total loss of cooling When this message appears discharge pres sure has exceeded the user programmable threshold and the micro is unloading the affected system to prevent shutdown on a manual high pressure cut out Reloading 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 i...

Page 48: ... 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 These Fault Messages apply only to chillers with 031 01096 001 and early versio...

Page 49: ... 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 1 H I G H O I L T E M P S Y S 2 H I G H O I L T E M P 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 O I L T E M P I N H I B S Y S 2 O I L T E M P I N H I B S Y S 1 H I M T R C U R R E N T S Y S 2 H I M T R C U R R E N T S Y S 1 P U M P D O W N F A I L S Y S 2 P U M P D O W N F A I L These Fault Messages apply only to chil...

Page 50: ...rough available 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...

Page 51: ...UST BE CHECKED AND PROPERLY PRO GRAMMED WHEN COMMISSIONING THE CHILLER FAILURE TO PROPERLY PROGRAM THESE VALUES MAY CAUSE DAMAGE TO THE CHILLER OR OPERA TION 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 YCR chillers should have the cut out set at 360 PSIG Chillers with water coole...

Page 52: ...the absolute maximum temperature capability of the electro mechanical components To program the OUTSIDE AIR TMP HIGH CUT OUT 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 100 0 130 0 F for this cut out NOTE This cut out does NOT ...

Page 53: ... 0 Example 085 PSIG RATE CONTROL TEMP The RATE CONTROL TEMP establishes a temperature range over which the micro may override normal system loading timers and react to actual rate of change of re turn and leaving water temperature This temperature range is slightly above the setpoint with its band width being programmable This control works in conjunction with the RATE SENSITIVITY which is also pr...

Page 54: ...t is adjustable from44 70PSIG IntheBRINE PROCESSMODE SW1 CLOSED the cut out is adjustable from 20 70 PSIG RATE SENSITIVITY The RATE SENSITIVITY establishes the rate of change of return or leaving water temperature where the micro will over ride 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 l...

Page 55: ...and date will be dis played when the SET TIME key is pressed CLOCK KEYS PROGRAMMING THE SYSTEM CLOCK AND DAILY START STOP SCHEDULE 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 t...

Page 56: ...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 each day or by press ing CANCEL and ENTER when the MONDAY START STOP schedule appears NOTE This will have no e...

Page 57: ...e ignored and the chiller will start up when water temperature allows unit switch permits and system switches permit Normally this key is not used unless an emergency forces the chiller to require operation during a period where the programmed Daily Schedule is calling for the chiller to be OFF Daily Schedule Shutdown Once activated MANUAL OVERRIDE is only active for a period of 30 minutes It is f...

Page 58: ... according to the user s application and Switch 4 of Dip Switch S1 on the Micro Board is properly configured to select Return or Leaving control the chilled liquid setpoints can then be programmed into the control panel Switch 4 of S1 must be properly programmed or an incorrect display message will appear when the CHILLED LIQUID TEMP RANGE key is pressed SEE SELEC TION OF RETURN OR LEAVING CHILLED...

Page 59: ...s well above or well below the desired setpoint will result To program the Chilled Liquid Setpoints press the 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...

Page 60: ...able limit The micro will accept a range of programmable values between 0 1 20 F NOTE When programming values between 0 1 9 9 F it is required to first key in a 0 or 00 Ex ample 05 9 F Loading may be inhibited or unloading may occur if the micro senses that the Rate Sensitivity is exceeded in the Control Range or Rate Control Range to prevent over shoot This action will override incremental loadin...

Page 61: ... 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 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...

Page 62: ... display will continue to show the LWT and Control Range message until another key is pressed CAUTION Too small of a CR selection will cause com pressor loader cycling If compressor cycling occurs 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 tem perature differential of the CR and or p...

Page 63: ...ERATURE CONTROL ABOVE THE RATE CONTROL TEMPRANGE h RATECONTROLTEMPRANGE RATE CONTROL TEMP 10 F i h CONTROLRANGE CR 44 46 F i BELOWTHE CONTROLRANGE 56 46 45 44 or initiate unloading if temperature drops faster than 2X the programmed Rate Sensitivity Above the RATE CONTROL TEMP RANGE the micro will attempt to load the chiller at 150 seconds intervals This allows the chiller to gain control of the wa...

Page 64: ...oad a stage 2 F below the tempera ture at which it was loaded assuming unloading tim ers and rate control software allows The RATE SENSITIVITY is a means of overriding the loading unloading timers when water temperatures are in the RATE CONTROL RANGE or the CONTROL RANGE This allows the micro to react to abrupt down ward changes in leaving or return water temperatures The ability to respond to rat...

Page 65: ... stan dard chillers may appear delayed time between stages increased when miss ing steps are activated or deactivated by the micro NOTE 1 The Lead Comp 2 Steps Lag Comp Off Step is skipped on a temperature drop 2 The micro controls loading and unload ing on a 10 STEP scale regardless of the number of stages present There fore loading and unloading responses on 7 Step optional chillers may ap pear ...

Page 66: ...ONTROL RANGE between the TAR GET and LOW LIMIT WATER TEMPERATURE As men tioned earlier in this manual the CONTROL RANGE is the temperature range of leaving water temperature that is acceptable to the user and has been previously pro grammed into memory using the CHILLED LIQUID TEMP RANGE KEY Usually this is a window of water tempera tures of about 2 3 F The micro will cause loading and unloading a...

Page 67: ... _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 4 LEAD COMP 1 STEP LAG COMP UNLOADED _ _ _ LEAD COMP 1 STEP LAG COMP UNLOADED 3 LEAD COMP UNLOADED LAG COMP UNLOADED _ _ _ LEAD COMP UNLOADED LAG COMP UNLOADED 2 LEAD COMP 1 STEP LAG COMP OFF _ _ _ LEAD COMP 1 STEP LAG COMP OFF 1 LEAD COMP UNLOADED LAG COMP OFF _ _ _ LEAD COMP UNLOADED LAG COMP OFF LEAD COMP OFF LAG COMP OFF _ _ _ LEAD COMP OFF LA...

Page 68: ...ssor starts If after 4 seconds the motor current drops below 15 FLA the micro will shut the compressor down NOTE Do not confuse FLA and RLA FLA full load amps is approximately 1 2 x RLA RLA run ning load amps specified on the motor name plate is typical current demand under rated op erating conditions in a fully loaded system There fore do not expect to see 100 FLA when the system is fully loaded ...

Page 69: ...ge pressure transducers are installed Oil Pressure Safety The Oil Pressure Safety assures that the compressor s mechanical components receive proper lubrication The micro begins monitoring compressor oil pressure after 4 seconds of operation For operating periods of 4 sec onds to 30 seconds oil pressure must be greater than 5 PSID From 30 seconds to 240 seconds oil pressure must be greater than 20...

Page 70: ...approximately 1 2 x RLA RLA run ning load amps specified on the motor name plate is typical current demand under rated op erating conditions in a fully loaded system There fore do not expect to see 100 FLA when the system is fully loaded In this condition currents may run approximately 65 86 FLA S Y S 1 H I G H M T R C U R R S Y S 2 H I G H M T R C U R R INDIVIDUAL SYSTEM START INHIBIT SAFETIES An...

Page 71: ...ecycle timer elapses This is the same anti recycle timer which is AUTOMATIC RESET SAFETIES An Automatic Reset Safety will shut the entire chiller down on a fault when the safety threshold is exceeded and allows automatic restart after the condition causing the shutdown clears Restart will occur only after anti recycle timers are satisfied and demand requires A reset hysteresis is built in so repet...

Page 72: ...cut out On water cooled chillers this safety reduces the chance of tripping the relief valve due to a very high rate of rise in pressureresultingfromacontrolsproblemwhichwouldcause 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 pressure cut out has opened and the compressor is in the midst of...

Page 73: ...start the system will cease to pump down Pumpdowns will begin again after a cooling start occurs This is to pre vent oil loss in the system However if one system reaches 120 pumpdowns while the other system is run ning for cooling the running lead compressor will be shut off if the off lag compressor is available for start At this point the lead compressor will pump down and shut off while the lag...

Page 74: ...l be temporarily stored in mem ory and transmission of this data will begin to the re mote printer As the data is transmitted it will be erased from memory A sample printout is shown in Fig 23 PRINT KEYS FIG 23 OPERATING DATA PRINTOUT 26572A D PRINT KEYS OPER DATA YORK INTERNATIONAL CORPORATION RECIPROCATING WATER CHILLERS SYSTEMSTATUS 8 45AM 4 17 98 SYS 1 COMPRESSOR RUNNING SYS 2 ANTI COIN TIMER ...

Page 75: ...G DISCHARGEPRESSURE 143 PSIG OILPRESSURE 75 PSID LIQUIDLINESOLENOID ON RUNPERMISSIVE ON STAGESOFLOADING 1 FORWARDFANS 2 REVERSEFANS OFF HOTGASBYPASSVALVE OFF SYSTEM2DATA COMPRESSORSTATUS ON MOTORAMPS 0 FLA SUCTIONPRESSURE 61 PSIG DISCHARGEPRESSURE 80 PSIG OILPRESSURE 1 PSID LIQUIDLINESOLENOID OFF RUNPERMISSIVE ON STAGESOFLOADING 1 FORWARDFANS 1 REVERSEFANS OFF HOTGASBYPASSVALVE OFF YORKINTERNATION...

Page 76: ...re offered NOTE Some of the information that may be recovered i e fan operation discharge pressures stages of loading etc may not apply to the chiller The micro is capable of operating these items and displaying information relating to them re gardlessofwhethertheyarepresentonthechiller When the OPER DATA key is pressed the following message will appear NOTE Depending upon the EPROM installed the ...

Page 77: ... last start is displayed This message provides a real time display of the time left on the Load Timer The Load Timer is a constantly recycling timer that the micro utilizes in conjunction with rate control and temperature deviation from setpoint to determine when loading should occur This message provides a real time display of the time left on the Unload Timer The Unload Timer is a con stantly re...

Page 78: ... water pump to close History The HISTORY key also allows the user to scroll through the SAFETY SHUTDOWN buffers to display information relating to the last 3 Safety Shutdowns which occurred Information contained in the SAFETY SHUTDOWN Buff ers is very important when attempting to troubleshoot a system problem This data reflects system conditions at the instant the fault occcured Information is sto...

Page 79: ...play shows the suction pressure of SYS 1 at the time of the fault This message indicates SYS 1 discharge pressure at the time of the fault This display will be a fixed value unless the Discharge Pressure Readout is installed This display shows the oil pressure of SYS 1 at the time of the fault This display informs the operator whether SYS 1 liquid line solenoid was energized ON or de energized OFF...

Page 80: ... SYS 2 liquid line solenoid was energized ON or de energized OFF at the time of the fault This message informs the operator if SYS 2 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 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 ...

Page 81: ... 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 120VAC external alarm circuit by others may be wired into the YORK supplied alarm contacts Any inductive load devices relay contactor supplied by the user which are connec...

Page 82: ...ckly 4 If the lead compressor is locked out faulted and waiting to restart SYS switch on the micro board is off or a run permissive is keeping an individual sys tem from running the lag compressor is swapped to the lead This is true regardless of whether the lag compressor is on or off If MANUAL Lead Lag is selected an external dry con tact switch must be wired into the chiller This contact is fie...

Page 83: ...ls is shown in Fig 27 MEMORY BATTERY BACK UP The Microprocessor board contains a Real Time Clock RTC I C Chip with an internal battery back up The bat tery back up assures that any programmed values clock all fault information accumulated information such as starts run time etc stored in the RTC memory is not lost when a power failure occurs regardless of the time period The battery is a 10 year l...

Page 84: ...ADING Pulldown demand limit ing and REMOTE SETPOINT RESET These functions can be easily utilized by connecting user supplied dry contacts to the terminals on the TB3 Terminal Block REMOTE START STOP BY A CYCLING DEVICE OR TIME CLOCK Remote START STOP is accomplished by connecting a time clock or other dry contact in series with the flow switch on terminals 13 14 See Fig 14 for the location of the ...

Page 85: ...its minimum step of capacity which places the entire system at minimum possible capacity To shut down the lag compressor a dry contact should be connected between terminals 13 16 See Fig 14 for the location of these terminals When the contact is closed the lag compressor will shut down Before the lead system can be unloaded to its minimum step of capacity the lag compressor must already be disable...

Page 86: ... the chilled water pump NOTE Any inductive devices contactor relay coil con nected to these contacts must be suppressed with YORK P N 031 00808 supplied by others Otherwise nuisance faults may occur CHILLER MODEL SYS OF OF UNLOADING STEPS YCWJ YCRJ CYLINDERS STANDARD OPTIONAL 45EE0 45E00 1 4 5 N A 55HE0 55H00 2 4 56HE0 56H00 1 4 6 N A 2 6 66KH0 66K00 1 6 67KH0 67K00 2 6 7 N A 77KH0 77K00 88MH0 88M...

Page 87: ...l wires metal chips etc 8 Visually inspect wiring power control Must meet NEC and all local codes See Fig 12 14 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 12 11 Assure 115VAC Control Power to TB1 has 30A minimum capacity See Fig 12 12 Be certain all control bulbs are ins...

Page 88: ...NCE for unit operation The compressor will start and a flow of liquid should be noted in the liquid indicator After several min utes of operation the bubbles will disappear and there will be a solid column of liquid when the unit is operating normally On start up foaming of the oil may be evident in the compressor oil sight glass After the water temperature has been pulled down to operating condit...

Page 89: ...to the piping Example LIQUID LINE PRESSURE 202 PSIG converted to 102 F Minus Liquid Line Temperature 90 F Subcooling 12 F Record SYS 1 _______ SYS 2 _______ The proper refrigerant charge is attained when subcooling is measured at 10 15 F Add charge as needed to in crease subcooling and remove charge as necessary to reduce subcooling Whenever removing charge be sure to recover it into an approved c...

Page 90: ...ompressor will load its 2nd step of loading if cooling demand requires temperature and rate control The lag com pressor remains unchanged at the 1st step of load ing 15 After 7 minutes of run time the lag compressor will load to its 2nd step of loading if cooling de mand requires 16 After 8 minutes of operation the oil pressure of the lag compressor must be 25 PSID and the suc tion pressure must b...

Page 91: ...ressor will unload two steps to its 1st step of 3 loading steps 12 After 10 minutes and 4 seconds of run time the motor current of the lag compressor must be 14 FLA and 115 FLA Oil pressure must be 5 PSID If these conditions are not met the lag compressor will shut down 13 After 10 minutes and 30 seconds of run time the oil pressure of the lag compressor must be 20 PSID and the suction pressure mu...

Page 92: ...re If it is necessary to charge oil refer to item 3 under the ANNUAL MAINTENANCE section 3 Check the refrigerant circuit for leaks 4 Operating Pressures and Temperatures Check to see that operating pressures and temperatures are within the LIMITATIONS shown in this book ANNUALMAINTENANCE It is recommended that the following items be checked annually 1 All items under WEEKLY MAINTENANCE 2 Operating...

Page 93: ...ank case to the proper level It is necessary that the suc tion end of the hand oil pump be kept submerged under the oil level in the container at all times to avoid entrance of air into the compressor I Before opening the suction or discharge stop valves connect a vacuum pump to the pumpout port in the discharge stop valve Pumpout port is port on valve stem side of valve With the vacuum line shuto...

Page 94: ...roprocessor in both return and in leaving water control LWT Control Hot Gas Operation The hot gas solenoid is energized when the leaving wa ter temperature falls below the Target water temperature if the compressor is on its minimum stage of loading Hot gas may then be fed according to the suction pres sure and the pressure regulating valve setting Once ac tivated the micro will keep the solenoid ...

Page 95: ... 001 YCRJ55H0 375 05886 001 YCRJ56H0 375 05886 001 YCRJ66H0 375 05886 001 YCRJ67K0 375 05886 002 YCRJ77K0 375 05886 002 YCRJ88M0 375 05886 003 YCRJ99M0 375 05886 004 In addition a 471 01232 101 kit must also be ordered The 471 01232 101 kit consists of a second Relay Out put Board It is not required if two Relay Boards are al ready installed in the control panel DISCHARGE PRESSURE READOUT OPTION T...

Page 96: ...rd is 25 feet Twisted pair shielded cable is required 3 The printer must be supplied a 115 VAC source 4 The printer may be left connected to the micro panel YORK INTERNATIONAL CORPORATION RECIPROCATING WATER CHILLERS SYSTEMSTATUS 8 45AM 6 3 98 SYS 1 COMPRESSOR RUNNING SYS 2 ANTI COIN TIMER 13 SEC RETURN WATER TEMP 65 0 DEGF LEAVING WATER TEMP 54 0 DEGF LOW WATER CUTOUT 36 0 DEGF SETPOINT TEMP 45 0...

Page 97: ...le as shown on the Micro Logic Board Do not connect at the printer end of the cable Printer Configuration 2 Switches on the printer must be properly configured Remove the paper roll to access these switches Place the switches in the following position SW 1 OFF SW 2 ON Obtaining a Print out A print out of current operating data may be obtained by pressing the OPER DATA key A snapshot will be taken ...

Page 98: ...ing the RE MOTE RESET TEMP RANGE Key on the Keypad All refresh requirements normally asssociated with PWM inputs will be automatically taken care of by the elec tronics in the option It is important to note that the maximum offset when this option is installed is 20 F This is due to the electronic s limitation of maximum 11 sec pulse If a greater than 20 F offset is required a user supplied PWM si...

Page 99: ...he REMOTE RESET TEMP SETPOINT RANGE page 84 for 40 F which will allow the R11 pot to be adjusted for an offset of as much as 20 F when the contact is closed The dry contact should be connected directly to the P1 1 J1 1 and P1 2 J1 2 terminals on the Remote Reset Board Fig 35 NOTE The coil of the controls used for reset must be suppressed Use YORK PIN 031 00808 000 sup pressor The Remote Setpoint R...

Page 100: ...rgize 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 CONTACTOR ENERGIZES 1 Improper system high voltage 1 Check system high voltage supply 2 Defective contactor contacts and 2 Check contacts and cont...

Page 101: ...ace transducer 7 Fouled compressor suction strainer 7 Remove and clean strainer 8 Faulty wiring to transducer 8 Check wiring High Dsch Fault 1 Cooling tower operational problems 1 Check fans fuses and contactors Cuts out on High 2 Too much refrigerant 2 Remove refrigerant Discharge Pressure as 3 Air in Refrigerant System 3 Evacuate and recharge sensed by 4 Defective discharge pressure 4 Replace di...

Page 102: ...d 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 either sight Oil Level glass at all ti...

Page 103: ...ed 3 Demand not great enough 3 OK Become familiar with control operation 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 af...

Page 104: ...103 217 4 40 0 104 219 2 40 6 105 221 0 41 1 106 222 8 41 7 107 224 6 42 2 108 226 4 42 8 109 228 2 43 3 110 230 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 ...

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York YCRJ45E00, Installation Operation & Maintenance

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