York YVAG012 Operation & Maintenance Manual Download Page 1

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DC INVERTER AIR-COOLED

CHILLER AND HEAT PUMP

Installation

Operation

Maintenance Manual

FORM NO.:

6U5M-A11M-NB-EN

YVAG012~040RSE

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

Summary of Contents for YVAG012

Page 1: ...AIR COOLED CHILLER AND HEAT PUMP Installation Operation Maintenance Manual FORM NO 6U5M A11M NB EN YVAG012 040RSE Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 2: ...13 INSTALLATION CLEARANCES 13 WATER SYSTEM INSTALLATION 15 UNIT EXTERNAL HEAD 21 ELECTRICAL CONNECTION 23 ACCESSORY DIMENSIONS 24 SECTION 3 ELECTRICAL CONTINUITY 26 ELECTRICAL CONNECTION 26 ELECTRICAL DIAGRAM 27 ELECTRICAL SCHEMATIC DIAGRAM 35 SECTION 4 WIRE CONTROLLER OPERATION 39 INTRODUCTION 39 INTERFACE 39 BASIC OPERATIONS 40 ADVANCED OPERATIONS 40 SECTION 5 MAINTENANCE 46 IMPORTANT 46 COMPRES...

Page 3: ...TERS 46 CONDENSER FAN MOTORS 46 OVERALL UNIT INSPECTION 46 MODBUS PROTOCOL 47 TROUBLE SHOOTING 50 TROUBLE SHOOTING CONT D 51 POISONOUS AND HARMFUL SUBSTANCE CONTENT TABLE UNIT 52 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 4: ...ernmental standards and regulations pertaining to the task in question Pay attention to keep this document and you can acquire it from local authorized YORK service center in case it would be lost 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 c...

Page 5: ... 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 rigging lifting and operating service personnel should verify whether the equipment has been modified and if current literature is available from the owner of the equipment prior to performing any work on the chiller CHANGE BARS Re...

Page 6: ... and a weather resistant microprocessor control center all mounted in a sheet metal shell BASIC UNIT NOMENCLATURE Named Y V A G 0 1 2 R S E 2 0 Number 1 2 3 4 5 6 7 8 9 10 11 12 The number 1 Y YORK The number 2 V Variable Frequency The number 3 A Air cooled The number 4 G Design Series The number 5 6 7 Nominal Capacity Unit kW The number 8 Specific Function R Integral Heat Pump The number 9 Single...

Page 7: ...ORM NO 6U5M A11M NB EN JOHNSON CONTROLS 7 FIGURE 2 YVAG020 033 DIMENSIONS FIGURE 3 YVAG040 DIMENSIONS Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 8: ...ter temperature range Enter water temperature Cooling 10 30 Heating 25 47 Cooling 10 30 Heating 25 53 Please note that The return water temperature control is default by the unit controller and return water temperature control is recommended The above data are obtained in the laboratory the practical use there will be deviation affected by the installation position and so on For applications with ...

Page 9: ...l be suitable for elevator or forklift truck or crane for convenience of lifting When transporting with a crane a canvas hammock shall be used to come round the unit base and be fastened If the packaging box has been removed in order to move the machine please apply suitable partition to protect the surface and the side panel as shown in the picture below During the transit the machine shall be ke...

Page 10: ...e units in operation 1 The nameplate content of the unit is identical with the order 2 The accompanying documents of the unit are complete 3 The accessories of the unit are in accordance with the items listed in the packing list 4 Immediately upon receiving the unit it should be inspected for possible damage which may have occurred during transit If damage is evident it should be noted in the carr...

Page 11: ...the heat exchanger part is without block protective baffle plate can be added to reduce the influence of operating noise of the unit Cold Climate Locations If the unit is operating in low ambient temperature be sure to follow the instructions listed below 1 A baffle plate installed on the airside of the unit is recommended to prevent exposure to snow in winter 2 In areas with large snow precipitat...

Page 12: ...65 YVAG 020 033 4 35 80 YVAG040 4 150 110 110 Draining There should be drainage way around the unit so that the rainwater and water generated from heating for defrosting and heating condensation can be discharged if there is no drainage way please add water pond on the bottom of the unit and lead it with pipeline to a suitable place 1 Drainage way 012 018 There is a 26mm and three 20mm drain holes...

Page 13: ...installed at a place with violent airflow such as exposed roof measures including parapet or blinds shall be taken to prevent turbulent flow from interfering the air flow into the unit If the unit needs to set parapet the height shall not be taller than the unit and the clearance between the unit and the parapet or the blinds shall also satisfy the minimum clearance requirement for unit installati...

Page 14: ... 3 300 800 Installation in rows Model 1 300 500 500 Model 2 300 500 Stack mounting 300 300 300 300 300 300 500 800 Model 2 300 300 300 300 300 300 300 Back wall Height unlimited 800 Back wall Front wall Side wall Height unlimited 500 800 Model 4 300 500 500 Model 3 300 500 500 500 500 500 500 500 500 1500mm h2 500mm h1 300 300 Back wall Front of the unit Side wall Height unlimited Front of the uni...

Page 15: ...he operating flow rate of the unit shall not exceed 40 of rated flow for each unit type too large or too small water flow rate would affect the normal use of the unit b The water flow direction of the unit shall be connected according to the inlet and outlet pipe marks on the unit otherwise the performance of the unit might be affected c The pipeline must have independent support and should not be...

Page 16: ...en drained n The fan coil in the water system shall be equipped with a three way valve or a by pass valve to make the water system circulate fluently during the period when anti freezing water pump is operating in winter o For module application a place for thermometer sensor shall be retained on the main outlet pipe of the water system so that the leaving water temperature sensor can be installed...

Page 17: ...each unit should be piped as shown Chilled water system for single unit FIGURE 9 SINGLE UNIT SYSTEM WITHOUT EXTERNAL PUMP FIGURE 10 SINGLE UNIT SYSTEM WITH EXTERNAL PUMP Notes Parts in the dotted box are optional components and if the site does not need installation the pipeline here can be directly connected Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindus...

Page 18: ...omponents and if the site does not need installation the pipeline here can be directly connected 2 In modular connection considering the balance of water pressure drop and water flow rate the same route design should be applied If pipelines could not be installed in the same route due to the limitation of installation space please contact the local JCI office for confirmation 3 In modular connecti...

Page 19: ...system is designed to work effectively within a maximum of 4 control boards communication addresses connected Follow the arrangements below for side by side and back by back layout Side by Side Layout FIGURE 13 SIDE BY SIDE LAYOUT Back By Back Layout FIGURE 14 BACK BY BACK LAYOUT Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 20: ...water temperature would affect defrosting when the unit is operating in heat mode for defrosting To avoid this buffer water tank should be applied or the diameter of main water pipe should be enlarged to meet the recommended range in the following table The referential installation methods for buffer water tank as shown below Expansion Tank Pot There is no expansion tank as standard components bui...

Page 21: ... 78 78 78 78 Maximum L 90 90 90 90 180 180 180 180 180 180 Minimum Water Pressure for Operation kPa 30 30 30 30 30 30 30 30 30 30 Maximum Water Pressure for Operation kPa 600 600 600 600 600 600 600 600 600 600 Notes The data above is suitable for the condition when the highest point of water system is 20 m higher than the unit The maximum water volume is only available to the unit with built in e...

Page 22: ...12 15 18 21 1 0 1 5 2 0 2 5 3 0 3 5 4 0 HYDRAULIC HEAD m WATER FLOW m h 012 018 PUMP HEAD CURVE YVAG012 YVAG014 YVAG016 018 8 12 16 20 24 28 32 1 0 2 0 3 0 4 0 5 0 6 0 7 0 HYDRAULIC HEAD m WATER FLOW m3 h 020 033 PUMP HEAD CURVE YVAG028 033 YVAG020 025 12 13 14 15 16 17 18 19 2 3 4 5 6 7 8 HYDRAULIC HEAD m WATER FLOW m3 h 040 PUMP HEAD CURVE Cooke Industries Phone 64 9 579 2185 Email sales cookein...

Page 23: ...tion will be available after being activated through HMI External Interlock The unit will be allowed to run only if the interlock is connected It is used to link external facilities like fire alarms in case there s an emergency cutoff It is wired to terminals 3 to 4 External interlock is short circuited before delivery Compressor Heater Compressor heaters are standard All compressors utilize one h...

Page 24: ...s electricity in control cabinet before power supply is cutoff 10 Never operate the wire controller with sharp materials for fear of scratching the wire controller screen Never contort or pull out electric wires in the control cabinet to prevent loose wiring and control failure Benzene diluents or chemical reagent is not allowed to clean the controller and control elements to avoid corrosion or ma...

Page 25: ...FILTER DIMENSION 012 018 FIGURE 22 WATER FILTER DIMENSION 020 033 FIGURE 23 WATER FILTER DIMENSION 040 Notes All dimensions are in mm unless specified otherwise Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 26: ...rload Earth leakage circuit breaker matching with working voltage of unit should be used 5 Only designated accessories by YORK can be used and services of installation and technology support can be obtained from manufacturers or authorized resellers Fail to correct installation for control accessories may cause malfunction of the controller or electric shock etc Users are not allowed to make any r...

Page 27: ...LLER CONNECT TO UNIT Notes 1 Total length of communication and power supply line should be within 15m 2 A B 12V and 0V should be connected correspondingly in case of malfunction or controller damage STEP 2 Panel Disassembly FIGURE 25 WIRE CONTROLLER STRUCTURE Notes As printed circuit board is on the front panel of controller be cautious when using flat head screwdriver 1 Modular Wire Controller Fr...

Page 28: ... Cable Connection 12V A B Wire Controller of Touch Screen A B12V 1 Modular 2 Modular 3 Modular 4 Modular L1 L2 L4 0 0 12V A B A B12V 0 0 A B B A G A B A B L3 B A G A B A B B A G A B B A G RS485 BAS Board YORK DRV 002 HL Wiring Terminal TB2 B RS485 BAS Board YORK DRV 002 HL RS485 BAS Board YORK DRV 002 HL RS485 BAS Board YORK DRV 002 HL FIGURE 27 COMMUNICATION WIRING DIAGRAM FOR MODULAR UNIT 012 01...

Page 29: ...TROL 020 040 Notes 1 Communication cables between host and wire controller should be 85 net type shielded wire of four core which length is within 15m 2 Communication cables between units and fan coils should be 85 net type shielded wire of two core specifications and length are as following table TABLE 8 COMMUNICATION CABLE SPECIFICATION Total length of communication cable from wire controller to...

Page 30: ...Cable selection specification above is suitable for the conditions where ambient temperature is under 40 local regulations should be referred to for practice 2 Leakage protector must be deployed and reliable ground connection should be conducted on site 3 For any discrepancy on site like capacitance decreasing refer to IEC standards and requirements by cable manufacturers for selection 4 Only copp...

Page 31: ... the requirement of user power supply voltage 012 018 units for 220 V and 230 V 020 040 units for 380 V and 400 V 3 Single Unit Wire Diagram L N PE QF L N PE POWER SULLY 220V 230V 50Hz QF Breaker KM2 Aulixiary electric heating SV Solenoid valve for floor heating RE Remote Switch C H Cooling Heating Switch component description COM1 KM2 SV A1 A2 KM2 SV RE C H COM 0V1 A1 B1 12V1 COM Common terminal ...

Page 32: ...y eletric heating KM3 AL Aive an alarm RE Remote Switch C H Cooling Heating Switch COM Common terminal for electronic B4 A4 BAS Modular units KT 2 HP 1HP 2 KT 1 PE The total water control of fan coil units FIGURE 35 SINGLE UNIT POWER SUPPLY CONNECTION 040 Notes 1 Terminal blocks of the power supply should be circular terminals while other control signal can be connected with U shape terminals 2 Wi...

Page 33: ...ressure welded with copper terminals 2 Directly intertwine the cable on the binding post is strictly forbidden Air Side Terminal Connect If the user need to operate the unit through solenoid valve connection point of the fan coil floor heating controller a fan coil linkage controller as option is necessary to be added The wiring schematic diagram is shown below TFX INPUT FAN COIL LINKAGE CONTROLLE...

Page 34: ... controller need to be connected with another power supply 2 All the controller of air side terminals need to be connected to the fan coil linkage controller 3 A single fan coil linkage controller can be connected with 8 temperature controllers at most 4 Fan coil linkage controllers can be in modular connection Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeind...

Page 35: ...2 B K 1 2 D I 3 Y E 1 2 D I 4 R D 1 2 颜色 C o l o r 棕色 B r o w n 代码 C o d e B N 蓝色 B l u e 绿黄色 G r e e n y e l l o w B U G N Y E 黄色 Y e l l o w 绿色 G r e e n Y E G N 白色 W h i t e 黑色 B l a c k 橙色 O r a n g e W H B K O G 红色 R e d R D 导线 W i r e 供应商接线 W i r i n g b y v e n d e r 工厂接线 W i r i n g b y f a c t o r y 用户接线 W i r i n g b y c u s t o m e r 警告机组必须断电 1 分钟后才能再 ...

Page 36: ...色 Green YE GN 白色 White 黑色 Black 橙色 Orange WH BK OG 红色 Red RD 导线 Wire 供应商接线 Wiring by vender 工厂接线 Wiring by factory 用户接线 Wiring by customer 警告机组必须断电1分钟后才能再次供电和维护 WARNING DO NOT POWER ON AND CARRY OUT MAINTENANCE UNLESS THE UNIT HAS BEEN POWERED OFF FOR AT LEAST 1 MINUTE RT1 CH1 FLS1 KM2 SV KT 2 LPS1 RT3 RT4 RT5 RT6 RT7 RT8 QF1 原理图 SCHEMATIC YVAG 014 016 018 PN 035W24820 007 SAP 5179667 HP1 P CH...

Page 37: ... 2 RT7 1 2 1 2 3 AI8 BK RT8 RT9 1 2 1 2 3 RT10 CON201 CON205 DI1 WH 1 2 TB2 DI2 BK 1 2 DI3 YE 1 2 DI4 RD 1 2 RE TB2 DI5 WH 1 2 AP4 SV2 PSF 95 98 AP3 KM3 SV1 TB3 EH AL T1 T2 T3 PE 5 1 L PE 3 N NOTES 1 QF WITH RCD IS SUPPLIED BY CUSTOMER 2 SW1 EXTERNAL SWITCH IS AN OPTION AND INSTALLED IN THE FIELD BY CUSTOMER 3 POSITION OF DIP SWITCH 4 THE DEFAULT STATE OF THE CIRCUIT BREAKER IS CLOSED 5 THE VOLTAG...

Page 38: ...5 3 1 YMSV PCN601 WH PCN602 RD N DO4 DO5 5 3 1 2 4 PCN603 YE KFWC DO6 DO7 DO8 5 3 1 2 4 PCN604 WH N 7 6 5 4 3 2 1 5 4 3 2 1 CON502 BK CON501 RD ON 1 2 3 4 5 6 7 8 SW301 ON 1 2 3 4 5 6 7 8 SW302 LPS 1 2 3 AI2 BU 1 2 3 AI1 RD RT1 1 2 3 AI3 WH RT3 RT4 1 2 RT5 1 2 RT6 1 2 RT7 1 2 1 2 3 AI8 BK RT8 RT9 1 2 1 2 3 RT10 DI1 WH 1 2 SRE DI2 BK 1 2 DI4 RD 1 2 RE DI5 WH 1 2 AMB SV2 95 98 KAWC YFSV KAH SAL KT K...

Page 39: ... avoid changes in hue INTRODUCTION The touch screen wire controller is standard optional for remote controls of YVAG units The functions of parameter setting operating status viewing and fault recording are available Instead of describing the information above the wire controller utilizes graphic icons in user interface INTERFACE Area 1 Date and time display Area 2 Timer display Area 3 Temperature...

Page 40: ...r DOWN key in daily display screen to set target liquid temperatures Press CONFIRM to finish the setting or the controller will automatically save if there s no operation for 10 seconds Press CANCEL to abandon the setting ADVANCED OPERATIONS Date and Time Press the TIMER and FUNCTION keys simultaneously for 5 seconds to enter the Date and Time setting screen The TIMER and SET icons will flicker wh...

Page 41: ...y display for 5 seconds to enter System Parameter Setting screen Repeat the operation to enter Module Parameter Setting screen The LOCK icon will appear while the function is activated In System Parameter Setting the parameters will be displayed in hour display area Area 1 in sequence by pressing FUNCTION key In Module Parameter Setting the modules can be switched over by pressing TIMER key Press ...

Page 42: ...aving water temperature for heating mode 13E Excessive lower unit leaving water temperature for heating mode 15E Excessive higher discharge temperature 1F Freezing protection of BPHE 9F Communication failure of unit between Microboard and driver 2p Mismatching of driver type 4p Compressor driver alarm 6p Excessive higher speed of fan 1 8p Excessive higher speed of fan 2 9p Excessive lower speed of...

Page 43: ...E Excessive lower ambient temperature for cooling mode 4E Excessive lower system leaving water temperature for cooling mode 6E Excessive higher system leaving water temperature for heating mode 7E Communication failure between principal unit and T8600 or BAS 9E Freezing protection in winter 10E Excessive lower unit leaving water temperature for cooling mode 11E Excessive higher unit leaving water ...

Page 44: ...uts are displayed in sequence in hour display area Area 1 by pressing UP and DOWN keys The modules can be switched over by pressing TIMER key Description of each running status parameters as shown in Table 21 TABLE 13 DESCRIPTION OF RUNNING STATUS 012 018 Running status No Description A1 AI1 Refrigerant temperature inlet accumulator A2 AI2 Saturate temperature of suction pressure A3 AI3 Discharge ...

Page 45: ...to enter Keylock function The LOCK icon will appear and all touch keys and the physical button will be disabled while the function is activated Press TIMER and DOWN again to terminate the function Pump Circulation Press COOLING key for 5 seconds in daily display to enter Pump Circulation function The PUMP icon will appear The pump will operate with no compressor running while this function is acti...

Page 46: ... rotary compressor to pump the refrigerant system down into a vacuum Doing so will cause internal arcing of the compressor motor which will result in failure of compressor ADD TROPICAL PREHEATING Air conditioning unit start up there will be three hours compressor preheating preheating after the completion of the compressor to start CONDENSER COILS Dirt should not be allowed to accumulate on the co...

Page 47: ...eters in HMI to enable and disable the BAS Start Stop and Operating Mode functions 6 Start Stop Status The Start Stop Command Register value 0 is only used to start stop the unit Actual Start Stop Status is accessible by reading Register value 100 TABLE 16 SYSTEM SETPOINTS NO Name Function Code Register Address Note System Setpoints 1 Chiller ON OFF 3 6 16 0 0 Invalid 1 On 2 Off 2 Mode Setting 3 6...

Page 48: ...lt Word 3 3 1157 Unit 1 4 Fault Word 4 3 1158 Unit 1 5 Fault Word 5 3 1159 Unit 1 6 Fault Word 6 3 1160 Unit 1 7 Fault Word 7 3 1161 Unit 1 8 Fault Word 8 3 1162 Unit 1 TABLE 19 FAULT DEFINITIONS Address Fault Name Note Class Fault Word 1 Bit0 Inlet Accumulator Temperature Sensor Fault Bit0 1 Fault Unit Bit1 Suction Pressure Transducer Fault Bit1 1 Fault Unit Bit2 Discharge Temperature Sensor Faul...

Page 49: ...essive Lower Unit Leaving Water Temperature For Heating Mode Bit14 1 Fault Unit Fault Word 6 Bit0 Excessive Higher Discharge Temperature Bit0 1 Fault Unit Bit8 Freezing Protection Of BPHE Bit8 1 Fault Unit Fault Word 7 Bit1 Communication Failure Of Unit Between Mainboard And Compressor Driver Bit1 1 Fault Unit Bit3 Mismatching Of Driver Type Bit3 1 Fault Unit Bit5 Compressor Driver Alarm Bit5 1 Fa...

Page 50: ... defective 4 Reduced flow of chilled 5 Defective suction pressure transducer low pressure switch or wiring 6 Fans not operating in heating mode 1 Repair leak if necessary and add refrigerant 2 Clean BPHE 3 Check the wiring or replace EEV 4 Check liquid flow rate Check operation of pump clean pump strainer purge chilled liquid system of air 5 Replace transducer low pressure switch or faulty wiring ...

Page 51: ... 3 Driver failure 4 Compressor failure 1 Compare the display with a thermometer Should be within 2 degrees 2 Replace defective part 3 Check driver running status and the flicker of LEDs 4 Diagnose cause of failure and replace Fan Protect 1 Power or communication loss 2 Internal fan fault 1 Check the wiring 2 Contract local service for further fault analysis Lack of Cooling or Heating Effect 1 Foul...

Page 52: ...equirements of GB T26572 regulations X It means the toxic and harmful substances in the parts at least in a homogeneous material content beyond the limited requirement of GB T26572 rules play x in the form due to technical reasons at present cannot replace follow up with the progress of technology will gradually improve 1 This product is discarded after please which is separated from the living ga...

Page 53: ...Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 54: ...Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 55: ...Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 56: ...on Co Ltd Johnson Controls is committed to the continuous product improvement Please note the product design may change without notification This manual is for reference only For the specific product specifications and performance Please refer to the purchase agreement SAP NO 5598564 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

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